OLE Service-G

L IEBEL- F LARSHEIM
Liebel-Flarsheim
Optistar LE
TM
Contrast
Delivery System
A 60 ml
10/15
/20 30 ml
ml
B 60 50ml ml
125 ml
Service and Parts Manual

802701-G
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I—INTRODUCTION
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802701-G May 2009

I-5
FOREWORD
Congratulations on the purchase of your Optistar LE Injection System. The
I—INTRODUCTION
Optistar LE represents our effort to provide a quality product to support better
healthcare throughout the world.
Regardless of how well equipment is designed, misuse or abuse will deny its
owner the expected quality of service. Misuse or abuse may occur unintention-
ally because the proper method of operating the equipment is unknown. Read
this manual carefully before operating the Optistar LE. Retain this manual for
future reference.
TECHNICAL SUPPORT
Phone No. 1-800-877-0791
RECORDING REFERENCE NUMBER AND SERIAL NUMBERS

The reference number (Ref. No.) and serial numbers (S/N) must be supplied
when requesting replacement parts or optional accessories. For convenience,
record the requested information below:
Ref.No. - (located on Power control)
Power Control S/N CI D
Powerhead S/N CI D
Console S/N CI D
Power Supply S/N CI D
Date of Installation / /
Installing Company __________________________________________
Address ____________________________________________________
Phone No. __________________________________________________
Software version numbers may be accessed via the System Info key on the
Results screen
Console ____________________________________________________
Powerpack __________________________________________________
Optistar™ LE is a trademark of Mallinckrodt, Inc. Optimark™ is a trademark of
Mallinckrodt, Inc.
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MEANINGS OF SYMBOLS USED IN THIS MANUAL

I—INTRODUCTION
Please regard any message that follows the word Danger, Warning or
Caution!
DANGER!
Hazards which will result in severe personal injury or death.
WARNING!
Hazards which could result in personal injury.
CAUTION!
Hazards which could result in equipment or property damage.
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MEANINGS OF SYMBOLS USED ON THE INJECTOR
I—INTRODUCTION
Symbol Definition
Console Connection identifier
Powerhead Connection identifier
Power Control identifier
Power Supply identifier
Hand start switch connection identifier
System OFF/ON (only for the Console)
Power OFF/ON
Ram movement/injector status identifier:

A-side Light and B-side Light OFF = Injector Disabled
A-side Light and B-side Light ON = Injector Enabled
A-side Light Flashing ; B-side Light OFF = A-side Ram moving
A-side Light OFF ; B-side Light Flashing = B-side Ram moving
Check to ensure air is removed from syringe and tubing

before injecting.
Start Injection
Stop Injection
Fluid Detect
802701-G May 2009

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Symbol Definition
I—INTRODUCTION
Equipment sensitive to Electrostatic Discharge.

DO NOT TOUCH exposed connectors.
MR Unsafe--an item that is known to pose hazards in all

MR MR environments.
MR Conditional--an item that has been demonstrated to pose

no know hazards in a specified MR environment with specified
MR conditions of use.
MR Safe--an item that poses no known hazards in all

MR MR environments.
<300G Locate in an area with magneticfields less than or

equal to 300 Gauss.
! ATTENTION! Consult User's/Service Manual.
European Union’s Waste Electrical and

Electric Equipment (WEEE).
CAUTION! Risk of electrical shock. Do not remove cover.

Refer servicing to qualified personnel.
250 V
4 AMP Fuse Rating (Voltage, Amperage, Type)
SLO-BLO
REF Reference
S/N Serial Number
P/N Part Number
V/A Volts Amps
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I-9
CLASSIFICATION IN ACCORDANCE WITH EN 60601
I—INTRODUCTION
TYPE OF PROTECTION AGAINST ELECTRIC SHOCK
Class I equipment
DEGREE OF PROTECTION AGAINST ELECTRIC SHOCK

Type CF applied part (Powerhead).
Type B applied part (Console and Power Control)
DEGREE OF PROTECTION AGAINST INGRESS OF WATER

Ordinary Equipment.
EMISSION STANDARD
The Optistar LE meets emission standard IEC60601-1-2 Class B
UL/CSA CLASSIFICATION
SSIFI OPTISTAR® INJECTION SYSTEM
(MEDICAL EQUIPMENT)
CL A
ED
WITH RESPECT TO ELECTRIC SHOCK,

®
C US FIRE AND MECHANICAL HAZARDS ONLY
33SL IN ACCORDANCE WITH UL60601-1, IEC60601-1,
CAN/CSA C22.2 No. 601.1
802701-G May 2009

I-10
ELECTROMAGNETIC COMPATIBILITY GUIDANCE

I—INTRODUCTION
The Optistar LE meets the radiated emissions (Class B) and immunity standard
IEC 60601-1-2 for medical devices.
CAUTION!
Portable and mobile RF communication equipment can affect opera-

tions of the Optistar LE.
WARNING!
Before removing any Power Control PC boards, ensure proper static

protection devices are used. Failure to follow this warning could result in
equipment damage.
WARNING!
Only cabling listed in this document can be used with the Optistar LE
equipment. Failure to follow this warning could result in equipment
damage.
ELECTROMAGNETIC COMPATIBILITY TABLES

Guidance and Manufacturer's Declaration - Electromagnetic Emissions
The "Optistar LE" is intended for use in the electromagnetic environment specified below. The
customer or the user of the "Optistar LE" should assure that it is used in such an environment.
Emissions Test Compliance Electromagnetic environment - guidance
RF emissions Group 1 The "Optistar LE" uses RF energy only for the
CISPR 11 internal function. Therefore, the RF emissions are
very low and are not likely to cause any
interference in nearby electronic equipment.
RF emissions Class B The "Optistar LE" is suitable for use in all
CISPR 11 establishments including domestic establishments
Harmonic Emissions Class A and those directly connected to the public low -
IEC 61000-3-2 voltage power supply network that supplies
Voltage fluctuations/ Complies buildings used for domestic purposes.
flicker emissions
Table 1
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Guidance and Manufacturer's Declaration - Electromagnetic Immunity
I—INTRODUCTION
The "Optistar LE" is intended for use in the electromagnetic environment specified below. The customer or
the user of the "Optistar LE" should assure that it is used in such an environment.
Immunity Test IEC 60601 Compliance Level Electromagnetic
Test Level Environment -
Guidance
Electrostatic discharge +/- 6 kV contact +/- 6 kV contact Floor should be wood,
(ESD) +/- 8 kV air +/- 8 kV air concrete or ceramic
IEC 61000-4-2 tile. If floors are
covered with synthetic
material, the relative
humidity should be less
than 30%.
Electrical Fast Transient +/- 2 kV for power +/- 2 kV for power Mains power quality
/ Burst supply lines supply lines should be that of a
IEC 61000-4-4 +/- 1 kV for input / +/- 1 kV for input / typical commercial or
output output hospital environment.
Surge +/- 1 kV differential +/- 1 kV differential Mains power quality
IEC 61000-4-5 mode mode should be that of a
typical commercial or
hospital environment.
Voltage dips, short <5% Ut <5% Ut Mains power quality
interrupts and voltage (>95 % dip in Ut) (>95 % dip in Ut) should be that of a
variations on power for 0.5 cycle for 0.5 cycle typical commercial or
supply input lines hospital environment.
IEC 61000-4-11 40% Ut 40% Ut If the user of the
(60% dip in Ut) (60% dip in Ut) "Optistar LE" requires
for 5 cycles for 5 cycles continued operation
during power mains
70% Ut 70% Ut interrupt, it is
(30% dip in Ut) (30% dip in Ut) recommended that the
for 25 cycles for 25 cycles "Optistar LE" be
powered for an
<5% Ut <5% Ut uninterruptible power
(>95% dip in Ut) (>95% dip in Ut) supply or a battery.
for 5 sec for 5 sec
Power frequency (50/60 3 A/m 3 A/m Power frequency
Hz) magnetic field magnetic fields should
IEC 61000-4-8 be at levels
characteristic of a
typical location in a
typical commercial or
hospital environment.
Note: Ut is the A.C. mains voltage prior to application of the test level.
Table 2
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Guidance and Manufacturer's Declaration - Electromagnetic Immunity

The "Optistar Elite” is intended for use in the electromagnetic environment specified below. The customer or
the user of the "Optistar LE" should assure that it is used in such an environment.
I—INTRODUCTION
Immunity Test IEC 60601 Compliance Level Electromagnetic

Test Level Environment - Guidance
Portable and mobile RF
communications
equipment should be
used no closer to any part
of the "Optistar LE",
including cables, than the
recommended separation
distance calculated from
the equation applicable to
the frequency of the
transmitter.
Recommended separation
distances
Conducted RF 3 Vrms 3 Vrms d = 1.2 P

IEC 61000-4-6 150 kHz to 80 MHz
Radiated RF 3 V/m 3 V/m d = 1.2 P

IEC 61000-4-3 80 MHz to 2.5 GHz (80 MHz to 800 MHz)
d = 2.3 P
(800 MHz to 2.5 GHz)
Where P is the maximum

output power rating of the
transmitter in watts (W)
according to the
transmitter manufacturer
and d is the recommended
separation in meters (m).
Field strengths from fixed

RF transmitters as
determined by an
electromagnetic site
surveya should be less
than the compliance level
in each frequency rangeb.
Interference may occur in

the vicinity of equipment
marked with the following
symbol
Note 1: At 80 MHz and 800 MHz, the higher frequency range applies.
Note 2: Three guidelines may apply in all situations. Electromagnetic propagation is affected by absorption and
reflection from structures, objects and people.
a Field strengths from fixed transmitters, such as base stations for radios (cellular/cordless) telephones and land
mobile radios, amateur radio, AM, FM radio broadcast and TV broadcast cannot be predicted theoretically with
accuracy. To assess the electromagnetic environment due to fixed RF transmitters, an electromagnetic site
survey should be considered. If the measured field strength in the location in which the "Optistar LE" is used
exceeds the applicable RF compliance level above, the "Optistar LE" should be observed to verify normal
operation. If abnormal performance is observed, additional measures may be necessary, such as reorienting
or relocating the "Optistar LE".
b Over the frequency range 150 kHz to 80 MHz, field strengths should be less than 3 V/m.
Table 3
802701-G May 2009
I-13
Recommended separation distances between portable and mobile RF communications equipment and the "Optistar LE"
I—INTRODUCTION
The "Optistar LE" is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled.
The customer or the user of the "Optistar LE" can help prevent electromagnetic interference by maintaining a minimum
distance between portable and mobile RF communications equipment (transmitters) and the "Optistar LE" as recommended
below, according to the maximum output power of the communications equipment.
Rated maximum output Separation distance according to frequency of transmitter (m)
power of transmitter 150 kHz to 80 Mhz 80 MHz to 800 MHz 800 MHz to 2.5 GHz
(W) d = 1.2 P d = 1.2 P d = 2.3 P
0.01 0.12 0.12 0.23
0.1 0.38 0.38 0.73
1 1.2 1.2 2.3
10 3.8 3.8 7.3
100 12 12 23
For transmitters rated at a maximum output power not listed above, the recommended separation distance d in meters m can
be estimated using the equation applicable to the frequency of the transmitter manufacturer.
Note 1: At 80 MHz and 800 MHz, the separation distance for the higher frequency range applies.
Note 2: These guidelines may not apply in all situations. Electromagnetic propagation is affected by absorption and
reflection from structures, objects and people.
Table 4
CE MARK INFORMATION
0123
Authorized EC Representative
TYCO HEALTHCARE UK LTD
154 FAREHAM ROAD
GOSPORT PO13 0AS UK
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I—INTRODUCTION
802701-G May 2009

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Table Of Contents
I—TABLE OF CONTENTS
FOREWORD.......................................................................................................................................................I-5
RECORDING REFERENCE NUMBER AND SERIAL NUMBERS ..........................................................I-5
MEANINGS OF SYMBOLS USED IN THIS MANUAL ............................................................................I-6
MEANINGS OF SYMBOLS USED ON THE INJECTOR .........................................................................I-7
CLASSIFICATION IN ACCORDANCE WITH EN 60601.........................................................................I-9
TYPE OF PROTECTION AGAINST ELECTRIC SHOCK ...............................................................I-9
DEGREE OF PROTECTION AGAINST ELECTRIC SHOCK .........................................................I-9
DEGREE OF PROTECTION AGAINST INGRESS OF WATER .....................................................I-9
EMISSION STANDARD ........................................................................................................................I-9
UL/CSA CLASSIFICATION ............................................................................................................................I-9
ELECTROMAGNETIC COMPATIBILITY GUIDANCE .......................................................................... I-10
ELECTROMAGNETIC COMPATIBILITY TABLES .................................................................................. I-10
CE MARK INFORMATION .......................................................................................................................... I-13
INTRODUCTION ..........................................................................................1-1-1
1.1 INDICATIONS FOR USE ................................................................................................................... 1-1-1
1.2 SERVICE TECHNICIAN QUALIFICATIONS ................................................................................. 1-2-1
1.3 CONFIGURATION OF UNIT............................................................................................................ 1-3-1
1.4 SAFETY FEATURES ........................................................................................................................... 1-4-1
1.4.1 SELF-TESTING DESIGN ...................................................................................................... 1-4-1
1.4.2 ELECTRICALLY ISOLATED SYRINGE ............................................................................. 1-4-1
1.4.3 SYRINGE CLARITY ............................................................................................................... 1-4-1
1.4.4 POSITIVE POSITIONING OF THE POWERHEAD ....................................................... 1-4-1
1.4.5 HAND START SWITCH OPERATION .............................................................................. 1-4-1
1.4.6 PHYSICAL STABILITY OF REMOTE STAND ................................................................. 1-4-2
1.5 SPECIFICATIONS ............................................................................................................................... 1-5-1
1.5.1 DIMENSIONS ......................................................................................................................... 1-5-1
1.5.2 WEIGHT ................................................................................................................................... 1-5-1
1.5.3 POWER REQUIREMENTS .................................................................................................. 1-5-1
1.5.3.1 POWER CABLES (POWER SUPPLY) ............................................................................ 1-5-1
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1.5.3.2 POWER CABLE SPECIFICATIONS ............................................................................... 1-5-2

1.5.4 ELECTRICAL LEAKAGE ...................................................................................................... 1-5-2

1.5.5 ENVIRONMENTAL ............................................................................................................... 1-5-2
1.5.6 COMPATIBLE SYRINGE SIZES .......................................................................................... 1-5-3
1.5.7 PROGRAMMABLE FLOW RATE (A-SIDE) ..................................................................... 1-5-4
1.5.8 PROGRAMMABLE FLOW RATE (B-SIDE) ..................................................................... 1-5-4
1.5.9 PROGRAMMABLE VOLUME (A-SIDE) .......................................................................... 1-5-4
1.5.10 PROGRAMMABLE VOLUME (B-SIDE) ........................................................................ 1-5-4
1.5.11 PROGRAMMABLE PRESSURE LIMIT (A-SIDE) ........................................................ 1-5-4
1.5.12 PROGRAMMABLE PRESSURE LIMIT (B-SIDE) ........................................................ 1-5-4
1.5.13 PROGRAMMABLE SCAN DELAY .................................................................................. 1-5-4
1.5.14 PROGRAMMABLE INJECT DELAY ............................................................................... 1-5-5
1.5.15 PROGRAMMABLE DRIP INJECTION PARAMETERS (B-SIDE) ............................ 1-5-5
1.5.16 PROTOCOL MEMORY ...................................................................................................... 1-5-5
1.5.17 INJECT RESULTS ................................................................................................................ 1-5-5
1.6 CONSUMABLES ................................................................................................................................. 1-6-1
1.6.1 COMPATIBLE SYRINGE ...................................................................................................... 1-6-2
1.6.2 LOW PRESSURE TUBING ................................................................................................... 1-6-2
1.6.3 MULTIPACK DISPOSABLES .............................................................................................. 1-6-2
1.6.4 OPTIMARK (GADOVERSETAMIDE INJECTION) PREFILLED SYRINGES ........... 1-6-2
1.6.5 PREFILLED SALINE SYRINGE ........................................................................................... 1-6-2
1.7 ACCESSORIES ...................................................................................................................................... 1-7-1
OVERVIEW OF SYSTEMFEATURES .............................................................2-1-1

2.1 GENERAL .............................................................................................................................................. 2-1-1
2.2 POWERHEAD ...................................................................................................................................... 2-1-2
2.3 CONSOLE ............................................................................................................................................. 2-1-3
2.4 REMOTE START .................................................................................................................................. 2-1-4
2.5 POWER SYSTEM ................................................................................................................................ 2-1-4
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BASIC OPERATIONS ....................................................................................3-1-1
3.1 TURNING SYSTEM POWER ON/OFF .......................................................................................... 3-1-1
3.1.1 STATUS INDICATORS .......................................................................................................... 3-1-1
3.1.2 INTRODUCTION TO PROGRAMMING.......................................................................... 3-1-2
3.1.3 INJECTION MODE ............................................................................................................... 3-1-3
3.1.4 PROGRESS SCREENS .......................................................................................................... 3-1-4
3.1.5 SINGLE PHASE INJECTION (A-SIDE) WITH SALINE FLUSH (B-SIDE): PROGRESS
SCREEN ................................................................................................................................... 3-1-5
3.1.6 TWO PHASE INJECTION (A-SIDE) WITH SALINE FLUSH (B-SIDE): PROGRESS
SCREEN ................................................................................................................................... 3-1-5
3.1.7 SINGLE PHASE INJECTION (A-SIDE) WITHOUT SALINE FLUSH: PROGRESS
SCREEN ................................................................................................................................... 3-1-6
3.1.8 DESCRIPTION OF STOP KEY/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/INFORMATION ON THE DRIP MODE SET
UP SCREEN ..........................................................................................................................3-1-11
HOW TO CHANGE PARAMETER VALUES ..................................................................3-1-11
DESCRIPTION OF PARAMETER KEYS .........................................................................3-1-11
DESCRIPTION OF INFORMATION DISPLAYED ON THE DRIP MODE SCREEN .........
3-1-11
3.1.9.3 ACCESSING THE DRIP INFUSION SCREEN............................................................3-1-12
3.1.9.4 DESCRIPTION OF KEYS/INFORMATION ON THE DRIP INFUSION SCREEN ...........
3-1-12
DESCRIPTION OF KEYS ...................................................................................................3-1-12
DESCRIPTION OF INFORMATION ...............................................................................3-1-13
3.1.10 PROTOCOL MEMORY ....................................................................................................3-1-14
3.1.10.1 RETRIEVING A PROTOCOL FROM MEMORY .....................................................3-1-15
3.1.10.2 DELETING A PROTOCOL FROM MEMORY .........................................................3-1-17
3.1.10.3 STORING A PROTOCOL IN MEMORY ...................................................................3-1-18
3.1.10.4 EDITING A PROTOCOL NAME................................................................................3-1-20
3.1.11 INJECTION RESULTS SCREEN .....................................................................................3-1-21
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MAINTENANCE AND CHECKOUT PROCEDURES ......................................4-1-1

4.1 MAINTENANCE SCHEDULE .......................................................................................................... 4-1-2

4.1.1 DAILY INSPECTION (REFER TO 4.6.1) ........................................................................... 4-1-2
4.1.2 OPERATIONAL CHECKOUT PROCEDURES ................................................................ 4-1-2
4.2.1 POWERHEAD CHECKOUT ITEMS REQUIRED ............................................................ 4-2-1
4.2.2 POWERHEAD OVERVIEW ................................................................................................. 4-2-1
4.2.3 POWERHEAD OPERATIONS ............................................................................................ 4-2-2
4.2.4 POWERHEAD STOP BUTTON CHECK .......................................................................... 4-2-2
4.2.5 SYRINGE DETECTION CHECK ......................................................................................... 4-2-2
4.2.6 LIMIT SWITCH CHECK ........................................................................................................ 4-2-3
4.2.7 RAM FACE CHECK ............................................................................................................... 4-2-4
4.2.8 FLOW RATE/VOLUME CHECK PROCEDURE .............................................................. 4-2-4
4.2.9 INJECTION PRESSURE CHECKS ..................................................................................... 4-2-6
4.3.1 CONSOLE OPERATIONS .................................................................................................... 4-3-1
4.3.2 REMOTE START OPERATIONS......................................................................................... 4-3-2
4.4.1 GROUND CONTINUITY ................................................................................................... 4-4-1
4.4.2 ELECTRICAL LEAKAGE (CHASSIS OR ENCLOSURE) ............................................... 4-4-2
4.4.3 GROUND IMPEDANCE ....................................................................................................... 4-4-3
4.5.1 POWER CONTROL ............................................................................................................... 4-5-1
4.5.2 GAUSS MEASURING METHOD ....................................................................................... 4-5-2
4.6 CLEANING PROCEDURES .............................................................................................................. 4-6-1
4.6.1 SYRINGE HOLDER ............................................................................................................... 4-6-1
4.6.2 POWERHEAD ....................................................................................................................... 4-6-1
4.6.3 CONSOLE................................................................................................................................ 4-6-1
4.6.4 POWER CONTROL ............................................................................................................... 4-6-1
4.6.5 POWER SUPPLY .................................................................................................................... 4-6-1
TROUBLESHOOTING ...................................................................................5-1-1
5.1 OVERVIEW ........................................................................................................................................... 5-1-1
5.1.1 OPTISTAR SERVICE KIT (OPTIONAL P/N 801210) ................................................... 5-1-2
5.1.2 GENERAL TROUBLESHOOTING GUIDELINES ........................................................... 5-1-3
5.2 SYSTEM GENERATED MESSAGES ............................................................................................... 5-2-1
5.2.1 ACTIVATING THE SYSTEM ERROR RESULTS LIBRARY .........................................5-2-10
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FIELD REPLACEABLE PARTS ......................................................................6-1-1
GENERAL INFORMATION ...................................................................................................................... 6-1-2
RETAINING SCREWS ...................................................................................................................... 6-1-2
TERMINOLOGY ................................................................................................................................ 6-1-2
REPLACEABLE PARTS .................................................................................................................... 6-1-2
6.2 CONSOLE ............................................................................................................................................. 6-2-1
6.2.1 CONSOLE REPLACEMENT COMPONENTS ................................................................ 6-2-2
6.2.2 CONSOLE COVER REMOVAL ........................................................................................... 6-2-7
6.2.3 CONSOLE CPU REMOVAL ................................................................................................ 6-2-7
6.2.4 DISPLAY SUBASSEMBLY REMOVAL ............................................................................. 6-2-8
6.2.5 TOUCHSCREEN REMOVAL ............................................................................................... 6-2-8
6.2.6 CONSOLE POWER SWITCH REMOVAL ........................................................................ 6-2-8
6.2.7 CONSOLE SWITCH BUTTON REMOVAL ...................................................................... 6-2-9
6.2.8 CONSOLE INTERFACE BOARD REMOVAL .................................................................. 6-2-9
6.2.9 CONSOLE ASSEMBLY .......................................................................................................6-2-10
6.3 POWERHEAD ...................................................................................................................................... 6-3-1
6.3.1 POWERHEAD REPLACEMENT COMPONENTS .......................................................... 6-3-2
6.3.2 POWERHEAD REMOVAL/INSTALLATION FROM STAND .....................................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
6.3.5 POWERHEAD CABLE REMOVAL/INSTALLATION ...................................................6-3-14
6.3.6 MOTOR REMOVAL/INSTALLATION ..............................................................................6-3-14
6.3.7 POWERHEAD END LIMIT SENSING BOARD REMOVAL/INSTALLATION ........6-3-15
6.3.8 LOAD CELL REMOVAL/INSTALLATION ......................................................................6-3-15
6.3.9 END LIMIT HARNESS REMOVAL/INSTALLATION ...................................................6-3-16
6.3.10 ENCODER HARNESS REMOVAL/INSTALLATION ..................................................6-3-16
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 .......................6-3-17
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6.3.14 SYRINGE NEST HOLDER REMOVAL/INSTALLATION ...........................................6-3-18

6.3.15 SUPPORT ARM REMOVAL/INSTALLATION .............................................................6-3-18

6.3.16 BEARING REMOVAL/INSTALLATION .......................................................................6-3-18
REMOVAL .............................................................................................................................6-3-18
REASSEMBLY ......................................................................................................................6-3-19
6.4 POWER CONTROL ............................................................................................................................ 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 ........... 6-4-7
6.4.9 POWERHEAD COMMUNICATION HARNESS (802213) REMOVAL/INSTALLATION
6-4-8
6.4.10 CONSOLE COMMUNICATION HARNESS (802214) REMOVAL/INSTALLATION ....
6-4-8
6.4.11 POWER SWITCH (802215) REMOVAL/INSTALLATION ........................................ 6-4-9
6.5 POWER SUPPLY ................................................................................................................................. 6-5-1
6.5.1 POWER SUPPLY REPLACEMENT COMPONENTS..................................................... 6-5-2
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
6.7 FILTER .................................................................................................................................................... 6-7-1
6.7.1 FILTER ASSEMBLY ................................................................................................................ 6-7-1
6.8 CABLES ................................................................................................................................................. 6-8-1
6.9 SERVICE KIT PARTS........................................................................................................................... 6-9-1
6.9.1 LOAD CELL SERVICE KIT (P/N 802741S) ..................................................................... 6-9-2
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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) ............................................................................ 6-9-2
6.9.4 FASTNER SERVICE KIT (P/N 802744) (CONT’D) ........................................................ 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) .......................................................... 6-9-4
6.10 GENDER CONNECTORS .............................................................................................................6-10-1
6.11 ACCESSORY ITEMS ......................................................................................................................6-11-1
THEORY OF OPERATION.............................................................................7-1-1
7.3 POWER SUPPLY ................................................................................................................................. 7-3-1
7.4 POWER CONTROL ............................................................................................................................ 7-4-1
7.4.4 CPU BOARD .........................................................................................................................7-4-11
7.4.1 POWER BOARD .................................................................................................................... 7-4-5
7.4.2 COMMUNICATION BOARD .............................................................................................. 7-4-7
7.4.3 DRIVER BOARD .................................................................................................................... 7-4-9
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
7.6 CONSOLE OVERVIEW ...................................................................................................................... 7-6-1
7.6.1 CONSOLE CPU ...................................................................................................................... 7-6-1
7.6.2 CIRCUIT DESCRIPTIONS ................................................................................................... 7-6-2
CALIBRATION ..............................................................................................8-1-1
8.1 OVERVIEW ........................................................................................................................................... 8-1-1
8.1.1 TOOLS AND EQUIPMENT NEEDED: .............................................................................. 8-1-1
8.1.2 FREQUENCY OF CALIBRATION ...................................................................................... 8-1-2
802701-G May 2009

I-22
8.1.3 CALIBRATION SET-UP ........................................................................................................ 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
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
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
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
SYSTEM INFORMATION ..............................................................................9-1-1

9.1 ACTIVATING SYSTEM INFORMATION SCREEN ...................................................................... 9-1-2
9.1.1 SETTING DISPLAY BRIGHTNESS .................................................................................... 9-1-3
9.1.2 CHANGE PRESSURE UNITS .............................................................................................. 9-1-3
802701-G May 2009

I-23
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 ...............................................10-1-1

10.1 OVERVIEW.......................................................................................................................................10-1-1
10.1.1 SOFTWARE TRANSFER FROM CD .............................................................................10-1-2
10.2 DOWNLOAD AND UPGRADE PROCEDURES .....................................................................10-2-1
10.2.1 POWER CONTROL DOWNLOAD ...............................................................................10-2-2
10.3 CONSOLE DOWNLOAD .............................................................................................................10-3-1
SCHEMATICS ..............................................................................................11-1-1
OVERVIEW .................................................................................................................................................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
CONSOLE SCHEMATIC 802101-C (1 OF 5) ...................................................................................11-3-1
CONSOLE INTERFACE SCHEMATIC 802102-C (1 OF 1) ............................................................11-3-6
802701-G May 2009

I-24
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-1-1

LIST OF CONTENTS ..................................................................................................................................A-1-2
INSTALLATION INSTRUCTIONS 802702 .................................................................................A-1-2
INDEX ...................................................................................................... IND-1-1
802701-G May 2009

1-1-1
1 INTRODUCTION
1—OVERVIEW
The purpose of this manual is to provide instructions for installation, service
and calibration of the Optistar LE. For further information about operation and
daily maintenance of the unit, refer to the Optistar LE Operator’s Manual.
1.1 INDICATIONS FOR USE

The Optistar LE Injection System is a contrast delivery system and is designed
to inject MR contrast media and flushing solutions into a patient’s vascular sys-
tem to obtain diagnostic images when used with Magnetic Resonance Imaging
equipment.
802701-G May 2009

1-1-2
1—OVERVIEW
802701-G May 2009

1-2-1
1.2 SERVICE TECHNICIAN QUALIFICATIONS

The Optistar LE Injector should be installed, serviced and calibrated ONLY
by qualified personnel who are completely familiar with the unit, have read
and understood this Installation, Service and Parts Manual, and are otherwise
trained in the service of equipment and procedures of this type. Failure to fol-
1—OVERVIEW
low these guidelines could result in serious injury to the service technician.
WARNING!
Federal (USA) law restricts this device to sale by or on the order of a physician.
(21CFR 801.109(6)(1).
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1-2-2
1—OVERVIEW
802701-G May 2009

1-3-1
1.3 CONFIGURATION OF UNIT

The Optistar LE is specially designed to be used in conjunction with
MRI equipment. The unit consists of the components shown in Figure 1-3-1.
The console, filter, and the power supply are not designed to be placed in the
1—OVERVIEW
MRI area and must be set up in a separate viewing room. The power control,
powerhead and remote stand have been specifically designed so that they may
remain in the MRI area throughout the procedure without interference.
NOTE: Refer to section 1.5.5 Environmental for further information concerning
component location.
802701-G May 2009

1-3-2
The console A contains a touch-sensitive display screen which provides the

ability to change the injection parameters, store protocols and retrieve proto-
cols. Information about the console is found in Chapter 3—Console Screens.
A hand start switch B , a remote control device which attaches to the rear
1—OVERVIEW
of the console, is included so that the injection process may be started and
stopped from outside the MRI area.
The powerhead C is specifically designed from materials which will not affect
nor be affected by the magnetic fields of the MR scanner. Note, however, the
Powerhead Cable Connector (connects into the Power Control) is MR condi-
tional. Information about the Powerhead is found in Chapter 4—Description of
the Powerhead.
The remote stand D allows easy placement of the powerhead for operator and
patient convenience.
The power system consists of one Power Control E1 , one Power Supply (with
mounting bracket) E2 and one EFI/RFI Filter E3 . Both the Power Control and
the Communication Cable (from the filter to the Power Control) are MR Condi-
tional. More information about the power system is found in Chapter 2—Power
ON / Power OFF.
802701-G May 2009

1-3-3
MR MR
MR
E3
C
1—OVERVIEW
Optis
tar Elite
TM
TM
E1
D
Dividing
B E2 Wall
Control and
Equipment Rooms Magnet Room
AC Outlet
Figure 1-3-1 Overview of System
NOTE: Refer to section 1.5.5 Environmental for further information concerning

component location and safety conditions.
802701-G May 2009

1-3-4
1—OVERVIEW
802701-G May 2009

1-4-1
1.4 SAFETY FEATURES

The Optistar LE has been designed to ensure the safety of both patient and
operator. Specific safety features include:
1.4.1 SELF-TESTING DESIGN
1—OVERVIEW
When the Optistar LE is switched ON, it automatically performs a series of
power-up tests to monitor the system status. If a problem is detected, an error
code message will appear in the system display. Also, during the enable pro-
cess and during an injection, all necessary functions are constantly checked. If
a fault is detected, the system will automatically shut down and an error code
message will be displayed. Refer to Chapter 5—System Generated Messages and
Alarms for error code messages.
1.4.2 ELECTRICALLY ISOLATED SYRINGE
All syringes are electrically isolated from any electrical contact with the injector.
1.4.3 SYRINGE CLARITY
Semitransparent syringes are used on the Optistar LE. If small air bubbles are
present, they can be seen by visual inspection.
1.4.4 POSITIVE POSITIONING OF THE POWERHEAD
A preset friction device in the powerhead holds the syringe in the desired posi-
tion during injection.
1.4.5 HAND START SWITCH OPERATION
Use of the hand start switch allows the operator to start and stop injections
from within the view/control room.
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1-4-2
1.4.6 PHYSICAL STABILITY OF REMOTE STAND

The weighted base of the remote stand along with large casters reduces the
possibility of tipping and increases its ability to roll over small cords. Looping
the cables over the cable hanger helps keep the cables away from the wheels.
1—OVERVIEW
WARNING!
To prevent operator injury, note that injector cables laying on the floor could
possibly cause a trip hazard.
802701-G May 2009

1-5-1
1.5 SPECIFICATIONS
1.5.1 DIMENSIONS
• Console 12.25” W X 8.5” H X 2.5” D
(311.15mm W X 215.9mm H X 63.5mm D)
1—OVERVIEW
• Console Base 9.5” W X 2.5” H X 7” D
(241.3mm W X 63.5mm H X 177.8mm D)
• Powerhead 7” W X 21.5” H X 5.5” D
(177.8mm W X 546.1mm H X 139.7mm D)
• Remote Stand 27” Diameter (base) X 47.5” H
(685.8mm diameter X 1206mm H)
• Power Control 10” W X 4.25” H X 15.25” D
(254mm W X 107.95mm H X 387.35mm D)
• Power Supply 10” W X 4.25” H X 9.5” D
(254mm W X 107.95mm H X 241.3mm D)
• Filter 4” W X 10.0” H X 3” D
(101.6mm x 254.0mm x 76.2mm)
1.5.2 WEIGHT
• Console 5.8 lb. (2.6 kg)
• Power Control 16 lb. (7.26 kg)
• Powerhead (w/arm and cable) 14.5 lb. (6.57 kg)
• Remote Stand 29 lb. (13.00 kg)
• Power Supply 11.5 lb. (5.21 kg)
• Filter 10 lb. (4.54 kg)
1.5.3 POWER REQUIREMENTS
• Power Supply
Voltage 115 VAC ± 10%
230 VAC ± 10%
Frequency 50/60 Hz ± 3Hz
Current 4 Amp.
802701-G May 2009

1-5-2
1.5.3.1 POWER CABLES (POWER SUPPLY)

• 115 VAC, Length 8 Ft (2.44m), Part Number 800918
• 220 VAC, Length 8 Ft, (2.44m) Part Number 800935
1—OVERVIEW
WARNING!
If the supplied power cables cannot be used due to non compatibility with
country specific outlets, then the following power cable specifications must be
met. Failure to follow this caution may result in damage to equipment or cause
personnel injury.
1.5.3.2 POWER CABLE SPECIFICATIONS

In addition to meeting all applicable electrical codes, substitute power cables
must meet the following specifications:
115 VAC
• IEC 60320 C13 Connector
• 3 x 18 AWG Conductors
• Maximum length = 8 Ft (2.44m)
230 VAC
• IEC 60320 C13 Connector
• 3 x 1.00mm² AWG Conductors
• Maximum length = 8 Ft (2.44m)
1.5.4 ELECTRICAL LEAKAGE
Chassis less than 300 microamps @ 115VAC
less than 500 microamps @ 230VAC
1.5.5 ENVIRONMENTAL
• Transport and Storage: -40° to +158° F (-40° to +70° C)
10% to 95% relative humidity
• Operation: 50° to +104° F (10° to +40°C)
30% to 75% relative humidity
• Biohazard Disposal: Dispose of biohazards in accordance with the require-
ments of your hospital, facility or local regulations.
• Electromagnetic Compatibility (EMC): The Optistar LE meets
EN60601-1-2 for level B conducted and radiated emissions and EMI immunity.
NOTE: If any anomalies in the injector performance are noticed, identify de-
vices within the immediate area that are capable of producing electromagnetic
interference and call a qualified service representative.
Btu Output: .............................................................. 510 Btu
802701-G May 2009
1-5-3
WARNING!
Safety in Magnetic Resonance Environment: Refer to Figure 1-3-1.

Optistar LE Injector: The Optistar LE Injector is to be used with magnet
1—OVERVIEW
strengths of up to 3.0T.
Remote Stand with Powerhead (NOT including Powerhead Cable Connector):
MR The Powerhead and Remote Stand are specifically designed from materials
which will not affect nor be affected by the magnetic fields of the MR scanner.
Note, however, the Powerhead Cable Connector (connects into the Power Con-
trol) is MR conditional.
Powerhead Cable Connector: The Powerhead Cable Connector is MR Con-
MR
ditional. During installation and removal, the Powerhead Cable Connector
should be carried with caution when within fields between 1,125G and 2000G.
The Powerhead Cable Connector should not be carried into fields higher than
2000G. NOTE: During operation the Powerhead Cable Connector is securely
connected to the Power Control and is in an area less than or equal to 300G.
Power Control: The Power Control is MR Conditional. During installation and
MR removal, the Power Control should not be carried into fields higher than 2000G.
During injector operation, the Power Control must be located in an area with a
field less than or equal to 300G.
Communication Cable Connectors: The Communication Cable Connectors are
MR Conditional. During installation and removal, the communication cable
MR
connectors should be carried with caution when within fields between 470G
and 3,200G. The Communication Cable Connectors should not be carried into
fields greater than 3,200G. NOTE: During operation the Communication Cable
Connectors are securely connected to the Power Control and Filter.
Console, Power Supply and Mounting Bracket, Hand Start Switch, and Filter:
MR The console, Power Supply and mounting bracket, hand start switch, and the
Filter are not designed to be placed in the MRI area and must be set up in a
separate viewing room.
DANGER!
Possible explosion hazard if used in the presence of flammable anesthetics.
CAUTION!
Only the powerhead is considered spill proof. If fluid is spilled on the console
or power control, remove the unit from operation and contact your authorized
service personnel.
802701-G May 2009

1-5-4
1.5.6 COMPATIBLE SYRINGE SIZES

Refer to Section 1.6 Consumables for more information.
• Mallinckrodt 10ml, 15ml, 20ml contrast prefilled syringe (used with supplied
adapter 802730)
1—OVERVIEW
• Mallinckrodt 30ml contrast prefilled syringe

• Mallinckrodt 60ml single-use, disposable syringe
• Mallinckrodt 50 and 125ml
1.5.7 PROGRAMMABLE FLOW RATE (A-SIDE)
• 60ml syringe: 0.1 - 10.0ml/sec
• 10ml, 15ml, 20ml, and 30ml syringe: 0.1 - 8.0ml/sec
1.5.8 PROGRAMMABLE FLOW RATE (B-SIDE)
• 50ml and 125ml syringe: 0.1 - 8.0ml/sec
• 60ml single-use, disposable syringe: 0.1 - 8.0ml/sec
1.5.9 PROGRAMMABLE VOLUME (A-SIDE)
• 10ml, 15ml, and 20ml syringe: 1ml to 20ml
• 30ml and 60ml syringe: 1ml to installed syringe size
1.5.10 PROGRAMMABLE VOLUME (B-SIDE)
• 50ml and 60ml syringe: 1ml to installed syringe size
• 125ml syringe: 1ml to 60ml (software limited)
1.5.11 PROGRAMMABLE PRESSURE LIMIT (A-SIDE)
• 10ml, 15ml, 20ml and 30ml syringe: 20-200PSI in increments of 20PSI
• 60ml syringe: 20-150PSI in increments of 20PSI
1.5.12 PROGRAMMABLE PRESSURE LIMIT (B-SIDE)
• 50ml syringe: 200PSI
802701-G May 2009

1-5-5
1.5.13 PROGRAMMABLE SCAN DELAY

0 - 1:00 (1 minute: 0 seconds) in increments of 1 second
1.5.14 PROGRAMMABLE INJECT DELAY
0 - 5:00 (5 minutes: 0 seconds) in increments of 1 second
1—OVERVIEW
1.5.15 PROGRAMMABLE DRIP INJECTION PARAMETERS (B-SIDE)
• Flow Rate: 0.5 - 1.0 ml/sec in increments of 0.1 ml/sec
• Volume: 0.1 - 3.0 ml in increments of 0.1 ml
• Interval: 1 - 60 seconds in increments of 1 sec
1.5.16 PROTOCOL MEMORY
The Optistar LE can store up to 20 protocols in memory.
1.5.17 INJECT RESULTS
The Optistar LE stores the results of the last 12 injected protocols.
802701-G May 2009

1-5-6
1—OVERVIEW
802701-G May 2009

1-6-1
1.6 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-
1—OVERVIEW
ment damage, and/or injector performance issues (i.e. incorrect volume deliv-
ery, incorrect flow rate delivery, incorrect pressure, etc.). Safety certification of
the consumables listed below has been performed in accordance to the appro-
priate EN60601-1 and/or EN60601-1-1 harmonized national standard.
WARNING!
BLACK BOX WARNING FOR OPTIMARK TM (GADOVERSETAMIDE INJECTION)
WARNING: NEPHROGENIC SYSTEMIC FIBROSIS. Gadolinium-based contrast

agents increase the risk for nephrogenic systemic fibrosis (NSF) in patients with:
· acute or chronic severe renal insufficiency (glomerular filtration

rate < 30 mL/min/1.73m2), or
· acute renal insufficiency of any severity due to the hepato-renal syndrome or

in the perioperative liver transplantation period.
In these patients, avoid use of gadolium-based contrast agents unless the diag-
nostic information is essential and not available with non-contrast enhanced
magnetic resonance imaging (MRI). NSF may result in fatal or debilitating sys-
temic fibrosis affecting the skin, muscle and internal organs. Screen all patients
for renal dysfunction by obtaining a history and/or laboratory tests. When
administering a gadolinium-based contrast agent, do not exceed the recom-
mended dose and allow a sufficient period of time for elimination of the agent
from the body prior to any readministration.
It is recommended that catheters, connectors and tubing used with the

Optistar LE Injection System be rated to accommodate pressure specification
of the installed syringe(s). If such products are rated at a pressure below speci-
fied (as indicated in section 1.5.11), it is the responsibility of the user to select a
pressure limit that is appropriate for the product. Setting of the pressure limit
{[PSI/KPA] key} is performed on the Main screen.
802701-G May 2009

1-6-2
1.6.1 COMPATIBLE SYRINGE

• Case, 60ml Optistar LE Syringe available from Mallinckrodt.
1.6.2 LOW PRESSURE TUBING
• 60” Coiled Y-Tubing (200 psi) available from Mallinckrodt.
1—OVERVIEW
• 90” Coiled Y-Tubing (200 psi) available from Mallinckrodt.

• 60” Coiled Tubing (300 psi) available from Mallinckrodt.
1.6.3 MULTIPACK DISPOSABLES
• Two 60ml syringes with 90” Coiled Y-Tubing available from Mallinckrodt.
1.6.4 OPTIMARK (GADOVERSETAMIDE INJECTION) PREFILLED SYRINGES
• 10mL Optimark (gadoversetamide injection) Prefilled Syringe
See black box warning for Optimark on page 1-1-5 and enclosed Optimark
package insert for full prescribing information.
1.6.5 PREFILLED SALINE SYRINGE
• 50ml Prefilled Sodium Chloride Injection, USP 0.9% Syringe
• 125ml Prefilled Sodium Chloride Injection, USP 0.9% Syringe (availability
dependent upon region)
Contact your local Mallinckrodt Customer Service Representative for orders.
802701-G May 2009

1-7-1
1.7 ACCESSORIES
A list of the accessories for use with the Optistar LE Injector is available through
your Mallinckrodt sales representative.
NOTE: The use of accessories not complying with the equivalent safety require-
1—OVERVIEW
ments of this equipment may lead to a reduced level of safety of the resulting
system. Consideration relating to the choice shall include:
• use of the accessory in the patient vicinity
• evidence that the safety certification of the accessory has been per-
formed in accordance to the appropriate EN60601-1 and/or
EN60601-1-1 harmonized national standard.
802701-G May 2009

1-7-2
1—OVERVIEW
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2-1-1
2 OVERVIEW OF SYSTEM
FEATURES
SYSTEM FEATURES
2—OVERVIEW OF
2.1 GENERAL
The Optistar LE consist of the components listed in Figure 2-1-1:
Power Control
Powerhead and
Remote Stand
Syringe Adapter
10/15/20ml
*Power Cable
10/15/2 30 60 ml
0 ml ml
B 60 50ml ml
125 ml
(See Note)
(Qty. = 2)
Power Supply
Console
EFI / RFI
Filter
Handswitch
Figure 2-1-1 System Components

Note: Power cables supplied with your system are determined by voltage re-
quirements as follows:
*For 115V models, use cable Part Number is 800918
*For 230V models, use cable Part Number is 800935
802701-G May 2009
2-1-2
2.2 POWERHEAD
The Powerhead is specially designed from materials which will not affect nor be
affected by the magnetic currents of the LE.
Injection Indicators
Reverse A & B Sides
Accelerator
A SIDE Button
SYSTEM FEATURES
2—OVERVIEW OF
Forward
Button
Stop
Syringe
Button
Adapter
Powerhead
Ram A A
10/15/ 30 60 ml
20 m ml
l
B 60 50m ml
125 m l
l
B SIDE
Air Check
Start
Button
Syringe
Holder Powerhead
Side A Ram B
Syringe
Holder
Side B
Figure 2-2-1 Powerhead
802701-G May 2009

2-1-3
2.3 CONSOLE
The Console contains a Touch Screen display, and buttons which provides ac-
cess to injection features. Connections are located at the back of the console
(Refer to Figure 2-3-1).
(Rear View)
SYSTEM FEATURES
2—OVERVIEW OF
Console Data
and Power
Connection J1
Remote Start
Connection J2
(Front View)
Touch
Sensitive
Display
Screen
System
ON/OFF Button
Figure 2-3-1 Console
802701-G May 2009

2-1-4
2.4 REMOTE START

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

SYSTEM FEATURES
2—OVERVIEW OF
The power system consists of one Power Supply.
CAUTION!
The Power Supply is not designed to be placed within the Magnet Room. It may
be
located in the Equipment room or Control room.
Power Supply Housing
ON/OFF Indicator
Figure 2-5-1. Power Supply Overview
802701-G May 2009

3-1-1
3 BASIC OPERATIONS
The intent of this chapter is to provide maintenance personnel with a basic

overview of operational features of the Optistar LE injection system. For in
depth operational information refer to the operator’s manual.
3.1 TURNING SYSTEM POWER ON/OFF
OPERATION
3—BASIC
Before system power is applied, ensure all cable connections are properly se-
cured. To power-up the system proceed as follows:
1. Switch Power Supply On. This switch is located on the rear of the power supply.
2. Switch Power Control On. This switch is located on back of power control.
3. Press the system On/Off button. This switch is located on the front of the console.
The button illuminates to indicate power to the console and powerhead is ON. The
injector will enable a power-up check sequence indicated by flashing the syringe
size indicators located on the powerhead.
4. Check status indicators.
5. To switch system power OFF, press the system On/Off button. Both the Power
Supply and Power Control can be left ON. This allows for quicker and easier restarts
from the Console.
NOTE: If the Power Control is switched OFF while the Console is still powered
on, an alarm message will be displayed at the Console. Cycle system power to
clear any alarm message.
3.1.1 STATUS INDICATORS
Normal Status
On the Power Control, the green power ON/OFF switch light should be illumi-
nated, this indicates the Power Control has DC power applied to it.
On the Power Supply, when the green LED light is ON this indicates the Power
Supply is functionally properly.
Fault Condition
A red alarm window will appear on the console. This symbol indicates the
Power Control has lost power.
802701-G May 2009

3-1-2
3.1.2 INTRODUCTION TO PROGRAMMING

All programming takes place at the Optistar LE console’s touch-sensitive
screens. Base functions are as follows:
Inject Mode
Progress Screens
Drip Mode
Protocol Memory
OPERATION
Injection Results/System Info screens

3—BASIC
Selecting and modifying information is accomplished by touch screen keys,

and screen value touch targets. The definition for each term is as follows:
Touch Screen Key: A touch screen key is used to select another display mode
(example: Drip Mode), or to reset screen value information. Touch screen keys
are presented as rectangular boxes, gray in color, with white lettering.
Touch Screen Values: Contain information about the protocol parameters
(example: Volume ml, Flow Rate ml/sec). Touch screen values are presented in
rounded corner boxes, light blue in color, with white lettering. To change any
one of these parameters, touch its screen value to highlight, then use the slider
bar at the bottom of the screen to increase or decrease the value. Using your
finger, you can touch the bar at the value you require, then use the left and
right arrows to maker smaller adjustments.
802701-G May 2009

3-1-3
3.1.3 INJECTION MODE
Pressing the console’s Inject Mode key A allows the operator to select from
the following three modes:
• Single phase contrast injection (A-side) without saline flush
• Single phase contrast injection (A-side) with single phase saline flush (B-side)
• Two phase contrast injection (A-side) with single phase saline flush (B-side)
A: 60 ml
OPERATION
Check for air in
3—BASIC
syringe and tubing
Volume
Remaining 60
Scan Delay
0
Flow Volume
ml/sec ml PSI
A 0.0 60 Max Vol

200
Time 1:30 Drip
Memory Inject Mode Results
A
Figure 3.1.1 Inject Mode Screen
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3-1-4
3.1.4 PROGRESS SCREENS
After pressing the Air Check key on the powerhead, a Start key A appears in
the top right of the screen. The operator may use this Start key, the Start key on
the powerhead, or the Hand Start switch to begin the injection. The Progress
screen is then displayed to follow the injection’s progress.
A
OPERATION
A: 60 ml
Start
3—BASIC
Volume
Remaining 60
Scan Delay
FLOW Volume
0
ml/sec ml PSI
A 0.0 0.0 Max Vol 200

Time 1:30 Drip
Inj. Mode > Disable
Figure 3-1-2 Progress Screen
802701-G May 2009

3-1-5
3.1.5 SINGLE PHASE INJECTION (A-SIDE)

WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN
Flow Volume Time

ml/sec ml
0:00
0.0 0.0 Scan Delay
0
A 60 ml
OPERATION
0 50 100 150 200
3—BASIC
Pressure
PSI
Stop
Flow Volume
ml/sec ml
0.0 0.0
B
60 ml
Figure 3-1-3 Single Phase Injection

with Saline Flush: Progress Screen
3.1.6 TWO PHASE INJECTION (A-SIDE)
WITH SALINE FLUSH (B-SIDE): PROGRESS SCREEN
Flow Volume
ml/sec ml Time
PH1 0.0 0.0 0:00
PH2 0.0 0.0 Scan Delay
0:00
A 60 ml
0 50 100 150 200
Pressure
PSI
Stop
Flow Volume
ml/sec ml
0.0 0.0
B
60 ml
Figure 3-1-4 Two Phase Injection

with Saline Flush: Progress Screen
802701-G May 2009

3-1-6
3.1.7 SINGLE PHASE INJECTION (A-SIDE)

WITHOUT SALINE FLUSH: PROGRESS SCREEN
Flow Volume
ml/sec ml Time
0.0 0.0 0:00
Scan Delay
0:00
A 60
OPERATION
ml
3—BASIC
Stop
0 50 100 150 200
Pressure
PSI
Figure 3-1-5 Single Phase Injection only-no

flush: Progress Screen
802701-G May 2009

3-1-7
3.1.8 DESCRIPTION OF STOP KEY/INFORMATION

DISPLAYED ON THE PROGRESS SCREENS
Refer to Figure 3-1-6.
Description of the Stop Key
The Stop key A is available on the console to stop the injection at any time.
Also, any key on the powerhead or pressing the hand start switch will stop
an injection. For more information about delivering an injection, see Chapter
5—Delivering an Injection In the Operators Manual.
OPERATION
Description of Information
3—BASIC
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 sy-
ringe symbol.
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 (15 minutes).
Scan Delay F counts down from the start of an injection so the operator may
accurately delay the scanner. An audible warning is emitted at the expiration of
the scan delay time.
The Pressure Indicator G shows the current pressure on the A side only.
802701-G May 2009

3-1-8
D E
Flow Volume
ml/sec ml Time
PH1 0.0 0.0 0:00 F
PH2 0.0 0.0 Scan Delay
C 0:00
A 60
OPERATION
ml
3—BASIC
B Pressure
0 50 100 150 200
G
PSI
D Stop A
Flow Volume
ml/sec ml
0.0 0.0
B
C 60 ml
Figure 3-1-6 Description of Information

on the Progress Screens
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3-1-9
3.1.9 DRIP MODE

This mode is used to keep the injection pathway open during patient set up
and between injections of contrast. The injector delivers a series of small vol-
umes, 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.
OPERATION
A: 60 ml
3—BASIC
Check for air in
syringe and tubing
Volume
Remaining 60
Scan Delay
0
Flow Volume
ml/sec ml PSI
A 0.0 60 Max Vol

200
Time 1:30 Drip A
Memory Inj. Mode > Results
Figure 3-1-7 Location of the Drip Mode key

on the Single Phase Injection Setup Screen
802701-G May 2009

3-1-10
Drip Mode B Drip Volume Drip Time

60 ml 0:00 Hr:Min
60
CANCEL
Check for air in

syringe and tubing
Flow Volume Interval

OPERATION
ml/sec ml sec
3—BASIC
0.0 0.0 0.0
Figure 3-1-8 Drip Mode Set up Screen
J I H
Drip Mode B Drip Volume Drip Time

60 ml 0:00 Hr:Min
60
CANCEL
G
D
Check for air in
syringe and tubing F
C Flow
ml/sec
Volume
ml
Interval
sec
E
0.0 0.0 0.0
B B
A
Figure 3-1-9 Description of Parameter Keys
and Information on the Drip Mode Screen
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3-1-11
3.1.9.2 DESCRIPTION OF PARAMETER KEYS/INFORMATION

ON THE DRIP MODE SET UP SCREEN
How to Change Parameter Values
To change the value of a parameter, select the desired parameter by touch-
ing its key. The key will highlight to indicate it is active. Using the slide bar A
located at the bottom of the screen, touch the bar at the value required, then
use the left and right arrows B to decrease or increase the value in smaller
increments.
OPERATION
3—BASIC
Description of Parameter Keys
Flow C is the rate of delivery of the saline solution (B-side syringe). Flow rate is
expressed in ml/s.
Volume D is the amount of saline delivered during each drip injection.
Interval E is the amount of time the injector pauses between each delivery of
drip injections.
“Check for air in syringe and tubing” message F acts as a reminder to the opera-
tor to confirm no air exists in the syringe and tubing prior to enabling a Drip
injection. If air is found in any part of the delivery system, take appropriate
action to remove all air. This message changes to a Start key once the air-
check key[ ] located on the powerhead has been pressed. Pressing Start
will begin the drip injection and display the Drip Infusion screen.
Pressing the Cancel key G will exit the Drip Mode screen and return to the
Injection setup screen from where the Drip Mode was accessed.
Description of Information Displayed on the Drip Mode Screen
Drip Volume I is calculated by the injector by subtracting the programmed

Volume value (B-side) from the Volume Remaining value (B-side) from the Injec-
tion Set up screen.
Drip Time H is calculated by the injector by the following formula:

Drip Cycles = Drip Volume/Volume
Drip Cycle Time = Volume/Flow + Interval
Drip Time = Drip Cycles X Drip Cycle Time
J A graphic representation of the volume remaining in the syringe is dis-
played.
802701-G May 2009

3-1-12
3.1.9.3 ACCESSING THE DRIP INFUSION SCREEN

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

3—BASIC
60 ml 0:00 Hr:Min
Stop and
Drip return to:
End
Drip
Inject Mode
0.8 ml/sec 0.0 ml 10 sec
Figure 3-1-10 Drip Infusion Screen
3.1.9.4 DESCRIPTION OF KEYS/INFORMATION

ON THE DRIP INFUSION SCREEN
Description of Keys
Pressing the Drip key A will exit the Drip Infusion screen and return to the Drip
Mode screen.
Pressing the Inject Mode key B will exit the Drip Infusion screen and display the
Injection setup screen from where the Drip Mode was accessed.
Also, pressing the Stop key on the powerhead or pressing once on the hand
start switch will exit the Drip Infusion screen and display the Injection setup
screen from where the Drip Mode was accessed.
802701-G May 2009

3-1-13
Description of Information
C The protocol’s programmed Flow, programmed Volume and programmed
Interval is displayed at the bottom of the screen.
D The calculated Drip Volume and Drip Time is displayed in the upper right-
hand corner.
E A graphic representation of the volume remaining in the syringe and the
end of the drip injection is displayed. Also, the saline drops located under the
syringe symbol flash to indicate delivery of the drip injection.
OPERATION
3—BASIC
E
D
Drip Infusion B Drip Volume Drip Time
60 ml 0:00 Hr:Min
Stop and
Drip return to:
End
Drip A
Inject Mode B
0.8 ml/sec 0.0 ml 10 sec
C
Figure 3-1-11 Description of Parameter Keys
and Information on the Drip Infusion Screen
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3-1-14
3.1.10 PROTOCOL MEMORY
The Memory key A , located in the lower left-hand corner of the display (see
Figure 3-1-12), allows access to the Memory List screen as shown in Figure 3-1-
13. The Optistar LE can store up to 20 protocols with a name length of up to 20
characters.
A: 60 ml Check for air in

syringe and tubing
Volume
60
OPERATION
Remaining
3—BASIC
Scan Delay
0
Flow Volume
ml/sec ml PSI
A 0.0 60 Max Vol

200
Time 1:30 Drip
A
Figure 3-1-12 Location of the Memory key
802701-G May 2009

3-1-15
Memory List
Page 1 DELETE EDIT NAME STORE
A B Scan
ml/sec ml PSI ml/sec ml Delay
2.6 40
S 83 9.0 50 17
3.3 47
D 72 7.8 27 26
6.0 46
3.3 5
V 72 7.8 3 60
6.0 13
OPERATION
3—BASIC
2.0 60
Curent 120 44
Value
< Memory > Inject Mode Results
Figure 3-1-13 Memory List Screen

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 not
displayed on Page 1, press the Memory> key 2B to display the page where the
desired protocol name is displayed. Once the protocol name is displayed, press on
its key 2A .
3. The protocol 3 is immediately displayed on the screen.
802701-G May 2009

3-1-16

syringe and tubing
3
Volume A: 60 ml Check for air in
Remaining 60 B: 60 ml syringe and tubing
Scan Delay
Protocol 1
0 Volume
60
Flow Volume Flow Volume Remaining
ml/sec ml ml/sec ml
PSI Scan Delay
A 2.0 16 Max Vol

200 A 2.6 40 17
Max Vol
PSI
Time 0:08 Drip A+B Time 0:00 90

Volume
Flow Volume Remaining 60
ml/sec ml
B 9.0 50 Max Vol Drip
1
OPERATION

3—BASIC
Memory List
A B Scan
2.6 40
Protocol 1 90 9.0 50 17
3.3 47
Dr Wagner 72 7.8 27 26
2 A 6.0
3.3
46
5
Protocol 2 72 7.8 3 60
6.0 13
2.0 16
Curent 200
2B
Value
Memory > Inject Mode Results
Figure 3-1-14 Retrieving a Protocol from Memory
802701-G May 2009

3-1-17
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.
OPERATION
3—BASIC
syringe and tubing
Volume
Remaining 60 Memory List
Scan Delay
Flow Volume
ml
0
4 Are You Sure?
Yes No
ml/sec
A
ml PSI ml/sec
B
ml
Scan
Delay
ml/sec PSI
2.6 40
A 2.0 16 Max Vol
200 Protocol 1 90 9.0 50 17
3.3 47
Time 0:08 Dr Wagner 72 7.8 27 26
6.0 46
Drip
3.3 5
Protocol 2 72 7.8 3 60
6.0 13
5.0 30
Test 1 80 -- -- --
-- --
3.3 50
Protocol 7 72 -- -- --
5.0 20
Memory Inj. Mode > Results 2.0 16
Curent 200 -- -- --
Value
1 Memory > Inject Mode Results
Memory List
3A ml/sec
A
ml PSI ml/sec
B
ml
Scan
Delay
2.6 40
Protocol 1 90 9.0 50 17
3.3 47
Dr Wagner 72 7.8 27 26
3B 6.0
3.3
46
5
Protocol 2 72 7.8 3 60
6.0 13
5.0 30
Test 1 80
3.3 50
Protocol 7 72
5.0 20
2.0 16
Curent 200
2
Value
Figure 3-1-15 Deleting a Protocol from Memory
802701-G May 2009

3-1-18
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 parameters
entered in Step 1 are shown at the bottom of the Memory List screen 2B .
3. Press the Store key 3 . NOTE: The Store feature only works when an empty memo-
ry location is available. To delete the contents of a memory location, refer to sec-
tion 3.6.2 Deleting a Protocol from Memory.
4. Locate an empty key 4A . If all the key locations on Page 1 are filled, press the
OPERATION
3—BASIC
Memory> key 4B to access a page with an empty key.

5. Press on the empty key to store the protocol in its location. The keyboard is dis-
played 5 to allow naming of the protocol.
6. Press the Enter key 6 on the keyboard. The protocols parameters and name is
stored in the selected location.
802701-G May 2009

3-1-19

syringe and tubing
5
Volume
Page 1 DELETE EDIT NAME STORE Cancel
Scan Delay
0 A B Scan
Flow Volume ml/sec ml PSI ml/sec ml Delay
ml/sec ml PSI
A 2.0 16 Max Vol

200 Protocol 1
0 1 2 3
Test
4 5 6 7 8 9
Time 0:08
Dr Wagner
Drip
Q W E R T Y U I O P
Protocol 2
A S D F G H J K L
Z X C V B N M
6
Caps On Cancel Space <- Enter
Curent 2.0 16 200
Value
2A < Memory > Inject Mode Results
OPERATION
3—BASIC
3 Memory List
A B Scan
2.6 40
Protocol 1 90 9.0 50 17
3.3 47
Dr Wagner 72 7.8 27 26
6.0 46
3.3 5
Protocol 2 72 7.8 3 60
6.0 13
4A
2B
2.0 16
Curent 200
Value
4B Memory > Inject Mode Results
Figure 3-1-16 Storing a Protocol in Memory
802701-G May 2009

3-1-20
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 with
the 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,
OPERATION
3—BASIC
is displayed.

syringe and tubing
3C
Volume
Page 1 DELETE EDIT NAME STORE Cancel
Scan Delay
0 A B Scan
Flow Volume ml/sec ml PSI ml/sec ml Delay
ml/sec ml PSI
A 2.0 16 Max Vol

200 Protocol 1
0 1 2 3
Dr Wagner
4 5 6 7 8 9
Time 0:08
Dr Wagner
Drip
Q W E R T Y U I O P
Protocol 2
A S D F G H J K L
Test 1
Z X C V B N M
Protocol 7
5
Caps On Cancel Space <- Enter
Curent 2.0 16 200 0
Value
1 < Memory > Inject Mode Results
3A Memory List
A B Scan
2.6 40
Protocol 1 90 9.0 50 17
3.3 47
Dr Wagner 72 7.8 27 26
3B 6.0
3.3
46
5
Protocol 2 72 7.8 3 60
6.0 13
5.0 30
Test 1 80
3.3 50
Protocol 7 72
5.0 20
2.0 16
Curent 200 0
2
Value
Figure 3-1-17 Editing a Protocol Name
802701-G May 2009

3-1-21
3.1.11 INJECTION RESULTS SCREEN
The Injection Results screen is accessed via a key A located on any three of
the inject mode screens. Refer to Figure 3-1-18. Page 1 of the Injection Results
screen lists the last 6 injections completed by date and time in descending
order. Press the Results key once again to list injections. The results include the
following information for each of the two phases in the A-side (if appropriate)
and for the B-side:
Flow Rate—the programmed flow rate,
Volume—the achieved volume
OPERATION
3—BASIC
PSI—Maximum injection pressure achieved (only for the A-side)

syringe and tubing
Volume
Remaining 60
Scan Delay
0
Flow Volume
ml/sec ml PSI
A 2.0 16 Max Vol

200
Time 0:08 Drip
Injection Results
Page 1
A: B:
No. Date - Time
Flow Vol PSI Flow Vol
2.2 9
1 26 Jan 01 10:26 4 1.5 125
- -
1.3 17
2 26 Jan 01 10:19 189 7.8 -
6.0 13
5.4 11
3 26 Jan 01 09:40 26 7.8 -
6.0 13
2.2 9
4 26 Jan 01 09:22 15 1.5 10
- -
5.4 11
5 26 Jan 01 09:19 26 7.8 -
6.0 13
2.2 18
6 26 Jan 01 08:57 - 1.5 10
- -
Memory Inject Mode Results System Info
Figure 3-1-18 Accessing the Injection Results Screen
802701-G May 2009

3-1-22
OPERATION
3—BASIC
802701-G May 2009

4-1-1
4 MAINTENANCE
AND CHECKOUT
PROCEDURES
This chapter contains maintenance procedures for the Optistar LE injector.

Guidelines for periodic inspections, testing, cleaning and lubrication are in-
cluded. Information about assembly and disassembly of the unit is contained in
4—MAINTENANCE
chapter 6.
PROCEDURES
CHECKOUT
A maintenance checklist is included in the front pocket of this manual. Fill in
the necessary information on a copy of the checklist and return to your service
center.
WARNING!
Preventive Maintenance on any unit must be performed by a Qualified

Technician who is completely familiar with the use and operation of the
Injector, trained by a Mallinckrodt instructor in the area of preventive
maintenance for the Injector and familiar with the content of the Opera-
tor’s manual and the Installation and Service manual.
802701-G May 2009

4-1-2
4.1 MAINTENANCE SCHEDULE

Preventive Maintenance should be performed at least once a year.
4.1.1 DAILY INSPECTION (REFER TO 4.6.1)
Optistar LE units need to be inspected daily as follows:
• Inspect the Powerhead, be sure both rams are functioning properly.
• Ensure all cable connections are secure.
4.1.2 OPERATIONAL CHECKOUT PROCEDURES
Procedures in this chapter check the performance of the major functions of the
4—MAINTENANCE
Optistar LE.
PROCEDURES
CHECKOUT
Checkout procedures are recommended at these times:

• 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 the operational procedures require more than one observation or re-
quire a sequence to be timed.
If these procedures 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.
Perform the following procedures OUTSIDE the magnet room.

To perform checkout procedures OUTSIDE the magnet room, disconnect com-
munication cable J3 from the back of the Power Control. Remove Powerhead
and Power Control from magnet room. At the Power Supply, disconnect cable
going to the Filter. Then use extension cable 801224-07 to connect the Power
Supply to Power Control J3.
Note: After check out operations are completed, return the Power Control to its
previously installed location in the magnet room.
802701-G May 2009

4-2-1
4.2.1 POWERHEAD CHECKOUT ITEMS REQUIRED

• Mallinckrodt 20ml, 30ml, 60ml and 125ml syringes
• The Optistar pressure gauge fixture is in the Optistar LE optional service
kit (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
4—MAINTENANCE
Injection Indicators
PROCEDURES
A & B Sides
CHECKOUT
Accelerator Reverse
A SIDE Button
Forward
Button
Stop Opti
Syringe sta
Button r Eli
te
TM
Adapter TM
Powerhead
Ram A
B SIDE
Air Check
Start
Button
Syringe
Holder Powerhead
Side A Ram B
Syringe
Holder
Side B
Figure 4-2-1 Powerhead
802701-G May 2009

4-2-2
4.2.3 POWERHEAD OPERATIONS

1. Remove syringes from the powerhead. Power up system.
2. On the A side, press and hold the powerhead Accelerator Button, then press and
hold either the Forward Button, or Reverse Button. Ensure ram moves freely in
both forward and reverse directions. Also, verify that the ram LED’s flash during
this procedure.
3. Repeat step 2 for the B side.
4. Exercise A side ram movement by pressing the Forward Button, or Reverse Button.
Ensure ram moves freely in both forward and reverse directions.
5. Repeat step 4 for the B side.
4—MAINTENANCE
PROCEDURES
6. Install 60ml syringe on A side. Program an A and B injection.

CHECKOUT
7. Press the Air Check button to enable the injection, then press the Start button on
the Powerhead. The injections you programmed should have activated verifying
the powerhead Start button and Air Check button are functioning properly.
4.2.4 POWERHEAD STOP BUTTON CHECK
1. Power up the system
2. Load 60ml syringe on A side, program an injection for either A or A & B rams.
3. On the Powerhead, press the Air Check button, then press the Start button. During
ram movement observe the Powerhead injection indicators. The injection indicator
light for the ram in motion should be flashing.
4. With ram movement taking place, press the Powerhead Stop Button. Ram move-
ment should stop and the Console will return to the injection mode screen.
4.2.5 SYRINGE DETECTION CHECK
1. Power up system as previously described.
2. Place 60ml syringes in the A & B sides of the injector head.
3. Verify console screen and powerhead indicates “60ml syringe”.
4. Remove syringes. Then place 30ml syringes in the A & B sides of the injector head.
Note: The 30mL syringe being used on the B-side in place of the 50mL syringe
injection will indicate 50mL.
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 Powerhead indi-
cates “10/15/20” and Console indicates “20”.
7. Place 125ml syringe in the B side. Verify console and powerhead indicate “125ml
syringe”.
802701-G May 2009

4-2-3
4.2.6 LIMIT SWITCH CHECK

The purpose of this check is to verify limit switch board (positioned in the
Powerhead) settings.
1. Power up the system as previously described.
2. Using the Powerhead controls, fully retract both Powerhead rams.
3. Place a 60ml syringe in the A side.
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.
4—MAINTENANCE
PROCEDURES
0 ml
CHECKOUT
Front Wiper
Figure 4-2-2
Press and hold the A side Reverse Button until ram retraction motion stops.
Verify on the Console screen, the Volume Remain field, is 63 mL (± 1 mL).
Repeat step 3 and 4 procedures for the B side Ram. If adjustments are required,
refer to Chapter 8.
802701-G May 2009

4-2-4
4.2.7 RAM FACE CHECK

Perform the following tests to confirm that the ram faces are not putting a pre-
load on the load cells before attempting to calibrate pressures.
1. Manual check of A & B side:
Verify that both the A and B ram faces are not in a bind. With your hand only, they
should be able to spin and pull-off. Also, note that the load cell holders shall re-
main secure while moving the ram faces.
2. Pressure Check of A side:
Install 60mL syringe and calibration fixture as illustrated in figure 4-2-6
4—MAINTENANCE
Pull the A side ram face outward approximately 1/8”.

PROCEDURES
CHECKOUT
With a full 60mL syringe, run a 10mL @ 4mL/sec. @ 100psi injection so that the
plunger stops with an adequate volume remaining to run the same injection with-
out retracting the ram.
Without retracting the ram, empty the syringe by manually pushing the plunger
to the expelled end, then repeat the same 10mL injection so the ram face does not
engage the pushrod at all.
Check the results screen and verify that the last injection did not achieve any pres-
sure (+20 PSI).
Note: If test steps 1 or 2 fail, the ram face must be repaired and all tests repeat-
ed.
4.2.8 FLOW RATE/VOLUME CHECK PROCEDURE

1. Retract each ram fully.
2. Install 2 empty 60ml syringes with the front wiper of the piston before the 40ml
tick indicating a volume greater than 40ml.
Note: Install syringes so that tick marks can easily be seen while installed in nest.
3. Use the forward jog key to move the ram forward and push the pushrod until the
front wiper is in the middle of the 40ml tick mark for each syringe.
Front Wiper
10
15
20
25
30
35
40
45
50
55
60
5
cc
MONOJECT
Figure 4-2-3 Front Wiper at 40ml Tick Mark

Note: If the font wiper moves past the 40ml tick mark then retract the ram, pull back
the plunger and repeat step 3.
802701-G May 2009

4-2-5
4. Program a two phase A and B injection with a flow rates of 1ml/s and volumes of
35ml.
Note: Make sure scan delay is not programmed.
5. Enable the system and run the injection.
6. While running injection, use the screen Time as your stop watch. When the text box
"Injection End" is displayed, note and record the time displayed.
Note: If time is not between the range 1:06 and 1:14, check setup and perform test
again. If time or tick mark is still not between the range specified, abort installation.
Flow Volume Time
4—MAINTENANCE
ml/sec ml
1:10
1.0 35.0
PROCEDURES
CHECKOUT
Scan Delay
0
A 60 ml
0 50 100 150 200
Pressure
PSI
Inject Mode
Flow Volume
ml/sec ml
1.0 35.0 Injection End

B
60 ml
Figure 4-2-4 Total Time and Injection Complete

7. Now look at the font wipers of the pistons.
The front of the wiper should be close to the 5ml tick mark on each syringe.
Front Wiper
10
15
20
25
30
35
40
45
50
55
60
5
cc
MONOJECT
Figure 4-2-5 Font Wiper at 5ml Tick Mark

If the front of the wiper is between the 4ml and 6ml tick mark, the volume is within
specification.
802701-G May 2009

4-2-6
4.2.9 INJECTION PRESSURE CHECKS

Note: The injector must be removed from the magnet room before performing
Pressure Verification checks.
The Pressure checks defined in this section will measure the flowrate to pres-
sure relationship. To measure this relationship, the pressure gauge fixture in
Figure 4-2-6 is placed in either Powerhead side, A or B. The side opposite the
pressure gauge fixture will then contain the syringe to apply pressure.
To check injection pressure, the following tools are required:
60mL syringe
4—MAINTENANCE
20mL syringe
PROCEDURES
CHECKOUT
30mL syringe
125mL syringe
Syringe Adaptor
Tool kit pressure gauge fixture
Water and container
Note: When performing pressure checks, a gauge reading variation of ± 20 PSI
is acceptable. If your reading is outside this parameter, repeat the check to
confirm your gauge is not the problem. If calibration is required, refer to chap-
ter 8 in this Manual.
For pressure checks in this section, the data listed in table 1 will be used:
Note: This table is for reference only. To perform pressure checks, use the direc-
tions on
the following pages.
INJECTION SYRINGE RAM PROGRAM FLOW PRESSURE
SIDE VALUE RATE VALUE
1 60 A 60mL 4mL/sec 150 PSI
4 60 B 60mL 4mL/sec 150 PSI
5 30 B 30mL 4mL/sec 200 PSI
6 125 B 60mL 4mL/sec 100 PSI
Table 1
Note: When performing the pressure checks, it is the peak PSI reading on the
gauge that is to be verified and recorded, not the average reading.
Note: When performing B side checks, program A ram for 1mL/sec, 1mL.
Note: The B side pressure value is = to the A-side value.
Note: The 30mL syringe being used on the B-side in place of the 50mL syringe
injection will indicate 50mL.
802701-G May 2009
4-2-7
To perform pressure check proceed as follows:

1. Remove injector from magnetic room.
2. Fully retract both A and B rams.
3. Manually fill a 60mL syringe.
Note: It may be necessary to perform the fill process several times to purge air
and completely fill the syringe and tubing.
4. Install filled 60mL syringe in side A
5. Connect clear pressure tube to the back of the pressure gauge fixture. Install the
pressure gauge check fixture in side B as illustrated in Figure 4-2-6.
4—MAINTENANCE
PROCEDURES
CHECKOUT
Pressure 100
200
Pressure
Gauge 50
Tube
Fixture 300
LE Base
Assembly
(Black)
60 mL
Syringe
60
55 mL
50
45
40
35
30
25
20
15
10
Powerhead Powerhead
5
'B' Side 'A' Side
Drain and
Fill Tubes
ml
125 ml
60
B 50 ml ml
5/20 l
10/1 30 ml
60 m
A
Water
Container
Figure 4-2-6. Pressure gauge fixture

Note: If the fixture's black LE base assembly is not fully inserted into B side so
that B side indicates a 50mL syringe, 200 PSI cannot be selected at the Console
802701-G May 2009

4-2-8
INJECTION #1 SIDE A 60 ML SYRINGE (4ML/SEC, 60ML, 150PSI) ± 20 PSI

1. At the Console, program side A for injection, then press the 'Air Check' button.
2. Press Start button and observe the pressure gauge reading. Verify peak reading is
within specified range, record peak reading.
3. Disconnect pressure gauge tube at syringe in side A.
4. Remove the syringe from side A.

4—MAINTENANCE
1. Retract ram A.
PROCEDURES
CHECKOUT
2. Manually fill the 30mL syringe.

3. Place 30mL syringe in side A.
4. Connect pressure gauge tube to syringe.
5. At the Console, program side A for injection, then press the 'Air Check' button.
within specified range, and record peak reading.
7. Disconnect pressure gauge tube at 30mL syringe in side A.
8. Retract ram A.
9. Remove 30mL syringe from side A.

1. Retract ram A.
2. Place 20mL adaptor in side A.
4. Place 20mL syringe in side A.
6. At the Console, program side A for injection, then press the Air Check button.
802701-G May 2009

4-2-9
8. Disconnect pressure gauge tube at 20mL syringe in side A.

9. Retract ram A.
10. Remove 20mL syringe and syringe adapter from side A.
INJECTION #4 SIDE B 60 ML SYRINGE (4 ML/SEC, 60ML, 150 PSI) ± 20 PSI

4—MAINTENANCE
2. Remove pressure gauge from side B and place in side A. Place 60 mL syringe
PROCEDURES
in ram B.
CHECKOUT
4. At the Console, program side 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 side B.
8. Retract ram B.
Note: If the pressure fixture's black LE base assembly is not fully inserted into
A- side so that A-side indicates a 30mL syringe, 200 PSI cannot be selected at
the Console
INJECTION #5 SIDE B 30 ML SYRINGE (4ML/SEC, 30ML, 200PSI) ± 20 PSI
Note: The 30mL syringe on the B side is used to simulate a 50mL syringe for
testing purposes.
4. Disconnect pressure gauge tube at syringe in side B.
6. Retract ram B.
802701-G May 2009

4-2-10
INJECTION #6 SIDE B 125 ML SYRINGE (4ML/SEC, 100PSI) ± 20PSI

1. Manually fill 125mL syringe.
2. Place 125mL syringe in side B.
5. Disconnect pressure gauge tube at syringe in side B.
4—MAINTENANCE
PROCEDURES

CHECKOUT
7. Remove pressure gauge fixture from side A.

8. Retract ram B.
ACHIEVED PRESSURE RESULTS ON A AND B RAM

After all pressure checks are complete, go to the Results Screen to view injec-
tion results. Compare achieved pressure values for the A ram injections to the
actual pressure gauge readings obtained in injections 1 thru 3. The readings
should be with in +/- 20 psi of the programmed pressure value. If your reading
is outside of this range, repeat the check to confirm your gauge is not the prob-
lem. If calibration is required, refer to Chapter 8 in this manual.
Return injector to magnet room.
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4-3-1
4.3.1 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. Af-
ter initialization, the last exited injection mode will be displayed. Also, the Console
ON/OFF button should be illuminated.
3. Press the Results button on the Main screen, then press the System Info button.
Verify correct date and time settings. Record Console and Power Control software
version on the PM Check list.
4. Press the Inject Mode button several times. The inject mode displayed should
4—MAINTENANCE
change each time it is pressed.
PROCEDURES
CHECKOUT
5. Press the Results button. The first 6 injections will be displayed. Press the Result
button again to display injections 7 through 12. The results listed are injections
completed by date and time in descending order.
6. Press the Memory button. The first 5 protocols for the injection mode selected
should be displayed. Continue to press the Memory button to increment pages
through all 20 protocols.
802701-G May 2009

4-3-2
4.3.2 REMOTE START OPERATIONS

1. Install 60ml syringe on A side. Program an A and B injection.
2. Press the Air Check button on the Powerhead or the “Enable” button on the Con-
sole. Press and release the Remote Start Button. The injection should have acti-
vated verifying the proper operation.
3. During an injection cycle, Press the Remote Start Button. The injection should stop
with the Injection Mode screen displayed.
(Rear View)
4—MAINTENANCE
PROCEDURES
Console Data
CHECKOUT
and Power
Connection J1
Remote Start
Connection J2
(Front View)
Touch
Sensitive
Display
Screen
System
ON/OFF Button
Figure 4-3-1 Console Overview
802701-G May 2009

4-4-1
4.4.1 GROUND CONTINUITY

1. Using the continuity/Diode checker function on a DMM or similar indicat-
ing device, ensure continuity exists between the AC plug ground pin and any
exposed (unpainted) metal surface that is conductively connected to all other
accessible metal. Refer to figure 4-4-1
DANGER!
If ground continuity is nonexistent, do not use the injector, contact an

authorized service representative. Failure to follow this instruction can
result in serious injury.
4—MAINTENANCE
PROCEDURES
CHECKOUT
Use Standoff
Connector for
Chassis (Earth)
Ground
Power Supply
TEST EQUIPMENT
O I J2 J1
Figure 4-4-1 Ground Continuity Check
802701-G May 2009

4-4-2
4.4.2 ELECTRICAL LEAKAGE (CHASSIS OR ENCLOSURE)

NOTE: This test is optional, and is intended as an example for facilities where
internal procedures may dictate it’s performance. The following information is
intended for qualified biomedical engineers or trained electrical technicians at
the facilities (install site).
1. Use leakage current test equipment to check the leakage through the power cord
ground with ground open. The leakage should be less than 300 microamperes for
U.L. listed models (domestic-UL60601-1) and less than 500 microamperes (export-
IEC 60601-1) for all others. If higher, check for the cause and repair.
Use Standoff Power Supply

Connector for
4—MAINTENANCE
Chassis (Earth)
PROCEDURES
Ground J2 J1
CHECKOUT
O I
LEAKAGE CURRENT Ground Clip Filter

TEST EQUIPMENT
Console
Power Control
J1, J2
Powerhead
Figure 4-4-2 Leakage Test Set-Up
WARNING!
If system leakage remains above 300 or 500 microamperes (115 Vac is

specified at 300 microamperes and 230 Vac is specified at 500 microam-
peres), do not use the injector as it may be an electric shock risk. Con-
tact an authorized service representative.
2. Disconnect the leakage test equipment.
802701-G May 2009

4-4-3
4.4.3 GROUND IMPEDANCE

NOTE: This test is optional, and is intended as an example for facilities where
internal procedures may dictate it’s performance. The following information is
intended for qualified biomedical engineers or trained electrical technicians at
the facilities (install site).
1. Refer to Figure 4-4-3. Run a current of 25 A (50 or 60 Hz) with a no-load voltage (not
to exceed 6 V) for at least 5 seconds through the protective earth pin in the mains
plug and Power Supply chassis.
2. The measured ground impedance must not exceed 0.1 ohms (if measured at
ground contact of the appliance inlet when tested without power cord) or 0.2
ohms (if measured at ground pin of power cord plug when tested with power cord
4—MAINTENANCE
plug).
PROCEDURES
CHECKOUT
Do not use injector if the system ground impedance exceeds 0.1 ohms (when
tested without power cord) or 0.2 ohms (when tested with power cord in-
stalled). Use of injector when ground impedance exceeds 0.1 ohms / 0.2 ohms
may pose an electric shock risk. Contact an authorized service representative.
WARNING!
Do not use the injector if the system ground impedance exceeds 0.1
ohms / 0.2 ohms. Use of injector when ground impedance exceeds
above limits may pose an electric shock risk. Contact an authorized ser-
vice representative.
Use Standoff Power Supply

Connector for
Chassis (Earth)
Ground O I J2 J1
GROUND IMPEDANCE
Ground Clip Filter
TEST EQUIPMENT
Console
Power Control
J1, J2
Powerhead
Figure 4-4-3 Ground Impedance Test Set-Up
802701-G May 2009

4-4-4
4—MAINTENANCE
PROCEDURES
CHECKOUT
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4-5-1
4.5.1 POWER CONTROL

1. Check all cable connections to the Power Control.
2. Visually inspect Power Control covers.
3. Check Power Control status light is on when power is applied.
4. Check Power Control is at its installed position located outside magnetic 300 gauss
and is mounted in its stand.
4—MAINTENANCE
PROCEDURES
CHECKOUT
802701-G May 2009

4-5-2
4.5.2 GAUSS MEASURING METHOD
CAUTION!
The Optistar LE injector will meet all performance specifications when

the power control is placed at any of the 4 specified power control posi-
tions. If the power control is positioned within a magnetic field higher
than 300 gauss then the injector may encounter alarms, rendering the
injector inoperable.
1. Only use gauss meter that has valid calibration date.
2. At the Power Control location, take measurements in eight different directions
4—MAINTENANCE
from the top of the Power Control approximately every 45 degrees, noting reading
PROCEDURES
at each position.
CHECKOUT
Note: If reading is higher than 300 gauss, reposition Power Control in Magnet
room.
3. Record the highest gauss reading from step 2.
Power Control
Figure 4-5-1 Power Control

Power Control
Power Control
Stand
Figure 4-5-2 Power Control on Stand
802701-G May 2009

4-6-1
4.6 CLEANING PROCEDURES

WARNING!
DO NOT use any solvents or alcohol based cleaners to clean the Power-
head, Console, Power Control or Power Supply.
4.6.1 SYRINGE HOLDER
On a daily basis, move the ram to the retracted position and wipe out the inside
of the syringe holder with a lint-free cloth sprayed with an all-purpose house-
hold cleaner. Remove any contrast build up around the syringe holder sensors.
4—MAINTENANCE
4.6.2 POWERHEAD
PROCEDURES
CHECKOUT
Clean the exterior of the powerhead by spraying a cloth with an all-purpose
household cleaner, then gently wipe clean.
4.6.3 CONSOLE
The console may be cleaned by using a lint-free cloth sprayed with an all-pur-
pose household cleaner. To clean the touch screen, use a damp nonabrasive
cloth and any commercially available non-ammonia and non-alcohol window
cleaner to regularly clean the surface. NOTE: The cleaning solution should be
applied to the cloth rather than the surface of the touch screen. The touch
screen is not water proof.
4.6.4 POWER CONTROL
Clean the exterior of the power control by spraying a cloth with an all-purpose
4.6.5 POWER SUPPLY
Clean the exterior of the power supply by spraying a cloth with an all-purpose
802701-G May 2009

4-6-2
4—MAINTENANCE
PROCEDURES
CHECKOUT
802701-G May 2009

5-1-1
5 TROUBLESHOOTING
5.1 OVERVIEW
The intention of the Chapter is to deliver information to the service technician
in order to track a problem to a subassembly so it can be replaced or repaired.
When a problem exists with the Optistar LE, a message will be displayed on the
console screen. A complete listing of these messages and their probable cause
is contained in this chapter.
5—TROUBLESHOOTING
Instructions for disassembly and reassembly of major injector components are
defined in chapter 6.
802701-G May 2009

5-1-2
5.1.1 OPTISTAR SERVICE KIT (OPTIONAL P/N 801210)

The tools listed below are supplied in the Optistar service kit. This kit is re-
quired for Optistar LE troubleshooting and calibration procedures.
Part # Descriptions Comments
801216 Case, Foam-Plastic Recommended to keep all the

unique tools together
801240 Pressure Calibration Fixture Required for Calibration
801202 Test Display Required for Calibration
801201 Test Switch Assembly Required for Calibration

5—TROUBLESHOOTING
801211 Cable Assembly 26 Position Required for Calibration

Socket to Socket. Length 18
inches
801212 Cable Assembly 20 Position Required for Calibration

Socket to Pin. Length 18 inches
801213 Screwdriver Titanium #2 Phillip Required for any disassembly within

magnet room
801257 Screwdriver Titanium 3/16 Slotted Required for D-shell backshell removal
801200 Spanner Wrench Non-Ferrous Required for adjustment of Powerhead

pivot (Optistar MR only).
801214 Wrench Titanium (3mm) Hex Required for removal of Powerhead from
stand and adjustment of Powerhead pivot
within magnet room. (Optistar MR Only)
801215 Wrench Titanium (4mm) Hex Required for adjustment of Powerhead

pivot within magnet room. (Optistar MR Only)
801254-10 Cable Assembly, Test 10 foot Required for adjustment of Powerhead

pivot within magnet room
(Optistar MR only).
802713 LE Pressure Fixture Base Required to calibrate Optistar LE
801224-07 Cable Assembly, 25 pin, D shell, M/F Required for testing outside of magnet
room.
Figure 5-1-1 Tool Kit
802701-G May 2009

5-1-3
5.1.2 GENERAL TROUBLESHOOTING GUIDELINES

We suggest these actions when first troubleshooting the Optistar LE; things to
try before taking anything apart, and to make the job easier.
1. Check indicator lights on Power Supply and Power Control to ensure adequate
power is present.
2. Verify the problem. Check the injector under the same conditions and settings that
it had when the problem occurred. If possible, try the injector in an isolated setting
to see if the problem can be duplicated.
3. Try different settings. Check the injector with different control settings than it had
when the problem occurred. Change the flow rate, volume and pressure. If anoth-
er size syringe is available, try it.
4. Use the checkout in chapter 4. This is a relatively quick way to check the major
5—TROUBLESHOOTING
functions. This is especially helpful if the accuracy is in question.
5. Visually inspect subassemblies and components before performing electrical tests
or calibration procedures. Specifically make sure cable plugs are firmly attached,
and cables are not crimped, or under tension. If the trouble is in the powerhead,
open the powerhead cover and inspect the powerhead while it operates. Look for
loose parts, loose connections, interference, and wear.
6. Isolate the fault. While trying different settings, and under different conditions, try
to isolate the specific problem.
7. Call your sales representative for service assistance, field service, and for replace-
ment parts or modules. If the system is new, still under warranty, or covered under
a service contract, call your sales representative before proceeding.
CAUTION!
Be extremely careful when the Optistar LE is open. Lethal voltages

are exposed. Be careful not to leave an open system unattended with
power plugged in. DISCONNECT THE POWER CORD BEFORE REMOVING
OR REPLACING BOARDS.
802701-G May 2009

5-1-4
5—TROUBLESHOOTING
802701-G May 2009

5-2-1
5.2 SYSTEM GENERATED MESSAGES

With these faults, a message appears on the system display. Use this chapter to
help find the possible cause and what to check.
The alarms are listed in numeric order as shown below, followed by a brief de-
scription. If an alarm fault occurs, find the alarm number on the list, then refer
to the expanded explanation given for that alarm in this chapter.
Each alarm includes a description message of what it means, probable causes,
and what action to take to remedy the problem. From these messages, the de-
fective subassembly (such as a circuit board or the powerhead) can be identi-
fied and replaced.
The Optistar LE also retains a history of reported alarms. Refer to Chapter 9 for
5—TROUBLESHOOTING
procedures.
Alarm
Number 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
802701-G May 2009

5-2-2
Alarm no. 1:
Meaning: Pressure limit malfunction
Cause: There are six 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
5—TROUBLESHOOTING
are in line, make sure they are open. Verify that the operator is not trying to
program high flow rates into a small needle. Keep in mind that the B side may
have a low pressure limit. In some cases the operator could program a high
pressure (180 to 200 psi limit) A side injection followed by a B side. Immediately
after the injector completes side A, side B will start. If the residual pressure from
the side A injection exceeds the pressure limit for side B the injector may trig-
ger 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. The error is generated from the UPP injector volume counter because it
reached the set value plus 1 ml.
Check: Position calibration, optical encoders on motors, loose connector or
printed circuit board.
Alarm no. 3:
Meaning: Flow Rate malfunction.
Cause: The optical encoders are used to control and monitor the flow rate. If the
flow rate exceeds the programmed flow rate this alarm will appear. The encoder
signals are monitored by the UPP counter on the microprocessor board.
Check: Optical encoders, loose connectors or printed circuit board.
802701-G May 2009

5-2-3
Alarm no. 6:
Meaning: Motor malfunction.
Cause: A-side or B-side motor encoder signals are missing 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.
5—TROUBLESHOOTING
Pressure limit is programmed to low.
Check: Verify that the powerhead ram is functioning by pressing the forward or
reverse buttons on the powerhead.
Alarm no. 9:
Meaning: Invalid Powerhead Pressure Measurement
Cause: The pressure measurement has generated a raw A/D value of 250 counts
or more.
Check: Replace CPU board in Power Control
Call Technical Support.
Alarm no. 13:
Meaning: FWD/REV limit sensor malfunction.
Cause: The A side and B side position limit switches are checked for both for-
ward and reverse switches being active at the same time. Alarm can occur at
power on check or during operation.
Faulty limit switch board.
Dirt is blocking light path.
Loose connection (?).
Check: Call Service.
802701-G May 2009

5-2-4
Alarm no. 14:

Meaning: Motor Control Watchdog Alarm.
Cause: The FPGA chip on the CPU board which controls motion contains a
watchdog timer. If this watchdog timer is not reset every 500ms or less, this
alarm will be activated.
CPU board malfunction.
Check: Call Technical Support.
Alarm no. 15:
Meaning: Changed Syringe Size Alarm.
5—TROUBLESHOOTING
Cause: During an injection the syringe sensor detected that the syringe size
changed which should not occur.
Possible causes:
If the alarm occurs while a syringe adapter is installed, the syringe adapter may
be moving and causing the syringe sensing switch to momentarily change
syringe sizes.
Faulty syringe sensor switch.
Faulty adapter.
Faulty bottom cover.
Faulty connection to syringe sensor.
Check: If the powerhead displays an incorrect syringe size, inspect the syringe
size switches for accumulated contrast sticking, an obstruction in the flange
slot, or defective powerhead PCB.
Note: Do not change syringe on either the A or B side until the entire injection
sequence is complete.
802701-G May 2009

5-2-5
Alarm no. 17:

Meaning: Power On Self Test Failure.
Possible causes:
Any one of the powerhead forward, reverse, fast, start, stop, and check switches
are closed during Power On Self Test.
Faulty Console RAM/ROM Memory.
Faulty Power Control RAM/ROM Memory.
Faulty UPP chip.
Faulty pressure sensor.
5—TROUBLESHOOTING
Check: A powerhead switch was unintentionally pressed during the power on
sequence. This includes changing syringe sizes during power on.
Alarm no. 20:
Meaning: Protocol Error.
Cause: CRC value appended to the volume and flow rate from the console did
not match the value calculated by the power control.
Faulty communication link between the Console and Power Control.
Incompatible software versions between Console and Power Control
Check: Call Technical Support.
Alarm no. 22:
Meaning: Syringe Pressure is Less Than Expected.
Note: Injection ran while in the 10/15/20 or 30mL modes.
Cause: Will cause alarm 22 if no back pressure is developed at 4mL after start of
injection.
Check: Verify that the syringe push-rod is making contact with A side ram. An
empty syringe can also cause this error.
802701-G May 2009

5-2-6
Alarm no. 23:

Meaning: Power Control NV Memory Checksum Alarm.
Cause: NV memory checksum does not agree with its last saved checksum.
Check: If software has just been downloaded into the Power Control CPU board,
refer to section 10.2.1.
Replace CPU Board in the Power Control.
Call service.
Alarm no. 24:
Meaning: Power Control firmware Checksum Alarm.
5—TROUBLESHOOTING
Cause: Power Control firmware checksum does not agree with its known check-
sum.
Check: If software has just been downloaded into the Power Control CPU board,
refer to section 10.2.1.
Replace CPU Board in the Power Control.
Call service.
Alarm no. 30:
Meaning: Touchscreen Alarm.
Cause: If the touchscreen is continuously activated during the power-up se-
quence, this alarm condition will occur.
Check: The touch screen should have nothing making contact with it during
power up.
Alarm no. 31:
Meaning: Remote Start Switch Connection Alarm.
Cause: The Remote Start Switch is improperly connected or becomes discon-
nected during an injection, this alarm condition will occur.
Check: Remote Start Switch connection.
802701-G May 2009

5-2-7
Alarm no. 33:

Meaning: Console Protocol Memory Checksum Alarm.
Cause: The Console protocol memory checksum is checked at power-up. If the
checksum does not agree with the last saved checksum, this alarm condition
will occur.
Check: Battery on Console CPU board is bad or loose.
Replace Console CPU board.
Call Service.
Alarm no. 34:
Meaning: Console Program Checksum Alarm.
5—TROUBLESHOOTING
Cause: If the Console firmware checksum does not agree with its known check-
sum, this alarm condition will occur.
Check 1: Download software.
Check 2: Replace Console CPU board.
Call Service.
Alarm no. 35:
Meaning: Either an injection motor timing error or undefined error message re-
ceived from the power pack.
Check: Call Service.
802701-G May 2009

5-2-8
Alarm no. 50:

Meaning: Power Control not Detected.
Cause: No communication between the Console and the Power Control during
Power. On Self Test.
Possible causes:
Power Control not turned on.
Faulty RS422 cable/connection.
Faulty data communications link to Power Supply
Faulty serial link EMI Filter.
5—TROUBLESHOOTING
Faulty Console RS422 line driver/receiver board.

Faulty Power Control RS422 line driver/receiver board.
Check: The power control is switched on (green indicator switch is on).
Check: J1 and J2 on the power supply are connected to the monitor, and the
power control.
802701-G May 2009

5-2-9
Alarm no. 90:

Meaning: Power Control/Communication Error.
There are 8 possible sub alarm codes associated with Alarm no. 90. Their format
is used to explain alarms on the 2 communications channels, COM1/COM2.
Where:
COM1/ = is the alarm number for communication channel 1
/COM2 = is the alarm number for communication channel 2
Alarm definitions and syntax are as follows:
0 = No Error
90 = Connect Error
5—TROUBLESHOOTING
92 = Framing Error
93 = Parity Error
95 = BCC Error (Checksum Error)
96 = Retry Error
98 = Overflow Framing Error
99 = Overflow Parity Error
100 = Framing and Parity Error
Cause: No communication for more than 30 seconds or bad communication
with may consecutive retries that fail during injector operation.
Possible causes:
Faulty RS422 cable/connection.
Faulty data communication link to Power Supply
Faulty serial link EMI Filter.
Faulty Console RS422 line driver/receiver board.
Faulty Power Control RS422 line driver/receiver board.
Check: Power Control to Console communication connections.
802701-G May 2009

5-2-10
5.2.1 ACTIVATING THE SYSTEM ERROR RESULTS LIBRARY

The alarm history library retains the last 10 alarm messages encountered. To
display these alarm messages proceed as follows:
1. Turn the console on.
2. Touch the Results button.
3. Touch the System Info button.
4. Touch the Alarm History button.
5. To return to the System Information screen, simply touch the System button.
5—TROUBLESHOOTING
802701-G May 2009

6-1-1
6 FIELD REPLACEABLE
PARTS
This chapter provides disassembly and assembly instructions for Optistar LE

field replaceable parts. These parts are defined in the following sections:
Section 6-2 Console
Section 6-3 Power Head
Section 6-4 Power Control
Section 6-5 Power Supply.
Section 6-6 Stand
6—DISASSEMBLY
REASSEMBLY
Section 6-7 Filter
Section 6-8 Cables
Section 6-9 Kit Part Numbers
When removing a specific item, follow the DISASSEMBLY instructions up to the
point where the removal of that particular item is discussed. To disassemble an
item may require sub components to be removed first. If this is the case, you
will be directed to perform the appropriate sub component instruction first. To
replace an item, follow the disassembly instructions in reverse order until the
unit is completely reassembled.
WARNING!
Always remove components from magnet room (Power Head and

Power Control) before disassembly. Failure to follow this warning could
result in personnel injury or equipment damage.
802701-G May 2009

6-1-2
GENERAL INFORMATION
RETAINING SCREWS
• Optistar LE components are retained with Non-Ferrous brass or blue stainless
steel screws. The blue dyed screws are made of a type of stainless steel that
is not attracted to a magnet. Always use Non-Ferrous screws if replacement
is required.
TERMINOLOGY
• The term Wire harness is used to identify internal unit cabling.
• The term Cable is used to identify cabling between each Optistar LE units.
REPLACEABLE PARTS
• Each section in this chapter identifies Optistar LE component replaceable
parts.
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009

6-2-1
6.2 CONSOLE
DANGER!
Before attempting any disassembly procedure, turn off all power to the

Optistar MR system.
The Console assembly consist of the following components:
• Cover
• Touchscreen
• Console CPU and Interface Board
• Harnesses
• Switch assembly
• Display subassembly
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009

6-2-2
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
6—DISASSEMBLY
REASSEMBLY
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
802701-G May 2009

6-2-3
25 28
18 27
26
31
6—DISASSEMBLY
REASSEMBLY
FRONT VIEW 16 29 30
2x REF XXXXXX-X
S/N xxxx-xxx
REF 2
22
18x
19 20
3x
BACK VIEW
1
4x
2
BACK VIEW 5x
802701-G May 2009 Figure 6-2-1 Console Assembly (P/N 802100)

6-2-4
24 12
3.0 REF
2x 23 3
21
12 REF 4x
17
4x
SEE NOTE 3
11
8
SEE NOTE 1
6—DISASSEMBLY
PIN 1
REASSEMBLY
FRONT COVER ASSEMBLY
14 17 2x
SEE NOTE 3
J3 15
6 5
13
NOTES:
1. THE INVERTER HARNESS IS ROUTED THROUGH THE NOTCH IN THE MOUNTING PLATE.
THE SWITCH ASSEMBLY IS CONNECTED TO J6 AND THE INVERTER HARNESS IS CONNECTED TO J7.
7
2. CONNECT INTERFACE CABLE FROM J3 OF INTERFACE BOARD TO J5 OF CONSOLE CPU BOARD.
3. THE #4 SCREW (ITEM 17) THREADED INTO THE PLASTIC COVERS (QTY. = 6) SHALL BE TORQUE LIMITED
TO 60 OZ/IN.
10
BACK COVER ASSEMBLY
802701-G May 2009 Figure 6-2-2 Console PCB Assembly (P/ N 802100)
6-2-5
12
90
22
05
-X
X
6—DISASSEMBLY
REASSEMBLY
TOP VIEW
BOTTOM VIEW
Figure 6-2-3 Display Subassembly (P/N 802116S)

802701-G May 2009
6-2-6
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-2-7
6.2.2 CONSOLE COVER REMOVAL

1. Place the console, with hinge plate attached, face down on a soft, clean surface to
prevent damage to the finish (i.e., table top with soft cloth in between console and
table).
2. To remove the hinge plate (item 22), remove the nine screws (item 24) and lock-
washers.
NOTE: If the hinge plate is not the item being serviced it can remain attached
to the back cover.
3. To remove the back cover (item 7), remove the four screws (item 1) and slowly lift
away from the front half without fully extending the D-shell harness assembly
(item 10).
NOTE: The harness assembly (item 10) must be disconnected from the console
6—ASSEMBLY &
DISASSEMBLY
CPU board at J5 before the back cover can be completely separated from the
front half of the console.
6.2.3 CONSOLE CPU REMOVAL
1. Perform Console Cover Removal procedure 6.2.2.
2. Disconnect the following four connectors at the Console CPU board:
Touchscreen cable from J2
Display cable (item 2) from J8
Switch assembly (item 8) from J6
Inverter cable (item 9) from J7
3. Remove two (2) screws retaining (item 3), lift console CPU PCB (item 3) of retaining
pegs.
802701-G May 2009

6-2-8
6.2.4 DISPLAY SUBASSEMBLY REMOVAL

Refer to Figure 6-2-2
1. Perform removal procedure 6.2.2, and 6.2.3.
2. Remove four (4) retaining screws securing the Display Subassembly (item 12) to the
front cover.
3. Remove Display Subassembly.
6.2.5 TOUCHSCREEN REMOVAL
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
6—ASSEMBLY &
DISASSEMBLY
1. Place the console, with hinge plate attached, face down on a soft, clean surface to
prevent damage to the finish (i.e., table top with soft cloth in between console and
table).
2. To remove the back cover (item 7), remove the four screws (item 1) and slowly lift
away from the front half without fully extending the D-shell harness assembly
(item 10) to expose the Display Subassembly.
NOTE: The harness assembly (item 10) does not have to be disconnected from
the console CPU board to remove the Console Power Switch Assembly.
3. Disconnect the Console Power Switch cable at the CPU board J6 connector.
4. Remove four (4) screws retaining the Display Subassembly and gently move it aside
until the Console Power Switch is exposed.
5. Remove four (4) retaining screws from the Console Power Switch mounting plate
(item 11) and remove button mounting plate. Then remove Console Power Switch
Assembly.
802701-G May 2009

6-2-9
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
the Interface board (item 4) J3 connector.
3. Remove two (2) mounting bracket retaining screws from (item 13). Remove Inter-
face Board (item 4) with mounting bracket (item 13).
4. Separate mounting bracket (item 13) from Interface Board (item 4) by removing
two (2) standoff nuts.
6—ASSEMBLY &
DISASSEMBLY
NOTE: Be sure to retain mounting bracket (item 13). This bracket must be in-
stalled to the Interface Board (item 4) when it is replaced.
802701-G May 2009

6-2-10
6.2.9 CONSOLE ASSEMBLY

Refer to Figures 6-2-1 thru 6-2-3.
1. Place the top cover on a soft, clean surface to prevent damage to the finish (i.e.,
table top with soft cloth in between cover and table). Position the cover so that its
inside surface faces up and the switch assembly is now in the upper left corner.
2. Push Console Switch button into the opening provided until seated.
NOTE: Clean mounting surface with alcohol before mounting switch.
3. Place Console Power Switch Assembly (item 8) over the Console Switch button.
Install Power Switch mounting plate (item 11).
4. Position the touch screen (item 5) over the large opening in the top cover so the
harness and connector are at the right side.
5. Move the Console Power Switch cable to side, then place the Display Subassembly
(item 12) over the touch screen so the harness and connector are at the right side.
Secure assembly with four (4) mounting screws (item 21).
6—ASSEMBLY &
DISASSEMBLY
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 provid-
ed. Secure mounting bracket to back cover with two (2) retaining screws.
9. Install harness assembly (item 10) to the Interface Board J3 connector.
10. Move back cover close to the front cover. Install Interface Board cable (item 10) to
J5 on the CPU board.
11. The software can be downloaded to the console if required. Refer to the down-
load process described in Chapter 10, Software Installation.
12. Place back cover onto front cover and install four (4) retaining screws.
13. Install three torque hinges (item 20) onto the back cover mounting pads using
nine screws with lockwashers (item 22).
802701-G May 2009

6-3-1
6.3 POWERHEAD
DANGER!
Before disassembling the Powerhead, follow the power off instructions

listed in each disassembly/assembly section.
WARNING!
Always remove Powerhead from magnet room before disassembly. Fail-

ure to follow this warning could result in personnel injury or equipment
damage.
The Powerhead assembly consist of the following components:
• Powerhead
6—DISASSEMBLY
A
10/15/20 30 60
ml
ml
ml
B 60 50 ml
REASSEMBLY
125 ml ml
Figure 6-3-1 Powerhead on Remote Stand
802701-G May 2009

6-3-2
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 SENSING
PCB ASSEMBLY 802307-1
Note: POWERHEAD ASSEMBLY 802300-D or later use SYRINGE SIZE SENSING
802743 Kit See Section 6-9 Kits, MOTOR REPLACEMENT ASSEMBLY DRIVE A 1
MAINFRAME, MACHINED 2
802371 GEAR, 24DP 32T 3
802746 Kit BEARING ADAPTER 4
MACHINED, MOTORMOUNT 5
PILOT, MOTOR GEAR 6
6—DISASSEMBLY
GUIDE PLATE 7
REASSEMBLY
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
802701-G May 2009

6-3-3
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
6—DISASSEMBLY
802382 PIVOT WASHER 35
REASSEMBLY
802383 CAP, PIVOT 36
802384 THRUST WASHER, PIVOT 37
802385 PILOT BUSHING, MOTOR 38
802744 Kit STANDOFF, M3 - 6MM 39
SHIELD, 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 SENSING
Note: POWERHEAD ASSEMBLY 802300-D or later use SYRINGE SIZE SENSING
802316 HARNESS ASSY, END LIMITS 48
802317 HARNESS ASSY, SIZE SENSING 49
802318 HARNESS ASSY, ENCODER 50
802701-G May 2009

6-3-4

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
6—DISASSEMBLY
REASSEMBLY
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
802701-G May 2009

6-3-5

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
6—DISASSEMBLY
TY-RAP TIES 84
REASSEMBLY
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
802701-G May 2009

6-3-6
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-3-7
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009 Figure 6-3-1 Powerhead Assembly (P/N 802300-B Sht 1)
6-3-8
DETAIL A
TOP VIEW
6—DISASSEMBLY
REASSEMBLY
BOTTOM VIEW
END VIEW
6-3-9
Optistar Elite
TM TM
Op
tis
ta r
TM
Eli
te
TM
6—DISASSEMBLY
REASSEMBLY
BACK VIEW
6-3-10
Power Control Powerhead Board

P1 Connector Wire Color Connectors J7, J8, J9
P1:24 BLACK J7-11
P1:9 RED J7-12
P1:39 BROWN J7-2
P1:25 YELLOW J7-1
P1:30 WHITE J7-3
GND SCREW NONE J7-4
P1:20 GREEN J7-5
P1:26 ORANGE J7-6
P1:40 BLUE J7-7
P1:13 BROWN J7-8
P1:41 YELLOW J7-9
P1:27 PINK J7-10
TAN
P1:8 BLACK J8-9
P1:22 RED J8-8
P1:29 WHITE J8-4
P1:43 GREEN J8-3
P1:37 ORANGE J8-2
P1:23 BLUE J8-1
6—DISASSEMBLY
P1:14 PURPLE J8-14

P1:42 SLATE J8-13 Pin 1
REASSEMBLY
P1:38 PURPLE J8-6 J8 Powerhead Board

P1:10 GRAY J8-7 (P/N 802301-1)
J7
P1:28 PINK J8-12 Connectors
GND SCREW NONE J8-15
P1:11 TAN J8-10 J9
P1:12 RED/YELLOW J8-11 P2 P1
P1:5 RED/GREEN J8-5 Pin 1
RED/BLACK - JA
P1:21 BLACK J9-1
P1:7 RED J9-2 JB Powerhead
P1:36 WHITE J9-3 Motor Connections
P1:6 GREEN J9-5 JB1
P1:35 ORANGE J9-6
P1:34 BLUE J9-4 JA1
J9-7
GND SCREW NONE J9-8
Power Control Powerhead

P2 Connector Wire Color Motor Connections
P2:18 BLUE JA-1
P2:23 YELLOW JA-3
P2:21 GREEN JA-4
GND SCREW NONE -
P2:17 WHITE/BLUE JB-1
P2:26 WHITE/YELLOW JB-3
P2:20 WHITE/GREEN JB-4
GND SCREW NONE -
P2:24 RED/BLUE JB1-1
P2:22 RED/YELLOW JB1-3
P2:27 RED/GREEN JB1-4
GND SCREW NONE -
P2:25 BLACK/BLUE JA1-1
P2:19 BLACK/YELLOW JA1-3
P2:28 BLACK/GREEN JA1-4
GND SCREW NONE -
802701-G May 2009

Figure 6-3-4 Powerhead Cable (P/N 802303-A)
6-3-11
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. Loosen the Powerhead arm phillips head screw. Lift the Powerhead and arm as-
sembly from stand.
5. To reinstall, perform the procedures above in reverse order.
Elite
TM
star
TM
Opti
Screw
P
B
60 ml ml 20 ml
30 15/
A
50 ml ml
10/
60 ml
125
6—DISASSEMBLY
REASSEMBLY
Rod
Tension
Adjustment
Figure 6-3-4 Powerhead removal
802701-G May 2009

6-3-12
6.3.3 POWERHEAD COVER REMOVAL/INSTALLATION

Powerhead covers consist of four units:
Syringe holder nest cover (item 83)
Bottom back cover (item 54)
Top cover (item 52)
Bottom front cover (item 53)
Note: Powerhead covers can be removed while mounted to the stand.
Note: Remove the Powerhead assembly from the magnet room during cover
removal and installation.
6.3.3.1 Syringe Holder Nest Cover Removal/Installation
6—DISASSEMBLY

REASSEMBLY
2. Remove Powerhead assembly from magnet room.

3. Remove all syringes if present.
4. Remove syringe holder nest cover (item 83) three (3) retaining screws. Remove
syringe holder nest cover (item 83).
6.3.3.2 Bottom Back Cover Removal/Installation
4. Remove bottom back cover (item 54) four (4) retaining screws. Remove bottom
back cover.
802701-G May 2009

6-3-13
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
6—DISASSEMBLY
REASSEMBLY
4. Remove syringe holder nest cover as described in section 6.3.3.1. Remove bottom
back cover as described in section 6.3.3.2.
5. Remove bottom back cover (item 53) eight (8) retaining screws. Remove bottom
front cover. Note: The top cover will be free to remove at this point.
802701-G May 2009

6-3-14
6.3.4 POWERHEAD BOARD REMOVAL/INSTALLATION

Remove Powerhead assembly from magnet room.
1. Remove all Powerhead covers as described in section 6.3.3. Refer to Figure 6-3-1
and 6-3-2.
2. Disconnect all connections to the Powerhead board.
3. Remove six (6) retaining screws (item 90) and lift off Powerhead board.
6.3.5 POWERHEAD CABLE REMOVAL/INSTALLATION
Disconnect the Powerhead cable from the Power Control. Remove Powerhead
assembly from magnet room.
1. Remove all Powerhead covers as described in section 6.3.3.
6—DISASSEMBLY
2. Remove four (4) retaining screws from shield motor cover (item 40). Also, remove
REASSEMBLY
two (2) Powerhead board rear retaining screws. Carefully slide shield motor cover
(item 40) off.
3. Cut rear cable wire Ty-wrap.
4. Before removing motor and encoder connectors, write down connector wire orien-
tations. This will ensure connectors are not flipped during the installation process.
Disconnect JA, JA1, JB, and JB1 connectors and ground wires. Also, disconnect the
ground wire connection next to the Powerhead cable retaining bracket.
5. At the Powerhead retaining bracket, cut the two (2) Ty-wraps (one on each side).
Remove four (4) retaining screws (item 60) the Powerhead retaining bracket. Care-
fully remove Powerhead cable.
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 orien-
tations. This will ensure connectors are not flipped during the installation process.
Disconnect JA, JA1, JB, and JB1 connectors and ground wires. Also, disconnect mo-
tor encoder connectors (item 50).
3. Remove three (3) motor retaining screws and washers (item 70 and 72). Remove
motor and gear assembly. Be careful not to lose pilot bearing (item 38).
802701-G May 2009

6-3-15
6.3.7 POWERHEAD END LIMIT SENSING BOARD

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
both set screws (item 59). With a 1.5 mm allen wrench, remove both set screws
(item 59).
6. At the Powerhead board, disconnect both size sensing cables (item 49).
7. Disconnect each connector at the Limit Sensing Boards (item 26). Take note of the
connectors used.
6—DISASSEMBLY
8. Remove six (6) screws (item 58) from guide plate (item 7). Carefully slide guide
REASSEMBLY
plate and ram assembly from base.
9. Carefully slide the Limit Sensing Boards (item 26) from their runners. Take note of
the position adjustment screws (item 27) are in, then remove adjustment screws
(item 27) from Limit Sensing Boards (item 26) using adjustment runner tool (P/N
802731).
10. To reinstall, perform the procedures above in reverse order. Ensure all O-rings are
properly lubricated.
Note: When reinstalling a Limit Sensing Board, ensure the load cell (item 23)
cable and conduit is correctly positioned in the slots provided. Also, End Limit
calibration must be performed when this board is replaced.
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
both set screws (item 59). With a 1 1/2 mm allen wrench, remove both set screws
(item 59).
6. Disconnect each connector at the Limit Sensing Boards (item 26). Take note of the
connectors used. Cut all Ty-wraps retaining the Limit Sensing Cable. Also, bend
cable retainers to allow for cable removal.
802701-G May 2009

6-3-16
7. Remove four (4) screws (item 60) from bushing retainer (item 17). Lift wiper (item
33) and bushing guide (item 9) from guide plate (item 7).
8. Remove load cell cable and conduit from power head by feeding connector end
through the opening provide in the guide plate (item 7).
9. To install load cell, perform the procedures above in reverse order.
Note: When installing a load cell kit, ensure the load cell (item 23) cable and
conduit is correctly positioned in the slots provided.
6.3.9 END LIMIT HARNESS REMOVAL/INSTALLATION
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
6—DISASSEMBLY
J3 and J4 connectors.
REASSEMBLY
3. Cut wire Ty-wraps retaining the harness.

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.
802701-G May 2009

6-3-17
6.3.11 SYRINGE SIZE SENSING BOARD REMOVAL/INSTALLATION

There are two (2) Syringe Size Sensing Boards for each ram. Refer to Figure 6-3-
2 for location and procedures.
1. Remove syringe holder nest cover as described in section 6.3.3.1.
2. Disconnect cable (item 49) connections from Syringe Size Sensing boards (item 47).
3. Remove Syringe Size Sensing board retaining screws (item 87) and detent syringe
holder (item 42).
6.3.12 DETENT SYRINGE HOLDER REMOVAL/INSTALLATION
6—DISASSEMBLY
1. Remove syringe holder nest cover as described in section 6.3.3.1.
REASSEMBLY
2. Disconnect cable (item 49) connections from Syringe Size Sensing boards (item 47).
3. Remove Syringe Size Sensing board retaining screws (item 87) and detent syringe
holder (item 42).
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
the syringe nest holder (item 8).
802701-G May 2009

6-3-18
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.
6.3.15 SUPPORT ARM REMOVAL/INSTALLATION
6—DISASSEMBLY
REASSEMBLY

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).
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, remove
two (2) Powerhead board rear retaining screws. Carefully slide shield motor cover
(item 40) off.
5. Remove the Powerhead cable as described in section 6.4.5.
6. Remove 6mm lead screw nut (item 68) from lead screw (item 15).
7. Remove Powerhead motors as described in section 6.3.6.
802701-G May 2009

6-3-19
8. Rotate lead screw (item 15) to access gear set screws. Loosen both gear set screws
(item 57). Then remove both lead screw gears (item 3).
9. Remove five (5) screws (item 58) from motor mount (item 5). Remove bearing as-
sembly from lead screws.
10. Remove bearing retaining ring (item 11) and bearings (item 10) from motor
mount housing (item 5).
Reassembly
11. Install new bearings into motor mount (item 5). Install bearing retaining ring (item
11). Note: Ensure the bearing retaining ring is fully seated during installation.
12. Slide motor mount assembly (item 5) onto lead screws and secure assembly with
five (5) mounting screws (item 58).
13. Install lead screw gears (item 3) onto lead screws (item 15). Ensure set screws are
positioned to contact the lead screw flat surfaces when tightened. At this time
simply snug the gear set screws on the lead screw flat surfaces, do not tighten the
gear set screws.
6—DISASSEMBLY
REASSEMBLY
Rotate both lead screws until the gear set screws are accessible after motors instal-
lation.
14. Reinstall motor assembly.
15. Reinstall 6mm lead screw nut (item 68) and tighten nut.
16. Tighten gear set screws (item 57).
17. Reinstall Powerhead cable.
18. Reinstall shield motor cover. Then reinstall all Powerhead covers.
802701-G May 2009

6-3-20
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-4-1
6.4 POWER CONTROL

DANGER!
Before attempting any disassembly procedure, turn off all power to the

Optistar LE system.
WARNING!
Always remove Power Control from magnet room before disassembly.

Failure to follow this warning could result in personnel injury or equip-
ment damage.
WARNING!
The Power Control contains special Non-Ferrous screws. They are identi-
fied by blue dye. Always use Non-Ferrous blue dye screws if replace-
ment is required. Failure to follow this warning could result in personnel
6—DISASSEMBLY
REASSEMBLY
injury or equipment damage.
WARNING!
Before removing any Power Control PC boards, ensure proper static

protection devices are used. Failure to follow this warning could result
in equipment damage.
Injector operations are controlled by the Power Control. PC boards and other
Power Control components are contained in the following four units: Backplate
Control, Front Control Encloser, Rear Control Encloser, and Front Control Cover.
Replacement components contained in these units are list in section 6-4-1.
Backplate
Rear Control
Control
Encloser
Front Control
Encloser
Front Control
Cover
Figure 6-4-1 Power Control Assembled Unit
802701-G May 2009

6-4-2
6.4.1 POWER CONTROL REPLACEMENT COMPONENTS

802200 POWER CONTROL ASSY
802251 FRONT CONTROL ENCLOSER 1
802252 REAR CONTROL ENCLOSER 2
802222 FRONT CONTROL COVER 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 INTERCONNECT BOARD ASSEMBLY 9
802263 EMI GASKET 10
6—DISASSEMBLY
REASSEMBLY
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 fasteners are part of Fastener Service Kit (P/N 802744)
802701-G May 2009

6-4-3
11
4
12
14 19 2x
18 11 REF
6x
7
10 FIBERGLASS SIDE
13 METAL SIDE
32
6—DISASSEMBLY
REASSEMBLY
2
4x
16 26
REF 12
6
REF 13
14
REF
8
9
15
21, 20
5
22,23
J1, J2
J3
12 TO COMMUNICATION BD.
EXPLODED VIEW (BOTTOM)
1 19
4x
REF XXXXX-X
S/N XXXX-XXXX
11 TO DRIVER BD.
REAR ASSEMBLY VIEW
802701-G May 2009 Figure 6-4-2 Power Control Assembly (P/N 802200)
6-4-4
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-4-5
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 con-
nections. Gently remove backplate cover (item 4) from rear enclosure cover (item
2).
7. On the Driver board (item 7), disconnect Head motor harness (item 11) from J2
connector.
8. On the Communication board (item 8), disconnect the following items:
6—DISASSEMBLY
Powerhead Communication harness (item 12) from J3 connector, Console Com-
REASSEMBLY
munication harness (item 13) from J2 connector, and Power Control switch harness
(item 14) from J1 connector.
9. The Backplate Cover (item 4) can be set aside.
10. To reinstall the Backplate Cover, perform steps 1 thru 8 in reverse order.
6.4.3 DRIVER BOARD (802203-1) REMOVAL/INSTALLATION
5. Remove Backplate Cover as described in section 6.3.2.
6. Remove two (2) screws (item 19). These screws secure the Driver Board heat sink to
the Rear Cover Enclosure.
7. Before removing the Driver Board (item 7) and shield (item 32), take note of its
countersink slot location in the Rear Cover Enclosure. Grasp Driver Board and
shield, then pull straight outward to disconnect from the Power Control Intercon-
nect Board (item 9).
8. To reinstall Driver Board, perform steps 1 thru 7 in reverse order.
802701-G May 2009

6-4-6
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
slot location in the Rear Cover Enclosure. Grasp Communication Board and pull
straight outward to disconnect from the Power Control Interconnect Board (item
9).
7. To reinstall Communication Board, perform steps 1 thru 7 in reverse order.
6.4.5 CPU BOARD (802201-1) REMOVAL/INSTALLATION
6—DISASSEMBLY
REASSEMBLY

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 in
the Rear Cover Enclosure. Grasp CPU Board and pull straight outward to disconnect
from the Power Control Interconnect Board (item 9).
7. To reinstall CPU Board, perform steps 1 thru 7 in reverse order.
802701-G May 2009

6-4-7
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 location
in the Rear Cover Enclosure. Grasp Power Board and pull straight outward to dis-
connect 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
6—DISASSEMBLY
REASSEMBLY
4. To remove the Interconnect Board, remove components as defined in the following
sections:
Section 6-4-2
Section 6-4-3
Section 6-4-4
Section 6-4-5
Section 6-4-6
5. Remove four (4) standoffs (item 16) from Rear Control Encloser (item 2).
6. When the Rear Control Encloser (item 2), and Front Control Encloser (item 3) are
separated, the Interconnect Board is free for removal.
NOTE: Take note of the Interconnect Board orientation before removal.
7. To reinstall Interconnect Board, perform steps 1 thru 7 in reverse order.
6.4.8 POWERHEAD MOTOR HARNESS (802212)
802701-G May 2009

6-4-8
5. At the rear of assembly, remove six (6) screws from Backplate Cover (item 4).
6. Gently remove Backplate Cover (item 4) from rear enclosure cover (item 2).
7. On the Driver board (item 7), disconnect Powerhead motor harness (item 11) from
J2 connector.
8. At the Backplate Cover (item 4), remove two (2) retaining screws from connector
(item 11).
6—DISASSEMBLY
9. Feed Head motor harness (item 11) through Backplate Cover (item 4) to remove.
REASSEMBLY
10. To reinstall the Powerhead motor harness, perform steps 1 thru 9 in reverse order.
6.4.9 POWERHEAD COMMUNICATION HARNESS (802213)
7. On the Communication board (item 8), disconnect Communication harness (item
12) from J3 connector.
8. At the Backplate Cover (item 4), remove two (2) retaining screws from connector
(item 12).
9. Feed Head Communication harness (item 12) through Backplate Cover (item 4) to
remove.
10. To reinstall the Communication harness, perform steps 1 thru 9 in reverse order.
6.4.10 CONSOLE COMMUNICATION HARNESS (802214)
802701-G May 2009

6-4-9
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).
6—DISASSEMBLY
9. To reinstall the Communication harness, perform steps 1 thru 8 in reverse order.
REASSEMBLY
6.4.11 POWER SWITCH (802215) REMOVAL/INSTALLATION
7. On the Communication board (item 8), disconnect Power harness (item 14) from J1
connector.
8. Grasp and squeeze Power Switch retaining clips while pushing forward to remove
from Backplate Cover (item 4).
9. Feed Power Switch harness (item 14) through Backplate Cover (item 4) to remove.
10. To reinstall the Power Switch and harness, perform steps 1 thru 9 in reverse order.
802701-G May 2009

6-4-10
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-5-1
6.5 POWER SUPPLY

The DC Power Supply (P/N 802450) is used to power the Optistar LE system.
Internal to the DC Power Supply are several key components. The primary
component is the switching Power Supply. This component can be one of two
brands: International Power, or Condor. The remaining components are the
same regardless of which switching Power Supply brand is present. Replace-
ment components for the Power Supply are list in section 6-5-1.
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009

6-5-2
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
6—DISASSEMBLY
REASSEMBLY
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 3
802701-G May 2009

6-5-3
WHITE
(TO TERMINAL #7)
12
BLACK
26
(TO TERMINAL #4) 18 (4 PLACES)
11
10
SEE NOTE 5 9
19
29
13
SEE NOTE
32 (4 PLACES)
14
16
NOTE
THE POWER SUPPLY, ITEM 6, MAY BE OF
MULTIPLE BRANDS AND APPEARANCE.
18 (8 PLACES)
6—DISASSEMBLY
SEE WIRING LABEL, ITEM 14, FOR AC
INPUT WIRING INSTRUCTION.
REASSEMBLY
15
BROWN (L) TO POWER SUPPLY

31
G/Y (GND) TO GROUND STUD
SEE GROUND
STUD FOR DETAILS 20
BLUE (N) TO POWER SUPPLY
BROWN (L) TO PCB-J7 BOTTOM VIEW 30

1
25 BLUE (N) TO PCB-J7

28
8
G/Y (GND) TO GROUND STUD
21
REAR PANEL WIRING DETAIL

5
18
23
4 REAR PANEL VIEW

7 (2 PLACES)
3
17 (2 PLACES)
2 27 (2 FUSES)
TO POWER SUPPLY GND
TO AC OUTLET GND 22
TO AC INLET GND
8 7 6 5 4 3 2 1
GROUND STUD DETAIL POWER SUPPLY OUTPUT TERMINAL DETAIL
Figure 6-5-1 Power Supply Components
802701-G May 2009

6-5-4
6.5.2 POWER SUPPLY FUSE REPLACEMENT

1. Remove all incoming power to the Power Supply. The fuse drawer, located at the
rear of the Power Supply resides in the AC inlet module (item 3). Two fuses are con-
tained in the fuse drawer.
2. With a small screw driver, push fuse drawer tabs in while gently prying from side to
side until removal is possible.
3. To reinstall fuse drawer, line up fuse drawer key and push in until a snap is heard.
6.5.3 REMOVAL OF POWER SUPPLY UNIT
1. Remove all incoming power to the Power Supply.
2. Disconnect all cabling to the Power Supply.
3. If the Power Supply unit is wall mounted, pull latch forward and lift up to remove
unit from wall mount bracket.
6—DISASSEMBLY
6.5.4 DC POWER SUPPLY REPLACEMENT

REASSEMBLY

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 on the insulator) when making terminal connections.
802701-G May 2009

6-5-5
6.5.5 PC BOARD REPLACEMENT

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 PC
board from backplate.
To reinstall PC board, perform the steps above in reverse order.
6.5.6 POWER ON/OFF SWITCH REPLACEMENT
6—DISASSEMBLY
REASSEMBLY
4. At the PC board, disconnect AC wire connector (item 11) to AC inlet module (item
3).
5. Remove four (4) screws (item 32) retaining Power Supply to frame. Move Power
Supply to the side to expose AC inlet module retainers.
6. Remove the three (3) leads from the AC inlet module (item 3).
7. The AC inlet module is retained to the backplate by four (4) retaining clips (two (2)
on each side). With a small screwdriver, push in on each retaining clip and remove
AC inlet module.
To reinstall AC inlet module, perform the steps above in reverse order.
802701-G May 2009

6-5-6
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 Power
Supply to the side to expose AC outlet retainers.
5. Remove three (3) wires from back of AC outlet (item 4).
6. The AC outlet module is retained to the backplate by two (2) retaining clips (one on
top and one on bottom side). With a small screw driver, push in on each retaining
clip and remove AC outlet module.
To reinstall AC outlet module, perform the steps above in reverse order.
6—DISASSEMBLY
6.5.8 LED ASSEMBLY REPLACEMENT

REASSEMBLY

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 front
cover. Remove front cover.
5. From inside of front cover, grasp LED socket and pull to remove. The LED green lens
is retained in the front cover by the socket. Be careful not to loose green lens when
removing socket.
6. To remove LED from socket, gently grab LED with a pair of needle nose pliers and
pull from socket.
To reinstall LED socket, perform the steps above in reverse order.
802701-G May 2009

6-6-1
6.6 REMOTE STAND

The Remote Stand consist of a stationary post, base and hanger.
6.6.1 REMOTE STAND REPLACEMENT COMPONENTS
802872 KIT, REMOTE STAND HARDWARE
802850 REMOTE STAND ASSEMBLY
Cable Hanger Stationary Post
6—DISASSEMBLY
REASSEMBLY
Wheelbase
Figure 6-6-1 Remote Stand Assembly
802701-G May 2009

6-6-2
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-7-1
6.7 FILTER
The Filter is replaced as an assembly.
6.7.1 FILTER ASSEMBLY
802600 FILTER ASSEMBLY
31.75mm
12.7mm 6.604mm (.260") (5 Places)
(1.25") 31.75mm Diameter
(.5")
(1.25")
76.2mm
(3")
(FRONT VIEW)
101.6mm
(4")
6—DISASSEMBLY
REASSEMBLY
270.0mm (10.63")
285.75mm (11.25")
76.2mm
(3.0") (SIDE VIEW)
457.2mm (18.0")
Figure 6-7-1 Filter Assembly
802701-G May 2009

6-7-2
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-8-1
6.8 CABLES
Replacement cables for the Optistar LE are illustrated in Figures 6-8-1 and 6-8-2.
For Powerhead and data cable pinout information refer to Chapter 6.11.1.
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009

6-8-2
CONTROL
ROOM
Handbutton
Connection J2
(P/N 802620 (2 m (6 ft)
(P/N 802622 (6 m (20 ft)
Console Console
Communication (P/N 802100)
and Power (Rear View)
Connection J1
* Data Cable and Power

(P/N 801224-07 (2 m (7 ft)
(P/N 801224-15 (4 m (15 ft)
(P/N 801224-25 (8 m (25 ft)
(P/N 801224-50 (15 m (50 ft)
(P/N 801224-75 (23 m (75 ft)
(P/N 801224-100 (30 m (100 ft) O I J2 J1 Power Supply
(P/N 801224-150 (46 m (150 ft) (P/N 802450)
(Rear View)
EQUIPMENT
ROOM
6—DISASSEMBLY
Fuse
REASSEMBLY
Holder
Socket 4 Amp Slow Blow
cable end P/N 172E0253
Power In
Filter (Qty 2)
115/230VAC ±10%
(P/N 802600)
MAGNET ROOM * NOTE: Do Not Exceed

Cable Length, (From Power Supply to Power Control) * Comm. Cable and Power
is 46 m (150 ft) (P/N 801224-07 (2 m (7 ft)
(P/N 801224-15 (4 m (15 ft)
Free Hanging (P/N 801224-25 (8 m (25 ft)
(P/N 801224-50 (15 m (50 ft)
D-Shell Connector
(P/N 801224-75 (23 m (75 ft)
Powerhead (P/N 801224-100 (30 m (100 ft)
(P/N 802300) (P/N 801224-150 (46 m (150 ft)
A
10/15/20 30 60
ml
ml
ml
B 60 50 ml
125 ml ml
J1, J2
Remote Stand
(P/N 802850)
Power Control
(P/N 802200) Note: Ensure
(Rear View) connector
orientation is
Powerhead Cable correct when
(P/N 802303) making
10 m (32.8 ft) connection
Figure 6-8-1 Cabling
802701-G May 2009

6-8-3
Handbutton
Connection J2
Console (P/N 802620 (2 m (6 ft)
(P/N 802100) (P/N 802622 (6 m (20 ft)
(Rear View)
Console
Communication
and Power
Connection J1
O I J2 J1
Power Supply
(P/N 802450)
(Rear View)
Fuse
Holder
CONTROL 4 Amp Slow Blow
P/N 172E0253
ROOM (Qty 2)
Power In
115/230VAC ±10%
* Comm. Cable and Power

(P/N 801224-07 (2 m (7 ft)
(P/N 801224-15 (4 m (15 ft)
(P/N 801224-25 (8 m (25 ft)
(P/N 801224-50 (15 m (50 ft)
(P/N 801224-75 (23 m (75 ft) Ground Cable
(P/N 801224-100 (30 m (100 ft)
6—DISASSEMBLY
(Keep short as possible)
(P/N 801224-150 (46 m (150 ft) (P/N 801259-1 (.5 m (1.5 ft)
REASSEMBLY
Socket (P/N 801259-3 (.9 m (3 ft)
EQUIPMENT (P/N 801259-7 (2 m (7 ft)
Filter cable end
ROOM (P/N 801259-15 (5 m (15 ft)
(P/N 802600)
Ground Strip
Data Cable Penetration Panel
(P/N 801224-03 (.9 m (3 ft) (Using available 25-pin pass through)
or
(P/N 801224-07 (2 m (7 ft)
* NOTE: Not To Exceed

MAGNET ROOM Cable Length, (From Power Supply to Power Control)
is 46 m (150 ft)
* Data Cable and Power
(P/N 801224-07 (2 m (7 ft)
(P/N 801224-15 (4 m (15 ft)
(P/N 801224-25 (8 m (25 ft)
(P/N 801224-50 (15 m (50 ft)
(P/N 801224-75 (23 m (75 ft)
Powerhead (P/N 801224-100 (30 m (100 ft)
(P/N 802300) (P/N 801224-150 (46 m (150 ft)
A
10/15/20 30 60
ml
ml
ml
B 60 50 ml
125 ml ml
J1, J2
Remote Stand
(P/N 802850)
Power Control
(P/N 802200) Note: Ensure
(Rear View) connector
orientation is
Powerhead Cable correct when
(P/N 802303) making
10 m (32.8 ft) connection
Figure 6-8-2 Cabling
802701-G May 2009

6-8-4
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-9-1
6.9 SERVICE KIT PARTS

Optistar LE service kit parts are defined in the following sections:
Refer to section 6.3 to view a find number illustration.
Section 6.9.1 Load Cell Service Kit (P/N 802741S)
Section 6.9.2 Bushing Replacement Service Kit (P/N 802742)
Section 6.9.3 Motor Replacement Service Kit (P/N 802743)
Section 6.9.4 Fastener Service Kit (P/N 802744)
Section 6.9.5 Bearing Replacement Kit (P/N 802746)
Section 6.9.6 Cover Kit (P/N 802747)
Section 6.9.7 Syringe Holder Service Kit (P/N 802748)
6—KIT PARTS
802701-G May 2009

6-9-2
6.9.1 LOAD CELL SERVICE KIT (P/N 802741S)

Find No. Part Description Quantity
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
6—KIT PARTS
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
802701-G May 2009

6-9-3
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
6—KIT PARTS
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
802701-G May 2009

6-9-4
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)

6—KIT PARTS

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
802701-G May 2009

6-9-5
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
6—KIT PARTS
47 PCB ASSEMBLY, SYRINGE SIZE SENSING 4
802701-G May 2009

6-9-6

6—KIT PARTS
802701-G May 2009

6-10-1
6.10 GENDER CONNECTORS

If an Optistar LE is to replace an Optistar MR; gender connectors can be used to
adapt existing cable connectors to the Optistar LE.
Gender Connectors:
25 pin to pin connector for power supply (P/N 240E3404).
25 pin socket to socket for Console (P/N 240E3405).
25 pin/socket feed through adapter for pin panel applications (P/N 240E3406).
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009

6-10-2
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

6-11-1
6.11 ACCESSORY ITEMS

The following accessories may be ordered from Liebel-Flarsheim to adapt to
the Optistar LE injector
Hand Button Start Switch Assembly:
Cable length 1.8m (6.0 feet) P/N 802620.
Cable length 6m (19.68 feet) P/N 802622.
Syringe Adapter 10/15/20mL
P/N 802730.
6—DISASSEMBLY
REASSEMBLY
802701-G May 2009

6-11-2
6—DISASSEMBLY

REASSEMBLY
802701-G May 2009

7-1-1
7 THEORY OF
OPERATION
This chapter describes design and function of the OptiVantage injector. Block
diagrams for the system are included for each assembly described. This chapter
is divided into the following sections:
Note: For additional information refer to Chapter 10 Schematics.
Section 7-2 System Block Diagram
Section 7-3 Power Supply
Section 7-4 Powerhead
Section 7-5 Console
7—THEORY OF
OPERATION
802701-G May 2009

7-1-2

7—THEORY OF
OPERATION
802701-G May 2009

7-2-1
LINE V
SYSTEM OVERVIEW 25 PIN D-SHELL
J1/J2
J1 SUPPLY BOX
CONSOLE
802100 802450
422
SUPPLY
POWER HEAD 802300
+27 V
"A" "B" ON/OFF
SYRINGE SIZE SYRINGE SIZE CLOSURE
SENSE BOARDS SENSE BOARDS
END LIMIT +27 V
BOARDS SWITCHED
J1/J2
25 PIN
A B D-SHELL
422 +27 V
SWITCHED
J10 J3 J4 J11
LIMIT SWITCHES FILTER
7—THEORY OF
SYRINGE SWITCHES
KEYPAD
OPERATION
HEAD MAIN BOARD KEYPAD
802301 J7, J8, J9 HEAD I/O
XDUCER
SWITCHES XDUCER EXITATION
ENCODERS
J12 LIGHT CONTROL 25 PIN
J6 D-SHELL
SIZE LEDS
J5
J1 J2
J3
XDUCER XDUCER D
J1 R C
ENC ENC A B
A B HEAD I O
CABLE V
E M
HOUSING
MOT MOT R
INTERCONNECT
JA, JA1 JB, JB1
S
U C
P P
J2 P U
B MOTOR DRIVE TO L
DRIVER Y
A MOTOR DRIVE
POWER CONTROL 802200
Figure 7-2-1 System Overview Block Diagram

802701-G May 2009
7-2-2

7—THEORY OF
OPERATION
802701-G May 2009

7-3-1
7.3 POWER SUPPLY

The Power Supply assembly houses a +27VDC nominal power supply, and in-
terface board. The interface board provides the following functions:
• Added AC line filter for the power supply
• Switching of the +27VDC to the system
• Communication pass through from the console to the power control
Refer to the Power Supply block diagram Figure 7-3-1.
Connectors J1 and J2 are wired identically and can be used for either the Con-
sole or the Power Control.
When the green LED on the Power Supply front panel is on, the +27VDC is
present inside the power supply assembly. The +27VDC is applied to J1 and J2
through U4, a solid state relay switched by a momentary closure from the Con-
sole ON/OFF switch.
7—POWER SUPPLY
802701-G May 2009

7-3-2
802450 SUPPLY BOX
POWER
SWITCH
LINE VOLTAGE
FILTER
CONNECTOR BD
802451-1
J1
422
27VDC
ON/OFF SUPPLY
+27 VDC
7—POWER SUPPLY
J2
ON/OFF
+27 VDC
SSR
422
802450 POWER SUPPLY ASSY., LE

BLOCK DIAGRAM
Figure 7-3-1 Power Supply Block Diagram
802701-G May 2009

7-4-1
7.4 POWER CONTROL

The Power Control consists of five main electrical assemblies:
1. Interconnect Assembly (P/N 802207-1)
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 other boards slide into the Power Control and mate with the interconnect
assembly. The interconnect assembly consists of two backplane boards con-
nected to each other by feed through capacitor filters. The assembly divides the
Power Control into the CPU/Power (front) section, and Driver/Communication
(back) section. The CPU/Power backplane board is (P/N 802205-1). The Driver/
Communication backplane board part number is 802206-1. All connections
7—POWER CONTROL
between the Power Control boards 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 sig-
nals EXCEPT the motor drive.
The Head Motors Harness (P/N 802212) carries the motor drive signals.
For additional information refer to Chapter 10 Schematics.
802701-G May 2009

7-4-2

7—POWER CONTROL
802701-G May 2009

7-4-11
7.4.4 CPU BOARD

The CPU board controls and monitors all system functions. The main micropro-
cessor, U13, is the Motorola MC 68332. System reset is handled by U19, which
holds the system in reset until Vcc is up. U9 is the 512K flash memory device
where the main program is stored. U2 and U5 make up the 16K of non-volatile
RAM, where calibration data, achieved value data, and other information is
stored. U3 and U8 are 128K SRAM.
The I/O mapping is handled by U16, an Altera FPGA. The CPU also uses U16 to
read the power head user buttons, syringe size switches, and the ram end limit
switches. All of these signals are isolated by optocouplers U34, U35, U36, and
U37. U30, also an Altera FPGA, is used to generate the motor drive signals and
monitor the motor speed and position. Additionally, the CPU monitors speed,
position and pressure through U1, a Universal Pulse Processor (UPP).
The pressure transducers, used to sense actual syringe pressure, are mounted
at the end of the power head rams. The transducers are supplied 2 VDC excita-
tion from the
D9 - U29:A - Q1 circuit on the CPU board. The excitation supply is a constant
7—POWER CONTROL
current type, so the 2V output is dependent upon both transducers being con-
nected. The millivolt level signal from the transducers is amplified to an approx-
imately 3.5 V max signal that is monitored by the CPU through the UPP.
802701-G May 2009

7-4-12

7—POWER CONTROL
802701-G May 2009

7-4-13
CPU MEMORY JTAG UPP & PLD

sh 1 sh 2 sh 3
J 10 U16 P-CONTROL
2
16 U9 8 J Test
32.8 KHz DATA
XTAL I/O 5 Points
FLASH
MEM DECODE
(16.777 MHz clk cyc)
10 *CSBOOT 256Kx16 ADR0-5 7 CAL *WT
U13 J PGM/DeBug TEST
CPU m/w P&E (29F400T) ADR11-15
Power ON MOT 68332 4 CTRL
BDM i/f Cable (EPM7128)
Detector 16 bit ext D Bus SZSW
32 bit Adr & int D Bus 16
mode 4 DATA 7
16 U3, U8 LCD
5 32
ADR SIM *CS3 *i/o-wrt *IRQ1
CPU 8 SRAM
TPU *CS8,9,10
STATUS 128Kx16 9.8304MHz
11
DS2- *CS0-CS10 (HM628128) Motor Clk
DS5 8 *IRQ1-IRQ7 16 MHz
XTAL
2
*DSACK 16 U2, U5 (4MHz clk cycle)
U1 *IRQ3
NVRAM
*CS5,6,7 8Kx16 8
7—POWER CONTROL
P7 UPP *IRQ5
STK12C68 UNIVERSAL
DATA 8 PULSE
PROC.
ADR 0-10 (HD3140-A)
+12V I/F & WAKEUP PLL 7 PR FLT
CALIB. I/F sh 6 sh 4 *sv-cs A/D 1 2
sh 5 Encoder A/B Ckls
input 1
Hi Spd
SW BOX I/F -5v 2
J 26 +5v -5v
IN/OUT BUF'S xvtr 4
6
CONTROL 4
JTAG
SPEAKER (to head) Pressure Input A J 10 U30 *IRQ2
CALIB (Motor) 26V&1
J 20 Sample & Hold 1
TEST &
7 (BB INA118)
DISPLAY CONSOLE (RS 422 drv) +5, +5VB, +12
8 (TO I/F, sh. 5) (fm PWR)
DATA MOTOR P
P1 CONTROL 4 2
Pressure Input B ADR 0-3
Sample & Hold P/M 32- (to DRVR)
Interface +12v 64- (BB INA118) (EPM9400) SIN/ P
Buffer P Lim SW 4 COS I
Circuitry 3
I O.C. N (to DRVR)
5 sel A/B
13 N Phase-Locked
& SPD
INTEGRATOR/ Loop (HC4046)
F - IN
OPTO FILTER 1.88 MhZ - 1.6 MhZ F - OUT (to PWR)
I/F (40-45 Hz Running) Main-
BUF'S Main- Cntrl
ACTIVITY Cntrl
7 LCD DETECT
8 (pwr on ena) 11.4 mA CONSTANT 802201-1
DATA CURRENT SOURCE +5v CPU BOARD
6 EX & CLK TO PRESSURE BRIDGE
BLOCK DIAGRAM
13 SZSW
Figure 7-4-5 CPU Block Diagram

802701-G May 2009
7-4-14

7—POWER CONTROL
802701-G May 2009

7-4-3
Calibration Download
Switch Box Connector
Connector
802215
Switch/Cable
Assembly
P J J
2 2 J P 1
J 3 3
6
CPU Mode J
Switches J 802214 Console
4 2 Communication
802204-1 J3
Harness
802201-1 8
S1 P J Communication Assembly
CPU Board 1 1
0 J P Board
J 8 2 2 2
J
7
J 0 2 3
Calibration
Display 2
2 0 802213 Head
Connector Communication
2 6 Harness
7—POWER CONTROL
Assembly
0
5
J P
P J 1 1
3 J1
3
802202-1 802203-1
Power Board Driver Board Head
Connector
P J
4 4
J2 J2
802212 Head
802207 Assembly Motors Harness
Assembly
802200 POWER CONTROL

BLOCK DIAGRAM
Figure 7-4-1 Power Control Block Diagram

802701-G May 2009
7-4-4

7—POWER CONTROL
802701-G May 2009

7-4-5
7.4.1 POWER BOARD

The Power Board converts the nominal +27VDC from the Power Supply Assem-
bly to the following voltages used by the system:
• +12VDC - Mostly for LED’s, interface and opto drive
• +5VDC - Logic power
• +22 to +24VDC - Motor raw supply
In addition, the Power Board provides voltage and current sense that can be
monitored by the Main CPU. The motor raw supply can be turned on or off by
the CPU, or switched from approximately +22VDC to +24VDC, depending on
motor requirements.
7—POWER CONTROL
802701-G May 2009

7-4-6
802202-1 POWER BOARD
FUSED 27VDC
SENSE V SENSE
5A
P3 +27 V U1
FUSE A SENSE
P4
+27 V
+12 V
+12VDC
U2
+5 VDC
7—POWER CONTROL
U3 +5 VDC
+22 -24 VDC

DC/DC
P3 MOT V
P4 DC/DC on
22 -24 VDC
PS1
P3 V CHANGE
802202-1POWER BOARD
BLOCK DIAGRAM
Figure 7-4-2 Power Board Block Diagram
802701-G May 2009

7-4-7
7.4.2 COMMUNICATION BOARD

The Communication Board provides the following functions:
• Carries all non-motor signals between the Power Control and the Power Head
cable
• Carries the noninal +27VDC from the Power Supply to the on/off switch, then
to the interconnect assembly.
• Converts the transmit and reveive signals from the CPU into RS-422 to the
console
Refer to the Communication Board block diagram Figure 7-4-3.
7—POWER CONTROL
802701-G May 2009

7-4-8
802204-1 COMMUNICATION BOARD

J3
HEAD I/O HEAD I/O P3
+27 VDC J2
FROM
SUPPLY BOX
ON/OFF
SWITCH
+27 VDC
P2
SWITCHED
J1
U2
TX+
TX
F
TX- I
COMMUNICATION L
TO/FROM T MAX 488 P3
7—POWER CONTROL
CONSOLE RX+ E
R RX
RX- S
J2
802204-1 COMMUNICATION BOARD

BLOCK DIAGRAM
Figure 7-4-3 Communication Board Block Diagram
802701-G May 2009

7-4-9
7.4.3 DRIVER BOARD

The Driver Board converts the 5v pulses generated by the CPU board into the
200VAC, 45 kHz motor drive signals. The motor drive signals consist of two sinu-
soidal waveforms (sin and cos), 90 degrees out of phase from each other, and a
return for each motor “layer”. Each motor consists of two separate “layers”, each
layer requiring the sin, and cos and return.
The same circuits are used to drive either the A or B motor.
In order to select the A motor, the CPU will pull P1:18 low, turning on U9, U10,
U11, and U12. this will connect the driver circuits to the A motor.
When selecting the B motor, the CPU pulls P1:17 low, turning on U13, U14, U15,
and U16. This connects the driver circuits to the B motor.
The CPU can also pull P1:19 low to short out the second inductor in each of the
driver circuits. This is done to retune the circuit to work at lower flow rates
7—POWER CONTROL
802701-G May 2009

7-4-10
802203-1 DRIVER BOARD
A SELECT
J1
+ 22 - 24 VDC TO A
MOTOR
DRIVE
DRIVE CIRCUIT
7—POWER CONTROL
COIL SWITCH TO B
MOTOR
B SELECT
P1
802203-1 DRIVER BOARD

BLOCK DIAGRAM
Figure 7-4-4 Driver Board Block Diagram
802701-G May 2009

7-5-1
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
only exception being the motor drive voltage, which connects directly to the
motors from the Powerhead cable.
7—POWERHEAD
Control of the A and B ram LED’s, and enabling of the syringe size LED’s is by
serial data shifted from the CPU using H_data and H_clock lines. Data is clocked
into U4 on the Powerhead board, than latched on U5.
Syringe size switch signals go directly to the CPU to sense what syringe is in-
stalled, and to U10 to light the apropriate Syringe Size LED on the keypad.
The keypad interface (U6, U7, U8, U16, U17) encodes 7 of the keypad switches
(all except the A and B speedup switches) into a three line binary code to the
CPU. A keypad fault (unconnected keypad) will cause an invalid code to the
CPU, triggering an error message.
The Powerhead contains optical encoders to control and monitor the position
and speed of the motors. The encoders are supplied with +5VDC, and U1, U2,
and U21 buffer encoder signals before going to the CPU board.
The end limit sensing boards are supplied +12VDC, and the limit signals pass
directly to the CPU.
The pressure transducer excitation voltage passes through from the CPU, the
tranducer outputs pass through to the CPU.
802701-G May 2009

7-5-2
7.5.2. END LIMIT SENSING BOARD

Refer to Chapter 10 schematic 802302.
There are two End Limit Sensing boards in the Powerhead, one for each ram.
The board has an optical interrupter at each end, and is actuated by a flag on
the ram. The sensor at the zero position (ram fully extended) is set exactly to
the ram position corresponding to an empty syringe, while the back sensor is
used to prevent ovrrun in the reverse direction.
7.5.3 SYRINGE SIZE BOARD
Refer to Chapter 11 schematic 802307.
There are four Syringe Size boards in the Powerhead. Each ram has two switch
board assemblies, one actuated by the syringe barrel and one activated by the
syringe flange. Different combinations of the syringe barrel and flange switches
are decoded by the CPU to determine what syringe is installed. The table below
shows the decoding for each syringe size.
A Side B Side
Switch Inputs
7—POWERHEAD
SIZE 0-A SIZE 1-A SIZE 0-B

(BARREL) (FLANGE) SYRINGE (BARREL) SYRINGE
OPEN OPEN N/A OPEN OPEN Mallinckrodt 125
OPEN CLOSED Mallinckrodt 10/15/20 OPEN CLOSED N/A
CLOSED OPEN Kendal 60 CLOSED OPEN Kendal 60
CLOSED CLOSED Mallinckrodt 30 CLOSED CLOSED Mallinckrodt 50
CLOSED = LOW
802701-G May 2009

KEYPAD
802301-1 HEAD BOARD
J12
SWITCHES J7
SPEEDUP A
TO POWER CONTROL
SPEEDUP B
SWITCHES SWITCHES - 7 LINES J8

ENCODE TO POWER CONTROL
KEYPAD FAULT
SYRINGE
SIZE
LEDS SIZE
LED
ENABLE
DECODE DECODE
A B
J10
FLANGE A J7
TO POWER CONTROL
FROM BARREL A
SYRINGE
SIZE
SENSE J11
SWITCHES FLANGE B J8
802307-1 TO POWER CONTROL
BARREL B
SIZE
SHIFT/ LED
J8 LATCH ENABLE
FROM CLOCK
POWER A
CONTROL RAM
DATA LEDS
B
DRIVERS
J7
J1 A TO POWER CONTROL
A
M
ENC
INDEX J8
A/B
TO POWER CONTROL
J2
B B
M
ENC
J9
2V EXITATION
A
TRANSDUCER
J5
TO POWER CONTROL
B
TRANSDUCER
J6
J3 J7
A LIMITS TO POWER CONTROL
802302-1
J4
B LIMITS J8
TO POWER CONTROL
802302-1
Figure 7-5-1 Powerhead Block Diagram
BLOCK DIAGRAM
802301-1 HEAD BOARD
802701-G May 2009
7—POWERHEAD
7-5-3
7-5-4

7—POWERHEAD
802701-G May 2009

7-6-1
7.6 CONSOLE OVERVIEW

The console provides the user interface through the color LCD and the touch
screen. Also, the console provides the system ON/OFF switch that is operable
only with the power pack circuit breaker in the ON position.
Refer to the Console block diagram Figure 7-6-1.
7.6.1 CONSOLE CPU
The Console CPU performs the following functions.
• Serial communications to the power control
• Stores all screen information
• Processes touch screen inputs
• Provides console PIC processor for system redundant processor
state machine
• Manages screen generation
• Provides BDM port for console software downloading
7—CONSOLE
802701-G May 2009

7-6-2
7.6.2 CIRCUIT DESCRIPTIONS

Interface Connection
The interface connector provides the means for the console to obtain power
from the supply as well as provide the path for the console to communicate
with the system.
RS422 Drivers and Receivers
The communication channel to and from the powerpack is accomplished using
RS422 drivers and receivers (MC3487 and MC3486 or equiv). The communica-
tions channel operates at a BAUD rate of 38400 bps with 1 start and 1 stop bit.
A communication packet is started by a start of command hardware signal
(RTS) and completed by this signal being de-asserted. For every command
packet, there must be an acknowledgment of validity.
Touch Screen Control
The quiescent state assumes the screen is not touched. Signal X+ is driven high
and X-, Y+ and Y- are high impedance. During this time the line SY- is monitored
by a comparator. If the screen is touched the comparator’s output will generate
an interrupt to the PIC (Peripheral Interface Control). Upon receipt of the inter-
7—CONSOLE
rupt, the X- line is driven low thus creating a voltage gradient across the X-axis.
The X coordinate is defined by the value digitized on the SY- channel corrected
by the difference between 5 volts and the value found on the SX+ channel.
Then X lines are allowed to float and Y+ is driven high and Y- is driven low. The
Y coordinate is then defined as the digitized value for the SX- channel corrected
by the difference between 5 volts and the value found on the SY+ channel.
The BYTEME signal is asserted and the X and Y coordinates are placed the SPI
transmit buffer.
RAM
The console PCB has a total of 4M bytes of memory organized as 1M x 32. The
RAM is the heart of the console control variables and data storage. All data
within these devices are lost when system power is removed.
802701-G May 2009

7-6-3
FLASH
The console contains 4M of FLASH memory which consists of 2-2MB chips. Each
FLASH device is divided up into 32-64KB sectors which are loaded with various
sections of the console software. The console software is divided as follows:
These devices contain the product software and the RTOS, all of the bit
mapped images used on the display screens, the basic set of languages used
and the fonts sets for all displayed text. Also, these devices contain the object
records which are used to build the screens. Objects are the devices which
combine images, text, and functionality. The screen records are simply the list
of objects and locations.
CPU
The console uses an MCF5307 as its main microprocessor. In addition to the
normal uses of a microprocessor, data flow to and from memory and peripheral
devices, the CPU communicates directly with the SED1355 graphic’s LCD panel
controller. The SED1355 gathers the information from the CPU to build the vari-
ous screen images. Once the data is organized the SED1355 will generate the
necessary control signals for the LCD display and display the image. The image
will be maintained by the SED1355 until the CPU provides a new or updates the
7—CONSOLE
current set of images.
802701-G May 2009

7—CONSOLE 7-6-4
Diag LEDS DS8 - DS 11
System
PIC ICSP J1
Interface
16F873
J5 U3 Touch J2
802701-G May 2009

802102-1 clock RTC
And SNAP
A0-A14 INV LCD Color
CAN Batt On Balt.
back J7 J8
U4 & U21 12C PS1
SRAM
D24 - D31
buss req. U16
On/Off 16Mhz
Y1
ADDR:A0 - A21
Display Aux
CPU CONTROL Controller RGB
Panel J6 SED1355 FOA output
MC5307e
U7 J3
DATA:D0 - D15
Isolator
U22
U8
PROG
:A0 - A21 & DATA
RS422/232 clk
MEM
2 MByte
Display Mem
GP I/O DATA:D0-D15 Flash
1Mx16 DRAM
U19
U6
GND +24V (4 Mbyte total)
Aux Spkr J9
PROG
:A0-A21
D1 & DATA
SPK MEM
SPK
Drvr. 2 Mbyte
U13 +5 DATA:D15 - D31
Switch & Jumper U20
U11 +12 Inputs (Config.

Options) SYS.
RAM
S1:A,B,C,D DATA:D0 - D31
U12 +3.3 4 Mbyte total
DRAM
Reset SW3 (2 chips)
DBUG J4 U17
ADDR - A0 - A21 (2X)
+3.3 +5 U18
Diag. LEDs
40 Mhz DS4-DS7
PUP Y2
Reset clk
U14
8-1-1
8 CALIBRATION
8.1 OVERVIEW
To perform these calibrations, the Powerhead and Power Control Covers must
be disassembled. For details, see Chapter 6.
WARNING!
Always remove Power Control and Power Head assembly from magnet
room
before disassembly and calibrating. Failure to follow this warning could
result in personnel injury or equipment damage.
8.1.1 TOOLS AND EQUIPMENT NEEDED:
The following items are part of the Optistar Service Kit (Reference Section 5.1.1)
Test Display (P/N 801202)
20 Conductor Ribbon Cable (P/N 801212)
8—CALIBRATION
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, and 125mL Syringes
10/15/20mL Adapter
Tap Water
802701-G May 2009

8-1-2
8.1.2 FREQUENCY OF CALIBRATION

The Optistar LE should be calibrated at least every 2 years or whenever a part
or component that is used for pressure limiting or Ram location has been re-
placed.
The following is a list of the various calibration procedures contained in this
chapter:
• Limit Switch Calibration. Forward and Reverse, Rams A & B (section 8.2).
• Pressure Adjustments (section 8.3)
Side A
60mL
30mL
10/15/20mL
Side B
60mL
50mL
125mL
• Additional Checks (section 8.5) Factory Adjusted
• Syringe Size Factor Check. section 8.4.1
8—CALIBRATION
802701-G May 2009

8-1-3
8.1.3 CALIBRATION SET-UP

Turn off power to the power supply and power control units.
1. Disconnect the 25 pin data/power cable from the Filter to the Power Control. Re-
move Powerhead and Power Control assemblies from the magnet room.
2. At the Power Supply, disconnect the data/power cable (J2) to the Filter. You will be
connecting a 25 pin jumper cable to supply data/power to the Power Control.
3. Remove the Power Control front cover to expose the edge of the CPU board.
4. Connect the Test Display and Test Switch Assembly, (via ribbon cables), to the CPU
board of the Power Control. (Test Display to J7, Test switch Assembly to J6).
5. Attach 25 pin to 25 pin jumper data/power cable from the Power Supply (J2) to the
Power Control (J3) connections.
Test Display
SYRINGE
F11ML
REST VOL. ML
F12 LIMIT
F10 F9 PRESSURE
250 200 100 50 40 30 20 10 P.S.I.
MODE F1
F13 F15
F16 F6 F14
F2 F3
FLOW RATE ML SEC VOLUME ML
F17 F7
F4 F5 F8
8—CALIBRATION
TIME
Up
Mode Test Switch
n
Ente
r Assembly
Dow
CPU J7
Board
CPU
SW 1
Note: ON position
is toward edge off
board J6
Figure 8-1-1 Test Unit Connections
802701-G May 2009

8-1-4
8.1.4 INITIALIZATION OF THE POWER CONTROL CPU RAM:

Initializing the CPU RAM will replace any stored calibration values with default
values. This procedure should be performed in the event of any major compo-
nent or board change.
1. Install the Test Display as described in the Calibration Set-UP section 8.1.3.
2. In the Power Control, Locate SW1 on the CPU board. Set all four dip switches to the
Closed, ON, position. (This would be toward the edge of the board)
3. Power UP the System in the sequence listed below:
1st Power Control
2nd Power Supply
3rd Console front panel “On/Off” button.
The system should power UP normally and all of the test display’s segments
should be on.
4. When initialization is complete, power DOWN the unit and reset SW1.
Note : After reinitializing the CPU RAM, the calibration procedure must be
performed.
Note : Initializing the CPU RAM will erase all pressure limit calibrations. They
will be replaced with default values. These default values should not be used
8—CALIBRATION
without performing the calibration procedure.
802701-G May 2009

8-1-5
8.1.5 ENTERING THE CALIBRATION MODE :

To enter Calibration Mode, proceed as follows:
1. Perform the calibration set-UP (refer to 8.1.2).
2. With system off, locate SW1 on the Power Control CPU board. Set dip 3 to ON and
ensure that 1, 2, and 4 are OFF.
3. Power UP the System in the following sequence:
1st Power Control
2nd Power Supply
3rd Console front panel “On/Off” button.
4. The system should power UP normally with the test display in Mode 0.
Note: Mode 0 is active when there is no number next to “Mode”.
8.1.6 TEST DISPLAY AND TEST SWITCH DESCRIPTIONS:
The Test Display and Test Switch Assembly are used in the calibration process.
Both items are illustrated below.
Test Switch Assembly Test Display
8—CALIBRATION
Mode SYRINGE
F11ML
Up F1 REST VOL. ML
F12 LIMIT
r
F10 F9 PRESSURE
Ente 250 200 100 50 40 30 20 10 P.S.I.
n
Dow
MODE F1
F13 F15
F16 F6 F14
F2 F3
FLOW RATE ML SEC VOLUME ML
F17 F7
F4 F5 F8
TIME
Figure 8-1-2 Test Components
802701-G May 2009

8-1-6
8.1.7 TEST SWITCH ASSEMBLY OVERVIEW

Test Switch Assembly functions are as follows:
‘UP’ key: Used to increase an adjustable value in a mode.
‘DOWN’ key: Used to decrease an adjustable value in a mode.
‘Enter’ key: Used to Update an adjusted value into memory.
‘Mode’ key: Used to cycle through the 8 different modes on the Test Display.
8.1.8 TEST DISPLAY OVERVIEW
For calibration, the Test Display has 8 different selectable modes. Each mode
selected will present its own unique values and fields.
Test Display mode selections are as follows:
• Mode 0 = Optic limit switch adjustment
• Mode 1 = Pressure adjustment
• Mode 2 = Not used
8—CALIBRATION
• Mode 6 = Power Factor test (Factory Adjusted)

• Mode 7 = See section 10.2.1
802701-G May 2009

8-1-7
8.1.9 MODE DESCRIPTIONS

Field descriptions and functions for each mode are as follows:
Note: In the descriptions which follow, the letter ‘F’ proceeds each definition.
This letter is merely a visual cross reference that relates to illustration Figure
8.1.2. For example, field 1 means location F1, on Figure 8.1.2 and so on.
MODE 0: F1, this field is blank when Mode 0 is selected.
F2 Displays ‘AH’ when Ram A is active. When ‘bH’ is displayed Ram B is active.
F3 ‘FoF’ = Front limit off; not blocked. ‘Fon’ = Front limit on; blocked.
F5 ‘boF’ = Back limit off; not blocked. ‘bon’ = Back limit on; blocked.
F7 Hexadecimal number representing position of the Ram.
F9 The Volume remaining. A decimal point needs to be understood one place
over to the left.
MODE 1: F1) Displays ‘1’
F2 displays ‘AH’ when Ram A is active. When ‘BH’ is displayed, Ram B is active.
F3 Indicates the actual pressure only after calibration during an injection.
8—CALIBRATION
F5 Displays the pressure limit selected on the console from the last completed
injection.
F6 Pressure calibration value for the active Ram and syringe.
F7 New pressure calibration value adjusted by using the UP and DOWN keys on
the Test Switch Assembly. When the ‘ENTER’ key is pressed, (on the Test Switch
assembly) this adjusted value will be copied to field F6 and thus into memory.
F8 Displays a hexadecimal number during the injection. This hex number
equals half of the actual pressure displayed in field F3 when converted to deci-
mal.
802701-G May 2009

8-1-8
MODE 6: F1) Displays ‘6’

F2 Displays ‘AH’ when Ram A is active. When ‘bH’ is displayed Ram B is active.
F3 Displays ‘Fr’ which stands for ‘flow rate’.
F5 This field indicates the flowrate of the active Ram. A decimal point is to be
understood two places over from the right. For example, ‘400’ would be 4.00
mL/s.
For pushbutton operation: ‘0’ = no Ram movement, ‘100’ = slow speed Ram
movement, ‘500’ = fast speed Ram movement.
Note:
A side forward and reverse 0, 100, 500
B side forward 0, 100, 500
Reverse 0, 100, 999 (with no syringe)
Reverse 0, 100, 500 (with syringe)
F6 Power factor number, (Not normally adjusted).
Ram A Ram B
60mL 493 60mL 493
30mL 470 50mL 588
10/15/20mL 257 125mL 1012
8—CALIBRATION
F7 New Power Factor value is adjusted by using the UP and DOWN keys on the
Test Switch. When the ‘ENTER’ key is pressed (on the Test Switch) this adjusted
value will be copied to field F6 and thus into memory.
F11
Ram A Ram B
60mL 9 60mL 6
30mL 7 50mL 8
10/15/20mL 5 125mL 10
802701-G May 2009

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

8.2.1 SETUP
1. Make sure both powerhead Rams are fully retracted & no adapters are installed.
2. Enter the Calibration Mode.
3. On the switch assembly, press the mode button repeatedly until mode 0 is selected
on the test display.
Note: Refer to 8.1.9 Mode Descriptions for Mode 0 field information.
4. Install a 60mL syringe on the ‘A’ Ram.
Note: the last fill/expel button pressed, Ram A or Ram B side, will determine
which Ram information; Ram A (AH) or B (bH) appears on the test display. Also,
note that when pressing a fill/expel button to toggle the display to the desired
Ram, the Ram has to physically move to toggle the display to that Ram. Sub-
sequently, the last Ram that physically moves becomes the active Ram on the
display.
Note: the volume indicated on the test display is missing a decimal point, it
must be moved over one position to the left. For example: 62 = 6.2 mL
Note: the console display volume will round to the nearest whole number dis-
8—CALIBRATION
played on the test display volume.
802701-G May 2009

8-2-2
8.2.2 FOREWORD LIMIT SWITCH CHECK & ADJUSTMENT (A)

1. Expel the syringe until the front wiper of the piston just barely touches the zero line
of the syringe. Reference the following figure:
0 ml Front Wiper
Figure 8-2-1 Syringe and Piston

2. If the Forward limit is set correctly, the following will be true:
8—CALIBRATION
The volume displayed on the test display shall be (00), which is 0.0 mL.
The limit switch status on the display shall be (Fon), or foreword limit switch =
on.
The limit switch status shall be (FoF) when the volume displayed on the test
display is (01) or higher.
3. If the statements in step 2 are not true, then the limit switch board for the Ram of
concern will have to be adjusted forward or backward.
4. To access adjustment screws, remove the powerhead lower front, middle covers,
and syringe holder nest cover. The top cover is now lose, be careful when rotat-
ing the powerhead. Facing the injector rams, the two adjustment screws reside on
the powerhead guide plate positioned vertical. A 3.5mm nut driver or tool (P/N
802731) is required to make adjustments. Refer to figure 6-3-1 (item 27) for adjust-
ment screw locations.
The top adjustment screw adjust the A ram limit.
The bottom adjustment screw adjust the B ram limit.
Adjustment screw rotation:
Clockwise rotation will provide more ram forward travel.
Counterclockwise rotation will provide more ram backward travel.
5. If the board had to be moved, make sure that the wiper of the Ram is centered
within the optic sensor and is in no danger of hitting the sensor.
802701-G May 2009
8-2-3
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 in
calibration mode.
The volume displayed on the test display shall be (713); or 71 mL when in
calibration mode
The limit switch status on the display shall be (bon) when the Ram reaches the
reverse limit
The limit switch status shall toggle to (boF) when the volume displayed on the
test display goes less than 713 on the test display.
8.2.4 FORWARD LIMIT SWITCH CHECK & ADJUSTMENT (RAM B)
Use the same procedure defined for Ram A forward limit switch check and
adjustment.
8.2.5 REVERSE LIMIT SWITCH CHECK (RAM B)
Use the same procedure defined for Ram A Reverse Limit Switch Check.
8—CALIBRATION
802701-G May 2009

8-2-4

8—CALIBRATION
802701-G May 2009

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

8.3.1 RAM FACE CHECK
Perform the following tests to confirm that the ram faces are not putting a pre-
load on the load cells before attempting to calibrate pressures.
1. Manual check of A & B side:
Verify that both the A and B ram faces are not in a bind. With you hand only,
they should be able to spin and pull-off. Also, note that the load cell holders
shall remain secure while moving the ram faces.
2. Pressure Check of A side:
Pull the A side ram face outward approximately 1/8”.
With a full 60mL syringe, run a 10mL @ 4mL/sec. @ 100psi injection so that the
plunger stops with a volume remaining adequate to run the same injection
without retracting the ram.
Without retracting the ram, empty the syringe and manually push the plunger
to the expelled end, then repeat the same 10mL injection so the ram face does
not engage the pushrod at all.
Check the results screen and verify that the last injection did not achieve any
8—CALIBRATION
pressure (-).
Note: If either step 1 or 2 test fail, the ram face must be repaired and both tests
repeated.
802701-G May 2009

8-3-2
8.3.2 SETUP
1. Enter the Calibration Mode by following the procedure in section 8.1.5.
2. Using the Test Switch Assembly, go to Mode 1.
Note: Refer to 8.1.9 Mode Descriptions for Mode 1 field information.
3. The pressure values displayed (to the right of the flow & volume box, F6 and F7)
shall both be defaulted to (0335) if the Ram Initialization has been performed and a
60mL syringe is installed.
4. Install the pressure gauge fixture as illustrated in Figure 8-3-1.
Note: the last fill/expel button pressed, Ram A or Ram B side, will determine
which Ram information; Ram A (AH) or B (bH) appears on the test display. Also,
note that when pressing a fill/expel button to toggle the display to the desired
Ram, the Ram has to physically move to toggle the display to that Ram. Sub-
sequently, the last Ram that physically moves becomes the active Ram on the
display.
Pressure 100
200
Pressure
Gauge 50
Tube
Fixture 300
8—CALIBRATION
LE Base
Assembly
(Black)
60 mL
Syringe
60
55 mL
50
45
40
35
30
25
20
15
Powerhead
10
Powerhead
5
'B' Side Ram

'A' Side Ram
Drain and
Fill Tubes
ml
125 ml
60
B 50 ml ml
5/20 l
10/1 30 ml
60 m
A
Water
Container
Figure 8-3-1 Pressure gauge fixture installed
802701-G May 2009

8-3-3
8.3.3 SIDE “A” 60 ML SYRINGE:

1. Connect syringe and the pressure test assembly to the ‘A’ Ram, refer to the pressure
test assembly description in this chapter. Fill syringe with tap water and purge the
air.
2. Go to the ‘A only’ mode screen on the console by pushing the “Inj. Mode” button
and program the following injection: 60 mL @ 4 mL/sec. @ 150 psi on side A.
3. Run the complete injection and note the following:
The peak measurement shall be 150 psi. ± 10
Note: the pressure bar graph on the console display will indicate a pressure
value slightly lower than 150 psi. This is normal since the bar graph is display-
ing the average pressure while the injector’s calibration point is peak.
Note: that after the injection, pressing the “Results” button on the console will
display the achieved parameters of the last 6 injections; (the last 12 if pressed
twice). The pressure listed on this screen is also an average pressure, and shall
be within ± 10 psi of the programmed and achieved peak values.
4. If the pressure needs to be adjusted, perform the following steps:
a. On the Test Switch Assembly, press the UP or DOWN buttons This action will
raise or lower the bottom (0335) value, F7, on the Test Display (Note that lower-
8—CALIBRATION
ing the number will increase the pressure).
b. After an adjusted value is displayed, press the Enter button on the Test
Switch Assembly. This will change the top value, F6 on the Test Display, to
match the lower value F7 that was just modified.
5. Repeat steps 1 through 4 as required until the 150 psi specification is reached.
Again, the pressure indicated on the results screen must match the calibration
point of 150 ± 10 psi as well.
6. Check no-load flow rate by performing the following steps:
a. Remove the syringe from the head.
b. Set UP the same shot as in step 2 above.
c. Toggle test display to mode 6
d. Run the shot. The flow rate displayed on the test display shall be 4.0 +/- .1
mL/sec., (390-410), indicated under “Volume ML”, F5.
e. Note that for all injections, the real-time flow rate is displayed while in this
mode, and that when pressure limiting is engaged, the real-time flow rate will
always be lower than programmed.
802701-G May 2009

8-3-4
8.3.4 SIDE “B” 60 ML SYRINGE:

1. While in Mode 1 on the Test Display, install a 60 mL syringe on side B with no sy-
ringe on side A.
2. Go to the A + B mode screen on console by pushing the “Inj. Mode” key and pro-
gram the following injection:
A side = 1 mL @ 1 mL/sec. @ 150 psi.
B side = 60 mL @ 4 mL/sec.
3. Run the injection. The measured peak shall be 150 psi. +/- 10 psi.
4. The Test Display will originally indicate a pressure limit value of (0330). This value
should be adjusted to achieve 150 psi. +/- 10 psi.
a. On the Test Switch Assembly, press the UP or DOWN buttons to change the
F7 bottom value UP or DOWN as required. Note, that lowering the number will
increase the pressure. After the adjusted value is displayed, press the Enter but-
ton. 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.
8—CALIBRATION
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 originally
indicate a pressure limit value of (0165) and should be adjusted accordingly to
achieve 100 psi. +/- 10 psi using the Test Switch Assembly.
802701-G May 2009

8-3-5
8.3.6 SIDE “A” 20 ML SYRINGES

1. Install the 20 mL adapter on side “A”.
2. Go to the ‘A only’ mode screen on the console by pushing the “Inj. Mode” button.
Note: On the test display, the injector defaults to (0625) for 20mL syringe.
3. With a 20mL syringe installed, program the following injection: 20mL, 4.0mL/s, 200
psi.
4. Run the injection. The measured peak shall be 200 psi +/- 10 psi.
5. If needed, adjust the pressure calibration value in field F6. (Note again that lower-
ing the number will increase the pressure.)
6. Repeat steps 4 & 5 above as many times as necessary to achieve the 200 psi specifi-
cation.
8.3.7 SIDE “A” 30 ML SYRINGE
1. Install the 30 mL syringe on side “A”.
Note: On the test display, the injector defaults to (0355).
2. Go to the ‘A only’ mode screen on the console by pushing the “Inj. Mode” button.
3. With a 30mL syringe installed, program the following injection: 30mL, 4.0mL/s, 200
8—CALIBRATION
psi.
6. Repeat steps 3 through 5 above as many times as necessary to achieve the 200 psi
specification.
802701-G May 2009

8-3-6
8.3.8 SIDE “B” 50 ML SYRINGE

Note: A 30mL syringe will be used on the B side to simulate a 50mL syringe for
calibration purposes.
1. Install the 30 mL syringe on side “B”.
2. On the A - B injection screen, program a 1mL/s, 1mL injection for A, and a 4mL/s
30mL injection for the B side. Set the maximum pressure at 200 psi.
Note: On the test display, the default value is (0365).
5. Repeat steps 3 through 5 above as many times as necessary to achieve the 200 psi
specification.
Note: The pressure fixture on the A - side must be fully inserted into the A - side
nest. If not fully inserted, the injector will see “60 mL” and not allow you to pro-
gram 200 psi max. pressure limit on the A - side.
8—CALIBRATION
802701-G May 2009

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

Note: The following items do not have to be performed as part of a regular
calibration process.
8.4.1 SYRINGE SIZE FACTOR CHECK, (POWER CONSUMPTION) :
The power consumption of the injector becomes higher at lower flow rates. To
compensate for this, different ‘power consumption’ values are in the software
depending on the size of the syringe installed. These default values are factory
adjusted and would not normally be changed.
1. Toggle the Test Display to mode 6 by pressing the “Mode” button on the Test Switch
Assembly.
2. Momentarily press a fill or expel button on the ‘A’ Ram on the power head to toggle
the Test Display to indicate the ‘A’ Ram information.
3. With no syringe adapters installed, (ready for a 60 mL syringe), the test display shall
indicate (493) for the A side.
4. Install a 30 mL syringe into the A side and confirm that the value on the Test Dis-
play changes to (470).
5. Repeat the above steps for the ‘B’ side.
125mL syringe B side = 1012
8—CALIBRATION
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 pro-
cess will allow the system to store the performed calibrations.
Note: All 4 switches on the Power Control CPU board shall be off.
802701-G May 2009

8-4-2

8—CALIBRATION
802701-G May 2009

8-5-1
8.5 EXIT CALIBRATION MODE:

Switch Console off first, then switch off Power Control
Switch #3 of SW1 on the CPU board of the Power Control to OFF
All calibrations are now saved and the system has exited the calibration mode
Note: This order must always be followed when exiting Calibration Mode.
Note: Properly switching the system off anywhere during the calibration pro-
cess will allow the system to store the performed calibrations
Note: All 4 switches on the Power Control CPU board shall be off
8—CALIBRATION
802701-G May 2009

8-5-2

8—CALIBRATION
802701-G May 2009

9-1-1
9 SYSTEM
INFORMATION
This chapter describes System Information mode features. From the System
Information screen the following features are available:
• Set Display Brightness
• Change Pressure Units
• Set Beeper Volume
• Change Language
• Set Date and Time
• View Alarm History
• Enter Service Mode
9—SYSTEM
SETUP
802701-G May 2009

9-1-2
9.1 ACTIVATING SYSTEM INFORMATION SCREEN

To activate the system information screen proceed as follows:
1. Turn on Console power.
2. Touch the Results screen button.
3. Touch the System Info screen button.
4. The System Information Screen will be displayed. To exit this screen, simply touch
either the Memory, Inject Mode, or Results buttons.
System Information
Display Brightness Low High Pressure Units PSI
Beeper Volume Off Low Med High
Software Versions Console: 0.00.06 Power Control:
Language English
Change Date Change Time
Service Mode
9—SYSTEM
SETUP
AUG 01-2002 14:15 Alarm History
802701-G May 2009

9-1-3
9.1.1 SETTING DISPLAY BRIGHTNESS

1. Activate System Information Screen as previously described.
2. Simply touch the appropriate screen button to adjust display brightness.
9.1.2 CHANGE PRESSURE UNITS
This feature will change Injection Mode screens to the pressure units selected.
2. Touch the Pressure Unit screen button. Pressure units will toggle between KPA and
PSI.
9.1.3 SET BEEPER VOLUME
2. Simply touch any one to the four Beeper Volume screen buttons. The beeper vol-
ume will 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 a
button is touched.
9.1.5 SET DATE AND TIME
9—SYSTEM
SETUP
2. Touch the either the Change Date or Change Time screen button.
3. Touch the arrow buttons provide to increment or decrement units.
4. To exit either function (Date or Time), simply touch the Change Date or Change
Time buttons.
9.1.6 VIEW ALARM HISTORY
2. Simply touch the Alarm History screen button. The alarm history screen will be
displayed.
3. Touch the System button to return to the System Information screen.
802701-G May 2009

9-1-4
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 missed during the calibration process. Simply repeat the calibration pro-
cess until the System Information screen is displayed.
Note: If one of the red touch targets does not appear, this means the touch
screen is physically misaligned. Refer to 6.2 for console procedures.
9—SYSTEM
SETUP
802701-G May 2009

10-1-1
10 SOFTWARE DOWNLOAD
AND UPGRADE
10.1 OVERVIEW
The Optistar LE software resides in FLASH memory that can be reprogrammed
without chip removal and replacement. This configuration uses a personal
computer to download the code to the memory ICs via a 10 pin serial port. The
minimum requirements to perform the software download are as follows:
• Personal Computer with, at a minimum, 386 processor, 8 megabytes of
RAM, CD reader, and a 25 pin D-shell parallel port.
• 904035, Software Download Adaptor Cable Assembly (for Power Control).
Use PROG32Z.EXE to download the Power Control software.
• 802683, Software Download Adaptor Cable Coldfire (for Console).
Use PROGCFZ.EXE to download the Console software.
• 25 pin PC interface extension cable, 2.5 ft. length maximum. Can be
purchased locally or from LF under P/N 900235.
• FIRMWARE, (CD-ROM).
Note: Main injector software is composed of two software sub-versions.
Both major components, Power Control, and Console must have a compat-
ible combination of software sub-versions in order for the injector to function
properly.
10—SOFTWARE
AND UPGRADE
DOWNLOAD
To check compatibility, compare the software sub-versions on the SYSTEM
INFO SCREEN with the readme.txt file supplied with the software.
To select the SYSTEM INFO SCREEN proceed as follows:
1. From the Main Injector Screen, press the Results button.
2. Press the System Info button. The SYSTEM INFO SCREEN will be displayed. Write
down the software versions displayed.
802701-G May 2009

10-1-2
10.1.1 SOFTWARE TRANSFER FROM CD

Using My Computer, Open and view the contents of the CD.
Highlight the folder on the CD with the name of the software version you are
installing (for example, V2.00). Then copy the entire folder to the root directory
on the C: drive by dragging the folder and dropping it on the C: drive. (You may
also use Copy and Paste.) When you are finished with this copy, there should be
a folder called “C:\V2.00” (for example) on your hard drive.
Open the new folder containing the new software (For example, C:\V2.00).
Click Edit, then Select All from the Windows drop down menu.
Right click on one of the selected files and select Properties.
Deselect the Read-only Box. Then click Apply, then OK.
If the new PROG32z.exe and PROGcfz.exe programs are already installed on
your computer, skip to Chapter 10.2. Otherwise, continue with these instruc-
tions.
Open and view the “pemicro” folder on the CD.
Run the “CD_setup.exe” program by double-clicking the file name. This will
install the PROG32z and PROGcfz files on your hard drive into the C:\pemicro
folder.
The “Welcome to the Install shield Wizard for PE’s Flash Programmer for TYCO”
Window appears. Click Next.
Read the License Agreement, select the “I accept the terms in the License
10—SOFTWARE
AND UPGRADE
DOWNLOAD
Agreement” box, and click Next.

On the Customer Information Window, enter your name, and click Next.
On the Destination Folder Window, ensure the folder name reads “C:\pemicro”,
and click Next. Change to “c:\pemicro” if necessary.
Click Install.
Click Finish.
802701-G May 2009

10-1-3
Remove the CD from the CD drive and click Yes to reboot your computer.
Now that the PROG programs have been installed on your computer, the paral-
lel port must be configured. Open the new “C:\pemicro” folder.
Run the addlpt.exe file by double-clicking it.
If “LPT1: Detected via BIOS at Hex address…” is displayed, select “Cancel”. (Your
parallel port has already been configured.)
If “LPT1: is not listed in BIOS” is displayed and is disabled, select “Use HEX 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
the addlpt.exe program, click Cancel to continue.
When you run the PROG32z or PROGcfz program for the first time, a Connec-
tion Assistant Dialogue Window will appear. The window under “Connection
port to PC” should read…
“LPT1 – Parallel Port 1 (Address $0378).
At the bottom of the dialogue box you may deselect the “Show this dialogue
before attempting to contact target.” When deselected, the Connection Assis-
tant Dialogue Window will only appear if an error is detected.
Also when you run the PROG32z or PROGcfz program for the first time, the
PROGxxx program will not know where to find the new software to be down-
loaded to the injector. So when you “Choose Module” for the first time, simply
10—SOFTWARE
navigate to the folder where the software resides (for example, C:\V2.00). When
AND UPGRADE
DOWNLOAD
you “Specify S Record” for the first time, navigate again to the folder where the
software resides. When the PROGxxx program is run again, it will remember the
folder where the software resides.
802701-G May 2009

10-1-4

10—SOFTWARE
AND UPGRADE
DOWNLOAD
802701-G May 2009

10-2-1
10.2 DOWNLOAD AND UPGRADE PROCEDURES

Procedures defined in this section will assume you have completed instructions
10.1.1 SOFTWARE TRANSFER TO PC PROCEDURE .
Note: Software updates to the Power Control could affect calibration parame-
ters. Check and log all calibration parameters before updating. Refer to Chapter
8 in this document for procedures.
WARNING!
Always remove Power Control and Power Head assembly from magnet
room before disassembly and upgrading. Failure to follow this warning
could result in personnel injury or equipment damage.
10—SOFTWARE
AND UPGRADE
DOWNLOAD
802701-G May 2009

10-2-2
10.2.1 POWER CONTROL DOWNLOAD

1. Using the Power Supply ON/OFF switch, ensure that the power to the injector is off.
2. Disconnect the 25 pin data/power cable from the Filter to the Power Control. Re-
move Powerhead and Power Control assemblies from the magnet room.
3. At the Power Supply, disconnect the data/power cable (J2) to the Filter. You will be
connecting a 25 pin jumper cable to supply data/power to the Power Control.
4. Connect the 25 pin D-Shell connector of the 904035 software download adapter
cable to the parallel port of the PC. If necessary use the extension cable.
5. Remove the Power Control front cover as described in Chapter 6.4.
6. Pull the Power Control CPU board outward to expose connector J4 as shown in Fig-
ure 7-2-1. Install software download adapter 904035 to the J4 connector, then slide
the CPU board inward until it is fully seated.
7. Attach 25 pin to 25 pin jumper data/power cable from the Power Supply (J2) to the
Power Control (J3) connection.
CPU
sw
J4
10—SOFTWARE
AND UPGRADE
DOWNLOAD
Red Wire
Figure 10-2-1 Power Control

cable location
8. Turn on power to the PC and Power Control.
9. Turn system power on using the console power ON/OFF button. Ignore any mes-
sages that appear on the console screen.
802701-G May 2009

10-2-3
10. Run the PROG32Z.exe file from C:\pemicro. This

RUN
should be opened from Windows PROG32Z.EXE
11. Verify “CHOOSE MODULE .32P” is selected and a

SELECT "CHOOSE
“Specify Programming Algorithm to Use!” pop-up
MODULE"
window is presented
12. Using the mouse, click the down arrow to the right of SELECT
the “Look in” field of the pop-up and navigate to the powerpack.32p
desired version folder, e.g. Optistar LE V02.00 soft-
ware. Select the powerpack.32p file and press enter.
PRESS
ENTER
13. Type a 0 (zero) in the “Base Address” pop up window

and press enter.
TYPE 0
PRESS
ENTER
10—SOFTWARE
AND UPGRADE
DOWNLOAD
14. Using the arrow keys on the PC keyboard select
“ERASE MODULE” and press enter. The status sec-
SELECT "ERASE
tion at the bottom of the screen will prompt the user MODULE"
when the task is complete.
PRESS
ENTER
CONTINUED
802701-G May 2009

10-2-4
POWER PACK
CONTINUED
15. Using the arrow keys on the PC keyboard

select “SPECIFY S RECORD” and press enter.
SELECT "SPECIFY 'S'
RECORD"
PRESS
ENTER
16. Using the mouse, click the down arrow to

the right of the “Lookin” field of the pop-up
and navigate to the desired version folder,
e.g. Optistar LE V02.00 software. Select the
SELECT powerpack.s19
powerpack.s19 file and press enter.
PRESS
17. Using the arrow keys on the PC keyboard
ENTER
select “PROGRAM MODULE” and press en-
ter. The status section at the bottom of the
screen will display “PROGRAMMED” when
the task is complete. SELECT "PROGRAM
MODULE"
10—SOFTWARE
AND UPGRADE
DOWNLOAD
PRESS
ENTER
18. Using the arrow keys on the PC Keyboard "PROGRAMMED"

select “QUIT” and press enter IS DISPLAYED
19. Remove power using the ON/OFF switch

on the power supply. SELECT
"QUIT"
20. When power control download is com-
plete, remove the PC data cable at the
power control CPU board. PRESS
ENTER
Note: One of the following two proce-
dures must be performed after down-
loading software into the CPU board.
PERFORM
If neither of these procedures is per- PROCEDURE
formed, Alarm 23 will occur at power 1 OR 2
802701-G May 2009

10-2-5
up. To decide which procedure to follow use the following

criteria:
• 21 Procedure 1 involves re-initializing the Power Control’s CPU RAM. This procedure
should be used in the event that the CPU board has been replaced. This procedure
will erase all pressure calibration values necessitating the complete calibration
procedure to be performed.
• 21 Procedure 2 will retain the current pressure calibration values stored in memory.
This procedure should only be used if neither the CPU board, nor any other major
component dealing with pressure has been replaced.
21. PROCEDURE 1
1. Perform the Initialization of the Power Control CPU Ram procedure as described in
section 8.1.4 in chapter 8.
2. Perform all calibration procedures as described in Chapter 8.
21. PROCEDURE 2
1. Connect the Test Display and the Test Switch assembly to the Power Control CPU
board as described in Chapter 8, section 8.1.3.
2. Set SW3 to the ON position. SW3 ON position is toward the edge of the CPU board.
3. Turn on the power to the injector.
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 dis-
play and note the value in the “TIME” window in the lower right section of the Test
Display. This is field F8. (Refer to figure 8-1-2 for field locations)
10—SOFTWARE
AND UPGRADE
5. Press the “Enter” button on the Test Switch assembly while observing field F8,
DOWNLOAD
“Time”, on the Test Display. The value in F8 will change after a few seconds.
6. After the value in F8 has changed, remove power from the injector by turning off
the Power Supply. Remove the Test Display and Test Switch assembly and return
SW3 to OFF.
7. Power on the injector. Check all calibration parameters. Refer to chapter 8.
802701-G May 2009

10-2-6

10—SOFTWARE
AND UPGRADE
DOWNLOAD
802701-G May 2009

10-3-1
10.3 CONSOLE DOWNLOAD

Note: The Console must be connected to the Power Control to complete this proce-
dure.
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 Adapter Cold-
fire cable to the parallel port of the PC. If necessary use the extension cable.
4. Connect the Software Download Adapter cable to the Console CPU board as
shown in Figure 10-3-1. Be sure the cable red wire (pin 1) is correctly oriented to
J4 pin 1 when making this connection.
5. Turn on power to the PC and Power Supply, then to the Power Control, then Con-
sole. Ignore any messages that appear on the console screen during the download-
ing process.
Software Download
Adapter Cable
J8
J2
Red Pin 1
J6
J5
1
J7
10—SOFTWARE
AND UPGRADE
DOWNLOAD
25 J4 1
Figure 10-3-1 Console Software

Download Cable orientation
802701-G May 2009

10-3-2
6. Run the PROGCFZ.exe file. This should be opened from RUN

Windows. PROGCFZ.EXE
7. Verify “CHOOSE MODULE .CFP” is selected and a ‘Specify SELECT "CHOOSE

Programming Algorithm to Use!” pop-up window is pres- MODULE"
ent.
8. Using the mouse, click the down arrow to the right of the
“look in” field of the pop-up and navigate to the desired
SELECT
version folder, e.g. Optistar LE V02.00 software. Select the
console.cfp
console.cfp file and press enter.
PRESS
ENTER
9. Type a 0 (zero) in the “Base Address” pop up window and

press enter. TYPE 0
PRESS
ENTER
10—SOFTWARE
10. Using the mouse or arrow keys on the PC keyboard se-

AND UPGRADE
SELECT "ERASE
DOWNLOAD
lect “ERASE MODULE” and press enter. The status section MODULE"
at the bottom of the screen will prompt the user when
the task is complete. The erase command may take
PRESS
30 seconds. Actual erase time will depend on the speed
ENTER
of your PC.
CONTINUED
802701-G May 2009

10-3-3
CONSOLE
CONTINUED
11. Using the mouse or arrow keys on the PC key-

board select “SPECIFY S RECORD” and press SELECT "SPECIFY
'S' RECORD"
enter.
PRESS ENTER
12. Using the mouse, click the down arrow to the

right of the “look in” field of the pop-up and nav- SELECT console.s19
igate to the desired version folder, e.g. Optistar
LE V02.00 software. Select the console.s19 file
and press enter again. PRESS ENTER
SELECT "PROGRAM
MODULE"
13. Using the mouse select “PROGRAM MODULE”
and press enter.
PRESS ENTER
"PROGRAMMED"
14. The program module command may take 160
10—SOFTWARE
IS DISPLAYED
AND UPGRADE
DOWNLOAD
seconds. Actual programming time will depend
on the speed of your PC.
SELECT
"QUIT"
15. Using the mouse or the arrow keys on the PC
Keyboard, select “QUIT” and press Enter.
PRESS
ENTER
16. Remove power using ON/OFF switch on the
power supply.
CONSOLE
COMPLETE
802701-G May 2009

10-3-4

10—SOFTWARE
AND UPGRADE
DOWNLOAD
802701-G May 2009

11-1-1
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
11—OVERVIEW
SCHEMATICS
802701-G May 2009

11-1-2

11—OVERVIEW
SCHEMATICS
802701-G May 2009

11-2-1
TPU0-3
ADDRESS
A0
A1
A2
A3
P7
A4
A5
A6
A7
A8
RXD
RXD-IN A9
TXD A10
A11
A12
A13
CPU-TXD A14
A15
A16
SPKR SPEAKER_OUT A17
A18
SYS_RESET
PCS1
DGND
PCS3 INIT_DONE
CPU-TXD
RXD
BERR BOOT_CRC
IPIPE
IFETCH
BKPT MR
SERIAL_OK
MR
FREEZE
TPU0-3
TS_OK
NMI
MR
11—POWER CONTROL
DS
SCHEMATICS
R/W
D0
D7
D8
DATA
D15
POWER CONTROL CPU SCHEMATIC 802201-D (1 OF 6)

802701-G May 2009
11-2-2
CS6 CS8 CS9

CS7 CS10 CS10
CS5
CS7
DATA DATA DATA
ADDRESS ADDRESS
11—POWER CONTROL
SCHEMATICS
CSBOOT
R/W
BOOT_PGM*

802701-G May 2009
11-2-3
DGND
8_MHZ
DATA
PH_A_A
ADDRESS
PH_B_A
PH_A_B
P7
PH_B_B
CS3
UPP-RDY
P-CONT
PHAI
DATA P-SIN
LCD
CS1
CS3
MR
M-SIN
P-COS
SV-CS DATA
M-COS
ADDRESS UPP-CS
P_SPD_CNG
A_MOT A_MOT
A-MOT
PH_C_A
PH_C_B
SZSW ADDRESS
SPD-CNG SPD_CNG
11—POWER CONTROL
P-CONT
SCHEMATICS
SZSW A_MOT
A_DRV_FQ B_MOT B-MOT
WDTP2
B_DRV_FQ
SYS-GO
P74
P75
JTAG-TMS-IN
n.c.
JTAG-TCK-IN
WDTP2
JTAG-TDI
JTAG-TDO
FB-UPA
FB-UPB
TCK
P75
P74
TDO SAMP-A
SAMP-B
SSR-ON SSR-ON

802701-G May 2009
11-2-4
+5V
K_6MA
-INA
+INA
SAMPAIN-
ASAMP-OUT
11—POWER CONTROL
SCHEMATICS
-IN-B
+IN-B
SAMPBIN-
BSAMP-OUT

802701-G May 2009
11-2-5
SZSW
SIZE0-A
SIZE1-A
SIZE0-B
SIZE1-B
H-CLK
FILSW0
H-DATA
FILSW1
PHA-A FILSW2
Q-SWA
PHB-A
Q-SW-B
11—POWER CONTROL
RESV
SCHEMATICS
F-LIM-A
BK-LIM-A
PHC-A
F-LIM-B
BK-LIM-B

802701-G May 2009
11-2-6
EX-IN0
EX-IN1
EX-IN2
EX-IN3
UP
DWN
MODE
ENTER
LCD
11—POWER CONTROL
SCHEMATICS
DATA

802701-G May 2009
11-2-7
6.3 A SLOW BLOW
11—POWER CONTROL
SCHEMATICS
POWER SCHEMATIC 802202-2-D
802701-G May 2009
11-2-8
11—POWER CONTROL
SCHEMATICS
DRIVER BOARD SCHEMATIC 802203-C

802701-G May 2009
11-2-9
11—POWER CONTROL
SCHEMATICS
COMMUNICATION BOARD SCHEMATIC 802204-A
802701-G May 2009
11-2-10
B_MOT
A_MOT
+5V
DGND
ANA_GND
RXD-IN
TXD
-INA
DGND
+INA
K_6MA
-INB
PHC-B
+IN-B
PHC-A
+26-IN
H-CLK
H-DATA
PHB-B
PHA-B
PHA-A
BK-LIM-B
F-LIM-B
BK-LIM-A
F-LIM-A DGND
n.c.
SIZE0-B
SIZE1-A
SIZE0-A
SIZE1-B
MOT_V
RESV
Q-SW-B
Q-SW-A
FILLSW_2
FILLSW_1
FILLSW_0 MOT-V-RET
n.c. n.c.
P_SPD_CNG
+12V
P-COS 26VA-AN6
P-SIN
M-COS 26V-AN4
M-SIN
+5V SSR-ON
+5V +5V +5V
+12V
DGND +26_FUSED
11—POWER CONTROL
SSR-ON
RESV2
P_SPD_CNG +12V
SPD_CNG-DRV
+5V
SCHEMATICS
+5V
26VA-AN6
26V-AN4 26V-AN4
SSR-ON
+26_FUSED
INTERCONNECT CPU BOARD SCHEMATIC 802205-A

802701-G May 2009
11-2-11
11—POWER CONTROL
SCHEMATICS
INTERCONNECT DRIVER BOARD SCHEMATIC 802206-A
802701-G May 2009
11-2-12

11—POWER CONTROL
SCHEMATICS
802701-G May 2009

11-3-1
11—CONSOLE
SCHEMATICS
CONSOLE SCHEMATIC 802101-C (1 OF 5)
802701-G May 2009
11-3-2
11—CONSOLE
SCHEMATICS

802701-G May 2009
11-3-3
11—CONSOLE
SCHEMATICS
802701-G May 2009
11-3-4
11—CONSOLE
SCHEMATICS

802701-G May 2009
11-3-5
11—CONSOLE
SCHEMATICS
802701-G May 2009
11-3-6
11—CONSOLE
SCHEMATICS
CONSOLE INTERFACE SCHEMATIC 802102-C (1 OF 1)

802701-G May 2009
11-4-1
11—POWERHEAD
SCHEMATICS
POWERHEAD SCHEMATIC 802301-D (1 OF 4)
802701-G May 2009
11-4-2
11—POWERHEAD
SCHEMATICS

802701-G May 2009
11-4-3
11—POWERHEAD
SCHEMATICS
802701-G May 2009
11-4-4
11—POWERHEAD
SCHEMATICS

802701-G May 2009
11-4-5
11—POWERHEAD
SCHEMATIC
END LIMIT SENSING SCHEMATIC 802302-A

802701-G May 2009
11-4-6
11—POWERHEAD
SCHEMATIC
SYRINGE SIZE SENSING SCHEMATIC 802307-A

802701-G May 2009
11-5-1
11—POWER SUPPLY
SCHEMATICS
POWER SUPPLY SCHEMATIC 802451-B
802701-G May 2009
11-5-2

11—POWER SUPPLY
SCHEMATICS
802701-G May 2009

11-6-1
SEE TABLE
HAND START SWITCH ASS'Y. LENGTH TABLE

PART NUMBER TITLE ASSEMBLED LENGTH REV.
802620 START SWITCH ASS'Y., HAND 2M 6.0' - 7.0" +2.0" A
802622 START SWITCH ASS'Y., HAND 2M 19.0' - 8.0" +4.0" A
WIRING DIAGRAM
Black
C 2
SW1 N.C. Red
11—HAND BUTTON
6
N.O.
PINS
White
C 3
SW2 N.C.
N.O. Green 1
PENDANT CONNECTOR
ASSEMBLY ASSEMBLY
CABLE SHIELD
NOTES: SEE NOTE 2
2. CABLE SHIELD TO BE TERMINATED TO MINI DIN CIRCULAR SHEEL.
HAND BUTTON 802620/802622

802701-G May 2009
11-6-2

11—HAND BUTTON
802701-G May 2009

11-7-1
Power Control Powerhead Board

P1 Connector Wire Color Connectors J7, J8, J9
P1:24 BLACK J7-11
P1:9 RED J7-12
P1:39 BROWN J7-2
P1:25 YELLOW J7-1
P1:30 WHITE J7-3
GND SCREW NONE J7-4
P1:20 GREEN J7-5
P1:26 ORANGE J7-6
P1:40 BLUE J7-7
P1:13 BROWN J7-8
P1:41 YELLOW J7-9
P1:27 PINK J7-10
TAN
P1:8 BLACK J8-9
P1:22 RED J8-8
P1:29 WHITE J8-4
P1:43 GREEN J8-3
P1:37 ORANGE J8-2
P1:23 BLUE J8-1
P1:14 PURPLE J8-14
P1:42 SLATE J8-13
P1:38 PURPLE J8-6
P1:10 GRAY J8-7
P1:28 PINK J8-12
GND SCREW NONE J8-15
P1:11 TAN J8-10
P1:12 RED/YELLOW J8-11
P1:5 RED/GREEN J8-5
RED/BLACK -
P1:21 BLACK J9-1
P1:7 RED J9-2
P1:36 WHITE J9-3
P1:6 GREEN J9-5
P1:35 ORANGE J9-6
P1:34 BLUE J9-4
J9-7
GND SCREW NONE J9-8
Pin 1
J8 Powerhead Board
J7 (P/N 802301-1)
Connectors
J9
P2 P1
Pin 1
JA
11—CABLES
JB Powerhead
Motor Connections
JB1
JA1
Power Control Powerhead

P2 Connector Wire Color Motor Connections
P2:18 BLUE JA-1
P2:23 YELLOW JA-3
P2:21 GREEN JA-4
GND SCREW NONE -
P2:17 WHITE/BLUE JB-1
P2:26 WHITE/YELLOW JB-3
P2:20 WHITE/GREEN JB-4
GND SCREW NONE -
P2:24 RED/BLUE JB1-1
P2:22 RED/YELLOW JB1-3
P2:27 RED/GREEN JB1-4
GND SCREW NONE -
P2:25 BLACK/BLUE JA1-1
P2:19 BLACK/YELLOW JA1-3
P2:28 BLACK/GREEN JA1-4
GND SCREW NONE -
POWERHEAD CABLE 802303-A

802701-G May 2009
11-7-2
14 1 25 13
PINS P1 S1 SOCKET
25 13 14 1
P1 SEE CHART S1
P2 +/- 1.0 ft. S2
P3 S3
P4 PART NUMBER LENGTH REVISION S4
P5 801224-03 3 FT. A S5
P6 801224-07 7 FT. A S6
P7 801224-15 15 FT. A S7
P8 S8
801224-25 25 FT. B
P9 S9
P10 801224-50 50 FT. B S10
P11 801224-75 75 FT. A S11
P12 801224-100 100 FT. A S12
P13 801224-150 150 FT. A S13
P14 S14
P15 S15
P16 S16
P17 S17
P18 S18
11—CABLES
P19 S19
P20 S20
P21 S21
P22 S22
P23 S23
P24 S24
P25 S25
SHIELD SHIELD
DATA CABLE 801224

802701-G May 2009
A-1-1
APPENDIX A
APPENDIX—A
802701-G May 2009

A-1-2
LIST OF CONTENTS
INSTALLATION INSTRUCTIONS 802702
APPENDIX—A
802701-G May 2009

IND-1-1
Index
A I
ACCESSORIES 1-7-1 INJECT RESULTS 1-5-5
ACCESSORY ITEMS 6-11-1 INSTALLATION INSTRUCTIONS 802702 A-1-2
ACTIVATING SYSTEM INFORMATION SCREEN 9-1-2
L
C
LOAD CELL REMOVAL/INSTALLATION 6-3-15
CABLES 6-8-1
CALIBRATION 8-1-1 M
CALIBRATION SET-UP 8-1-3
MOTOR REMOVAL/INSTALLATION 6-3-14
CHANGE PRESSURE UNITS 9-1-3
CHANGING LANGUAGES 9-1-3 P
CONFIGURATION OF UNIT 1-3-1
CONSOLE ASSEMBLY 6-2-10 PHYSICAL STABILITY 1-4-2
CONSOLE ASSEMBLY (P/N 902300) 6-2-3 POSITIVE POSITIONING OF THE POWERHEAD 1-4-1
CONSOLE COVER REMOVAL 6-2-7 POWERHEAD BOARD REMOVAL/INSTALLATION 6-3-
CONSOLE CPU REMOVAL 6-2-7 14
CONSOLE INTERFACE BOARD REMOVAL 6-2-9 POWERHEAD CABLE REMOVAL/INSTALLATION 6-3-
CONSOLE PCB ASSEMBLY (P/ N 902300) 6-2-4 14
CONSOLE POWER SWITCH REMOVAL 6-2-8 POWERHEAD COVER REMOVAL/INSTALLATION 6-3-
CONSOLE REPLACEMENT COMPONENTS 6-2-2 12
CONSUMABLES 1-6-1 POWERHEAD END LIMIT SENSING BOARDREMOVAL/
INSTALLAT 6-3-15
D POWERHEAD REMOVAL/INSTALLATION FROM STAND
6-3-11
DC POWER SUPPLY REPLACEMENT 6-5-4
POWER CONTROL REPLACEMENT COMPONENTS
DIMENSIONS 1-5-1
6-4-2
DISPLAY SUBASSEMBLY (P/N 802116S) 6-2-5
POWER REQUIREMENTS 1-5-1
E POWER SUPPLY 6-5-1
POWER SUPPLY FUSE REPLACEMENT 6-5-4
ELECTRICALLY ISOLATED SYRINGE 1-4-1 POWER SUPPLY REPLACEMENT COMPONENTS 6-5-2
ELECTRICAL LEAKAGE 1-5-2 PREVENTIVE MAINTENANCE 4-1-2
ENCODER HARNESS REMOVAL/INSTALLATION 6-3-16 PROGRAM. DRIP INJECTION PARAMETERS (B-SIDE)
END LIMIT HARNESS REMOVAL/INSTALLATION 6-3-16 1-5-5
ENVIRONMENTAL 1-5-2 PROGRAMMABLE FLOW RATE (A-SIDE) 1-5-4
EXIT CALIBRATION MODE 8-4-1 PROGRAMMABLE FLOW RATE (B-SIDE) 1-5-4
PROGRAMMABLE INJECT DELAY 1-5-5
F PROGRAMMABLE PRESSURE LIMIT (A-SIDE) 1-5-4
FIELD REPLACEABLEPARTS 6-1-1 PROGRAMMABLE PRESSURE LIMIT (B-SIDE) 1-5-4 IND—INDEX
FILTER ASSEMBLY 6-7-1 PROGRAMMABLE SCAN DELAY 1-5-4
FREQUENCY OF CALIBRATION 8-1-2 PROGRAMMABLE VOLUME (A-SIDE) 1-5-4
PROGRAMMABLE VOLUME (B-SIDE) 1-5-4
G PROTOCOL MEMORY 1-5-5
GENDER CONNECTORS 6-10-1 R

GROUND CONTINUITY 4-4-1
REMOTE STAND 6-6-1
H
HAND START SWITCH OPERATION 1-4-1
HISTORY ALARM LIBRARY 5-2-10
802701-G May 2009

IND-1-2
S
SAFETY FEATURES 1-4-1
SCHEMATICS 11-1-1
SCREEN CALIBRATION 9-1-4
SELF-TESTING DESIGN 1-4-1
SERVICE KIT PARTS 6-9-1
SERVICE MODE 9-1-4
SETTING DISPLAY BRIGHTNESS 9-1-3
SET BEEPER VOLUME 9-1-3
SET DATE AND TIME 9-1-3
SOFTWARE DOWNLOAD AND UPGRADE 10-1-1
SPECIFICATIONS 1-5-1
SYRINGE CLARITY 1-4-1
SYRINGE SIZES 1-5-3
SYRINGE SIZE SENSING BOARD REMOVAL/INSTALLA-
TION 6-3-17
SYSTEM GENERATED MESSAGES 5-2-1
T
TOUCHSCREEN REMOVAL 6-2-8
V
VIEW ALARM HISTORY 9-1-3
W
WEIGHT 1-5-1
IND—INDEX
802701-G May 2009

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

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L IEBEL- F LARSHEIM

Service and Parts Manual

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802701-G May 2009

RECORDING REFERENCE NUMBER AND SERIAL NUMBERS

Ref.No. - (located on Power control)

Power Control S/N CI D

Power Supply S/N CI D

802701-G May 2009

MEANINGS OF SYMBOLS USED IN THIS MANUAL

Hazards which will result in severe personal injury or death.

Hazards which could result in personal injury.

Hazards which could result in equipment or property damage.

802701-G May 2009

MEANINGS OF SYMBOLS USED ON THE INJECTOR

Console Connection identifier

Powerhead Connection identifier

Power Control identifier

Power Supply identifier

Hand start switch connection identifier

System OFF/ON (only for the Console)

Ram movement/injector status identifier:

Check to ensure air is removed from syringe and tubing

802701-G May 2009

Equipment sensitive to Electrostatic Discharge.

MR Unsafe--an item that is known to pose hazards in all

MR Conditional--an item that has been demonstrated to pose

MR Safe--an item that poses no known hazards in all

<300G Locate in an area with magneticfields less than or

! ATTENTION! Consult User's/Service Manual.

European Union’s Waste Electrical and

CAUTION! Risk of electrical shock. Do not remove cover.

S/N Serial Number

P/N Part Number

V/A Volts Amps

802701-G May 2009

CLASSIFICATION IN ACCORDANCE WITH EN 60601

DEGREE OF PROTECTION AGAINST ELECTRIC SHOCK

Type B applied part (Console and Power Control)

DEGREE OF PROTECTION AGAINST INGRESS OF WATER

WITH RESPECT TO ELECTRIC SHOCK,

802701-G May 2009

ELECTROMAGNETIC COMPATIBILITY GUIDANCE

Portable and mobile RF communication equipment can aﬀect opera-

Before removing any Power Control PC boards, ensure proper static

ELECTROMAGNETIC COMPATIBILITY TABLES

802701-G May 2009

Guidance and Manufacturer's Declaration - Electromagnetic Immunity

802701-G May 2009

Guidance and Manufacturer's Declaration - Electromagnetic Immunity

Immunity Test IEC 60601 Compliance Level Electromagnetic

Conducted RF 3 Vrms 3 Vrms d = 1.2 P

Radiated RF 3 V/m 3 V/m d = 1.2 P

Where P is the maximum

Field strengths from fixed

Interference may occur in

802701-G May 2009

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