Haemonetics PCS2 Service manual

HAEMONETICS

PCS

Service and Maintenance Manual

HAEMONETICS

PCS®2

Part Number 38855-00

Rev. D, June 2003

HAEMONETICS CORPORATION 400 Wood Road, Braintree, MA 02184

Service and Maintenance Manual

PROPRIETARY MATERIAL

Information and descriptions contained herein are the property of Haemonetics Corporation. Except where indicated, such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of Haemonetics Corporation.

TRADEMARKS

HAEMONETICS®and PCS®2 are registered trademarks of Haemonetics Corporation.

ii PCS2 Service Manual

Chapter 1, Introduction

General..........................................................................................................................................1-1

Additional Support .......................................................................................................................1-2

Chapter 2, Machine Part Replacement Reference

Cautions........................................................................................................................................2-1

Static Discharge............................................................................................................................2-1

Notes.............................................................................................................................................2-1

Rear Panel.....................................................................................................................................2-2

Fan Assembly.........................................................................................................................2-2

Cover Stops.............................................................................................................................2-2

Cuff Connector.......................................................................................................................2-2

Front Panel....................................................................................................................................2-2

Donor Line Air Detectors 1 and 2..........................................................................................2-3

Compressor.............................................................................................................................2-3

Front Panel Distribution Board...............................................................................................2-4

Card Cage.....................................................................................................................................2-4

Centrifuge Distribution Card..................................................................................................2-4

Processor Card........................................................................................................................2-5

Main Program Chip Assembly...............................................................................................2-5

Safety Card.............................................................................................................................2-5

Driver Card.............................................................................................................................2-6

Backplane Card (Mother Board) ............................................................................................2-6

Top Deck Assembly......................................................................................................................2-6

AC Air Detector................................................................................................................2-6

Blood Line Air Detector...................................................................................................2-7

Line Sensor.............................................................................................................................2-7

Top Deck Distribution Board..................................................................................................2-7

Plasma Weigher Assembly ...........................................................................................................2-8

Weigher Arm Assembly .........................................................................................................2-8

Table of Contents

Chapter 2, Machine Part Replacement Reference, cont.

Load Cell ................................................................................................................................2-8

Pinch Valves ...........................................................................................................................2-9

AC/Blood Pump Assembly...................................................................................................2-10

Rotor...............................................................................................................................2-10

Motor..............................................................................................................................2-11

SPM/DPM Sensor Assembly................................................................................................2-11

Centrifuge Assembly..................................................................................................................2-12

Cover Halves ..................................................................................................................2-12

Bushing Adjustment Kit.................................................................................................2-13

Cover Switch Assembly .................................................................................................2-15

Cover Latch ....................................................................................................................2-15

Fluid Sensor Assembly...................................................................................................2-16

Bowl Optics Assembly...................................................................................................2-16

Top Cover Assembly ..................................................................................................................2-17

Membrane Panel Assembly..................................................................................................2-17

Control Panel Distribution Cable....................................................................................2-18

Display Distribution Board...................................................................................................2-20

Vacuum Display....................................................................................................................2-20

Membrane Panel...................................................................................................................2-20

Power Entry Module...................................................................................................................2-21

Fuse.......................................................................................................................................2-21

Power Supply Assembly.............................................................................................................2-21

Replace Todd Power Supply with Todd Power Supply........................................................2-21

Replace Todd Power Supply with Condor Power Supply....................................................2-22

Replace Condor Power Supply with Condor Power Supply................................................2-23

Centrifuge Controller Card...................................................................................................2-24

AC and Saline Pole Holder Assembly........................................................................................2-24

Drain Tube Assembly.................................................................................................................2-24

Photoelectric Assembly..............................................................................................................2-24

Line Conditioner.........................................................................................................................2-25

Table 2-1, PCS2 Component Calibration and Diagnostic Matrix ..............................................2-26

Chapter 3, Basic Care and Preventive Maintenance

Initial Inspection...........................................................................................................................3-1

Visual Inspection ....................................................................................................................3-1

Ensure Initial Operational Integrity........................................................................................3-2

Record the Program Revision Level.......................................................................................3-2

System Cleaning...........................................................................................................................3-2

Equipment Integrity Inspection....................................................................................................3-2

Electrical Connections Inspection..........................................................................................3-2

toc-ii PCS2 Service Manual

PCS2 Service Manual toc-iii

Chapter 3, Preventive Maintenance, cont.

Pneumatic Connections Inspection.........................................................................................3-2

Hardware Inspection...............................................................................................................3-2

Consumables Replacement...........................................................................................................3-3

Filter Inspection......................................................................................................................3-3

Calibration Testing .......................................................................................................................3-3

Power Supply Voltages Test ...................................................................................................3-3

Valves Test..............................................................................................................................3-4

Valve Occlusion Test ..............................................................................................................3-4

Weigher Test...........................................................................................................................3-5

DPM Sensor Test....................................................................................................................3-5

Cuff Test .................................................................................................................................3-6

Display Test ............................................................................................................................3-6

Keyboard Test.........................................................................................................................3-6

Centrifuge Testing ........................................................................................................................3-7

Fluid Sensor Test ....................................................................................................................3-7

Centrifuge Cover and Lock Functional Test...........................................................................3-7

Centrifuge Speed and Bowl Vibration Test............................................................................3-7

Donor Lights Test ...................................................................................................................3-7

Line Sensor Test .....................................................................................................................3-8

Bowl Optics Signal Test .........................................................................................................3-8

Air Detector Test ..................................................................................................................3-10

PCS2 Functional Test ...........................................................................................................3-10

Safety Testing .............................................................................................................................3-12

Leakage Current ...................................................................................................................3-12

Ground Continuity................................................................................................................3-12

Chapter 4, Calibration

Calibration Procedures .................................................................................................................4-1

Power Supply Voltages...........................................................................................................4-1

Todd Power Supply...........................................................................................................4-1

Condor Power Supply.......................................................................................................4-3

Bowl Optics Signal.................................................................................................................4-3

Line Sensor Signal..................................................................................................................4-6

A/D .........................................................................................................................................4-6

Cuff...................................................................................................................................4-6

Weigher.............................................................................................................................4-7

P/N 36924-00 Weigher Arm .......................................................................................4-7

P/N 52025-00 Weigher Arm .......................................................................................4-8

Weigher Calibration When Using Collection Bottles.................................................4-8

Weigher Calibration When Using Collection Bags ....................................................4-9

Chapter 4, Calibration, cont.

Weigher Calibration When Using Collection Bottles and Bags .................................4-9

DPM ..............................................................................................................................4-9

Centrifuge.............................................................................................................................4-10

Safety System.......................................................................................................................4-11

Chapter 5, Installation and Configuration

Initial Inspection...........................................................................................................................5-1

Overall Cosmetic Check.........................................................................................................5-1

Internal Workmanship ............................................................................................................5-1

Configuration of Protocol Parameters..........................................................................................5-1

Language Configuration.........................................................................................................5-1

Protocol Selection...................................................................................................................5-2

Machine Settings ....................................................................................................................5-3

Serial Number Configuration .................................................................................................5-4

Collection Weight Configuration............................................................................................5-4

Bowl Configuration................................................................................................................5-5

Testing ..........................................................................................................................................5-6

Valves Test..............................................................................................................................5-6

Weigher Test...........................................................................................................................5-6

DPM Sensor Test....................................................................................................................5-7

Cuff Test .................................................................................................................................5-7

Display Test ............................................................................................................................5-7

Keyboard Test.........................................................................................................................5-8

Centrifuge Testing ..................................................................................................................5-8

Fluid Sensor Test ..............................................................................................................5-8

Centrifuge Cover & Lock Function Test ..........................................................................5-8

Centrifuge Speed and Bowl Vibration Test......................................................................5-8

Donor Lights Test ...................................................................................................................5-9

Line Sensor Test .....................................................................................................................5-9

Bowl Optics Signal Test .........................................................................................................5-9

Air Detector Test ..................................................................................................................5-11

PCS2 Functional Test ...........................................................................................................5-11

Leakage Current ...................................................................................................................5-13

Ground Continuity................................................................................................................5-13

Machine Transfers......................................................................................................................5-14

Source Plasma Customers Only ...........................................................................................5-14

PCS2 Machine Transfer Verfication Form ...........................................................................5-15

toc-iv PCS2 Service Manual

PCS2 Service Manual toc-v

Chapter 6, Troubleshooting

Messages.......................................................................................................................................6-1

Status Messages......................................................................................................................6-2

Error Messages.......................................................................................................................6-2

CPU Error Messages ........................................................................................................6-3

Notes ..............................................................................................................................6-4

CPU Error Message List...................................................................................................6-5

Safety System Error Messages.............................................................................................6-32

Command Register.........................................................................................................6-33

Table 6-1, Error Codes of the Command Register....................................................6-33

Fault Register..................................................................................................................6-33

Table 6-2, Error Codes of the Fault Register ............................................................6-34

Critical Register..............................................................................................................6-35

Table 6-3, Error Codes of the Critical Register ........................................................6-35

Chapter 7, Repair Parts List

PCS2 Exploded View ...................................................................................................................7-2

PCS2 Exploded View with Callouts.............................................................................................7-3

PCS2 Centrifuge Exploded Views with Callouts.........................................................................7-4

PCS2 Card Cage and Air Filters Exploded Views with Callouts.................................................7-5

PCS2 Power Supply Assembly Exploded Views with Callouts...................................................7-6

PCS2 Pump Assembly Exploded View with Callouts..................................................................7-7

Parts List by Assembly.................................................................................................................7-8

Used PCS2 Parts Return Procedure............................................................................................7-12

Chapter 8, Cleaning and Maintenance

Overview.......................................................................................................................................8-1

Cleaning........................................................................................................................................8-1

Routine Cleaning Schedule ....................................................................................................8-1

Cleaning Supplies Needed......................................................................................................8-2

Cleaning the PCS2..................................................................................................................8-2

Membrane Panel and Outer Cabinet.................................................................................8-2

Donor Pressure Monitor (DPM).......................................................................................8-3

Air Detectors.....................................................................................................................8-3

Line Sensor.......................................................................................................................8-3

Centrifuge Well.................................................................................................................8-4

Fluid Sensor......................................................................................................................8-7

Bowl Optics Lens .............................................................................................................8-7

Blood and Anticoagulant Pumps......................................................................................8-8

Chapter 8, Cleaning and Maintenance, cont.

Air Filters..........................................................................................................................8-9

Internal Chassis.................................................................................................................8-9

Leakage Current Check..............................................................................................................8-10

Return Goods Authorization (RGA)...........................................................................................8-11

RGA Procedure.....................................................................................................................8-11

Haemonetics Quality Program....................................................................................................8-12

Chapter 9, Technical Bulletins

toc-vi PCS2 Service Manual

This Service Manual is designed to provide detailed information for the installation and maintenance of the PCS2, which is a plasma collection system.

The manual contains nine chapters, including:

Chapter 1, Introduction

Describes the PCS2 Service Manual.

Chapter 2, Machine Part Replacement Reference

Describes detailed steps in disassembling the PCS2 and its subsystems.

Chapter 3, Basic Care and Preventive Maintenance

Describes detailed preventive maintenance procedures.

Chapter 4, Calibration

Describes detailed calibration procedures.

Chapter 5, Installation and Configuration

Describes detailed installation procedures and configuration of protocol parameters procedures.

Chapter 6, T

roubleshooting

Describes each of the CPU and safety system generated error messages, and describes detailed troubleshooting steps to resolve the problems.

Chapter 7, Repair Parts List

Provides exploded views of the PCS2 and its subsystems with part number and description call-outs. Includes parts list in assembly outline format for each available repair part or assembly.

Chapter 1

Introduction

General

Chapter 8, Cleaning and Maintenance

Describes routine maintenance procedures.

Chapter 9, Technical Bulletins.

Provides area to store Technical Bulletins.

Many factors affect the performance of component collection devices including the functional integrity of the instrument, the consistency of the disposable set, and the quality of the blood from the donor.

When the PCS2 is properly calibrated and maintained, the instrument is very reliable and predictable and is designed to withstand substantial abuse. There may be times, however, that a component may fail prematurely, or damage may occur during transport or as the result of fluid contamination.

In designing this manual, Haemonetics has attempted to address all possible service scenarios. There may be situations which were not predicted, and in such cases Haemonetics Product Support can be relied upon to provide outstanding service support. Product support can be obtained through the Haemonetics Hot Line at 800-356-3506.

1-2 PCS2 Service Manual

Additional

Support

Chapter 2 Machine Part Replacement Reference

Extreme caution should be exercised when working inside the PCS2 cabinet to avoid electrical shock. Particularly avoid contact with AC power connections and any electrolytic capacitors on printed circuit boards. Whenever possible, AC power should be disconnected from the PCS2 before opening the cabinet.

The PCS2 uses static sensitive electronics. Serious damage may occur to the sensitive electronics if static discharge is not controlled. Internal components should only be handled after proper precautions have been taken to prevent static discharge.

To reassemble the PCS2, reverse the disassembly steps. In some cases, Reassembly Notes have been added to direct your attention to any important steps.

For brevity, a procedure often will reference another procedure. For instance, when removing the top deck, the instructions will ask you to remove the centrifuge. Locate the centrifuge removal procedure for instructions on that particular step.

In most cases there is more than one way to remove a particular assembly. These instructions provide the most logical approach to disassembling the PCS2. With experience, you may develop a less methodical approach. You are encouraged to use whatever method best suits your particular situation.

When replacing certain machine components, it may be necessary to calibrate that component as well as other peripheral components. Calibration steps are listed in each component’s replacement procedure when needed. In addition, Table 2-1 at the end of this chapter provides a Component Calibration and Diagnostic Matrix indicating any necessary calibrations and diagnostic checks required for the specific component replacement.

Cautions

Static

Discharge

Notes

2-2 PCS2 Service Manual

1. Remove (3) Phillips head screws from the bottom edge of the rear panel.

2. Pull bottom edge 6" away from the cabinet, then pull the rear panel down and away from the upper lip of the cabinet.

3. Unplug the fans at P407 on the centrifuge distribution board.

4. Disconnect the cuff pneumatic line at the quick disconnect, approximately 12 inches from the rear panel.

5. Remove the ground wire from the ground lug on the rear panel.

an Assembly

1. Remove the rear panel.

2. Remove (2) nuts for each fan to be removed.

Note: All four fans should be replaced at the same time, even if only one

is failing.

Cover Stops

1. Remove the rear panel.

2. Remove (2) Phillips head screws for each cover stop to be removed.

Cuff Connector

1. Remove the rear panel.

2. Remove connector nut.

3. Push connector out of panel from rear.

1. Tilt the cabinet back slightly, and remove the (3) Phillips head screws from the bottom edge of the front panel.

2. Pull the front panel away from the cabinet, then pull the panel down and away from the upper lip of the cabinet.

3. Disconnect the cuff pneumatic line at the quick disconnect.

4. Disconnect the ribbon cable P503/703 at P703 on the mother backplane card.

5. Remove the ground wire from the ground lug on the front panel.

Rear Panel

Front Panel

Chapter 2, Machine Part Replacement Reference 2-3

Donor Line Air Detectors 1 and 2

1. Remove the front panel. (See page 2-2.)

2. Disconnect air detector from P701 for DLAD1 and/or P702 for DLAD2 on the front panel distribution board.

3. Remove (2) Phillips head screws from each air detector. Be aware of nylon spacers between air detector mounting holes and front panel.

4. Firmly press the air detector head (from the front) through the panel. This is normally a very tight fit, and may have been lubricated with silicone vacuum grease when assembled.

Donor Line 1 and 2 Reassemb

ly Notes

1. Air detector connectors are keyed to ensure proper location, but the air detectors themselves could accidentally be installed in the wrong location. The Donor Line Air Detector #1 at P701 is located in the upper panel location, and the Donor Line Air Detector #2 at P702 is located in the lower panel location.

2. When installing the air detector, be sure the grommet is in place in the panel, and lubricate the grommet inner diameter with silicone vacuum grease to ease the installation of the air detector head.

Note: LED to be located toward the inside of the front panel.

3. When reassembling, assure white nylon spacers are placed between air detectors and front panel at the mounting holes.

Compressor

1. Remove the front panel. (See page 2-2.)

2. Disconnect the compressor at P704 on the front panel distribution board.

3. Remove O-ring around compressor clip, if present.

4. Unclasp the compressor from the front panel mounting clip.

5. Disconnect the compressor from the pneumatic harness at any convenient junction.

6. Recalibrate compressor. Refer to Chapter 4, Calibration.

Compressor Reassemb

ly Notes

The compressor has a pressure port (P) and a vacuum port (V) that may not be labeled. The vacuum port (V) has tubing with a filter attached to it for drawing in air. The pressure port (P) has tubing with a filter attached, which is then connected to the pressure transducer and cuff pneumatic harness. If the tubing attached to the pressure and vacuum ports are crossed, the compressor will run but there will be no pressure output (cuff will not inflate).

2-4 PCS2 Service Manual

Note: The filters should be replaced when a new compressor is installed.

Front Panel Distribution Board

1. Remove the front panel. (See page 2-2.)

2. Disconnect P701, 702, 703, and 704 from the front panel distribution board.

3. Disconnect the ground wire from TS1.

4. Disconnect the compressor pneumatic line at the cuff pressure sensor. (P2 Port)

5. Remove (4) Phillips head screws at the front panel distribution board corners.

6. Recalibrate the compressor. Refer to Chapter 4, Calibration.

1. Remove the front and rear panels. (See page 2-2.)

2. From the front cavity, disconnect P501, P502, P503, P504, P506, P507, and TS1 ground from the backplane card. Label cables as they are removed.

3. Follow the directions for each of the following card cage boards. The cage is ultimately removed along with the backplane card.

4. Remove (4) Phillips head screws securing the card cage frame to the cabinet bases (2 in front, 2 in back).

5. Move the frame toward the rear of the cabinet, and slide out the back cavity of the cabinet.

Car

d Cage Reassembly Notes

The (3) main cards use similar backplane connectors, but the red keys prevent installing the card in the wrong location.

Centrifuge Distribution Card

1. Remove the front and rear panels. (See page 2-2.)

2. Disconnect P408 and P409 from the centrifuge distribution card (1/2 size board located at the far right of the card cage), then unclasp the black card levers and partially slide the centrifuge distribution card out of the card cage.

3. From the rear cavity, disconnect P404, P405, P406, P407, and ground wire at TS1 from the centrifuge distribution card, then completely remove the centrifuge distribution card from the card cage.

Card Cage

Chapter 2, Machine Part Replacement Reference 2-5

Processor Car

1. Remove the rear panel. (See page 2-2.)

2. Unclasp the card levers and unplug the processor card from the backplane card (located at far left of the card cage).

3. Slide the card out of the card cage.

4. If replacing the processor card, refer to Chapter 4 for calibration of the bowl optics signal, line sensor signal, A/D, centrifuge, and safety system, and Chapter 5 for configuration.

Note: Processor card MUST have Main Program IC (P/N 37008-01) chip

in position U26 prior to reassembly. Also, verify that the correct program version for your facility is installed. If program version is not correct contact the Haemonetics Hot Line.

Main Program Chip Assembly

1. Remove the processor card. (See above.)

2. Using an antistatic IC removal tool for a 32 pin IC, gently pull the main program IC from chip location U26. A future program upgrade may also utilize U23. If the IC removal tool is not available, use flat blade screwdriver to gently pry between IC chip and IC carrier from end to end until IC chip is out.

Note: Do NOT bend IC chip legs.

Main Pr

ogram Chip Reassembly Notes

The Main Program IC chip must be installed properly or the chip will be destroyed. At one end of the chip there is a small notch (half circle). This notch must align with the white notch silk-screened on the Processor card (notch points toward the backplane connectors).

Safety Car

1. Remove the rear panel. (See page 2-2.)

2. Unclasp the card levers and unplug the safety card from the backplane card (located as second card from the left in the card cage).

3. Slide the card out of the card cage.

4. If replacing the safety card, refer to Chapter 4, Calibration, for calibration of the safety system.

2-6 PCS2 Service Manual

Driver Card

1. Remove the rear panel. (See page 2-2.)

2. Unclasp the card levers and unplug the driver card from the backplane card (located as third card from the left in the card cage).

3. Slide the card out of the card cage.

4. If replacing the driver card, refer to Chapter 4, Calibration, for calibration of the safety system.

Backplane Card (Mother Boar

1. See all steps to removing the card cage. (See page 2-4.)

2. Remove (7) large Phillips head screws securing the backplane card to the card cage frame.

1. Remove the front and rear panels. (See page 2-2.)

2. Remove the centrifuge assembly. (See page 2-12.)

3. Disconnect P504 from the backplane card and thread ribbon cable through the rear panel.

4. Disconnect P501, P502, and P506 from the backplane card.

5. Disconnect the ground wire at the top deck ground bus that connects to the side panel ground bus.

6. Using a 3/8" wrench (or equivalent), remove the (4) #10-32 nuts that secure the top deck to the cabinet.

7. Firmly grasp the top deck and pull away from the cabinet.

AC Air Detector

1. Remove the front and rear panels. (See page 2-2.)

2. Disconnect P605 from the top deck distribution board.

3. Remove the right handle by removing the (2) Phillips head screws securing the inner and outer panels.

Note: It may be easier to access the screws if the AC pump is removed.

(See page 2-10.)

4. Remove the (2) Phillips head screws securing the air detector to the top deck.

5. Firmly press the air detector head (from the top) through the top deck. This is a very tight fit.

Note: See reassembly notes below.

Top Deck

Assembly

Chapter 2, Machine Part Replacement Reference 2-7

Blood Line Air Detector

1. Remove the front and rear panels. (See page 2-2.)

2. Remove blood pump assembly for easier access. (See page 2-10.)

3. Disconnect P606 from the top deck distribution board.

4. Remove the (2) Phillips head screws securing the air detector to the top deck.

5. Firmly press the air detector head (from the top) through the top deck. This is a very tight fit.

Note: See the following reassembly notes.

C and Blood Line Air Detector Reassembly Notes

1. Apply a light film of silicone vacuum grease to the air detector grommet before attempting to install the air detector.

2. If both top deck air detectors are removed, be sure to return the correct air detectors to the correct locations. The plugs are keyed, so use the descriptions on the top deck distribution board for identification. P605 is for the AC and P606 is for the Blood Line Air Detector.

3. LED is located toward the front of unit.

Line Sensor

1. Remove the rear panel. (See page 2-2.)

2. Disconnect P607 from the top deck distribution board.

3. Remove the (2) Phillips head screws securing the line sensor to the top deck.

Note: It may be necessary to use a ratchet or stubby screwdriver to access

these screws. If you still have trouble, you may have to slide the card cage back.

Line Sensor Reassemb

ly Notes

1. Be sure the line sensor gasket is in place between the sensor and the top deck before securing.

2. Calibrate the line sensor. Refer to the procedure in Chapter 4, Calibration.

Top Deck Distribution Board

1. Remove the front and rear panels. (See page 2-2.)

2. Remove the centrifuge. (See page 2-12.)

3. Remove the pumps. (See page 2-10.)

4. Remove or slide back the card cage (See page 2-4.)

2-8 PCS2 Service Manual

5. Disconnect all electrical connections on the top deck distribution board including the ground.

6. Remove the (6) Phillips head screws securing the top deck distribution board to the top deck.

Note: The top deck assembly may be removed as an alternative method.

(See page 2-6.)

Weigher Arm Assembly

Note: Extreme care must be used when doing this.

1. Remove the Phillips screw securing the weigher arm to the load cell standoff.

2. Remove the arm from the load cell upper standoff.

eigher Arm Reassembly Notes

The weigher arm is secured to the load cell by a screw mounted to the hexagonal shaped upper standoff assembly. The upper standoff is permanently attached to the stainless steel stud, connecting to the lower square standoff mounted inside the spring clip. This mounting configuration allows the lower standoff to be rotated in one of four positions. When securing the weigher arm to the upper standoff, ensure the weigher arm is adjusted to be perpendicular to the machine cabinet when the lower standoff is in one of its four positions. This may prove to be difficult without securing the load cell upper standoff with a 1/4 inch open wrench under the top deck while tightening the weigher arm screw. If tightened properly the arm and lower standoff will rotate as an integral piece. Purple Loctite must be used on the screw that attaches the weigher arm to the upper standoff.

Load Cell

Note: The load cell is a sensitive device and should be handled with care.

1. Remove the front and rear panels. (See page 2-2.)

2. Disconnect P506 from the backplane card and thread the cable around the side of the card cage.

3. Remove the weigher arm assembly (See above.)

4. Remove the centrifuge assembly (See page 2-12.) or slide the card cage back (See page 2-4.) approximately six inches to allow clearance to the weigher load cell.

5. Using a 7/32" wrench (or equivalent), remove the (2) M3 nuts, washers, and compression springs securing the load cell to the top deck.

Plasma

Weigher

Assembly

Chapter 2, Machine Part Replacement Reference 2-9

Load Cell Reassembly Notes

1. When routing the P506 wire, run the wire between the front panel and the pinch valves. Do NOT run the wire between the backplane card and the pinch valves. This could cause the machine to short out.

2. When attaching the load cell to the top deck, the spring fits over the securing shaft first, then the washer and then the nut. When tightening the nuts, tighten until nut is even with the bottom of stud. Turn nut six more complete revolutions.

3. Recalibrate the weigher assembly following the procedure in Chapter 4, Calibration.

Load Cell Lo

wer Standoff Replacement

Note: The load cell lower standoff replacement should only be performed

by Haemonetics personnel.

1. Remove the load cell assembly. (See page 2-8.)

2. Using a 1/4" wrench, secure the load cell’s upper standoff and using a 5/64" hex wrench, remove the setscrew located inside the load cell’s lower standoff. (Save this setscrew as it will be reinstalled in the replacement standoff.)

3. Securing the upper standoff, unscrew and remove the lower standoff from the load cell assembly.

Note: Do not remove the upper standoff from the load cell assembly.

Load Cell Lo

wer Standoff Reassembly Notes

1. When installing the replacement standoff, ensure that the standoff is between the spring clip.

2. When securing the standoff to the load cell assembly, tighten the upper standoff to the lower standoff until the entire assembly is hand tight, and then secure the standoff assembly by tightening the setscrew in the lower standoff using the 5/64" hex wrench.

3. Ensure that the upper standoff rotates smoothly and easily with a slight click before reinstalling the load cell assembly.

4. Recalibrate the weigher assembly, following the procedure in Chapter 4, Calibration, after the load cell and weigher arm have been reinstalled.

Pinch Valves

1. Remove the front panel. (See page 2-2.)

2. Using 11/16" wrench (or equivalent), remove (1) #8-32 nut securing the ground wire of the valve to be removed to the ground lug.

2-10 PCS2 Service Manual

3. Disconnect P608 for the Saline Valve, P609 for the Plasma Valve, and/or P611 for the Donor Valve.

4. Using 11/16" wrench (or equivalent), remove (2) #8-32 nuts securing the valve to the cabinet top deck.

5. Pull valve down through the top deck.

Note: The pinch valves’ harnesses may be tie-wrapped together. The tie-

wraps will need to be cut if the valve is to be removed.

Pinc

h Valve Reassembl

y Notes

1. Lightly lubricate the inside surface of the pinch valve gasket with silicone vacuum grease.

2. Install the gasket into the cabinet with the ridged lip facing up.

3. Slide the pinch valve into the gasket and mount into place.

4. Wipe excess grease from the pinch valve.

5. The three pinch valves are identical. Be sure to install the electrical connector in the proper location on the top deck distribution board. P608 is the Saline Valve, P609 is the Plasma Valve, and P611 is the Donor Valve.

AC/Blood Pump Assembly

1. Remove the rear panel. (See page 2-2.)

2. Disconnect P614 and P615 for the AC Pump, or P616 and P617 for the Blood Pump from the top deck distribution board.

3. Remove the (4) Phillips screws securing the pump assembly to the top deck.

4. Partially pull the pump assembly out of the top deck, and remove the (1) Phillips head screw securing the ground wire to the pump motor.

C/Blood Pump Reassembly Notes

1. When placing the pump back into the top deck, assure the gasket is between the top deck and the pump.

2. Ensure that the ground wire is reattached.

Rotor

1. Using a 5/32" hex wrench, remove the (1) #10-32 socket head screw securing the pump rotor to the pump shaft.

2. Pull the rotor out of the pump housing.

Note: If the rotor cannot be removed easily, contact the Haemonetics Hot

Line. Serious damage may occur to the pump assembly if too much force is used.

Chapter 2, Machine Part Replacement Reference 2-11

Rotor Reassembly Notes

When placing the rotor back into the pump housing, ensure that the slot on the underside of the rotor is aligned with the pin on the pump motor shaft. Do NOT overtighten the rotor screw.

Motor

1. Remove the pump assembly. (See page 2-10.)

2. Remove the pump rotor assembly. (See page 2-10.)

3. Using a 7/64" hex wrench, remove the (4) #6-32 socket head screws securing the pump housing to the pump motor. (Mark the position of the motor on the pump housing. This is functionally unimportant but will keep the reassembly process consistent).

4. Gently twist the pump head and lift it from the motor.

Caution: Do not attempt to disassemble the pump motor. Serious damage to the motor may result.

SPM/DPM Sensor Assemb

Note: List number 06002-110-NA machines do not have the SPM.

Note: The SPM/DPM is not utilized by the PCS2 safety system for

Platelet Poor Plasma (PPP) collection.

Note: With a thin wall socket, and a bit of experience, you may be able to

remove these sensors without removing the top deck.

1. Remove the rear panel. Remove the top deck (page 2-6) or remove the Blood Pump Assembly.

2. Disconnect P603 (for the SPM) or P604 (for the DPM) from the top deck distribution board.

3. Remove the ground wire from the SPM/DPM sensor assembly.

4. Remove the (2) nuts securing the SPM/DPM sensor assembly to the top deck.

5. Pull the SPM/DPM sensor assembly out of the top deck.

Note: The procedures in steps 6 and 7 should not be performed unless the

SPM/DPM sensor board is being replaced.

6. With or without first removing the SPM/DPM sensor assembly from the top deck, remove the (2) Phillips head screws securing the SPM/DPM sensor board to the SPM/DPM sensor assembly.

7. Gently twist and pull the SPM/DPM sensor board from the SPM/DPM pressure fitting.

8. We do not advise further disassembly of the SPM/DPM sensor assembly.

9. If replacing the DPM, recalibrate the DPM and Safety System, referring to the procedures in Chapter 4, Calibration.

2-12 PCS2 Service Manual

1. Remove the front and rear panels. (See page 2-2.)

2. Using a #8 hex bit, remove the (4) shoulder screws securing the centrifuge base to the centrifuge mounting fluid drain assembly.

3. Disconnect P404 and P406 from the centrifuge distribution card.

4. Disconnect the ground braid wire clamps Phillips head screws at the rear of the cabinet.

5. Remove the (2) optic cables from the photoelectric assembly by unscrewing the (2) plastic thumb screw fasteners.

6. If present, you may need to remove a retaining screw located at the front, right side of the centrifuge mounting fluid drain assembly.

7. Disconnect the ground wire located in the rear of the centrifuge.

8. Disconnect J3 from the centrifuge controller card at the front of the cabinet.

9. Carefully lift the centrifuge up and away from the top deck of the cabinet.

Centrifug

e Reassembly Notes

1. The centrifuge must be centered in the top deck cavity to prevent contact of the centrifuge with the cabinet during operation. If true centering cannot be achieved, ensure that the centrifuge is at least 1/16" from the cabinet, measured at four points separated by 90 degrees.

2. The centrifuge location is adjusted by loosening the four centrifuge mounting screws under the cabinet, and manipulating the centrifuge on the centrifuge mounting fluid drain assembly.

3. Install the centrifuge on the centrifuge mount, and tighten the four shoulder screws.

4. Adjust the centrifuge location, then tighten the four screws and recheck location of centrifuge.

5. Recalibrate the centrifuge and bowl optics, referring to the procedures in Chapter 4, Calibration.

ver Halves

1. Open the centrifuge cover halves.

2. Using a #8 hex bit, remove the (1) shoulder screw securing each cover half and pull the cover away from the cover hinge.

3. The centrifuge cover halves are a matched pair. It is very important that the components of each cover half are kept together if the cover halves are to be disassembled further.

Centrifuge

Assembly

Chapter 2, Machine Part Replacement Reference 2-13

Bushing Adjustment Kit

Note: For this procedure you should have the following equipment:

Screwdriver 1/8" L-hex wrench or equivalent 1/2" box wrench or equivalent Primer “T” P/N 10425-01 Loctite #222 (purple) P/N 10422-00 Hinge Bushing Adjustment Kit P/N 38064-00 Torque wrench (set to 15/16 in./lb) with a regular 6-point 1/2" socket

Warning!

Primer “T” activator is flammable and may be harmful if it comes in contact with skin or eyes. It is recommended that eye protection and rubber gloves be worn when using Primer “T.” Do not use near heat or an open flame.

1. Ensure the centrifuge cover is in the “unlocked” (or up) position.

2. Using the screwdriver, remove the two (2) headless shoulder screws at the centrifuge cover hinge area. These are the screws that are set inside the brass bushings. Apply the Primer “T” activator to the screws and set them aside.

3. Using the L-Hex wrench, temporarily fasten the centrifuge cover hinge on the right side with hex head shoulder screw, P/N 13833-19. Tighten the screw until the top hinge is drawn up against the base hinge. (See illustration below.)

2-14 PCS2 Service Manual

4. Using the 1/2" box wrench, fasten the left side of the cover hinge using the Bushing Press Tool, P/N 38067-02, and tighten until the bushing makes contact against the base hinge. (This tool will physically push the bushing into the cover hinge.) Next, tighten the Bushing Press Tool with a torque wrench set to 15/16 in./lb., until the click of the torque wrench is heard. This will ensure a firm press of the bushing against the base hinge. (See illustration below.)

Warning!

Failure to use a torque wrench set to the correct torque could cause damage to the bushings and render the centrifuge cover inoperable.

5. Check to make sure there is no side to side movement between the centrifuge cover hinge and the base hinge.

6. Remove the Bushing Press Tool from the left side of the centrifuge cover. Apply a couple of drops of purple Loctite to one of the previously removed headless shoulder screws and install in the cover.

7. Remove the shoulder screw from the right side of the centrifuge cover. Apply a couple of drops of purple Loctite to the previously removed headless shoulder screws and install in the cover.

Centrifug

e Cover Reassembly Notes

1. The hex shoulder screws are designed to be completely tightened and a nylon washer is fitted to provide a moderate amount of rotational resistance for each cover half. In some cases, completely tightening the shoulder screw may result in an immobile cover half due to an oversized nylon washer. In either case, it is extremely important that the shoulder screw is secured to the cover hinge with Loctite. Otherwise the shoulder screw may loosen and cause the cover half to vibrate.

2. Also, since the cover halves are hinged, they must be aligned so they simultaneously touch the cover latch when closed.

3. First mount one cover half completely.

4. Lower the cover half and slide it closed against the cover latch.

5. Position the second cover half, with the nylon washer installed, along the cover latch and the cover hinge.

6. Carefully slide the cover halves open (they are now geared), while maintaining the proper cover hinge position, then raise the cover halves.

7. Loctite and install the shoulder screw into the second cover half.

Chapter 2, Machine Part Replacement Reference 2-15

8. Test the position of the two cover halves when closed against the cover latch.

Cover Switch Assembl

1. Remove the centrifuge from the cabinet.

2. Remove the (2) #4 socket head screws or Phillips head screws securing the cover switch assembly to the centrifuge well.

3. Pull the cover switch assembly away from the centrifuge well.

ver Switch Reassembly Notes

1. The cover switch assembly mounting position is a calibration step.

2. Set switch engagement of cover switch assembly to the bottom of the shaft so that there is 3/8 to 5/8 clockwise turn of the centrifuge knob after both switches have been disengaged.

Cover Latch

Note: The cover latch is not designed for disassembly. These instructions

are provided in case the cover latch requires replacement.

1. Remove the knob disk. This can be accomplished by placing a thin flat screwdriver in the gap between the knob disk and the knob and tapping on the back of the handle of the screwdriver until the cap detaches from the knob.

Note: The knob disk is loctited to the knob. It may be difficult to detach

and require more force to separate it from the knob. Do not worry about damaging these components as they are going to be replaced.

2. Remove the centrifuge from the cabinet.

3. Remove the cover switch assembly from the centrifuge.

4. Remove the knob by unscrewing the retaining screw and unscrewing the knob from the centrifuge lock shaft.

5. Twist the centrifuge shaft spacer counterclockwise using vice grips or locking pliers. As the centrifuge shaft spacer is removed, the centrifuge lock shaft will drop out from the bottom of the centrifuge cap assembly. Save the spring for reuse with replacement parts.

6. Place the compression spring on the replacement lock shaft and insert it into the centrifuge cap assembly.

7. Prime and loctite the lock shaft threads at the base only, and then screw the centrifuge shaft spacer (threads up) on the lock shaft until the spacer bottoms out. Be sure that no loctite is touching the centrifuge cap assembly where the shaft and the spacer come into contact with the centrifuge cap assembly.

2-16 PCS2 Service Manual

8. Thread the large knurled centrifuge knob (flat side up) onto the lock shaft.

9. Install the o-ring into the channel of the centrifuge knob cap. Apply a light coating of vacuum grease or o-ring lubricant.

10. Apply a small amount of purple loctite onto the top of the lock shaft and thread the knob cap onto the shaft. Tighten the cap down using a small set of needle-nose or snap-ring pliers.

11. Close centrifuge cover halves to check the general operation of the assembly.

12. Apply a small amount of green loctite to the underside edge of the knob disk and set it onto the knob cap. Wipe off any excess loctite.

13. Install the cover switch assembly and calibrate the switch position.

14. Install the centrifuge into the cabinet.

Fluid Sensor Assembly

1. Remove the (1) center Phillips head screw from the fluid sensor assembly pcb.

2. Gently twist the fluid sensor assembly out of the centrifuge well.

3. When reinstalling, place a bead of rtv around sensor housing to seal.

Note: Ensure that the rtv does not cover the face of the detector.

wl Optics Assembly

Note: Do not perform this procedure unless you have the necessary test

fixtures to realign after reassembly. (This includes the optical alignment fixture and photographic gray card. See Chapter 4, Calibration.)

1. Remove the (1) Phillips head screw securing the ground to the optics assembly.

2. Using a 1/4" wrench (or equivalent), remove the (4) #4-40 hex nuts securing the optics assembly to the centrifuge well and pull off the (2) wedge-shaped spacers.

3. Gently push the top of the optics assembly into the centrifuge well, and guide the optics pipe through the cavity.

4. To remove the optics cable, firmly hold the optics assembly and, using a locking plier, grip the brass threaded coupler and unscrew the optics cable from the optics assembly.

5. Very carefully, remove any debris in the optics assembly (cable) threaded hole. Any dried primer/Loctite could interfere with the transmission of light.

Chapter 2, Machine Part Replacement Reference 2-17

Bowl Optics Reassemb

ly Notes

Refer to Chapter 4, Calibration, to properly adjust and calibrate the optics after reassembly.

1. Remove the front and rear panels. (See page 2-2.)

2. Disconnect P504 from the backplane card (located in the lower right hand corner).

3. Disconnect the display ground wire from the ground bus on the cabinet side (located on the left side when looking from the front of the cabinet).

4. Remove the (2) lower Phillips head screws securing the membrane panel ribbon cable to the upper deck (located above the card cage at the rear of the cabinet).

5. Using a #10 hex bit, remove the (2) shoulder screws securing the top cover assembly to the top deck while supporting the top cover assembly.

Membrane P

anel Assembly

1. Remove the (2) Phillips head screws securing the fiberglass decorative panel to the top cover assembly (inside hinge area).

2. Remove the (3) Phillips head screws securing the membrane panel to the top cover assembly.

3. Simultaneously pull the base of the membrane panel down and away from the top cover assembly to disengage the top panel catches from the catch plate.

4. Carefully pull the top of the membrane panel down to expose the inner wiring of the membrane panel.

5. Remove the (1) Phillips head screw on the top cover, securing the ground wire from the membrane panel to the top cover ground surface.

6. Disconnect the ribbon cable from the card cage assembly by following steps 1-4 of the disassembly instructions for the top cover assembly or go to step 7.

7. Using a 1/4" wrench (or equivalent), remove the (2) #4-40 nuts securing the ground from the ribbon cable to the top cover mounting plate.

8. Using a 1/4" wrench (or equivalent), remove the (2) #4-40 nuts securing the ribbon cable strain relief.

9. Disconnect P804 from the display distribution board.

Top Cover

Assembly

2-18 PCS2 Service Manual

Control Panel Distribution Cable

Note: The old-style cable is a multicolored ribbon cable and the new-style

cable is a solid blue ribbon cable.

Remo

al of the old cable.

1. Remove front and rear panel assembly.

2. Remove decorative and membrane panel assembly.

3. Remove the old cable assembly and the two brackets, discard all three components and retain the screws for use later.

4. Remove the retainer pad in the cover that the cable lay across and discard.

5. Remove the two Allen shoulder screws that secure the top cover to the deck.

6. Remove the two Phillips head screws holding the third cable bracket attached to the top deck (above card cage), discard bracket and retain screws for use later.

Installation of ne

w cable and parts.

1. Mount the body clamp (P/N 47132-02) to the deck using the two #632 x 3/8" long Phillips flat head screws (removed above) with a drop of purple Loctite. (Orient so that the long step is toward the centrifuge cut-out.)

2. Reinstall the top cover onto the top deck assembly, using the two Allen head shoulder screws removed above.

Note: Reinstall all ground wires that may have been removed when

removing the old cable, except the ground wire with the old cable. This ground wire and old cable are to be discarded.

3. On the membrane panel assembly, connect one end of the new distribution cable assembly (35231-00) to the display dist. PCB connector (P804). Secure the copper tape under the strain relief block and secure with the two #6-32 small pattern keps nuts (removed previously).

Note IMPORTANT: The strain relief block must be in the center of the

copper tape.

4. Install the new retainer pad (P/N 13549-02) onto the back of the decorative panel, centered on the radius and aligned with the edge.

5. Cut the EMI shielding tape (P/N 47015-00) into two 2" ± ¼" pieces, remove the protective paper from one piece and attach it lengthwise to the top cover, gray portion at the bottom, align with the center of the hinge nut plate and then affix onto the hinge nut plate about halfway up the hinge.

Note: Make sure that the hole for the decorative panel is not covered.

Chapter 2, Machine Part Replacement Reference 2-19

Remove the protective paper from the other piece of tape and attach it in the same manner inline with the other hinge nut plate.

6. Reinstall the membrane panel onto the top cover.

7. Reinstall the decorative panel onto the top cover.

8. Cut double-sided tape (P/N 18142-00) to a length of 1½" ± ¼". Adhere the tape to the underside of one of the EMI ferrite attenuators (P/N 39475-00).

9. Sandwich the ribbon cable from the top cover assembly between the attenuator with the tape and the attenuator (P/N 39475-00) without the tape at approximately 4" ± ¼" from the end of the cable jacket.

Note: The attenuator with the tape must be toward the card cage.

10. Install the two spring clips (P/N 47241-00) over each end as shown, reference balloon #50.

Note: The flat end of the spring clip must be toward the card cage.

11. Remove the protective paper from the tape on the attenuator and adhere the attenuator assembly with the ribbon cable to the top of the card cage.

Note: Do not cover slots in top of card cage.

12. Apply purple Loctite to the threads of the two #6-32 x 3/8" Phillips flat head screws (removed previously). Make sure the ribbon cable from the cover assembly is centered in the deck body clamp and secure the copper tape of the cable assembly under the strap clamp (P/N 47133-02) and secure in place with the Loctited screws.

Note IMPORTANT: The copper tape must be centered in the strap

clamp.

13. Reinstall cable connector into the backplane card.

14. Complete a Diagnostic and Functional Test according to the procedure outlined in Chapter 3.

+ 104 hidden pages