802701-c optistar le

Liebel-Flarsheim

ContrastDelivery System

Service and Parts Manual802701-C

L IEBEL-FLARSHEIM

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml

LEOptistar TM

LE

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 cleanPowerhead”

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 topart 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 FluidDetection, 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 informationto illustrations.

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FOREWORD

Congratulations on the purchase of your Liebel-Flarsheim Optistar LE InjectionSystem. The Optistar LE represents our effort to provide a quality product tosupport better health care throughout the world.

Regardless of how well equipment is designed, misuse or abuse will deny itsowner the expected quality of service. Misuse or abuse may occur unintentionallybecause the proper method of operating the equipment is unknown. Read thismanual carefully before operating the Optistar LE. Retain this manual for futurereference.

LIEBEL-FLARSHEIM TECHNICAL SUPPORTPhone No. 1-800-877-0791

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 thelisted 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 theResults screen.

Console______________________________________________

Powerhead ___________________________________________

Powerpack ___________________________________________

Optistar™ LE is a trademark of Mallinckrodt, Inc.

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802701-C May 2003

MEANINGS OF SYMBOLS USED IN THIS MANUAL

Please regard any message that follows the word Danger, Warning orCaution!

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 personalinjury.

Non-Anesthetic proof

! Attention, consult accompanying documents.

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

Protective earth (ground).

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802701-C May 2003

MEANINGS OF SYMBOLS USED ON THE INJECTOR

Console connection identifier or Console software versionidentifier.

Powerhead connection identifier.

Power Control connection identifier.

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

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802701-C May 2003

CLASSIFICATION IN ACCORDANCE WITH I.E.C. 601

Type of protection against electric shockClass 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 waterOrdinary Equipment.

C

LAS S I F I ED

¨

OPTISTAR™ LE

C US

Optistar LECLASSIFIED BY UNDERWRITERS LABORATORIES INC.

WITH RESPECT TO ELECTRIC SHOCK, FIRE AND MECHANICALHAZARDS ONLY IN ACCORDANCE WITH UL 2601-1

33SL

Optistar LECLASSIFIED WITH RESPECT TO ELECTRIC SHOCK, FIRE MECHANICALAND OTHER SPECIFIED HAZARDS ONLY IN ACCORDANCE WITH CAN/

CSA C22.2 NO. 601.1,33SL

0123

Authorized EC RepresentativeTYCO HEALTHCARE UK LTD154 FAREHAM ROADGOSPORT PO13 OAS UK

EMISSION’S STANDARD

The Optistar LE meets emission’s standardIEC 601-1-2 Class B

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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

EMISSION’S STANDARD ........................................................................................ I-4

INTRODUCTION ................................................................................ 1-1-11.1 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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1.4 CONSUMABLES ..........................................................................................1-1-5

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 SYSTEMFEATURES ........................................................................................ 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

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BASIC OPERATIONS........................................................................ 3-1-13.1 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/INFORMATIONDISPLAYED 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/INFORMATIONON 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/INFORMATIONON 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

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MAINTENANCEAND 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

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TROUBLESHOOTING ....................................................................... 5-1-15.1 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

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FIELD REPLACEABLEPARTS................................................................................................ 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 6-3-4 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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6.3.5 POWERHEAD CABLE REMOVAL/INSTALLATION ..........................6-3-14

6.3.6 MOTOR REMOVAL/INSTALLATION..................................................6-3-15

6.3.7 POWERHEAD END LIMIT SENSING BOARDREMOVAL/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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6.5 POWER SUPPLY ..........................................................................................6-5-1

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

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THEORY OFOPERATION ...................................................................................... 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

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CALIBRATION ................................................................................... 8-1-18.1 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

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SYSTEMINFORMATION .................................................................................. 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

SOFTWARE DOWNLOAD AND UPGRADE ..................................... 10-1-110.1 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 Controlcable location ....................................................................................10-2-2

10.3 CONSOLE DOWNLOAD ..........................................................................10-3-1

Figure 10-3-1 Console SoftwareDownload Cable orientation ..............................................................10-3-1

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SCHEMATICS .................................................................................... 11-1-1OVERVIEW ........................................................................................................11-1-1

POWER CONTROL CPU SCHEMATIC 802201-D (1 OF 6) .............................11-2-1






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




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-1-1LIST OF CONTENTS.......................................................................................... A-1-2

INSTALLATION INSTRUCTIONS 802702 ................................................... A-1-2

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

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INTRODUCTION

The purpose of this manual is to provide instructions for installation, service and calibra-tion of the Optistar LE. For further information about operation and daily maintenance ofthe unit, refer to the Optistar LE Operator’s Manual.

1.1 INDICATIONS FOR USE

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

1.2 SERVICE TECHNICIAN QUALIFICATIONS

The Optistar LE Injector should be installed, serviced and calibrated ONLY by qualifiedpersonnel who are completely familiar with the unit, have read and understood thisInstallation, Service and Parts Manual, and are otherwise trained in the service of equip-ment and procedures of this type. Failure to follow these guidelines could result in seriousinjury to the service technician.

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1.3 SPECIFICATIONS

1.3.1 DIMENSIONS

• Console: 12.25”W x 8.5”H x 2.5”D (311.15mm x 215.9mm x 63.5mm)

• Console Base: 9.5”W x 2.5”H x 7”D (241.3mm x 63.5mm x 177.8mm)

• Power Control: 10.”W x 4.25”H x 15.25”D (254mm x 107.95mm x 387.3mm)

• Remote Stand: 27”W x 43”H x to 53”H (adjustable) (685.8mm x 1092.2mm Hto 1346.2mm adjustable)

• Powerhead: 7”W x 21.5”H x 5.5”D (177.8mm x 546.1mm x 139.7mm)

• Filter: 4”W x 10.00”H x 3”D (101.6mm x 254.00mm x 76.2mm)

• Power Supply: 10”W 4.25”H x 9.5”D (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 115 VAC ± 10%230 VAC ± 10%

Frequency 50/60 Hz ± 3Hz

Current 4 Amp

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1.3.4 ELECTRICAL LEAKAGE

• Chassis: Less than 300 microamps

1.3.5 ENVIRONMENTAL

• Transport and Storage: -4°F to 140°F (-20°C to 60°C);10% to 100% relative humidity

• Disposable Products: -40°F to 118°F (-40°C to 48°C);10% to 100% relative humidity

• Operation: +59°F to 95°F (15°C to 35°C)30% to 75% relative humidity; 700kPa to 1060kPa atmospheric pressure

• Biohazard Disposal: Dispose of biohazards in accordance with the require-ments of you hospital, facility or local regulations

• Electromagnetic Compatibility (EMC): The Optistar LE meets EN60601-1-2for level B conducted and radiated emissions and EMI immunity

NOTE: If any anomalies in the injector performance are noticed, identifydevices within the immediate area that are capable of producing electromag-netic 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 islocated beyond the 5 gauss limit. Operating the console or power supply withinmagnetic 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 yourauthorized service personnel.

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1.3.6 SYRINGE SIZE

• 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



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.

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1.4 CONSUMABLES

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, equip-ment damage, and/or injector performance issues (i.e. incorrect volume delivery,incorrect flow rate delivery, incorrect pressure, etc.). Safety certification of thecunsumables listed below has been performed in accordance to the appropriateEN 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 Tubingavailable 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.

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OVERVIEW OF SYSTEMFEATURES

2.1 GENERAL

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

Handswitch

Power Control

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

Console

Power Supply

EFI / RFI Filter

Powerhead andRemote Stand

Syringe Adapter10/15/20ml

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml

Figure 2-1-1 System Components

Note: Power cables supplied with your system are determined by voltage requirements asfollows:

*For 115V models, use cable Part Number is 800918

*For 230V models, use cable Part Number is 800935

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2.2 POWERHEAD

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

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml

PowerheadRam B

SyringeHolderSide B

SyringeHolderSide A

StopButton

Injection IndicatorsA & B Sides

PowerheadRam A

SyringeAdapter

A SIDE

B SIDE

Reverse Button

Start Button

Air Check

Accelerator

ForwardButton

Figure 2-2-1 Powerhead

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2.3 CONSOLE

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

(Rear View)

Remote StartConnection J2

Console Data and Power

Connection J1

(Front View)

SystemON/OFF Button

TouchSensitiveDisplayScreen

Figure 2-3-1 Console

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2.4 REMOTE START

The Remote Start device which attaches to the rear of the console is included so that theinjection 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 belocated in the Equipment room or Control room.

ON/OFF Indicator

Power Supply Housing

Figure 2-5-1. Power Supply Overview

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3 BASIC OPERATIONS

The intent of this chapter is to provide maintenance personnel with a basic overview ofoperational features of the Optistar LE injection system. For indepth operational informa-tion refer to the operator’s manual.

3.1 TURNING SYSTEM POWER ON/OFF

Before system power is applied, ensure all cable connections are properly secured. Topower-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. Theinjector will enable a power-up check sequence indicated by flashing the syringe sizeindicators located on the powerhead.

4. Check status indicators.

5. To switch system power OFF, press the system On/Off button. Both the PowerSupply and Power Control can be left ON. This allows for quicker and easier restartsfrom the Console.

NOTE: If the Power Control is switched OFF while the Console is still powered on, analarm message will be displayed at the Console. Cycle system power to clear any alarmmessage.

3.1.1 STATUS INDICATORS

Normal Status

On the Power Control, the green power ON/OFF switch light should be illuminated, thisindicates 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 isfunctionally properly.

Fault Condition

A red alarm window will appear on the console. This symbol indicates the Power Controlhas lost power.

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3.1.2 INTRODUCTION TO PROGRAMMING

All programming takes place at the Optistar LE console’s touch-sensitive screens. Basefunctions 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 screenvalue 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 asrectangular 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 cornerboxes, 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 toincrease or decrease the value. Using your finger, you can touch the bar at the value yourequire, then use the left and right arrows to maker smaller adjustments.

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3.1.3 INJECTION MODE

Pressing the console’s Inject Mode key A allows the operator to select from the follow-ing 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)

VolumeRemaining 60

A: 60 ml Check for air insyringe and tubing

ATime 1:30

ResultsInject ModeMemory

Drip

Max Vol

Flowml/sec

Volumeml

60PSI

200

Scan Delay

0

0.0

A

Figure 3.1.1 Inject Mode Screen

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3.1.4 PROGRESS SCREENS

After pressing the Air Check key on the powerhead, a Start key A appears in the topright 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 tofollow the injection’s progress.

AFLOWml/sec

Volumeml

VolumeRemaining 60

A: 60 ml

Scan Delay

PSI

Max Vol

Time 1:30 Drip

Inj. Mode > Disable

0.0 0.0

0

200

Start

A

Figure 3-1-2 Progress Screen

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3.1.5 SINGLE PHASE INJECTION (A-SIDE)WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN

A

B60

Scan Delay

0

Time

0:00

0 50 100 150 200Pressure

PSI

ml

60 ml

Volumeml

Flowml/sec

0.00.0

Volumeml

Flowml/sec

0.00.0

Stop

Figure 3-1-3 Single Phase Injectionwith Saline Flush: Progress Screen

3.1.6 TWO PHASE INJECTION (A-SIDE)WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN

A

B60

Volumeml

Flowml/sec

PH1

PH2

Volumeml

Flowml/sec

Scan Delay

0:00

Time

0:00

0 50 100 150 200Pressure

PSI

ml

60 ml

0.00.00.00.0

0.00.0

Stop

Figure 3-1-4 Two Phase Injectionwith Saline Flush: Progress Screen

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3.1.7 SINGLE PHASE INJECTION (A-SIDE)WITHOUT SALINE FLUSH: PROGRESS SCREEN

A

0 50 100 150 200Pressure

PSI

60 ml

Scan Delay

0:00

Time

0:00

Volumeml

Flowml/sec

0.00.0

Stop

Figure 3-1-5 Single Phase Injection only-noflush: Progress Screen

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3.1.8 DESCRIPTION OF STOP KEY/INFORMATIONDISPLAYED 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, anykey on the powerhead or pressing the hand start switch will stop an injection. For moreinformation about delivering an injection, see Chapter 5—Delivering an Injection In theOperators 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 sym-bol.

D The protocol’s 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 (15minutes).

Scan Delay F counts down from the start of an injection so the operator may accuratelydelay 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.

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Stop

A

B60

Volumeml

Flowml/sec

PH1

PH2

Volumeml

Flowml/sec

Scan Delay

0:00

Time

0:00

0 50 100 150 200Pressure

PSI

ml

60 ml

0.00.00.00.0

0.00.0

B

D

C

C

D E

F

GA

Figure 3-1-6 Description of Informationon the Progress Screens

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3.1.9 DRIP MODE

This mode is used to keep the injection pathway open during patient set up and betweeninjections 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.

VolumeRemaining 60


ATime 1:30

ResultsInj. Mode >Memory

Drip

Max Vol

Flowml/sec

Volumeml

60PSI

200

Scan Delay

0

0.0

A

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

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BDrip Mode

CANCEL

Drip Volume Drip Time

Check for air in

syringe and tubing

60

Flowml/sec

Volumeml

0.0Interval

sec

0.00.0

60 ml 0:00 Hr:Min

Figure 3-1-8 Drip Mode Set up Screen

BDrip Mode

CANCEL


Check for air in

syringe and tubing

60

Flowml/sec

Volumeml

0.0Interval

sec

0.00.0

60 ml 0:00 Hr:Min

A

B

C E

F

G

HIJ

D

B

Figure 3-1-9 Description of Parameter Keysand Information on the Drip Mode Screen

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3.1.9.2 DESCRIPTION OF PARAMETER KEYS/INFORMATIONON THE DRIP MODE SET UP SCREEN


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 todecrease 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 ex-pressed 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 dripinjections.

“Check for air in syringe and tubing”message F acts as a reminder to the operator toconfirm no air exists in the syringe and tubing prior to enabling a Drip injection. If air isfound 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 theDrip Infusion screen.

Pressing the Cancel key G will exit the Drip Mode screen and return to the Injectionsetup 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 Volumevalue (B-side) from the Volume Remaining value (B-side) from the Injection Set upscreen.

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.

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3.1.9.3 ACCESSING THE DRIP INFUSION SCREEN

Pressing the Start key on the Drip Mode screen begins the drip injection and displays theDrip Infusion screen. See Figure 3-1-10. The Powerhead ram of syringe B delivers a dripinjection of the operator programmed flow and volume. Once the volume is delivered, theram will pause until the operator programmed interval has expired. This cycle continuesuntil the Drip Volume is delivered.

BDrip Infusion

DripEnd

Flow Volume Interval

0.8 ml/sec 0.0 ml 10 sec

Stop andreturn to:


60 ml 0:00 Hr:Min

Drip

Inject Mode

Figure 3-1-10 Drip Infusion Screen

3.1.9.4 DESCRIPTION OF KEYS/INFORMATIONON THE DRIP INFUSION SCREEN


Description of Keys

Pressing the Drip key A will exit the Drip Infusion screen and return to the Drip Modescreen.

Pressing the Inject Mode key B will exit the Drip Infusion screen and display the Injec-tion setup screen from where the Drip Mode was accessed.

Also, pressing the Stop key on the powerhead or pressing once on the hand start switchwill exit the Drip Infusion screen and display the Injection setup screen from where theDrip Mode was accessed.

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Description of Information

C The protocol’s programmed Flow, programmed Volume and programmed Interval isdisplayed at the bottom of the screen.

D The calculated Drip Volume and Drip Time is displayed in the upper right-handcorner.

E A graphic representation of the volume remaining in the syringe and the end of thedrip injection is displayed. Also, the saline drops located under the syringe symbol flashto indicate delivery of the drip injection.

BDrip Infusion

DripEnd

Flow Volume Interval

0.8 ml/sec 0.0 ml 10 sec

Stop andreturn to:


60 ml 0:00 Hr:Min

Drip

Inject Mode

C

A

DE

B

Figure 3-1-11 Description of Parameter Keysand Information on the Drip Infusion Screen

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3.1.10 PROTOCOL MEMORY

The Memory key A , located in the lower left-hand corner of the display (see Figure 3-1-12), allows access to the Memory List screen as shown in Figure 3-1-13. The Optistar LEcan store up to 20 protocols with a name length of up to 20 characters.

VolumeRemaining 60


ATime 1:30


Drip

Max Vol

Flowml/sec

Volumeml

60PSI

200

Scan Delay

0

0.0

A

Figure 3-1-12 Location of the Memory key

CurentValue

< Memory > Inject Mode

DELETEPage 1

Memory List

Aml/sec ml PSI ml/sec

B ScanDelayml

EDIT NAME STORE

Results

S

D

V3.3 5

72 60

3.3 47

6.0 13

6.0 4672 26

2.6 4083 17

3

27

50

7.8

7.8

9.0

2.0 60120 44

Figure 3-1-13 Memory List Screen

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3.1.10.1 RETRIEVING A PROTOCOL FROM MEMORY


1. Press the Memory key 1 to access the Memory List screen.

2. Press on the desired protocol’s name key 2A . If the desired protocol name is notdisplayed on Page 1, press the Memory> key 2B to display the page where the de-sired protocol name is displayed. Once the protocol name is displayed, press on itskey 2A .

3. The protocol 3 is immediately displayed on the screen.

CurentValue

Memory > Inject Mode

DELETEPage 1

Memory List


B ScanDelayml

EDIT NAME STORE

Results

Protocol 1

Dr Wagner

Protocol 23.3 5

72 60

3.3 47

6.0 13

6.0 4672 26

2.6 4090 17

3

27

50

7.8

7.8

9.0

2.0 16200

VolumeRemaining 60


ATime 0:08


Drip

Max Vol

Flowml/sec

Volumeml

16PSI

200

Scan Delay

0

2.0

1

2B

2A

VolumeRemaining 60

VolumeRemaining 60

A: 60 mlB: 60 ml Protocol 1

Check for air insyringe and tubing

A

A+B Time 0:00

B

Volumeml

40

Volumeml

50

Flowml/sec

2.6

Flowml/sec

9.0

Scan Delay

17PSI

90

Memory Inj. Mode >

Max Vol

Max Vol Drip

Results

3

Figure 3-1-14 Retrieving a Protocol from Memory

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3.1.10.2 DELETING A PROTOCOL FROM MEMORY



2. If needed, press the Memory> key 2 to locate the desired protocol to delete.

3. Press the Delete key 3A then the Protocol’s name key 3B .

4. Press the Yes key 4 located under the “Are You Sure?” prompt.

5. The protocol is deleted.

CurentValue


DELETEPage 1

Memory List


B ScanDelayml

EDIT NAME STORE

Results

Protocol 1

Dr Wagner

Protocol 23.3 5

72 60

3.3 47

6.0 13

6.0 4672 26

2.6 4090 17

3

27

50

7.8

7.8

Test 15.0 30

80

Protocol 73.3 505.0 20

72

9.0

2.0 16200

VolumeRemaining 60


ATime 0:08


Drip

Max Vol

Flowml/sec

Volumeml

16PSI

200

Scan Delay

0

2.0

1

2

3B

3A

CurentValue


Page 1

Memory List


B ScanDelayml

EDIT NAME

Yes No

STORE

Are You Sure?4

Results

Protocol 1

Dr Wagner

Protocol 23.3 5

72 60

3.3 47

6.0 13

6.0 4672 26

2.6 4090 17

3

27

50

7.8

7.8

Test 15.0 30-- --

80 ------

Protocol 73.3 505.0 20

72 ------

----

9.0

2.0 16200 --

DELETE

Figure 3-1-15 Deleting a Protocol from Memory

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3.1.10.3 STORING A PROTOCOL IN MEMORY


1. Select the desired Inject Mode and enter desired parameters.

2. Press the Memory key 2A to access the Memory List screen. Note the parametersentered 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 emptymemory location is available. To delete the contents of a memory location, refer tosection 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 theMemory> 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 dis-played 5 to allow naming of the protocol.

6. Press the Enter key 6 on the keyboard. The protocols parameters and name is storedin the selected location.

CurentValue


DELETEPage 1

Memory List


B ScanDelayml

EDIT NAME STORE

Results

Protocol 1

Dr Wagner

Protocol 23.3 5

72 60

3.3 47

6.0 13

6.0 4672 26

2.6 4090 17

3

27

50

7.8

7.8

9.0

2.0 16200

VolumeRemaining 60


ATime 0:08


Drip

Max Vol

Flowml/sec

Volumeml

16PSI

200

Scan Delay

0

2.0

2B

4B

3

4A

5

2A

6Caps On

CurentValue

2.0 16 200


DELETEPage 1

Memory List


B ScanDelayml

STOREEDIT NAME Cancel

Results

Cancel Space <- Enter

TestProtocol 1

Protocol 2

0 1 2 3 4 5 6 7 8 9

Q W E R T Y U I O P

A S D F G H J K L

Z X C V B N M

Dr Wagner

Figure 3-1-16 Storing a Protocol in Memory

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3.1.10.4 EDITING A PROTOCOL NAME



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 Protocol’s name key 3B . The keyboard withthe protocol’s 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, isdisplayed.

CurentValue


DELETEPage 1

Memory List


B ScanDelayml

EDIT NAME STORE

Results

Protocol 1

Dr Wagner

Protocol 23.3 5

72 60

3.3 47

6.0 13

6.0 4672 26

2.6 4090 17

3

27

50

7.8

7.8

9.0

2.0 16200 0

VolumeRemaining 60


ATime 0:08


Drip

Max Vol

Flowml/sec

Volumeml

16PSI

200

Scan Delay

0

2.0

1

2

3A

3B

3C

5Caps On

CurentValue

2.0 16 200


DELETEPage 1

Memory List


B ScanDelayml

EDIT NAME STORE Cancel

Results

0

Cancel Space <- Enter

Dr WagnerProtocol 1

Dr Wagner

Protocol 2

Test 1

Protocol 7

0 1 2 3 4 5 6 7 8 9

Q W E R T Y U I O P

A S D F G H J K L

Z X C V B N M

Test 1 5.0 3080

Protocol 7 3.3 505.0 20

72

Figure 3-1-17 Editing a Protocol Name

3.1.11 INJECTION RESULTS SCREEN

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The Injection Results screen is accessed via a key A located on any three of the injectmode screens. Refer to Figure 3-1-18. Page 1 of the Injection Results screen lists the last6 injections completed by date and time in descending order. Press the Results key onceagain to list injections. The results include the following information for each of the twophases in the A-side (if appropriate) and for the B-side:

Flow Rate—the programmed flow rate,

Volume—the achieved volume

PSI—Maximum injection pressure achieved (only for the A-side)

VolumeRemaining 60


ATime 0:08


Drip

Max Vol

Flowml/sec

Volumeml

16PSI

200

Scan Delay

0

2.0

A

Memory Inject Mode

Page 1Injection Results

No. Date - TimeA: B:

Flow FlowVol VolPSI

4 1.5 125

7.8 -

7.8 -

1.5 10

7.8 -

1.5 10

189

26

15

26

--

18

13

11

-

9

13

11

13

17

-

9

-

2.2

6.0

5.4

-

2.2

6.0

5.4

6.0

1.3

-

2.226 Jan 01 10:26

26 Jan 01 10:19

26 Jan 01 09:40

26 Jan 01 09:22

26 Jan 01 09:19

26 Jan 01 08:57

1

2

3

4

5

6

Results System Info

Figure 3-1-18 Accessing the Injection Results Screen

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4 MAINTENANCEAND CHECKOUTPROCEDURES

This chapter contains maintenance procedures for the Optistar LE injector. Guidelines forperiodic inspections, testing, cleaning and lubrication are included. Information aboutassembly 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 informa-tion on a copy of the checklist.

WARNING!

Preventive Maintenance on any unit must be performed by a Qualified Technicianwho is completely familiar with the use and operation of the Injector, trained by aMallinckrodt instructor in the area of preventive maintenance for the Injector andfamiliar with the content of the Operator’s manual and the Installation and Servicemanual.

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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.

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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 thisprocedure require more than one observation or require a sequence to be timed.

If this procedure cannot be completed or if the Optistar LE doesn’t 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 servicekit (refer to chapter 5)

water and container

syringe adapter

• Optistar LE Preventive Maintenance Checklist

4.2.2 POWERHEAD OVERVIEW

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

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml

PowerheadRam B

SyringeHolderSide B

SyringeHolderSide A

StopButton

Injection IndicatorsA & B Sides

PowerheadRam A

SyringeAdapter

A SIDE

B SIDE

Reverse Button

Start Button

Air Check

Accelerator

ForwardButton

Figure 4-2-1 Powerhead

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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 holdeither the Forward Button, or Reverse Button. Ensure ram moves freely in bothforward and reverse directions. Also, verify that the ram LED’s come on during thisprocedure.

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, thenpress the Start button. The injections you programmed should have activated verify-ing 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 changeeach time it is pressed.

4. Press the Results button. The first 6 injections will be displayed. Press the Resultbutton again display injections 7 through 12. The results listed are injections com-pleted by date and time in descending order.

5. Press the Memory button. The first 5 protocols for the injection mode selected shouldbe displayed. Continue to press the Memory button to increment pages through all 20protocols.

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 inthe memory location you selected.

To edit the memory name or delete it, simply use the buttons provided.

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4.2.5 REMOTE START OPERATIONS

1. Program an A & B injection. Press the Air Check button on the Powerhead. Pressand release the Remote Start Button. The injection should have activated verifyingthe properly operation.

2. During an injection cycle, Press the Hand button. The injection should stop with theinjection 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. Duringram movement observe the Powerhead injection indicators. The injection indicatorlight for the ram in motion should be flashing.

4. With ram movement taking place, press the Powerhead Stop Button. Ram movementshould 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 mLsyringe" for the B side.

6. Remove syringes. Then place 10/15/20 adaptor in the A side. Verify console andpowerhead indicate “10/15/20”.

7. Place 125mL syringe in the B side. Verify console and powerhead indicate “125mLsyringe”.

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4.2.8 LIMIT SWITCH CHECK

The purpose of this check is to verify limit switch board (positioned in the Powerhead)settings were not disturbed during shipment.

1. Power up the system as previously described

2. Using the Powerhead controls, fully retract both Powerhead ram.

3. Place a 60 mL syringe in the A Powerhead ram.

4. On the Powerhead, press and hold the A side Forward Button until ram motion stops.Observe the 0 mark on the syringe, the front wiper should be engaging the 0 mark.Also, on the Console screen, observe the Volume Remain field, it should be 0.0.

0 ml

Figure 4-2-2

Press and hold the A side Reverse Button until ram retraction motion stops. Verify onthe Console screen, the Volume Remain field, is 63 mL.

Repeat step 4 procedures for the B side Ram. If adjustments are required, refer toChapter 8.

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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

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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 thesyringe 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 adamp nonabrasive cloth towel and any commercially available non-ammonia windowcleaner to regularly clean the surface. The cleaning solution should be applied to thetowel rather than the surface of the touch screen. The touch screen has air vents and isnot designed with water tight bezels so fluid ingress may occur from behind the panel ifnot cleaned carefully.

4.3.4 POWER CONTROL

Clean the exterior of the power control by spraying a cloth with an all-purpose householdcleaner, then gently wipe clean.

4.3.5 POWER SUPPLY

Clean the exterior of the power supply by spraying a cloth with an all-purpose householdcleaner, then gently wipe clean.

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5 TROUBLESHOOTING

5.1 OVERVIEW

The intention of the Chapter is to deliver information to the service technician in order totrack a problem to a subassembly so it can be replaced or repaired. When a problemexists with the Optistar LE, a message will be displayed on the console screen. A com-plete listing of these messages and their probable cause is contained in this chapter.

Instructions for disassembly and reassembly of major injector components are defined inchapter 6.

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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 forOptistar LE troubleshooting and calibration procedures.

Part # Descriptions Comments

801216

801240

801202

801201

801211

801212

801213

801257

801200

801214

801215

801254-10

802713

801224-07

Case, Foam-Plastic

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

Screwdriver Titanium 3/16 Slotted

Spanner Wrench Non-Ferrous

Wrench Titanium (3mm) Hex

Wrench Titanium (4mm) Hex

Cable Assembly, Test 10 foot

LE Pressure Fixture Base

Cable Assembly, 25 pin, D shell, M/F

Recommended to keep all theunique tools together

Required for Calibration





Required for any disassembly withinmagnet room

Required for D-shell backshell removal

Required for adjustment of Powerheadpivot (Optistar MR only).

Required for removal of Powerhead from stand and adjustment of Powerhead pivotwithin magnet room.

Required for adjustment of Powerheadpivot 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 magnetroom.

Figure 5-1-1 Tool Kit

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5.1.2 GENERAL TROUBLESHOOTING GUIDELINES

We suggest these actions when first troubleshooting the Optistar LE; things to try beforetaking anything apart, and to make the job easier.

1. Check indicator lights on Power Supply and Power Control to ensure adequate poweris present.

2. Verify the problem. Check the injector under the same conditions and settings that ithad when the problem occurred. If possible, try the injector in an isolated setting tosee if the problem can be duplicated.

3. Try different settings. Check the injector with different control settings than it hadwhen the problem occurred. Change the flow rate, volume and pressure. If anothersize syringe is available, try it.

4. Use the checkout in chapter 4. This is a relatively quick way to check the majorfunctions. This is especially helpful if the accuracy is in question.

5. Visually inspect subassemblies and components before performing electrical tests orcalibration procedures. Specifically make sure cable plugs are firmly attached, andcables are not crimped, or under tension. If the trouble is in the powerhead, open thepowerhead 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 toisolate the specific problem.

7. Call your sales representative for service assistance, field service, and for replacementparts or modules. If the system is new, still under warranty, or covered under aservice contract, call your sales representative before proceeding.

CAUTION!

Be extremely careful when the Optistar LE is open. Lethal voltages are exposed. Becareful not to leave an open system unattended with power plugged in. DISCONNECTTHE POWER CORD BEFORE REMOVING OR REPLACING BOARDS.

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5.2 SYSTEM GENERATED MESSAGES

With these faults, a message appears on the system display. Use this chapter to help findthe 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 expandedexplanation given for that alarm in this chapter.

Each alarm includes a description message of what it means, probable causes, and whataction 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 proce-dures.

AlarmNumber Fault Message

1 Pressure Limit Alarm

2 Over Volume Alarm

3 Over Flow Rate Alarm

6 Motor Alarm

9 Invalid Powerhead Pressure Measurement Alarm

13 Forward/Reverse Limit Sensor Alarm

14 Motor Control Watchdog Alarm

15 Changed Syringe Size Sensing Alarm

17 Power-On Self Test Alarm

20 Protocol Parameter Alarm

22 Syringe Pressure is less than Expected Alarm

23 Power Control NV Memory Checksum Alarm

24 Power Control Firmware Checksum Alarm

30 Touchscreen Alarm

31 Remote Start Switch Connection Alarm

33 Console Protocol Memory Checksum Alarm

34 Console Program Checksum Alarm

35 Unknown Error/timing error

50 Power Control not Detected Alarm

90 Power Control/Console Communication Alarm

Table 5-2-1 Alarm listing

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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 inline, make sure they are open. Verify that the operator is not trying to program high flowrates into a small needle. Keep in mind that the B side may have a low pressure limit. Insome cases the operator could program a high pressure (180 to 200 psi limit) A sideinjection followed by a B side. Immediately after the injector completes side A, side Bwill start. If the residual pressure from the side A injection exceeds the pressure limit forside B the injector may trigger a pressure limit malfunction alarm or a hardware alarm.

Alarm no. 2:

Meaning: Volume over error.

Cause: The volume delivered exceeded the programmed volume by more than 1 ml. Theerror is generated from the UPP injector volume counter because it reached the set valueplus 1 ml.

Check: Position calibration, optical encoders on motors, loose connector or printed circuitboard.

Alarm no. 3:

Meaning: Flow Rate malfunction.

Cause: The optical encoders are used to control and monitor the flow rate. If the flow rateexceeds the programmed flow rate this alarm will appear. The encoder signals are moni-tored by the UPP counter on the microprocessor board.

Check: Optical encoders, loose connectors or printed circuit board.

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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 reversebuttons 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 andreverse switches being active at the same time. Alarm can occur at power on check orduring operation.


Faulty limit switch board.

Dirt is blocking light path.

Loose connection (?).

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Check: Call Service.

Alarm no. 14:

Meaning: Motor Control Watchdog Alarm.

Cause: The FPGA chip on the CPU board which controls motion contains a watchdogtimer. If this watchdog timer is not reset every 500ms or less, this alarm will be activated.


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 changedwhich should not occur.

Possible causes:

If the alarm occurs while a syringe adapter is installed, the syringe adapter may be mov-ing and causing the syringe sensing switch to momentarily change syringe sizes.

Faulty syringe sensor switch.

Faulty adapter.

Faulty bottom cover.

Faulty connection to syringe sensor.

Check: If the powerhead displays an incorrect syringe size, inspect the syringe sizeswitches for accumlated contrast sticking, an obstruction in the flange slot, or defectivepowerhead PCB.

Note: Do not change syringe on either the A or B side until the entire injection sequenceis complete.

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Alarm no. 17:

Meaning: Power On Self Test Failure.

Possible causes:

Any one of the powerhead forward, reverse, fast, start, stop, and check switches areclosed 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 matchthe value calculated by the power control.


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 injec-tion.

Check: Verify that the syringe push-rod is making contact with A side ram. An emptysyringe can also cause this error.

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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 tosection 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 tosection 10.2.1.

Replace CPU Board in the Power Control.

Call service.

Alarm no. 30:

Meaning: Touchscreen Alarm.

Cause: If the touchscreen is continuously activated during the power-up sequence, thisalarm 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 disconnectedduring an injection, this alarm condition will occur.

Check: Remote Start Switch connection.

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Alarm no. 33:

Meaning: Console Protocol Memory Checksum Alarm.

Cause: The Console protocol memory checksum is checked at power-up. If the checksumdoes 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, thisalarm condition will occur.

Check: Replace Console CPU board.

Call Service.

Alarm no. 35:

Meaning: Either an injection motor timing error or undefined error message receivedfrom the power pack.

Check: Call Service.

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Alarm no. 50:

Meaning: Power Control not Detected.

Cause: No communication between the Console and the Power Control during Power. OnSelf 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 con-trol.

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Alarm no. 90:

Meaning: Power Control/Communication Error.

There are 8 possible sub alarm codes associated with Alarm no. 90. Their format is usedto 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 Error90 = Connect Error92 = Framing Error93 = Parity Error95 = BCC Error (Checksum Error)96 = Retry Error98 = Overflow Framing Error99 = Overflow Parity Error100 = Framing and Parity Error

Cause: No communication for more than 30 seconds or bad communication with mayconsecutive 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.

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5.2.1 ACTIVATING THE SYSTEM ERROR RESULTS LIBRARY

The alarm history library retains the last 10 alarm messages encountered. To display thesealarm 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.

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6 FIELD REPLACEABLEPARTS

This chapter provides disassembly and assembly instructions for Optistar LE field re-placeable 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 pointwhere the removal of that particular item is discussed. To disassemble an item mayrequire sub components to be removed first. If this is the case, you will be directed toperform the appropriate sub component instruction first. To replace an item, follow thedisassembly 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 injuryor equipment damage.

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GENERAL INFORMATION

RETAINING SCREWS

• Optistar LE components are retained with Non-Ferrous brass or blue stainlesssteel screws. The blue dyed screws are made of a type of stainless steel that isnot attracted to a magnet. Always use Non-Ferrous screws if replacement isrequired.

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.

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6.2 CONSOLE

DANGER!

Before attempting any disassembly procedure, turn off all power to the OptistarMR system.

The Console assembly consist of the following components:

• Cover

• Touchscreen

• Console CPU and Interface Board

• Harnesses

• Switch assembly

• Display subassembly

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6.2.1 CONSOLE REPLACEMENT COMPONENTS

Part No. Description Find No.

802100 CONSOLE ASSEMBLY

M4-.7 X 10 MM PLASTIC PHILLIPS PAN HEAD SCREW 1

FOOT-RUBBER-CONSOLE 2

802101-1 CONSOLE CPU BOARD 3

802102-1 INTERFACE BOARD 4

802104 TOUCHSCREEN, 10.4" 5

802106 CONSOLE FRONT COVER 6

802107 CONSOLE BACK COVER 7

802114 CONSOLE SWITCH ASSEMBLY 8

LOCTITE 222,PURPLE,THREAD LOCK 9

802110 INTERFACE CABLE ASSEMBLY 10

802115 MOUNTING PLATE, BUTTON 11

802116S DISPLAY SUBASSEMBLY 12

802130 MOUNTING BRACKET, COMM-BOARD 13

SPACER,CAP 14

GASKET, DIN-CONNECTOR 15

JACKNUT KIT 16

SCREW, FOR PLASTIC, #4 HI/LOW 17

TIE ON ARROWHEAD 18

PLATE,HINGE,FINISHED 19

HINGE, CONSTANT TORQUE 20

SCREW,M4X.7,10MM,PR,PH,LOCKWSH 21

SCREW,PT3.5,12MM,SS(FOR THERMO PLASTICS) 22

SCREW,M4X.7 8MM PR PH W/LW 23

PCB SUPPORT 24

LABEL, LF LOGO 25

LABEL, CONNECTOR ID, CONSOLE 26

LABEL,SERIAL NUMBER 27

802108 SWITCH BUTTON, CONSOLE 28

SCREW-4-40X5/16 PH 29

WASHER #4 INT TOOTH 30

LABEL,ATTENTION 31

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

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

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6.2.2 CONSOLE COVER REMOVAL


1. Place the console, with hinge plate attached, face down on a soft, clean surface toprevent damage to the finish (i.e., table top with soft cloth in between console andtable).

2. To remove the hinge plate (item 22), remove the nine screws (item 24) and lockwash-ers.

NOTE: If the hinge plate is not the item being serviced it can remain attached to the backcover.


3. To remove the back cover (item 7), remove the four screws (item 1) and slowly liftaway 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 CPUboard at J5 before the back cover can be completely separated from the front half of theconsole.

6.2.3 CONSOLE CPU REMOVAL


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 retainingpegs.

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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 thefront cover.

3. Remove Display Subassembly.

6.2.5 TOUCHSCREEN REMOVAL


1. Perform removal procedure 6.2.2, 6.2.3, and 6.2.4.

2. Lift Touchscreen from front cover.

6.2.6 CONSOLE POWER SWITCH REMOVAL


1. Place the console, with hinge plate attached, face down on a soft, clean surface toprevent damage to the finish (i.e., table top with soft cloth in between console andtable).

2. To remove the back cover (item 7), remove the four screws (item 1) and slowly liftaway 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 theconsole 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 asideuntil 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 SwitchAssembly.

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6.2.7 CONSOLE SWITCH BUTTON REMOVAL


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


1. Perform removal procedure 6.2.2.

2. Remove harness assembly (item 10) from Interface board (item 4), disconnect at theInterface board (item 4) J3 connector.

3. Remove two (2) mounting bracket retaining screws from (item 13). Remove InterfaceBoard (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 tothe Interface Board (item 4) when it is replaced.

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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., tabletop with soft cloth in between cover and table). Position the cover so that its insidesurface 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).

4. Position the touch screen (item 5) over the large opening in the top cover so theharness 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 J5on the CPU board.

11. The software can be downloaded to the console if required. Refer to the downloadprocess 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 ninescrews with lockwashers (item 22).

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6.3 POWERHEAD

DANGER!

Before disassembling the Powerhead, follow the power off instructions listed ineach disassembly/assembly section.

WARNING!

Always remove Powerhead from magnet room before disassembly. Failure tofollow this warning could result in personnel injury or equipment damage.

The Powerhead assembly consist of the following components:

• Powerhead

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml

Figure 6-3-1 Powerhead on Remote Stand

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6.3.1 POWERHEAD REPLACEMENT COMPONENTS

Item No. Part Description Find No.

802300 POWERHEAD ASSY

Note: POWERHEAD ASSEMBLY 802300-C or earlier use SYRINGE SIZE SENSINGPCB ASSEMBLY 802307-1

Note: POWERHEAD ASSEMBLY 802300-D or later use SYRINGE SIZE SENSINGPCB ASSEMBLY 802313-1

802743 Kit See Section 6-9 Kits, MOTORREPLACEMENT ASSEMBLY DRIVE A 1

MAINFRAME, MACHINED 2

802371 GEAR, 24DP 32T 3

802746 Kit BEARING ADAPTER 4

MACHINED, MOTORMOUNT 5

PILOT, MOTOR GEAR 6

GUIDE PLATE 7

802748 Kit See Section 6-9 Kits, SYRINGE HOLDER SERVICE KIT 8

802327 GUIDE BUSHING 9

802746 Kit See Section 6-9 Kits, BEARING REPLACEMENT SERVICE KIT 10

802746 Kit RETAINING RING, 1-3/8 11

802744 Kit

FLAG, A-SIDE 12

METRIC, LEAD NUT 13

FLAG, B-SIDE 14

METRIC, LEAD SCREW 15

RAM 16

802742 Kit See Section 6-9 Kits, BUSHING REPLACEMENT SERVICE KIT 17

802388 HOLDER, LOAD CELL 18

802744 Kit SCREW, SET, M6, 12MM, SS-A4, BLUE 19

802386 PRESSURE WASHER 20

802389 RAM FACE 21

802344 ROD, OUTER SUPPORT 22

802741S Kit See Section 6-9 Kits, LOAD CELL SERVICE KIT 23

BLOCK, ADJUSTMENT 24

PIVOT 25

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6.3.1 POWERHEAD REPLACEMENT COMPONENTS (CONT’D)


802302-1 PCB ASSY, END LIMIT SENSING 26

802744 Kit SCREW, ADJUSTMENT 27

802744 Kit O RING, -008 28

802315 KEYPAD ASSY, POWERHEAD 29

802747 Kit

802301-1 PCB ASSY, POWERHEAD 30

802110 CABLE ASSY, INTERFACE 31

802303 CABLE ASSY, POWERHEAD 32

802332 WIPER 33

802381 PIVOT BUSHING 34

802382 PIVOT WASHER 35

802383 CAP, PIVOT 36

802384 THRUST WASHER, PIVOT 37

802385 PILOT BUSHING, MOTOR 38

802744 Kit STANDOFF, M3 - 6MM 39

SHEILD, MOTOR 40

802744 Kit 1/8" DOWEL PIN, 316 S.S. 41

802903 DETENT, SYRINGE HOLDER 42

802744 Kit

802748 Kit

802368 MACHINED, SUPPORT ARM 43

ADHESIVE,SILICONE,CLEAR 44

802747 Kit LENS,INDICATOR 45

802744 Kit RETAINING RING 46

802313-1 PCB ASSY, SYRINGE SIZE SENSING 47

Note: POWERHEAD ASSEMBLY 802300-C or earlier use SYRINGE SIZE SENSINGPCB ASSEMBLY 802307-1

Note: POWERHEAD ASSEMBLY 802300-D or later use SYRINGE SIZE SENSINGPCB ASSEMBLY 802313-1

802316 HARNESS ASSY, END LIMITS 48

802317 HARNESS ASSY, SIZE SENSING 49

802318 HARNESS ASSY, ENCODER 50

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802743 Kit GEAR, 24DP 24T 51

802747 Kit See Section 6-9 Kits, POWERHEAD COVER SERVICE KIT 52

802396 BOTTOM COVER, FRONT, POWERHEAD 53

802397 BOTTOM COVER, BACK, POWERHEAD 54

802744 See Section 6-9 Kits, FASTNER SERVICE KIT

802748 Kit SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE 56

802744 Kit

802744 Kit SCREW, SET, M4, SS-A4, BLUE 57

802743 Kit

802744 Kit SCREW, M4, 12MM, SHCS, SS-A4, BLUE 58

802744 Kit SCREW, SET, M3, 5MM,SS-A4, BLUE 59

802741S Kit

802744 Kit SCREW, M3, 8MM, PR, FH, SS-A4, BLUE 60

802742 Kit

802744 Kit SCREW, M4, 12MM,BHCS,SS-A4,BLUE 61

802744 Kit SCREW, M4, 10MM, PR, PH, SS-A4, BLUE DYE 62


802679 CLAMP, VINYL COATED 64

GROMMET, CONTINUOUS 66

802744 Kit NUT, M6, HEX, NYLON INSERT, SS-A4, BLUE 67

802744 Kit NUT, M5, HEX, NYLON INSERT, SS-A4, BLUE 68

802744 Kit WASHER, FLAT, M5, SS-A4, BLUE DYE 69

802744 Kit WASHER, SPRING LOCK, M4, SS-A4, BLUE DYE 70

802743 Kit

802744 Kit WASHER, EXT. TOOTH, M3, SS-A4, BLUE DYE 71

802744 Kit SCREW, M4, 50MM, SHCS, SS-A4, BLUE 72

802744 Kit O-RING, -022 73

802741S Kit

802657 KNOB, M8 74

802744 Kit WASHER-#14S BRASS FLAT 75

LOCTITE 242,BLUE,NUT LOCK 76

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SEALANT, SILICONE LUBRICANT 77

802311 GASKET, EMI, POWER HEAD 78

LOCTITE 609,GREEN,RET COMPOUND 79

PRIMER-LOCQUIC GRADE T 80

GREASE-MULTI-PURPOSE AEROSOL 81


802748 Kit

802901 NEST COVER, SYRINGE HOLDER 83

802730 SYRINGE ADAPTER (WITH LABEL)

802748 Kit

TY-RAP TIES 84

802748 Kit LABEL, 30/60ML, FLUID DETECTION 85

802748 Kit LABEL, 50/60ML, FLUID DETECTION 86

802744 Kit SCREW, M2.5, 10MM, PR,PH,SS-A4,BLUE 87

802748 Kit

802744 Kit SCREW, M3, 8MM, PH,PR,SS-A4,BLUE 88

802744 Kit CABLE CLAMP, 9/16" 89

802744 Kit SCREW,M3, 6MM, PR, PH,SS-A4,BLUE 90

LABEL, S/N 91

LABEL,DIRECTION-ENABLE/INJECT 92

802744 Kit WASHER, FLAT, M3, SSA4, BLUE DYE 94

802744 Kit WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE 95

802748 Kit

802744 Kit STAND OFF , 3/16" X 1", M3 96

802748 Kit

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

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Powerhead Board(P/N 802301-1)Connectors

J8

J7

J9

PowerheadMotor Connections

JA

JB

JB1

JA1

P1P2Pin 1

Pin 1

P1:8 BLACK J8-9P1:22 RED J8-8P1:29 WHITE J8-4P1:43 GREEN J8-3P1:37 ORANGE J8-2P1:23 BLUE J8-1P1:14 PURPLE J8-14P1:42 SLATE J8-13P1:38 PURPLE J8-6P1:10 GRAY J8-7P1:28 PINK J8-12GND SCREW NONE J8-15P1:11 TAN J8-10P1:12 RED/YELLOW J8-11P1:5 RED/GREEN J8-5 RED/BLACK -

P1:24 BLACK J7-11P1:9 RED J7-12P1:39 BROWN J7-2P1:25 YELLOW J7-1P1:30 WHITE J7-3GND SCREW NONE J7-4P1:20 GREEN J7-5P1:26 ORANGE J7-6P1:40 BLUE J7-7P1:13 BROWN J7-8P1:41 YELLOW J7-9P1:27 PINK J7-10 TAN

P1:21 BLACK J9-1P1:7 RED J9-2P1:36 WHITE J9-3P1:6 GREEN J9-5P1:35 ORANGE J9-6P1:34 BLUE J9-4 J9-7GND SCREW NONE J9-8

P2:18 BLUE JA-1P2:23 YELLOW JA-3P2:21 GREEN JA-4GND SCREW NONE -P2:17 WHITE/BLUE JB-1P2:26 WHITE/YELLOW JB-3P2:20 WHITE/GREEN JB-4GND SCREW NONE -P2:24 RED/BLUE JB1-1P2:22 RED/YELLOW JB1-3P2:27 RED/GREEN JB1-4GND SCREW NONE -P2:25 BLACK/BLUE JA1-1P2:19 BLACK/YELLOW JA1-3P2:28 BLACK/GREEN JA1-4GND SCREW NONE -

Wire ColorPowerheadMotor Connections

Power ControlP2 Connector

Power ControlP1 Connector Wire Color

Powerhead BoardConnectors J7, J8, J9

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

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6.3.2 POWERHEAD REMOVAL/INSTALLATION FROM STAND


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 ensurethe spring loaded height adjustment rod stays in position when the Powerhead isremoved.

WARNING!

The stand height adjustment rod is under tension. Turn the height adjustment ringclockwise to the full locked position before removing Powerhead.

5. Loosen the Powerhead arm philips head screws. Lift the Powerhead and arm assem-bly from stand.

6. To reinstall, perform the procedures above in reverse order.

BA

50 ml60 ml

125 ml

60 ml30 ml

10/15/20 mlLE

Optistar TM

LE

Powerhead

TensionAdjustment

Screw

Elevating Post

Adjustment Nut

Figure 6-3-4 Powerhead removal

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6.3.3 POWERHEAD COVER REMOVAL/INSTALLATION


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 removaland installation.

6.3.3.1 Syringe Holder Nest Cover Removal/Installation


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. Removesyringe holder nest cover (item 83).


6.3.3.2 Bottom Back Cover Removal/Installation




4. Remove bottom back cover (item 54) four (4) retaining screws. Remove bottom backcover.


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6.3.3.3 Top Cover Removal/Installation




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. Dis-connect the keypad connector at the keypad, and remove top cover.


6.3.3.4 Bottom Front Cover Removal/Installation




4. Remove syringe holder nest cover as described in section 6.3.3.1. Remove bottomback cover as described in section 6.3.3.2.

5. Remove bottom back cover (item 53) eight (8) retaining screws. Remove bottom frontcover. Note: The top cover will be free to remove at this point.


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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 6-3-1and 6-3-2.

2. Disconnect all connections to the Powerhead board.

3. Remove six (6) retaining screws (item 90) and lift off Powerhead board.


6.3.5 POWERHEAD CABLE REMOVAL/INSTALLATION


Disconnect the Powerhead cable from the Power Control. Remove Powerhead assemblyfrom 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, removetwo (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 orienta-tions. This will ensure connectors are not flipped during the installation process.Disconnect JA, JA1, JB, and JB1 connectors and ground wires. Also, disconnect theground 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. Care-fully remove Powerhead cable.


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6.3.6 MOTOR REMOVAL/INSTALLATION

Refer to Figure 6-3-1 and 6-3-2.


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 orienta-tions. This will ensure connectors are not flipped during the installation process.Disconnect JA, JA1, JB, and JB1 connectors and ground wires. Also, disconnectmotor encoder connectors (item 50).

3. Remove three (3) motor retaining screws and washers (item 70 and 72). Removemotor and gear assembly. Be careful not to lose pilot bearing (item 38).


6.3.7 POWERHEAD END LIMIT SENSING BOARDREMOVAL/INSTALLATION


1. Move both rams to their middle retracted position.



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 bothset 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 theconnectors used.

8. Remove six (6) screws (item 58) from guide plate (item 7). Carefully slide guide plateand ram assembly from base.

9. Carefully slide the Limit Sensing Boards (item 26) from their runners. Take note ofthe position adjustment screws (item 27) are in, then remove adjustment screws (item27) 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 areproperly lubricated.

Note: When reinstalling a Limit Sensing Board, ensure the load cell (item 23) cable andconduit is correctly positioned in the slots provided. Also, End Limit calibration must beperformed when this board is replaced.

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6.3.8 LOAD CELL REMOVAL/INSTALLATION


1. Move both rams to their middle retracted position.



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 bothset 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 theconnectors used. Cut all Ty-wraps retaining the Limit Sensing Cable. Also, bendcable retainers to allow for cable removal.

7. Remove four (4) screws (item 60) from bushing retainer (item 17). Lift wiper (item33) and bushing guide (item 9) from guide plate (item 7).

8. Remove load cell cable and conduit from power head by feeding connector endthrough 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 iscorrectly positioned in the slots provided.

6.3.9 END LIMIT HARNESS REMOVAL/INSTALLATION




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 J3and J4 connectors.

3. Cut wire Ty-wraps retaining the harness.


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6.3.10 ENCODER HARNESS REMOVAL/INSTALLATION




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.


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 forlocation and procedures.


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 syringeholder (item 42).


6.3.12 DETENT SYRINGE HOLDER REMOVAL/INSTALLATION



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 syringeholder (item 42).


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6.3.13 SYRINGE SIZE SENSING HARNESS REMOVAL/INSTALLATION




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 thesyringe nest holder (item 8).


6.3.14 SYRINGE NEST HOLDER REMOVAL/INSTALLATION


1. Move both rams to their middle retracted position


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).

5. Remove four (4) screws retaining the syringe nest holder (item 8) to the support rods.Remove the syringe nest holder.


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6.3.15 SUPPORT ARM REMOVAL/INSTALLATION



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).


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6.3.16 BEARING REMOVAL/INSTALLATION


Removal

1. Move both rams to the fully extended position.



4. Remove four (4) retaining screws from shield motor cover (item 40). Also, removetwo (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 bearingassembly from lead screws.

10. Remove bearing retaining ring (item 11) and bearings (item 10) from motor mounthousing (item 5).

Reassembly

11. Install new bearings into motor mount (item 5). Install bearing retaining ring (item11). 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 arepositioned to contact the lead screw flat surfaces when tightened. At this time simplysnug the gear set screws on the lead screw flat surfaces, do not tighten the gear setscrews.

Rotate both lead screws until the gear set screws are accessible after motors installa-tion.

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.

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6.4 POWER CONTROL

DANGER!

Before attempting any disassembly procedure, turn off all power to the OptistarLE system.

WARNING!

Always remove Power Control from magnet room before disassembly. Failure tofollow this warning could result in personnel injury or equipment damage.

WARNING!

The Power Control contains special Non-Ferrous screws. They are identified byblue dye. Always use Non-Ferrous blue dye screws if replacement is required.Failure to follow this warning could result in personnel injury or equipmentdamage.

WARNING!

Before removing any Power Control PC boards, ensure proper static protectiondevices are used. Failure to follow this warning could result in equipment dam-age.

Injector operations are controlled by the Power Control. PC boards and other PowerControl components are contained in the following four units: Backplate Control, FrontControl Encloser, Rear Control Encloser, and Front Control Cover. Replacement compo-nents contained in these units are list in section 6-4-1.

Front ControlEncloser

Rear ControlEncloser

Front ControlCover

BackplateControl

Figure 6-4-1 Power Control Assembled Unit

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6.4.1 POWER CONTROL REPLACEMENT COMPONENTS


802200 POWER CONTROL ASSY

802251 FRONT CONTROL ENCLOSER 1

802252 REAR CONTROL ENCLOSER 2

802222 FRONT CONTROLCOVER 3

802237 BACKPLATE, CONTROL 4

802201-1 CPU BOARD ASSEMBLY 5

802202-1 POWER BOARD ASSEMBLY 6

802203-1 DRIVER BOARD ASSEMBLY 7

802204-1 COMMUNICATION BOARD ASSEMBLY 8

802207-1 INTERCONNECT BOARD ASSEMBLY 9

802263 EMI GASKET 10

802212 POWERHEAD MOTORS HARNESS ASSEMBLY 11

802213 POWERHEAD COMMUNICATION HARNESS ASSEMBLY 12

802214 CONSOLE COMMUNICATION HARNESS ASSEMBLY 13

802215 POWER CONTROL SWITCH 14

802635 RUBBER FOOT 15

802261S STAND OFF ASSEMBLY 16

LABEL, S/N 17

NON-FERROUS SCREW, M5, 10MM, PR, PH, SS-A4, BLUE DYE 18

NON-FERROUS SCREW, M4, 10MM, PR, PH, SS-A4, BLUE DYE 19

802711 JACK SCREW KIT, SOCKET 20


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

NON-FERROUS WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE 23

LABEL, POWERHEAD ICON 24

LABEL, POWER SUPPLY ICON 25

172E0016 6.3 Amp SLOW BLOW FUSE 26

POWER CONTROL SHIELD 32

Note: All fastners are part of Fastner Service Kit (P/N 802744)

802701-C May 2003

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

REAR ASSEMBLY VIEW

EXPLODED VIEW (BOTTOM)

15

26

J1, J2

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6.4.2 BACKPLATE COVER REMOVAL/INSTALLATION



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 connec-tions. 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 J2connector.

8. On the Communication board (item 8), disconnect the following items:Powerhead Communication harness (item 12) from J3 connector, Console Communi-cation harness (item 13) from J2 connector, and Power Control switch harness (item14) 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






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 tothe Rear Cover Enclosure.

7. Before removing the Driver Board (item 7) and shield (item 32), take note of itscountersink slot location in the Rear Cover Enclosure. Grasp Driver Board and andsheild, then pull straight outward to disconnect from the Power Control InterconnectBoard (item 9).

8. To reinstall Driver Board, perform steps 1 thru 7 in reverse order.

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6.4.4 COMMUNICATION BOARD (802204-1) REMOVAL/INSTALLATION






5. Remove Backplate Cover as described in section 6.3.2.

6. Before removing the Communication Board (item 8), take note of its countersink slotlocation in the Rear Cover Enclosure. Grasp Communication Board and pull straightoutward 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



2. Disconnect cabling to the Power Control Unit.


4. Remove four (4) screws (item 19) from Front Cover Encloser item 1.

5. Remove Front Control Cover (item 3).

6. Before removing the CPU Board item 5, take note of its countersink slot location inthe Rear Cover Enclosure. Grasp CPU Board and pull straight outward to disconnectfrom the Power Control Interconnect Board (item 9).

7. To reinstall CPU Board, perform steps 1 thru 7 in reverse order.

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6.4.6 POWER BOARD (802202-1) REMOVAL/INSTALLATION





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 locationin the Rear Cover Enclosure. Grasp Power Board and pull straight outward to discon-nect 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





4. To remove the Interconnect Board, remove components as defined in the followingsections:

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) areseparated, 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.

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6.4.8 POWERHEAD MOTOR HARNESS (802212)REMOVAL/INSTALLATION






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 J2connector.

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








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) toremove.

10. To reinstall the Communication harness, perform steps 1 thru 9 in reverse order.

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6.4.10 CONSOLE COMMUNICATION HARNESS (802214)REMOVAL/INSTALLATION








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








7. On the Communication board (item 8), disconnect Power harness (item 14) from J1connector.

8. Grasp and squeeze Power Switch retaining clips while pushing forward to removefrom 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.

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6.5 POWER SUPPLY

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

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6.5.1 POWER SUPPLY REPLACEMENT COMPONENTS


802450 POWER SUPPLY ASSEMBLY, LE

802711 JACK SCREW KIT, SOCKET 1

240E3335 AC INLET MODULE, FILTERED, 6A 2

240E3336 FUSE DRAWER, AC INLET MODULE 3

240E3337 AC OUTLET 4

251769 HARNESS CLAMP-1/2" DIA. 5

340E0025 POWER SUPPLY, +27 VDC 6

380E0072 TERMINAL,STUD MOUNT,DUAL .250 90 DEGREE 7

802451-1 POWER SUPPLY LE BOARD ASSEMBLY 9

802402 INSULATOR, POWER SUPPLY 10

802403 AC DISTRIBUTION HARNESS ASSEMBLY 11

802404 DC DISTRIBUTION HARNESS ASSEMBLY 12

802407 LED ASSY 13

LABEL, WIRING 14

802435 FRONT COVER 15

802635 FOOT, RUBBER 16

NUT,M4X.7,HEX,W/LOCKWASHER 17

SCREW,M4X.7,10MM,PR,TH,BLK 18

802428 POWER SUPPLY HOUSING 19

LABEL,WARNING(SHOCK&EXPLOSION HAZARD) 20

LABEL, RATING, POWER SUPPLY 21

LABEL, FUSE ID, 4AMP 22

LABEL, AC OUTLET 23

GROUND LABEL-CARD 25

802455 BACKPLATE, ELECTRONICS 26

172E0061 FUSE-4AMP,SLO-BLO 5MM 27

LABEL, CONNECTOR I.D. 28

TY-RAP TIES 29


LABEL,MAGNET CAUTION 31

SCREW, M4 X .7, 6MM, PR, PH, W/LW 32

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NOTETHE POWER SUPPLY, ITEM 6, MAY BE OF MULTIPLE BRANDS AND APPEARANCE. SEE WIRING LABEL, ITEM 14, FOR AC INPUT WIRING INSTRUCTION.

SEE NOTE

(8 PLACES)

(4 PLACES)

WHITE(TO TERMINAL #7)

BLACK(TO TERMINAL #4)

SEE NOTE

SEE GROUNDSTUD FOR DETAILS

25

BROWN (L) TO POWER SUPPLY

G/Y (GND) TO GROUND STUD

BLUE (N) TO POWER SUPPLY

BROWN (L) TO PCB-J7

31

20

BOTTOM VIEW

BLUE (N) TO PCB-J7

G/Y (GND) TO GROUND STUD

REAR PANEL WIRING DETAIL

301

28

8

21

518

23

4

3

27222

(2 FUSES)

REAR PANEL VIEW7 (2 PLACES)

12345678

POWER SUPPLY OUTPUT TERMINAL DETAILGROUND STUD DETAIL

17 (2 PLACES)

TO POWER SUPPLY GND

TO AC INLET GNDTO AC OUTLET GND

(4 PLACES)

Figure 6-5-1 Power Supply Components

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6.5.2 POWER SUPPLY FUSE REPLACEMENT


1. Remove all incoming power to the Power Supply. The fuse drawer, located at the rearof the Power Supply resides in the AC inlet module (item 3). Two fuses are containedin the fuse drawer.

2. With a small screw driver, push fuse drawer tabs in while gently prying from side toside 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 removeunit from wall mount bracket.

6.5.4 DC POWER SUPPLY REPLACEMENT


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) connec-tion is exposed. Disconnect LED harness connection.

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 onthe insulator) when making terminal connections.

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6.5.5 PC BOARD REPLACEMENT




3. Gently slide Power Supply frame from housing until LED harness (item 13) connec-tion is exposed. Disconnect LED harness connection at the PC board.

4. Disconnect two (2) AC distribution connectors (item 11), and DC distribution con-nectors (item 12) at the PC board.

5. Remove six (6) jacknuts (connection side) securing PC board to backplate. Lift PCboard from backplate.

To reinstall PC board, perform the steps above in reverse order.

6.5.6 POWER ON/OFF SWITCH REPLACEMENT





4. At the PC board, disconnect AC wire connector (item 11) to AC inlet module (item3).

5. Remove four (4) screws (item 32) retaining Power Supply to frame. Move PowerSupply 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 removeAC inlet module.

To reinstall AC inlet module, perform the steps above in reverse order.

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6.5.7 AC OUTLET REPLACEMENT



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 PowerSupply 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 ontop and one on bottom side). With a small screw driver, push in on each retaining clipand remove AC outlet module.

To reinstall AC outlet module, perform the steps above in reverse order.

6.5.8 LED ASSEMBLY REPLACEMENT



2. Remove four (4) buttonhead screws from rear of Power Supply housing (item 18).


4. Remove four (4) buttonhead screws (item 18) from Power Supply housing frontcover. Remove front cover.

5. From inside of front cover, grasp LED socket and pull to remove. The LED greenlens is retained in the front cover by the socket. Be careful not to loose green lenswhen removing socket.

6. To remove LED from socket, gently grab LED with a pair of needle nose pliers andpull from socket.

To reinstall LED socket, perform the steps above in reverse order.

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6.6 REMOTE STAND

The Remote Stand consist of a stationary post, base and hanger.

6.6.1 REMOTE STAND REPLACEMENT COMPONENTS


802500 REMOTE STAND ASSEMBLY

Elevating Post

Cable Hanger Stationary Post

Wheelbase

Figure 6-6-1 Remote Stand Assembly

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6.7 FILTER

The Filter is replaced as an assembly.

6.7.1 FILTER ASSEMBLY


802600 FILTER ASSEMBLY

31.75mm(1.25")

12.7mm(.5")

270.0mm (10.63")

285.75mm (11.25")

6.604mm (.260") (5 Places)

457.2mm (18.0")

76.2mm(3.0")

(FRONT VIEW)

(SIDE VIEW)

76.2mm(3")

101.6mm(4")

31.75mm Diameter(1.25")

Figure 6-7-1 Filter Assembly

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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.

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EQUIPMENT ROOM

CONTROLROOM

Console (P/N 802100)(Rear View)

MR

Filter(P/N 801223)

MAGNET ROOM

Free HangingD-Shell Connector

HandbuttonConnection J2

Socketcable end

* Data Cable and Power(P/N 801224-07 7 Ft)(P/N 801224-15 15 Ft)(P/N 801224-25 25 Ft)(P/N 801224-50 50 Ft)(P/N 801224-75 75 Ft)(P/N 801224-100 100 Ft)(P/N 801224-150 150 Ft)

Powerhead(P/N 802300)

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

Remote Stand(P/N 802500)

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


Power In115/230VAC ±10%

FuseHolder

4 Amp Slow BlowP/N 172E0253

(Qty 2)

O I


Connection J1

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

J1J2

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml

Power Supply (P/N 802450)(Rear View)

J1, J2

Note: Ensureconnectororientation iscorrect whenmaking connection

Figure 6-8-1 Cabling

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EQUIPMENT ROOM

CONTROLROOM

MR

Filter(P/N 801223)

MAGNET ROOM


Socketcable end







FuseHolder


(Qty 2)


Connection J1


BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml



O I J1J2

Penetration Panel(Using open 25-pin pass through)

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

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

or(P/N 801224-07 7Ft)


J1, J2


Figure 6-8-2 Cabling

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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)

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6.9.1 LOAD CELL SERVICE KIT (P/N 802741S)

Find No. Part Description Quanity

23 LOAD CELL ASSY 1

20 PRESSURE WASHER 1

18 HOLDER, LOAD CELL 1

21 RAM FACE 1

73 O-RING, 022 2

59 SCREW, SET, M3, 5MM, SS-A4, BLUE 1

6.9.2 BUSHING REPLACEMENT SERVICE KIT (P/N 802742)


17 RETAINING, BUSHING 1

9 GUIDE BUSHING 1

33 WIPER 1


97 GASKET, RAM 2

6.9.3 MOTOR REPLACEMENT SERVICE KIT (P/N 802743)


1 MOTOR/ENCODER ASSY DRIVE A 1

51 GEAR, 24DP 24T 1

70 WASHER, SPRING LOCK, M4, SS-A4, BLUE DYE 3

57 SCREW, SET, M4, SS-A4, BLUE 2

72 SCREW, M4, 50MM, SHCS, SS-A4, BLUE 3

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6.9.4 FASTNER SERVICE KIT (P/N 802744)


SEALANT, SILICONE LUBRICANT

TY-RAP TIES 8

75 WASHER-#14S BRASS FLAT 2

27 SCREW, ADJUSTMENT 2

67 NUT, M6, HEX, NYLON INSERT, SS-A4, BLUE 2

56 SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE 6

82 SCREW, M3, 10MM, PR, PH, SS-A4, BLUE DYE 6

69 WASHER, FLAT, M5, SS-A4, BLUE DYE 1

95 WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE 8

71 WASHER, EXT. TOOTH, M3, SS-A4, BLUE DYE 8



70 WASHER, SPRING LOCK, M4, SS-A4, BLUE DYE 15

94 WASHER, FLAT, M3, SSA4, BLUE DYE 4

28 O RING, -008 2

39 STANDOFF, M3 - 6MM 4

61 SCREW, M4, 12MM,BHCS,SS-A4,BLUE 4

41 1/8" DOWEL PIN, 316 S.S. 1

57 SCREW, SET, M4, SS-A4, BLUE 8


87 SCREW, M2.5, 10MM, PR,PH,SS-A4,BLUE 4


46 RETAINING RING 1

11 RETAINING RING, 1-3/8 2

60 SCREW, M3, 8MM, PR, FH, SS-A4, BLUE 10

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6.9.4 FASTNER SERVICE KIT (P/N 802744) (CONT’D)


73 O-RING, -022 4

68 NUT, M5, HEX, NYLON INSERT, SS-A4, BLUE 2

59 SCREW, SET, M3, 5MM,SS-A4, BLUE 2

88 SCREW, M3, 8MM, PH,PR,SS-A4,BLUE 8


90 SCREW,M3, 6MM, PR, PH,SS-A4,BLUE 8

89 CABLE CLAMP, 9/16" 1

96 STAND OFF , 3/16" X 1", M3 2


6.9.5 BEARING REPLACEMENT SERVICE KIT (P/N 802746)


GREASE-MULTI-PURPOSE AEROSOL

10 BEARING ASSEMBLY, NON-FERROUS 1

4 BEARING ADAPTER 2

11 RETAINING RING, 1-3/8 1

6.9.6 POWERHEAD TOP COVER SERVICE KIT (P/N 802747)


29 KEYPAD ASSEMBLY 1

52 TOP COVER 1

45 LENS, INDICATOR 2

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6.9.7 SYRINGE HOLDER SERVICE KIT (P/N 802748)


56 SCREW, M2.5, 6MM, PR, PH, SS-A4, BLUE DYE 2


95 WASHER, EXT. TOOTH, M2.5, SS-A4, BLUE DYE 4

87 SCREW, M2.5, 10MM, PR,PH,SS-A4,BLUE 2

96 STAND OFF , 3/16" X 1", M3 2

8 NEST, SYRINGE HOLDER 1

83 NEST COVER, SYRINGE HOLDER 1


85 LABEL, 30/60ML, FLUID DETECTION 1

86 LABEL, 50/60ML, FLUID DETECTION 1

71 WASHER, EXT TOOTH 2

47 PCB ASSEMBLY, SYRINGE SIZE SENSING 4

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6.10 GENDER CONNECTORS

OVERVIEW

If an Optistar LE is to replace an Optistar MR; gender connectors can be used to adaptexisting 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).

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ISA

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6.11 ACCESSORY ITEMS

GENERAL

The following accessories may be ordered from Liebel-Flarsheim to adapt to the OptistarLE 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.

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7 THEORY OFOPERATION

This chapter describes the design and function of the Optistar LE injector. Block dia-grams for the system are included for each assembly described. This chapter is dividedinto the following sections:

Note: For additional information refer to Chapter 10 Schematics.

Section 7-2 System Block Diagram

Section 7-3 Power Supply

Section 7-4 Power Control

Section 7-5 Powerhead

Section 7-6 Console

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POWER HEAD 802300

"A"SRINGE SIZE

SENSE BOARDS

END LIMITBOARDS

"B"SYRINGE SIZE

SENSE BOARDS

J3J10 J11J4

HEAD MAIN BOARD802301

J12

KEYPAD

SWITCHES

SIZE LEDS

J1 J2J5

J6

J7, J8, J9

ENCA

ENCB

XDUCERA

XDUCERB

DRIVER

INTERCONNECT

B MOTOR DRIVE

A MOTOR DRIVEPOWER CONTROL 802200

TODRIVER

HEADCABLE

HOUSING

SUPPLY

CPU

COM

J3

25 PIND-SHELL

FILTER

422 +27 VSWITCHED

MOTMOT

JA, JA1 JB, JB1

A B

J1/J225 PIN

D-SHELL

+27 V

SUPPLY

LINE V

SUPPLY BOX802450422

J1

25 PIN D-SHELL J1/J2

CONSOLE802100

SYSTEM OVERVIEW

ON/OFFCLOSURE

+27 VSWITCHED

LIMIT SWITCHESSYRINGE SWITCHESKEYPADXDUCERXDUCER EXITATIONENCODERSLIGHT CONTROL

HEAD I/O

J1

J2

Figure 7-2-1 System Overview Block Diagram

Th

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7.3 POWER SUPPLY

The Power Supply assembly houses a +27VDC nominal power supply, and interfaceboard. 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 thePower Control.

When the green LED on the Power Supply front panel is on, the +27VDC is presentinside the power supply assembly. The +27VDC is applied to J1 and J2 through U4, asolid state relay switched by a momentary closure from the Sonsole ON/OFF switch.

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802450 SUPPLY BOX

802450 POWER SUPPLY ASSY., LEBLOCK DIAGRAM

ON/OFF

J1

J2

SSR

FILTERLINE VOLTAGE

POWERSWITCH

27VDCSUPPLY

CONNECTOR BD802451-1

+27 VDC

ON/OFF

+27 VDC

422

422

Figure 7-3-1 Power Supply Block Diagram

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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)


The interconnect assembly is fixed in place as part of the Power Control chassis; the otherboards slide into the Power Control and mate with the interconnect assembly. The inter-connect assembly consists of two backplane boards connected to each other by feedthrough capacitor filters. The assembly divides the Power Control into the CPU/Power(front) section, and Driver/Communication (back) section. The CPU/Power backplaneboard will be on of two possible part numbers: 802208-1 (Universal) or 802205-1. TheDriver/Communication backplane board part number is 802206-1. All connections be-tween 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.

The Head Communication Harness Assembly (P/N 802213) carries all head signalsEXCEPT 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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CalibrationSwitch BoxConnector

Download Connector

CPU ModeSwitches

J6

J4

S1802201-1

CPU Board

802202-1Power Board

802204-1Communication

Board

802200 POWER CONTROLBLOCK DIAGRAM

P2

J2

J2

802203-1Driver Board

J2

802208/802205

802206

P1

J1

J1P3

J3

J2

J1

J3

J3

802215Switch/CableAssembly

802214 ConsoleCommunicationHarnessAssembly

802213 HeadCommunicationHarnessAssembly

HeadConnector

802212 HeadMotors HarnessAssembly

802207 Assembly

P4

J4

J7

J2

CalibrationDisplayConnector

P2

J2

P1

J1

P3

J3

Figure 7-4-1 Power Control Block Diagram

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7.4.1 POWER BOARD

The Power Board converts the nominal +27VDC from the Power Supply Assembly to thefollowing voltages used by the system:

• +12VDC - Mostly for LED’s, interface and opto drive

• +5VDC - Logic power

• +22 to +24VDC - Most raw supply


In addition, the Power Board provides voltage and current sense that can be monitored bythe Main CPU. The motor raw supply can be turned on or off by the CPU, or switchedfrom approximately +22VDC to +24VDC, depending on motor requirements.


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802202-1 POWER BOARD

802202-1POWER BOARDBLOCK DIAGRAM

+27 V

5AFUSE

DC/DC on

V CHANGE

P4

P3

+22 -24 VDCDC/DC

22 -24 VDC

+5 VDC

+5 VDC

+12 V

SENSE

U1+27 VP3

P4

FUSED 27VDC

V SENSE

A SENSE

MOT VP3

+12VDCU2

U3

PS1

Figure 7-4-2 Power Board Block Diagram

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7.4.2 COMMUNICATION BOARD

The Communication Board provides the following functions:

• Carries all non-motor signals between the Power Control and the Power Headcable

• Carries the noninal +27VDC from the Power Supply to the on/off switch, thento the interconnect assembly.

• Converts the transmit and reveive signals from the CPU into RS-422 to theconsole



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FILTERS

HEAD I/O

MAX 488

TX

P3

P2

P3

J1

J2

J3

HEAD I/O

802204-1 COMMUNICATION BOARD

802204-1 COMMUNICATION BOARDBLOCK DIAGRAM

J2

U2

RX

+27 VDCFROM

SUPPLY BOX

ON/OFFSWITCH

COMMUNICATIONTO/FROMCONSOLE

+27 VDCSWITCHED

TX+

TX-

RX+

RX-

Figure 7-4-3 Communication Board Block Diagram

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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, andcos 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, andU12. 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, andU16. 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 drivercircuits. This is done to retune the circuit to work at lower flow rates



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DRIVECIRCUIT

P1

J1

A SELECT

+ 22 - 24 VDC

DRIVE

COIL SWITCH

B SELECT

802203-1 DRIVER BOARD

802203-1 DRIVER BOARDBLOCK DIAGRAM

TO AMOTOR

TO BMOTOR

Figure 7-4-4 Driver Board Block Diagram

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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 systemin reset until Vcc is up. U9 is the 512K flash memory device where the main program isstored. 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 thepower head user buttons, syringe size switches, and the ram end limit switches. All ofthese signals are isolated by optocouplers U34, U35, U36, and U37. U30, also an AlteraFPGA, is used to generate the motor drive signals and monitor the motor speed andposition. Additionally, the CPU monitors speed, position and pressure through U1, aUniversal Pulse Processor (UPP).

The pressure transducers, used to sense actual syringe pressure, are mounted at the end ofthe power head rams. The transducers are supplied 2 VDC excitation from theD9 - U29:A - Q1 circuit on the CPU board. The excitation supply is a constant currenttype, so the 2V output is dependent upon both transducers being connected. The millivoltlevel signal from the transducers is amplified to an approximately 3.5 V max signal that ismonitored by the CPU through the UPP.



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Power ONDetector

32.8 KHzXTAL

(16.777 MHz clk cyc)

CPUMOT 68332

16 bit ext D Bus32 bit Adr & int D Bus

CPUSTATUS

DS2-DS5

CALIB. I/F sh 6

SW BOXIN/OUT

CONTROL

CALIBTEST &

DISPLAY

4mode

5

16

32

8

11

8

2

26

20

+12V

Hi SpdI/F

BUF'S

10J4

PGM/DeBugm/w P&E

BDM i/f Cable

CPUsh 1

I/F & WAKEUPsh 5

DATA

ADR

TPU

*CS0-CS10

*IRQ1-IRQ7

*DSACK

4

P1

64-PIN

SPEAKER (to head)

CONSOLE (RS 422 drv)

+12v

513

Main-Cntrl

SZSW13

ACTIVITYDETECT

(pwr on ena)

J6

J7

InterfaceBuffer

Circuitry

LCD7

DATA8

6 EX & CLK

OPTOI/F

BUF'S

Encoder A/B Ckls

*CS5,6,7

16

*CS8,9,10

U9

FLASHMEM

256Kx16(29F400T)

U3, U8

SIMSRAM

128Kx16(HM628128)

U2, U5

NVRAM8Kx16

STK12C68

MEMORYsh 2

JTAG

J2

10

8DATA

ADR0-5

ADR11-15

SZSW

LCD

*CS3

7

P7

DATA

ADR 0-10

*sv-cs

8

(4MHz clk cycle)

16 MHzXTAL

9.8304MHzMotor Clk

*IRQ1

*IRQ3

*IRQ5

26V&1

(fm PWR)

(to DRVR)

(to DRVR)

(to PWR)

P2

32-PIN

Main-Cntrl

3

4P/MSIN/COS

*IRQ2(Motor)

+5, +5VB, +12(TO I/F, sh. 5)8

4

U30

MOTORCONTROL

(EPM9400)

F - IN F - OUT

Lim SW

ADR 0-3

DATA

Pressure Input ASample & Hold(BB INA118)

Pressure Input BSample & Hold(BB INA118)

Phase-LockedLoop (HC4046)

1.88 MhZ - 1.6 MhZ(40-45 Hz Running)

INTEGRATOR/FILTER

+5v11.4 mA CONSTANTCURRENT SOURCE

TO PRESSURE BRIDGE

2

2

A/D 1input 1

U1

UPPUNIVERSAL

PULSEPROC.

(HD3140-A)

J5

TestPoints

P-CONTROL

*WT

UPP & PLDsh 3

4

10

JTAG

J1

-5v-5vxvtr+5v

PLL 7 PR FLTsh 4

8

*i/o-wrt

U16

I/ODECODE

7 CALTESTCTRL

(EPM7128)

16

16

*CSBOOT

O.C.sel A/B& SPD

U13

802201-1CPU BOARD

BLOCK DIAGRAM

Figure 7-4-5 CPU Block Diagram

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802701-C May 2003

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7.5 POWERHEAD

For signal details to and from the Powerhead, refer to the Chapter 6 Cables.


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 onlyexception being the motor drive voltage, which connects directly to the motors from thePowerhead cable.

Control of the A and B ram LED’s, and enabling of the syringe size LED’s is by serialdata shifted from the CPU using H_data and H_clock lines. Data is clocked into U4 onthe Powerhead board, than latched on U5.

Syring size switch signals go directly to the CPU to sense what syringe is installed, and toU10 to light the apropriate Syringe Siz LED on the keypad.

The keypad interface (U6, U7, U8, U16, U17) encodes 7 of the keypad switches (allexcept the A and B speedup switches) into a three line binary code to the CPU. A keypadfault (unconnected keypad) will cause an invalid code to the CPU, triggering an errormessage.

The Powerhead contains optical encoders to control and monitor the position and speedof the motors. The encoders are supplied with +5VDC, and U1, U2, and U21 bufferencoder signals before going to the CPU board.

The end limit sensing boards are supplied +12VDC, and the limit signals pass directly tothe CPU.

The pressure transducer excitation voltage passes through from the CPU, the tranduceroutpurs pass through to the CPU.

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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 boardhas an optical interrupter at each end, and is actuated by a flag on the ram. The sensor atthe zero position (ram fully extended) is set exactly to the ram position corresponding toan 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 boardassemblies, 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 todetermine what syringe is installed. The table below shows the decoding for each syringesize.

A Side

Switch Inputs

SIZE 0-A SIZE 1-A

(BARREL) (FLANGE) SYRINGE

OPEN OPEN N/A

OPEN CLOSED Mallinckrodt 10/15/20

CLOSED OPEN Kendal 60

CLOSED CLOSED Mallinckrodt 30

B Side

SIZE 0-B

(BARREL) SYRINGE

OPEN OPEN Mallinckrodt 125

OPEN CLOSED N/A

CLOSED OPEN Kendal 60

CLOSED CLOSED Mallinckrodt 50

CLOSED = LOW

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802701-C May 2003

7—P

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8023

01-1

HE

AD

BO

AR

D

J12

SP

EE

DU

P A

SP

EE

DU

P B

KE

YPA

D

SW

ITC

HE

S

SW

ITC

HE

SS

WIT

CH

ES

- 7

LIN

ES

KE

YPA

D F

AULT

TO P

OW

ER

CO

NT

RO

L

J7 J8 J7 J8 J7 J8 J9 J7 J8

EN

CO

DE

TO P

OW

ER

CO

NT

RO

L

TO P

OW

ER

CO

NT

RO

L

SIZ

ELE

DE

NA

BLE

DE

CO

DE

AD

EC

OD

EB

SY

RIN

GE

SIZ

ELE

DS

FLA

NG

E A

BA

RR

EL

AF

RO

MS

YR

ING

ES

IZE

SE

NS

ES

WIT

CH

ES

8023

07-1

FLA

NG

E B

BA

RR

EL

B

FR

OM

PO

WE

RC

ON

TR

OL

CLO

CK

DAT

A

J10

J11

J8S

HIF

T/

LAT

CH

RA

MLE

DS

SIZ

ELE

DE

NA

BLE

A B

TO P

OW

ER

CO

NT

RO

L

TO P

OW

ER

CO

NT

RO

L

TO P

OW

ER

CO

NT

RO

L

TO P

OW

ER

CO

NT

RO

L

2V E

XIT

ATIO

N

DR

IVE

RS

A

IND

EX

A/B B

AE

NC

M

BE

NC

M

AT

RA

NS

DU

CE

R

BT

RA

NS

DU

CE

RJ6

A L

IMIT

S80

2302

-1

J4

B L

IMIT

S80

2302

-1TO

PO

WE

R C

ON

TR

OL

TO P

OW

ER

CO

NT

RO

L

J2J1 J5 J3

802301-1 HEAD BOARDBLOCK DIAGRAM

Figure 7-5-1 Powerhead Block Diagram

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802701-C May 2003

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802701-C May 2003

7.6 CONSOLE OVERVIEW

The console provides the user interface through the color LCD and the touchscreen. Also, the console provides the system ON/OFF switch that is operableonly with the power pack circuit breaker in the ON position.


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 processorstate machine

• Manages screen generation

• Provides BDM port for console software downloading

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7.6.2 CIRCUIT DESCRIPTIONS

Interface Connection

The interface connector provides the means for the console to obtain power fromthe supply as well as provide the path for the console to communicate with thesystem.

RS422 Drivers and Receivers

The communication channel to and from the powerpack is accomplished usingRS422 drivers and receivers (MC3487 and MC3486 or equiv). The communica-tions channel operates at a BAUD rate of 38400 bps with 1 start and 1 stop bit. Acommunication packet is started by a start of command hardware signal (RTS)and completed by this signal being de-asserted. For every command packet, theremust be an acknowledgment of validity.

Touch Screen Control

The quiescent state assumes the screen is not touched. Signal X+ is driven highand X-, Y+ and Y- are high impedance. During this time the line SY- is monitoredby a comparator. If the screen is touched the comparator’s output will generate aninterrupt 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 Xcoordinate is defined by the value digitized on the SY- channel corrected by thedifference between 5 volts and the value found on the SX+ channel. Then X linesare allowed to float and Y+ is driven high and Y- is driven low. The Y coordinate isthen defined as the digitized value for the SX- channel corrected by the differencebetween 5 volts and the value found on the SY+ channel. The BYTEME signal isasserted 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. TheRAM is the heart of the console control variables and data storage. All data withinthese devices are lost when system power is removed.

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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 withvarious sections of the console software. The console software is divided asfollows:

These devices contain the product software and the RTOS, all of the bit mappedimages used on the display screens, the basic set of languages used and the fontssets for all displayed text. Also, these devices contain the object records whichare 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 thenormal uses of a microprocessor, data flow to and from memory and peripheraldevices, the CPU communicates directly with the SED1355 graphic’s LCD panelcontroller. The SED1355 gathers the information from the CPU to build thevarious screen images. Once the data is organized the SED1355 will generate thenecessary control signals for the LCD display and display the image. The imagewill be maintained by the SED1355 until the CPU provides a new or updates thecurrent set of images.

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8 CALIBRATION

8.1 OVERVIEW

To perform these calibrations, the Powerhead and Power Control Covers must be disas-sembled. For details, see Chapter 6.

WARNING!

Always remove Power Control and Power Head assembly from magnet roombefore disassembly and calibrating. Failure to follow this warning could resultin 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

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8.1.2 FREQUENCY OF CALIBRATION

The Optistar LE should be calibrated at least every 2 years or whenever a part or compo-nent 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

60mL30mL10/15/20mL

Side B

60mL50mL125mL

• Additional Checks (section 8.5) Factory Adjusted

• Syringe Size Factor Check. section 8.4.1

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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. RemovePowerhead and Power Control assemblies from the magnet room.

2. At the Power Supply, disconnect the data/power cable (J2) to the Filter. You will beconnecting 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 CPUboard 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 thePower Control (J3) connection.

CPUBoard

J7

J6

CPUSW 1

Note: ON positionis toward edge offboard

Test Switch Assembly

MODE

LIMIT

PRESSURE

P.S.I.

SYRINGE

FLOW RATE VOLUME

TIME

REST VOL. ML

ML MLSEC

250 200 100 50 40 30 20 10

F11ML

F10F12

F13 F15

F16

F17

F2 F3 F14

F4 F5

F9

F6

F7 F8

F1

UpMode

DownEnter

Test Display

Figure 8-1-1 Test Unit Connections

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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 boardchange.

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 theClosed, ON, position. (This would be toward the edge of the board)

3. Power UP the System in the sequence listed below:1st Power Control2nd Power Supply3rd Console front panel “On/Off” button.

The system should power UP normally and all of the test display’s segments should beon.

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 bereplaced with default values. These default values should not be used without performingthe calibration procedure.

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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 andensure that 1, 2, and 4 are OFF.

3. Power UP the System in the following sequence:1st Power Control2nd Power Supply3rd 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. Bothitems are illustrated below.

UpMode

DownEnter

MODE

LIMIT

PRESSURE

P.S.I.

SYRINGE

FLOW RATE VOLUME

TIME

REST VOL. ML

ML MLSEC

250 200 100 50 40 30 20 10

F11ML

F10F12

F13 F15

F16

F17

F2 F3 F14

F4 F5

F9

F6

F7 F8

Test Switch Assembly Test Display

F1

F1

Figure 8-1-2 Test Components

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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 selectedwill 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 6 = Power Factor test (Factory Adjusted)

• Mode 7 = See section 10.2.1

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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 letteris 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 theleft.

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 TestSwitch Assembly. When the ‘ENTER’ key is pressed, (on the Test Switch assembly) thisadjusted value will be copied to field F6 and thus into memory.

F8 Displays a hexadecimal number during the injection. This hex number equals half ofthe actual pressure displayed in field F3 when converted to decimal.

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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 understoodtwo 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, 500B 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 Ram B60mL 493 60mL 49330mL 470 50mL 58810/15/20mL 257 125mL 1012

F7 New Power Factor value is adjusted by using the UP and DOWN keys on the TestSwitch. When the ‘ENTER’ key is pressed (on the Test Switch) this adjusted value will becopied to field F6 and thus into memory.

F11

Ram A Ram B60mL 9 60mL 630mL 7 50mL 810/15/20mL 5 125mL 10

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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 onthe 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 Raminformation; Ram A (AH) or B (bH) appears on the test display. Also, note that whenpressing a fill/expel button to toggle the display to the desired Ram, the Ram has tophysically move to toggle the display to that Ram. Subsequently, the last Ram that physi-cally moves becomes the active Ram on the display.

Note: the volume indicated on the test display is missing a decimal point, it must bemoved 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 onthe test display volume.

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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 lineof 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 testdisplay is (01) or higher.

3. If the statements in step 2 are not true, then the limit switch board for the Ram ofconcern will have to be adjusted forward or backward.

4. To access adjustment screws, remove the Powerhead lower front, middle covers, andsyringe holder nest cover. The top cover is now lose, be careful when rotating thePowerhead. Facing the injector rams, the two adjustment screws reside on thePowerhead 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 screwlocations.

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 withinthe optic sensor and is in no danger of hitting the sensor.

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8.2.3 REVERSE LIMIT SWITCH CHECK (A)

1. Retract the Ram to it’s 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 incalibration mode.

The volume displayed on the test display shall be (713); or 71 mL when incalibration mode

The limit switch status on the display shall be (bon) when the Ram reaches thereverse limit

The limit switch status shall toggle to (boF) when the volume displayed on thetest 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.

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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 theload 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, theyshould be able to spin and pull-off. Also, note that the load cell holders shall remainsecure 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 theplunger stops with a volume remaining adequate to run the same injection withoutretracting the ram.

Without retracting the ram, empty the syringe and manually push the plunger to theexpelled end, then repeat the same 10mL injection so the ram face does not engagethe 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.

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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 a60mL 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 Raminformation; Ram A (AH) or B (bH) appears on the test display. Also, note that whenpressing a fill/expel button to toggle the display to the desired Ram, the Ram has tophysically move to toggle the display to that Ram. Subsequently, the last Ram that physi-cally moves becomes the active Ram on the display.

B

A

50 ml 60 ml 125 ml

60 ml 30 ml10/15/20 ml

5

10

15

20

25

30

35

40

45

50

55

60

mL mL

50

55

50

100200

300

WaterContainer

Powerhead'A' Side Ram

Powerhead'B' Side Ram

Drain andFill Tubes

Pressure GaugeFixture

Pressure Tube

60 mLSyringe

LE Base Assembly(Black)

Figure 8-3-1 Pressure gauge fixture installed

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8.3.3 SIDE “A” 60 ML SYRINGE:

1. Connect syringe and the pressure test assembly to the ‘A’ Ram, refer to the pressuretest 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 andprogram 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 slightlylower than 150 psi. This is normal since the bar graph is displaying the average pressurewhile the injector’s calibration point is peak.

Note: that after the injection, pressing the “Results” button on the console will display theachieved parameters of the last 6 injections; (the last 12 if pressed twice). The pressurelisted on this screen is also an average pressure, and shall be within ± 10 psi. of theprogrammed 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 willraise or lower the bottom (0335) value, F7, on the Test Display (Note that loweringthe number will increase the pressure).

b. After an adjusted value is displayed, press the Enter button on the Test SwitchAssembly. This will change the top value, F6 on the Test Display, to match thelower value F7 that was just modified.

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 belower than programmed.

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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 nosyringe on side A.

2. Go to the A + B mode screen on console by pushing the “Inj. Mode” key and programthe 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 valueshould be adjusted to achieve 150 psi. +/- 10 psi.

a. On the Test Switch Assembly, press the UP or DOWN buttons to change the F7bottom value UP or DOWN as required. Note, that lowering the number willincrease 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.

4. Adjust pressure in the same manner as the A side. The Test Display will originallyindicate a pressure limit value of (0165) and should be adjusted accordingly toachieve 100 psi. +/- 10 psi using the Test Switch Assembly.

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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, 200psi.

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 loweringthe number will increase the pressure.)

6. Repeat steps 4 & 5 above as many times as necessary to achieve the 200 psi specifica-tion.

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, 200psi.



6. Repeat steps 3 through 5 above as many times as necessary to achieve the 200 psispecification.

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8.3.8 SIDE “B” 50 ML SYRINGE

Note: A 30mL syringe will be used on the B side to simulate a 50mL syringe forcalibration 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/s30mL injection for the B side. Set the maximum pressure at 200 psi.

Note: On the test display, the default value is (0365).



5. Repeat steps 3 through 5 above as many times as necessary to achieve the 200 psispecification.

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8.4 ADDITIONAL CHECKS (FACTORY ADJUSTED)

Note: The following items do not have to be performed as part of a regular calibrationprocess.

8.4.1 SYRINGE SIZE FACTOR CHECK, (POWER CONSUMPTION) :

The power consumption of the injector becomes higher at lower flow rates. To compen-sate for this, different ‘power consumption’ values are in the software depending on thesize of the syringe installed. These default values are factory adjusted and would notnormally be changed.

1. Toggle the Test Display to mode 6 by pressing the “Mode” button on the Test SwitchAssembly.

2. Momentarily press a fill or expel button on the ‘A’ Ram on the power head to togglethe Test Display to indicate the ‘A’ Ram information.

3. With no syringe adapters installed, (ready for a 60 mL syringe), the test display shallindicate (493) for the A side.

4. Install a 30 mL syringe into the A side and confirm that the value on the Test Displaychanges 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:

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 willallow the system to store the performed calibrations.

Note: All 4 switches on the Power Control CPU board shall be off.

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8.5 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 willallow the system to store the performed calibrations

Note: All 4 switches on the Power Control CPU board shall be off

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9 SYSTEMINFORMATION

This chapter describes System Information mode features. From the System Informationscreen 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

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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 toucheither the Memory, Inject Mode, or Results buttons.

Inject Mode Memory Results

Alarm History

Service Mode

HighLowDisplay Brightness PSIPressure Units

System Information

HighMedLowOffBeeper Volume

Software Versions Console: 0.00.06 Power Control:

Language English

Change TimeChange Date

AUG 01-2002 14:15

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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.


2. Touch the Pressure Unit screen button. Pressure units will toggle between KPA andPSI.

9.1.3 SET BEEPER VOLUME


2. Simply touch any one to the four Beeper Volume screen buttons. The beeper volumewill change each time a button is touched.

9.1.4 CHANGING LANGUAGES

This feature will change display information to the language selected.


2. Simply touch the Language screen button. The language will change each time abutton is touched.

9.1.5 SET DATE AND TIME


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 ChangeTime buttons.

9.1.6 VIEW ALARM HISTORY


2. Simply touch the Alarm History screen button. The alarm history screen will bedisplayed.

3. Touch the System button to return to the System Information screen.

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9.2 SERVICE MODE

In Service Mode the following features are available:

• Screen Calibration

To access this mode proceed as follows:


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 dis-played.

Note: If the red touch targets continue to reappear, this means a touch target was missedduring the calibration process. Simply repeat the calibration process until the SystemInformation screen is displayed.

Note: If one of the red touch targets does not appear, this means the touch screen isphysically misaligned. Refer to 6.2 for console procedures.

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10 SOFTWARE DOWNLOADAND UPGRADE

10.1 OVERVIEW

The Optistar LE software resides in FLASH memory that can be reprogrammedwithout chip removal and replacement. This configuration uses a personal computerto download the code to the memory ICs via a 10 pin serial port. The minimumrequirements to perform the software download are as follows:

• Personal Computer with, at a minimum, 386 processor, 8 megabytes ofRAM, 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 bepurchased 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 combi-nation of software sub-versions in order for the injector to function properly.

To check compatibility, compare the software sub-versions on the SYSTEM INFOSCREEN 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. Writedown the software versions displayed.

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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 install-ing (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 Copyand 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 yourcomputer, 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 installthe PROG32z and PROGcfz files on your hard drive into the C:\pemicro folder.

The “Welcome to the Install shield Wizard for PE’s Flash Programmer for TYCO”Window appears. Click Next.

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”, andclick 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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Now that the PROG programs have been installed on your computer, the parallel portmust 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”. (Yourparallel port has already been configured.)

If “LPT1: is not listed in BIOS” is displayed and is disabled, select “Use HEX Ad-dress” and enter an address of “0378”.

Click OK.

If the parallel port has been configured and an error occurs when you try to exit theaddlpt.exe program, click Cancel to continue.

When you run the PROG32z or PROGcfz program for the first time, a ConnectionAssistant 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 beforeattempting to contact target.” When deselected, the Connection Assistant DialogueWindow will only appear if an error is detected.

Also when you run the PROG32z or PROGcfz program for the first time, thePROGxxx program will not know where to find the new software to be downloaded tothe injector. So when you “Choose Module” for the first time, simply navigate to thefolder where the software resides (for example, C:\V2.00). When you “Specify SRecord” 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 thesoftware resides.

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10.2 DOWNLOAD AND UPGRADE PROCEDURES

Procedures defined in this section will assume you have completed instructions10.1.1 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 inthis document for procedures.

WARNING!

Always remove Power Control and Power Head assembly from magnet roombefore disassembly and upgrading. Failure to follow this warning could result inpersonnel injury or equipment damage.

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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. RemovePowerhead and Power Control assemblies from the magnet room.

3. At the Power Supply, disconnect the data/power cable (J2) to the Filter. You will beconnecting 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 cableto 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 inFigure 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 thePower Control (J3) connection.

J4

sw

CPU

Red Wire

Figure 7-2-1 Power Controlcable 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 messagesthat appear on the console screen.

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10. Run the PROG32Z.exe file. This should be openedfrom Windows

11. Verify “CHOOSE MODULE .32P” is selected.

12. Using the mouse, select the powrpack.32p file andpress enter.

13. Type a 0 (zero) in the “Base Address” pop upwindow and press enter.

14. Using the arrow keys on the PC keyboard select“ERASE MODULE” and press enter. The statussection at the bottom of the screen will prompt theuser when the task is complete.

RUNPROG32Z.EXE

SELECT "CHOOSEMODULE"

SELECTpowrpack.32p

PRESSENTER

CONTINUED

TYPE 0TYPE 0

PRESSENTER

SELECT "ERASEMODULE"

PRESSENTER

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15. Using the arrow keys on the PC key-board select “SPECIFY S RECORD”and press enter.

16. Using the mouse, select thepowrpack.s19 file and press enteragain.

17. Using the arrow keys on the PC key-board select “PROGRAM MODULE”and press enter. The status section atthe bottom of the screen will display“PROGRAMMED” when the task iscomplete.

18. Using the arrow keys on the PC Key-board select “QUIT” and press enter

19. Remove power using the ON/OFFswitch on the power supply.

20. When power control download iscomplete, remove the PC data cable atthe power control CPU board.

POWER PACKPOWER PACKCONTINUEDCONTINUED

SELECT "PROGRAMSELECT "PROGRAMMODULE"MODULE"

"PROGRAMMED""PROGRAMMED" IS DISPLAYED IS DISPLAYED

PRESSPRESSENTERENTER

SELECT powrpack.s19SELECT powrpack.s19


SELECT "SPECIFY 'S'SELECT "SPECIFY 'S'RECORD" RECORD"


SELECTSELECT"QUIT""QUIT"


PERFORMPROCEDURE

1 OR 2

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Note: One of the following two procedures must be performed after downloadingsoftware into the CPU board. If neither of these procedures is performed, Alarm 23will occur at power up. To decide which procedure to follow use the followingcriteria:

• 21 Procedure 1 involves re-initializing the Power Control’s CPU RAM. This proce-dure should be used in the event that the CPU board has been replaced. This proce-dure will erase all pressure calibration values necessitating the complete calibrationprocedure 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 majorcomponent dealing with pressure has been replaced.

21. PROCEDURE 1

1. Perform the Initialization of the Power Control CPU Ram procedure as described insection 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 CPUboard 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.

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 displayand note the value in the “TIME” window in the lower right section of the TestDisplay. 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 thePower Supply. Remove the Test Display and Test Switch assembly and return SW3to OFF.

7. Power on the injector. Check all calibration parameters. Refer to chapter 8.

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10.3 CONSOLE DOWNLOAD

Note: The Console must be connected to the Power Control to complete thisprocedure.

1. Ensure power to the injector is off.

2. Remove the console’s back cover as described in Chapter 6.2.

3. Connect the 25 pin D-Shell connector of 802683 Software Download AdapterColdfire 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 shownin Figure 10-3-1. Be sure the cable red wire (pin 1) is correctly oriented to J4 pin1 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 downloadingprocess.

Software DownloadAdapter Cable

Red Pin 1

J7

J6

J2 J8

J5

25 J4 1

1

Figure 10-3-1 Console SoftwareDownload Cable orientation

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6. Run the PROGCFZ.exe file. This should be opened fromWindows.

7. Verify “CHOOSE MODULE .CFP” is selected.

8. Using the mouse, select the console.cfp file and pressenter.

9. Type a 0 (zero) in the “Base Address” pop up window andpress enter.

10. Using the mouse or arrow keys on the PC keyboard select“ERASE MODULE” and press enter. The status section atthe bottom of the screen will prompt the user when thetask is complete. The erase command may take30 seconds. Actual erase time will depend on the speed ofyour PC.

RUNPROGCFZ.EXE

SELECT "CHOOSEMODULE"

SELECTconsole.cfp

CONTINUED

TYPE 0

PRESSENTER

PRESSENTER

SELECT "ERASEMODULE"

PRESSENTER

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11. Using the mouse or arrow keys on the PCkeyboard select “SPECIFY S RECORD”and press enter.

12. Using the mouse or arrow keys on the PCkeyboard select the console.s19 file andpress enter again.

13. Using the mouse select “PROGRAMMODULE” and press enter.

14. The program module command may take160 seconds. Actual programming timewill depend on the speed of your PC.

15. Using the mouse or the arrow keys on thePC Keyboard, select “QUIT” and pressEnter.

16. Remove power using ON/OFF switch onthe power supply.

CONSOLECONSOLECOMPLETECOMPLETE

CONSOLECONSOLECONTINUEDCONTINUED

SELECT "PROGRAMSELECT "PROGRAMMODULE"MODULE"

"PROGRAMMED""PROGRAMMED" IS DISPLAYED IS DISPLAYED

PRESS ENTERPRESS ENTER

SELECT console.s19SELECT console.s19


SELECT "SPECIFYSELECT "SPECIFY'S' RECORD" 'S' RECORD"


SELECTSELECT"QUIT""QUIT"


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Overview

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11 SCHEMATICS

OVERVIEW

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

Overview

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P7P7

TPU0-TPU0-3ADDRESSADDRESS

CPU-TXDCPU-TXD

DGNDDGND

DATADATA

RXD-INRXD-IN RXDRXD

R/R/W

BKPTBKPT

BERRBERR

PCS1PCS1

SPKRSPKR

TPU0-TPU0-3

SERIAL_OKSERIAL_OK

BOOT_CRCBOOT_CRC

DSDS

NMINMI

D15D15

D7D7

D0D0

RXRXD

TXDTXD

TS_OKTS_OK

INIT_DONEINIT_DONE

D8D8

CPU-TXDCPU-TXD

SPEAKER_OUTSPEAKER_OUT

MRMR

SYS_RESETSYS_RESET

MRMR

IPIPIPIPE

A16A16

A1A13

A10A10

A7A7

A4A4

A1A1

MRMR

FREEZEFREEZE

IFETCHIFETCH

A18A18

A17A17

A15A15

A14A14

A12A12

A11A11

A9A9

A8A8

A6A6

A5A5

A3A3

A2A2

A0A0

PCS3PCS3

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

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BOOT_PGM*BOOT_PGM*

CS7CS7

CS6CS6

DATADATADATADATA

CS7CS7

CS8CS8

CS10CS10 CS1CS10

CS9CS9

ADDRESSADDRESSADDRESSADDRESS

CS5CS5

CSBOOTCSBOOT

DATDATA

R/R/W


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PH_A_BPH_A_B

PHAIPHAI

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PH_B_BPH_B_B

SZSWSZSW

n.c.n.c.

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SZSWSZSW

DATADATA

DGNDDGND

WDTP2WDTP2

SYS-GOSYS-GO

LCLCD

SSR-ONSSR-ON

P74P74

P75P75

PH_C_BPH_C_B

SPD_CNGSPD_CNG

P_SPD_CNGP_SPD_CNG

ADDRESSADDRESS UPP-CSUPP-CS

A

8_MHZ8_MHZ

P-CONTP-CONT

ADDRESSADDRESS

DATDATA

PH_A_APH_A_A

SAMP-SAMP-A

SAMP-SAMP-B

P75P75

A_DRV_FQA_DRV_FQ

B_DRV_FQB_DRV_FQ

SSR-ONSSR-ON

JTAG-TCK-INJTAG-TCK-IN

B_MOTB_MOT

A_MOTA_MOT

B-MOTB-MOT

P-COSP-COS

WDTP2WDTP2

PH_B_APH_B_A

P74P74

PH_C_APH_C_A

P-SIP-SIN

DATADATA

ADDRESSADDRESS

FB-UPAFB-UPA

CS3CS3

UPP-RDYUPP-RDY

JTAG-TMS-INJTAG-TMS-IN

M-SIM-SIN

TDOTDO

TCKTCK

FB-UPBFB-UPB

MRMR

P-CONTP-CONT

M-COSM-COS

A-MOTA-MOT

CS1CS1

SV-CSSV-CS

JTAG-TDJTAG-TDI

SPD-CNGSPD-CNG

A_MOTA_MOT

CS3CS3

JTAG-TDJTAG-TDO


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BSAMP-OUTBSAMP-OUT

SAMPBIN-SAMPBIN-

ASAMP-OUTASAMP-OUT

SAMPAIN-SAMPAIN-

K_6MAK_6MA

+5V+5V

-IN-B-IN-B

+INA+INA

+IN-+IN-B

-IN-INA


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BK-LIM-BK-LIM-A

RESVRESV

Q-SW-Q-SW-B

PHC-APHC-A

PHA-APHA-A

BK-LIM-BK-LIM-B

F-LIM-F-LIM-A

Q-SWAQ-SWA

SIZE0-SIZE0-A

SZSWSZSW

H-DATAH-DATA

H-CLKH-CLK

PHB-APHB-A

FILSW1FILSW1

FILSW2FILSW2

FILSW0FILSW0

SIZE1-SIZE1-B

SIZE0-SIZE0-B

SIZE1-SIZE1-A


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LCLCD

DATADATA

ENTERENTER

UPUP

EX-INEX-IN3

EX-INEX-IN0

DWNDWN

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EX-INEX-IN1

EX-INEX-IN2


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6.3 A SLOW BLOW

POWER SCHEMATIC 802202-2-D

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DRIVER BOARD SCHEMATIC 802203-C

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COMMUNICATION BOARD SCHEMATIC 802204-A

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+5V+5V

26V-AN426V-AN4

n.c.n.c.

SSR-ONSSR-ON

+5V+5V +5V+5V +5V+5V

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+12V+12V

SSR-ONSSR-ON

P_SPD_CNGP_SPD_CNG

26V-AN426V-AN4

DGNDDGND

26V-AN426V-AN4

26VA-AN626VA-AN6

+5V+5V +5V+5V

M-SIM-SIN

P-COSP-COS

MOT-V-RETMOT-V-RETFILLSW_0FILLSW_0

Q-SW-Q-SW-AFILLSW_2FILLSW_2

MOT_VMOT_V

SIZE0-ASIZE0-A

BK-LIM-BK-LIM-A

PHA-PHA-A

PHB-PHB-B

+IN-+IN-BPHC-PHC-A

K_6MAK_6MA

-IN-INADGNDDGND

DGNDDGND

A_MOTA_MOT

RESV2RESV2P_SPD_CNGP_SPD_CNGSPD_CNG-DRVSPD_CNG-DRV

M-COSM-COS+5V+5V

+12V+12V

+12V+12V

FILLSW_1FILLSW_1

RESVRESV

SIZE0-BSIZE0-BSIZE1-ASIZE1-A

SIZE1-BSIZE1-B

Q-SW-Q-SW-B

H-DATAH-DATAPHA-PHA-B

F-LIM-F-LIM-B

H-CLKH-CLK

BK-LIM-BK-LIM-B

RXD-INRXD-IN

+INA+INA-IN-INB

ANA_GNDANA_GND

PHC-PHC-B

TXDTXD

B_MOTB_MOT

SSR-ONSSR-ON

P-SIP-SIN

F-LIM-F-LIM-A

+26-IN+26-IN

26VA-AN626VA-AN6

+26_FUSED26_FUSED

+26_FUSED+26_FUSED

INTERCONNECT CPU BOARD SCHEMATIC 802205-A

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INTERCONNECT DRIVER BOARD SCHEMATIC 802206-A

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

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

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CONSOLE SCHEMATIC 802101-C (1 OF 5)

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CONSOLE INTERFACE SCHEMATIC 802102-C (1 OF 1)

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POWERHEAD SCHEMATIC 802301-D (1 OF 4)

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END LIMIT SENSING SCHEMATIC 802302-A

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SYRINGE SIZE SENSING SCHEMATIC 802307-A

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POWER SUPPLY SCHEMATIC 802451-B

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HAND BUTTON 802620/802622

BlackRed

White

Green

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POWERHEAD CABLE 802303-A

Powerhead Board(P/N 802301-1)Connectors

J8

J7

J9

PowerheadMotor Connections

JA

JB

JB1

JA1

P1P2Pin 1

Pin 1

P1:8 BLACK J8-9P1:22 RED J8-8P1:29 WHITE J8-4P1:43 GREEN J8-3P1:37 ORANGE J8-2P1:23 BLUE J8-1P1:14 PURPLE J8-14P1:42 SLATE J8-13P1:38 PURPLE J8-6P1:10 GRAY J8-7P1:28 PINK J8-12GND SCREW NONE J8-15P1:11 TAN J8-10P1:12 RED/YELLOW J8-11P1:5 RED/GREEN J8-5 RED/BLACK -

P1:24 BLACK J7-11P1:9 RED J7-12P1:39 BROWN J7-2P1:25 YELLOW J7-1P1:30 WHITE J7-3GND SCREW NONE J7-4P1:20 GREEN J7-5P1:26 ORANGE J7-6P1:40 BLUE J7-7P1:13 BROWN J7-8P1:41 YELLOW J7-9P1:27 PINK J7-10 TAN

P1:21 BLACK J9-1P1:7 RED J9-2P1:36 WHITE J9-3P1:6 GREEN J9-5P1:35 ORANGE J9-6P1:34 BLUE J9-4 J9-7GND SCREW NONE J9-8

P2:18 BLUE JA-1P2:23 YELLOW JA-3P2:21 GREEN JA-4GND SCREW NONE -P2:17 WHITE/BLUE JB-1P2:26 WHITE/YELLOW JB-3P2:20 WHITE/GREEN JB-4GND SCREW NONE -P2:24 RED/BLUE JB1-1P2:22 RED/YELLOW JB1-3P2:27 RED/GREEN JB1-4GND SCREW NONE -P2:25 BLACK/BLUE JA1-1P2:19 BLACK/YELLOW JA1-3P2:28 BLACK/GREEN JA1-4GND SCREW NONE -

Wire ColorPowerheadMotor Connections

Power ControlP2 Connector

Power ControlP1 Connector Wire Color

Powerhead BoardConnectors J7, J8, J9

Cab

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802701-C May 2003

DATA CABLE 801224

P1P2P3P4P5P6P7P8P9P10P11P12P13P14P15P16P17P18P19P20P21P22P23P24P25SHEILD

S1S2S3S4S5S6S7S8S9S10S11S12S13S14S15S16S17S18S19S20S21S22S23S24S25SHEILD

AP

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802701-C May 2003

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APPENDIX A

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802701-C May 2003

LIST OF CONTENTS

INSTALLATION INSTRUCTIONS 802702

802702-C May 2003 2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 I - 1 Phone: (513) 761-2700 FAX: (513) 948-7226

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 causepersonnel injury.

WARNING!

Always remove Power Control and Power Head assembly from magnet roombefore disassembly. Failure to follow this warning could result in personnel injuryor equipment damage.

CAUTION!

This installation must be performed by a Qualified Technician who iscompletely familiar with the use and operation of the injector, and trained by aMallinckrodt instructor.

CAUTION!

Electronic components, contained within the injector, may be damaged by impact.Exercise caution while handling the injector units; avoid dropping theunit or subjecting it to other physical shock.

WARNING!

Optistar LE components must only be placed in the areas listed below. Failure tofollow 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.

Liebel-Flarsheim

Installation Instructions

L IEBEL-FLARSHEIM

LEOptistar TM

LE

802702-C May. 2003 2111 East Galbraith Rd Cincinnati, Ohio 45237-1640 I - 2 Phone: (513) 761-2700 FAX: (513) 948-7226

RECEIVING INSPECTION

The Optistar LE injector should be subjected to inspection immediately upon arrival at its ship-ping destination. You should have one carton which contains individual packing cartons for eachof the components. Refer to Table 1 below, and Figure 1 for carton components. For part num-bers, Refer to Figures 8 and 9.

CartonComponent

Numbers

ComponentDescription

1 Power Control Assembly

2 Accessory Components

Filter

Stand Hanger

Power Supply Wall Mount Kit

Cable for Power Supply

Hand Switch

Data Cables

Manuals

3 Console Assembly

4 Powerhead Assembly and Syringe Adaptors

5 Power Supply Assembly

6 Power Control Stand

7 Stand Post

8 Wheel Base for Stand

Table 1


BOX #4

BOX #5

BOX #6

BOX #7

BOX #1

BOX #2 (Under Box #8)

BOX #8(Placed on Top Box #2)

BOX #3 Shipping Skid

Carton Assembly

Figure 1 Shipping Carton Contents


REMOTE STAND ASSEMBLY/POWERHEAD INSTALLATION

CAUTION!

Remote Stand assembly and Powerhead Installation should not be performed in themagnet room. Failure to follow this caution may result in damage to magnetic equip-ment.

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 PostAdjustment Nut

Cable Hanger Stationary Post

Wheelbase

Figure 2 Remote Stand Components


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 tightenset screw until seated. Swivel Powerhead to ensure there is proper rotation.

BA

50 ml60 ml

125 ml

60 ml30 ml

10/15/20 mlLE

Optistar TM

LE

Powerhead

TensionAdjustment

Screw

Elevating Post

Adjustment Nut

Figure 3 Powerhead Installation/Adjustment


POWER SUPPLY INSTALLATION

• The DC Power Supply can either be located near the Console in the Control room or in theEquipment 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) orthird 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 couldresult in personnel injury or equipment damage.

WARNING!

Do not penetrate magnet room shield to install Wall Mount Bracket. Failure to followthis 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 mount-ing screws will not penetrate the magnet room shield.

Ensure the power supply mounting location allows good air circulation. Also, be sure the rearof 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 flatfasteners 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.


M4 Fastener #10 Flat HeadFastener

Power SupplyHousing(P/N 802428)

#10 FlatFastener

Wall MountBracket(P/N 802631)

Wall MountRetaining Clip(P/N 802630)

Wall MountPlate(P/N 802632)

M4 Fastener

WALL STUD

10"

10" 5"

Figure 4 Power Supply Wall Installation


FILTER DIMENSIONS

For Filter dimensions refer to the Figure 5 below. For installation instructions contact your localsales representative.

31.75mm(1.25")

12.7mm(.5")

270.0mm (10.63")

285.75mm (11.25")

6.604mm (.260") (5 Places)

457.2mm (18.0")

76.2mm(3.0")

(FRONT VIEW)

(SIDE VIEW)

76.2mm(3")

101.6mm(4")

31.75mm Diameter(1.25")

Figure 5 Filter Dimensions


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 inFigure 6 below.

First ChoicePosition P.C. against wall

and centered with magnetas shown.

Flux Linesof Magnet

Flux Linesof Magnet

Cable Exit

MR

SCANNER

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.

Second ChoicePosition P.C. against wall

as shown

Figure 6 Power Control Placement in MR room


POWER REQUIREMENTS

• Console

Voltage 24 VDC ± 10%

• Power Supply

Voltage 115 VAC ± 10%230 VAC ± 10%

Frequency 50/60 Hz

Current 4 Amp


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 shieldedwall)

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 panelgrounding strip.

6. In the Magnet Room, connect the 25 pin data cable from filter, or penetration panel if appli-cable, to the Power Control.

7. Connect Power head cable to Power Control.

CAUTION!

When connecting Powerhead cable to the Power Control, ensure that connectorhousing is correctly oriented (black arrows aligned) and fully seated before attemptingto 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 tofollow this caution may result in damage to magnet equipment or cause personnelinjury.

Note: The total cumulative length of cable from the Power Supply to the Power Control shouldnot exceed 150 feet.


O I

25 PinConnector To

Console and FilterPower Supply

On/Off

Power In115/230VAC ±10% Cable

Retainer

FuseHolder


(Qty 2)

Power Supply (Rear View)

Power Supply AC Cable Retainer (Rear View)

O I


CableRetainer

Figure 7. Power Supply Connections


EQUIPMENT ROOM

CONTROLROOM


MR

Filter(P/N 801223)

MAGNET ROOM

Free HangingD-Shell Connector


Socketcable end








FuseHolder


(Qty 2)

O I


Connection J1


J1J2

BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml


J1, J2


Figure 8. Component and Cabling Overview-Power Supply located in Equipment Room

-Filter permanently mounted on shielded wall option shown


EQUIPMENT ROOM

CONTROLROOM

MR

Filter(P/N 801223)

MAGNET ROOM


Socketcable end







FuseHolder


(Qty 2)


Connection J1


BA

50 ml60 ml125 ml

60 ml30 ml10/15/20 ml



O I J1J2

Penetration Panel(Using open 25-pin pass through)

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

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

or(P/N 801224-07 7Ft)


J1, J2


Figure 9. Component and Cabling Overview-Power Supply mounted in Control Room Configuration

-Filter using the penetration panel pass-through option shown


CHECKOUT

After installation is complete perform the following procedures. For in-depth operational proce-dures 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 powerto the console and powerhead is ON. At this time the Power Control Power ON switch willilluminate. The injector will enable a power-up check sequence indicated by flashing thesyringe 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 leftON. 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 alarmmessage will be displayed at the Console. Cycle System power to clear any alarm message.


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.

Inject Mode Memory Results

Alarm History

Service Mode

HighLowDisplay Brightness PSIPressure Units

System Information

HighMedLowOffBeeper Volume

Software Versions Console: 0.00.06 Power Control:

Language English

Change TimeChange Date

AUG 01-2002 14:15

Figure 10 Date and Time Menu


POWERHEAD STOP BUTTON CHECK


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 rammovement observe the Powerhead injection indicators. The indicator light for the ram inmotion should be flashing.

4. With ram movement taking place, press the Powerhead Stop Button. Ram movement shouldstop and the console will return to the injection mode screen.

REMOTE START CHECK


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 move-ment 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 powerheadindicate “10/15/20”.

7. Place 125mL syringe in the B side. Verify console and powerhead indicate “125mL syringe”.


LIMIT SWITCH CHECK

The purpose of this check is to verify limit switch board (positioned in the Powerhead) settingswere 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. Ob-serve the 0 mark on the syringe, the front wiper should be engaging the 0 mark. Also, on theConsole 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 theConsole screen, the Volume Remain field, is 63mL.

Repeat step 4 procedure for the B side Ram. If adjustments are required, refer to Chapter 8 inyour service manual.


RAM FACE CHECK

Perform the following tests to confirm that the ram faces are not putting a pre-load on the loadcells 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 beable to spin and pull-off. Also, note that the load cell holders shall remain secure whilemoving 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 plungerstops 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 expelledend, 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.


INJECTION PRESSURE VERIFICATION

The Pressure checks defined in this section will measure the flowrate to pressure relationship. Tomeasure this relationship, the pressure gauge fixture in Figure 12 is placed in either Powerheadram, A or B. The ram opposite the pressure gauge fixture will then contain the syringe to applypressure.

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 preci-sion instruments. When performing pressure checks, a gauge reading variation of ± 20 PSI isacceptable. If your reading is outside this parameter, repeat the check to confirm your gauge isnot 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 onthe following pages.

INJECTION SYRINGE RAMSIDE

PROGRAMVALUE

FLOWRATE

PRESSUREVALUE

1 60 A 60mL 4mL/sec 150 PSI

2 60 B 60mL 4mL/sec 150 PSI


4 30 B 30mL 4mL/sec 200 PSI


6 125 B 60mL 4mL/sec 100 PSI

Table 2

Note: When performing the pressure checks, it is the peak PSI reading on the gauge that is tobe 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


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 completelyfill 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 pressuregauge check fixture in ram B as illustrated in Figure 12.

B

A

50 ml 60 ml 125 ml

60 ml 30 ml10/15/20 ml

5

10

15

20

25

30

35

40

45

50

55

60

mL mL

50

55

50

100200

300

WaterContainer

Powerhead'A' Side Ram

Powerhead'B' Side Ram

Drain andFill Tubes

Pressure GaugeFixture

Pressure Tube

60 mLSyringe

LE Base Assembly(Black)

Figure 12. Pressure gauge fixture


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 withinspecified 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.


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.


7. Disconnect pressure gauge tube at 30mL syringe in ram A.

8. Retract ram A.

9. Remove 30mL syringe from ram A.


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.



4. Place 20mL syringe in ram A.


6. At the Console, program ram A for injection, then press the Air Check button.


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



2. Remove pressure gauge from ram B and place in ram A. Place 60 mL syringein ram B.


4. At the Console, program ram B for injection, then press the Air Check button.


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.


9. Place 30mL syringe in ram B.


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



4. Disconnect pressure gauge tube at syringe in 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.


2. Place 125mL syringe in ram B.



5. Disconnect pressure gauge tube at syringe in 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. Com-pare achieved pressure values for the A ram injection to the actual pressure gauge readingsobtained in injections 1, 3, and 5. The readings should be with in +/- 20 psi of the programmedpressure value.


OPTISTAR LE HISTORY RECORD

To facilitate requests for information, replacement parts or optional accessories, please record theinformation on pages 25 and 26. Then return pages 25 and 26 to the address listed below:

Mallinckrodt, Liebel-Flarsheim Business2111 East Galbraith Road

Cincinnati, Ohio 45237 - 1640(Attn: Service)

Fax No. 513 - 948 - 7226

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OPTISTAR LE INFORMATION

INSTALLATION PRESSURE CHECK DATA

INJECTION RAMSIDE

SYRINGESIZE

PROGRAMFLOWRATE

PROGRAMVOLUME

PRESSUREGAUGE

READING

ACHIEVEDPRESSUREREADING

I—In

dex

I-1-1

802701-C May 2003

Index

A

ACCESSORY ITEMS 6-11-1

ACTIVATING SYSTEM INFORMATIONSCREEN 9-1-2

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

D

DC POWER SUPPLY REPLACEMENT 6-5-4

Dimensions 1-1-2

Display Subassembly (P/N 802116S) 6-2-5

E

ENCODER HARNESSREMOVAL/INSTALLATION 6-3-17

END LIMIT HARNESSREMOVAL/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

H

history alarm library 5-2-10

I

Inject Results 1-1-4

INSTALLATION INSTRUCTIONS 802702 A-1-2

L

LOAD CELL REMOVAL/INSTALLATION 6-3-16

M

MOTOR REMOVAL/INSTALLATION 6-3-15

P

POWER CONTROL REPLACEMENTCOMPONENTS 6-4-2

Power Requirements 1-1-2

POWER SUPPLY 6-5-1

POWER SUPPLY FUSE REPLACEMENT 6-5-4

POWER SUPPLY REPLACEMENTCOMPONENTS 6-5-2

POWERHEAD BOARDREMOVAL/INSTALLATION 6-3-14

POWERHEAD CABLEREMOVAL/INSTALLATION 6-3-14

POWERHEAD COVERREMOVAL/INSTALLATION 6-3-12

POWERHEAD END LIMIT SENSINGBOARDREMOVAL/INSTALLAT 6-3-15

powerhead REMOVAL/INSTALLATIONFROM 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

I—In

dex

I-1-2

802701-C May 2003

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 BOARDREMOVAL/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

Liebel-Flarsheim2111 E. GALBRAITH ROAD CINCINNATI, OHIO 45237-1640

802701-c optistar le

Documents

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limit sensing boards

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load cell holders