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L IEBEL- F LARSHEIM Liebel-Flarsheim

Optistar LE
TM

Contrast Delivery System

ml 10/15 30 60 /20 ml ml

B 60 50 ml ml
125 ml

Service and Parts Manual


802701-C

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

RECORDING SERIAL NUMBERS AND SOFTWARE VERSIONS


To facilitate requests for information, replacement parts or optional accessories, please record the serial numbers (S/N) located on the components along with the listed data. Unit S/N (located on power control) Powerhead S/N Console S/N Date of Installation / /

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

I-2 MEANINGS OF SYMBOLS USED IN THIS MANUAL


IIntroduction

Please regard any message that follows the word Danger, Warning or Caution!
DANGER!

Hazards which will result in severe personal injury or death.

WARNING!

Hazards which could result in personal injury.

CAUTION!

Hazards which could result in equipment or property damage.

WARNING! Electrical hazards which could result in personal injury.

Non-Anesthetic proof

!
115V

Attention, consult accompanying documents.

115 V.A.C. (alternating current).

Protective earth (ground).

802701-C May 2003

I-3 MEANINGS OF SYMBOLS USED ON THE INJECTOR


Console connection identifier or Console software version identifier. Powerhead connection identifier. Power Control connection identifier.
IIntroduction

Handswitch connection identifier.

System OFF/ON (only for the Console).

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

802701-C May 2003

I-4 CLASSIFICATION IN ACCORDANCE WITH I.E.C. 601


IIntroduction

Type of protection against electric shock Class I equipment

Degree of protection against electric shock Type CF applied part (Powerhead).

Type B applied part (Console and Power Control)

Degree of Protection against ingress of water Ordinary Equipment.


SSIFIE

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

802701-C May 2003

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

INTRODUCTION ................................................................................ 1-1-1


1.1 INDICATIONS FOR USE ..............................................................................1-1-1 1.2 SERVICE TECHNICIAN QUALIFICATIONS .................................................1-1-1 1.3 SPECIFICATIONS ........................................................................................1-1-2 1.3.1 DIMENSIONS .....................................................................................1-1-2 1.3.2 WEIGHT ............................................................................................. 1-1-2 1.3.3 POWER REQUIREMENTS ................................................................1-1-2 1.3.4 ELECTRICAL LEAKAGE ....................................................................1-1-3 1.3.5 ENVIRONMENTAL .............................................................................1-1-3 1.3.6 SYRINGE SIZE ..................................................................................1-1-4 1.3.7 PROGRAMMABLE FLOW RATE (A SIDE) ........................................1-1-4 1.3.8 PROGRAMMABLE FLOW RATE (B SIDE) ........................................1-1-4 1.3.9 PROGRAMMABLE VOLUME (A SIDE) ..............................................1-1-4 1.3.10 PROGRAMMABLE VOLUME (B SIDE) ............................................1-1-4 1.3.11 PROGRAMMABLE PRESSURE LIMIT (A SIDE) .............................1-1-4 1.3.12 PROGRAMMABLE PRESSURE LIMIT (B SIDE) .............................1-1-4 1.3.13 SCAN DELAY TIMER .......................................................................1-1-4 1.3.14 STORED PROTOCOLS ...................................................................1-1-4 1.3.15 INJECT RESULTS ............................................................................1-1-4

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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

OVERVIEW OF SYSTEM FEATURES ........................................................................................ 2-1-1


2.1 GENERAL .....................................................................................................2-1-1 Figure 2-1-1 System Components ...................................................... 2-1-1 2.2 POWERHEAD ..............................................................................................2-1-2 Figure 2-2-1 Powerhead ......................................................................2-1-2 2.3 CONSOLE ....................................................................................................2-1-3 Figure 2-3-1 Console ..........................................................................2-1-3 2.4 REMOTE START .......................................................................................... 2-1-4 2.5 POWER SYSTEM .........................................................................................2-1-4 Figure 2-5-1. Power Supply Overview .................................................2-1-4

802701-C May 2003

iii BASIC OPERATIONS ........................................................................ 3-1-1


Table Of Contents

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

802701-C May 2003

iv MAINTENANCE AND CHECKOUT PROCEDURES .................................................... 4-1-1


4.1 MAINTENANCE SCHEDULE ....................................................................... 4-1-2 4.1.1 DAILY INSPECTION ...........................................................................4-1-2 4.2 OPERATIONAL CHECKOUT PROCEDURES..............................................4-2-1 4.2.1 ITEMS REQUIRED .............................................................................4-2-1 4.2.2 POWERHEAD OVERVIEW ................................................................ 4-2-1 Figure 4-2-1 Powerhead ......................................................................4-2-1 4.2.3 POWERHEAD OPERATIONS ............................................................ 4-2-2 4.2.4 CONSOLE OPERATIONS ..................................................................4-2-2 4.2.5 REMOTE START OPERATIONS ........................................................ 4-2-3 4.2.6 POWERHEAD STOP BUTTON CHECK ............................................4-2-3 4.2.7 SYRINGE DETECTION CHECK ........................................................ 4-2-3 4.2.8 LIMIT SWITCH CHECK ......................................................................4-2-4 4.2.9 RAM FACE CHECK, REFER TO APPENDIX A, INSTALLATION INSTRUCTIONS 802702. .......................................... 4-2-5 4.2.10 INJECTION PRESSURE VERIFICATION, REFER TO APPENDIX A, INSTALLATION INSTRUCTIONS 802702 ........................................... 4-2-5 4.3 CLEANING PROCEDURES .........................................................................4-3-1 4.3.1 SYRINGE HOLDER AND ADAPTER .................................................4-3-1 4.3.2 POWERHEAD ....................................................................................4-3-1 4.3.3 CONSOLE ..........................................................................................4-3-1 4.3.4 POWER CONTROL ............................................................................4-3-1 4.3.5 POWER SUPPLY ............................................................................... 4-3-1

Table Of Contents

802701-C May 2003

v TROUBLESHOOTING ....................................................................... 5-1-1


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

802701-C May 2003

vi FIELD REPLACEABLE PARTS................................................................................................ 6-1-1


GENERAL INFORMATION ..................................................................................6-1-2 RETAINING SCREWS ..................................................................................6-1-2 TERMINOLOGY ........................................................................................... 6-1-2 REPLACEABLE PARTS ...............................................................................6-1-2 6.2 CONSOLE ....................................................................................................6-2-1 6.2.1 CONSOLE REPLACEMENT COMPONENTS ...................................6-2-2 6.2.2 CONSOLE COVER REMOVAL ..........................................................6-2-7 6.2.3 CONSOLE CPU REMOVAL ...............................................................6-2-7 6.2.4 DISPLAY SUBASSEMBLY REMOVAL ...............................................6-2-8 6.2.5 TOUCHSCREEN REMOVAL ..............................................................6-2-8 6.2.6 CONSOLE POWER SWITCH REMOVAL ..........................................6-2-8 6.2.7 CONSOLE SWITCH BUTTON REMOVAL .........................................6-2-9 6.2.8 CONSOLE INTERFACE BOARD REMOVAL .....................................6-2-9 6.2.9 CONSOLE ASSEMBLY ....................................................................6-2-10 6.3 POWERHEAD ..............................................................................................6-3-1 Figure 6-3-1 Powerhead on Remote Stand .........................................6-3-1 6.3.1 POWERHEAD REPLACEMENT COMPONENTS...............................6-3-2 Figure 6-3-1 Powerhead Assembly (P/N 802300-B Sht 1) .................6-3-7 Figure 6-3-2 Powerhead Assembly (P/N 802300-B Sht 2) .................6-3-8 Figure 6-3-3 Powerhead Assembly (P/N 802300-B Sht 3) .................6-3-9 Figure 6-3-4 Powerhead Cable (P/N 802303-A) ..............................6-3-10 6.3.2 POWERHEAD REMOVAL/INSTALLATION FROM STAND ...............6-3-11 Figure 6-3-4 Powerhead removal ...................................................... 6-3-11 6.3.3 POWERHEAD COVER REMOVAL/INSTALLATION .......................... 6-3-12 6.3.3.1 Syringe Holder Nest Cover Removal/Installation ................... 6-3-12 6.3.3.2 Bottom Back Cover Removal/Installation ............................... 6-3-12 6.3.3.3 Top Cover Removal/Installation ..............................................6-3-13 6.3.3.4 Bottom Front Cover Removal/Installation ............................... 6-3-13 6.3.4 POWERHEAD BOARD REMOVAL/INSTALLATION .......................... 6-3-14

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802701-C May 2003

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

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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

802701-C May 2003

ix THEORY OF OPERATION ...................................................................................... 7-1-1


Figure 7-2-1 System Overview Block Diagram....................................7-2-1 7.3 POWER SUPPLY ..........................................................................................7-2-1 Figure 7-3-1 Power Supply Block Diagram .........................................7-2-2 7.4 POWER CONTROL ......................................................................................7-4-1 Figure 7-4-1 Power Control Block Diagram .........................................7-4-3 7.4.1 POWER BOARD ................................................................................7-4-5 Figure 7-4-2 Power Board Block Diagram ...........................................7-4-6 7.4.2 COMMUNICATION BOARD ...............................................................7-4-7 Figure 7-4-3 Communication Board Block Diagram ............................7-4-8 7.4.3 DRIVER BOARD ................................................................................7-4-9 Figure 7-4-4 Driver Board Block Diagram .........................................7-4-10 7.4.4 CPU BOARD .................................................................................... 7-4-11 Figure 7-4-5 CPU Block Diagram ......................................................7-4-13 7.5 POWERHEAD ..............................................................................................7-5-1 7.5.1 POWERHEAD MAIN BOARD ............................................................7-5-1 7.5.2. END LIMIT SENSING BOARD ..........................................................7-5-2 7.5.3 SYRINGE SIZE BOARD .....................................................................7-5-2 Figure 7-5-1 Powerhead Block Diagram .............................................7-5-3 7.6 CONSOLE OVERVIEW ................................................................................7-6-1 7.6.1 CONSOLE CPU .................................................................................7-6-1 7.6.2 CIRCUIT DESCRIPTIONS .................................................................7-6-2 Figure 7-6-1 Console Block Diagram 1/2 ...........................................7-6-4

Table Of Contents

802701-C May 2003

x CALIBRATION ................................................................................... 8-1-1


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

802701-C May 2003

xi SYSTEM INFORMATION .................................................................................. 9-1-1


9.1 ACTIVATING SYSTEM INFORMATION SCREEN ........................................9-1-2 9.1.1 SETTING DISPLAY BRIGHTNESS ....................................................9-1-3 9.1.2 CHANGE PRESSURE UNITS ............................................................9-1-3 9.1.3 SET BEEPER VOLUME .....................................................................9-1-3 9.1.4 CHANGING LANGUAGES .................................................................9-1-3 9.1.5 SET DATE AND TIME.........................................................................9-1-3 9.1.6 VIEW ALARM HISTORY ....................................................................9-1-3 9.2 SERVICE MODE ..........................................................................................9-1-4 9.2.1 SCREEN CALIBRATION ....................................................................9-1-4

Table Of Contents

SOFTWARE DOWNLOAD AND UPGRADE ..................................... 10-1-1


10.1 OVERVIEW ...............................................................................................10-1-1 10.1.1 SOFTWARE TRANSFER FROM CD..............................................10-1-2 10.2 DOWNLOAD AND UPGRADE PROCEDURES .......................................10-2-1 10.2.1 POWER CONTROL DOWNLOAD ..................................................10-2-2 Figure 7-2-1 Power Control cable location ....................................................................................10-2-2 10.3 CONSOLE DOWNLOAD ..........................................................................10-3-1 Figure 10-3-1 Console Software Download Cable orientation ..............................................................10-3-1

802701-C May 2003

xii SCHEMATICS .................................................................................... 11-1-1


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

APPENDIX A ..................................................................................... A-1-1


LIST OF CONTENTS .......................................................................................... A-1-2 INSTALLATION INSTRUCTIONS 802702 ................................................... A-1-2

Index ...................................................................................................... I-1-1

802701-C May 2003

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.

1.1 INDICATIONS FOR USE


The Optistar LE is designed to inject a MR contrast medium into the vascular system for MR procedures as prescribed by qualified health care professionals. Contraindications for the use of this device are determined by the prescribing physician at the time of use based upon the contrast media package inserts.

1.2 SERVICE TECHNICIAN QUALIFICATIONS


The Optistar LE Injector should be installed, serviced and calibrated ONLY by qualified personnel who are completely familiar with the unit, have read and understood this Installation, Service and Parts Manual, and are otherwise trained in the service of equipment and procedures of this type. Failure to follow these guidelines could result in serious injury to the service technician.

802701-C May 2003

1-1-2 1.3 SPECIFICATIONS


1Overview

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

115 VAC 10% 230 VAC 10% 50/60 Hz 3Hz 4 Amp

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

1-1-5 1.4 CONSUMABLES


1Overview
WARNING!

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.

802701-C May 2003

1-1-6

1Overview

802701-C May 2003

2-1-1

2
2.1 GENERAL

OVERVIEW OF SYSTEM FEATURES

The Optistar LE consist of the components listed in Figure 2-1-1:


2OVERVIEW OF SYSTEM FEATURES
Power Control Powerhead and Remote Stand
Syringe Adapter 10/15/20ml
ml 10/15/2 30 60 0 ml ml

B 60 50 ml ml
125 ml

*Power Cable (See Note) (Qty. = 2)

Power Supply Console

EFI / RFI Filter

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

802701-C May 2003

2-1-2 2.2 POWERHEAD


The Powerhead is specially designed from materials which will not affect nor be affected by the magnetic currents of the LE.

A SIDE

Accelerator Forward Button

Reverse Button

Injection Indicators A & B Sides

Syringe Adapter

Stop Button

2OVERVIEW OF SYSTEM FEATURES

Powerhead Ram A

ml 10/15/ 30 60 20 m ml l

B 60 50 m m l
125 m l l

B SIDE

Air Check Start Button

Syringe Holder Side A

Syringe Holder Side B

Powerhead Ram B

Figure 2-2-1 Powerhead

802701-C May 2003

2-1-3 2.3 CONSOLE


The Console contains a Touch Screen display, and buttons which provides access to injection features. Connections are located at the back of the console (Refer to Figure 2-3-1).

(Rear View)

Console Data and Power Connection J1

2OVERVIEW OF SYSTEM FEATURES

Remote Start Connection J2

(Front View)

Touch Sensitive Display Screen

System ON/OFF Button

Figure 2-3-1 Console

802701-C May 2003

2-1-4 2.4 REMOTE START


The Remote Start device which attaches to the rear of the console is included so that the injection process may be started and stopped from outside the MRI area.

2.5 POWER SYSTEM


The power system consists of one Power Supply. CAUTION! The Power Supply is not designed to be placed within the Magnet Room. It may be located in the Equipment room or Control room.
2OVERVIEW OF SYSTEM FEATURES
Power Supply Housing

ON/OFF Indicator

Figure 2-5-1. Power Supply Overview

802701-C May 2003

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 TURNING SYSTEM POWER ON/OFF


Before system power is applied, ensure all cable connections are properly secured. To power-up the system proceed as follows: 1. Switch Power Supply On. This switch is located on the rear of the power supply. 2. Switch Power Control On. This switch is located on back of power control. 3. Press the system On/Off button. This switch is located on the front of the console. The button illuminates to indicate power to the console and powerhead is ON. The injector will enable a power-up check sequence indicated by flashing the syringe size indicators located on the powerhead. 4. Check status indicators. 5. To switch system power OFF, press the system On/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. 3.1.1 STATUS INDICATORS Normal Status On the Power Control, the green power ON/OFF switch light should be illuminated, this indicates the Power Control has DC power applied to it. On the Power Supply, when the green LED light is ON this indicates the Power Supply is functionally properly. Fault Condition A red alarm window will appear on the console. This symbol indicates the Power Control has lost power.
3BASIC OPERATION

802701-C May 2003

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

802701-C May 2003

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

Check for air in syringe and tubing


Volume Remaining

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

802701-C May 2003

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

Inj. Mode >

Disable

Figure 3-1-2 Progress Screen

802701-C May 2003

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

Figure 3-1-5 Single Phase Injection only-no flush: Progress Screen

3BASIC OPERATION

802701-C May 2003

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

802701-C May 2003

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

Figure 3-1-6 Description of Information on the Progress Screens

3BASIC OPERATION

802701-C May 2003

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

Check for air in syringe and tubing


Volume Remaining

60
Scan Delay

Flow
ml/sec

Volume
ml

0
PSI

0.0

60

Max Vol

200
Drip

Time 1:30

3BASIC OPERATION

Memory

Inj. Mode >

Results

Figure 3-1-7 Location of the Drip Mode key on the Single Phase Injection Setup Screen

802701-C May 2003

3-1-10

Drip Mode

B
60

Drip Volume 60 ml

Drip Time 0:00 Hr:Min


CANCEL

Check for air in syringe and tubing

Flow
ml/sec

Volume
ml

Interval
sec

0.0

0.0

0.0

Figure 3-1-8 Drip Mode Set up Screen

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

Check for air in syringe and tubing

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

802701-C May 2003

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

802701-C May 2003

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 Time 0:00 Hr:Min

Drip End

Stop and
return to:

Drip

Inject Mode

Flow

Volume ml/sec

Interval

0.8

0.0

ml

10

sec

Figure 3-1-10 Drip Infusion Screen


3BASIC OPERATION

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.

802701-C May 2003

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

802701-C May 2003

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

Check for air in syringe and tubing


Volume Remaining

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

Figure 3-1-12 Location of the Memory key

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

2.6 3.3 6.0 3.3 6.0

Curent Value < Memory >

2.0

60

120 Results

44

Inject Mode

Figure 3-1-13 Memory List Screen

802701-C May 2003

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

Check for air in syringe and tubing

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

A+B Time 0:00


Flow
ml/sec

90
Volume Remaining

Volume
ml

60
Drip

B
Memory Inj. Mode

9.0

50

Max Vol

>

Results

Memory

Inj. Mode >

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

2.6 3.3 6.0 3.3 6.0

Dr Wagner Protocol 2

2B

Curent Value Memory >

2.0

16

200 Results

Inject Mode

Figure 3-1-14 Retrieving a Protocol from Memory

802701-C May 2003

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

EDIT NAME A ml 40 47 46 5 13 30 -50 20 16

STORE B Scan Delay 17 26 60 ----

Flow
ml/sec

Volume
ml

0
PSI

Are You Sure?


Yes

ml/sec 2.6 3.3 6.0 3.3 6.0 5.0 -3.3 5.0

PSI 90 72 72 80 72 200

ml/sec 9.0 7.8 7.8 ----

ml 50 27 3 ---Results

2.0

16

Max Vol

200
Drip

Protocol 1 Dr Wagner Protocol 2 Test 1 Protocol 7

Time 0:08

Memory

Inj. Mode >

Results

Curent Value Memory >

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

Dr Wagner Protocol 2 Test 1 Protocol 7


Curent Value Memory >

Inject Mode

Figure 3-1-15 Deleting a Protocol from Memory

802701-C May 2003

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

Protocol 1 Dr Wagner Protocol 2


A S Z Caps On D X Cancel 16 Inject Mode F C 0 Q 1 W 2 E 3 R

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 >

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

Protocol 1 Dr Wagner Protocol 2

2.6 3.3 6.0 3.3 6.0

4A 2B 4B
Curent Value Memory > 2.0 16 200 Results

Inject Mode

Figure 3-1-16 Storing a Protocol in Memory


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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

Check for air in syringe and tubing


Volume Remaining

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

Protocol 1 Dr Wagner Protocol 2


A S Z D X Cancel 16 0 Q 1 W 2 E 3 R

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

Curent Value < Memory >

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

2.6 3.3 6.0 3.3 6.0 5.0 3.3 5.0 2.0

3B

Dr Wagner Protocol 2 Test 1 Protocol 7


Curent Value Memory >

Inject Mode

Figure 3-1-17 Editing a Protocol Name 3.1.11 INJECTION RESULTS SCREEN

802701-C May 2003

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

Inj. Mode >

Results

Injection Results Page 1


No. 1 2 3 4 5 6 Date - Time
26 Jan 01 10:26

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

1.3 6.0 5.4 6.0 2.2 5.4 6.0 2.2 -

26 Jan 01 10:19 26 Jan 01 09:40

7.8

26 Jan 01 09:22

15

1.5 7.8

10 -

26 Jan 01 09:19 26 Jan 01 08:57

26 -

1.5

10

Memory

Inject Mode

Results

System Info

Figure 3-1-18 Accessing the Injection Results Screen

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3-1-20

3BASIC OPERATION

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4-1-1

MAINTENANCE AND CHECKOUT PROCEDURES

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.

4MAINTENANCE CHECKOUT PROCEDURES

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4-1-2 4.1 MAINTENANCE SCHEDULE


Preventive Maintenance should be performed at least once a year. 4.1.1 DAILY INSPECTION Although the Optistar LE is maintenance free, units need to be inspected prior to use. Inspect the Powerhead, be sure both rams are functioning properly. Ensure all cable connections are secure.

4MAINTENANCE CHECKOUT PROCEDURES

802701-C May 2003

4-2-1 4.2 OPERATIONAL CHECKOUT PROCEDURES


This procedure checks the performance of the major functions of the Optistar LE. This checkout is recommended at these times: Before using the unit for the first time As part of a routine preventive maintenance program If a problem or mis-calibration is suspected After repairs Be certain to read through the steps carefully before performing them. Some steps in this procedure require more than one observation or require a sequence to be timed. If this procedure cannot be completed or if the Optistar LE doesnt perform as described, stop the checkout and discontinue use of the injector. Call for service. 4.2.1 ITEMS REQUIRED Mallinckrodt 20ml, 30ml, 60ml and 125ml syringes The Optistar pressure guage fixture is in the Optistar optional service kit (refer to chapter 5) water and container syringe adapter Optistar LE Preventive Maintenance Checklist 4.2.2 POWERHEAD OVERVIEW
4MAINTENANCE CHECKOUT PROCEDURES

Figure 4-2-1 below illustrates the powerhead functional components


Injection Indicators A & B Sides

A SIDE

Accelerator Forward Button

Reverse Button

Syringe Adapter Powerhead Ram A

Stop Button

ml 10/15/ 30 60 20 ml ml

B 60 50 ml ml
125 ml

B SIDE

Air Check Start Button

Syringe Holder Side A

Syringe Holder Side B

Powerhead Ram B

Figure 4-2-1 Powerhead


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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.

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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

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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

4MAINTENANCE CHECKOUT PROCEDURES

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.

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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

4MAINTENANCE CHECKOUT PROCEDURES

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4-2-6

4MAINTENANCE CHECKOUT PROCEDURES

802701-C May 2003

4-3-1 4.3 CLEANING PROCEDURES


4.3.1 SYRINGE HOLDER AND ADAPTER On a daily basis, move the ram to the retract position and wipe out the inside of the syringe holder with a damp, lint-free towel. 4.3.2 POWERHEAD The exterior of the powerhead may be cleaned with a damp cloth. DO NOT use any solvents to clean the Powerhead. 4.3.3 CONSOLE The console may be dusted by using a lint-free cloth. To clean the touch screen, use a damp nonabrasive cloth towel and any commercially available non-ammonia window cleaner to regularly clean the surface. The cleaning solution should be applied to the towel rather than the surface of the touch screen. The touch screen has air vents and is not designed with water tight bezels so fluid ingress may occur from behind the panel if not cleaned carefully. 4.3.4 POWER CONTROL Clean the exterior of the power control by spraying a cloth with an all-purpose household cleaner, then gently wipe clean. 4.3.5 POWER SUPPLY Clean the exterior of the power supply by spraying a cloth with an all-purpose household cleaner, then gently wipe clean.
4MAINTENANCE CHECKOUT PROCEDURES

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4-3-2

4MAINTENANCE CHECKOUT PROCEDURES

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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

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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

Descriptions Case, Foam-Plastic

Comments Recommended to keep all the unique tools together Required for Calibration Required for Calibration Required for Calibration Required for Calibration

801240 801202 801201 801211

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

Required for Calibration

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

Screwdriver Titanium 3/16 Slotted Spanner Wrench Non-Ferrous

5TROUBLESHOOTING

801200

801214

Wrench Titanium (3mm) Hex

801215

Wrench Titanium (4mm) Hex

801254-10

Cable Assembly, Test 10 foot

802713 801224-07

LE Pressure Fixture Base Cable Assembly, 25 pin, D shell, M/F

Figure 5-1-1 Tool Kit

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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

802701-C May 2003

5-1-4

5TROUBLESHOOTING

802701-C May 2003

5-2-1 5.2 SYSTEM GENERATED MESSAGES


With these faults, a message appears on the system display. Use this chapter to help find the possible cause and what to check. The alarms are listed in numeric order as shown below, followed by a brief description. If an alarm fault occurs, find the alarm number on the list, then refer to the expanded explanation given for that alarm in this chapter. Each alarm includes a description message of what it means, probable causes, and what action to take to remedy the problem. From these messages, the defective subassembly (such as a circuit board or the powerhead) can be identified and replaced. The Optistar LE also retains a history of reported alarms. Refer to Chapter 9 for procedures.
Alarm Number 1 2 3 6 9 13 14 15 17 20 22 23 24 30 31 33 34 35 50 90

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

Table 5-2-1 Alarm listing

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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.

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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

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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.

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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

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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.

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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

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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

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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

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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

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6-1-1

FIELD REPLACEABLE PARTS

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

802701-C May 2003

6-1-2 GENERAL INFORMATION


RETAINING SCREWS Optistar LE components are retained with Non-Ferrous brass or blue stainless steel screws. The blue dyed screws are made of a type of stainless steel that is not attracted to a magnet. Always use Non-Ferrous screws if replacement is required. TERMINOLOGY The term Wire harness is used to identify internal unit cabling. The term Cable is used to identify cabling between each Optistar LE units. REPLACEABLE PARTS Each section in this chapter identifies Optistar LE component replaceable parts.

6DISASSEMBLY REASSEMBLY

802701-C May 2003

6-2-1 6.2 CONSOLE


DANGER! Before attempting any disassembly procedure, turn off all power to the Optistar MR system. The Console assembly consist of the following components: Cover Touchscreen Console CPU and Interface Board Harnesses Switch assembly Display subassembly

6DISASSEMBLY REASSEMBLY

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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
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6-2-3

6DISASSEMBLY REASSEMBLY

802701-C May 2003

Figure 6-2-1 Console Assembly (P/N 802100)

6-2-4

6DISASSEMBLY REASSEMBLY

802701-C May 2003

Figure 6-2-2 Console PCB Assembly (P/ N 802100)

6-2-5

12

6DISASSEMBLY REASSEMBLY

TOP VIEW BOTTOM VIEW

802701-C May 2003

Figure 6-2-3 Display Subassembly (P/N 802116S)

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

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

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).

802701-C May 2003

6-3-1 6.3 POWERHEAD


DANGER! Before disassembling the Powerhead, follow the power off instructions listed in each disassembly/assembly section. WARNING! Always remove Powerhead from magnet room before disassembly. Failure to follow this warning could result in personnel injury or equipment damage. The Powerhead assembly consist of the following components: Powerhead

ml 10/15/ 30 60 20 ml ml

B 50 ml 125 60 ml
ml

6DISASSEMBLY REASSEMBLY

Figure 6-3-1 Powerhead on Remote Stand

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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

802742 Kit 802388 802744 Kit 802386 802389 802344

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

802701-C May 2003

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

802701-C May 2003

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

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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

802701-C May 2003

6DISASSEMBLY REASSEMBLY

6-3-6

802701-C May 2003

6-3-7

6DISASSEMBLY REASSEMBLY

802701-C May 2003

Figure 6-3-1 Powerhead Assembly (P/N 802300-B Sht 1)

6-3-8

DETAL A TOP VIEW

6DISASSEMBLY REASSEMBLY

BOTTOM VIEW

END VIEW

802701-C May 2003

Figure 6-3-2 Powerhead Assembly (P/N 802300-B Sht 2)

6-3-9

6DISASSEMBLY REASSEMBLY

BACK VIEW
802701-C May 2003

Figure 6-3-3 Powerhead Assembly (P/N 802300-B Sht 3)

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

Powerhead Board (P/N 802301-1) Connectors

P2

P1

Pin 1

JA JB JB1 JA1 Powerhead Motor Connections

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 -

802701-C May 2003

Figure 6-3-4 Powerhead Cable (P/N 802303-A)

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

Elevating Post Adjustment Nut Tension Adjustment

Figure 6-3-4 Powerhead removal

802701-C May 2003

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.

802701-C May 2003

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

802701-C May 2003

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

802701-C May 2003

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

802701-C May 2003

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.

802701-C May 2003

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

802701-C May 2003

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.

802701-C May 2003

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

802701-C May 2003

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.

802701-C May 2003

6-4-1 6.4 POWER CONTROL


DANGER! Before attempting any disassembly procedure, turn off all power to the Optistar LE system. WARNING! Always remove Power Control from magnet room before disassembly. Failure to follow this warning could result in personnel injury or equipment damage. WARNING! The Power Control contains special Non-Ferrous screws. They are identified by blue dye. Always use Non-Ferrous blue dye screws if replacement is required. Failure to follow this warning could result in personnel injury or equipment damage. WARNING! Before removing any Power Control PC boards, ensure proper static protection devices are used. Failure to follow this warning could result in equipment damage.
6DISASSEMBLY REASSEMBLY

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

Figure 6-4-1 Power Control Assembled Unit

802701-C May 2003

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)

NON-FERROUS SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE 22

802701-C May 2003

6-4-3

26

6DISASSEMBLY REASSEMBLY

15

J1, J2

EXPLODED VIEW (BOTTOM)

REAR ASSEMBLY VIEW


802701-C May 2003

Figure 6-4-2 Power Control Assembly (P/N 802200)

6DISASSEMBLY REASSEMBLY

6-4-4

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

6-4-10

6DISASSEMBLY REASSEMBLY

802701-C May 2003

6-5-1 6.5 POWER SUPPLY


The DC Power Supply (P/N 802450) is used to power the Optistar LE system. Internal to the DC Power Supply are several key components. The primary component is the switching Power Supply. This component can be one of two brands: International Power, or Condor. The remaining components are the same regardless of which switching Power Supply brand is present. Replacement components for the Power Supply are list in section 6-5-1.

6DISASSEMBLY REASSEMBLY

802701-C May 2003

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

802701-C May 2003

6-5-3

WHITE (TO TERMINAL #7) BLACK (TO TERMINAL #4) (4 PLACES)

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

BROWN (L) TO PCB-J7

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

REAR PANEL VIEW

27 (2 FUSES)

TO AC OUTLET GND

TO AC INLET GND

8 GROUND STUD DETAIL

7 6 5

4 3 2

POWER SUPPLY OUTPUT TERMINAL DETAIL

Figure 6-5-1 Power Supply Components


802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

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.

802701-C May 2003

6-6-1 6.6 REMOTE STAND


The Remote Stand consist of a stationary post, base and hanger. 6.6.1 REMOTE STAND REPLACEMENT COMPONENTS Part No. 802500 Description REMOTE STAND ASSEMBLY Find No.

Elevating Post

Cable Hanger

Stationary Post

Wheelbase

6DISASSEMBLY REASSEMBLY

Figure 6-6-1 Remote Stand Assembly

802701-C May 2003

6DISASSEMBLY REASSEMBLY

6-6-2

802701-C May 2003

6-7-1 6.7 FILTER


The Filter is replaced as an assembly. 6.7.1 FILTER ASSEMBLY Part No. 802600 Description FILTER ASSEMBLY Find No.

12.7mm (.5")

31.75mm (1.25")

31.75mm Diameter (1.25")

6.604mm (.260") (5 Places)

76.2mm (3")

(FRONT VIEW)
101.6mm (4")

270.0mm (10.63") 285.75mm (11.25")

6DISASSEMBLY REASSEMBLY

76.2mm (3.0")

(SIDE VIEW)

457.2mm (18.0")

Figure 6-7-1 Filter Assembly

802701-C May 2003

6DISASSEMBLY REASSEMBLY

6-7-2

802701-C May 2003

6-8-1 6.8 CABLES


Replacement cables for the Optistar LE are illustrated in Figures 6-8-1 and 6-8-2. For Powerhead and data cable pinout information refer to Chapter 6.11.1.

6DISASSEMBLY REASSEMBLY

802701-C May 2003

6-8-2

CONTROL ROOM

Handbutton Connection J2

Console Data and Power Connection J1

Console
(P/N 802100)

(Rear View)

* 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)

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)

Power In 115/230VAC 10%

MAGNET ROOM

6DISASSEMBLY REASSEMBLY

* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)

* 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)

Free Hanging D-Shell Connector

Powerhead
(P/N 802300)
ml 10/15/20 30 60 ml ml

B 60 50 ml ml
125 ml

J1, J2

Remote Stand (P/N 802500)

Power Control
(P/N 802200) (Rear View)
MR

Powerhead Cable (P/N 802303) 10m (32.8 Ft)

Note: Ensure connector orientation is correct when making connection

Figure 6-8-1 Cabling

802701-C May 2003

6-8-3

Console
(P/N 802100)

Handbutton Connection J2

(Rear View)

Console Data and Power Connection J1


O I

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)

Power In 115/230VAC 10%

Ground Cable Socket cable end


(P/N (P/N (P/N (P/N 801259-1 1.5 Ft) 801259-3 3 Ft) 801259-7 7 Ft) 801259-15 15 Ft)

EQUIPMENT ROOM

Filter
(P/N 801223)

Data Cable
(P/N 801224-03 3Ft) or (P/N 801224-07 7Ft)

Penetration Panel (Using open 25-pin pass through)

6DISASSEMBLY REASSEMBLY

MAGNET ROOM

* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)

* Data Cable and Power


(P/N (P/N (P/N (P/N (P/N (P/N (P/N
ml 10/15/20 30 60 ml ml

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

Remote Stand (P/N 802500)

Power Control
(P/N 802200) (Rear View)
MR

Powerhead Cable (P/N 802303) 10m (32.8 Ft)

Note: Ensure connector orientation is correct when making connection

Figure 6-8-2 Cabling

802701-C May 2003

6DISASSEMBLY REASSEMBLY

6-8-4

802701-C May 2003

6-9-1 6.9 SERVICE KIT PARTS


Optistar LE service kit parts are defined in the following sections: Refer to section 6.3 to view a find number illustration. Section 6.9.1 Load Cell Service Kit (P/N 802741S) Section 6.9.2 Bushing Replacement Service Kit (P/N 802742) Section 6.9.3 Motor Replacement Service Kit (P/N 802743) Section 6.9.4 Fastener Service Kit (P/N 802744) Section 6.9.5 Bearing Replacement Kit (P/N 802746) Section 6.9.6 Cover Kit (P/N 802747) Section 6.9.7 Syringe Holder Service Kit (P/N 802748)

6KIT PARTS

802701-C May 2003

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

802701-C May 2003

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

802701-C May 2003

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

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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

802701-C May 2003

6-9-6

6KIT PARTS

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6-10-1 6.10 GENDER CONNECTORS


OVERVIEW If an Optistar LE is to replace an Optistar MR; gender connectors can be used to adapt existing cable connectors to the Optistar LE. Gender Connectors: 25 pin to pin connector for power supply (P/N 240E3404). 25 pin socket to socket for Console (P/N 240E3405). 25 pin/socket feed throught adapter for pin panel applications (P/N 240E3406).

6DISASSEMBLY REASSEMBLY

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6-10-2

6DISASSEMBLY REASSEMBLY

802701-C May 2003

6-11-1 6.11 ACCESSORY ITEMS


GENERAL The following accessories may be ordered from Liebel-Flarsheim to adapt to the Optistar LE injector Hand Button Start Switch Assembly: Cable length 1.8m (6.0 feet) P/N 802620. Cable length 6m (19.68 feet) P/N 802622. Syringe Adapter 10/15/20mL P/N 802730.

6DISASSEMBLY REASSEMBLY

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6-11-2

6DISASSEMBLY REASSEMBLY

802701-C May 2003

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

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7-1-2

7THEORY OF OPERATION

802701-C May 2003

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

LINE V 25 PIN D-SHELL J1/J2 SUPPLY BOX 802450 SUPPLY +27 V

Theory of OPERATION

B 422

J1/J2 25 PIN D-SHELL +27 V SWITCHED

J10

J3

J4

J11 LIMIT SWITCHES SYRINGE SWITCHES KEYPAD XDUCER XDUCER EXITATION ENCODERS LIGHT CONTROL FILTER HEAD I/O

KEYPAD SWITCHES

HEAD MAIN BOARD 802301

J7, J8, J9

J12 SIZE LEDS J6

25 PIN D-SHELL

J1

J2

J5 J3
XDUCER A XDUCER B

ENC A MOT JA, JA1

ENC B MOT JB, JB1

J1 HEAD CABLE HOUSING

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

POWER CONTROL 802200

Figure 7-2-1 System Overview Block Diagram


802701-C May 2003

7-2-2

Theory of OPERATION

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7-3-1 7.3 POWER SUPPLY


The Power Supply assembly houses a +27VDC nominal power supply, and interface board. The interface board provides the following functions: Added AC line filter for the power supply Switching of the +27VDC to the system Communication pass through from the console to the power control Refer to the Power Supply block diagram Figure 7-3-1. Connector J1 and J2 is wired identically and can be used for either the Console or the Power Control. When the green LED on the Power Supply front panel is on, the +27VDC is present inside the power supply assembly. The +27VDC is applied to J1 and J2 through U4, a solid state relay switched by a momentary closure from the Sonsole ON/OFF switch.

7Power Supply

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7-3-2

802450 SUPPLY BOX

POWER SWITCH

FILTER

LINE VOLTAGE

CONNECTOR BD 802451-1 J1 422

ON/OFF

27VDC SUPPLY

+27 VDC

ON/OFF

J2

7Power Suppy

+27 VDC SSR

422

802450 POWER SUPPLY ASSY., LE BLOCK DIAGRAM

Figure 7-3-1 Power Supply Block Diagram

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7-4-1 7.4 POWER CONTROL


The Power Control consist of five main electrical assemblies: 1. Interconnect Assembly (P/N 802207) 2. Power Board (P/N 802202-1) 3. CPU Board (P/N 802201-1) 4. Communication Board (P/N 802204-1) 5. Driver Board (P/N 802203-1) Refer to the Power Supply block diagram Figure 7-4-1. The interconnect assembly is fixed in place as part of the Power Control chassis; the other boards slide into the Power Control and mate with the interconnect assembly. The interconnect assembly consists of two backplane boards connected to each other by feed through capacitor filters. The assembly divides the Power Control into the CPU/Power (front) section, and Driver/Communication (back) section. The CPU/Power backplane board will be on of two possible part numbers: 802208-1 (Universal) or 802205-1. The Driver/Communication backplane board part number is 802206-1. All connections between the Power Control board are through the interconnect assembly. The Console Communication Harness (P/N 802214) provides two functions: 1. Carries the +27VDC nominal. 2. Carries Console communication.
7Power Control

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.

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7-4-2

7Power Control

802701-C May 2003

7-4-3

7Power Control

Calibration Switch Box Connector

Download Connector 802215 Switch/Cable Assembly

CPU Mode Switches

J 6

P 2 J 4

J 2

J 3

P 3

J 1 J 2 802214 Console Communication Harness Assembly

S1

802201-1 CPU Board


J 2

P 1

J 1

Calibration Display Connector

J 7

P 3

J 3

802202-1 Power Board


P 4 J 4

8 0 2 2 0 8 / 8 0 2 2 0 5

8 0 2 2 0 6

J 2

P 2

802204-1 Communication Board

J3

J 3 802213 Head Communication Harness Assembly

J 1

P 1

J1

802203-1 Driver Board


J2 J2

Head Connector

802207 Assembly

802212 Head Motors Harness Assembly

802200 POWER CONTROL BLOCK DIAGRAM

Figure 7-4-1 Power Control Block Diagram


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7-4-4

7Power Control

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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

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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

+22 -24 VDC DC/DC P3 P4 DC/DC on PS1 MOT V 22 -24 VDC

P3

V CHANGE

802202-1POWER BOARD BLOCK DIAGRAM

Figure 7-4-2 Power Board Block Diagram


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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

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7-4-8

802204-1 COMMUNICATION BOARD J3 HEAD I/O HEAD I/O P3

+27 VDC FROM SUPPLY BOX

J2

ON/OFF SWITCH J1

+27 VDC SWITCHED

P2

U2 TX+ COMMUNICATION TO/FROM CONSOLE TXF I L T E R S J2 TX MAX 488 RX P3

RX+ RX-

7Power Control

802204-1 COMMUNICATION BOARD BLOCK DIAGRAM

Figure 7-4-3 Communication Board Block Diagram


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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

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7-4-10

802203-1 DRIVER BOARD

A SELECT

J1

+ 22 - 24 VDC

TO A MOTOR DRIVE CIRCUIT

DRIVE

7Power Control

COIL SWITCH

TO B MOTOR

B SELECT P1

802203-1 DRIVER BOARD BLOCK DIAGRAM

Figure 7-4-4 Driver Board Block Diagram


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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

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7-4-12

7Power Control

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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

UPP & PLD sh 3

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

U9 FLASH MEM 256Kx16 (29F400T)

DATA ADR0-5 ADR11-15 SZSW

J Test 5 Points *WT

*CSBOOT

Power ON Detector mode 4

16

U3, U8 SIM SRAM 128Kx16 (HM628128)

LCD *CS3

*CS8,9,10

9.8304MHz Motor Clk 16 MHz XTAL

16 *CS5,6,7

U2, U5 NVRAM 8Kx16 STK12C68 8 8

(4MHz clk cycle) U1 P7 DATA ADR 0-10 UPP UNIVERSAL PULSE PROC. (HD3140-A) A/D 1 input 1 2 2 *IRQ3 *IRQ5

CALIB. I/F sh 6 SW BOX J IN/OUT 6 CONTROL CALIB TEST & DISPLAY

+12V Hi Spd I/F BUF'S SPEAKER (to head)

I/F & WAKEUP sh 5 +5v 4

Encoder A/B Ckls -5v xvtr -5v

PLL 7 PR FLT sh 4

*sv-cs

26

4 JTAG J 10 1 8 U30 *IRQ2 (Motor)

J 7

20 CONSOLE (RS 422 drv) P1

Pressure Input A Sample & Hold (BB INA118)

26V&1
(fm PWR)

+5, +5VB, +12 (TO I/F, sh. 5) MOTOR CONTROL (EPM9400) 3 F - IN


O.C. sel A/B & SPD

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)

ADR 0-3 Lim SW 4

4 P/M SIN/ COS

P 2

64P I N

32- (to DRVR) P I N (to DRVR)

INTEGRATOR/ FILTER
MainCntrl

F - OUT MainCntrl

(to PWR)

11.4 mA CONSTANT CURRENT SOURCE TO PRESSURE BRIDGE

+5v

802201-1 CPU BOARD BLOCK DIAGRAM

SZSW

Figure 7-4-5 CPU Block Diagram


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7-4-14

7Power Control

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7-5-1 7.5 POWERHEAD


For signal details to and from the Powerhead, refer to the Chapter 6 Cables. Refer to Figure 7-5-1. The boards located in the Powerhead are as follows: 1. Powerhead main board (P/N 802301-1). 2. End limit sensing board (one on each side, A and B) (P/N 802302-1). 3. Syringe size sensing board (two per side, flange and barrel for A and B) (P/N 802307-1). 4. Keypad Assembly, which is part of cover kit (P/N 802747) 7.5.1 POWERHEAD MAIN BOARD Refer to Chapter 11 schematic 802301 The Powerhead main board handles all signals to and from the Powerhead, the only exception being the motor drive voltage, which connects directly to the motors from the Powerhead cable. Control of the A and B ram LEDs, and enabling of the syringe size LEDs is by serial data shifted from the CPU using H_data and H_clock lines. Data is clocked into U4 on the Powerhead board, than latched on U5. Syring size switch signals go directly to the CPU to sense what syringe is installed, and to U10 to light the apropriate Syringe Siz LED on the keypad.
7Powerhead

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.

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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

OPEN CLOSED OPEN CLOSED

SYRINGE Mallinckrodt 125 N/A Kendal 60 Mallinckrodt 50

7Powerhead

CLOSED = LOW

802701-C May 2003

KEYPAD

802301-1 HEAD BOARD


SWITCHES SPEEDUP A SPEEDUP B J7 TO POWER CONTROL J12

SWITCHES SWITCHES - 7 LINES ENCODE KEYPAD FAULT SYRINGE SIZE LEDS

J8 TO POWER CONTROL

DECODE A

DECODE B

SIZE LED ENABLE

J10 FLANGE A BARREL A J7 TO POWER CONTROL

J11 FLANGE B BARREL B J8 TO POWER CONTROL

FROM SYRINGE SIZE SENSE SWITCHES 802307-1

J8 CLOCK FROM POWER CONTROL DATA

SHIFT/ LATCH

SIZE LED ENABLE A RAM LEDS B DRIVERS J7 J1 A TO POWER CONTROL

A ENC INDEX A/B J2 M B ENC B J8 TO POWER CONTROL

2V EXITATION
A TRANSDUCER

J9 J5 TO POWER CONTROL

B TRANSDUCER

J6

J3 A LIMITS 802302-1 J4 B LIMITS 802302-1


802701-C May 2003

J7 TO POWER CONTROL

802301-1 HEAD BOARD BLOCK DIAGRAM

7-5-3

7Powerhead

Figure 7-5-1 Powerhead Block Diagram

J8

TO POWER CONTROL

7-5-4

7Powerhead

802701-C May 2003

7-6-1 7.6 CONSOLE OVERVIEW


The console provides the user interface through the color LCD and the touch screen. Also, the console provides the system ON/OFF switch that is operable only with the power pack circuit breaker in the ON position. Refer to the Power Supply block diagram Figure 7-6-1. 7.6.1 CONSOLE CPU The Console CPU performs the following functions. Serial communications to the power control Stores all screen information Processes touch screen inputs Provides console PIC processor for system redundant processor state machine Manages screen generation Provides BDM port for console software downloading

7Console

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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

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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

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7-6-4

7Console

Diag LEDS

DS8 - DS 11

802701-C May 2003

System Interface J5 802102-1 PIC 16F873 U3


ICSP J1 Touch J2 A0-A14 CAN U4 & U21 12C buss req. On/Off ADDR:A0 - A21 CONTROL 16Mhz Y1 D24 - D31 INV J7 RTC And Batt back SRAM U16 SNAP On Balt. PS1 clock

LCD Color J8

Panel J6 DATA:D0 - D15

CPU MC5307e
Isolator U22

Display Controler SED1355 FOA U7

Aux RGB output J3

U8
:A0 - A21 clk

RS422/232

GP I/O Aux Spkr J9

DATA:D0-D15

PROG & DATA MEM 2 MByte Flash U19


(4 Mbyte total)

GND +24V

Display Mem 1Mx16 DRAM U6 :A0-A21

D1 SPK +5 +12 +3.3 S1:A,B,C,D Switch & Jumper Inputs (Config. Options) DATA:D0 - D31 SPK Drvr. DATA:D15 - D31

Figure 7-6-1 Console Block Diagram 1/2


PROG & DATA MEM 2 Mbyte
U20

U13

U11

U12

SYS. RAM 4 Mbyte total DRAM ADDR - A0 - A21 (2X) Diag. LEDs DS4-DS7

Reset SW3 DBUG J4

+3.3 +5 40 Mhz Y2 clk

(2 chips) U17 U18

PUP Reset U14

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

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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

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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

LIMIT PRESSURE P.S.I.

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

CPU Board CPU SW 1

J7

n Dow

r Ente

Test Switch Assembly

Note: ON position is toward edge off board J6

Figure 8-1-1 Test Unit Connections

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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

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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 Switch Assembly

Test Display

Up

Mode

SYRINGE

F1

F11ML
REST VOL. ML

F12
250 200 100 50 40 30 20 10

LIMIT PRESSURE P.S.I.

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

Figure 8-1-2 Test Components

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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

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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

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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

F11 Ram A 60mL 30mL 10/15/20mL 9 7 5 Ram B 60mL 6 50mL 8 125mL 10

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8-2-1 8.2 LIMIT SWITCH CALIBRATION (MODE 0):


8.2.1 SETUP 1. Make sure both powerhead Rams are fully retracted & no adapters are installed. 2. Enter the Calibration Mode. 3. On the switch assembly, press the mode button repeatedly until mode 0 is selected on the test display. Note: Refer to 8.1.9 Mode Descriptions for Mode 0 field information. 4. Install a 60mL syringe on the A Ram. 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. Note: the volume indicated on the test display is missing a decimal point, it must be moved over one position to the left. For example: 62 = 6.2 mL Note: the console display volume will round to the nearest whole number displayed on the test display volume.

8CALIBRATION

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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.
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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

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8-2-4

8CALIBRATION

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8-3-1 8.3 PRESSURE ADJUSTMENTS: (MODE 1)


8.3.1 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 you 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: 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 tests repeated.
8CALIBRATION

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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.

Pressure Gauge Fixture LE Base Assembly (Black)

100 50

200

300

Pressure Tube

60 mL Syringe

8CALIBRATION

Drain and Fill Tubes

Water Container

Figure 8-3-1 Pressure gauge fixture installed

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Powerhead 'B' Side Ram

mL

10

15

20

25

30

35

40

45

50

55

60

Powerhead 'A' Side Ram

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.

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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.

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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

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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

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8-4-1 8.4 ADDITIONAL CHECKS (FACTORY ADJUSTED)


Note: The following items do not have to be performed as part of a regular calibration process. 8.4.1 SYRINGE SIZE FACTOR CHECK, (POWER CONSUMPTION) : The power consumption of the injector becomes higher at lower flow rates. To compensate for this, different power consumption values are in the software depending on the size of the syringe installed. These default values are factory adjusted and would not normally be changed. 1. Toggle the Test Display to mode 6 by pressing the Mode button on the Test Switch Assembly. 2. Momentarily press a fill or expel button on the A Ram on the power head to toggle the Test Display to indicate the A Ram information. 3. With no syringe adapters installed, (ready for a 60 mL syringe), the test display shall indicate (493) for the A side. 4. Install a 30 mL syringe into the A side and confirm that the value on the Test Display changes to (470). 5. Repeat the above steps for the B side. 60mL syringe B side = 1012 50mL syringe B side = 588 8.4.2 EXIT CALIBRATION MODE:
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.

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8-4-2

8CALIBRATION

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8-5-1 8.5 EXIT CALIBRATION MODE:


Switch Console off first, then switch off Power Control Switch #3 of SW1 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

8CALIBRATION

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8-5-2

8CALIBRATION

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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

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9-1-2 9.1 ACTIVATING SYSTEM INFORMATION SCREEN


To activate the system information screen proceed as follows: 1. Turn on Console power. 2. Touch the Results screen button. 3. Touch the System Info screen button. 4. The System Information Screen will be displayed. To exit this screen, simply touch either the Memory, Inject Mode, or Results buttons.

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

Change Time Service Mode

9SYSTEM SETUP

AUG 01-2002

14:15

Alarm History

Memory

Inject Mode

Results

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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

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9-1-4 9.2 SERVICE MODE


In Service Mode the following features are available: Screen Calibration To access this mode proceed as follows: 1. Activate System Information Screen as previously described. 2. Press and hold the Hand button, then touch the Service Mode screen button. 9.2.1 SCREEN CALIBRATION 1. Activate service mode as previously described. 2. Touch the Screen Cal screen button. 3. Touch upper left corner red square. 4. Touch lower right corner red square. 5. Touch the center red square. 6. When screen calibration is complete, the System Information screen will be displayed. Note: If the red touch targets continue to reappear, this means a touch target was missed during the calibration process. Simply repeat the calibration process until the System Information screen is displayed. Note: If one of the red touch targets does not appear, this means the touch screen is physically misaligned. Refer to 6.2 for console procedures.
9SYSTEM SETUP

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10-1-1

DOWNLOAD 10 SOFTWARE AND UPGRADE


10.1 OVERVIEW
The Optistar LE software resides in FLASH memory that can be reprogrammed without chip removal and replacement. This configuration uses a personal computer to download the code to the memory ICs via a 10 pin serial port. The minimum requirements to perform the software download are as follows: Personal Computer with, at a minimum, 386 processor, 8 megabytes of RAM, CD reader, and a 25 pin D-shell parallel port. 904035, Software Download Adaptor Cable Assembly (for Power Control). Use PROG32Z.EXE to download the Power Control software. 802683, Software Download Adaptor Cable Coldfire (for Console). Use PROGCFZ.EXE to download the Console software. 25 pin PC interface extension cable, 2.5 ft. length maximum. Can be purchased locally or from LF under P/N 900235. FIRMWARE, (CD-ROM). Note: Main injector software is composed of two software sub-versions. Both major components, Power Control, and Console must have a compatible combination of software sub-versions in order for the injector to function properly. To check compatibility, compare the software sub-versions on the SYSTEM INFO SCREEN with the readme.txt file supplied with the software. To select the SYSTEM INFO SCREEN proceed as follows: 1. From the Main Injector Sceeen, press the Results button. 2. Press the System Info button. The SYSTEM INFO SCREEN will be displayed. Write down the software versions displayed.
10Software Download and Upgrade

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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.

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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.

10Software Download and Upgrade

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10Software Download and Upgrade

10-1-4

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10-2-1 10.2 DOWNLOAD AND UPGRADE PROCEDURES


Procedures defined in this section will assume you have completed instructions 10.1.1 SOFTWARE TRANSFER TO PC PROCEDURE . Note: Software updates to the Power Control could effect calibration parameters. Check and log all calibration parameters before updating. Refer to Chapter 8 in this document for procedures. WARNING! Always remove Power Control and Power Head assembly from magnet room before disassembly and upgrading. Failure to follow this warning could result in personnel injury or equipment damage.

10Software Download and Upgrade

802701-C May 2003

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.

10Software Download and Upgrade

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.

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10-2-3
10. Run the PROG32Z.exe file. This should be opened from Windows

RUN PROG32Z.EXE

11. Verify CHOOSE MODULE .32P is selected.

SELECT "CHOOSE MODULE"

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

10Software Download and Upgrade

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.

SELECT "ERASE MODULE"

PRESS ENTER

CONTINUED

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10-2-4

POWER PACK CONTINUED

15. Using the arrow keys on the PC keyboard select SPECIFY S RECORD and press enter.

SELECT "SPECIFY 'S' RECORD" PRESS ENTER

16. Using the mouse, select the powrpack.s19 file and press enter again.

SELECT powrpack.s19

PRESS ENTER

10Software Download and Upgrade

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.

SELECT "PROGRAM MODULE"

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

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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.

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10Software Download and Upgrade

10-2-6

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10-3-1 10.3 CONSOLE DOWNLOAD


Note: The Console must be connected to the Power Control to complete this procedure. 1. Ensure power to the injector is off. 2. Remove the consoles back cover as described in Chapter 6.2. 3. Connect the 25 pin D-Shell connector of 802683 Software Download Adapter Coldfire cable to the parallel port of the PC. If necessary use the extension cable. 4. Connect the Software Download Adapter cable to the Console CPU board as shown in Figure 10-3-1. Be sure the cable red wire (pin 1) is correctly oriented to J4 pin 1 when making this connection. 5. Turn on power to the PC and Power Supply, then to the Power Control, then Console. Ignore any messages that appear on the console screen during the downloading process.
Software Download Adapter Cable

J2 J6

J8

Red Pin 1

10Software Download and Upgrade

J5

J7

25

J4

Figure 10-3-1 Console Software Download Cable orientation

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10-3-2

6. Run the PROGCFZ.exe file. This should be opened from Windows.

RUN PROGCFZ.EXE

7. Verify CHOOSE MODULE .CFP is selected.

SELECT "CHOOSE MODULE"

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

10Software Download and Upgrade

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.

SELECT "ERASE MODULE"

PRESS ENTER

CONTINUED

802701-C May 2003

10-3-3

CONSOLE CONTINUED

11. Using the mouse or arrow keys on the PC keyboard select SPECIFY S RECORD and press enter.

SELECT "SPECIFY 'S' RECORD" 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.

SELECT "PROGRAM MODULE"

PRESS ENTER

10Software Download and Upgrade

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

802701-C May 2003

10Software Download and Upgrade

10-3-4

802701-C May 2003

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

802701-C May 2003

11-1-2

Overview SCHEMATICS
802701-C May 2003

11-2-1

Power Control SCHEMATICS

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

POWER CONTROL CPU SCHEMATIC 802201-D (1 OF 6)


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11-2-2

Power Control SCHEMATICS

CS6 CS5 CS7 CS7

CS8 CS10 CS10 CS1

CS9

DATA

DATA

DATA DAT

ADDRESS

ADDRESS

CSBOOT R/W R/ BOOT_PGM*

POWER CONTROL CPU SCHEMATIC 802201-D (2 OF 6)


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11-2-3

Power Control SCHEMATICS

DGND

A 8_MHZ

DATA

ADDRESS

PH_A_A PH_B_A PH_A_B PH_B_B P7

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

JTAG-TMS-IN n.c. JTAG-TCK-IN WDTP2 FB-UPA FB-UPB

JTAG-TDI JTAG-TD JTAG-TDO JTAG-TD

TCK P75 TDO P74 SAMPSAMP-A SAMP-B SAMPSSR-ON SSR-ON

POWER CONTROL CPU SCHEMATIC 802201-D (3 OF 6)


802701-C May 2003

11-2-4

+5V

Power Control SCHEMATICS

K_6MA

-INA -IN

+INA

SAMPAIN-

ASAMP-OUT

-IN-B

+IN-B +IN-

SAMPBIN-

BSAMP-OUT

POWER CONTROL CPU SCHEMATIC 802201-D (4 OF 6)


802701-C May 2003

11-2-5

Power Control SCHEMATICS

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-

POWER CONTROL CPU SCHEMATIC 802201-D (5 OF 6)


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11-2-6

Power Control SCHEMATICS

EX-IN0 EX-IN EX-IN1 EX-IN EX-IN2 EX-IN EX-IN3 EX-IN

UP DWN MODE ENTER

LCD LC

DATA

POWER CONTROL CPU SCHEMATIC 802201-D (6 OF 6)


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11-2-7

Power Control SCHEMATICS

6.3 A SLOW BLOW

POWER SCHEMATIC 802202-2-D


802701-C May 2003

11-2-8

Power Control SCHEMATICS

DRIVER BOARD SCHEMATIC 802203-C


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11-2-9

Power Control SCHEMATICS

COMMUNICATION BOARD SCHEMATIC 802204-A


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11-2-10

Power Control SCHEMATICS

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

P-SIN P-SI M-SIN M-SI +5V +12V DGND +5V

P-COS M-COS SSR-ON +5V

26VA-AN6 26V-AN4 +5V

+26_FUSED 26_FUSED

SSR-ON RESV2 SPD_CNG-DRV +5V P_SPD_CNG +5V +12V

26VA-AN6 26V-AN4 26V-AN4 SSR-ON +26_FUSED

INTERCONNECT CPU BOARD SCHEMATIC 802205-A


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11-2-11

Power Control SCHEMATICS

INTERCONNECT DRIVER BOARD SCHEMATIC 802206-A


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11-2-12

Power Control SCHEMATICS

INTERCONNECT CPU UNIVERSAL SCHEMATIC 802208-A (1 OF 2)


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11-2-13

Power Control SCHEMATICS

INTERCONNECT CPU UNIVERSAL SCHEMATIC 802208-A (2 OF 2)


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11-2-14

Power Control SCHEMATICS


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11-3-1

Console SCHEMATICS

CONSOLE SCHEMATIC 802101-C (1 OF 5)


802701-C May 2003

11-3-2

Console SCHEMATICS

CONSOLE SCHEMATIC 802101-C (2 OF 5)


800701-C May 2003

11-3-3

Console SCHEMATICS

CONSOLE SCHEMATIC 802101-C (3 OF 5)


802701-C May 2003

11-3-4

Console SCHEMATICS

CONSOLE SCHEMATIC 802101-C (4 OF 5)


800701-C May 2003

11-3-5

Console SCHEMATICS

CONSOLE SCHEMATIC 802101-C (5 OF 5)


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11-3-6

Console SCHEMATICS

CONSOLE INTERFACE SCHEMATIC 802102-C (1 OF 1)


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11-4-1

Powerhead SCHEMATICS

POWERHEAD SCHEMATIC 802301-D (1 OF 4)


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11-4-2

Powerhead SCHEMATICS

POWERHEAD SCHEMATIC 802301-D (2 OF 4)


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11-4-3

Powerhead SCHEMATICS

POWERHEAD SCHEMATIC 802301-D (3 OF 4)


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11-4-4

Powerhead SCHEMATICS

POWERHEAD SCHEMATIC 802301-D (4 OF 4)


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11-4-5

Powerhead SCHEMATIC

END LIMIT SENSING SCHEMATIC 802302-A


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11-4-6

Powerhead SCHEMATIC

SYRINGE SIZE SENSING SCHEMATIC 802307-A


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11-5-1

Power Supply SCHEMATICS

POWER SUPPLY SCHEMATIC 802451-B


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11-5-2

Power Supply SCHEMATICS

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11-6-1

Hand Button

Black Red White Green

HAND BUTTON 802620/802622


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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

Powerhead Board (P/N 802301-1) Connectors

P2

P1

Pin 1

JA JB JB1 JA1 Powerhead Motor Connections

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

POWERHEAD CABLE 802303-A


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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

DATA CABLE 801224


802701-C May 2003

A-1-1

APPENDIX A

APPENDIXA

802701-C May 2003

A-1-2 LIST OF CONTENTS


INSTALLATION INSTRUCTIONS 802702

APPENDIXA

802701-C May 2003

L IEBEL- F LARSHEIM Liebel-Flarsheim

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

802702-C May 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

I-2

BOX #1

BOX #2 (Under Box #8)

BOX #6

BOX #7 BOX #5

BOX #8 (Placed on Top Box #2) BOX #4

BOX #3

Shipping Skid

Carton Assembly

Figure 1 Shipping Carton Contents

802702-C May 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

I-3

REMOTE STAND ASSEMBLY/POWERHEAD INSTALLATION


CAUTION! Remote Stand assembly and Powerhead Installation should not be performed in the magnet room. Failure to follow this caution may result in damage to magnetic equipment. Refer to Figure 1 Shipping Carton Contents. 1. Place Remote Stand wheelbase on the floor. 2. Insert stationary post assembly into base and rotate clockwise until secured. 3. Install Cable Hanger by snapping into the mount provided on the stationary post. 4. The Remote Stand Assembly is now complete and ready for Powerhead installation.

Elevating Post Adjustment Nut

Cable Hanger

Stationary Post

Wheelbase

Figure 2 Remote Stand Components

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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

Elevating Post Adjustment Nut Tension Adjustment

Figure 3 Powerhead Installation/Adjustment

802702-C May 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

I-5

POWER SUPPLY INSTALLATION


The DC Power Supply can either be located near the Console in the Control room or in the Equipment Room. The preferred location is as close to the Filter as possible. The Filter can be mounted on the shield wall by an Original Equipment Manufacture (OEM) or third party, or the signals from the Filter can go through the penetration panel. The procedures below describe how to install Power Supply wall mount kit (P/N 802617). WARNING! Do not install DC power supply in magnet room. Failure to follow this warning could result in personnel injury or equipment damage. WARNING! Do not penetrate magnet room shield to install Wall Mount Bracket. Failure to follow this warning could result in personnel injury or equipment damage. Refer to Figure 4. 1. Select a sub wall mounting location for the power supply. Ensure wall mount bracket mounting screws will not penetrate the magnet room shield. Ensure the power supply mounting location allows good air circulation. Also, be sure the rear of the power supply is accessible for cable installation. 2. Mount kit wall bracket (P/N 802631) to either wood or metal wall stud using the #10 flat fasteners supplied in the kit. Ensure the wide part of the bracket is facing down. 3. Mount kit wall mount plate (P/N 802632), and wall mount retaining clip (P/N 802630) to the bottom of the power supply using three (3) #M4 fasteners.

802702-C May. 2003

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

Wall Mount Bracket (P/N 802631)

10"
M4 Fastener #10 Flat Fastener

10"

5"

Power Supply Housing (P/N 802428)

Figure 4 Power Supply Wall Installation

802702-C May 2003

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")

31.75mm Diameter (1.25")

6.604mm (.260") (5 Places)

76.2mm (3")

(FRONT VIEW)
101.6mm (4")

270.0mm (10.63") 285.75mm (11.25")

76.2mm (3.0")

(SIDE VIEW)

457.2mm (18.0")

Figure 5 Filter Dimensions

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

I-8

POWER CONTROL PLACEMENT AND ORIENTATION GUIDELINES


Refer to Figure 6 for placement orientation and location. The Power Control unit should be located in one of the two positions as illustrated in Figure 6 below.

Cable Exit

Second Choice Position P.C. against wall as shown

MR SCANNER

First Choice Position P.C. against wall and centered with magnet as shown.

Power Control Placement Guidelines


1. The Power Control shall be placed in the lowest practical gauss level location. 2. The Power Control shall be oriented so that the cable exit is parallel to the flux lines of the magnet. 3. There are no specific placement guidelines for the Power Head, Remote Stand, or cables.

Flux Lines of Magnet

Flux Lines of Magnet

Figure 6 Power Control Placement in MR room

802702-C May 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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%

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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.

802702-C May 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

I - 11

Power Supply On/Off

25 Pin Connector To Console and Filter

Power Supply (Rear View)

Fuse Power In Holder 115/230VAC 10% 4 Amp Slow Blow P/N 172E0253 (Qty 2)

Cable Retainer

Power Supply AC Cable Retainer (Rear View)


O I

Power In 115/230VAC 10%

Cable Retainer

Figure 7. Power Supply Connections

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

I - 12

CONTROL ROOM

Handbutton Connection J2

Console Data and Power Connection J1

Console
(P/N 802100)

(Rear View)

* 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)

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)

Power In 115/230VAC 10%

MAGNET ROOM

* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)

* 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)

Free Hanging D-Shell Connector

Powerhead
(P/N 802300)
ml 10/15/20 30 60 ml ml

B 60 50 ml ml
125 ml

J1, J2

Remote Stand (P/N 802500)

Power Control
(P/N 802200) (Rear View)
MR

Powerhead Cable (P/N 802303) 10m (32.8 Ft)

Note: Ensure connector orientation is correct when making connection

Figure 8. Component and Cabling Overview -Power Supply located in Equipment Room -Filter permanently mounted on shielded wall option shown

802702-C May 2003

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)

Console Data and Power Connection J1


O I

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)

Power In 115/230VAC 10%

Ground Cable Socket cable end


(P/N (P/N (P/N (P/N 801259-1 1.5 Ft) 801259-3 3 Ft) 801259-7 7 Ft) 801259-15 15 Ft)

EQUIPMENT ROOM

Filter
(P/N 801223)

Data Cable
(P/N 801224-03 or (P/N 801224-07 3Ft) 7Ft)

Penetration Panel (Using open 25-pin pass through)

MAGNET ROOM

* NOTE: Recommended Data Cable Length, (From Power Supply to Power Control) is 46m (150 Ft)

* Data Cable and Power


(P/N (P/N (P/N (P/N (P/N (P/N (P/N
ml 10/15/20 30 60 ml ml

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

Remote Stand (P/N 802500)

Power Control
(P/N 802200) (Rear View)
MR

Powerhead Cable (P/N 802303) 10m (32.8 Ft)

Note: Ensure connector orientation is correct when making connection

Figure 9. Component and Cabling Overview -Power Supply mounted in Control Room Configuration -Filter using the penetration panel pass-through option shown

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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.

802702-C May 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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

Change Time Service Mode

AUG 01-2002

14:15

Alarm History

Memory

Inject Mode

Results

Figure 10 Date and Time Menu

802702-C May. 2003

2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

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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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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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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.

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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

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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.

Pressure Gauge Fixture LE Base Assembly (Black)

100 50

200

300

Pressure Tube

60 mL Syringe

Drain and Fill Tubes

Water Container

Figure 12. Pressure gauge fixture

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2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 Phone: (513) 761-2700 FAX: (513) 948-7226

Powerhead 'B' Side Ram

mL

10

15

20

25

30

35

40

45

50

55

60

Powerhead 'A' Side Ram

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.

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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.

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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.

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OPTISTAR LE HISTORY RECORD


To facilitate requests for information, replacement parts or optional accessories, please record the information on pages 25 and 26. Then return pages 25 and 26 to the address listed below: Mallinckrodt, Liebel-Flarsheim Business 2111 East Galbraith Road Cincinnati, Ohio 45237 - 1640 (Attn: Service) Fax No. 513 - 948 - 7226

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:

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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

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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

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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

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NOTES

Liebel-Flarsheim
2111 E. GALBRAITH ROAD CINCINNATI, OHIO 45237-1640