PCS2 Service and Maintenance Manual Rev d April 2003

Page 1

HAEMONETICS

®

PCS 2

®

Service and

Maintenance Manual

Page 2

HAEMONETICS

®

PCS 2

®

Service and Maintenance Manual

HAEMONETICS CORPORATION

400 Wood Road, Braintree, MA 02184

Part Number 38855-00

Rev. D, June 2003

Page 3

ii

PCS2 Service Manual

© 1994 Haemonetics Corporation

All Rights Reserved

Printed in U.S.A.

First Printing, April 1994

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.

Page 5

toc-ii

PCS2 Service Manual

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

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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

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PCS2 Service Manual

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

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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

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PCS2 Service Manual

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

Page 10

Chapter 1

Introduction

General

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, Troubleshooting

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.

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PCS2 Service Manual

Chapter 8, Cleaning and Maintenance

Describes routine maintenance procedures.

Chapter 9, Technical Bulletins.

Provides area to store Technical Bulletins.

Additional

Support

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.

Page 12

Chapter 2

Machine Part Replacement Reference

Cautions

Static

Discharge

Notes

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.

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PCS2 Service Manual

Rear Panel

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.

Fan 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.

Front Panel

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.

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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 Reassembly 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 Reassembly 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).

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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.

Card Cage

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.

Card 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.

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Chapter 2, Machine Part Replacement Reference

2-5

Processor Card

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 Program 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 Card

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.

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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 Board)

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.

Top Deck

Assembly

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.

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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.

AC 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 Reassembly 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.

2.

3.

4.

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

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

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

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

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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.)

Plasma

Weigher

Assembly

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.

Weigher 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.

Page 20

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 Lower 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 Lower 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.

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

Pinch Valve Reassembly 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.

AC/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.

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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 Assembly

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.

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PCS2 Service Manual

Centrifuge

Assembly

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.

Centrifuge 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.

Cover 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.

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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.)

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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.

Centrifuge 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.