HAEMONETICS Cell Saver 5 Service Manual

Service manual

0123

HAEMONETICS CORPORATION
400 Wood Road, Braintree, MA
02184, USA

SM-CS5-01-EN(AB)
July 2015

2

Publication information

Copyright Notice

Confidential/ Proprietary Notices

©1994, 2005, 2012, 2015 Haemonetics Corporation

The contents of this manual are the property of the Haemonetics Corporation.

Any information or descriptions contained in this manual may not be
reproduced and released to any of the general public, or used in conjunction
with any professional instruction without written consent of Haemonetics
Corporation, USA.

Use of any portion(s) of this document to copy, translate, disassemble or
decompile, or create or attempt to create by reverse engineering (or otherwise)
the source code from the object code of Haemonetics products is expressly
prohibited.

Disclaimer This manual is intended as a guide to provide the user with necessary

instructions on the proper use and maintenance of certain Haemonetics
Corporation products. This manual should be used in conjunction with
instruction and training supplied by qualified Haemonetics personnel.

Any failure to follow the instructions as described could result in impaired
product function, injury to the user or others, or void applicable product
warranties. Haemonetics accepts no responsibility for liability resulting from
improper use or maintenance of its products.

Utilization of Haemonetics products may require the user to handle and
dispose of blood-contaminated material. Users must fully understand and
implement all regulations governing the safe handling of blood products and
waste, including the policies and procedures of their facility.

Handling and use of any blood products collected or stored using Haemonetics
equipment are subject to the decisions of the attending physician or other
qualified medical personnel. Haemonetics makes no warranty with respect to
such blood products.

Patient diagnosis is the sole responsibility of the attending physician or other
qualified medical personnel.

The screenshots appearing in this manual are provided for illustrative purposes
only and may differ from the actual software screens. All organization, donor/
patient, and user names in this manual are fictitious. Any similarity to the name
of an organization or person is unintentional.

P/N SM-CS5-01-EN, Manual revision: AB Haemonetics® Cell Saver® 5/5+ Service Manual

3

Document Updates

Trademarks and Patents

The document is furnished for information use only, is subject to change
without notice and should not be construed as a commitment by Haemonetics
Corporation. Haemonetics Corporation assumes no responsibility or liability for
any errors or inaccuracies that may appear in the informational content
contained in this material. For the purpose of clarity, Haemonetics Corporation
considers only the most recent version of this document to be valid.

Haemonetics®, THE Blood Management Company®, and Cell Saver® are
trademarks or registered trademarks of the Haemonetics Corporation in the
United States and/or other countries.

Other product names in this document may be trademarks of their respective
proprietors and are used for identification purposes only.

Reader comments

Any comments or suggestions regarding this publication are welcomed and
should be forwarded to the attention of:

Haemonetics Software Solutions

Corporate headquarters International headquarters

Haemonetics Corporation Haemonetics S.A.
400 Wood Road Rue des Fléchères
Braintree, MA 02184 Signy Centre
U.S.A. P.O. Box 262
Tel.: [phone] Signy-Centre, Switzerland
Fax: [phone] Tel.: [phone]

Fax: [phone]

RxOnly Caution: USA Federal Law restricts the sale, distribution, or use of this device

to, by, or on the order of a licensed healthcare practitioner.

Haemonetics Worldwide

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

Please direct any written inquiries to the appropriate address. For a list of
worldwide office locations and contact information, visit

www.haemonetics.com/officelocations.

Table of Contents

Publication information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Copyright Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Confidential/Proprietary Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Document Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Trademarks and Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

RxOnly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Haemonetics Worldwide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Chapter 1, Introduction

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

What is the purpose of this manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Symbols found in this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Symbols found on the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Additional support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Chapter 2, Principles of operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Safety card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Function and safety structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Safety card state codes/interface requirements . . . . . . . . . . . . . . . . . . .28

Safety operational sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Application phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Design overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Timing and watchdog logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Code/state decoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Safety evaluation circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Miscellaneous circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Valve driver card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Pneumatic valve drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Pneumatic compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

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Safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Motor driver card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Pump motor drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Centrifuge controller and driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Processor card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Microprocessor kernel PALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Interrupt control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Digital I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

RS232 port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Display and keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Other features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Analog section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Analog multiplexer and test logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Programmable gain amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

A/D converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Hardware components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Photoelectric assembly (sensor head) . . . . . . . . . . . . . . . . . . . . . . . . . .67

Photoelectric assembly (power block) . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Pump motor driver and encoder feedback . . . . . . . . . . . . . . . . . . . . . . .68

High-pressure air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Pump platen position switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Proximity sensor (disposable loaded sensor) . . . . . . . . . . . . . . . . . . . . .69

Centrifuge motor stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Load cell (waste bag weigher). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Reservoir level sensor gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Compression load cell (clamped line detector) . . . . . . . . . . . . . . . . . . . .73

Air detector sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Assembly pinch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Todd power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Condor power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Bowl optics - single lens (CS5 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Bowl optics - dual lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Line sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Turbidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Power-on self test (POST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Wash (70 mL bowl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Sequester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Air detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Reservoir level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

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Clamped line sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

CRC16 and checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Data acquisition card (european software only) . . . . . . . . . . . . . . . . . . . . . .98

General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Voltage and current requirements range . . . . . . . . . . . . . . . . . . . . . . . . .99

Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Data card schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Functional modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Thermal printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Nonthermal printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Chapter 3, European setup options

Data card kit installation procedure

(optional, european software only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Thermal printer installation procedure

(optional, european software only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Nonthermal printer installation procedure

(optional, european software only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

PC installation procedure

(optional, european software only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Data acquisition testing

(optional, european software only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Data transfer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

7

Chapter 4, Preventive Maintenance / Calibration

Initial inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Ensure initial operational integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Record the program revision level. . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Preventive maintenance frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

System cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Centrifuge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Disposable manifold area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Membrane panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Air sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

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Outside of cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Equipment integrity inspection and consumables replacement . . . . . . . . .142

Electrical connections inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Hardware inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

220V Fuse Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Consumables replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Component testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Audible alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Power supply test — Todd power supply. . . . . . . . . . . . . . . . . . . . . . . .147

Power supply test - Condor power supply . . . . . . . . . . . . . . . . . . . . . . .148

Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Setup procedure for optics, date/time . . . . . . . . . . . . . . . . . . . . . . . . . .149

Pump platen sensor and disposable loaded sensor test . . . . . . . . . . . .154

Air Detector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Centrifuge cover function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Screen/ keypad test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Fluid sensor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Centrifuge test and calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Waste bag weigher calibration test . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

Waste bag weigher calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

Reservoir level sensor calibration test. . . . . . . . . . . . . . . . . . . . . . . . . .161

Reservoir level sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Clamped line sensor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

Clamped line sensor calibration: 230V devices only . . . . . . . . . . . . . . .163

Line sensor calibration test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

Line sensor calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

Bowl optics sensor calibration test - single beam . . . . . . . . . . . . . . . . .166

Bowl optics sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Internal inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171

System test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172

Functional run test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174

Bowl vibration test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175

Pump occlusion test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

Ground continuity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Leakage current test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Preventive maintenance checklist example . . . . . . . . . . . . . . . . . . . . . . . .179

Sample Service report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

Chapter 5, Troubleshooting

Error messages/symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

Display error history (US software only) - safety system error messages .200

Data downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

Items needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

Data download procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214

Retrieving data (US software) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

Retrieving data (European software). . . . . . . . . . . . . . . . . . . . . . . . . . .218

Retrieving data to Excel format (optional) . . . . . . . . . . . . . . . . . . . . . . .221

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Data interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222

Chapter 6, Disassembly

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234

Handling precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235

Rear panel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

Removing the rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

Removing the rear fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

Front panel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237

Disconnecting the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237

Removing the weigher load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237

Removing the weigher pivot bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237

Fluid deck assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239

Removing the fluid deck cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239

Disassembling the fluid deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239

Disassembling the display/keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

Disassembling the control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241

Disassembling the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242

Disassembling the backlight PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242

Disassembling the switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

Disassembling the pinch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

Compressor module assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245

Disassembling the compressor module. . . . . . . . . . . . . . . . . . . . . . . . .245

Disassembling the fluid deck PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . .245

Disassembling the three-valve manifold . . . . . . . . . . . . . . . . . . . . . . . .246

Disassembling the pneumatics PCB final assembly . . . . . . . . . . . . . . .246

Disassembling the compressor assembly . . . . . . . . . . . . . . . . . . . . . . .247

Pump rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248

Removing the pump rotor from the fluid deck . . . . . . . . . . . . . . . . . . . .248

Disassembling the pump platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248

Pump motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249

Disassembling the pump motor assembly. . . . . . . . . . . . . . . . . . . . . . .249

Assembling the pump motor assembly . . . . . . . . . . . . . . . . . . . . . . . . .249

Air detector assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251

Platen position switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

Disassembling the platen position switch assembly . . . . . . . . . . . . . . .252

Assembling the platen position switch assembly. . . . . . . . . . . . . . . . . .252

Disposable loaded sensor and proximity sensor assemblies . . . . . . . . . . .253

Disassembling the disposable loaded sensor assembly . . . . . . . . . . . .253

Proximity sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

Anvil door and anvil door lever assembly . . . . . . . . . . . . . . . . . . . . . . . . . .254

Disassembling the anvil door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254

Disassembling the anvil door lever assembly . . . . . . . . . . . . . . . . . . . .254

Clamped line sensor, line sensor, and fluid sensor assemblies . . . . . . . . .255

Disassembling the clamped line sensor assembly . . . . . . . . . . . . . . . .255

Disassembling the line sensor assembly. . . . . . . . . . . . . . . . . . . . . . . .255

Disassembling the fluid sensor assembly . . . . . . . . . . . . . . . . . . . . . . .255

Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256

9

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10

Disassembling the power supply assembly. . . . . . . . . . . . . . . . . . . . . .256

Assembling the power supply assembly . . . . . . . . . . . . . . . . . . . . . . . .256

Power entry module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Removing the power entry module . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Assembling the power entry module . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Removing the fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Optics module assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258

Disassembling the photoelectric assembly . . . . . . . . . . . . . . . . . . . . . .258

Line filter (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259

Disassembling the line filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259

Assembling the line filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259

AC power On/Off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260

Disassembling the AC power On/Off switch . . . . . . . . . . . . . . . . . . . . .260

Assembling the AC power On/Off switch . . . . . . . . . . . . . . . . . . . . . . . .260

Centrifuge assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

Ordering the correct hinge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262

Disassembling the centrifuge cover. . . . . . . . . . . . . . . . . . . . . . . . . . . .263

Disassembling the centrifuge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263

Mechanical chuck centrifuge motor removal and cleaning . . . . . . . . . .263

Single lens optics assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271

Dual lens optics assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271

Disassembling the fluid sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273

Centrifuge arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273

IV pole assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276

Telescoping IV pole modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276

Removing the existing (non-telescoping) IV pole . . . . . . . . . . . . . . . . .276

Removing the existing (telescoping) IV pole . . . . . . . . . . . . . . . . . . . . .280

Installing the new IV pole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281

Assembling the outer reservoir assembly . . . . . . . . . . . . . . . . . . . . . . .284

Reservoir load cell and harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289

Reassembling the old style IV pole (non-telescoping). . . . . . . . . . . . . .290

Reassembling the new style IV pole (telescoping) . . . . . . . . . . . . . . . .291

Installing the load cell and harness . . . . . . . . . . . . . . . . . . . . . . . . . . . .292

Card cage assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298

Disassembling the motor driver card . . . . . . . . . . . . . . . . . . . . . . . . . . .298

Disassembling the safety card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298

Disassembling the valve driver card . . . . . . . . . . . . . . . . . . . . . . . . . . .298

Disassembling the processor card . . . . . . . . . . . . . . . . . . . . . . . . . . . .299

Disassembling the backplane PCB assembly . . . . . . . . . . . . . . . . . . . .299

Appendix A, Parts listing

Display/keyboard assembly and overlays. . . . . . . . . . . . . . . . . . . . . . . . . .302

Top deck assembly, spring plunger, IV pole knobs. . . . . . . . . . . . . . . . . . .304

Fluid deck assemblies, cabinet sub assemblies, centrifuge header arm, and

drain tube assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305

Fluid deck assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305

Cabinet sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306

Centrifuge and drain tube assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .307

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11

IV pole upgrade kit and old style assembly . . . . . . . . . . . . . . . . . . . . . . . .309

Panels, card cages, cables, and power cord assemblies . . . . . . . . . . . . . . 311

Centrifuge cover and fluid deck assemblies, cover lock upgrade kits, and mis-

cellaneous centrifuge cover and drain parts . . . . . . . . . . . . . . . . . . . . . . . .313

Gray card, fixture, and socket parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315

Miscellaneous parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316

Cart assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316

Operation manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317

Data Card (230V machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318

Appendix B, Schematics

CS5/CS5+ elect system diagram, 37468 . . . . . . . . . . . . . . . . . . . . . . . . . .320

Cell Saver 5/5+ pneumatic schematic (mechanical chuck) , 47568 . . . . . .321

Deck distribution board, 34436 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322

Advanced backplane, 49485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

Chapter 1

Introduction

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

What is the purpose of this manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Symbols found in this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Symbols found on the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Additional support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

14 Introduction

Overview

What is the purpose of this manual?

This service manual provides detailed information for the installation and
maintenance of the Haemonetics® Cell Saver® 5 Autologous Blood Recovery
System.

The manual includes the following:

 Detailed descriptions of the device and all components

 How to troubleshoot and repair any difficulties

 How to properly maintain the device

Use this manual in conjunction with training supplied by qualified Haemonetics
personnel.

This manual covers device list numbers

 02005-110

 02005-110-EP

 02005-110-EPJ

 02005-220-E

 02005-220-EP

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Introduction 15

Symbols

Symbols found in this document

Symbols found on the device

The terms Note, Caution, and Warning are used in this manual, with the
following symbols, to emphasize certain details for the operator:

Note: Provides useful information regarding a procedure or operating
technique when using Haemonetics material.

Caution: Advises the operator against initiating an action or creating a situa­tion which could result in damage to equipment, or impair the quality of the
blood products; personal injury is unlikely.

Warning: Advises the operator against initiating an action or creating a
situation which could result in serious personal injury to the donor, the
operator, or the blood product recipient.

The following symbols may be found on the device or device packaging:

Attention

Consult accompanying documents.

Type CF

Type CF applied part provides a particular degree of protection
against electric shock; particularly regarding allowable-leak-
age current and reliability-of-the-protective-earth connection.

Electrical and electronic equipment waste (applies to EU
only)

Dispose of the device using a separate collection method (ac­cording to EU and local regulation for waste electrical and
electronic equipment).

IPX1

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

Protection against ingress vertically dripping water

Indicates that the enclosure of the device is designed to be
drip-proof, providing a higher-than-ordinary protection level
from drips, leaks, and spills.

Manufacturer

Alternating Current

16 Introduction

Fuse

Equipotentiality

Identifies the terminals, which, when connected together,
brings various parts of a system to the same potential.

Authorized representative in the European Community

Rx only (applies to USA only)

Federal (USA) law restricts the sale of the device to be includ­ed by or on the order of a physician, only.

Serial number

Catalog number

0123

ETL

Laser radiation

Shock hazard

CE Mark

General symbol for recovery/recyclable

To indicate that a material is part of a recovery/recycling pro­cess.

Note: Applicable only to those products or materials for which,
at the end of life, there is a well-defined collection route and re-

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Introduction 17

cycling process, and which does not significantly impair the ef­fectiveness of other recycling schemes.

250 mmHg

Maximum vacuum

Pollution control mark

Pollution control mark for products containing any of the six ref­erenced substances (Lead, Mercury, Cadmium, and so on) ac­cording to new Chinese regulations.

Storage conditions, humidity level

Storage conditions, temperature level

Storage conditions, keep dry

Fragile, handle with care

This end up

Read the instruction manual

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

18 Introduction

System overview

All Haemonetics Cell Saver® Autologous Blood Recovery Systems process
whole blood salvaged from the surgical field so that it may be reinfused to the
patient. Inside a spinning processing chamber (bowl) red blood cells (RBCs)
are separated from other blood components, such as platelets and plasma,
and from debris suctioned from the surgical site. The separated RBC are then
washed with saline solution. The washed, packed RBC may then be reinfused
to the patient. The Cell Saver 5/5+ can also collect platelet rich plasma (PRP)
before surgery.

The Cell Saver 5/5+ represents the fifth generation of Cell Saver 5/5+
Autologous Blood Collection Systems from Haemonetics. The CS5/CS5+
provides the highest level of automation available in a blood salvage system.

The design goal of the CS5/CS5+ was to produce a system that would rapidly
process a large volume of salvaged blood while keeping operation simple.
Great attention was given to keeping the control panel simple while providing
the operator with constant feedback on the operation of the device.

The control-panel displays only the keys that are available to the operator.
Manual operation keys are not visible in the automatic mode.

The tubing harness uses a manifold, so that the disposable setup is faster and
easier, while the possibility of improperly installing the tubing into the valves is
eliminated. The processing chamber, a Latham bowl, is held in place with a
mechanical chuck, making installation faster and easier. The top portion of the
bowl is visible, so that the operator can monitor blood separation.

The Cell Saver 5/5+ system consists of two parts: a device and a single-use
disposable set.

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Introduction 19

The major device components are identified in Figure 1.

Reservoir holder
with level sensor

Pigtails for saline,

anticoagulant and

Control panel

Fluid deck (with
valves, air detectors,
and pump)

reinfusion bags

Centrifuge
(with bowl optics
and fluid sensors)

Cover lock

Effluent-line sensor

Waste-bag
weigher hooks

Figure 1, Haemonetics® Cell Saver® 5+ Autologous Blood Recovery System

 The centrifuge holds the disposable bowl in place and spins it at high

speed. Inside the bowl, red blood cells (RBCs) are separated from other
blood components, debris, and saline.

 Bowl optics monitor the spinning bowl to determine the appropriate

moment to initiate certain actions such as cell washing.

 Valves control the fluid pathway of the disposable tubing set.

 A pump moves fluids through the tubing set. Salvaged whole blood is

brought from the reservoir into the bowl for processing. Saline wash
solution is brought from the saline bags on the IV pole to the bowl to wash
RBCs. The final product, washed packed RBCs, is pumped to a reinfusion
bag.

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

20 Introduction

 An effluent line sensor monitors the line from the bowl to the waste bag

to ensure that a minimum of RBC are lost and that the Wash mode is
complete.

 A waste bag weigher alerts the operator when the waste bag is full.

Figure 2 identifies major disposable set components:

HAEMONETICS

IOOO
9OO
8OO

7OO

6OO
5OO

4OO

Reinfusion bag

3OO

Saline (yellow) line

2OO

IOO

MILLILITERS

(APPROXIMATE)

DO NOT USE WITH PRESSURE CUFF

To reservoir

To saline bags

Reinfusion (blue) line

Reservoir (red) line

Centrifuge bowl

Tubing manifold

10

9
8
7
6

5
4

3
2

1

Waste bag

Figure 2, Cell Saver 5/5+ disposable set

 The bowl is the main disposable component. Inside the spinning bowl,

RBCs are separated from other blood components and from debris that
may have been collected along with the whole blood. The 70 ml bowl is
the blow-molded-bowl design (not shown).

 A tubing manifold is installed into a keyed slot on the CS5/CS5+ deck.

The keyed slot ensures that the tubing lines are installed in the
appropriate valves. There are three lines and three corresponding valves.
(The red line leads to the reservoir, the yellow line leads to the saline
bags, and the blue line leads to the reinfusion bag.)

 A waste bag holds the supernatant and waste fluids, which flow out of the

spinning bowl as the red blood cells (RBCs) are washed.

 A reservoir (not shown) stores whole blood and saline, which are

collected from the surgical field. The reservoir has a gross filter, which
removes large debris. The red line of the CS5/CS5+ disposable set
attaches to the reservoir.

 Two saline bags (not shown) are connected to the bag spikes on the

yellow saline line.

 A reinfusion bag is connected to the blue reinfusion line. After they are

processed, washed red blood cells suspended in saline are sent to this
bag.

P/N SM-CS5-01-EN, Manual revision: AB Haemonetics® Cell Saver® 5/5+ Service Manual

Introduction 21

Additional support

Many factors affect the performance of blood processing instruments, including
the functional integrity of the device, the consistency of the disposable set, and
the quality of blood salvaged.

This manual attempts to anticipate any service needs of the Cell Saver 5/5+. If
this manual does not answer your questions, call the Haemonetics Customer
Care Center at [phone]. For locations outside the U.S., contact the
Haemonetics local office.

See “Haemonetics Worldwide” on page 3 for a list of local offices.

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

Chapter 2

Principles of operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Safety card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Function and safety structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Safety card state codes/interface requirements . . . . . . . . . . . . . . . . . . .28

Safety operational sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Application phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Design overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Timing and watchdog logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Code/state decoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Safety evaluation circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Miscellaneous circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Valve driver card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Pneumatic valve drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Pneumatic compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Motor driver card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Circuit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Pump motor drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Centrifuge controller and driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Processor card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Microprocessor kernel PALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Bus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Interrupt control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Digital I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

RS232 port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Display and keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

24 Principles of operation

Other features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Analog section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Analog multiplexer and test logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Programmable gain amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

A/D converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Hardware components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Photoelectric assembly (sensor head) . . . . . . . . . . . . . . . . . . . . . . . . . .67

Photoelectric assembly (power block) . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Pump motor driver and encoder feedback . . . . . . . . . . . . . . . . . . . . . . .68

High-pressure air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Pump platen position switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Proximity sensor (disposable loaded sensor) . . . . . . . . . . . . . . . . . . . . .69

Centrifuge motor stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Load cell (waste bag weigher). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Reservoir level sensor gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Compression load cell (clamped line detector) . . . . . . . . . . . . . . . . . . . .73

Air detector sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Assembly pinch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Todd power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Condor power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Bowl optics - single lens (CS5 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Bowl optics - dual lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Line sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Turbidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Power-on self test (POST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Wash (70 mL bowl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Sequester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Air detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Reservoir level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Clamped line sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

CRC16 and checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Data acquisition card (european software only) . . . . . . . . . . . . . . . . . . . . . .98

General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Voltage and current requirements range . . . . . . . . . . . . . . . . . . . . . . . . .99

Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Data card schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Functional modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Thermal printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Nonthermal printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

P/N SM-CS5-01-EN, Manual revision: AB Haemonetics® Cell Saver® 5/5+ Service Manual

Principles of operation 25

Introduction

CS5/CS5+ devices manufactured after approximately October 2000 no longer
utilize the backplane PCB (P/N 36728-00) with the personality PCB (P/N
37253-00). These PCBs are combined in the new backplane PCB (P/N 49488-

00). The CS5/CS5+Service Manual chapters (Chapter 2, "Principles of

operation", Chapter 5, "Troubleshooting"; and Chapter 6, "Disassembly")

assume this newer configuration of the backplane PCB (P/N 49488-00). For
guidance on operation, troubleshooting, or disassembly of the older versions
of PCBs, refer to prior revisions of the CS5 Service Manual or contact the
Haemonetics Customer Care Center.

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

26 Principles of operation

Safety card

Safety features The following safety features are designed into the Cell Saver® 5:

 Electrical safety

 IEC 601-1:1988 medical equipment requirements for safety

 EN 601-1-2:1993 EMC compliance

 Logic supply over/under voltage

 Overspeed limit for centrifuge

 Mechanical safety

 Centrifuge/pump construction

 Interlocks

 Cabinet design

 Protection from over/under pressure

 Pump agreement (direction/speed) with device state

Function and safety structure

 Motor driver-fault detection

 Continual checking of CPU status and motor/valve feedback in order

to confirm device state

The safety card addresses all aspects of pump agreement with device state
and several aspects of electrical and mechanical safety.

The following is an outline of the function and safety structure employed by the
CS5/CS5+:

 A single microprocessor (μP) has control tasks for the function of the

system.

 The safety system consists of an independent, hardware safety board —

CS5/CS5+ safety card.

 The μP performs a self-test during T1-test (RAM, ROM, registers and

safety I/O) to verify its functionality.

 The safety system is tested by the μP, before every procedure, to see

whether it can fulfill its tasks in the correct manner.

 The μP and safety card read the same input signals.

 The μP sends test codes to the safety card; if any disagreement occurs,

the safety card sends an error message to the μP.

 Both the μP and the safety card are able to stop the function of the system

by independent shutdown paths (de-energizing motor and valves) and
initiate acoustical alarms (unsafe equipment state).

 When the μP T1 and safety card tests are completed the CS5/CS5+ is

considered a one-channel system (single fault analysis).

P/N SM-CS5-01-EN, Manual revision: AB Haemonetics® Cell Saver® 5/5+ Service Manual

Principles of operation 27

Sensor
T

Theory of operation

The safety card is a system that accepts direct CPU information as to the
device state; it independently verifies this state via a pump encoder and valve
feedback; it tests all appropriate sensor-safety limits, as defined for this state;
and if a fault condition is detected, it removes power from both pumps and
valves. Further, whenever a fault condition exists, an audible alarm is sounded
and information, as to its cause, is latched and made available to the CPU for
diagnostic purposes.

For a better understanding of how the safety card is integrated and used within
the CS5/CS5+, refer to the block diagram in Figure 3.

First, note that the upper relay, known as the safety or K1, controls the power
applied to both the valves and pumps. This relay will be opened whenever a
critical fault condition is indicated by the CPU or safety card.

The output contact of K1 is sensed and the on/off status is readable by the
CPU. At power-up and at the start of each procedure, this relay is tested by the
CPU.

The second relay is known as the pump or K2 relay and it controls the power
applied to the pumps. The safety card has exclusive control over it. The status
of this relay is also sensed and made available to both the CPU and the safety
card.

K1 and K2 will be opened whenever a safety fault is encountered by the safety
card.

est

Signals

Sensors

K2 is opened/closed for each safety card test executed at the beginning of a
procedure or when a standby (Manual/Stop) mode is required.

Fault

Summer

Drv

CPU

Relay Feedback

Drv

+28v

+
–

Safety/
Master Relay
K1

Valve

Power

Safety

+
–

Pump Relay
K2

Pump

Power

Isolated
Outputs

Card

Sensor

Relay Feedback

Figure 3, Safety card functional block diagram

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

28 Principles of operation

Safety card state codes/ interface requirements

Input register

The sole input port, for the safety card, is an 8-bit register (supporting read
back), which accepts state/test codes from the CPU. These codes are used by
the safety card in order to verify the device state as indicated by independent
sensors.

Whenever a new, device state (determined by valve and pump operation) is
called for, a code, representing this state, must be issued by the CPU.

This code is written to the safety card before the actual change of device state
is executed. This allows the safety card to distinguish between a normal state
advance and a state fault condition.

Data format

The 8-bit data information is partitioned into two fields. The first field consists
of 5 bits (D0 through D4) and is dedicated to command/state information. (Each
code possesses a minimum Hamming Distance of two.) The second field,
formed by the remaining bits (D5 through D7), is used to provide test signals.
A description of each field is given in Table 1.

Note: In order for the safety card to recognize the correct pump activity when
transitioning from one state to another, it will be necessary to transition through
the Pause or Standby state first (i.e., change code, because re-issued codes
are not recognized).

Table 1, Test code field

D7 D6 D5 Test

identifier

0 0 0 Nul No testing

0 1 0 State test Normally during the test phase

1 0 0 Beeper test To avoid annoying beeps during

1 1 0 Time base test Intended to be used to simulate a

Test description

generation of a state fault is
inhibited (replaced by a motor­movement fault). This code is
used as an override to ensure
that a state fault can open the
pump relay.

test, the beeper is disabled. This
code allows a test beep and is
required in order to enter the
application phase.

safety card clock failure, it also
aids (reduces the time required)
to synchronize the watchdog
signal.

P/N SM-CS5-01-EN, Manual revision: AB Haemonetics® Cell Saver® 5/5+ Service Manual

Principles of operation 29

Table 1, Test code field (Continued)

Safety operational sequence

D7 D6 D5 Test

identifier

0 0 1 Spare test Reserved for interlock application

0 1 1 Not used

1 1 1 Not used

1 0 1 Not used

1 1 1 Not used

Test description

Input register guidelines

After a code is issued by the CPU, proper pump and valve commands should
be issued (executing the code action).

Refer to the flow chart in Figure 4 as an aid in understanding the system
interactions with the safety card.

Haemonetics® Cell Saver® 5/5+ Service Manual P/N SM-CS5-01-EN, Manual revision: AB

30 Principles of operation

There are two basic phases of operation to consider for the safety card: the test
phase and application phase.

Test Phase

Application Phase

Power On Reset

Test Entry Code

Timing Verification

Relay Testing
Beeper Check

State Fault Test

Recovery Path

Application Entry Code

Watchdog, 5V Supply Pumps and
Clamps Continuously Monitored

Pause

Standby

Conc

Pump Relay
Deenergized

During Pause Interlocks May Be Tested.

**

Figure 4, Safety card test-flow diagram

**

Clear Test Checklist

*

Normal

Operation

Standby Code

Check Interlocks

*

Test Checklist

*

Sequence Tests

Allowed

WashFill

Return

“Load

*

Disposable”

Test phase

The sequence starting point is defined by entry into the test phase. This phase
is entered whenever the safety card receives a start code.

There are two ways that can happen:

 At power-up, the start code is obtained by default via the bus reset signal.

 During operation by direct CPU input of this code — used before initiating

a new procedure.

During this phase, the complete end-to-end testing of the safety card is
accomplished by the CPU outputting state codes and exercising sensor test­lines, then verifying the pump relay response and the safety card’s output
register data.

The key differences in functionality between test and application phases are:

P/N SM-CS5-01-EN, Manual revision: AB Haemonetics® Cell Saver® 5/5+ Service Manual