_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 1 of 10

http://www.gambro.com/en/usa_tech/ 800-525-2623 303-222-6500

Technical Update TAA.TU.12025 rev. 1 Effective: 12 MAR 2012CO# 12058

Product: Prismaflex

Subject: Troubleshooting I2C Problems in Prismaflex

From: Colin Campbell

Abstract: This document describes how to troubleshoot problems relating to the I2C serial

communications bus network that interconnects cards, scales, pumps and the loader inside the Prismaflex system. The key symptoms are Communications and Memory Error alarm messages on the screen. The primary troubleshooting tool is a “Ping” software program on the Revision 5.10 CD (p/n G5001808) which can be used on machines that operate on either rev. 5.10 or 3.20. By using the Ping tool and by selectively disconnecting I2C devices from the bus one can isolate which device is causing the problem.

Hardware Overview: Figure 1 shows the I2C bus connections between the applicable devices.

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 2 of 10

Figure 1 The Carrier Board (on behalf of the PC104/PCM control computer board) manages much of the communications. It conducts a “roll call” during the boot-up process and frequently afterwards to see if all the devices on the I2C bus are alive and well. It addresses each one individually and expects a reply from them. If that isn’t successful, error messages are displayed on the current screen and on the Examine Alarms screen with the message “Malfunction: Communication Error (x)” where the “x” can be a number from 1 to 7. The devices are connected by I2C cables of various lengths such as the one in Figure 2 to the right. Each cable is shown in the diagram as a thin line connecting one device to another. Each device has two identical I2C connectors on it. Note: These I2C cables are not spared by Gambro.

Figure 2 Rev. 5.10 CD Ping Tool The CD that the new 5.10 software comes on also has a set of factory programs including the Ping tool for use in troubleshooting I2C serial network connection problems. CAUTION: Do not attempt to use the other programs on the CD which can damage the software stored on the Prismaflex machine. Only use the Ping tool as instructed below. Instructions for loading and running the Ping tool: 1. Use the Hex wrench to open the back door of the Prismaflex. 2. With the power off, plug a PS/2 type keyboard into the keyboard cable socket on the PCM board. See

the figures below: Turn the power switch on. Locate the CD reader mounted sidewise on the left side of the machine. Press the button to open its drawer. Carefully move cables out of the way in order to gently pull the CD drawer all the way out so that you can insert the CD onto the center spindle. Close the drawer and turn the power off again.

3. Wait about 10 seconds and turn the power back on again. The processors will begin booting up and

you will see a familiar BIOS boot-up screen but with the phrases “Boot from CD” and “PrismaCD boot … “ on the bottom that indicates that it sees the bootable CD installed and will boot from it. See Figure 3 below. If you don’t see these phrases and instead it boots up the usual way go to the end of

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 3 of 10

this document for instructions on how to change the boot preferences in the BIOS software.

Figure 3

4. Instead of booting the usual Prismaflex application software it will boot the factory utilities from the CD and display the screen shown in figure 4.

Figure 4

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 4 of 10

5. Press the number 7 key on the PC/AT keyboard to bring the “Slave Test Menu” to the screen shown in figure 5.

Figure 5 6. On the PC/AT keyboard press the number 1 key to run the “Ping slaves” program. The result of the

Ping test will be shown in a screen like the example in Figure 6. The devices the Carrier successfully talked to will be listed by name and with “….OK” after the name. Devices that did not respond to the Ping request will have the phrase “….Failed” after their name such as the Line Set Loader in the example shown. If a single device fails, like in this example, and the devices before and after it can communicate then it’s probably simply a failure of that device. Replace that device and run the Ping test again to see if the problem is solved.

Figure 6

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 5 of 10

Other Failure Modes and Bus Re-configuration Experiments: If a device fails in such a way that it shorts the I2C bus data or clock line to ground it will cause the entire bus to not operate and all the devices will fail and the display will look like Figure 7. When the entire bus is not operating (but the Carrier board is operating as indicated by the “Carrier ….OK” message) then the challenge is to determine which device is causing the whole bus to fail. The tactic then becomes to reconfigure the bus by disconnecting one or more devices to find the culprit. When the culprit is disconnected from the bus the other devices should communicate successfully.

Figure 7 For example, we could borrow the longest cable, which usually connects the PIB Board to the ARPS Board, to connect the Carrier Board to only the PBP Pump as illustrated in Figure 8. The I2C cables usually connected to the Carrier Board and the device to test (PBP pump in this example) are disconnected just for this experiment. The display will show whether the one device that is connected works or not and the other devices that are not connected will show as Failed on the screen.

Figure 8

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 6 of 10

With this method each device can be tested individually to determine which ones can communicate and which ones can’t. Another re-configure scheme is to test a group of devices at a time to find the culprit. For example, disconnect the I2C cable between the ARPS Board and the Effluent Scale. See the illustration in Figure 9. When the Ping test is run it should show the four cards (Carrier, Protective, PIB, and ARPS) as “OK” but the devices starting from the Effluent scale and ending with the Blood Pump will fail since they are not currently connected. If any or all of those four cards fail then the problem lies among those four. The heavy black arrow indicates the four devices that are connected to the Carrier board.

Figure 9 If the cards test ok, you can expand the bus further by reconnecting the cable from the ARPS to Effluent Scale and disconnecting the cable from the Replacement Scale to the Syringe Pump. Now you would expect the devices from the Carrier to the Replacement Scale to be “OK”. If not, then the problem lies in that group. See Figure 10.

Figure 10

A different diagnostic clue is to look at the green LEDs on the slave pumps. If the bus is good all the way around to each of the slave pumps their green LED will be lit. If it’s not lit communications are not getting to it or that pump is bad. This only applies when the system boots up with the normal operating software; those LEDs don’t turn on when using the Ping tool.

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 7 of 10

Another reconfiguration variation can be to connect some early devices in the sequence and some later devices and leave out some in the middle. For example, if you suspect the Loader is killing the whole bus (a real case) you can configure like figure 11. Disconnect the suspect Loader in two steps: Step 1: Keep the bus connections intact from the Carrier to the Effluent Pump and use the Ping test to verify that much works. Step 2: Then borrow the long cable from the PIB board to the ARPS board and connect it from the Carrier to the 2nd (unused) I2C connector on the Blood Pump and use the Ping test to verify that this last segment of the bus works. This confirms all except the Loader are good and you can test the Loader individually like shown in Figure 8 above to confirm it’s bad. Figure 11 It’s handy to fabricate your own long custom I2C cable for such experimenting so that you don’t have to borrow one from the bus sequence like mentioned above. With it you can disconnect one or more devices and/or jumper around the suspect device(s) to have all the remaining devices connected for the Ping Test (see Figure 12 below). The black connectors at each end of the cable can be fabricated using Phoenix spare parts: connectors part number 6943195 and female pins 6939730 and use approximately 0.22mm gauge insulated stranded copper wire. Figure 12 7. When finished using the Ping tool, simply take the CD out of the CD reader drive, close the drive

drawer, turn the power off for approximately 10 seconds and turn power back on again. Let the system boot normally and wait a couple of minutes to see if Communications Error alarms have been solved.

I2C Board and the Power Supervision Board As part of the Rev 5.10 upgrade the I2C Board is replaced by the Power Supervision Board. They are located as shown in the bottom of Figure 9. The I2C Board simply provides an external connector for the internal I2C bus in the system. It doesn’t have an address and the Carrier Board doesn’t talk specifically to it. It can be disconnected without causing malfunctions while you are troubleshooting. When connected, its I2C sockets can be used for convenient access to the bus. The Power Supervision Board monitors the +5V power in the system by monitoring the +5V line in the I2C cabling. If the +5V goes away during treatment for any reason the board will emit its own alarm signal

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 8 of 10

powered by a big capacitor underneath the board. While troubleshooting the I2C you can disconnect the Power Supervision Board to perform the operations described above and then reconnect it again before returning the system for use in the ICU.

I2C Board Power Supervision Board

How to change the BIOS to boot from the 5.1 CD Normally, the BIOS software causes the CPU to boot from the “C: disk” (the Compact Flash in the Prismaflex). To use the Ping tool we want it to boot from the CD, if present, instead. To do this the BIOS must be configured to look for bootable software on the CD first and use it, if present, and boot from the disk if the CD isn’t present. To change the BIOS boot preferences (if necessary) connect the external PC keyboard into the keyboard socket and insert the 5.1 software CD into the CD drive as shown on page 2. When you first turn on the power press the Delete key several times when you see the first screen in Figure 13 below: (The wording in the CMOS screens may look a little different than these samples depending on the software version of the CMOS, but the functionality is very similar.) Figure 13 This will interrupt the boot process and take you to the CMOS SETUP UTILITY screens like Figure 14 below:

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 9 of 10

Use the PC keyboard up/down arrow keys to move the red highlight bar down to “BIOS FEATURES SETUP” (or “Advanced BIOS features” in other revs) and press the Enter key. This will take you to the screen in figure 15 below Figure 14 Use the keyboard up or down arrow keys to move the red highlight to the row labeled “Boot Sequence” ( or “First Boot Device”). Use the keyboard Page Up or Page Down keys to cycle through the available values until it says CDROM, C, A (or “CDROM”) and press the Enter key. Press the keyboard Esc key to exit back to the previous screen as shown in Figure 16 below: Figure 15

_________________________________________________________________________________________________________ Gambro Form# TAA.FRM.0137 Rev. 2 USA Technical Assistance Services CO# 11037; Effective 19-Jan-2011 Page 10 of 10

Press the keyboard F10 key to Save and Exit Setup. To answer the prompt “SAVE to CMOS and EXIT (Y/N)?” press the keyboard “Y” key to say Yes and press the Enter key to quit the CMOS configuration screen. Figure 16 Once you exit the CMOS configuration software the system will go back to the booting sequence and boot from the CD so that you can run the Ping tool. After you are done with the Ping utility you can take the CD out and store it in a safe place again. If you changed the booting sequence to use the Ping tool you may need to change it back to the previous configuration to boot the regular software from the “disk” (typically labeled HDD 0).