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Optistar LE
TM
ml 10/15 30 60 /20 ml ml
B 60 50 ml ml
125 ml
REVISION HISTORY
REVISION B, DATE 12/02 Cover page terminology changed to Optistar LE Contrast Delivery System Page I-4, New CE mark information added to bottom of page. Page 1-1-5, part number 801104 for 60ml Optistar LE Syringe available from Mallinckrodt changed to part number 801801. Page 1-1-5, section 1.4.4, OPTIMARK PREFILLED SYRINGE information added. Page 4-3-1, section 4.3.2, POWERHEAD, added information Do Not use any solvents to clean Powerhead Page 6-3-2, Two notes added regarding the Syringe Size Sensing PCB. Page 6-3-3, SYRINGE SIZE SENSING board part number 802307-1 was changed to 802313-1. Page 6-3-5, Syringe Adapter part number 802730 was added. Page 6-4-2, Item 26, Part number 172E0071 FUSE FAST BLOW 5x20mm was changed to part number (172E0016) 6.3 Amp Slow Blow Fuse. Page 6-9-2, Find No. 60, changed Quanity to 4. Also, added Find No. 97. Page 6-9-5, Added Find No. 71 and 47. Removed: Adapter Syringe Holder, Label 10/15/20 Fluid Detection, and Backer Plate, Syringe Detent. Page 11-2-7, Power Schematic 802202-2-D was updated with new fuse information REVISION C, DATE 5/03 Pages 6-8-2 and 6-8-3, added bell connector information to illustrations Figure 6-8-1 and 6-8-2. Appendix A Installation instructions 802702-C, page I-11, added CAUTION under step 7. Appendix A page 13 and 14, added Powerhead to Power Control connector housing information to illustrations.
I-1 FOREWORD
Congratulations on the purchase of your Liebel-Flarsheim Optistar LE Injection System. The Optistar LE represents our effort to provide a quality product to support better health care throughout the world. Regardless of how well equipment is designed, misuse or abuse will deny its owner the expected quality of service. Misuse or abuse may occur unintentionally because the proper method of operating the equipment is unknown. Read this manual carefully before operating the Optistar LE. Retain this manual for future reference. LIEBEL-FLARSHEIM TECHNICAL SUPPORT Phone No. 1-800-877-0791
IIntroduction
Installing Company ___________________________________ Address _____________________________________________ Phone Number _______________________________________ Software version numbers may be accessed via the System Info key on the Results screen. Console ______________________________________________ Powerhead ___________________________________________ Powerpack ___________________________________________ Optistar LE is a trademark of Mallinckrodt, Inc.
802701-C May 2003
Please regard any message that follows the word Danger, Warning or Caution!
DANGER!
WARNING!
CAUTION!
Non-Anesthetic proof
!
115V
Power ON/OFF.
Enable/Ram movement identifier: A side/B side (Light on=Enabled, Light blinking=injecting or ram is moving).
Check to ensure that no air is in syringe before injecting. Power Supply. Remote Stand Elevation Lock Fluid Detect Symbol
OPTISTAR LE
LA
US
Optistar LE CLASSIFIED BY UNDERWRITERS LABORATORIES INC. WITH RESPECT TO ELECTRIC SHOCK, FIRE AND MECHANICAL HAZARDS ONLY IN ACCORDANCE WITH UL 2601-1 33SL Optistar LE CLASSIFIED WITH RESPECT TO ELECTRIC SHOCK, FIRE MECHANICAL AND OTHER SPECIFIED HAZARDS ONLY IN ACCORDANCE WITH CAN/ CSA C22.2 NO. 601.1, 33SL
0123
Authorized EC Representative TYCO HEALTHCARE UK LTD 154 FAREHAM ROAD GOSPORT PO13 OAS UK
EMISSIONS STANDARD
The Optistar LE meets emissions standard IEC 601-1-2 Class B
Table Of Contents
Table Of Contents
REVISION HISTORY ................................................................................................. II FOREWORD ............................................................................................................ I-1 RECORDING SERIAL NUMBERS AND SOFTWARE VERSIONS ......................... I-1 MEANINGS OF SYMBOLS USED IN THIS MANUAL ............................................. I-2 MEANINGS OF SYMBOLS USED ON THE INJECTOR ......................................... I-3 CLASSIFICATION IN ACCORDANCE WITH I.E.C. 601 .......................................... I-4 Type of protection against electric shock ................................................. I-4 Degree of protection against electric shock ............................................. I-4 Degree of Protection against ingress of water ......................................... I-4 EMISSIONS STANDARD ........................................................................................ I-4
ii
1.4 CONSUMABLES ..........................................................................................1-1-5
Table Of Contents
1.4.1 SYRINGES .........................................................................................1-1-5 1.4.2 LOW PRESSURE TUBING ................................................................ 1-1-5 1.4.3 MULTIPACK DISPOSABLES ..............................................................1-1-5 1.4.4 OPTIMARK PREFILLED SYRINGES ................................................. 1-1-5
3.1 TURNING SYSTEM POWER ON/OFF .........................................................3-1-1 3.1.1 STATUS INDICATORS ........................................................................3-1-1 3.1.2 INTRODUCTION TO PROGRAMMING ..............................................3-1-2 3.1.3 INJECTION MODE .............................................................................3-1-3 3.1.4 PROGRESS SCREENS .....................................................................3-1-4 3.1.5 SINGLE PHASE INJECTION (A-SIDE) WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN ....................3-1-5 3.1.6 TWO PHASE INJECTION (A-SIDE) WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN ....................3-1-5 3.1.7 SINGLE PHASE INJECTION (A-SIDE) WITHOUT SALINE FLUSH: PROGRESS SCREEN ...........................3-1-6 3.1.8 DESCRIPTION OF STOP KEY/INFORMATION DISPLAYED ON THE PROGRESS SCREENS ...................................3-1-7 Description of the Stop Key .................................................................3-1-7 Description of Information ....................................................................3-1-7 3.1.9 DRIP MODE .......................................................................................3-1-9 3.1.9.1 ACCESSING THE DRIP MODE ......................................................3-1-9 3.1.9.2 DESCRIPTION OF PARAMETER KEYS/INFORMATION ON THE DRIP MODE SET UP SCREEN ..........................................3-1-11 How to Change Parameter Values .....................................................3-1-11 Description of Parameter Keys ..........................................................3-1-11 Description of Information Displayed on the Drip Mode Screen ........3-1-11 3.1.9.3 ACCESSING THE DRIP INFUSION SCREEN ..............................3-1-12 3.1.9.4 DESCRIPTION OF KEYS/INFORMATION ON THE DRIP INFUSION SCREEN ..................................................3-1-12 Description of Keys ............................................................................3-1-12 Description of Information ..................................................................3-1-13 3.1.10 PROTOCOL MEMORY ...................................................................3-1-14 3.1.10.1 RETRIEVING A PROTOCOL FROM MEMORY ..........................3-1-15 3.1.10.2 DELETING A PROTOCOL FROM MEMORY ..............................3-1-16 3.1.10.3 STORING A PROTOCOL IN MEMORY .......................................3-1-17 3.1.10.4 EDITING A PROTOCOL NAME .................................................3-1-18 3.1.11 INJECTION RESULTS SCREEN ...................................................3-1-18
Table Of Contents
5.1 OVERVIEW ...................................................................................................5-1-1 5.1.1 OPTISTAR SERVICE KIT (OPTIONAL P/N 801210) .........................5-1-2 Figure 5-1-1 Tool Kit ............................................................................5-1-2 5.1.2 GENERAL TROUBLESHOOTING GUIDELINES ...............................5-1-3 5.2 SYSTEM GENERATED MESSAGES ...........................................................5-2-1 Table 5-2-1 Alarm listing ......................................................................5-2-1 Alarm no. 1: ..................................................................................................5-2-2 Alarm no. 2: ..................................................................................................5-2-2 Alarm no. 3: ..................................................................................................5-2-2 Alarm no. 6: ..................................................................................................5-2-3 Alarm no. 9: ..................................................................................................5-2-3 Alarm no. 13: ................................................................................................5-2-3 Alarm no. 14: ................................................................................................5-2-4 Alarm no. 15: ................................................................................................5-2-4 Alarm no. 17: ................................................................................................5-2-5 Alarm no. 20: ................................................................................................5-2-5 Alarm no. 22: ................................................................................................5-2-5 Alarm no. 23: ................................................................................................5-2-6 Alarm no. 24: ................................................................................................5-2-6 Alarm no. 30: ................................................................................................5-2-6 Alarm no. 31: ................................................................................................5-2-6 Alarm no. 33: ................................................................................................5-2-7 Alarm no. 34: ................................................................................................5-2-7 Alarm no. 35: ................................................................................................5-2-7 Alarm no. 50: ................................................................................................5-2-8 Alarm no. 90: ................................................................................................5-2-9 5.2.1 ACTIVATING THE SYSTEM ERROR RESULTS LIBRARY .............5-2-10
Table Of Contents
vii
6.3.5 POWERHEAD CABLE REMOVAL/INSTALLATION ..........................6-3-14
Table Of Contents
6.3.6 MOTOR REMOVAL/INSTALLATION ..................................................6-3-15 6.3.7 POWERHEAD END LIMIT SENSING BOARD REMOVAL/INSTALLATION ................................................................6-3-15 6.3.8 LOAD CELL REMOVAL/INSTALLATION ...........................................6-3-16 6.3.9 END LIMIT HARNESS REMOVAL/INSTALLATION ...........................6-3-16 6.3.10 ENCODER HARNESS REMOVAL/INSTALLATION ........................6-3-17 6.3.11 SYRINGE SIZE SENSING BOARD REMOVAL/INSTALLATION .....6-3-17 6.3.12 DETENT SYRINGE HOLDER REMOVAL/INSTALLATION .............6-3-17 6.3.13 SYRINGE SIZE SENSING HARNESS REMOVAL/INSTALLATION 6-3-18 6.3.14 SYRINGE NEST HOLDER REMOVAL/INSTALLATION ..................6-3-18 6.3.15 SUPPORT ARM REMOVAL/INSTALLATION ..................................6-3-19 6.3.16 BEARING REMOVAL/INSTALLATION............................................6-3-20 Removal .............................................................................................6-3-20 Reassembly ....................................................................................... 6-3-20 6.4 POWER CONTROL ......................................................................................6-4-1 Figure 6-4-1 Power Control Assembled Unit .......................................6-4-1 6.4.1 POWER CONTROL REPLACEMENT COMPONENTS .....................6-4-2 6.4.2 BACKPLATE COVER REMOVAL/INSTALLATION .............................6-4-5 6.4.3 DRIVER BOARD (802203-1) REMOVAL/INSTALLATION .................. 6-4-5 6.4.4 COMMUNICATION BOARD (802204-1) REMOVAL/INSTALLATION . 6-4-6 6.4.5 CPU BOARD (802201-1) REMOVAL/INSTALLATION ........................6-4-6 6.4.6 POWER BOARD (802202-1) REMOVAL/INSTALLATION .................. 6-4-7 6.4.7 INTERCONNECT BOARD (802207-1) REMOVAL/INSTALLATION ...6-4-7 6.4.8 POWERHEAD MOTOR HARNESS (802212) REMOVAL/INSTALLATION ..................................................................6-4-8 6.4.9 POWERHEAD COMMUNICATION HARNESS (802213) REMOVAL/INSTALLATION ..................................................................6-4-8 6.4.10 CONSOLE COMMUNICATION HARNESS (802214) REMOVAL/INSTALLATION ..................................................................6-4-9 6.4.11 POWER SWITCH (802215) REMOVAL/INSTALLATION .................. 6-4-9
viii
6.5 POWER SUPPLY .......................................................................................... 6-5-1
Table Of Contents
6.5.1 POWER SUPPLY REPLACEMENT COMPONENTS ......................... 6-5-2 Figure 6-5-1 Power Supply Components ............................................6-5-3 6.5.2 POWER SUPPLY FUSE REPLACEMENT .........................................6-5-4 6.5.3 REMOVAL OF POWER SUPPLY UNIT ..............................................6-5-4 6.5.4 DC POWER SUPPLY REPLACEMENT ............................................. 6-5-4 6.5.5 PC BOARD REPLACEMENT .............................................................6-5-5 6.5.6 POWER ON/OFF SWITCH REPLACEMENT.....................................6-5-5 6.5.7 AC OUTLET REPLACEMENT ............................................................ 6-5-6 6.5.8 LED ASSEMBLY REPLACEMENT .....................................................6-5-6 6.6 REMOTE STAND .......................................................................................... 6-6-1 6.6.1 REMOTE STAND REPLACEMENT COMPONENTS ......................... 6-6-1 Figure 6-6-1 Remote Stand Assembly ................................................6-6-1 6.7 FILTER ..........................................................................................................6-7-1 6.7.1 FILTER ASSEMBLY ............................................................................6-7-1 Figure 6-7-1 Filter Assembly ...............................................................6-7-1 6.8 CABLES ........................................................................................................ 6-8-1 Figure 6-8-1 Cabling ........................................................................... 6-8-2 Figure 6-8-2 Cabling ........................................................................... 6-8-3 6.9 SERVICE KIT PARTS ...................................................................................6-9-1 6.9.1 LOAD CELL SERVICE KIT (P/N 802741S) ........................................ 6-9-2 6.9.2 BUSHING REPLACEMENT SERVICE KIT (P/N 802742) ..................6-9-2 6.9.3 MOTOR REPLACEMENT SERVICE KIT (P/N 802743) .....................6-9-2 6.9.4 FASTNER SERVICE KIT (P/N 802744) .............................................6-9-3 6.9.5 BEARING REPLACEMENT SERVICE KIT (P/N 802746) .................6-9-4 6.9.6 POWERHEAD TOP COVER SERVICE KIT (P/N 802747) .................6-9-4 6.9.7 SYRINGE HOLDER SERVICE KIT (P/N 802748) ..............................6-9-5 6.10 GENDER CONNECTORS ........................................................................6-10-1 6.11 ACCESSORY ITEMS ................................................................................ 6-11-1
Table Of Contents
8.1 OVERVIEW ...................................................................................................8-1-1 8.1.1 TOOLS AND EQUIPMENT NEEDED: ................................................8-1-1 8.1.2 FREQUENCY OF CALIBRATION ......................................................8-1-2 8.1.3 CALIBRATION SET-UP ......................................................................8-1-3 Figure 8-1-1 Test Unit Connections .....................................................8-1-3 8.1.4 INITIALIZATION OF THE POWER CONTROL CPU RAM: ................ 8-1-4 8.1.5 ENTERING THE CALIBRATION MODE : ........................................... 8-1-5 8.1.6 TEST DISPLAY AND TEST SWITCH DESCRIPTIONS: .................... 8-1-5 Figure 8-1-2 Test Components ............................................................ 8-1-5 8.1.7 TEST SWITCH ASSEMBLY OVERVIEW ........................................... 8-1-6 8.1.8 TEST DISPLAY OVERVIEW ..............................................................8-1-6 8.1.9 MODE DESCRIPTIONS .....................................................................8-1-7 8.2 LIMIT SWITCH CALIBRATION (MODE 0): ...................................................8-2-1 8.2.1 SETUP ...............................................................................................8-2-1 8.2.2 FOREWORD LIMIT SWITCH CHECK & ADJUSTMENT (A) ............. 8-2-2 Figure 8-2-1 Syringe and Piston ......................................................... 8-2-2 8.2.3 REVERSE LIMIT SWITCH CHECK (A) .............................................8-2-3 8.2.4 FORWARD LIMIT SWITCH CHECK & ADJUSTMENT (RAM B) ....... 8-2-3 8.2.5 REVERSE LIMIT SWITCH CHECK (RAM B) .....................................8-2-3 8.3 PRESSURE ADJUSTMENTS: (MODE 1) .....................................................8-3-1 8.3.1 RAM FACE CHECK ............................................................................8-3-1 8.3.2 SETUP ...............................................................................................8-3-2 Figure 8-3-1 Pressure gauge fixture installed ..................................... 8-3-2 8.3.3 SIDE A 60 ML SYRINGE: ................................................................8-3-3 8.3.4 SIDE B 60 ML SYRINGE: ................................................................8-3-4 8.3.5 SIDE B 125 ML SYRINGE: ..............................................................8-3-4 8.3.6 SIDE A 20 ML SYRINGES ...............................................................8-3-5 8.3.7 SIDE A 30 ML SYRINGE .................................................................8-3-5 8.3.8 SIDE B 50 ML SYRINGE .................................................................8-3-6 8.4 ADDITIONAL CHECKS (FACTORY ADJUSTED) .........................................8-4-1 8.4.1 SYRINGE SIZE FACTOR CHECK, (POWER CONSUMPTION) : ...... 8-4-1 8.4.2 EXIT CALIBRATION MODE: ..............................................................8-4-1 8.5 EXIT CALIBRATION MODE: .........................................................................8-5-1
Table Of Contents
OVERVIEW ........................................................................................................11-1-1 POWER CONTROL CPU SCHEMATIC 802201-D (1 OF 6) .............................11-2-1 POWER CONTROL CPU SCHEMATIC 802201-D (2 OF 6) .............................11-2-2 POWER CONTROL CPU SCHEMATIC 802201-D (3 OF 6) .............................11-2-3 POWER CONTROL CPU SCHEMATIC 802201-D (4 OF 6) .............................11-2-4 POWER CONTROL CPU SCHEMATIC 802201-D (5 OF 6) .............................11-2-5 POWER CONTROL CPU SCHEMATIC 802201-D (6 OF 6) .............................11-2-6 POWER SCHEMATIC 802202-2-D ...................................................................11-2-7 DRIVER BOARD SCHEMATIC 802203-C ........................................................11-2-8 COMMUNICATION BOARD SCHEMATIC 802204-A .......................................11-2-9 INTERCONNECT CPU BOARD SCHEMATIC 802205-A ............................... 11-2-10 INTERCONNECT DRIVER BOARD SCHEMATIC 802206-A .........................11-2-11 INTERCONNECT CPU UNIVERSAL SCHEMATIC 802208-A (1 OF 2) .........11-2-12 INTERCONNECT CPU UNIVERSAL SCHEMATIC 802208-A (2 OF 2) .........11-2-13 CONSOLE SCHEMATIC 802101-C (1 OF 5)....................................................11-3-1 POWERHEAD SCHEMATIC 802301-D (1 OF 4) .............................................. 11-4-1 POWERHEAD SCHEMATIC 802301-D (2 OF 4) .............................................. 11-4-2 POWERHEAD SCHEMATIC 802301-D (3 OF 4) .............................................. 11-4-3 POWERHEAD SCHEMATIC 802301-D (4 OF 4) .............................................. 11-4-4 END LIMIT SENSING SCHEMATIC 802302-A .................................................11-4-5 SYRINGE SIZE SENSING SCHEMATIC 802307-A .........................................11-4-6 POWER SUPPLY SCHEMATIC 802451-B .......................................................11-5-1 HAND BUTTON 802620/802622 ......................................................................11-6-1 POWERHEAD CABLE 802303-A .....................................................................11-7-1 DATA CABLE 801224 .......................................................................................11-7-2
1-1-1
INTRODUCTION
1Overview
The purpose of this manual is to provide instructions for installation, service and calibration of the Optistar LE. For further information about operation and daily maintenance of the unit, refer to the Optistar LE Operators Manual.
1.3.1 DIMENSIONS Console: 12.25W x 8.5H x 2.5D (311.15mm x 215.9mm x 63.5mm) Console Base: 9.5W x 2.5H x 7D (241.3mm x 63.5mm x 177.8mm) Power Control: 10.W x 4.25H x 15.25D (254mm x 107.95mm x 387.3mm) Remote Stand: 27W x 43H x to 53H (adjustable) (685.8mm x 1092.2mm H to 1346.2mm adjustable) Powerhead: 7W x 21.5H x 5.5D (177.8mm x 546.1mm x 139.7mm) Filter: 4W x 10.00H x 3D (101.6mm x 254.00mm x 76.2mm) Power Supply: 10W 4.25H x 9.5D (254mm x 107.95mm x 241.3mm) 1.3.2 WEIGHT Control Console: 5.8lb. (2.6 kg) Power Control: 16lb. (7.26 kg) Powerhead (w/arm and cable) 14.5lb. (6.57 kg) Remote Stand: 29lb. (13.00 kg) Power Supply: 11.5lb. (5.21 kg) Filter: 10lb. (4.54 kg) 1.3.3 POWER REQUIREMENTS Power Supply Voltage Frequency Current
1-1-3
1.3.4 ELECTRICAL LEAKAGE
1Overview
Chassis: Less than 300 microamps 1.3.5 ENVIRONMENTAL Transport and Storage: -4F to 140F (-20C to 60C); 10% to 100% relative humidity Disposable Products: -40F to 118F (-40C to 48C); 10% to 100% relative humidity Operation: +59F to 95F (15C to 35C) 30% to 75% relative humidity; 700kPa to 1060kPa atmospheric pressure Biohazard Disposal: Dispose of biohazards in accordance with the requirements of you hospital, facility or local regulations Electromagnetic Compatibility (EMC): The Optistar LE meets EN60601-1-2 for level B conducted and radiated emissions and EMI immunity NOTE: If any anomalies in the injector performance are noticed, identify devices within the immediate area that are capable of producing electromagnetic interference and call a qualified service representative. DANGER! Possible explosion hazard if used in the presence of flammable anesthetics.
WARNING!
The injector console and power supply may only be operated in an area that is located beyond the 5 gauss limit. Operating the console or power supply within magnetic fields that are higher than this limit may cause the unit to malfunction, resulting in operator or patient injury.
WARNING!
Only the powerhead is considered spill proof. If fluid is spilled on the console, power supply, or power control, remove the unit from operation and contact your authorized service personnel.
1-1-4
1.3.6 SYRINGE SIZE
1Overview
Mallinckrodt 10 ml, 15 ml, 20 ml, 30 ml contrast prefilled syringe. Mallinckrodt 60 ml single-use, disposable syringe. Mallinckrodt 50 ml, and 125 ml saline prefilled syringe. 1.3.7 PROGRAMMABLE FLOW RATE (A SIDE) 60ml syringe - 0.1 - 10.0 ml/s 10, 15, 20 ml, and 30 ml syringe - 0.1 - 8.0 ml/s 1.3.8 PROGRAMMABLE FLOW RATE (B SIDE) 50 ml and 125 ml saline prefilled syringe - 0.1 - 8.0 ml/s 60 ml single-use, disposable syringe - 0.1 - 8.0 ml/s 1.3.9 PROGRAMMABLE VOLUME (A SIDE) 60 ml: 1 ml to installed syringe size 10, 15, 20, and 30 ml syringe: 1 ml to installed syringe size 1.3.10 PROGRAMMABLE VOLUME (B SIDE) 50 ml and 60 ml syringe: 1 ml to installed syringe size 125 ml syringe: 1 to 60 ml (software limited) 1.3.11 PROGRAMMABLE PRESSURE LIMIT (A SIDE) 10, 15, 20, and 30 ml syringe: 20 - 200 PSI in increments of 20 PSI 60 ml: 20 - 150 PSI in increments of 20 PSI 1.3.12 PROGRAMMABLE PRESSURE LIMIT (B SIDE) 50 ml syringe: 200 PSI 60 ml syringe: 150 PSI 125 ml syringe: 100 PSI 1.3.13 SCAN DELAY TIMER 0 to 60 seconds in increments of 1 second 1.3.14 STORED PROTOCOLS The Optistar LE can store up to 20 protocols in memory. 1.3.15 INJECT RESULTS The Optistar LE stores the results of the last 12 injected protocols.
This device has been approved for use with only the consumables listed below. Use of other consumables could result in patient injury, operator injury, equipment damage, and/or injector performance issues (i.e. incorrect volume delivery, incorrect flow rate delivery, incorrect pressure, etc.). Safety certification of the cunsumables listed below has been performed in accordance to the appropriate EN 60601-1 and/or EN 60601-1-1 harmonized national standard. 1.4.1 SYRINGES P/N 801801: Case - 60ml Optistar LE Syringe available from Mallinckrodt 1.4.2 LOW PRESSURE TUBING P/N 801106: 60 Coiled Y Tubing available from Mallinckrodt P/N 801107: 90 Coiled Y Tubing available from Mallinckrodt P/N 601195: 60 Coiled Tubing available from Mallinckrodt 1.4.3 MULTIPACK DISPOSABLES P/N 801800: Two 60ml Optistar LE syringes with 90 Coiled Y Tubing available from Mallinckrodt 1.4.4 OPTIMARK PREFILLED SYRINGES NDC Code 0019-1177-10 10ml. NDC Code 0019-1177-15 15ml. NDC Code 0019-1177-20 20ml. NDC Code 0019-1177-30 30ml.
1-1-6
1Overview
2-1-1
2
2.1 GENERAL
B 60 50 ml ml
125 ml
Handswitch
Figure 2-1-1 System Components Note: Power cables supplied with your system are determined by voltage requirements as follows: *For 115V models, use cable Part Number is 800918 *For 230V models, use cable Part Number is 800935
A SIDE
Reverse Button
Syringe Adapter
Stop Button
Powerhead Ram A
ml 10/15/ 30 60 20 m ml l
B 60 50 m m l
125 m l l
B SIDE
Powerhead Ram B
(Rear View)
(Front View)
ON/OFF Indicator
3-1-1
BASIC OPERATIONS
The intent of this chapter is to provide maintenance personnel with a basic overview of operational features of the Optistar LE injection system. For indepth operational information refer to the operators manual.
3-1-2
3.1.2 INTRODUCTION TO PROGRAMMING All programming takes place at the Optistar LE consoles touch-sensitive screens. Base functions are as follows: Inject Mode Progress Screens Drip Mode Protocol Memory Injection Results/System Info screens Selecting and modifying information is accomplished by touch screen keys, and screen value touch targets. The definition for each term is as follows: Touch Screen Key: A touch screen key is used to select another display mode (example: Drip Mode), or to reset screen value information. Touch screen keys are presented as rectangular boxes, gray in color, with white lettering. Touch Screen Values: Contain information about the protocol parameters (example: Volume ml, Flow Rate ml/sec). Touch screen values are presented in rounded corner boxes, light blue in color, with white lettering. To change any one of these parameters, touch its screen value to highlight, then use the slider bar at the bottom of the screen to increase or decrease the value. Using your finger, you can touch the bar at the value you require, then use the left and right arrows to maker smaller adjustments.
3BASIC OPERATION
3-1-3
3.1.3 INJECTION MODE Pressing the consoles Inject Mode key A allows the operator to select from the following three modes: Single phase contrast injection (A-side) without saline flush Single phase contrast injection (A-side) with single phase saline flush (B-side) Two phase contrast injection (A-side) with single phase saline flush (B-side)
A: 60 ml
60
Scan Delay
Flow
ml/sec
Volume
ml
0
PSI
0.0
60
Max Vol
200
Drip
Time 1:30
3BASIC OPERATION
Memory
Inject Mode
Results
A
Figure 3.1.1 Inject Mode Screen
3-1-4
3.1.4 PROGRESS SCREENS After pressing the Air Check key on the powerhead, a Start key A appears in the top right of the screen. The operator may use this Start key, the Start key on the powerhead, or the Hand Start switch to begin the injection. The Progress screen is then displayed to follow the injections progress.
A
A: 60 ml
Volume Remaining
Start
60
Scan Delay
FLOW ml/sec
Volume
ml
0
PSI
0.0
Time
0.0
1:30
Max Vol
200
Drip
3BASIC OPERATION
Disable
3-1-5
3.1.5 SINGLE PHASE INJECTION (A-SIDE) WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN
Flow
ml/sec
Volume
ml
Time
0:00
Scan Delay
0.0
0.0
A
0 50 100
60
150
ml
200
Pressure PSI
Stop
Flow
ml/sec
Volume
ml
0.0
0.0
60
ml
Figure 3-1-3 Single Phase Injection with Saline Flush: Progress Screen 3.1.6 TWO PHASE INJECTION (A-SIDE) WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN
Flow
ml/sec
Volume
ml
3BASIC OPERATION
Time
PH1 PH2
0.0 0.0
0.0 0.0
0:00
Scan Delay
A
0 50 100
0:00
60
150
ml
200
Pressure PSI
Stop
Flow
ml/sec
Volume
ml
0.0
0.0
60
ml
Figure 3-1-4 Two Phase Injection with Saline Flush: Progress Screen
802701-C May 2003
3-1-6
3.1.7 SINGLE PHASE INJECTION (A-SIDE) WITHOUT SALINE FLUSH: PROGRESS SCREEN
Flow
ml/sec
Volume
ml
Time
0.0
0.0
0:00
Scan Delay
A
0 50
0:00
60
100 150
ml
200
Stop
Pressure PSI
3BASIC OPERATION
3-1-7
3.1.8 DESCRIPTION OF STOP KEY/INFORMATION DISPLAYED ON THE PROGRESS SCREENS Refer to Figure 3-1-6. Description of the Stop Key The Stop key A is available on the console to stop the injection at any time. Also, any key on the powerhead or pressing the hand start switch will stop an injection. For more information about delivering an injection, see Chapter 5Delivering an Injection In the Operators Manual. Description of Information
B The triangles in front of the syringe symbol flash to indicate delivery of the injection. The two-phase progress screen also flashes the phase currently being delivered.
C The amount of volume remaining in the syringe is displayed within the syringe symbol. D The protocols programmed Flow and programmed Volume is displayed. Time E is a counter that returns the screen to the set up mode when it reaches 15:00 (15 minutes). Scan Delay F counts down from the start of an injection so the operator may accurately delay the scanner. An audible warning is emitted at the expiration of the scan delay time. The Pressure Indicator G shows the current pressure on the A side only.
3BASIC OPERATION
3-1-8
D
Flow
ml/sec
E
Volume
ml
Time
PH1 PH2
C B D
0.0 0.0
0.0 0.0
0:00
Scan Delay
A
0 50 100
0:00
60
150
ml
200
Pressure PSI
Stop
Flow
ml/sec
G A
Volume
ml
B
C
0.0
0.0
60
ml
3BASIC OPERATION
3-1-9
3.1.9 DRIP MODE This mode is used to keep the injection pathway open during patient set up and between injections of contrast. The injector delivers a series of small volumes, or drip injections, of saline from syringe B. 3.1.9.1 ACCESSING THE DRIP MODE Drip Mode is accessed via a key A located on any three of the inject mode screens. Refer to Figures 3-1-7, 3-1-8, and 3-1-9.
A: 60 ml
60
Scan Delay
Flow
ml/sec
Volume
ml
0
PSI
0.0
60
Max Vol
200
Drip
Time 1:30
3BASIC OPERATION
Memory
Results
Figure 3-1-7 Location of the Drip Mode key on the Single Phase Injection Setup Screen
3-1-10
Drip Mode
B
60
Drip Volume 60 ml
Flow
ml/sec
Volume
ml
Interval
sec
0.0
0.0
0.0
J
Drip Mode
3BASIC OPERATION
I
60 ml
H
Drip Time 0:00 Hr:Min
CANCEL
B
60
Drip Volume
G F E
D C
Flow
ml/sec
Volume
ml
Interval
sec
0.0
0.0
0.0
B A
Figure 3-1-9 Description of Parameter Keys and Information on the Drip Mode Screen
3-1-11
3.1.9.2 DESCRIPTION OF PARAMETER KEYS/INFORMATION ON THE DRIP MODE SET UP SCREEN Refer to Figure 3-1-9. How to Change Parameter Values To change the value of a parameter, select the desired parameter by touching its key. The key will highlight to indicate it is active. Using the slide bar A located at the bottom of the screen, touch the bar at the value required, then use the left and right arrows B to decrease or increase the value in smaller increments. Description of Parameter Keys Flow C is the rate of delivery of the saline solution (B-side syringe). Flow rate is expressed in ml/s. Volume D is the amount of saline delivered during each drip injection. Interval E is the amount of time the injector pauses between each delivery of drip injections. Check for air in syringe and tubingmessage F acts as a reminder to the operator to confirm no air exists in the syringe and tubing prior to enabling a Drip injection. If air is found in any part of the delivery system, take appropriate action to remove all air. This message changes to a Start key once the air-check key[ ] located on the powerhead has been pressed. Pressing Start will begin the drip injection and display the Drip Infusion screen. Pressing the Cancel key G will exit the Drip Mode screen and return to the Injection setup screen from where the Drip Mode was accessed. Description of Information Displayed on the Drip Mode Screen Drip Volume I is calculated by the injector by subtracting the programmed Volume value (B-side) from the Volume Remaining value (B-side) from the Injection Set up screen. Drip Time H is calculated by the injector by the following formula: Drip Cycles = Drip Volume/Volume Drip Cycle Time = Volume/Flow + Interval Drip Time = Drip Cycles X Drip Cycle Time J A graphic representation of the volume remaining in the syringe is displayed.
3BASIC OPERATION
3-1-12
3.1.9.3 ACCESSING THE DRIP INFUSION SCREEN Pressing the Start key on the Drip Mode screen begins the drip injection and displays the Drip Infusion screen. See Figure 3-1-10. The Powerhead ram of syringe B delivers a drip injection of the operator programmed flow and volume. Once the volume is delivered, the ram will pause until the operator programmed interval has expired. This cycle continues until the Drip Volume is delivered.
Drip Infusion
Drip Volume 60 ml
Drip End
Stop and
return to:
Drip
Inject Mode
Flow
Volume ml/sec
Interval
0.8
0.0
ml
10
sec
3.1.9.4 DESCRIPTION OF KEYS/INFORMATION ON THE DRIP INFUSION SCREEN Refer to Figure 3-1-11. Description of Keys Pressing the Drip key A will exit the Drip Infusion screen and return to the Drip Mode screen. Pressing the Inject Mode key B will exit the Drip Infusion screen and display the Injection setup screen from where the Drip Mode was accessed. Also, pressing the Stop key on the powerhead or pressing once on the hand start switch will exit the Drip Infusion screen and display the Injection setup screen from where the Drip Mode was accessed.
3-1-13
Description of Information C The protocols programmed Flow, programmed Volume and programmed Interval is displayed at the bottom of the screen. D The calculated Drip Volume and Drip Time is displayed in the upper right-hand corner. E A graphic representation of the volume remaining in the syringe and the end of the drip injection is displayed. Also, the saline drops located under the syringe symbol flash to indicate delivery of the drip injection.
E
Drip Infusion
D
Drip Volume 60 ml Drip Time 0:00 Hr:Min
Drip End
Stop and
return to:
Drip
A B
3BASIC OPERATION
Inject Mode
Flow
Volume
Interval
0.8
ml/sec
0.0
ml
10
sec
C
Figure 3-1-11 Description of Parameter Keys and Information on the Drip Infusion Screen
3-1-14
3.1.10 PROTOCOL MEMORY The Memory key A , located in the lower left-hand corner of the display (see Figure 3-112), allows access to the Memory List screen as shown in Figure 3-1-13. The Optistar LE can store up to 20 protocols with a name length of up to 20 characters.
A: 60 ml
60
Scan Delay
Flow
ml/sec
Volume
ml
0
PSI
0.0
60
Max Vol
200
Drip
Time 1:30
Memory
Inject Mode
Results
A
3BASIC OPERATION
Memory List
Page 1
DELETE EDIT NAME A ml 40 47 46 5 13 STORE B PSI 83 72 72 ml/sec 9.0 7.8 7.8 ml 50 27 3 Scan Delay 17 26 60 ml/sec
S D V
2.0
60
120 Results
44
Inject Mode
3-1-15
3.1.10.1 RETRIEVING A PROTOCOL FROM MEMORY Refer to Figure 3-1-14. 1. Press the Memory key 1 to access the Memory List screen. 2. Press on the desired protocols name key 2A . If the desired protocol name is not displayed on Page 1, press the Memory> key 2B to display the page where the desired protocol name is displayed. Once the protocol name is displayed, press on its key 2A . 3. The protocol 3 is immediately displayed on the screen.
A: 60 ml
Check for air in syringe and tubing
Volume Remaining
3
A: 60 ml B: 60 ml
60
Scan Delay
Protocol 1
Flow
ml/sec
Flow
ml/sec
Volume
ml
0
PSI
Volume
ml
Volume Remaining
60
Scan Delay
2.0
16
Max Vol
200
Drip
2.6
40
Max Vol
17
PSI
Time 0:08
90
Volume Remaining
Volume
ml
60
Drip
B
Memory Inj. Mode
9.0
50
Max Vol
>
Results
Memory
Results
Memory List
Page 1
DELETE EDIT NAME A ml 40 47 46 5 13 STORE B PSI 90 72 72 ml/sec 9.0 7.8 7.8 ml 50 27 3 Scan Delay 17 26 60
3BASIC OPERATION
ml/sec
Protocol 1
Dr Wagner Protocol 2
2B
2.0
16
200 Results
Inject Mode
3-1-16
3.1.10.2 DELETING A PROTOCOL FROM MEMORY Refer to Figure 3-1-15. 1. Press the Memory key 1 to access the Memory List screen. 2. If needed, press the Memory> key 2 to locate the desired protocol to delete. 3. Press the Delete key 3A then the Protocols name key 3B . 4. Press the Yes key 4 located under the Are You Sure? prompt. 5. The protocol is deleted.
A: 60 ml
Check for air in syringe and tubing
Volume Remaining
60
Scan Delay
Memory List
Page 1
No
DELETE
Flow
ml/sec
Volume
ml
0
PSI
PSI 90 72 72 80 72 200
ml 50 27 3 ---Results
2.0
16
Max Vol
200
Drip
Time 0:08
Memory
Results
2.0
Inject Mode
Memory List
Page 1
DELETE EDIT NAME A ml 40 47 46 5 13 30 50 20 16 STORE B PSI 90 72 72 80 72 200 Results ml/sec 9.0 7.8 7.8 ml 50 27 3 Scan Delay 17 26 60
3A
3BASIC OPERATION
Protocol 1
ml/sec 2.6 3.3 6.0 3.3 6.0 5.0 3.3 5.0 2.0
3B
Inject Mode
3-1-17
3.1.10.3 STORING A PROTOCOL IN MEMORY Refer to Figure 3-1-16. 1. Select the desired Inject Mode and enter desired parameters. 2. Press the Memory key 2A to access the Memory List screen. Note the parameters entered in Step 1 are shown at the bottom of the Memory List screen 2B . 3. Press the Store key 3 . NOTE: The Store feature only works when an empty memory location is available. To delete the contents of a memory location, refer to section 3.6.2 Deleting a Protocol from Memory. 4. Locate an empty key 4A . If all the key locations on Page 1 are filled, press the Memory> key 4B to access a page with an empty key. 5. Press on the empty key to store the protocol in its location. The keyboard is displayed 5 to allow naming of the protocol. 6. Press the Enter key 6 on the keyboard. The protocols parameters and name is stored in the selected location.
A: 60 ml
Check for air in syringe and tubing
Volume Remaining
5
Memory List
Page 1
DELETE EDIT NAME A ml STORE B PSI ml/sec ml Cancel Scan Delay
60
Scan Delay
Flow
ml/sec
Volume
ml
0
ml/sec
PSI
2.0
16
Max Vol
200
Drip
Test
4 T G V Space 200 Results 5 Y H B 6 U J N <7 I K M Enter 8 O L 9 P
Time 0:08
Memory
Inject Mode
Results
Curent Value
2.0
3BASIC OPERATION
Memory List
Page 1
DELETE EDIT NAME A ml 40 47 46 5 13 STORE B PSI 90 72 72 ml/sec 9.0 7.8 7.8 ml 50 27 3 Scan Delay 17 26 60 ml/sec
4A 2B 4B
Curent Value Memory > 2.0 16 200 Results
Inject Mode
3-1-18
3.1.10.4 EDITING A PROTOCOL NAME Refer to Figure 3-1-17. 1. Press the Memory key 1 to access the Memory List screen. 2. If needed, press the Memory> key 2 to locate the desired protocol name to edit. 3. Press the Edit Name key 3A , then the Protocols name key 3B . The keyboard with the protocols name appears 3C . 4. Using the keyboard, enter the new name. 5. Press the enter key 5 . The Memory List screen, along with the renamed protocol, is displayed.
A: 60 ml
3C
Memory List
Page 1
DELETE EDIT NAME A ml STORE B PSI ml/sec ml Cancel Scan Delay
60
Scan Delay
Flow
ml/sec
Volume
ml
0
ml/sec
PSI
2.0
16
Max Vol
200
Drip
Dr Wagner
4 T F C G V Space 200 Results 5 Y H B 6 U J N <7 I K M Enter 0 8 O L 9 P
Time 0:08
Test 1 Protocol 7
Memory Inj. Mode >
Caps On
Results
2.0
Inject Mode
3A
3BASIC OPERATION
Memory List
Page 1
DELETE EDIT NAME A ml 40 47 46 5 13 30 50 20 16 STORE B PSI 90 72 72 80 72 200 Results 0 ml/sec 9.0 7.8 7.8 ml 50 27 3 Scan Delay 17 26 60 ml/sec
Protocol 1
3B
Inject Mode
3-1-19
The Injection Results screen is accessed via a key A located on any three of the inject mode screens. Refer to Figure 3-1-18. Page 1 of the Injection Results screen lists the last 6 injections completed by date and time in descending order. Press the Results key once again to list injections. The results include the following information for each of the two phases in the A-side (if appropriate) and for the B-side: Flow Ratethe programmed flow rate, Volumethe achieved volume PSIMaximum injection pressure achieved (only for the A-side)
A: 60 ml
Check for air in syringe and tubing
Volume Remaining
60
Scan Delay
Flow
ml/sec
Volume
ml
0
PSI
2.0
16
Max Vol
200
Drip
Time 0:08
Memory
Results
A:
Flow 2.2 Vol 9 17 13 11 13 9 11 13 18 189 26 PSI 4 Flow 1.5 7.8
B:
Vol 125 -
3BASIC OPERATION
7.8
26 Jan 01 09:22
15
1.5 7.8
10 -
26 -
1.5
10
Memory
Inject Mode
Results
System Info
3-1-20
3BASIC OPERATION
4-1-1
This chapter contains maintenance procedures for the Optistar LE injector. Guidelines for periodic inspections, testing, cleaning and lubrication are included. Information about assembly and disassembly of the unit is contained in chapter 6. A checklist is included in the front pocket of this manual. Fill in the necessary information on a copy of the checklist. WARNING! Preventive Maintenance on any unit must be performed by a Qualified Technician who is completely familiar with the use and operation of the Injector, trained by a Mallinckrodt instructor in the area of preventive maintenance for the Injector and familiar with the content of the Operators manual and the Installation and Service manual.
A SIDE
Reverse Button
Stop Button
ml 10/15/ 30 60 20 ml ml
B 60 50 ml ml
125 ml
B SIDE
Powerhead Ram B
4-2-2
4.2.3 POWERHEAD OPERATIONS 1. Remove syringes from the powerhead. Power up system. 2. On the A side, press and hold the powerhead Accelerator Button, then press and hold either the Forward Button, or Reverse Button. Ensure ram moves freely in both forward and reverse directions. Also, verify that the ram LEDs come on during this procedure. 3. Repeat step 2 for the B side. 4. Exercise A side ram movement by pressing the Forward Button, or Reverse Button. Ensure ram moves freely in both forward and reverse directions. 5. Repeat step 4 for the B side. 6. Program an A & B injection. Press the Air Check button to enable the injection, then press the Start button. The injections you programmed should have activated verifying the powerhead Start button and Air Check button are functioning properly. 4.2.4 CONSOLE OPERATIONS 1. Turn on the Power Control, and Power Supply. 2. On the console, Press the Power ON/OFF button. The system should power up. After initialization, the last exited injection mode will be displayed. Also, the ON/ OFF LED button should be on. 3. Press the Inject Mode button several times. The inject mode displayed should change each time it is pressed.
4MAINTENANCE CHECKOUT PROCEDURES
4. Press the Results button. The first 6 injections will be displayed. Press the Result button again display injections 7 through 12. The results listed are injections completed by date and time in descending order. 5. Press the Memory button. The first 5 protocols for the injection mode selected should be displayed. Continue to press the Memory button to increment pages through all 20 protocols. 6. Press the Store button. Press a memory location box, then key in a Memory name. Press the Enter button. The Current Value programmed information will be entered in the memory location you selected. To edit the memory name or delete it, simply use the buttons provided.
4-2-3
4.2.5 REMOTE START OPERATIONS 1. Program an A & B injection. Press the Air Check button on the Powerhead. Press and release the Remote Start Button. The injection should have activated verifying the properly operation. 2. During an injection cycle, Press the Hand button. The injection should stop with the injection mode screen displayed. 4.2.6 POWERHEAD STOP BUTTON CHECK 1. Power up the system 2. With no syringe present, program an injection for either A or A & B rams. 3. On the Powerhead, press the Air Check button, then press the Start button. During ram movement observe the Powerhead injection indicators. The injection indicator light for the ram in motion should be flashing. 4. With ram movement taking place, press the Powerhead Stop Button. Ram movement should stop and the Console will return to the injection mode screen. 4.2.7 SYRINGE DETECTION CHECK 1. Power up system as previously described. 2. Place 60mL syringe in the A & B side of the injector head. 3. Verify console screen and powerhead indicates "60 mL syringe". 4. Remove syringes. Then place 30mL syringe in the A & B side of the injector head. 5. Verify console and powerhead indicates "30 mL syringe" for the A side, and "50 mL syringe" for the B side. 6. Remove syringes. Then place 10/15/20 adaptor in the A side. Verify console and powerhead indicate 10/15/20. 7. Place 125mL syringe in the B side. Verify console and powerhead indicate 125mL syringe.
4MAINTENANCE CHECKOUT PROCEDURES
4-2-4
4.2.8 LIMIT SWITCH CHECK The purpose of this check is to verify limit switch board (positioned in the Powerhead) settings were not disturbed during shipment. 1. Power up the system as previously described 2. Using the Powerhead controls, fully retract both Powerhead ram. 3. Place a 60 mL syringe in the A Powerhead ram. 4. On the Powerhead, press and hold the A side Forward Button until ram motion stops. Observe the 0 mark on the syringe, the front wiper should be engaging the 0 mark. Also, on the Console screen, observe the Volume Remain field, it should be 0.0.
0 ml
Figure 4-2-2 Press and hold the A side Reverse Button until ram retraction motion stops. Verify on the Console screen, the Volume Remain field, is 63 mL. Repeat step 4 procedures for the B side Ram. If adjustments are required, refer to Chapter 8.
4-2-5
4.2.9 RAM FACE CHECK, REFER TO APPENDIX A, INSTALLATION INSTRUCTIONS 802702. 4.2.10 INJECTION PRESSURE VERIFICATION, REFER TO APPENDIX A, INSTALLATION INSTRUCTIONS 802702
4-2-6
4-3-2
5-1-1
5
5.1 OVERVIEW
TROUBLESHOOTING
The intention of the Chapter is to deliver information to the service technician in order to track a problem to a subassembly so it can be replaced or repaired. When a problem exists with the Optistar LE, a message will be displayed on the console screen. A complete listing of these messages and their probable cause is contained in this chapter. Instructions for disassembly and reassembly of major injector components are defined in chapter 6.
5TROUBLESHOOTING
5-1-2
5.1.1 OPTISTAR SERVICE KIT (OPTIONAL P/N 801210) The tools listed below are supplied in the Optistar service kit. This kit is required for Optistar LE troubleshooting and calibration procedures.
Part # 801216
Comments Recommended to keep all the unique tools together Required for Calibration Required for Calibration Required for Calibration Required for Calibration
Pressure Calibration Fixture Test Display Test Switch Assembly Cable Assembly 26 Position Socket to Socket. Length 18 inches Cable Assembly 20 Position Socket to Pin. Length 18 inches Screwdriver Titanium #2 Phillip
801212
801213
Required for any disassembly within magnet room Required for D-shell backshell removal Required for adjustment of Powerhead pivot (Optistar MR only). Required for removal of Powerhead from stand and adjustment of Powerhead pivot within magnet room. Required for adjustment of Powerhead pivot with magnet room. Required for adjustment of Powerhead pivot within magnet room (Optistar MR only). Required to calibrate Optistar LE Required for testing outside of magnet room.
801257
5TROUBLESHOOTING
801200
801214
801215
801254-10
802713 801224-07
5-1-3
5.1.2 GENERAL TROUBLESHOOTING GUIDELINES We suggest these actions when first troubleshooting the Optistar LE; things to try before taking anything apart, and to make the job easier. 1. Check indicator lights on Power Supply and Power Control to ensure adequate power is present. 2. Verify the problem. Check the injector under the same conditions and settings that it had when the problem occurred. If possible, try the injector in an isolated setting to see if the problem can be duplicated. 3. Try different settings. Check the injector with different control settings than it had when the problem occurred. Change the flow rate, volume and pressure. If another size syringe is available, try it. 4. Use the checkout in chapter 4. This is a relatively quick way to check the major functions. This is especially helpful if the accuracy is in question. 5. Visually inspect subassemblies and components before performing electrical tests or calibration procedures. Specifically make sure cable plugs are firmly attached, and cables are not crimped, or under tension. If the trouble is in the powerhead, open the powerhead cover and inspect the powerhead while it operates. Look for loose parts, loose connections, interference, and wear. 6. Isolate the fault. While trying different settings, and under different conditions, try to isolate the specific problem. 7. Call your sales representative for service assistance, field service, and for replacement parts or modules. If the system is new, still under warranty, or covered under a service contract, call your sales representative before proceeding. CAUTION! Be extremely careful when the Optistar LE is open. Lethal voltages are exposed. Be careful not to leave an open system unattended with power plugged in. DISCONNECT THE POWER CORD BEFORE REMOVING OR REPLACING BOARDS.
5TROUBLESHOOTING
5-1-4
5TROUBLESHOOTING
Fault Message Pressure Limit Alarm Over Volume Alarm Over Flow Rate Alarm Motor Alarm Invalid Powerhead Pressure Measurement Alarm Forward/Reverse Limit Sensor Alarm Motor Control Watchdog Alarm Changed Syringe Size Sensing Alarm Power-On Self Test Alarm Protocol Parameter Alarm Syringe Pressure is less than Expected Alarm Power Control NV Memory Checksum Alarm Power Control Firmware Checksum Alarm Touchscreen Alarm Remote Start Switch Connection Alarm Console Protocol Memory Checksum Alarm Console Program Checksum Alarm Unknown Error/timing error Power Control not Detected Alarm Power Control/Console Communication Alarm
5TROUBLESHOOTING
5-2-2
Alarm no. 1: Meaning: Pressure limit malfunction Cause: There are four possible causes for a Pressure Limit Malfunction: measured pressure exceeding the maximum pressure limit for more than one second. the measured pressure value not changing within the last 10 seconds. the motor reversing direction for 2 consecutive seconds. if the servo becomes overheated. Ram face has become jammed on load cell holder Bad cable at J5 or J6 on the Powerhead board Check: An obstruction in the tubing or catheter caused an alarm. Make sure the injection tubing is not kinked or pinched. If any stopcock values are in line, make sure they are open. Verify that the operator is not trying to program high flow rates into a small needle. Keep in mind that the B side may have a low pressure limit. In some cases the operator could program a high pressure (180 to 200 psi limit) A side injection followed by a B side. Immediately after the injector completes side A, side B will start. If the residual pressure from the side A injection exceeds the pressure limit for side B the injector may trigger a pressure limit malfunction alarm or a hardware alarm. Alarm no. 2: Meaning: Volume over error.
5TROUBLESHOOTING
Cause: The volume delivered exceeded the programmed volume by more than 1 ml. The error is generated from the UPP injector volume counter because it reached the set value plus 1 ml. Check: Position calibration, optical encoders on motors, loose connector or printed circuit board. Alarm no. 3: Meaning: Flow Rate malfunction. Cause: The optical encoders are used to control and monitor the flow rate. If the flow rate exceeds the programmed flow rate this alarm will appear. The encoder signals are monitored by the UPP counter on the microprocessor board. Check: Optical encoders, loose connectors or printed circuit board.
5-2-3
Alarm no. 6: Meaning: Motor malfunction. Cause: A-side or B-side motor encoder signals are disconnected during an injection. Possible causes are: Faulty motor driver board in the power control. Faulty motor in powerhead. Faulty connection to motor or motor encoder. Overheated. Fluid path blocked. Pressure limit is programmed to low. Check: Verify that the powerhead ram is functioning by pressing the forward or reverse buttons on the powerhead. Alarm no. 9: Meaning: Invalid Powerhead Pressure Measurement Cause: The pressure measurement has generated a raw A/D value of 250 counts or more. Check: Replace CPU board in Power Control Call Technical Support. Alarm no. 13: Meaning: FWD/REV limit sensor malfunction. Cause: The A side and B side position limit switches are checked for both forward and reverse switches being active at the same time. Alarm can occur at power on check or during operation. Possible causes are: Faulty limit switch board. Dirt is blocking light path. Loose connection (?).
5TROUBLESHOOTING
5-2-4
Check: Call Service. Alarm no. 14: Meaning: Motor Control Watchdog Alarm. Cause: The FPGA chip on the CPU board which controls motion contains a watchdog timer. If this watchdog timer is not reset every 500ms or less, this alarm will be activated. Possible causes are: CPU board malfunction. Check: Call Technical Support. Alarm no. 15: Meaning: Changed Syringe Size Alarm. Cause: During an injection the syringe sensor detected that the syringe size changed which should not occur. Possible causes: If the alarm occurs while a syringe adapter is installed, the syringe adapter may be moving and causing the syringe sensing switch to momentarily change syringe sizes. Faulty syringe sensor switch.
5TROUBLESHOOTING
Faulty adapter. Faulty bottom cover. Faulty connection to syringe sensor. Check: If the powerhead displays an incorrect syringe size, inspect the syringe size switches for accumlated contrast sticking, an obstruction in the flange slot, or defective powerhead PCB. Note: Do not change syringe on either the A or B side until the entire injection sequence is complete.
5-2-5
Alarm no. 17: Meaning: Power On Self Test Failure. Possible causes: Any one of the powerhead forward, reverse, fast, start, stop, and check switches are closed during Power On Self Test. Faulty Console RAM/ROM Memory. Faulty Power Control RAM/ROM Memory. Faulty UPP chip. Faulty pressure sensor. Check: A powerhead switch was unintentionally pressed during the power on sequence. This includes changing syringe sizes during power on. Alarm no. 20: Meaning: Protocol Error. Cause: CRC value appended to the volume and flow rate from the console did not match the value calculated by the power control. Possible causes are: Faulty communication link between the Console and Power Control. Incompatible software versions between Console and Power Control Check: Call Technical Support. Alarm no. 22: Meaning: Syringe Pressure is Less Than Expected. Note: Injection ran while in the 10/15/20 or 30mL modes. Cause: Will cause alarm 22 if no back pressure is developed at 4mL after start of injection. Check: Verify that the syringe push-rod is making contact with A side ram. An empty syringe can also cause this error.
5TROUBLESHOOTING
5-2-6
Alarm no. 23: Meaning: Power Control NV Memory Checksum Alarm. Cause: NV memory checksum does not agree with its last saved checksum. Check: If software has just been downloaded into the Power Control CPU board, refer to section 10.2.1. Replace CPU Board in the Power Control. Call service. Alarm no. 24: Meaning: Power Control firmware Checksum Alarm. Cause: Power Control firmware checksum does not agree with its known checksum. Check: If software has just been downloaded into the Power Control CPU board, refer to section 10.2.1. Replace CPU Board in the Power Control. Call service. Alarm no. 30: Meaning: Touchscreen Alarm.
5TROUBLESHOOTING
Cause: If the touchscreen is continuously activated during the power-up sequence, this alarm condition will occur. Check: The touch screen should have nothing making contact with it during power up. Alarm no. 31: Meaning: Remote Start Switch Connection Alarm. Cause: The Remote Start Switch is improperly connected or becomes disconnected during an injection, this alarm condition will occur. Check: Remote Start Switch connection.
5-2-7
Alarm no. 33: Meaning: Console Protocol Memory Checksum Alarm. Cause: The Console protocol memory checksum is checked at power-up. If the checksum does not agree with the last saved checksum, this alarm condition will occur. Check: Battery on Console CPU board is bad or loose. Replace Console CPU board. Call Service. Alarm no. 34: Meaning: Console Program Checksum Alarm. Cause: If the Console firmware checksum does not agree with its known checksum, this alarm condition will occur. Check: Replace Console CPU board. Call Service. Alarm no. 35: Meaning: Either an injection motor timing error or undefined error message received from the power pack. Check: Call Service.
5TROUBLESHOOTING
5-2-8
Alarm no. 50: Meaning: Power Control not Detected. Cause: No communication between the Console and the Power Control during Power. On Self Test. Possible causes: Power Control not turned on. Power Supply is not turned on. Faulty RS422 cable/connection. Faulty data communications link to Power Supply Faulty serial link EMI Filter. Faulty Console RS422 line driver/receiver board. Faulty Power Control RS422 line driver/receiver board. Check: The power control is switched on (green indicator switch is on). Check: J1 and J2 on the power supply are connected to the monitor, and the power control.
5TROUBLESHOOTING
5-2-9
Alarm no. 90: Meaning: Power Control/Communication Error. There are 8 possible sub alarm codes associated with Alarm no. 90. Their format is used to explain alarms on the 2 communications channels, COM1/COM2. Where: COM1/ = is the alarm number for communication channel 1 /COM2 = is the alarm number for communication channel 2 Alarm definitions and syntax are as follows: 0 = No Error 90 = Connect Error 92 = Framing Error 93 = Parity Error 95 = BCC Error (Checksum Error) 96 = Retry Error 98 = Overflow Framing Error 99 = Overflow Parity Error 100 = Framing and Parity Error Cause: No communication for more than 30 seconds or bad communication with may consecutive retries that fail during injector operation. Possible causes: Faulty RS422 cable/connection. Faulty data communication link to Power Supply Faulty serial link EMI Filter. Faulty Console RS422 line driver/receiver board. Faulty Power Control RS422 line driver/receiver board. Check: Power Control to Console communication connections.
5TROUBLESHOOTING
5-2-10
5.2.1 ACTIVATING THE SYSTEM ERROR RESULTS LIBRARY The alarm history library retains the last 10 alarm messages encountered. To display these alarm messages proceed as follows: 1. Turn the console on. 2. Touch the Results button. 3. Touch the System Info button. 4. Touch the Alarm History button. 5. To return to the System Information screen, simply touch the System button.
5TROUBLESHOOTING
6-1-1
This chapter provides disassembly and assembly instructions for Optistar LE field replaceable parts. These parts are defined in the following sections: Section 6-2 Console Section 6-3 Power Head Section 6-4 Power Control Section 6-5 Power Supply. Section 6-6 Stand Section 6-7 Filter Section 6-8 Cables Section 6-9 Kit Part Numbers When removing a specific item, follow the DISASSEMBLY instructions up to the point where the removal of that particular item is discussed. To disassemble an item may require sub components to be removed first. If this is the case, you will be directed to perform the appropriate sub component instruction first. To replace an item, follow the disassembly instructions in reverse order until the unit is completely reassembled. WARNING! Always remove components from magnet room (Power Head and Power Control) before disassembly. Failure to follow this warning could result in personnel injury or equipment damage.
6DISASSEMBLY REASSEMBLY
6DISASSEMBLY REASSEMBLY
6DISASSEMBLY REASSEMBLY
6-2-2
6.2.1 CONSOLE REPLACEMENT COMPONENTS Part No. 802100 Description CONSOLE ASSEMBLY M4-.7 X 10 MM PLASTIC PHILLIPS PAN HEAD SCREW FOOT-RUBBER-CONSOLE 802101-1 802102-1 802104 802106 802107 802114 802110 802115 802116S 802130 CONSOLE CPU BOARD INTERFACE BOARD TOUCHSCREEN, 10.4" CONSOLE FRONT COVER CONSOLE BACK COVER CONSOLE SWITCH ASSEMBLY LOCTITE 222,PURPLE,THREAD LOCK INTERFACE CABLE ASSEMBLY MOUNTING PLATE, BUTTON DISPLAY SUBASSEMBLY MOUNTING BRACKET, COMM-BOARD SPACER,CAP GASKET, DIN-CONNECTOR
6DISASSEMBLY REASSEMBLY
Find No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
JACKNUT KIT SCREW, FOR PLASTIC, #4 HI/LOW TIE ON ARROWHEAD PLATE,HINGE,FINISHED HINGE, CONSTANT TORQUE SCREW,M4X.7,10MM,PR,PH,LOCKWSH SCREW,PT3.5,12MM,SS(FOR THERMO PLASTICS) SCREW,M4X.7 8MM PR PH W/LW PCB SUPPORT LABEL, LF LOGO LABEL, CONNECTOR ID, CONSOLE LABEL,SERIAL NUMBER 802108 SWITCH BUTTON, CONSOLE SCREW-4-40X5/16 PH WASHER #4 INT TOOTH LABEL,ATTENTION
802701-C May 2003
6-2-3
6DISASSEMBLY REASSEMBLY
6-2-4
6DISASSEMBLY REASSEMBLY
6-2-5
12
6DISASSEMBLY REASSEMBLY
6-2-6
6DISASSEMBLY REASSEMBLY
802701-C May 2003
6-2-7
6.2.2 CONSOLE COVER REMOVAL Refer to Figure 6-2-1. 1. Place the console, with hinge plate attached, face down on a soft, clean surface to prevent damage to the finish (i.e., table top with soft cloth in between console and table). 2. To remove the hinge plate (item 22), remove the nine screws (item 24) and lockwashers. NOTE: If the hinge plate is not the item being serviced it can remain attached to the back cover. Refer to Figure 6-2-2. 3. To remove the back cover (item 7), remove the four screws (item 1) and slowly lift away from the front half without fully extending the D-shell harness assembly (item 10). NOTE: The harness assembly (item 10) must be disconnected from the console CPU board at J5 before the back cover can be completely separated from the front half of the console. 6.2.3 CONSOLE CPU REMOVAL Refer to Figure 6-2-2. 1. Perform Console Cover Removal procedure 6.2.2. 2. Disconnect the following four connectors at the Console CPU board: Touchscreen cable from J2 Display cable (item 2) from J8 Switch assembly (item 8) from J6 Inverter cable (item 9) from J7 3. Remove two (2) screws retaining (item 3), lift console CPU PCB (item 3) of retaining pegs.
6ASSEMBLY & DISASSEMBLY
6-2-8
6.2.4 DISPLAY SUBASSEMBLY REMOVAL Refer to Figure 6-2-2 1. Perform removal procedure 6.2.2, and 6.2.3. 2. Remove four (4) retaining screws securing the Display Subassembly (item 12) to the front cover. 3. Remove Display Subassembly. 6.2.5 TOUCHSCREEN REMOVAL Refer to Figure 6-2-2 1. Perform removal procedure 6.2.2, 6.2.3, and 6.2.4.
6ASSEMBLY & DISASSEMBLY
2. Lift Touchscreen from front cover. 6.2.6 CONSOLE POWER SWITCH REMOVAL Refer to Figure 6-2-2 1. Place the console, with hinge plate attached, face down on a soft, clean surface to prevent damage to the finish (i.e., table top with soft cloth in between console and table). 2. To remove the back cover (item 7), remove the four screws (item 1) and slowly lift away from the front half without fully extending the D-shell harness assembly (item 10) to expose the Display Subassembly. NOTE: The harness assembly (item 10) does not have to be disconnected from the console CPU board to remove the Console Power Switch Assembly. 3. Disconnect the Console Power Switch cable at the CPU board J6 connector. 4. Remove four (4) screws retaining the Display Subassembly and gently move it aside until the Console Power Switch is exposed. 5. Remove four (4) retaining screws from the Console Power Switch mounting plate (item 11) and remove button mounting plate. Then remove Console Power Switch Assembly.
6-2-9
6.2.7 CONSOLE SWITCH BUTTON REMOVAL Refer to Figure 6-2-1 1. Perform removal procedure 6.2.6 to expose the Console Switch Button. 2. Push the Console Switch Button from the front cover seat. 6.2.8 CONSOLE INTERFACE BOARD REMOVAL Refer to Figure 6-2-1 1. Perform removal procedure 6.2.2. 2. Remove harness assembly (item 10) from Interface board (item 4), disconnect at the Interface board (item 4) J3 connector.
6ASSEMBLY & DISASSEMBLY
3. Remove two (2) mounting bracket retaining screws from (item 13). Remove Interface Board (item 4) with mounting bracket (item 13). 4. Separate mounting bracket (item 13) from Interface Board (item 4) by removing two (2) standoff nuts. NOTE: Be sure to retain mounting bracket (item 13). This bracket must be installed to the Interface Board (item 4) when it is replaced.
6-2-10
6.2.9 CONSOLE ASSEMBLY Refer to Figures 6-2-1 thru 6-2-3. 1. Place the top cover on a soft, clean surface to prevent damage to the finish (i.e., table top with soft cloth in between cover and table). Position the cover so that its inside surface faces up and the switch assembly is now in the upper left corner. 2. Push Console Switch button into the opening provided until seated. NOTE: Clean mounting surface with alcohol before mounting switch. 3. Place Console Power Switch Assembly (item 8) over the Console Switch button. Install Power Switch mounting plate (item 11).
6ASSEMBLY & DISASSEMBLY
4. Position the touch screen (item 5) over the large opening in the top cover so the harness and connector are at the right side. 5. Move the Console Power Switch cable to side, then place the Display Subassembly (item 12) over the touch screen so the harness and connector are at the right side. Secure assembly with four (4) mounting screws (item 21).
CAUTION!
Do not over-tighten screws. Over-tightening the screw will damage the unit. 6. Mount the Console CPU board (item 3) on the standoffs provided. Install two (2) retaining screws to secure the CPU board. Install the following cables: Touchscreen cable to J2 Display cable (item 2) to J8 Switch assembly cable (item 8) to J6 Inverter cable (item 8) to J7 7. Place the back cover (item 7) on a bench with the inside surface facing up. 8. Install Interface Board (item 4) and mounting bracket (item 13) in the slots provided. Secure mounting bracket to back cover with two (2) retaining screws. 9. Install harness assembly (item 10) to the Interface Board J3 connector. 10. Move back cover close to the front cover. Install Interface Board cable (item 10) to J5 on the CPU board. 11. The software can be downloaded to the console if required. Refer to the download process described in Chapter 10, Software Installation. 12. Place back cover onto front cover and install four (4) retaining screws. 13. Install three torque hinges (item 20) onto the back cover mounting pads using nine screws with lockwashers (item 22).
ml 10/15/ 30 60 20 ml ml
B 50 ml 125 60 ml
ml
6DISASSEMBLY REASSEMBLY
6-3-2
6.3.1 POWERHEAD REPLACEMENT COMPONENTS Item No. 802300 Part Description POWERHEAD ASSY Find No.
Note: POWERHEAD ASSEMBLY 802300-C or earlier use SYRINGE SIZE SENSING PCB ASSEMBLY 802307-1 Note: POWERHEAD ASSEMBLY 802300-D or later use SYRINGE SIZE SENSING PCB ASSEMBLY 802313-1 802743 Kit 802371 802746 Kit See Section 6-9 Kits, MOTORREPLACEMENT ASSEMBLY DRIVE A 1 MAINFRAME, MACHINED GEAR, 24DP 32T BEARING ADAPTER MACHINED, MOTORMOUNT PILOT, MOTOR GEAR GUIDE PLATE 802748 Kit 802327 802746 Kit 802746 Kit 802744 Kit
6DISASSEMBLY REASSEMBLY
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
See Section 6-9 Kits, SYRINGE HOLDER SERVICE KIT GUIDE BUSHING See Section 6-9 Kits, BEARING REPLACEMENT SERVICE KIT RETAINING RING, 1-3/8 FLAG, A-SIDE METRIC, LEAD NUT FLAG, B-SIDE METRIC, LEAD SCREW RAM
See Section 6-9 Kits, BUSHING REPLACEMENT SERVICE KIT HOLDER, LOAD CELL SCREW, SET, M6, 12MM, SS-A4, BLUE PRESSURE WASHER RAM FACE ROD, OUTER SUPPORT BLOCK, ADJUSTMENT PIVOT
802741S Kit See Section 6-9 Kits, LOAD CELL SERVICE KIT
6-3-3
6.3.1 POWERHEAD REPLACEMENT COMPONENTS (CONTD) Item No. 802302-1 802744 Kit 802744 Kit 802315 802747 Kit 802301-1 802110 802303 802332 802381 802382 802383 802384 802385 802744 Kit 802744 Kit 802903 802744 Kit 802748 Kit 802368 802747 Kit 802744 Kit 802313-1 MACHINED, SUPPORT ARM ADHESIVE,SILICONE,CLEAR LENS,INDICATOR RETAINING RING PCB ASSY, SYRINGE SIZE SENSING 43 44 45 46 47 PCB ASSY, POWERHEAD CABLE ASSY, INTERFACE CABLE ASSY, POWERHEAD WIPER PIVOT BUSHING PIVOT WASHER CAP, PIVOT THRUST WASHER, PIVOT PILOT BUSHING, MOTOR STANDOFF, M3 - 6MM SHEILD, MOTOR 1/8" DOWEL PIN, 316 S.S. DETENT, SYRINGE HOLDER 30 31 32 33 34 35 36 37 38 39 40 41 42
6DISASSEMBLY REASSEMBLY
Part Description PCB ASSY, END LIMIT SENSING SCREW, ADJUSTMENT O RING, -008 KEYPAD ASSY, POWERHEAD
Find No. 26 27 28 29
Note: POWERHEAD ASSEMBLY 802300-C or earlier use SYRINGE SIZE SENSING PCB ASSEMBLY 802307-1 Note: POWERHEAD ASSEMBLY 802300-D or later use SYRINGE SIZE SENSING PCB ASSEMBLY 802313-1 802316 802317 802318 HARNESS ASSY, END LIMITS HARNESS ASSY, SIZE SENSING HARNESS ASSY, ENCODER 48 49 50
6-3-4
6.3.1 POWERHEAD REPLACEMENT COMPONENTS (CONTD) Item No. 802743 Kit 802747 Kit 802396 802397 802744 802748 Kit 802744 Kit 802744 Kit 802743 Kit 802744 Kit 802744 Kit 802741S Kit 802744 Kit 802742 Kit 802744 Kit 802744 Kit
6DISASSEMBLY REASSEMBLY
Part Description GEAR, 24DP 24T See Section 6-9 Kits, POWERHEAD COVER SERVICE KIT BOTTOM COVER, FRONT, POWERHEAD BOTTOM COVER, BACK, POWERHEAD See Section 6-9 Kits, FASTNER SERVICE KIT SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE SCREW, SET, M4, SS-A4, BLUE SCREW, M4, 12MM, SHCS, SS-A4, BLUE SCREW, SET, M3, 5MM,SS-A4, BLUE SCREW, M3, 8MM, PR, FH, SS-A4, BLUE SCREW, M4, 12MM,BHCS,SS-A4,BLUE SCREW, M4, 10MM, PR, PH, SS-A4, BLUE DYE SCREW, M5, 10MM, PR, PH, SS-A4, BLUE DYE CLAMP, VINYL COATED GROMMET, CONTINUOUS NUT, M6, HEX, NYLON INSERT, SS-A4, BLUE NUT, M5, HEX, NYLON INSERT, SS-A4, BLUE WASHER, FLAT, M5, SS-A4, BLUE DYE WASHER, SPRING LOCK, M4, SS-A4, BLUE DYE WASHER, EXT. TOOTH, M3, SS-A4, BLUE DYE SCREW, M4, 50MM, SHCS, SS-A4, BLUE O-RING, -022 KNOB, M8 WASHER-#14S BRASS FLAT LOCTITE 242,BLUE,NUT LOCK
Find No. 51 52 53 54 56 57 58 59 60 61 62 63 64 66 67 68 69 70 71 72 73 74 75 76
802744 Kit 802679 802744 Kit 802744 Kit 802744 Kit 802744 Kit 802743 Kit 802744 Kit 802744 Kit 802744 Kit 802741S Kit 802657 802744 Kit
6-3-5
6.3.1 POWERHEAD REPLACEMENT COMPONENTS (CONTD) Item No. 802311 Part Description SEALANT, SILICONE LUBRICANT GASKET, EMI, POWER HEAD LOCTITE 609,GREEN,RET COMPOUND PRIMER-LOCQUIC GRADE T GREASE-MULTI-PURPOSE AEROSOL 802744 Kit 802748 Kit 802901 802730 802748 Kit TY-RAP TIES 802748 Kit 802748 Kit 802744 Kit 802748 Kit 802744 Kit 802744 Kit 802744 Kit SCREW, M3, 8MM, PH,PR,SS-A4,BLUE CABLE CLAMP, 9/16" SCREW,M3, 6MM, PR, PH,SS-A4,BLUE LABEL, S/N LABEL,DIRECTION-ENABLE/INJECT 802744 Kit 802744 Kit 802748 Kit 802744 Kit 802748 Kit STAND OFF , 3/16" X 1", M3 96 WASHER, FLAT, M3, SSA4, BLUE DYE WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE 88 89 90 91 92 94 95
6DISASSEMBLY REASSEMBLY
Find No. 77 78 79 80 81 82 83
SCREW, M3, 10MM, PR, PH, SS-A4, BLUE DYE NEST COVER, SYRINGE HOLDER SYRINGE ADAPTER (WITH LABEL)
84 85 86 87
LABEL, 30/60ML, FLUID DETECTION LABEL, 50/60ML, FLUID DETECTION SCREW, M2.5, 10MM, PR,PH,SS-A4,BLUE
6DISASSEMBLY REASSEMBLY
6-3-6
6-3-7
6DISASSEMBLY REASSEMBLY
6-3-8
6DISASSEMBLY REASSEMBLY
BOTTOM VIEW
END VIEW
6-3-9
6DISASSEMBLY REASSEMBLY
BACK VIEW
802701-C May 2003
6-3-10
Power Control P1 Connector P1:24 P1:9 P1:39 P1:25 P1:30 GND SCREW P1:20 P1:26 P1:40 P1:13 P1:41 P1:27 P1:8 P1:22 P1:29 P1:43 P1:37 P1:23 P1:14 P1:42 P1:38 P1:10 P1:28 GND SCREW P1:11 P1:12 P1:5 P1:21 P1:7 P1:36 P1:6 P1:35 P1:34 GND SCREW Power Control P2 Connector P2:18 P2:23 P2:21 GND SCREW P2:17 P2:26 P2:20 GND SCREW P2:24 P2:22 P2:27 GND SCREW P2:25 P2:19 P2:28 GND SCREW
Wire Color BLACK RED BROWN YELLOW WHITE NONE GREEN ORANGE BLUE BROWN YELLOW PINK TAN BLACK RED WHITE GREEN ORANGE BLUE PURPLE SLATE PURPLE GRAY PINK NONE TAN RED/YELLOW RED/GREEN RED/BLACK BLACK RED WHITE GREEN ORANGE BLUE NONE
Powerhead Board Connectors J7, J8, J9 J7-11 J7-12 J7-2 J7-1 J7-3 J7-4 J7-5 J7-6 J7-7 J7-8 J7-9 J7-10 J8-9 J8-8 J8-4 J8-3 J8-2 J8-1 J8-14 J8-13 J8-6 J8-7 J8-12 J8-15 J8-10 J8-11 J8-5 J9-1 J9-2 J9-3 J9-5 J9-6 J9-4 J9-7 J9-8 Powerhead Motor Connections JA-1 JA-3 JA-4 JB-1 JB-3 JB-4 JB1-1 JB1-3 JB1-4 JA1-1 JA1-3 JA1-4
Pin 1
J8 J7 J9
P2
P1
Pin 1
6DISASSEMBLY REASSEMBLY
Wire Color BLUE YELLOW GREEN NONE WHITE/BLUE WHITE/YELLOW WHITE/GREEN NONE RED/BLUE RED/YELLOW RED/GREEN NONE BLACK/BLUE BLACK/YELLOW BLACK/GREEN NONE -
6-3-11
6.3.2 POWERHEAD REMOVAL/INSTALLATION FROM STAND Refer to Figure 6-3-4. 1. Turn off all power to the Optistar LE injector. 2. Remove Powerhead communications cable at the Power Control. 3. Remove Powerhead and Stand assembly from magnet room. 4. Turn the Stand height adjustment ring clockwise to lock in position. This will ensure the spring loaded height adjustment rod stays in position when the Powerhead is removed. WARNING! The stand height adjustment rod is under tension. Turn the height adjustment ring clockwise to the full locked position before removing Powerhead. 5. Loosen the Powerhead arm philips head screws. Lift the Powerhead and arm assembly from stand. 6. To reinstall, perform the procedures above in reverse order.
Powerhead
Screw
Op
6DISASSEMBLY REASSEMBLY
tist
ar
TM
LE
30 ml ml 20 A 10/15/
60 ml
ml ml B 60125
50 ml
6-3-12
6.3.3 POWERHEAD COVER REMOVAL/INSTALLATION Refer to Figure 6-3-3. Powerhead covers consist of four units: Sringe holder nest cover (item 83) Bottom back cover (item 54) Top cover (item 52) Bottom front cover (item 53) Note: Powerhead covers can be removed while mounted to the stand. Note: Remove the Powerhead assembly from the magnet room during cover removal and installation. 6.3.3.1 Syringe Holder Nest Cover Removal/Installation 1. Turn off all power to the Optistar LE injector. 2. Remove Powerhead assembly from magnet room. 3. Remove all syringes if present. 4. Remove syringe holder nest cover (item 83) three (3) retaining screws. Remove syringe holder nest cover (item 83). 5. To reinstall, perform the procedures above in reverse order.
6DISASSEMBLY REASSEMBLY
6.3.3.2 Bottom Back Cover Removal/Installation 1. Turn off all power to the Optistar LE injector. 2. Remove Powerhead assembly from magnet room. 3. Remove all syringes if present. 4. Remove bottom back cover (item 54) four (4) retaining screws. Remove bottom back cover. 5. To reinstall, perform the procedures above in reverse order.
6-3-13
6.3.3.3 Top Cover Removal/Installation 1. Turn off all power to the Optistar LE injector. 2. Remove Powerhead assembly from magnet room. 3. Remove all syringes if present. 4. Remove all bottom covers as described in sections 6.3.3.1, 6.3.3.3 and 6.3.3.4. 5. Lift top cover off until keypad assembly (item 29) cable connector is exposed. Disconnect the keypad connector at the keypad, and remove top cover. 6. To reinstall, perform the procedures above in reverse order. 6.3.3.4 Bottom Front Cover Removal/Installation 1. Turn off all power to the Optistar LE injector. 2. Remove Powerhead assembly from magnet room. 3. Remove all syringes if present. 4. Remove syringe holder nest cover as described in section 6.3.3.1. Remove bottom back cover as described in section 6.3.3.2. 5. Remove bottom back cover (item 53) eight (8) retaining screws. Remove bottom front cover. Note: The top cover will be free to remove at this point. 6. To reinstall, perform the procedures above in reverse order.
6DISASSEMBLY REASSEMBLY
6-3-14
6.3.4 POWERHEAD BOARD REMOVAL/INSTALLATION Remove Powerhead assembly from magnet room. 1. Remove all Powerhead covers as described in section 6.3.3. Refer to Figure 6-3-1 and 6-3-2. 2. Disconnect all connections to the Powerhead board. 3. Remove six (6) retaining screws (item 90) and lift off Powerhead board. 4. To reinstall, perform the procedures above in reverse order. 6.3.5 POWERHEAD CABLE REMOVAL/INSTALLATION Refer to Figure 6-3-2 Disconnect the Powerhead cable from the Power Control. Remove Powerhead assembly from magnet room. 1. Remove all Powerhead covers as described in section 6.3.3. 2. Remove four (4) retaining screws from shield motor cover (item 40). Also, remove two (2) Powerhead board rear retaining screws. Carefully slide shield motor cover (item 40) off. 3. Cut rear cable wire Ty-wrap. 4. Before removing motor and encoder connectors, write down connector wire orientations. This will ensure connectors are not flipped during the installation process. Disconnect JA, JA1, JB, and JB1 connectors and ground wires. Also, disconnect the ground wire connection next to the Powerhead cable retaining bracket. 5. At the Powerhead retaining bracket, cut the two (2) Ty-wraps (one on each side). Remove four (4) retaining screws (item 60) the Powerhead retaining bracket. Carefully remove Powerhead cable. 6. To reinstall, perform the procedures above in reverse order.
6DISASSEMBLY REASSEMBLY
6-3-15
6.3.6 MOTOR REMOVAL/INSTALLATION Refer to Figure 6-3-1 and 6-3-2. Remove Powerhead assembly from magnet room. 1. Remove the bottom back cover as described in section 6.3.3.2. 2. Before removing motor and encoder connectors, write down connector wire orientations. This will ensure connectors are not flipped during the installation process. Disconnect JA, JA1, JB, and JB1 connectors and ground wires. Also, disconnect motor encoder connectors (item 50). 3. Remove three (3) motor retaining screws and washers (item 70 and 72). Remove motor and gear assembly. Be careful not to lose pilot bearing (item 38). 4. To reinstall, perform the procedures above in reverse order. 6.3.7 POWERHEAD END LIMIT SENSING BOARD REMOVAL/INSTALLATION Refer to Figure 6-3-1 and 6-3-2. 1. Move both rams to their middle retracted position. 2. Remove Powerhead assembly from magnet room. 3. Remove all Powerhead covers as described in section 6.3.3. 4. Position Powerhead with rams in the vertical position. 5. Remove both ram face caps (item 21). Remove inner O-ring (item 73) to expose both set screws (item 59). With a 1.5 mm allen wrench, remove both set screws (item 59). 6. At the Powerhead board, disconnect both size sensing cables (item 49). 7. Disconnect each connector at the Limit Sensing Boards (item 26). Take note of the connectors used. 8. Remove six (6) screws (item 58) from guide plate (item 7). Carefully slide guide plate and ram assembly from base. 9. Carefully slide the Limit Sensing Boards (item 26) from their runners. Take note of the position adjustment screws (item 27) are in, then remove adjustment screws (item 27) from Limit Sensing Boards (item 26) using adjustment runner tool (P/N 802731). 10. To reinstall, perform the procedures above in reverse order. Ensure all O-rings are properly lubricated. Note: When reinstalling a Limit Sensing Board, ensure the load cell (item 23) cable and conduit is correctly positioned in the slots provided. Also, End Limit calibration must be performed when this board is replaced.
6DISASSEMBLY REASSEMBLY
6-3-16
6.3.8 LOAD CELL REMOVAL/INSTALLATION Refer to Figure 6-3-1 1. Move both rams to their middle retracted position. 2. Remove Powerhead assembly from magnet room. 3. Remove all Powerhead covers as described in section 6.3.3. 4. Position Powerhead with rams in the vertical position. 5. Remove both ram face caps (item 21). Remove inner O-ring (item 73) to expose both set screws (item 59). With a 1 1/2 mm allen wrench, remove both set screws (item 59). 6. Disconnect each connector at the Limit Sensing Boards (item 26). Take note of the connectors used. Cut all Ty-wraps retaining the Limit Sensing Cable. Also, bend cable retainers to allow for cable removal. 7. Remove four (4) screws (item 60) from bushing retainer (item 17). Lift wiper (item 33) and bushing guide (item 9) from guide plate (item 7). 8. Remove load cell cable and conduit from power head by feeding connector end through the opening provide in the guide plate (item 7). 9. To install load cell, perform the procedures above in reverse order. Note: When installing a load cell kit, ensure the load cell (item 23) cable and conduit is correctly positioned in the slots provided. 6.3.9 END LIMIT HARNESS REMOVAL/INSTALLATION
6DISASSEMBLY REASSEMBLY
Refer to Figure 6-3-2. Remove Powerhead assembly from magnet room. 1. Remove all Powerhead covers as described in section 6.3.3. 2. Disconnect End Limit harness (item 48) connections at the End Limit Sensing board (item 26). At the Powerhead board (item 30), Disconnect the End Limit harness at J3 and J4 connectors. 3. Cut wire Ty-wraps retaining the harness. 4. To reinstall, perform the procedures above in reverse order.
6-3-17
6.3.10 ENCODER HARNESS REMOVAL/INSTALLATION Refer to Figure 6-3-2. Remove Powerhead assembly from magnet room. 1. Remove all Powerhead covers as described in section 6.3.3. 2. Disconnect Encoder harness (item 50) connections at the Powerhead board (item 30) and at the motors (item 1). 3. Cut wire Ty-wraps retaining the Encoder harnesses. 4. To reinstall, perform the procedures above in reverse order. 6.3.11 SYRINGE SIZE SENSING BOARD REMOVAL/INSTALLATION There are two (2) Syringe Size Sensing Boards for each ram. Refer to Figure 6-3-2 for location and procedures. Remove Powerhead assembly from magnet room. 1. Remove syringe holder nest cover as described in section 6.3.3.1. 2. Disconnect cable (item 49) connections from Syringe Size Sensing boards (item 47). 3. Remove Syringe Size Sensing board retaining screws (item 87) and detent syringe holder (item 42). 4. To reinstall, perform the procedures above in reverse order. 6.3.12 DETENT SYRINGE HOLDER REMOVAL/INSTALLATION Refer to Figure 6-3-2. Remove Powerhead assembly from magnet room. 1. Remove syringe holder nest cover as described in section 6.3.3.1. 2. Disconnect cable (item 49) connections from Syringe Size Sensing boards (item 47). 3. Remove Syringe Size Sensing board retaining screws (item 87) and detent syringe holder (item 42). 4. To reinstall, perform the procedures above in reverse order.
6DISASSEMBLY REASSEMBLY
6-3-18
6.3.13 SYRINGE SIZE SENSING HARNESS REMOVAL/INSTALLATION Refer to Figure 6-3-2. Remove Powerhead assembly from magnet room. 1. Remove all Powerhead covers as described in section 6.3.3. 2. Disconnect cable (item 49) connections from Syringe Size Sensing boards (item 47) and at the Powerhead board (item 30) J10 and J11 connectors. 3. Cut wire Ty-wraps from outer support rods (item 22). 3. Feed Syringe Size Sensing cable (item 49) connectors through the slot provided in the syringe nest holder (item 8). 4. To reinstall, perform the procedures above in reverse order. 6.3.14 SYRINGE NEST HOLDER REMOVAL/INSTALLATION Refer to Figure 6-3-1 and 6-3-2. 1. Move both rams to their middle retracted position 2. Remove Powerhead assembly from magnet room. 3. Remove syringe nest holder cover as described in section 6.3.3.1. 4. Disconnect cable (item 49) connections from Syringe Size Sensing boards (item 47) and feed cable connectors through the slot provided in the syringe nest holder (item 8).
6DISASSEMBLY REASSEMBLY
5. Remove four (4) screws retaining the syringe nest holder (item 8) to the support rods. Remove the syringe nest holder. 6. To reinstall, perform the procedures above in reverse order.
6-3-19
6.3.15 SUPPORT ARM REMOVAL/INSTALLATION Refer to Figure 6-3-1. Remove Powerhead assembly from magnet room. 1. Rotate knob (item 74) counterclockwise to remove. 2. Remove pivot cap (item 36). 3. Remove retaining ring (item 46). 4. Slide Powerhead from support arm (item 43). 5. To reinstall, perform the procedures above in reverse order.
6DISASSEMBLY REASSEMBLY
6-3-20
6.3.16 BEARING REMOVAL/INSTALLATION Refer to Figure 6-3-1 and 6-3-2. Removal 1. Move both rams to the fully extended position. 2. Remove Powerhead assembly from magnet room. 3. Remove all Powerhead covers as described in section 6.3.3. 4. Remove four (4) retaining screws from shield motor cover (item 40). Also, remove two (2) Powerhead board rear retaining screws. Carefully slide shield motor cover (item 40) off. 5. Remove the Powerhead cable as described in section 6.4.5. 6. Remove 6mm lead screw nut (item 68) from lead screw (item 15). 7. Remove Powerhead motors as described in section 6.3.6. 8. Rotate lead screw (item 15) to access gear set screws. Loosen both gear set screws (item 57). Then remove both lead screw gears (item 3). 9. Remove five (5) screws (item 58) from motor mount (item 5). Remove bearing assembly from lead screws. 10. Remove bearing retaining ring (item 11) and bearings (item 10) from motor mount housing (item 5). Reassembly
6DISASSEMBLY REASSEMBLY
11. Install new bearings into motor mount (item 5). Install bearing retaining ring (item 11). Note: Ensure the bearing retaining ring is fully seated during installation. 12. Slide motor mount assembly (item 5) onto lead screws and secure assembly with five (5) mounting screws (item 58). 13. Install lead screw gears (item 3) onto lead screws (item 15). Ensure set screws are positioned to contact the lead screw flat surfaces when tightened. At this time simply snug the gear set screws on the lead screw flat surfaces, do not tighten the gear set screws. Rotate both lead screws until the gear set screws are accessible after motors installation. 14. Reinstall motor assembly. 15. Reinstall 6mm lead screw nut (item 68) and tighten nut. 16. Tighten gear set screws (item 57). 17. Reinstall Powerhead cable. 18. Reinstall shield motor cover. Then reinstall all Powerhead covers.
Injector operations are controlled by the Power Control. PC boards and other Power Control components are contained in the following four units: Backplate Control, Front Control Encloser, Rear Control Encloser, and Front Control Cover. Replacement components contained in these units are list in section 6-4-1.
Backplate Control Rear Control Encloser Front Control Encloser Front Control Cover
6-4-2
6.4.1 POWER CONTROL REPLACEMENT COMPONENTS Part No. 802200 802251 802252 802222 802237 802201-1 802202-1 802203-1 802204-1 802207-1 802263 802212 802213 802214 802215 802635
6DISASSEMBLY REASSEMBLY
Description POWER CONTROL ASSY FRONT CONTROL ENCLOSER REAR CONTROL ENCLOSER FRONT CONTROLCOVER BACKPLATE, CONTROL CPU BOARD ASSEMBLY POWER BOARD ASSEMBLY DRIVER BOARD ASSEMBLY COMMUNICATION BOARD ASSEMBLY INTERCONNECT BOARD ASSEMBLY EMI GASKET POWERHEAD MOTORS HARNESS ASSEMBLY POWERHEAD COMMUNICATION HARNESS ASSEMBLY CONSOLE COMMUNICATION HARNESS ASSEMBLY POWER CONTROL SWITCH RUBBER FOOT STAND OFF ASSEMBLY LABEL, S/N
Find No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 32
802261S
NON-FERROUS SCREW, M5, 10MM, PR, PH, SS-A4, BLUE DYE NON-FERROUS SCREW, M4, 10MM, PR, PH, SS-A4, BLUE DYE 802711 JACK SCREW KIT, SOCKET LOCTITE 222,PURPLE,THREAD LOCK NON-FERROUS WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE LABEL, POWERHEAD ICON LABEL, POWER SUPPLY ICON 172E0016 6.3 Amp SLOW BLOW FUSE POWER CONTROL SHIELD Note: All fastners are part of Fastner Service Kit (P/N 802744)
6-4-3
26
6DISASSEMBLY REASSEMBLY
15
J1, J2
6DISASSEMBLY REASSEMBLY
6-4-4
6-4-5
6.4.2 BACKPLATE COVER REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Remove all external connections 3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. At the rear of assembly, remove six (6) screws from backplate cover (item 4). 6. When removing the backplate cover, keep in mind there are internal harness connections. Gently remove backplate cover (item 4) from rear enclosure cover (item 2). 7. On the Driver board (item 7), disconnect Head motor harness (item 11) from J2 connector. 8. On the Communication board (item 8), disconnect the following items: Powerhead Communication harness (item 12) from J3 connector, Console Communication harness (item 13) from J2 connector, and Power Control switch harness (item 14) from J1 connector. 9. The Backplate Cover (item 4) can be set aside. 10. To reinstall the Backplate Cover, perform steps 1 thru 8 in reverse order. 6.4.3 DRIVER BOARD (802203-1) REMOVAL/INSTALLATION Refer to Figure 6-4-2.
6DISASSEMBLY REASSEMBLY
1. Turn off all power to the Optistar LE injector. 2. Remove all external connections 3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. Remove Backplate Cover as described in section 6.3.2. 6. Remove two (2) screws (item 19). These screws secure the Driver Board heat sink to the Rear Cover Enclosure. 7. Before removing the Driver Board (item 7) and shield (item 32), take note of its countersink slot location in the Rear Cover Enclosure. Grasp Driver Board and and sheild, then pull straight outward to disconnect from the Power Control Interconnect Board (item 9). 8. To reinstall Driver Board, perform steps 1 thru 7 in reverse order.
6-4-6
6.4.4 COMMUNICATION BOARD (802204-1) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Remove all external connections 3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. Remove Backplate Cover as described in section 6.3.2. 6. Before removing the Communication Board (item 8), take note of its countersink slot location in the Rear Cover Enclosure. Grasp Communication Board and pull straight outward to disconnect from the Power Control Interconnect Board (item 9). 7. To reinstall Communication Board, perform steps 1 thru 7 in reverse order. 6.4.5 CPU BOARD (802201-1) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Disconnect cabling to the Power Control Unit. 3. Remove Power Control from Magnet Room. 4. Remove four (4) screws (item 19) from Front Cover Encloser item 1.
6DISASSEMBLY REASSEMBLY
5. Remove Front Control Cover (item 3). 6. Before removing the CPU Board item 5, take note of its countersink slot location in the Rear Cover Enclosure. Grasp CPU Board and pull straight outward to disconnect from the Power Control Interconnect Board (item 9). 7. To reinstall CPU Board, perform steps 1 thru 7 in reverse order.
6-4-7
6.4.6 POWER BOARD (802202-1) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Disconnect cabling to the Power Control Unit. 3. Remove Power Control from Magnet Room. 4. Remove four (4) screws (item 19) from Front Cover Encloser item 1. 5. Remove Front Control Cover item (3). 6. Before removing the Power Board (item 6), take note of its countersink slot location in the Rear Cover Enclosure. Grasp Power Board and pull straight outward to disconnect from the Power Control Interconnect Board (item 9). 7. To reinstall CPU Board, perform steps 1 thru 7 in reverse order. 6.4.7 INTERCONNECT BOARD (802207-1) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Disconnect cabling to the Power Control Unit. 3. Remove Power Control from Magnet Room. 4. To remove the Interconnect Board, remove components as defined in the following sections:
6DISASSEMBLY REASSEMBLY
Section 6-4-2 Section 6-4-3 Section 6-4-4 Section 6-4-5 Section 6-4-6 5. Remove four (4) standoffs (item 16) from Rear Control Encloser (item 2). 6. When the Rear Control Encloser (item 2), and Front Control Encloser (item 3) are separated, the Interconnect Board is free for removal. NOTE: Take note of the Interconnect Board orientation before removal. 7. To reinstall Interconnect Board, perform steps 1 thru 7 in reverse order.
6-4-8
6.4.8 POWERHEAD MOTOR HARNESS (802212) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Remove all external connections 3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. At the rear of assembly, remove six (6) screws from Backplate Cover (item 4). 6. Gently remove Backplate Cover (item 4) from rear enclosure cover (item 2). 7. On the Driver board (item 7), disconnect Powerhead motor harness (item 11) from J2 connector. 8. At the Backplate Cover (item 4), remove two (2) retaining screws from connecter (item 11). 9. Feed Head motor harness (item 11) through Backplate Cover (item 4) to remove. 10. To reinstall the Powerhead motor harness, perform steps 1 thru 9 in reverse order. 6.4.9 POWERHEAD COMMUNICATION HARNESS (802213) REMOVAL/INSTALLATION Refer to Figure 6-4-2.
6DISASSEMBLY REASSEMBLY
1. Turn off all power to the Optistar LE injector. 2. Remove all external connections 3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. At the rear of assembly, remove six (6) screws from Backplate Cover (item 4). 6. Gently remove Backplate Cover (item 4) from rear enclosure cover (item 2). 7. On the Communication board (item 8), disconnect Communication harness (item 12) from J3 connector. 8. At the Backplate Cover (item 4), remove two (2) retaining screws from connector (item 12). 9. Feed Head Communication harness (item 12) through Backplate Cover (item 4) to remove. 10. To reinstall the Communication harness, perform steps 1 thru 9 in reverse order.
6-4-9
6.4.10 CONSOLE COMMUNICATION HARNESS (802214) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Remove all external connections 3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. At the rear of assembly, remove six (6) screws from Backplate Cover (item 4). 6. Gently remove Backplate Cover (item 4) from rear enclosure cover (item 2). 7. On the Communication board (item 8), disconnect Communication harness (item 12) from J2 connector. 8. At the Backplate Cover (item 4), remove two (2) retaining socket standoffs (item 20) from connector (item 13). 9. To reinstall the Communication harness, perform steps 1 thru 8 in reverse order. 6.4.11 POWER SWITCH (802215) REMOVAL/INSTALLATION Refer to Figure 6-4-2. 1. Turn off all power to the Optistar LE injector. 2. Remove all external connections
6DISASSEMBLY REASSEMBLY
3. Remove Power Control from Magnet Room. 4. Position Power Control Upside down. 5. At the rear of assembly, remove six (6) screws from Backplate Cover (item 4). 6. Gently remove Backplate Cover (item 4) from rear enclosure cover (item 2). 7. On the Communication board (item 8), disconnect Power harness (item 14) from J1 connector. 8. Grasp and squeeze Power Switch retaining clips while pushing forward to remove from Backplate Cover (item 4). 9. Feed Power Switch harness (item 14) through Backplate Cover (item 4) to remove. 10. To reinstall the Power Switch and harness, perform steps 1 thru 9 in reverse order.
6-4-10
6DISASSEMBLY REASSEMBLY
6DISASSEMBLY REASSEMBLY
6-5-2
6.5.1 POWER SUPPLY REPLACEMENT COMPONENTS Part No. 802450 802711 240E3335 240E3336 240E3337 251769 340E0025 380E0072 802451-1 802402 802403 802404 802407 802435 802635
6DISASSEMBLY REASSEMBLY
Description POWER SUPPLY ASSEMBLY, LE JACK SCREW KIT, SOCKET AC INLET MODULE, FILTERED, 6A FUSE DRAWER, AC INLET MODULE AC OUTLET HARNESS CLAMP-1/2" DIA. POWER SUPPLY, +27 VDC TERMINAL,STUD MOUNT,DUAL .250 90 DEGREE POWER SUPPLY LE BOARD ASSEMBLY INSULATOR, POWER SUPPLY AC DISTRIBUTION HARNESS ASSEMBLY DC DISTRIBUTION HARNESS ASSEMBLY LED ASSY LABEL, WIRING FRONT COVER FOOT, RUBBER NUT,M4X.7,HEX,W/LOCKWASHER SCREW,M4X.7,10MM,PR,TH,BLK
Find No. 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32
802428
POWER SUPPLY HOUSING LABEL,WARNING(SHOCK&EXPLOSION HAZARD) LABEL, RATING, POWER SUPPLY LABEL, FUSE ID, 4AMP LABEL, AC OUTLET GROUND LABEL-CARD
802455 172E0061
BACKPLATE, ELECTRONICS FUSE-4AMP,SLO-BLO 5MM LABEL, CONNECTOR I.D. TY-RAP TIES LOCTITE 222,PURPLE,THREAD LOCK LABEL,MAGNET CAUTION SCREW, M4 X .7, 6MM, PR, PH, W/LW
6-5-3
SEE NOTE
SEE NOTE
(4 PLACES)
NOTE
(8 PLACES)
THE POWER SUPPLY, ITEM 6, MAY BE OF MULTIPLE BRANDS AND APPEARANCE. SEE WIRING LABEL, ITEM 14, FOR AC INPUT WIRING INSTRUCTION.
BROWN (L) TO POWER SUPPLY SEE GROUND STUD FOR DETAILS G/Y (GND) TO GROUND STUD BLUE (N) TO POWER SUPPLY
6DISASSEMBLY REASSEMBLY
31 20
BOTTOM VIEW 1
30
25
BLUE (N) TO PCB-J7 28 8 G/Y (GND) TO GROUND STUD 21 REAR PANEL WIRING DETAIL 5 23 7 17 (2 PLACES)
TO POWER SUPPLY GND
18
(2 PLACES) 3 2 22
27 (2 FUSES)
TO AC OUTLET GND
TO AC INLET GND
7 6 5
4 3 2
6-5-4
6.5.2 POWER SUPPLY FUSE REPLACEMENT Refer to Figure 6-5-1. 1. Remove all incoming power to the Power Supply. The fuse drawer, located at the rear of the Power Supply resides in the AC inlet module (item 3). Two fuses are contained in the fuse drawer. 2. With a small screw driver, push fuse drawer tabs in while gently prying from side to side until removal is possible. 3. To reinstall fuse drawer, line up fuse drawer key and push in until a snap is heard. 6.5.3 REMOVAL OF POWER SUPPLY UNIT 1. Remove all incoming power to the Power Supply. 2. Disconnect all cabling to the Power Supply. 3. If the Power Supply unit is wall mounted, pull latch forward and lift up to remove unit from wall mount bracket. 6.5.4 DC POWER SUPPLY REPLACEMENT Refer to Figure 6-5-1. 1. Perform REMOVAL OF POWER SUPPLY UNIT steps. 2. Remove four (4) buttonhead screws (item 18) from rear of Power Supply housing. 3. Gently slide Power Supply frame from housing until LED harness (item 13) connection is exposed. Disconnect LED harness connection.
6DISASSEMBLY REASSEMBLY
4. Disconnect AC wiring from terminal strip location (item 11). 5. Disconnect DC distribution wiring at the terminal strip (item 12). 6. Remove four (4) screws (item 3)2 retaining Power Supply to frame. To reinstall Power Supply, perform the steps above in reverse order. Note: When reinstalling Power Supply, be sure to follow label wiring diagram (located on the insulator) when making terminal connections.
6-5-5
6.5.5 PC BOARD REPLACEMENT Refer to Figure 6-5-1. 1. Perform REMOVAL OF POWER SUPPLY UNIT steps. 2. Remove four (4) buttonhead screws (item 18) from rear of Power Supply housing. 3. Gently slide Power Supply frame from housing until LED harness (item 13) connection is exposed. Disconnect LED harness connection at the PC board. 4. Disconnect two (2) AC distribution connectors (item 11), and DC distribution connectors (item 12) at the PC board. 5. Remove six (6) jacknuts (connection side) securing PC board to backplate. Lift PC board from backplate. To reinstall PC board, perform the steps above in reverse order. 6.5.6 POWER ON/OFF SWITCH REPLACEMENT Refer to Figure 6-5-1. 1. Perform REMOVAL OF POWER SUPPLY UNIT steps. 2. Remove four (4) buttonhead screws (item 18) from rear of Power Supply housing. 3. Gently slide Power Supply frame from housing until LED harness (item 13) connection is exposed. Disconnect LED harness connection at the PC board. 4. At the PC board, disconnect AC wire connector (item 11) to AC inlet module (item 3).
6DISASSEMBLY REASSEMBLY
5. Remove four (4) screws (item 32) retaining Power Supply to frame. Move Power Supply to the side to expose AC inlet module retainers. 6. Remove the three (3) leads from the AC inlet module (item 3). 7. The AC inlet module is retained to the backplate by four (4) retaining clips (two (2) on each side). With a small screwdriver, push in on each retaining clip and remove AC inlet module. To reinstall AC inlet module, perform the steps above in reverse order.
6-5-6
6.5.7 AC OUTLET REPLACEMENT Refer to Figure 6-5-1. 1. Perform REMOVAL OF POWER SUPPLY UNIT steps. 2. Remove four (4) buttonhead screws from rear of Power Supply housing (item 18). 3. Gently slide Electronics Backplate frame from housing until LED harness (item 13) connection is exposed. Disconnect LED harness connection at the PC board. 4. Remove four (4) screws (item 3)2 retaining Power Supply to frame. Move Power Supply to the side to expose AC outlet retainers. 5. Remove three (3) wires from back of AC outlet (item 4). 6. The AC outlet module is retained to the backplate by two (2) retaining clips (one on top and one on bottom side). With a small screw driver, push in on each retaining clip and remove AC outlet module. To reinstall AC outlet module, perform the steps above in reverse order. 6.5.8 LED ASSEMBLY REPLACEMENT Refer to Figure 6-5-1. 1. Perform REMOVAL OF POWER SUPPLY UNIT steps. 2. Remove four (4) buttonhead screws from rear of Power Supply housing (item 18). 3. Gently slide Power Supply frame from housing until LED harness (item 13) connection is exposed. Disconnect LED harness connection at the PC board.
6DISASSEMBLY REASSEMBLY
4. Remove four (4) buttonhead screws (item 18) from Power Supply housing front cover. Remove front cover. 5. From inside of front cover, grasp LED socket and pull to remove. The LED green lens is retained in the front cover by the socket. Be careful not to loose green lens when removing socket. 6. To remove LED from socket, gently grab LED with a pair of needle nose pliers and pull from socket. To reinstall LED socket, perform the steps above in reverse order.
Elevating Post
Cable Hanger
Stationary Post
Wheelbase
6DISASSEMBLY REASSEMBLY
6DISASSEMBLY REASSEMBLY
6-6-2
12.7mm (.5")
31.75mm (1.25")
76.2mm (3")
(FRONT VIEW)
101.6mm (4")
6DISASSEMBLY REASSEMBLY
76.2mm (3.0")
(SIDE VIEW)
457.2mm (18.0")
6DISASSEMBLY REASSEMBLY
6-7-2
6DISASSEMBLY REASSEMBLY
6-8-2
CONTROL ROOM
Handbutton Connection J2
Console
(P/N 802100)
(Rear View)
J2
J1
Power Supply
(P/N 802450)
EQUIPMENT ROOM
Socket cable end Filter
(P/N 801223)
(Rear View)
Fuse Holder 4 Amp Slow Blow P/N 172E0253 (Qty 2)
MAGNET ROOM
6DISASSEMBLY REASSEMBLY
* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)
Powerhead
(P/N 802300)
ml 10/15/20 30 60 ml ml
B 60 50 ml ml
125 ml
J1, J2
Power Control
(P/N 802200) (Rear View)
MR
6-8-3
Console
(P/N 802100)
Handbutton Connection J2
(Rear View)
J2
J1
Power Supply
(P/N 802450)
(Rear View)
Fuse Holder 4 Amp Slow Blow P/N 172E0253 (Qty 2)
CONTROL ROOM
* Data Cable and Power
(P/N (P/N (P/N (P/N (P/N (P/N (P/N 801224-07 7 Ft) 801224-15 15 Ft) 801224-25 25 Ft) 801224-50 50 Ft) 801224-75 75 Ft) 801224-100 100 Ft) 801224-150 150 Ft)
EQUIPMENT ROOM
Filter
(P/N 801223)
Data Cable
(P/N 801224-03 3Ft) or (P/N 801224-07 7Ft)
6DISASSEMBLY REASSEMBLY
MAGNET ROOM
* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)
Powerhead
(P/N 802300)
A
801224-07 7 Ft) 801224-15 15 Ft) 801224-25 25 Ft) 801224-50 50 Ft) 801224-75 75 Ft) 801224-100 100 Ft) 801224-150 150 Ft)
J1, J2
B 60 50 ml ml
125 ml
Power Control
(P/N 802200) (Rear View)
MR
6DISASSEMBLY REASSEMBLY
6-8-4
6KIT PARTS
6-9-2
6.9.1 LOAD CELL SERVICE KIT (P/N 802741S) Find No. 23 20 18 21 73 59 Part Description LOAD CELL ASSY PRESSURE WASHER HOLDER, LOAD CELL RAM FACE O-RING, 022 SCREW, SET, M3, 5MM, SS-A4, BLUE 6.9.2 BUSHING REPLACEMENT SERVICE KIT (P/N 802742) Find No. 17 9 33 60 97 Part Description RETAINING, BUSHING GUIDE BUSHING WIPER SCREW, SET, M3, 8MM, SS-A4, BLUE GASKET, RAM 6.9.3 MOTOR REPLACEMENT SERVICE KIT (P/N 802743) Find No.
6KIT PARTS
Quanity 1 1 1 1 2 1
Quanity 1 1 1 4 2
Part Description MOTOR/ENCODER ASSY DRIVE A GEAR, 24DP 24T WASHER, SPRING LOCK, M4, SS-A4, BLUE DYE SCREW, SET, M4, SS-A4, BLUE SCREW, M4, 50MM, SHCS, SS-A4, BLUE
Quanity 1 1 3 2 3
1 51 70 57 72
6-9-3
6.9.4 FASTNER SERVICE KIT (P/N 802744) Find No. Part Description SEALANT, SILICONE LUBRICANT TY-RAP TIES 75 27 67 56 82 69 95 71 62 63 70 94 28 39 61 41 57 72 87 58 46 11 60 WASHER-#14S BRASS FLAT SCREW, ADJUSTMENT NUT, M6, HEX, NYLON INSERT, SS-A4, BLUE SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE SCREW, M3, 10MM, PR, PH, SS-A4, BLUE DYE WASHER, FLAT, M5, SS-A4, BLUE DYE WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE WASHER, EXT. TOOTH, M3, SS-A4, BLUE DYE SCREW, M4, 10MM, PR, PH, SS-A4, BLUE DYE SCREW, M5, 10MM, PR, PH, SS-A4, BLUE DYE WASHER, SPRING LOCK, M4, SS-A4, BLUE DYE WASHER, FLAT, M3, SSA4, BLUE DYE O RING, -008 STANDOFF, M3 - 6MM SCREW, M4, 12MM,BHCS,SS-A4,BLUE 1/8" DOWEL PIN, 316 S.S. SCREW, SET, M4, SS-A4, BLUE SCREW, M4, 50MM, SHCS, SS-A4, BLUE SCREW, M2.5, 10MM, PR,PH,SS-A4,BLUE SCREW, M4, 12MM, SHCS, SS-A4, BLUE RETAINING RING RETAINING RING, 1-3/8 SCREW, M3, 8MM, PR, FH, SS-A4, BLUE 8 2 2 2 6 6 1 8 8 22 7 15 4 2 4 4 1 8 6 4 13 1 2 10
6KIT PARTS
Quanity
6-9-4
6.9.4 FASTNER SERVICE KIT (P/N 802744) (CONTD) Find No. 73 68 59 88 19 90 89 96 42 Part Description O-RING, -022 NUT, M5, HEX, NYLON INSERT, SS-A4, BLUE SCREW, SET, M3, 5MM,SS-A4, BLUE SCREW, M3, 8MM, PH,PR,SS-A4,BLUE SCREW, SET, M6, 12MM, SS-A4, BLUE SCREW,M3, 6MM, PR, PH,SS-A4,BLUE CABLE CLAMP, 9/16" STAND OFF , 3/16" X 1", M3 DETENT, SYRINGE HOLDER 6.9.5 BEARING REPLACEMENT SERVICE KIT (P/N 802746) Find No. 10 4 11
6KIT PARTS
Quanity 4 2 2 8 1 8 1 2 2
Part Description GREASE-MULTI-PURPOSE AEROSOL BEARING ASSEMBLY, NON-FERROUS BEARING ADAPTER RETAINING RING, 1-3/8
Quanity 1 2 1
6.9.6 POWERHEAD TOP COVER SERVICE KIT (P/N 802747) Find No. 29 52 45 Part Description KEYPAD ASSEMBLY TOP COVER LENS, INDICATOR Quanity 1 1 2
6-9-5
6.9.7 SYRINGE HOLDER SERVICE KIT (P/N 802748) Find No. 56 82 95 87 96 8 83 42 85 86 71 47 Part Description SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE SCREW, M3, 10MM, PR, PH, SS-A4, BLUE DYE WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE SCREW, M2.5, 10MM, PR,PH,SS-A4,BLUE STAND OFF , 3/16" X 1", M3 NEST, SYRINGE HOLDER NEST COVER, SYRINGE HOLDER DETENT, SYRINGE HOLDER LABEL, 30/60ML, FLUID DETECTION LABEL, 50/60ML, FLUID DETECTION WASHER, EXT TOOTH PCB ASSEMBLY, SYRINGE SIZE SENSING Quanity 2 3 4 2 2 1 1 2 1 1 2 4
6KIT PARTS
6-9-6
6KIT PARTS
6DISASSEMBLY REASSEMBLY
6-10-2
6DISASSEMBLY REASSEMBLY
6DISASSEMBLY REASSEMBLY
6-11-2
6DISASSEMBLY REASSEMBLY
7-1-1
7
Section 7-3 Power Supply Section 7-4 Power Control Section 7-5 Powerhead Section 7-6 Console
THEORY OF OPERATION
This chapter describes the design and function of the Optistar LE injector. Block diagrams for the system are included for each assembly described. This chapter is divided into the following sections: Note: For additional information refer to Chapter 10 Schematics. Section 7-2 System Block Diagram
7THEORY OF OPERATION
7-1-2
7THEORY OF OPERATION
7-2-1
SYSTEM OVERVIEW
CONSOLE 802100 POWER HEAD 802300 "A" SRINGE SIZE SENSE BOARDS END LIMIT BOARDS "B" SYRINGE SIZE SENSE BOARDS ON/OFF CLOSURE +27 V SWITCHED J1 422
Theory of OPERATION
B 422
J10
J3
J4
J11 LIMIT SWITCHES SYRINGE SWITCHES KEYPAD XDUCER XDUCER EXITATION ENCODERS LIGHT CONTROL FILTER HEAD I/O
KEYPAD SWITCHES
J7, J8, J9
25 PIN D-SHELL
J1
J2
J5 J3
XDUCER A XDUCER B
D R I V E R INTERCONNECT S U P P L Y
C O M
B MOTOR DRIVE
J2 TO DRIVER
C P U
A MOTOR DRIVE
7-2-2
Theory of OPERATION
7Power Supply
7-3-2
POWER SWITCH
FILTER
LINE VOLTAGE
ON/OFF
27VDC SUPPLY
+27 VDC
ON/OFF
J2
7Power Suppy
422
The Head Communication Harness Assembly (P/N 802213) carries all head signals EXCEPT the motor drive. The Head Motors Harness (P/N 802212) carries the motor drive signals. For additional information refer to Chapter 10 Schematics.
7-4-2
7Power Control
7-4-3
7Power Control
J 6
P 2 J 4
J 2
J 3
P 3
S1
P 1
J 1
J 7
P 3
J 3
8 0 2 2 0 8 / 8 0 2 2 0 5
8 0 2 2 0 6
J 2
P 2
J3
J 1
P 1
J1
Head Connector
802207 Assembly
7-4-4
7Power Control
7-4-5
7.4.1 POWER BOARD The Power Board converts the nominal +27VDC from the Power Supply Assembly to the following voltages used by the system: +12VDC - Mostly for LEDs, interface and opto drive +5VDC - Logic power +22 to +24VDC - Most raw supply Refer to the Power Supply block diagram Figure 7-4-2. In addition, the Power Board provides voltage and current sense that can be monitored by the Main CPU. The motor raw supply can be turned on or off by the CPU, or switched from approximately +22VDC to +24VDC, depending on motor requirements. For additional information refer to Chapter 11 Schematics.
7Power Control
7-4-6
802202-1 POWER BOARD FUSED 27VDC SENSE P3 +27 V 5A FUSE U1 P4 +27 V V SENSE A SENSE
+12 V U2 +12VDC
+5 VDC U3 +5 VDC
7Power Control
P3
V CHANGE
7-4-7
7.4.2 COMMUNICATION BOARD The Communication Board provides the following functions: Carries all non-motor signals between the Power Control and the Power Head cable Carries the noninal +27VDC from the Power Supply to the on/off switch, then to the interconnect assembly. Converts the transmit and reveive signals from the CPU into RS-422 to the console Refer to the Power Supply block diagram Figure 7-4-3. For additional information refer to Chapter 11 Schematics.
7Power Control
7-4-8
J2
ON/OFF SWITCH J1
P2
RX+ RX-
7Power Control
7-4-9
7.4.3 DRIVER BOARD The Driver Board converts the 5v pulses generated by the CPU board into the 200VAC, 45 kHz motor drive signals. The motor drive signals consist of two sinusoidal waveforms (sin and cos), 90 degrees out of phase from each other, and a return for each motor layer. Each motor consists of two separate layers, each layer requiring the sin, and cos and return. The same circuits are used to drive either the A or B motor. In order to select the A motor, the CPU will pull P1:18 low, turning on U9, U10, U11, and U12. this will connect the driver circuits to the A motor. When selecting the B motor, the CPU pulls P1:17 low, turning on U13, U14, U15, and U16. This connects the driver circuits to the B motor. The CPU can also pull P1:19 low to short out the second inductor in each of the driver circuits. This is done to retune the circuit to work at lower flow rates Refer to the Power Supply block diagram Figure 7-4-4. For additional information refer to Chapter 11 Schematics.
7Power Control
7-4-10
A SELECT
J1
+ 22 - 24 VDC
DRIVE
7Power Control
COIL SWITCH
TO B MOTOR
B SELECT P1
7-4-11
7.4.4 CPU BOARD The CPU board controls and monitors all system functions. The main microprocessor, U13, is the Motorola MC 68332. System reset is handled by U19, which holds the system in reset until Vcc is up. U9 is the 512K flash memory device where the main program is stored. U2 and U5 make up the 16K of non-volatile RAM, where calibration data, achieved value data, and other information is stored. U3 and U8 are 128K SRAM. The I/O mapping is handled by U16, an Altera FPGA. The CPU also uses U16 to read the power head user buttons, syringe size switches, and the ram end limit switches. All of these signals are isolated by optocouplers U34, U35, U36, and U37. U30, also an Altera FPGA, is used to generate the motor drive signals and monitor the motor speed and position. Additionally, the CPU monitors speed, position and pressure through U1, a Universal Pulse Processor (UPP). The pressure transducers, used to sense actual syringe pressure, are mounted at the end of the power head rams. The transducers are supplied 2 VDC excitation from the D9 - U29:A - Q1 circuit on the CPU board. The excitation supply is a constant current type, so the 2V output is dependent upon both transducers being connected. The millivolt level signal from the transducers is amplified to an approximately 3.5 V max signal that is monitored by the CPU through the UPP. Refer to the Power Supply block diagram Figure 7-4-5. For additional information refer to Chapter 11 Schematics.
7Power Control
7-4-12
7Power Control
7-4-13
7Power Control
CPU sh 1
MEMORY sh 2
JTAG J 2 10 8 I/O DECODE 7 CAL TEST CTRL (EPM7128) 7 *i/o-wrt *IRQ1 U16
P-CONTROL
32.8 KHz XTAL (16.777 MHz clk cyc) 10 U13 CPU MOT 68332 16 bit ext D Bus 32 bit Adr & int D Bus 16 5 CPU STATUS DS2DS5 8 11 8 2 32 J 4 PGM/DeBug m/w P&E BDM i/f Cable DATA ADR TPU *CS0-CS10 *IRQ1-IRQ7 *DSACK
16
*CSBOOT
16
LCD *CS3
*CS8,9,10
16 *CS5,6,7
(4MHz clk cycle) U1 P7 DATA ADR 0-10 UPP UNIVERSAL PULSE PROC. (HD3140-A) A/D 1 input 1 2 2 *IRQ3 *IRQ5
PLL 7 PR FLT sh 4
*sv-cs
26
J 7
26V&1
(fm PWR)
DATA Interface Buffer Circuitry 13 OPTO I/F BUF'S 7 LCD 8 DATA 6 EX & CLK ACTIVITY DETECT (pwr on ena) 13 +12v 5 Pressure Input B Sample & Hold (BB INA118)
Phase-Locked Loop (HC4046) 1.88 MhZ - 1.6 MhZ (40-45 Hz Running)
P 2
64P I N
INTEGRATOR/ FILTER
MainCntrl
F - OUT MainCntrl
(to PWR)
+5v
SZSW
7-4-14
7Power Control
The keypad interface (U6, U7, U8, U16, U17) encodes 7 of the keypad switches (all except the A and B speedup switches) into a three line binary code to the CPU. A keypad fault (unconnected keypad) will cause an invalid code to the CPU, triggering an error message. The Powerhead contains optical encoders to control and monitor the position and speed of the motors. The encoders are supplied with +5VDC, and U1, U2, and U21 buffer encoder signals before going to the CPU board. The end limit sensing boards are supplied +12VDC, and the limit signals pass directly to the CPU. The pressure transducer excitation voltage passes through from the CPU, the tranducer outpurs pass through to the CPU.
7-5-2
7.5.2. END LIMIT SENSING BOARD Refer to Chapter 10 schematic 802302. There are two End Limit Sensing boards on each Powerhead, one for each ram. The board has an optical interrupter at each end, and is actuated by a flag on the ram. The sensor at the zero position (ram fully extended) is set exactly to the ram position corresponding to an empty syringe, while the back sensor is used to prevent ovrrun in the reverse direction. 7.5.3 SYRINGE SIZE BOARD Refer to Chapter 10 schematic 802307. There are four Syringe Size boards on each Powerhead. Each ram has two switch board assemblies, one actuated by the syringe barrel and one activated by the syringe flange. Different combinations of the syringe and flange switches are decoded by the CPU to determine what syringe is installed. The table below shows the decoding for each syringe size.
A Side Switch Inputs SIZE 0-A (BARREL) OPEN OPEN CLOSED CLOSED SIZE 1-A (FLANGE) OPEN CLOSED OPEN CLOSED SYRINGE N/A Mallinckrodt 10/15/20 Kendal 60 Mallinckrodt 30 B Side SIZE 0-B (BARREL) OPEN OPEN CLOSED CLOSED
7Powerhead
CLOSED = LOW
KEYPAD
J8 TO POWER CONTROL
DECODE A
DECODE B
SHIFT/ LATCH
2V EXITATION
A TRANSDUCER
J9 J5 TO POWER CONTROL
B TRANSDUCER
J6
J7 TO POWER CONTROL
7-5-3
7Powerhead
J8
TO POWER CONTROL
7-5-4
7Powerhead
7Console
7-6-2
7.6.2 CIRCUIT DESCRIPTIONS Interface Connection The interface connector provides the means for the console to obtain power from the supply as well as provide the path for the console to communicate with the system. RS422 Drivers and Receivers The communication channel to and from the powerpack is accomplished using RS422 drivers and receivers (MC3487 and MC3486 or equiv). The communications channel operates at a BAUD rate of 38400 bps with 1 start and 1 stop bit. A communication packet is started by a start of command hardware signal (RTS) and completed by this signal being de-asserted. For every command packet, there must be an acknowledgment of validity. Touch Screen Control The quiescent state assumes the screen is not touched. Signal X+ is driven high and X-, Y+ and Y- are high impedance. During this time the line SY- is monitored by a comparator. If the screen is touched the comparators output will generate an interrupt to the PIC (Peripheral Interface Control). Upon receipt of the interrupt, the X- line is driven low thus creating a voltage gradient across the X-axis. The X coordinate is defined by the value digitized on the SY- channel corrected by the difference between 5 volts and the value found on the SX+ channel. Then X lines are allowed to float and Y+ is driven high and Y- is driven low. The Y coordinate is then defined as the digitized value for the SX- channel corrected by the difference between 5 volts and the value found on the SY+ channel. The BYTEME signal is asserted and the X and Y coordinates are placed the SPI transmit buffer. RAM The console PCB has a total of 4M bytes of memory organized as 1M x 32. The RAM is the heart of the console control variables and data storage. All data within these devices are lost when system power is removed.
7Console
7-6-3
FLASH The console contains 4M of FLASH memory which consists of 2-2MB chips. Each FLASH device is divided up into 32-64KB sectors which are loaded with various sections of the console software. The console software is divided as follows: These devices contain the product software and the RTOS, all of the bit mapped images used on the display screens, the basic set of languages used and the fonts sets for all displayed text. Also, these devices contain the object records which are used to build the screens. Objects are the devices which combine images, text, and functionality. The screen records are simply the list of objects and locations. CPU The console uses an MCF5307 as its main microprocessor. In addition to the normal uses of a microprocessor, data flow to and from memory and peripheral devices, the CPU communicates directly with the SED1355 graphics LCD panel controller. The SED1355 gathers the information from the CPU to build the various screen images. Once the data is organized the SED1355 will generate the necessary control signals for the LCD display and display the image. The image will be maintained by the SED1355 until the CPU provides a new or updates the current set of images.
7Console
7-6-4
7Console
Diag LEDS
DS8 - DS 11
LCD Color J8
CPU MC5307e
Isolator U22
U8
:A0 - A21 clk
RS422/232
DATA:D0-D15
GND +24V
D1 SPK +5 +12 +3.3 S1:A,B,C,D Switch & Jumper Inputs (Config. Options) DATA:D0 - D31 SPK Drvr. DATA:D15 - D31
U13
U11
U12
SYS. RAM 4 Mbyte total DRAM ADDR - A0 - A21 (2X) Diag. LEDs DS4-DS7
8-1-1
8
8.1 OVERVIEW
CALIBRATION
To perform these calibrations, the Powerhead and Power Control Covers must be disassembled. For details, see Chapter 6. WARNING! Always remove Power Control and Power Head assembly from magnet room before disassembly and calibrating. Failure to follow this warning could result in personnel injury or equipment damage. 8.1.1 TOOLS AND EQUIPMENT NEEDED: The following items are part of the Optistar Service Kit (Reference Section 5.1.1) Test Display (P/N 801202) 20 Conductor Ribbon Cable (P/N 801212) Test Switch Assembly (P/N 801201) 26 Conductor Ribbon Cable (P/N 801211) MR Pressure Calibration Fixture (P/N 801240) 25 to 25 pin jumper cable for power supply to power control connector (P/N 801224-07) The items below are not part of the Optistar Service Kit 60mL, 20mL, 30mL, 50mL, and 125mL Syringes 10/15/20mL Adapter Tap Water
8CALIBRATION
8-1-2
8.1.2 FREQUENCY OF CALIBRATION The Optistar LE should be calibrated at least every 2 years or whenever a part or component that is used for pressure limiting or Ram location has been replaced. The following is a list of the various calibration procedures contained in this chapter: Limit Switch Calibration. Forward and Reverse, Rams A & B (section 8.2). Pressure Adjustments (section 8.3) Side A 60mL 30mL 10/15/20mL Side B 60mL 50mL 125mL Additional Checks (section 8.5) Factory Adjusted Syringe Size Factor Check. section 8.4.1
8CALIBRATION
8-1-3
8.1.3 CALIBRATION SET-UP Turn off power to the power supply and power control units. 1. Disconnect the 25 pin data/power cable from the Filter to the Power Control. Remove Powerhead and Power Control assemblies from the magnet room. 2. At the Power Supply, disconnect the data/power cable (J2) to the Filter. You will be connecting a 25 pin jumper cable to supply data/power to the Power Control. 3. Remove the Power Control front cover to expose the edge of the CPU board. 4. Connect the Test Display and Test Switch Assembly, (via ribbon cables), to the CPU board of the Power Control. (Test Display to J7, Test switch Assembly to J6). 5. Attach 25 pin to 25 pin jumper data/power cable from the Power Supply (J2) to the Power Control (J3) connection.
Test Display
SYRINGE
F11ML
REST VOL. ML
F12
250 200 100 50 40 30 20 10
F10
MODE
F9
F1
F13 F16 F6 F2 F3
FLOW RATE ML SEC VOLUME ML
F15 F14
F17
F4
F5
F7
F8
TIME
8CALIBRATION
Up
Mode
J7
n Dow
r Ente
8-1-4
8.1.4 INITIALIZATION OF THE POWER CONTROL CPU RAM: Initializing the CPU RAM will replace any stored calibration values with default values. This procedure should be performed in the event of any major component or board change. 1. Install the Test Display as described in the Calibration Set-UP section 8.1.3. 2. In the Power Control, Locate SW1 on the CPU board. Set all four dip switches to the Closed, ON, position. (This would be toward the edge of the board) 3. Power UP the System in the sequence listed below: 1st Power Control 2nd Power Supply 3rd Console front panel On/Off button. The system should power UP normally and all of the test displays segments should be on. 4. When initialization is complete, power DOWN the unit and reset SW1. Note : After reinitializing the CPU RAM, the calibration procedure must be performed. Note : Initializing the CPU RAM will erase all pressure limit calibrations. They will be replaced with default values. These default values should not be used without performing the calibration procedure.
8CALIBRATION
8-1-5
8.1.5 ENTERING THE CALIBRATION MODE : To enter Calibration Mode, proceed as follows: 1. Perform the calibration set-UP (refer to 8.1.2). 2. With system off, locate SW1 on the Power Control CPU board. Set dip 3 to ON and ensure that 1, 2, and 4 are OFF. 3. Power UP the System in the following sequence: 1st Power Control 2nd Power Supply 3rd Console front panel On/Off button. 4. The system should power UP normally with the test display in Mode 0. Note: Mode 0 is active when there is no number next to Mode. 8.1.6 TEST DISPLAY AND TEST SWITCH DESCRIPTIONS: The Test Display and Test Switch Assembly are used in the calibration process. Both items are illustrated below.
Test Display
Up
Mode
SYRINGE
F1
F11ML
REST VOL. ML
F12
250 200 100 50 40 30 20 10
Dow
r Ente
MODE
F10
F1
F9
8CALIBRATION
F13 F16 F6 F2 F3
FLOW RATE ML SEC VOLUME ML
F15 F14
F17
F4
F5
F7
F8
TIME
8-1-6
8.1.7 TEST SWITCH ASSEMBLY OVERVIEW Test Switch Assembly functions are as follows: UP key: Used to increase an adjustable value in a mode. DOWN key: Used to decrease an adjustable value in a mode. Enter key: Used to Update an adjusted value into memory. Mode key: Used to cycle through the 8 different modes on the Test Display. 8.1.8 TEST DISPLAY OVERVIEW For calibration, the Test Display has 8 different selectable modes. Each mode selected will present its own unique values and fields. Test Display mode selections are as follows: Mode 0 = Optic limit switch adjustment Mode 1 = Pressure adjustment Mode 2 = Not used Mode 3 = Not used Mode 4 = Not used Mode 5 = Not used Mode 6 = Power Factor test (Factory Adjusted) Mode 7 = See section 10.2.1
8CALIBRATION
8-1-7
8.1.9 MODE DESCRIPTIONS Field descriptions and functions for each mode are as follows: Note: In the descriptions which follow, the letter F proceeds each definition. This letter is merely a visual cross reference that relates to illustration Figure 8.1.2. For example, field 1 means location F1, on Figure 8.1.2 and so on. MODE 0: F1, this field is blank when Mode 0 is selected. F2 Displays AH when Ram A is active. When bH is displayed Ram B is active. F3 FoF = Front limit off; not blocked. Fon = Front limit on; blocked. F5 boF = Back limit off; not blocked. bon = Back limit on; blocked. F7 Hexadecimal number representing position of the Ram. F9 The Volume remaining. A decimal point needs to be understood one place over to the left. MODE 1: F1) Displays 1 F2 displays AH when Ram A is active. When BH is displayed, Ram B is active. F3 Indicates the actual pressure only after calibration during an injection. F5 Displays the pressure limit selected on the console from the last completed injection. F6 Pressure calibration value for the active Ram and syringe. F7 New pressure calibration value adjusted by using the UP and DOWN keys on the Test Switch Assembly. When the ENTER key is pressed, (on the Test Switch assembly) this adjusted value will be copied to field F6 and thus into memory. F8 Displays a hexadecimal number during the injection. This hex number equals half of the actual pressure displayed in field F3 when converted to decimal.
8CALIBRATION
8-1-8
MODE 6: F1) Displays 6 F2 Displays AH when Ram A is active. When bH is displayed Ram B is active. F3 Displays Fr which stands for flow rate. F5 This field indictes the flowrate of the active Ram. A decimal point is to be understood two places over from the right. For example, 400 would be 4.00 mL/s. For pushbutton operation: 0 = no Ram movement, 100 = slow speed Ram movement, 500 = fast speed Ram movement. Note: A side forward and reverse 0, 100, 500 B side forward 0, 100, 500 Reverse 0, 100, 999 (with no syringe) Reverse 0, 100, 500 (with syringe) F6 Power factor number, (Not normally adjusted). Ram A 60mL 30mL 10/15/20mL 493 470 257 Ram B 60mL 493 50mL 588 125mL 1012
F7 New Power Factor value is adjusted by using the UP and DOWN keys on the Test Switch. When the ENTER key is pressed (on the Test Switch) this adjusted value will be copied to field F6 and thus into memory.
8CALIBRATION
8CALIBRATION
8-2-2
8.2.2 FOREWORD LIMIT SWITCH CHECK & ADJUSTMENT (A) 1. Expel the syringe until the front wiper of the piston just barely touches the zero line of the syringe. Reference the following figure:
0 ml
Figure 8-2-1 Syringe and Piston 2. If the Forward limit is set correctly, the following will be true: The volume displayed on the test display shall be (00), which is 0.0 mL. The limit switch status on the display shall be (Fon), or foreword limit switch = on. The limit switch status shall be (FoF) when the volume displayed on the test display is (01) or higher. 3. If the statements in step 2 are not true, then the limit switch board for the Ram of concern will have to be adjusted forward or backward. 4. To access adjustment screws, remove the Powerhead lower front, middle covers, and syringe holder nest cover. The top cover is now lose, be careful when rotating the Powerhead. Facing the injector rams, the two adjustment screws reside on the Powerhead guide plate positioned vertical. A 3.5mm nut driver or tool (P/N 802731) is required to make adjustments. Refer to figure 6-3-1 (item 27) for adjustment screw locations. The top adjustment screw adjust the A ram limit. The bottom adjustment screw adjust the B ram limit. Adjustment screw rotation: Clockwise rotation will provide more ram forward travel. Counterclockwise rotation will provide more ram backward travel. 5. If the board had to be moved, make sure that the wiper of the Ram is centered within the optic sensor and is in no danger of hitting the sensor.
802701-C May 2003
8CALIBRATION
8-2-3
8.2.3 REVERSE LIMIT SWITCH CHECK (A) 1. Retract the Ram to its full limit. 2. If the Reverse limit is set correctly, the following will be true: The volume displayed on the test display shall be (630); or 63 mL when not in calibration mode. The volume displayed on the test display shall be (713); or 71 mL when in calibration mode The limit switch status on the display shall be (bon) when the Ram reaches the reverse limit The limit switch status shall toggle to (boF) when the volume displayed on the test display goes less than 713 on the test display. 8.2.4 FORWARD LIMIT SWITCH CHECK & ADJUSTMENT (RAM B) Use the same procedure defined for Ram A forward limit switch check and adjustment. 8.2.5 REVERSE LIMIT SWITCH CHECK (RAM B) Use the same procedure defined for Ram A Reverse Limit Switch Check.
8CALIBRATION
8-2-4
8CALIBRATION
8-3-2
8.3.2 SETUP 1. Enter the Calibration Mode by following the procedure in section 8.1.5. 2. Using the Test Switch Assembly, go to Mode 1. Note: Refer to 8.1.9 Mode Descriptions for Mode 1 field information. 3. The pressure values displayed (to the right of the flow & volume box, F6 and F7) shall both be defauted to (0335) if the Ram Initialization has been performed and a 60mL syringe is installed. 4. Install the pressure gauge fixture as illustrated in Figure 8-3-1. Note: the last fill/expel button pressed, Ram A or Ram B side, will determine which Ram information; Ram A (AH) or B (bH) appears on the test display. Also, note that when pressing a fill/expel button to toggle the display to the desired Ram, the Ram has to physically move to toggle the display to that Ram. Subsequently, the last Ram that physically moves becomes the active Ram on the display.
100 50
200
300
Pressure Tube
60 mL Syringe
8CALIBRATION
Water Container
mL
10
15
20
25
30
35
40
45
50
55
60
60 m 10/1 30 ml 5/20 l ml
B 50 ml
60 125 ml ml
8-3-3
8.3.3 SIDE A 60 ML SYRINGE: 1. Connect syringe and the pressure test assembly to the A Ram, refer to the pressure test assembly description in this chapter. Fill syringe with tap water and purge the air. 2. Go to the A only mode screen on the console by pushing the Inj. Mode button and program the following injection: 60 mL @ 4 mL/sec. @ 150 psi. on side A. 3. Run the complete injection and note the following: The peak measurement shall be 150 psi. 10 Note: the pressure bar graph on the console display will indicate a pressure value slightly lower than 150 psi. This is normal since the bar graph is displaying the average pressure while the injectors calibration point is peak. Note: that after the injection, pressing the Results button on the console will display the achieved parameters of the last 6 injections; (the last 12 if pressed twice). The pressure listed on this screen is also an average pressure, and shall be within 10 psi. of the programmed and achieved peak values. 4. If the pressure needs to be adjusted, perform the following steps: a. On the Test Switch Assembly, press the UP or DOWN buttons This action will raise or lower the bottom (0335) value, F7, on the Test Display (Note that lowering the number will increase the pressure). b. After an adjusted value is displayed, press the Enter button on the Test Switch Assembly. This will change the top value, F6 on the Test Display, to match the lower value F7 that was just modified.
8CALIBRATION
5. Repeat steps 1 through 4 as required until the 150 psi. specification is reached. Again, the pressure indicated on the results screen must match the calibration point of 150 10 psi. as well. 6. Check no-load flow rate by performing the following steps: a. Remove the syringe from the head. b. Set UP the same shot as in step 2 above. c. Toggle test display to mode 6 d. Run the shot. The flow rate displayed on the test display shall be 4.0 +/- .1 mL/ sec., (390-410), indicated under Volume ML, F5. e. Note that for all injections, the real-time flow rate is displayed while in this mode, and that when pressure limiting is engaged, the real-time flow rate will always be lower than programmed.
8-3-4
8.3.4 SIDE B 60 ML SYRINGE: 1. While in Mode 1 on the Test Display, install a 60 mL syringe on side B with no syringe on side A. 2. Go to the A + B mode screen on console by pushing the Inj. Mode key and program the following injection: A side = 1 mL @ 1 mL/sec. @ 150 psi. B side = 60 mL @ 4 mL/sec. 3. Run the injection. The measured peak shall be 150 psi. +/- 10 psi. 4. The Test Display will originally indicate a pressure limit value of (0330). This value should be adjusted to achieve 150 psi. +/- 10 psi. a. On the Test Switch Assembly, press the UP or DOWN buttons to change the F7 bottom value UP or DOWN as required. Note, that lowering the number will increase the pressure. After the adjusted value is displayed, press the Enter button. This will change the top F6 value to match the lower F7 value. 5. Repeat this process as many times as necessary to achieve the specification above. 8.3.5 SIDE B 125 ML SYRINGE: 1. Replace the 60 mL syringe with a 125 mL syringe. 2. Setup the same injection as in step 2 of section 8.3.4. 3. Run the injection. The measured peak shall be 100 psi. +/- 10 psi.
8CALIBRATION
4. Adjust pressure in the same manner as the A side. The Test Display will originally indicate a pressure limit value of (0165) and should be adjusted accordingly to achieve 100 psi. +/- 10 psi using the Test Switch Assembly.
8-3-5
8.3.6 SIDE A 20 ML SYRINGES 1. Install the 20 mL adapter on side A. 2. Go to the A only mode screen on the console by pushing the Inj. Mode button. Note: On the test display, the injector defaults to (0625) for 20mL syringe. 3. With a 20mL syringe installed, program the following injection: 20mL, 4.0mL/s, 200 psi. 4. Run the injection. The measured peak shall be 200 psi +/- 10 psi. 5. If needed, adjust the pressure calibration value in field F6. (Note again that lowering the number will increase the pressure.) 6. Repeat steps 4 & 5 above as many times as necessary to achieve the 200 psi specification. 8.3.7 SIDE A 30 ML SYRINGE 1. Install the 30 mL syringe on side A. Note: On the test display, the injector defaults to (0355). 2. Go to the A only mode screen on the console by pushing the Inj. Mode button. 3. With a 30mL syringe installed, program the following injection: 30mL, 4.0mL/s, 200 psi. 4. Run the injection. The measured peak shall be 200 psi +/- 10 psi. 5. If needed, adjust the pressure calibration value in field F6. (Note again that lowering the number will increase the pressure.) 6. Repeat steps 3 through 5 above as many times as necessary to achieve the 200 psi specification.
8CALIBRATION
8-3-6
8.3.8 SIDE B 50 ML SYRINGE Note: A 30mL syringe will be used on the B side to simulate a 50mL syringe for calibration purposes. 1. Install the 30 mL syringe on side B. 2. On the A - B injection screen, program a 1mL/s, 1mL injection for A, and a 4mL/s 30mL injection for the B side. Set the maximum pressure at 200 psi. Note: On the test display, the default value is (0365). 3. Run the injection. The measured peak shall be 200 psi +/- 10 psi. 4. If needed, adjust the pressure calibration value in field F6. (Note again that lowering the number will increase the pressure.) 5. Repeat steps 3 through 5 above as many times as necessary to achieve the 200 psi specification.
8CALIBRATION
Switch Console off first, then switch off Power Supply. Switch SW3 on the CPU board of the Power Control to OFF. All calibrations are now saved and the system has exited the calibration mode. Note: This order must always be followed when exiting Calibration Mode. Note: Properly switching the system off anywhere during the calibration process will allow the system to store the performed calibrations. Note: All 4 switches on the Power Control CPU board shall be off.
8-4-2
8CALIBRATION
8CALIBRATION
8-5-2
8CALIBRATION
9-1-1
SYSTEM INFORMATION
This chapter describes System Information mode features. From the System Information screen the following features are available: Set Display Brightness Change Pressure Units Set Beeper Volume Change Language Set Date and Time View Alarm History Enter Service Mode
9SYSTEM SETUP
System Information
Display Brightness Beeper Volume Software Versions Language
Change Date Low High
Pressure Units
Med High
PSI
Off
Low
Console: 0.00.06
Power Control:
English
9SYSTEM SETUP
AUG 01-2002
14:15
Alarm History
Memory
Inject Mode
Results
9-1-3
9.1.1 SETTING DISPLAY BRIGHTNESS 1. Activate System Information Screen as previously described. 2. Simply touch the appropriate screen button to adjust display brightness. 9.1.2 CHANGE PRESSURE UNITS This feature will change Injection Mode screens to the pressure units selected. 1. Activate System Information Screen as previously described. 2. Touch the Pressure Unit screen button. Pressure units will toggle between KPA and PSI. 9.1.3 SET BEEPER VOLUME 1. Activate System Information Screen as previously described. 2. Simply touch any one to the four Beeper Volume screen buttons. The beeper volume will change each time a button is touched. 9.1.4 CHANGING LANGUAGES This feature will change display information to the language selected. 1. Activate System Information Screen as previously described. 2. Simply touch the Language screen button. The language will change each time a button is touched. 9.1.5 SET DATE AND TIME 1. Activate System Information Screen as previously described. 2. Touch the either the Change Date or Change Time screen button. 3. Touch the arrow buttons provide to increment or decrement units. 4. To exit either function (Date or Time), simply touch the Change Date or Change Time buttons. 9.1.6 VIEW ALARM HISTORY 1. Activate System Information Screen as previously described. 2. Simply touch the Alarm History screen button. The alarm history screen will be displayed. 3. Touch the System button to return to the System Information screen.
9SYSTEM SETUP
10-1-1
10-1-2
10.1.1 SOFTWARE TRANSFER FROM CD Using My Computer, Open and view the contents of the CD. Highlight the folder on the CD with the name of the software version you are installing (for example, V2.00). Then copy the entire folder to the root directory on the C: drive by dragging the folder and dropping it on the C: drive. (You may also use Copy and Paste.) When you are finished with this copy, there should be a folder called C:\V2.00 (for example) on your hard drive. Open the new folder containing the new software (For example, C:\V2.00). Click Edit, then Select All from the Windows drop down menu. Right click on one of the selected files and select Properties. Deselect the Read-only Box. Then click Apply, then OK. If the new PROG32z.exe and PROGcfz.exe programs are already installed on your computer, skip to Chapter 10.2. Otherwise, continue with these instructions. Open and view the pemicro folder on the CD. Run the CD_setup.exe program by double-clicking the file name. This will install the PROG32z and PROGcfz files on your hard drive into the C:\pemicro folder. The Welcome to the Install shield Wizard for PEs Flash Programmer for TYCO Window appears. Click Next.
10Software Download and Upgrade
Read the License Agreement, select the I accept the terms in the License Agreement box, and click Next. On the Customer Information Window, enter your name, and click Next. On the Destination Folder Window, ensure the folder name reads C:\pemicro, and click Next. Change to c:\pemicro if necessary. Click Install. Click Finish. Remove the CD from the CD drive and click Yes to reboot your computer.
10-1-3
Now that the PROG programs have been installed on your computer, the parallel port must be configured. Open the new C:\pemicro folder. Run the addlpt.exe file by double-clicking it. If LPT1: Detected via BIOS at Hex address is displayed, select Cancel. (Your parallel port has already been configured.) If LPT1: is not listed in BIOS is displayed and is disabled, select Use HEX Address and enter an address of 0378. Click OK. If the parallel port has been configured and an error occurs when you try to exit the addlpt.exe program, click Cancel to continue. When you run the PROG32z or PROGcfz program for the first time, a Connection Assistant Dialogue Window will appear. The window under Connection port to PC should read LPT1 Parallel Port 1 (Address $0378). At the bottom of the dialogue box you may deselect the Show this dialogue before attempting to contact target. When deselected, the Connection Assistant Dialogue Window will only appear if an error is detected. Also when you run the PROG32z or PROGcfz program for the first time, the PROGxxx program will not know where to find the new software to be downloaded to the injector. So when you Choose Module for the first time, simply navigate to the folder where the software resides (for example, C:\V2.00). When you Specify S Record for the first time, navigate again to the folder where the software resides. When the PROGxxx program is run again, it will remember the folder where the software resides.
10-1-4
10-2-2
10.2.1 POWER CONTROL DOWNLOAD 1. Using the Power Supply ON/OFF switch, ensure that the power to the injector is off. 2. Disconnect the 25 pin data/power cable from the Filter to the Power Control. Remove Powerhead and Power Control assemblies from the magnet room. 3. At the Power Supply, disconnect the data/power cable (J2) to the Filter. You will be connecting a 25 pin jumper cable to supply data/power to the Power Control. 4. Connect the 25 pin D-Shell connector of the 904035 software download adapter cable to the parallel port of the PC. If necessary use the extension cable. 5. Remove the Power Control front cover as described in Chapter 6.4. 6. Pull the Power Control CPU board outward to expose connector J4 as shown in Figure 7-2-1. Install software download adapter 904035 to the J4 connector. Slide the CPU board inward until it is fully seated. 7. Attach 25 pin to 25 pin jumper data/power cable from the Power Supply (J2) to the Power Control (J3) connection.
CPU sw J4
Red Wire
Figure 7-2-1 Power Control cable location 8. Turn on power to the PC and Power Control. 9. Turn system power on using the console power ON/OFF button. Ignore any messages that appear on the console screen.
10-2-3
10. Run the PROG32Z.exe file. This should be opened from Windows
RUN PROG32Z.EXE
12. Using the mouse, select the powrpack.32p file and press enter.
SELECT powrpack.32p
PRESS ENTER
13. Type a 0 (zero) in the Base Address pop up window and press enter.
TYPE 0
PRESS ENTER
14. Using the arrow keys on the PC keyboard select ERASE MODULE and press enter. The status section at the bottom of the screen will prompt the user when the task is complete.
PRESS ENTER
CONTINUED
10-2-4
15. Using the arrow keys on the PC keyboard select SPECIFY S RECORD and press enter.
16. Using the mouse, select the powrpack.s19 file and press enter again.
SELECT powrpack.s19
PRESS ENTER
17. Using the arrow keys on the PC keyboard select PROGRAM MODULE and press enter. The status section at the bottom of the screen will display PROGRAMMED when the task is complete.
PRESS ENTER
"PROGRAMMED" IS DISPLAYED
18. Using the arrow keys on the PC Keyboard select QUIT and press enter 19. Remove power using the ON/OFF switch on the power supply. 20. When power control download is complete, remove the PC data cable at the power control CPU board.
SELECT "QUIT"
PRESS ENTER
PERFORM PROCEDURE 1 OR 2
10-2-5
Note: One of the following two procedures must be performed after downloading software into the CPU board. If neither of these procedures is performed, Alarm 23 will occur at power up. To decide which procedure to follow use the following criteria: 21 Procedure 1 involves re-initializing the Power Controls CPU RAM. This procedure should be used in the event that the CPU board has been replaced. This procedure will erase all pressure calibration values necessitating the complete calibration procedure to be performed. 21 Procedure 2 will retain the current pressure calibration values stored in memory. This procedure should only be used if neither the CPU board, nor any other major component dealing with pressure has been replaced. 21. PROCEDURE 1 1. Perform the Initialization of the Power Control CPU Ram procedure as described in section 8.1.4 in chapter 8. 2. Perform all calibration procedures as described in Chapter 8. 21. PROCEDURE 2 1. Connect the Test Display and the Test Switch assembly to the Power Control CPU board as described in Chapter 8, section 8.1.3. 2. Set SW3 to the ON position. SW3 ON position is toward the edge of the CPU board. 3. Turn on the power to the injector.
10Software Download and Upgrade
Note: The console will display Alarm 23 at power up. This is normal. 4. Using the Test Switch assembly as per section 8.1.7, go to mode 7 on the test display and note the value in the TIME window in the lower right section of the Test Display. This is field F8. (Refer to figure 8-1-2 for field locations) 5. Press the Enter button on the Test Switch assembly while observing field F8, Time, on the Test Display. The value in F8 will change after a few seconds. 6. After the value in F8 has changed, remove power from the injector by turning off the Power Supply. Remove the Test Display and Test Switch assembly and return SW3 to OFF. 7. Power on the injector. Check all calibration parameters. Refer to chapter 8.
10-2-6
J2 J6
J8
Red Pin 1
J5
J7
25
J4
10-3-2
RUN PROGCFZ.EXE
8. Using the mouse, select the console.cfp file and press enter.
SELECT console.cfp
PRESS ENTER
9. Type a 0 (zero) in the Base Address pop up window and press enter.
TYPE 0
PRESS ENTER
10. Using the mouse or arrow keys on the PC keyboard select ERASE MODULE and press enter. The status section at the bottom of the screen will prompt the user when the task is complete. The erase command may take 30 seconds. Actual erase time will depend on the speed of your PC.
PRESS ENTER
CONTINUED
10-3-3
CONSOLE CONTINUED
11. Using the mouse or arrow keys on the PC keyboard select SPECIFY S RECORD and press enter.
12. Using the mouse or arrow keys on the PC keyboard select the console.s19 file and press enter again.
SELECT console.s19
PRESS ENTER
13. Using the mouse select PROGRAM MODULE and press enter.
PRESS ENTER
14. The program module command may take 160 seconds. Actual programming time will depend on the speed of your PC.
"PROGRAMMED" IS DISPLAYED
15. Using the mouse or the arrow keys on the PC Keyboard, select QUIT and press Enter. 16. Remove power using ON/OFF switch on the power supply.
SELECT "QUIT"
PRESS ENTER
CONSOLE COMPLETE
10-3-4
11-1-1
11
OVERVIEW
Overview SCHEMATICS
SCHEMATICS
Schematics presented in this chapter are divided into the following sections: Section 11-2 Power Control Section 11-3 Console Section 11-4 Powerhead Section 11-5 Power Supply Section 11-6 Hand Button Section 11-7 Cabling
11-1-2
Overview SCHEMATICS
802701-C May 2003
11-2-1
TPU0-3 TPU0A0 A1 A2 P7 A3 A4 A5 A6 A7 RXD-IN RXD TXD A8 A9 A10 A11 A12 A13 A1 CPU-TXD A14 A15 A16 SPKR SPEAKER_OUT A17 A18
ADDRESS
SYS_RESET PCS1 PCS3 CPU-TXD RX RXD BERR IPIPE IPIP IFETCH BKPT MR FREEZE TPU0-3 TPU0TS_OK MR SERIAL_OK BOOT_CRC DGND INIT_DONE
NMI
MR DS
R/W R/
D0
D7
D8 DATA
D15
11-2-2
CS9
DATA
DATA
DATA DAT
ADDRESS
ADDRESS
11-2-3
DGND
A 8_MHZ
DATA
ADDRESS
CS3 UPP-RDY
P-CONT
PHAI DATA LCD LC P-SIN P-SI CS1 CS3 MR M-SIN M-SI P-COS SV-CS ADDRESS UPP-CS P_SPD_CNG A_MOT PH_C_A PH_C_B SZSW ADDRESS SPD-CNG SPD_CNG A_MOT DATA DAT M-COS
A-MOT
P-CONT SZSW WDTP2 SYS-GO P74 P75 A_DRV_FQ B_DRV_FQ A_MOT B_MOT B-MOT
11-2-4
+5V
K_6MA
-INA -IN
+INA
SAMPAIN-
ASAMP-OUT
-IN-B
+IN-B +IN-
SAMPBIN-
BSAMP-OUT
11-2-5
SZSW
SIZE0-A SIZE0-
SIZE1-A SIZE1-
SIZE0-B SIZE0-
SIZE1-B SIZE1-
H-CLK
FILSW0
H-DATA FILSW1
PHA-A
FILSW2
Q-SWA PHB-A
Q-SW-B Q-SW-
RESV
F-LIM-A F-LIM-
BK-LIM-A BK-LIM-
PHC-A
F-LIM-B F-LIM-
BK-LIM-B BK-LIM-
11-2-6
LCD LC
DATA
11-2-7
11-2-8
11-2-9
11-2-10
A_MOT
B_MOT
+5V DGND
ANA_GND TXD DGND K_6MA PHC-B PHCPHC-A PHCH-DATA PHA-B PHAPHA-A PHAF-LIM-B F-LIMF-LIM-A F-LIMn.c. SIZE1-A SIZE1-B Q-SW-B Q-SWFILLSW_2 FILLSW_0 n.c. +12V n.c. RXD-IN -INA -IN +INA -INB -IN +IN-B +INH-CLK PHB-B PHBBK-LIM-B BK-LIMBK-LIM-A BK-LIMSIZE0-B SIZE0-A RESV Q-SW-A Q-SWFILLSW_1 MOT-V-RET MOT_V DGND +26-IN
P_SPD_CNG
+26_FUSED 26_FUSED
11-2-11
11-2-12
11-2-13
11-2-14
11-3-1
Console SCHEMATICS
11-3-2
Console SCHEMATICS
11-3-3
Console SCHEMATICS
11-3-4
Console SCHEMATICS
11-3-5
Console SCHEMATICS
11-3-6
Console SCHEMATICS
11-4-1
Powerhead SCHEMATICS
11-4-2
Powerhead SCHEMATICS
11-4-3
Powerhead SCHEMATICS
11-4-4
Powerhead SCHEMATICS
11-4-5
Powerhead SCHEMATIC
11-4-6
Powerhead SCHEMATIC
11-5-1
11-5-2
11-6-1
Hand Button
11-6-2
Hand Button
802701-C May 2003
11-7-1
Power Control P1 Connector P1:24 P1:9 P1:39 P1:25 P1:30 GND SCREW P1:20 P1:26 P1:40 P1:13 P1:41 P1:27 P1:8 P1:22 P1:29 P1:43 P1:37 P1:23 P1:14 P1:42 P1:38 P1:10 P1:28 GND SCREW P1:11 P1:12 P1:5 P1:21 P1:7 P1:36 P1:6 P1:35 P1:34 GND SCREW
Wire Color BLACK RED BROWN YELLOW WHITE NONE GREEN ORANGE BLUE BROWN YELLOW PINK TAN BLACK RED WHITE GREEN ORANGE BLUE PURPLE SLATE PURPLE GRAY PINK NONE TAN RED/YELLOW RED/GREEN RED/BLACK BLACK RED WHITE GREEN ORANGE BLUE NONE
Powerhead Board Connectors J7, J8, J9 J7-11 J7-12 J7-2 J7-1 J7-3 J7-4 J7-5 J7-6 J7-7 J7-8 J7-9 J7-10 J8-9 J8-8 J8-4 J8-3 J8-2 J8-1 J8-14 J8-13 J8-6 J8-7 J8-12 J8-15 J8-10 J8-11 J8-5 J9-1 J9-2 J9-3 J9-5 J9-6 J9-4 J9-7 J9-8
Pin 1
Cables
J8 J7 J9
P2
P1
Pin 1
Power Control P2 Connector P2:18 P2:23 P2:21 GND SCREW P2:17 P2:26 P2:20 GND SCREW P2:24 P2:22 P2:27 GND SCREW P2:25 P2:19 P2:28 GND SCREW
Wire Color BLUE YELLOW GREEN NONE WHITE/BLUE WHITE/YELLOW WHITE/GREEN NONE RED/BLUE RED/YELLOW RED/GREEN NONE BLACK/BLUE BLACK/YELLOW BLACK/GREEN NONE -
Powerhead Motor Connections JA-1 JA-3 JA-4 JB-1 JB-3 JB-4 JB1-1 JB1-3 JB1-4 JA1-1 JA1-3 JA1-4
11-7-2
Cables
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 SHEILD
S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23 S24 S25 SHEILD
A-1-1
APPENDIX A
APPENDIXA
APPENDIXA
Installation Instructions
OVERVIEW
The purpose of this instruction sheet is to provide procedures for installing the Optistar LE Digital Injection System. CAUTION! Titanium tools must be use when performing any adjustment in the magnet room. Failure to follow this caution may result in damage to magnet equipment or cause personnel injury. WARNING! Always remove Power Control and Power Head assembly from magnet room before disassembly. Failure to follow this warning could result in personnel injury or equipment damage. CAUTION! This installation must be performed by a Qualified Technician who is completely familiar with the use and operation of the injector, and trained by a Mallinckrodt instructor. CAUTION! Electronic components, contained within the injector, may be damaged by impact. Exercise caution while handling the injector units; avoid dropping the unit or subjecting it to other physical shock. WARNING! Optistar LE components must only be placed in the areas listed below. Failure to follow this warning may result in damage to magnet equipment CONTROL ROOM: Console, and Power Supply EQUIPMENT ROOM: Filter, and Power Supply MAGNET ROOM: Powerhead, Remote Stand, and Power Control Optistar LE is a trademark of Mallinckrodt, Inc.
Optistar LE
TM
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I-1
RECEIVING INSPECTION
The Optistar LE injector should be subjected to inspection immediately upon arrival at its shipping destination. You should have one carton which contains individual packing cartons for each of the components. Refer to Table 1 below, and Figure 1 for carton components. For part numbers, Refer to Figures 8 and 9.
Carton Component Numbers 1 2 Component Description Power Control Assembly Accessory Components Filter Stand Hanger Power Supply Wall Mount Kit Cable for Power Supply Hand Switch Data Cables Manuals Console Assembly Powerhead Assembly and Syringe Adaptors Power Supply Assembly Power Control Stand Stand Post Wheel Base for Stand
3 4 5 6 7 8
Table 1
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I-2
BOX #1
BOX #6
BOX #7 BOX #5
BOX #3
Shipping Skid
Carton Assembly
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I-3
Cable Hanger
Stationary Post
Wheelbase
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I-4
POWERHEAD INSTALLATION
Refer to figure 3. 1. Carefully lift Powerhead assembly and install on Stand Elevating Rod. 2. The Powerhead is secured to the Stands Elevating Rod by one set screw. Install and tighten set screw until seated. Swivel Powerhead to ensure there is proper rotation.
Powerhead
Screw
Op
tist
ar
TM
LE
30 ml ml 20 A 10/15/
60 ml
ml ml B 60125
50 ml
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I-5
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
I-6
WALL STUD
Wall Mount Retaining Clip (P/N 802630) Wall Mount M4 Fastener Plate (P/N 802632) #10 Flat Head Fastener
10"
M4 Fastener #10 Flat Fastener
10"
5"
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
I-7
FILTER DIMENSIONS
For Filter dimensions refer to the Figure 5 below. For installation instructions contact your local sales representative.
31.75mm (1.25")
12.7mm (.5")
76.2mm (3")
(FRONT VIEW)
101.6mm (4")
76.2mm (3.0")
(SIDE VIEW)
457.2mm (18.0")
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I-8
Cable Exit
MR SCANNER
First Choice Position P.C. against wall and centered with magnet as shown.
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I-9
POWER REQUIREMENTS
Console Voltage Power Supply Voltage Frequency Current 115 VAC 10% 230 VAC 10% 50/60 Hz 4 Amp 24 VDC 10%
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I - 10
CABLE CONNECTIONS
Power Supply Located In Equipment Room Configuration Refer to Figure 7, 8, and 9. 1. Connect 115VAC cable (P/N 800918) or 230VAC cable (P/N 800935) to Power Supply. Clamp wire with the cable retainer provided. 2. Connect 25 pin data cable from console to Power Supply. 3. Connect 25 pin data cable from Power Supply to filter (equipment room side). Optional Penetration Panel Pass Through (Refer to Figure 9) Use steps 4 and 5 only if going through the penetration panel (Filter not installed on shielded wall) 4. Connect 25 pin data extension cable (short as practical maximum of 7 Ft) from Filter 25 pin, 18 inch pig tail to empty 25 pin male connector on penetration panel. 5. Connect (short as practical) ground cable, (P/N 801259-x), from Filter to penetration panel grounding strip. 6. In the Magnet Room, connect the 25 pin data cable from filter, or penetration panel if applicable, to the Power Control. 7. Connect Power head cable to Power Control.
CAUTION!
When connecting Powerhead cable to the Power Control, ensure that connector housing is correctly oriented (black arrows aligned) and fully seated before attempting to tighten thumbscrews. Failure to follow this caution may result in equipment failure. 8. Connect the Handswitch to the Console.
CAUTION!
Exercise caution when handling D-shell connectors in the magnet room. Failure to follow this caution may result in damage to magnet equipment or cause personnel injury. Note: The total cumulative length of cable from the Power Supply to the Power Control should not exceed 150 feet.
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I - 11
Fuse Power In Holder 115/230VAC 10% 4 Amp Slow Blow P/N 172E0253 (Qty 2)
Cable Retainer
Cable Retainer
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I - 12
CONTROL ROOM
Handbutton Connection J2
Console
(P/N 802100)
(Rear View)
J2
J1
Power Supply
(P/N 802450)
EQUIPMENT ROOM
Socket cable end Filter
(P/N 801223)
(Rear View)
Fuse Holder 4 Amp Slow Blow P/N 172E0253 (Qty 2)
MAGNET ROOM
* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)
Powerhead
(P/N 802300)
ml 10/15/20 30 60 ml ml
B 60 50 ml ml
125 ml
J1, J2
Power Control
(P/N 802200) (Rear View)
MR
Figure 8. Component and Cabling Overview -Power Supply located in Equipment Room -Filter permanently mounted on shielded wall option shown
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
I - 13
Console
(P/N 802100)
Handbutton Connection J2
(Rear View)
J2
J1
Power Supply
(P/N 802450)
(Rear View)
Fuse Holder 4 Amp Slow Blow P/N 172E0253 (Qty 2)
CONTROL ROOM
* Data Cable and Power
(P/N (P/N (P/N (P/N (P/N (P/N (P/N 801224-07 7 Ft) 801224-15 15 Ft) 801224-25 25 Ft) 801224-50 50 Ft) 801224-75 75 Ft) 801224-100 100 Ft) 801224-150 150 Ft)
EQUIPMENT ROOM
Filter
(P/N 801223)
Data Cable
(P/N 801224-03 or (P/N 801224-07 3Ft) 7Ft)
MAGNET ROOM
* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)
Powerhead
(P/N 802300)
A
801224-07 7 Ft) 801224-15 15 Ft) 801224-25 25 Ft) 801224-50 50 Ft) 801224-75 75 Ft) 801224-100 100 Ft) 801224-150 150 Ft)
J1, J2
B 60 50 ml ml
125 ml
Power Control
(P/N 802200) (Rear View)
MR
Figure 9. Component and Cabling Overview -Power Supply mounted in Control Room Configuration -Filter using the penetration panel pass-through option shown
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I - 14
CHECKOUT
After installation is complete perform the following procedures. For in-depth operational procedures refer to the Optistar LE Operator's Manual. TURNING SYSTEM POWER ON 1. Switch ON Power Supply. The green LED will illuminate to indicate power is ON. 2. Switch ON Power Control system. 3. At the Console, press the System ON/OFF button. The button illuminates to indicate power to the console and powerhead is ON. At this time the Power Control Power ON switch will illuminate. The injector will enable a power-up check sequence indicated by flashing the syringe size indicators located on the powerhead. TURNING SYSTEM POWER OFF At the Console, push System OFF button. Both the Power Supply and Power Control can be left ON. This allows for quicker and easier restarts from the Console. Note: If the Power Control is switched OFF while the console is still powered on, an alarm message will be displayed at the Console. Cycle System power to clear any alarm message.
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I - 15
CLOCK VERIFICATION To verify correct clock settings select the System Information screen as follows: 1. Press the Console on power button. 2. Touch the Results screen button. 3. Touch the System Info screen button. 4. The System Information Screen Date and Time Setting will be displayed.
System Information
Display Brightness Beeper Volume Software Versions Language
Change Date Low High
Pressure Units
Med High
PSI
Off
Low
Console: 0.00.06
Power Control:
English
AUG 01-2002
14:15
Alarm History
Memory
Inject Mode
Results
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I - 16
POWERHEAD STOP BUTTON CHECK 1. Power up the system 2. With no syringe present, program an injection for either A or A + B rams. 3. On the Powerhead, press the Air Check button. Then press the Start button. During ram movement observe the Powerhead injection indicators. The indicator light for the ram in motion should be flashing. 4. With ram movement taking place, press the Powerhead Stop Button. Ram movement should stop and the console will return to the injection mode screen. REMOTE START CHECK 1. Power up the system 2. With no syringe present, program an injection for either A + B ram. 3. Press the Air Check button on the Powerhead. 4. Start the injection with the Remote Start button. 5. With ram movement taking place, press the Stop button on the Console screen. Ram movement should stop. SYRINGE DETECTION CHECK 1. Power up system as previously described. 2. Place 60mL syringe in the A & B side of the injector head. 3. Verify console screen and powerhead indicates "60mL syringe". 4. Remove syringes. Then place 30mL syringe in the A & B side of the injector head. 5. Verify console and powerhead indicates "30mL syringe" for the A side, and "50mL syringe" for the B side. 6. Remove syringes. Then place 10/15/20 adaptor in the A side. Verify console and powerhead indicate 10/15/20. 7. Place 125mL syringe in the B side. Verify console and powerhead indicate 125mL syringe.
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I - 17
LIMIT SWITCH CHECK The purpose of this check is to verify limit switch board (positioned in the Powerhead) settings were not disturbed during shipment. 1. Power up the system as previously described 2. Using the Powerhead controls, fully retract both Powerhead rams. 3. Place a 60mL syringe in either A or B Powerhead rams. 4. On the Powerhead, press and hold the A side Forward Button until ram motion stops. Observe the 0 mark on the syringe, the front wiper should be engaging the 0 mark. Also, on the Console screen, observe the Volume Remain field, it should be 0.0.
0 ml
Figure 11 Press and hold the A side Reverse Button until ram retraction motion stops. Verify on the Console screen, the Volume Remain field, is 63mL. Repeat step 4 procedure for the B side Ram. If adjustments are required, refer to Chapter 8 in your service manual.
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I - 18
RAM FACE CHECK Perform the following tests to confirm that the ram faces are not putting a pre-load on the load cells before attempting to calibrate pressures. 1. Manual check of A & B side: Verify that both the A and B ram faces are not in a bind. With your hand only, they should be able to spin and pull-off. Also, note that the load cell holders shall remain secure while moving the ram faces. 2. Pressure Check of A side: Install 60mL syringe and calibration fixture as illustrated in figure 12 Pull the A side ram face outward approximately 1/8. With a full 60mL syringe, run a 10mL @ 4mL/sec. @ 100psi injection so that the plunger stops with a volume remaining adequate to run the same injection without retracting the ram. Without retracting the ram, empty the syringe and manually push the plunger to the expelled end, then repeat the same 10mL injection so the ram face does not engage the pushrod at all. Check the results screen and verify that the last injection did not achieve any pressure (-). Note: If either step 1 or 2 test fail, the ram face must be repaired and both test repeated.
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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INJECTION PRESSURE VERIFICATION The Pressure checks defined in this section will measure the flowrate to pressure relationship. To measure this relationship, the pressure gauge fixture in Figure 12 is placed in either Powerhead ram, A or B. The ram opposite the pressure gauge fixture will then contain the syringe to apply pressure. To check injection pressure, the following tools are required: 60mL syringe 20mL syringe 30mL syringe 125mL syringe Syringe Adaptor Tool kit pressure gauge fixture Water and container Note: Optistar LE pressure calibrations were established at the manufacturing site using precision instruments. When performing pressure checks, a gauge reading variation of 20 PSI is acceptable. If your reading is outside this parameter, repeat the check to confirm your gauge is not the problem. If calibration is required, refer to the Service Manual. For pressure checks in this section, the data listed in table 2 will be used: Note: This table is for reference only. To perform pressure checks, use the directions on the following pages.
INJECTION 1 2 3 4 5 6 SYRINGE 60 60 30 30 20 125 RAM SIDE A B A B A B PROGRAM VALUE 60mL 60mL 30mL 30mL 20mL 60mL FLOW RATE 4mL/sec 4mL/sec 4mL/sec 4mL/sec 4mL/sec 4mL/sec PRESSURE VALUE 150 PSI 150 PSI 200 PSI 200 PSI 200 PSI 100 PSI
Table 2 Note: When performing the pressure checks, it is the peak PSI reading on the gauge that is to be verified and recorded, not the average reading. Note: When performing B side checks, program A ram for 1mL/sec, 1mL. Note: The B side pressure value is = to the A-side value
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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To perform pressure check proceed as follows: 1. Fully retract both A and B rams. 2. Manually fill a 60mL syringe. Note: It may be necessary to perform the fill process several times to purge air and completely fill the syringe and tubing. 3. Install filled 60mL syringe in ram A 4. Connect clear pressure tube to the back of the pressure gauge fixture. Install the pressure gauge check fixture in ram B as illustrated in Figure 12.
100 50
200
300
Pressure Tube
60 mL Syringe
Water Container
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
mL
10
15
20
25
30
35
40
45
50
55
60
60 m 10/1 30 ml 5/20 l ml
B 50 ml
60 125 ml ml
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INJECTION #1 RAM A 60 ML SYRINGE (4 ML/SEC, 60ML, 150 PSI) 20 PSI 1. At the Console, program ram A for injection, then press the 'Check' button. 2. Press Start button and observe the pressure gauge reading. Verify peak reading is within specified range. 3. Disconnect pressure gauge tube at syringe in ram A. 4. Remove the syringe in ram A. INJECTION #3 RAM A 30 ML SYRINGE (4 ML/SEC, 30ML, 200 PSI) 20 PSI 1. Retract ram A. 2. Manually fill the 30mL syringe. Note: It may be necessary to perform the fill process several times to purge air and completely fill the syringe and tubing. 3. Place 30mL syringe in ram A. 4. Connect pressure gauge tube to syringe. 5. At the Console, program ram A for injection, then press the 'Check' button. 6. Press Start button and observe the pressure gauge reading. Verify peak reading is within specified range. 7. Disconnect pressure gauge tube at 30mL syringe in ram A. 8. Retract ram A. 9. Remove 30mL syringe from ram A.
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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INJECTION #5 RAM A 20 ML SYRINGE (4ML/SEC, 20ML, 200 PSI) 20 PSI 1. Retract ram A. 2. Place 20mL adaptor in ram A. 3. Manually fill the 20mL syringe. Note: It may be necessary to perform the fill process several times to purge air and completely fill the syringe and tubing. 4. Place 20mL syringe in ram A. 5. Connect pressure gauge tube to syringe. 6. At the Console, program ram A for injection, then press the Air Check button. 7. Press Start button and observe the pressure gauge reading. Verify peak reading is within specified range. 8. Disconnect pressure gauge tube at 20mL syringe in ram A. 9. Retract ram A. 10. Remove 20mL syringe from ram A and syringe adapter. 11. Move pressure gauge fixture from ram B to ram A. INJECTION #2 RAM B 60 ML SYRINGE (4 ML/SEC, 60ML, 150 PSI) 20 PSI 1. Manually fill the 60mL syringe. Note: It may be necessary to perform the fill process several times to purge air and completely fill the syringe and tubing. 2. Remove pressure gauge from ram B and place in ram A. Place 60 mL syringe in ram B. 3. Connect pressure gauge tube to syringe. 4. At the Console, program ram B for injection, then press the Air Check button. 5. Press Start button and observe the pressure gauge reading. Verify peak reading is within specified range. 6. When injection is complete, disconnect pressure gauge tube at syringe in ram B. 7. Remove 60mL syringe from ram B. 8. Retract ram B. Note: It may be necessary to perform the fill process several times to purge air and completely fill the syringe and tubing. 9. Place 30mL syringe in ram B.
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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INJECTION #4 RAM B 30 ML SYRINGE (4 ML/SEC, 30ML, 200PSI) 20 PSI Note: The 30mL syringe on the B side is used to simulate a 50mL syringe for testing purposes. 1. Manually fill the 30mL syringe 2. At the Console, program ram B for injection, then press the Air Check button. 3. Press Start button and observe the pressure gauge reading. Verify peak reading is within specified range. 4. Disconnect pressure gauge tube at syringe in ram B. 5. Remove 30mL syringe from ram B. 6. Remove 30mL syringe and from ram B. 7. Retract ram B. INJECTION #6 RAM B 125 ML SYRINGE (4 ML/SEC 100PSI) 20 PSI 1. Manually fill 125mL syringe. Note: It may be necessary to perform the fill process several times to purge air and completely fill the syringe and tubing. 2. Place 125mL syringe in ram B. 3. At the Console, program ram B for injection, then press the Air Check button. 4. Press Start button and observe the pressure gauge reading. Verify peak reading is within specified range. 5. Disconnect pressure gauge tube at syringe in ram B. 6. Remove 125mL syringe from ram B. 7. Remove pressure gauge fixture from ram A. 8. Remove 125mL syringe and from ram B. 9. Retract ram B. ACHIEVED PRESSURE RESULTS ON A RAM After all pressure checks are complete, go to the Result Screen to view injection results. Compare achieved pressure values for the A ram injection to the actual pressure gauge readings obtained in injections 1, 3, and 5. The readings should be with in +/- 20 psi of the programmed pressure value.
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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CUSTOMER INFORMATION Customer Name: Address: City, State, Country: Contact Person: Room Number:
EMI/RFI FILTER INFORMATION Part Number: Serial Number: Manufacture: Installation Company:
INSTALLER INFORMATION Company Name: Installers Name: Address: City, State, Country: Phone/Fax Number: Installation Date:
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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OPTISTAR LE INFORMATION Power Control S/N: Powerhead S/N: Console S/N: Power Supply S/N: Software Version Power Control: Software Version Console: Note: Software versions are displayed during Power-Up
INSTALLATION PRESSURE CHECK DATA INJECTION RAM SIDE SYRINGE SIZE PROGRAM FLOW RATE PROGRAM VOLUME PRESSURE GAUGE READING ACHIEVED PRESSURE READING
2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226
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I-1-1 Index
IIndex
A
ACCESSORY ITEMS 6-11-1 ACTIVATING SYSTEM INFORMATION SCREEN 9-1-2
H
history alarm library 5-2-10
I
Inject Results 1-1-4 INSTALLATION INSTRUCTIONS 802702 A-1-2
C
CABLES 6-8-1 CALIBRATION 8-1-1 Calibration Set-UP 8-1-3 CHANGE PRESSURE UNITS 9-1-3 CHANGING LANGUAGES 9-1-3 CONSOLE ASSEMBLY 6-2-10 Console Assembly (P/N 902300) 6-2-3 CONSOLE COVER REMOVAL 6-2-7 CONSOLE CPU REMOVAL 6-2-7 CONSOLE INTERFACE BOARD REMOVAL 6-2-9 Console PCB Assembly (P/ N 902300) 6-2-4 CONSOLE POWER SWITCH REMOVAL 6-2-8 CONSOLE REPLACEMENT COMPONENTS 6-2-2 CONSUMABLES 1-1-5
L
LOAD CELL REMOVAL/INSTALLATION 6-3-16
M
MOTOR REMOVAL/INSTALLATION 6-3-15
P
POWER CONTROL REPLACEMENT COMPONENTS 6-4-2 Power Requirements 1-1-2 POWER SUPPLY 6-5-1 POWER SUPPLY FUSE REPLACEMENT 6-5-4 POWER SUPPLY REPLACEMENT COMPONENTS 6-5-2 POWERHEAD BOARD REMOVAL/INSTALLATION 6-3-14 POWERHEAD CABLE REMOVAL/INSTALLATION 6-3-14 POWERHEAD COVER REMOVAL/INSTALLATION 6-3-12 POWERHEAD END LIMIT SENSING BOARDREMOVAL/INSTALLAT 6-3-15 powerhead REMOVAL/INSTALLATION FROM STAND 6-3-11 Preventive Maintenance 4-1-2 Programmable Flow Rate (A Side) 1-1-4 Programmable Flow Rate (B Side) 1-1-4 Programmable Pressure Limit (A SIDE) 1-1-4 Programmable Pressure Limit (B SIDE) 1-1-4 Programmable Volume (A Side) 1-1-4 Programmable Volume (B Side) 1-1-4
D
DC POWER SUPPLY REPLACEMENT 6-5-4 Dimensions 1-1-2 Display Subassembly (P/N 802116S) 6-2-5
E
ENCODER HARNESS REMOVAL/INSTALLATION 6-3-17 END LIMIT HARNESS REMOVAL/INSTALLATION 6-3-16 Exit Calibration Mode 8-4-1
F
FIELD REPLACEABLEPARTS 6-1-1 FILTER ASSEMBLY 6-7-1 FREQUENCY OF CALIBRATION 8-1-2
G
GENDER CONNECTORS 6-10-1
I-1-2
IIndex
R
RECEIVING INSPECTION I - 2 REMOTE STAND 6-6-1
S
Scan Delay Timer 1-1-4 SCHEMATICS 11-1-1 Screen Calibration 9-1-4 SERVICE KIT PARTS 6-9-1 SERVICE MODE 9-1-4 SET BEEPER VOLUME 9-1-3 SET DATE AND TIME 9-1-3 SETTING DISPLAY BRIGHTNESS 9-1-3 SOFTWARE DOWNLOAD AND UPGRADE 10-1-1 Stored Protocols 1-1-4 Syringe Size 1-1-4 SYRINGE SIZE SENSING BOARD REMOVAL/INSTALLATION 6-3-17 SYSTEM GENERATED MESSAGES 5-2-1
T
TOUCHSCREEN REMOVAL 6-2-8
V
VIEW ALARM HISTORY 9-1-3
W
Weight 1-1-2
NOTES
Liebel-Flarsheim
2111 E. GALBRAITH ROAD CINCINNATI, OHIO 45237-1640