尤斯特拉HL20 Service Manual

JOSTRA HL 20
Service Manual
JOSTRA HL 20
Notes
Service Manual
Revision 00
JOSTRA HL 20
Contents
Contents
1
1.1
Purpose (Read this First) ....................................................... 1-1
1.2
1.2.1
Service ....................................................................................... 1-1

General ................................................................................. 1-1
1.2.2
Hazard notices ..................................................................... 1-1
1.2.3
Preventive maintenance......................................................... 1-2
1.2.4
Functional check .................................................................... 1-2
1.2.5
To the responsible service personnel..................................... 1-2
1.3
Special Notes .......................................................................... 1-3
1.4
Manuals .................................................................................... 1-3
1.5
Definitions and Abbreviations ............................................... 1-4
1.6
Location of Signs and Labels ................................................ 1-6
Revision 00
General
Description
2.1
Introduction ............................................................................. 2-1
2.2
2.2.1
Functional elements ............................................................... 2-2

Console ................................................................................ 2-2
2.2.2
Module Access Bay .............................................................. 2-3
2.2.3
System Control Panel ........................................................... 2-4
2.2.4
System Monitor Unit ............................................................. 2-5
2.2.5
Pump Front Panel ................................................................ 2-6
2.3
2.3.1
Technical Data ......................................................................... 2-7

Performance Standards ....................................................... 2-7
2.3.2
Console ................................................................................ 2-7
2.3.3
Pumps .................................................................................. 2-9
2.3.4
System Control Panel ......................................................... 2-10
2.3.5
Display Monitor ................................................................... 2-10
2.3.6
Air Bubble Detection ........................................................... 2-11
2.3.7
Ultrasonic Level Detection .................................................. 2-11
2.3.8
Capacitive Level Detection.................................................. 2-11
2.3.9
Temperature Measurement ................................................ 2-12
2.3.10
Pressure Control ................................................................ 2-12
2.3.11
Input/Output devices .......................................................... 2-13
2.3.12
Heater Cooler Unit .............................................................. 2-13
2.3.13
JOCAP ............................................................................... 2-14
Service Manual
Contents
JOSTRA HL 20
ii
Function
3.1
Principles of Operation .......................................................... 3-1
3.2
3.2.1
Mains and Battery Operation ................................................. 3-2

Start Options of the HL 20 .................................................... 3-2
3.2.2
Voltage Display .................................................................... 3-3
3.2.3
Mains Operation ................................................................... 3-4
3.2.4
Battery Operation ................................................................. 3-4
3.2.5
Charging the Battery ............................................................ 3-6
3.3
System Control Panel (SCP) .................................................. 3-7
3.4
System Monitor Unit (SMU) .................................................. 3-10
3.5
3.5.1
Pumps .................................................................................... 3-13

Single Head Pump (RPM) .................................................. 3-13
3.5.2
Twin Head Pump (TPM) ..................................................... 3-19
3.6
3.6.1
Console .................................................................................. 3-23

The Mains Power Supply ................................................... 3-24
3.6.2
The Main Transformer ........................................................ 3-25
3.6.3
The Power Supply Board ................................................... 3-27
3.6.4
The Battery ......................................................................... 3-30
3.7
3.7.1
Modules ................................................................................. 3-31

19" Rack and the Rear Panel Board .................................. 3-31
3.7.2
Power Supply Module (PSM) ............................................. 3-35
3.7.3
Console Control Module (CCM) ......................................... 3-36
3.7.4
Battery Charger Module (BCM) .......................................... 3-40
3.7.5
Control Panel and HCU Interconnection Module (CHI) ...... 3-42
3.7.6
Monitor Interface Module (MIM) ......................................... 3-42
3.7.7
Air Bubble Detector Module (ABD) ..................................... 3-45
3.7.8
Ultrasonic Level Detector Module (ULD) ............................ 3-49
3.7.9
Quad Temperature Module (QTM) ..................................... 3-52
3.7.10
Dual Pressure Modules (DPM) ........................................... 3-54
3.7.11
Air Emboli Protection Module (AEP) .................................. 3-57
3.7.12
Analog I/O Module (AIO) .................................................... 3-60
3.7.13
Digital I/O Module (DIO) ..................................................... 3-63
3.8
3.8.1
Interconnection Overview .................................................... 3-65

Power Distribution .............................................................. 3-65
3.8.2
Single Signal Paths ............................................................ 3-66
3.8.3
Digital Communication Path ............................................... 3-68
Service Manual
Revision 00
JOSTRA HL 20
3.9
3.9.1
Interfaces ............................................................................... 3-70

The ConsolePump Interface ............................................. 3-71
3.9.2
The System Control Panel interface ................................... 3-72
3.9.3
The System Monitor Unit interface ..................................... 3-73
3.9.4
The Console Control Module Interface ............................... 3-74
3.9.5
The Power Supply Module Interface .................................. 3-75
3.9.6
The Universal Module Interface ......................................... 3-76
3.9.7
The Self Test and Operation Status Outputs ..................... 3-77
Trouble Shooting
4.1
Alarm Response ...................................................................... 4-1
4.2
4.2.1
Alarm Tables ........................................................................... 4-2

Console ................................................................................ 4-2
4.2.2
Pump and Twin Pump .......................................................... 4-3
4.2.3
Bubble Module ..................................................................... 4-4
4.2.4
Level Module ........................................................................ 4-5
4.2.5
Pressure Module .................................................................. 4-6
4.2.6
Temperature Module ............................................................ 4-7
4.2.7
"Pulsatile" Module ................................................................ 4-8
4.3
4.3.1
Pumps ...................................................................................... 4-9

Reports on the Pump Flow Display ...................................... 4-9
4.3.2
Reports in the Pump Window ............................................... 4-9
4.3.3
In Case of Pump Error ........................................................ 4-10
4.4
4.4.1
Console .................................................................................. 4-11

Mains Power Failure ........................................................... 4-11
4.4.2
Error Reports ...................................................................... 4-11
4.4.3
Error Messages .................................................................. 4-12
4.4.4
Error Report EM7f .............................................................. 4-13
4.5
4.5.1
Modules ................................................................................. 4-14

Bubble and Level Detection Errors ..................................... 4-14
4.5.2
Pressure Module Errors ..................................................... 4-15
4.5.3
Temperature Module Errors ............................................... 4-15
Revision 00
Contents
Maintenance
5.1
5.1.1
Cleaning and Disinfection ...................................................... 5-1

General ................................................................................. 5-1
5.1.2
Pumps .................................................................................. 5-1
5.1.3
Sensors ................................................................................ 5-2
5.1.4
Jamming ON/OFF Buttons ................................................... 5-2
Service Manual
iii
Contents
JOSTRA HL 20
5.2
5.2.1
Preventive Maintenance ......................................................... 5-3

General ................................................................................ 5-3
5.2.2
Preventive Maintenance Interval .......................................... 5-3
5.2.3
Console mechanics .............................................................. 5-3
5.2.4
Pump mechanics .................................................................. 5-4
5.2.5
Pump electronics .................................................................. 5-4
5.2.6
System Control Panel and System Monitoring Unit ............. 5-5
5.2.7
Battery back-up .................................................................... 5-5
5.2.8
Others .................................................................................. 5-6
5.2.9
Electrical safety ..................................................................... 5-6
5.2.10
Preventive Maintenance Checklist ....................................... 5-7
5.3
5.3.1
Extensive Preventive Maintenance ....................................... 5-9

General ................................................................................ 5-9
5.3.2
Initial inspection .................................................................. 5-10
5.3.3
HL 20 Console .................................................................... 5-13
5.3.4
Single Pump ........................................................................ 5-16
5.3.5
Belt Replacement, Single Pump.......................................... 5-20
5.3.6
Twin Pump ......................................................................... 5-21
5.3.7
Belts with Pulley Replacement, Twin Pump ....................... 5-23
5.3.8
Extensive Preventive Maintenance Checklist ..................... 5-26
iv
Service
6.1
General ..................................................................................... 6-1
6.2
6.2.1
Operations Prior to Adjustment ............................................ 6-2

Open/Close SCP/SMU ......................................................... 6-2
6.2.2
Install Pump ......................................................................... 6-3
6.2.3
Remove Pump ...................................................................... 6-3
6.2.4
Open/Close Pump ................................................................ 6-4
6.2.5
Open/Close Console ............................................................ 6-5
6.2.6
Remove Module ................................................................... 6-6
6.2.7
Open/Close Module .............................................................. 6-7
6.3
6.3.1
SCP Adjustments .................................................................... 6-7

SCP Time and Date Setting ................................................. 6-7
6.4
6.4.1
SMU Adjustments ................................................................... 6-8

SMU Display Adjustments .................................................... 6-8
6.5
6.5.1
Pump Adjustments ................................................................. 6-9

Tube Installation ................................................................... 6-9
6.5.2
Occlusion Setting ................................................................. 6-9
6.5.3
Flow Rate Calibration ........................................................... 6-9
6.5.4
Belt replacement ................................................................. 6-11
6.5.5
Optical Tachometer Board Ajustment ................................ 6-11
Service Manual
Revision 00
JOSTRA HL 20
6.6
6.6.1
Console Adjustments ........................................................... 6-11

Mast Angle ......................................................................... 6-11
6.7
6.7.1
Module Adjustments ............................................................. 6-12

Power Percentage Adjustment CCM ............................... 6-12
6.7.2
Dual Pressure Module ........................................................ 6-12
6.8
6.8.1
Check Procedures ................................................................ 6-13

Checklist ............................................................................. 6-13
6.8.2
Pump Alarm Check Procedures ...................................... 6-21
6.9
6.9.1
Field Test Procedure ............................................................ 6-22

General ............................................................................... 6-22
6.9.2
Initial Inspection .................................................................. 6-24
6.9.3
Battery Capacity ................................................................. 6-25
6.9.4
Pressure Channels Calibration ........................................... 6-26
6.9.5
Stop Functions ................................................................... 6-27
6.9.6
Control Functions ............................................................... 6-28
6.9.7
Twin Pump Cardioplegia Slave Mode ................................ 6-33
6.9.8
Speed Accuracy ................................................................. 6-33
6.9.9
Pump Alarms ...................................................................... 6-34
6.9.10
Timers ................................................................................ 6-35
6.9.11
Temperature Module .......................................................... 6-35
6.9.12
Air Bubble Detector ............................................................ 6-36
6.9.13
Electrical Safety Test .......................................................... 6-37
6.9.14
User Setting Worksheet ..................................................... 6-38
6.9.15
Field Test Checklist ............................................................ 6-39
Revision 00
Contents
Installation
7.1
7.1.1
Unpacking ................................................................................ 7-1

Transport Package ............................................................... 7-1
7.1.2
General Unpacking ............................................................... 7-1
7.1.3
Cleaning ............................................................................... 7-1
7.2
7.2.1
Check after Installation .......................................................... 7-2

Consol mechanism ............................................................... 7-2
7.2.2
Total assembly ..................................................................... 7-2
7.2.3
Pump mechanism ................................................................. 7-2
7.2.4
Pump electronics .................................................................. 7-3
7.2.5
System Control Panel and System Monitoring Unit ............. 7-4
7.2.6
Battery backup ..................................................................... 7-4
7.2.7
Others ................................................................................... 7-4
7.2.8
Electrical safety .................................................................... 7-5
7.2.9
Formal handover .................................................................. 7-5
7.2.10
Installation Checklist ............................................................. 7-6
Service Manual
Contents
JOSTRA HL 20
Appendix A
Description of the HL-20 Selftest .......................................... A-1
Appendix B
Console Wiring Diagram ..........................................................B-1
vi
Service Manual
Revision 00
JOSTRA HL 20
1. General
General
1.1
Purpose (Read this First)

The purpose of this service manual is to describe the JOSTRA Heart Lung
Machine HL 20 system in order to give understanding necessary for making
checks after installation, adjustments, locating and repairing faults etc.
The manual covers:
Right and left oriented consoles
Two, four and five pump consoles
The monitoring modules including the System Control Panel and the
System Monitoring Unit.
1.2
Service
1.2.1
General
Responsibility for the safe functioning of the equipment reverts to the owner or
user in all cases in which service or repair has been done by a non-professional
or by persons who are not employed by or authorized by MAQUET, and when
the equipment is used for other than its intended purpose.
In addition to the Important information given here and in the related documents
(e. g. in the User's Manual), always pay attention to applicable local and
national regulations.
1.2.2
Hazard notices
WARNING
Service by unqualified service engineer!

Only service engineers trained and authorized by MAQUET shall be
permitted to perform installation, service or maintenance of the HL 20.
Service by an unqualified service engineer may result in injury to the
technician, the patient, other personnel or may cause damage to the
equipment.
CAUTION
ESD sensitive components!

When handling ESD-sensitive devices, established procedures must be
observed to prevent damage.
When working with ESD sensitive components, always use a grounded
wrist band and a grounded work surface. Adequate service tools must
always be used.
Revision 00
Service Manual
1-1
1. General
JOSTRA HL 20
Before disassembling or assembling of the HL 20, make sure that the:

Main Power Switch switch is set to Off.
Mains power cable is disconnected.
The unit is cleaned according to instructions in the User's Manual.
With power supply connected to the HL 20, there are energized electrical
components inside the unit. All personnel must exercise extreme caution if fault
tracing or adjustments are performed with power supply connected.
1.2.3
Preventive maintenance
The HL 20 must be serviced at regular intervals by personnel trained and
authorized by MAQUET. Refer to chapter 5. Maintenance. Any maintenance
or service must be noted in a log book provided.
1.2.4
Functional check
After any installation, maintenance or service intervention in the HL 20, perform
functions checks according to instructions in chapter 6. Service.
1.2.5
To the responsible service personnel

The contents of this document are not binding. If any significant difference is
found between the product and this document, please contact MAQUET for
further information.
We reserve the right to modify products without amending this document or
advising the user.
Only personnel trained and authorized by MAQUET shall be permitted to
perform installation, service or maintenance of the HL 20.
Only MAQUET genuine spare parts must be used. PC boards (spare parts)
must always be kept in a package for sensitive electronic devices. MAQUET will
not otherwise assume responsibility for the materials used, the work performed
or any possible consequences of same.
Surface mounted components on the PC boards must not be replaced. The PC
board is the only available spare part. The information in this manual regarding
components on the PC boards is intended for troubleshooting only.
Many circuit boards have jumpers which require proper placement for correct
operation. Verify jumper settings on new boards are identical with boards being
replaced. If installing a newer revision board then contact MAQUET Technical
Support for assistance.
Special waste. This product contains electronic and electrical components.
Discard disposable, replaced and left-over parts in accordance with appropriate
industrial and environmental standards.
1-2
Service Manual
Revision 00
JOSTRA HL 20
1.3
1. General
Special Notes
Pay attention to the special notes in the manual.
WARNING
Danger of severe personal injury!

An instruction or procedure, which if not carried out correctly, may result
in injury to the technician, the patient or other personnel.
CAUTION
Danger of damage to the equipment!

An instruction or procedure, which if not carried out correctly, may
damage the equipment.
NOTE
1.4
Notes are used to provide important or explanatory information.
Manuals
The HL 20 comprises a number of units. Some of these have their own
instruction manual and are therefore only described in brief in this manual.
Service documentation for the HL 20 consists of:
Revision 00
Manual
Contents
Users Manual
Practical and functional description of the

HL 20. The Users Manual is an
indispensable complement to the Service
Manual for proper servicing.
Service Manual
This Manual. Includes a brief description of

the HL 20 Self-test
Description of the HL 20 Selftest
Describes how to perform and evaluate all

self-tests on the HL 20.
Spare Parts information
Spare Parts information is published in the

HL 20 Spare Parts List.
Service Manual
1-3
1. General
1.5
JOSTRA HL 20
Definitions and Abbreviations
Mnemonic
Meaning
ABD
Air Bubble Detector
ABS
Air Bubble Sensor
ADC
Analogue to Digital Converter
AIO
Analogue In/Out Module
BCM
Battery Charger Module
CCB
Console Control Board
CCM
Console Control Module
CUED
The Control Unit Error Display. This is the display normally used for
displaying the real time clock, but can display a Master Error Code or a Panel
Error code. A master error is displayed in the form EMnn where nn is a
hexadecimal error code - HEC. A panel error is displayed on the form EPnn
where nn is a HEC.
DIO
Digital In/Out Module
DPM
Dual Pressure Module
External output
Output to an external device, such as a probe, a sensor or external

equipment such as a computer or a recorder.
Front panel
The front panel of a unit. On the pump front panel means the tilted panel with
flow knob and displays. On a module front panel means the panel with
external equipment connections, intervention switches etc.
Group
A group is a pump or the monitoring system.
HEC
Hexadecimal Error Code. Refer to Description of the HL 20 Self-test for the

used hexadecimal error codes.
MIM
Monitor Interface Module
MPU
Micro Processing Unit. Incorporates a microprocessor, some memory, serial

and parallel in/out ports and more. Almost every unit in HL 20 contains an
MPU.
MSG Display
The eight digit lower display on the pump's front panel which normally is
displaying the pump mode and tube size, but also is used when stepping
through the hierarchical menu.
ODU
With ODU means the connector on the bottom side of a pump and on the top
side of the console connecting the pump to the system.
Output
Output from a unit to the HL 20 system.
PCB
Printed Circuit Board
PSB
Power Supply Board
PSM
Power Supply Module
PWM
Pulse Width Modulation/Modulated etc.
QTM
Quad Temperature Module
RP
Rear Panel board of the 19" rack
RPM Display
The four digit display on the pump's front panel, normally showing the pump
speed in rpm or the calculated flow in lpm. This display is also used to report
internal pump faults.
SCP
System Control Panel
1-4
Service Manual
Revision 00
JOSTRA HL 20
1. General
Mnemonic
Meaning
SMU
System Monitoring Unit
Sqw signal
Square wave signal
ULD
Ultrasonic Level Detector Module
Unit
A module, a pump, the SCP or the SMU
Connectors are expressed as

Ln:a
where
L
is a letter - normally P
is a board unique connector number and
is a connector unique pin number
or
Ln:a-b
where
a-b
means all pins from pin a to pin b.
Example:
P1:3-4
means connector P1, pins 3 and 4
Test points
Abbreviations used for 0V:
0Vl = 0 V logic. To be used when measuring +5 V.
0Vm = 0 V monitor. To be used when measuring +24 V.
0Vp = 0 V pump. To be used when measuring +24 V.
0Vs = 0 V signal. To be used when measuring +12 V and -12 V.
Revision 00
Service Manual
1-5
1. General
1.6
JOSTRA HL 20
Location of Signs and Labels
This label is placed on the SCP,

the SMU, on each module
inside the Module Access Door
and on the bottom side of each
Pump.
This label is placed to the right

inside the Module Access Door.
The HL 20 Rear Side
1-6
Service Manual
Revision 00
JOSTRA HL 20
2. Description
Description
2.1
Introduction
The Jostra Heart Lung Machine HL 20 is a modular equipment system for the
regulation, control and monitoring of extracorporeal circulation.
The System Control Panel (SCP) contains all the controls necessary to run and
monitor all system functions, except individual pump settings. External ECG
signals and pressure traces, separate information windows for Cardioplegia and
bypass timing, different data pages of programmed presets and digital input
devices etc. can be displayed on the System Monitoring Unit (SMU).
Electronic modules for the supervision and control of various functions are
installed in a Module Bay at the rear of the Console.
An integrated data collection system collects and records data from all the
modules, and certain other external data inputs connected to the HL 20. This
information is written to Memory Cards for later retrieval and analysis.
The HL 20 is available with either two, four or five pump bays. In each bay a
single head pump or a twin head pump may be mounted. The SMU and SCP
can be mounted at the left, right or centered above the pumps. On right or left
oriented consoles, an integral writing surface folds down in front of the SCP.
More detailed information can be found in the User Manual.
7
7
5
6
4
2
3
1.
2.
3.
4.
Console
Pump Module
Writing board
System Control Panel (SCP)
5.
6.
7.
8.
System Monitoring Unit (SMU)

Halogen lamp
Infusion masts
Module Access Bay
(rear side of the Console)
HL 20 Main Parts
Revision 00
Service Manual
2-1
2. Description
JOSTRA HL 20
2.2
Functional elements
2.2.1
Console
The basic component of the HL 20 is the Console. It contains the complete
power supply for the pumps, the monitoring system and the halogen lamps. The
emergency battery power system is standard equipment on the HL 20 and is
installed inside the Console. The individual supervisory modules are installed
inside the Console and are accessible by opening the rear access door.
Front view
1. Main Switch
2. Monitoring System Switch
3. Battery Operation Warning Light
4. Battery Charging Indicator Light

5. Individual Pump Power Switches
Rear view
6. Module Access Door
HL 20 Console Functional elements
2-2
Service Manual
Revision 00
JOSTRA HL 20
2.2.2
2. Description
Module Access Bay

The individual monitoring modules of the Jostra HL 20 Heart Lung Machine are
installed in the Module Bay at the rear of the Console. Open the Module Access
Door at the back of the Console for access to the modules.
M IM
4-pump version
Inside the module box
Under the transparent flap

2-pump version
1.
2.
3.
4.
5.
6.
7.
Circuit-breaker for the distributor socket

Circuit-breakers for the pumps
Circuit-breaker for the Monitoring System
Main Circuit-breaker
System Ground
Circuit-breaker for the 24 V socket
Socket for an additional Halogen Lamp
(24V)
8. Power Supply Module
9. Air Emboli Protection Module (or Air
Protection Module)
10. Blank
11.
12.
13.
14.
15.
16.
17.
18.
19.

Analog In/Out Module
Dual Pressure Module, channel 1+2
Dual Pressure Module, channel 3+4
Console Control Module and Battery
Charger Module
System Control Panel socket
Digital In/Out Module
Sockets for EGB and RCU
Monitoring modules on 2-pump and 4-pump versions.
Revision 00
Service Manual
2-3
2. Description
2.2.3
JOSTRA HL 20

Switches and controls on the SCP are grouped into sections by function.
System Control Panel SCP
2-4
Service Manual
Revision 00
JOSTRA HL 20
2.2.4
2. Description
System Monitor Unit

The System Monitor Unit consists of a flat screen display and a keypad. The
screen display is capable of displaying multiple pages of information including
real-time ECG and pressure traces as well as multiple data pages.
The keys on the System Monitor Unit are used for recording events and
switching to different displays
Front view
1.
2.
3.
4.
5.
6.
7.
Flat Screen Display

Fast button
Stop button
Page Select button
Event Table button
Recording ON button
Recording OFF button
Side view
8. Event keys
9. Clear button
10.Enter button
11.OK LED
12.COM LED
13. (Not Used)
14.Screen Brightness adj.
15.ECG Curve amplitude adj.

16.Pressure Curve amplitude
adj.
17.ECG Curve position adj.
18.Pressure Curve position adj.
19.Memory Card slot
System Monitor Unit and Screen Adjustments
Revision 00
Service Manual
2-5
2. Description
2.2.5
JOSTRA HL 20
Pump Front Panel

The RPM, RPM and TPM Pump Modules are intended to be used as
components of the Jostra HL 20 Heart Lung Machine.
The RPM pump has a single pump head, and the TPM pump has two smaller
heads in the same package. Each head of the TPM pump can be controlled
independently, and the functions are the same as on the single head pump.
Various supervisory modules which monitor and control pump functions are
built into the HL 20.
RPM Front Panel
TPM Front Panel

1.
2.
3.
4.
5.
6.
7.
2-6
Speed Control Knob

Flow scale (LPM)
Speed scale (RPM)
Reverse buttons
Speed/Flow display
RPM/LPM button
RPM LED
Service Manual
8. LPM LED
9. Monitoring module intervention
LEDs
10.Status display
11.Menu button
12.Set button
13.Reverse Safety button (only TPM)
Revision 00
JOSTRA HL 20
2. Description
2.3
Technical Data
2.3.1
Performance Standards
The Jostra HL 20 meets following standards:
2.3.2
IEC 60 601-1, IEC 60 601-1-1, IEC 60 601-1-2
Safety class: type B
Electrical safety: Class 1
Classification (MDD Annex IX): IIb
Console
General
Line voltage, nominal .................................... 230 VAC, 50-60 Hz. Can be
optionally wired for 115 VAC,
60 Hz, 16 Amps.
Battery switch-over voltage ........................... ~ 196 VAC
Maximum current consumption ..................... 7 A
Power supply fuse ......................................... 16 A
Main fuse ....................................................... 7 A
Pump fuses.................................................... 16 A
Monitoring system fuse ................................. 16 A
Distributor socket fuse................................... 12 A
Batteries ........................................................ Two 12 V, 30 AH, gel-filled
Fuse for the halogen lamps........................... 3 A
Operating temperature .................................. 10C to 40C
(50 F to 104 F)
Storage temperature ..................................... 0C to 50C
(32 F to 122 F)
Dimensions (mm)
2-Pump consoles
Measurements: W D H............................ 493 600 1485
(19 24 58 in.)
Weight ........................................................... 50 kg (110 lb.)
4-Pump consoles
Measurements: W D H............................ 855 600 1485
(34 24 58 in.)
Weight ........................................................... 80 kg (176 lb.)
5-Pump consoles
Measurements: W D H ........................... 1036 600 1485
(41 24 58 in.)
Weight ........................................................... 96 kg (211 lb.)
Revision 00
Service Manual
2-7
2. Description
JOSTRA HL 20
All systems include:

Console control module .................................CCM
Power supply (DC to DC converter) ..............PSM
Internal Battery Charger ...............................BCM
Halogen Spotlight ..........................................24 Volt
Console accessories
Top Shelf, 4-pump console............................MTS
Top Shelf, 5-pump console............................MTS
Cross Mast, 4-pump console .........................CRM
Cross Mast, 5-pump console .........................CRM
Venous Clamps
Venous clamp, standard ................................VCS
Venous clamp, fast-acting ............................VCQ
Gas flow meters: for supplying the oxygenator with gas mixture
Gas flow meter, 2 tubes.................................GFM
O2: 0.2 to 15 LPM
CO2: 0.1 to 2 LPM
Gas flow meter, 3 tubes.................................GFM
O2: 0.2 to 15 LPM
CO2: 0.1 to 2 LPM
O2/CO2: 0.2 to 15 LPM
Sechrist gas blender, 2 hose .........................SGB
(O2/Air mixtures)
O2/Air: 0.2 to 1 LPM
and O2/Air: 2 to 10 LPM
Sechrist gas blender, 3 hose .........................SGB
(O2/Air/CO2 mixtures)
CO2: 0.2 to 1.4 LPM
Electronic gas blender, 2 hose ......................EGB
(O2/Air mixtures)
Console grounding cable .....................CEC
2-8
Service Manual
Revision 00
JOSTRA HL 20
2.3.3
2. Description
Pumps
Single Head Roller Pumps:
Universal tubing clamp system ..................... RPM
Insert tubing clamp system............................ RPM
Twin Head Roller Pumps:

TwinPump...................................................... TPM
Pump Accessories
Hand crank, single pump............................... HCS
Hand crank, TwinPump ................................ HCT
Adjustment screwdriver ................................. ASD
Pump Technical Data

The pumps conforms to:
IEC 60 601-1
Safety class: type B
Electrical safety: Class 1
Water protection: IP 64 (splashing water protected)
Specifications common to both single and TwinPump, unless noted.

Voltage supply ............................................... +24 V
Maximum Stalled Current ............................. 16 Amp at 24 V
Rotation Capabilities
Forward or reverse speed .......................... 0-250 RPM
Slave speed, single pump........................... 80-120% of master
( 5 RPM at 100 RPM master speed)
Cardioplegia slave speed , Twin Pump ...... 0.1% to 102% of master
RPM Display precision................................ 1 RPM
RPM Display resolution .............................. 1 RPM
Flow rates, single pumps
1/2" tubing ................................................... 0-10 LPM
3/8" tubing ................................................... 0-6.6 LPM
1/4" tubing ................................................... 0-3.2 LPM
Flow rates, Twin Pump
1/4" tubing ................................................... 0-1.5 LPM
Accuracy of LPM display
1/2" tubing ................................................... 0.15 LPM
3/8" tubing ................................................... 0.15 LPM
1/4" tubing ................................................... 0.018 LPM
Revision 00
Service Manual
2-9
2. Description
JOSTRA HL 20
Resolution of LPM display

1/2" tubing ...................................................0.1 LPM
3/8" tubing ...................................................0.1 LPM
1/4" tubing ...................................................0.01 LPM
Display range of Cardioplegia pump:
1/4" tubes ....................................................up to 655 Liter
3/8" or 1/2" tubes.........................................up to 6 553 Liter
Time.............................................................up to 65 535 Sec
(up to 18 hours)
Pulsatile RPM Pump Mode
Base flow range...........................................0 to 100%
Pulse start range .........................................0 to 60%
Pulse stop range .........................................20 to 80%
Triggering range (external)..........................40 to 200 BPM
Triggering range (internal)...........................40 to 180 BPM
Upper pulse rate alarm................................80 to 200 BPM
Lower pulse rate alarm................................40 to 100 BPM
Trigger accuracy ......................................... 2 BPM
Pulse Assist (weaning) mode......................1:1, 1:2, 1:3
Max. deviation of flow in case of error ...........10%
Max. tube diameter, single pump...................5/8" 3/32" (20.6 mm)
Max. tube diameter, Twin Pump ....................1/4" 3/32" (8.8 mm)
Pump Measurements:
Single Pump LWH ..................................180 375 270 mm
(7 15 10.6 In.)
Twin Pump LWH .....................................180 375 285 mm
(7 15 11.2 In.)
Weight
Single pump ...................................................Approx. 18 kg (40 Lb.)
TwinPump ......................................................Approx. 14 kg (31 Lb.)
2.3.4

System Control Panel (4 Pressure) .....SCP
2.3.5
Display Monitor
System monitor unit .............................SMU
Includes 24 programmable event buttons
Screen type....................................................EL display
Resolution ......................................................640 400
Monitor interface module .....................MIM

2-10
Service Manual
Revision 00
JOSTRA HL 20
2.3.6
2. Description
Air Bubble Detection

Air Bubble Detector module.................ABD
Module measurements L W H ............... 175 70 130 mm
(7 3 5 inches)
Sensitivity: Immediate pump stop: bubbles larger than 5 mm
Detection: bubbles larger than 300 m
Tube sizes ..................................................... 1/4", 3/8", 1/2"
wall thickness range ................................ 1/16" to 3/32"
Ultrasonic energy at sensor ......................... 0.1 Ws
Bubble detector accessories

Air bubble sensor .......................................... ABS
Bubble sensor measurements LWH ........ 90 45 38 mm
(3.5 2 1.5 in.)
Ultrasonic gel ................................................ UGD
Bubble sensor holder .................................... BSH
Sensor insert, BSI ......................................... 1/4" 1/16" tube
1/4" 3/32" tube
3/8" 1/16" tube
3/8" 3/32" tube
1/2" 1/16" tube
1/2" 3/32" tube
2.3.7
Ultrasonic Level Detection

Level Detector Module ..........................ULD
Energy emitted at sensor .............................. 1 Ws max.
Level Detector disposables

Level sensor holder ....................................... LSH
Ultrasound gel with dispenser ....................... UGD
2.3.8
Capacitive Level Detection

Level Detector Module ..........................AEP
Capacitive Level Sensor .......................CLS
Level Sensor Pad (disposables) ..........LSP
Revision 00
Service Manual
2-11
2. Description
2.3.9
JOSTRA HL 20
Temperature Measurement
Quad temperature module ...................QTM
Measurements, LWH.................................175 35 130 mm
(7 1.4 5 in.)
Display range .................................................0 to 50 C
(32 to 122F)
Resolution ......................................................0.1 C
Display refresh rate........................................1 Hz
Temperature measurement Accessories

Thermistor temperature probe, adult .............TTP
Thermistor temperature probe, pediatric .......TTP
Temperature Probe Box ................................TPB
Other probes available on request
2.3.10
Pressure Control
Dual pressure module ..........................DPM
Measurements, LWH.................................175 35 130 mm
(7 1.4 5 in.)
Display
Range .........................................................- 997 to +997 mm Hg
Resolution ...................................................1 mm Hg
Accuracy......................................................1% of full scale
Linearity.......................................................< 1% of full scale
Capture range ...............................................150 mm Hg
Gain adjustment.............................................30%
Transducer current supply .............................+5 Volt
Alarm range ...................................................through full scale
Control loop precision ....................................2 digits
Reaction time ................................................ 5 seconds
Pressure measurement accessories
Pressure transducer ............................EPT

(similar to Spectramed P 23 XL)
Measurement range.......................................-50 to 300 mm Hg
Pressure transducer holder .................PTH
2-12
Service Manual
Revision 00
JOSTRA HL 20
2.3.11
2. Description
Input/Output devices
Analogue In / Out module.....................AIO
Input impedance all ports .............................. 10 k
Min. Input voltage for full-scale..................... 0.25 VDC
Max. Input voltage for full-scale..................... 2.5 VDC
(range internally adjustable)
Pin allocation of the sockets, Analog In / Out Module

Input
Output
Input
Pin 1
ECG curve input
Pin 15
Pressure 2 curve
output
Pin 2
Pressure curve input
Pin 16
Pressure 1 average
output
Pin 3
Systolic pressure input
Pin 17
Pressure 2 average
output
Pin 4
Diastolic pressure input
Pin 18
Temperature 1 output
Pin 5
Mean pressure input
Pin 19
Pin 6
Free input
Pin 20
Pin 7
Free input
Pin 21
Pin 8
Free input
Pin 22
Arterial flow output
Pin 9
Circuit ground
Pin 23
Free output
Pin 10 13
Not connected
Pin 24
Circuit ground
Pin 14
Pressure 1 curve output
Pin 25
Ground
Digital Input-Output module.................DIO

In general, the HL 20 can send and receive digital signals to any system with an
industry standard input or output. Per customer request, the HL 20 will be
configured to communicate with specific devices.
2.3.12
Heater Cooler Unit

Heater Cooler Unit ........................................ HCU
Remote control Unit for HCU 20-600 ............ RCU
Remote control Cable.................................... RCC
Water Supply tubing ...................................... WST
Blanket Connection Kit .................................. BCK
Thermostatic water mixer .............................. TWM
Revision 00
Service Manual
2-13
2. Description
2.3.13
JOSTRA HL 20
JOCAP
JOCAP Serial Reader............................JSR
Software Package and User Manual included.
Computer requirements (PC 486 or compatible)
RAM.............................................................16 Mbyte
HDD.............................................................300 Mbyte
Windows......................................................3.x or 95
Connection ..................................................standard serial RS232 port
JOCAP memory card, 512 Kb .....................JMC
Shock, water, HF and magnetic resistant. Contactless coupled.
Measurements ...............................................120 54 4 mm
(5 2 1/4 in.)
2-14
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Function
3.1
Principles of Operation
The JOSTRA Heart Lung Machine HL 20 consists of four main parts
System Monitoring Unit (SMU)
Pumps (2, 4 or 5)
Console
Power Supply
Control Modules
The SCP is the system main computer as well as the users main interface to
the HL 20 system. It communicates with the SMU, the pumps and the modules
via the central databus (DINBUS). Individual pump settings are however made
on each pump.
The Monitoring Modules DPM, AEP, ULD and ABD can influence any required
pump.
See the other sections of this manual for details.
The HL 20 Block Diagram
Revision 00
Service Manual
3-1
3. Function
JOSTRA HL 20
3.2
Mains and Battery Operation
3.2.1
Start Options of the HL 20

The HL 20 system is started with the ON/OFF button (1). The system
monitoring units (2) and the pumps (5) can be switched ON/OFF separately
with the corresponding ON/OFF buttons.
The system monitoring units are the SCP, the SMU and all control modules
except the CCM
1. Main Switch
2. Monitoring System Switch
3. Battery Operation Warning Light
4. Battery Chargin Indicator Light

5. Individual Pump Power Switches
HL 20 ON/OFF buttons and indicators
The buttons 1,2 and 5 are lit when ON and mains supply is available. When
mains supply is not available and the machine is run on batteries, button 1 is
not lit. The indicator 3 is lit at power failure and the indicator 4 is lit at battery
charge.
3-2
Service Manual
Revision 00
JOSTRA HL 20
3.2.2
3. Function
Voltage Display
On the Console
The Battery Power Control indicator is illuminated at power failure and as long
as the line power is out.
The Battery Charge Control indicator is illuminated as long as the batteries are
charging.
On the SCP
1. Voltage Display
2. Battery Voltage button
3. Power Control indicators

4. Alarm OFF button
Console power information on the SCP.

During normal operation, line voltage as a percent of nominal is displayed in the
Voltage Display (1). The Power Control indicator (3) Mains is illuminated.
When the HL 20 is switched to battery operation
Voltage Display (1) begins to blink and battery voltage is displayed
Power Control indicator (3) Battery is illuminated
An acoustic alarm sounds.
The alarm can be switched OFF by pressing the Alarm OFF button (4).
Battery voltage can be checked at any time by pressing the Battery Voltage
button (2). Battery voltage in volts will be displayed as long as the button is
pressed.
Revision 00
Service Manual
3-3
3. Function
3.2.3
JOSTRA HL 20
Mains Operation
The HL 20 is designed to operate from conventional 220 to 240 (optionally 110
to 120) V AC. When operating in this mode, line voltage as a percent of nominal
is displayed in the Console window on the SCP.
That is, when 230 VAC (or optional 100-120 VAC) is detected by the system,
100% is displayed in the window. The lamp next to "Mains" is illuminated,
showing that the system is operating from Mains or line power.
3.2.4
Battery Operation
The power supply in the CCM constantly monitors input voltage. If the line
voltage falls below 85 % 5 % of the nominal voltage, the HL 20 unit is
automatically switched to battery operation.
The Console display on the SCP begins to blink, the "Battery" lamp on the SCP
is illuminated and an acoustic alarm sounds. The alarm can be switched OFF
by pressing the button with the blinking loudspeaker logo on the SCP. The
voltage display blinks, battery voltage is displayed and the "Battery" lamp on the
SCP is illuminated as long as the system is in battery operation. The Battery
Power Control indicator on the Console is lit.
WARNING
Battery Power.
Battery Power is not available if the Main Switch is OFF.
If adequate mains power is restored, the system automatically switches back to

mains.
The battery system on the HL 20 will run the complete system; all pumps,
supervisory modules, monitoring and recording continue to function completely
in case of power outage.
3-4
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Battery Operation Time

The following diagram[CE1] shows the drop of voltage during the discharging
process. Fully charged batteries have a voltage of about 27.4 volts.
27.4V
Battery-voltage curve during battery back-up mode

The battery voltage drops relatively slowly at the beginning of battery operation.
As the battery becomes exhausted, the voltage drops more rapidly.
The CCM monitors the battery voltage during battery operation.
When the voltage has dropped to 23 volts, there is only enough power for a few
more minutes of operation. The system warns the operator of the impending
halt by sounding an acoustic alarm. A double beep sounds which cannot be
silenced and the Battery Operation Warning Lamp on the console blinks.
When the battery voltage drops to 19.2 volts, operation of the pump motors
becomes unpredictable, and the system halts. At this point, a continuous tone is
heard, which can be switched off only by switching the Main Switch OFF.
Battery operation time depends on
the condition of the batteries (age and charge)
the load powered by the batteries.
The total length of battery operation time of the complete system (one arterial
pump at 4 LPM, three sucker pumps 50 RPM, display and monitoring) is
approximately 1.5 hours.
Revision 00
Service Manual
3-5
3. Function
JOSTRA HL 20
However; in an extended power outage (power failure), an early decision to

shut down non-critical pumps can significantly extend the battery operation
time. The perfusionist should plan to balance battery operation time against
pump requirements in case of power failure of uncertain duration. The following
table is intended to be a rough guide to the relative amount of power consumed
during battery operation of an HL 20 using two pumps only.
Relative Power Consumption:
Arterial Pump (3/8" tube, 4 LPM, 21 C blood, 100 mm Hg) ..............53%
Sucker Pump (3/8" tube, 1 LPM) .......................................................30%
System usage, complete ...................................................................11%
Halogen lamp.....................................................................................6%
To ensure maximum available battery capacity, the batteries should be
replaced every two years. See Maintenance.
3.2.5
Charging the Battery

The battery is automatically charged whenever the HL 20 is connected to line
voltage and the Main Switch on the front of the Console is switched ON. If the
batteries are being charged, the yellow Battery Charging Lamp on the Console
is illuminated.
WARNING
Do not cover the console when connected to the mains.

The batteries may overheat during charging if air circulation is restricted.
Fully discharged batteries require about 15 hours to recharge. During overnight

charging, plug the HL 20 in to line voltage, switch ON the Main Switch, and
switch OFF each individual pump module.
3-6
Service Manual
Revision 00
JOSTRA HL 20
3.3
3. Function

The SCP is the HL 20 users main interface and houses the system main
computer. It communicates with every smart module (module with MPU) in the
HL 20 system. The user can make input via the different SCP control buttons
and get information like various measurements, limits, alarms, overrides and
errors.
The SCP consists of two boards:
Revision 00
Display Board
Master Panel Board
Service Manual
3-7
3. Function
JOSTRA HL 20
Display Board
IC15
IC5
PM
PP
Master Panel Board
3-8
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Jumper Settings
Verify jumper settings on new boards are identical with boards being replaced.
If installing a newer revision board then contact MAQUET Technical Support for
assistance.
Test Points
TP0
Ground
TP1
Ground
TP2
+5V DC
TP3
+12V DC
TP5
+5V DC adjusted with Pot 1 5mV
TP6
TP7
+5V DC
TP8
Ground
TP9
Protective earth
Fuses
F1
1A
F2
4A
Surface mounted components must not be replaced. The PC board is the only
available spare part. The information above is intended for troubleshooting only.
Wiring
Revision 00
Cable
Connected
Panel cable
running through a mast to the connector on the

Rack.
Service Manual
3-9
3. Function
3.4
JOSTRA HL 20
System Monitor Unit (SMU)

The main task of the SMU is to display signals and measurements like:
the arterial pulsatile pump curve
the cardioplega window(s)
external signals from the DIO if programmed to.
ECG and pressure curves if connected to the AIO
It also handles:
sending R-trig signal to the SCP
accepting data from user to record into JOCAP
The JOCAP recorder is mounted inside the SMU. Several push buttons on the
SMU front is designated for the JOCAP system.
3-10
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Monitor Board
Jumper Settings
assistance.
Test Points
Revision 00
TP1
Protective earth
TP2
+5V ref.
TP3
0Vs
TP4
0Vl
TP5
+5V DC
TP6
+12V DV
TP7
-12V DC
TP8
VSYNC
TP9
HSYNC
TP10TP12
R-trig adjustment
Service Manual
3-11
3. Function
JOSTRA HL 20
Fuses
F1
4A
F2
1A
F3
1A
F4
4A
Wiring
3-12
Cable
Connected
Monitor cable
running through a mast to the MIM.
Service Manual
Revision 00
JOSTRA HL 20
3. Function
3.5
Pumps
3.5.1
Single Head Pump (RPM)

P6
Front Panel Board

Front Panel Board
JMP 1
closed
Note: Jumper 1 can be removed to silence the pump while
doing service.
P6
Revision 00
to connect the service terminal when running self test
Service Manual
3-13
3. Function
JOSTRA HL 20
Motor Control Board (on pumps delivered before june 1996)

Motor Control Board (on pumps delivered before June 1996)
JMP 2
closed
Test Points
Motor Control Board (on pumps delivered before June 1996)
TP0
Ground
TP1
Ground
TP2
Check for +5.1 0.1V
TP3
Check for +12 0.5V
TP4
Check for -12 0.5V
Motor Control Module 1 (on pumps delivered before june 1996)
3-14
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Test Points
Motor Control Module 1 (on pumps delivered before June 1996)
TP1
Ground
TP5
+5.000 0.005V DC ref. (Adjust with POT1)
TP6
+5.000 0.005V (Adjust with POT3)
Top view
Bottom view
Safety System Board
Jumper Settings
Safety System Board
assistance.
Test Points
Safety System Board
Revision 00
TP1
0Vs
TP5
+5.000 0.005V (Adjust with POT1 older revision boards).
Service Manual
3-15
3. Function
JOSTRA HL 20
Motor Control Board (on pumps delivered after June 1996)
Jumper Settings
Motor Control Board
assistance.
Test Points
Motor Control Board (on pumps delivered after June 1996)
3-16
TP0
Ground
TP1
Ground
TP2
Check for +5.1 0.1V
TP3
Check for +12 0.5V
TP4
Check for -12 0.5V
TP5
+24V
TP6
0Vp
TP7
Mot_Pwm
TP8
Motor
TP105
+15V 0.5V
TP106
Check for +5.000 0.005V
TP107
Set_val
TP108
Act_speedwal
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Top view
Bottom view
Pump Control Board
Jumper Settings
Pump Control Board
assistance.
Test Points
Pump Control Board
Revision 00
TP0
0Vl
TP1
0Vs
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
Service Manual
3-17
3. Function
JOSTRA HL 20
RPM Optical Tacho Board
Test Points
RPM Optical Tacho Board
TP1
Reflex detector signal 1
TP2
Reflex detector signal 2
TP3
Ground
Pump Interconnection Board
Test Points
Pump Interconnection Board
TP1
3-18
0Vs
Service Manual
Revision 00
JOSTRA HL 20
3.5.2
3. Function
Twin Head Pump (TPM)
Front Panel Board

TPM Front Panel Board
BR 1
open Note:
This jumper may be closed only in order to run

pump 2 without the pump 1 electronics.
Top view
Bottom view
Safety System Board
Jumper Settings
Safety System Board
assistance.
Test Points
Safety System Board
Revision 00
TP1
Ground
TP5
+5.000 0.005V (Adjust with P1)
Service Manual
3-19
3. Function
JOSTRA HL 20
TPM Motor Control Board
Jumper Settings
assistance.
Test Points
TP0
0Vl
TP1
0Vs
TP2
Check for +5.1 0.1V
TP3
Check for +12 0.5V
TP4
Check for -12 0.5V
TP7
Motor_Pwm
TP8
Motor
TP10
Tacho voltage
TP11
NOTE: POT1 adjusts the pump speed.
3-20
Service Manual
Revision 00
JOSTRA HL 20
3. Function
TPM Control Board
Jumper Settings
TPM Control Board
assistance.
Test Points
TPM Control Board
Revision 00
TP0
0Vl
TP1
0Vs
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
Service Manual
3-21
3. Function
JOSTRA HL 20
TPM Interconnection Board
TPM Optical Tacho Board
Test Points
TPM Optical Tacho Board
A special test cable might be needed to access the test points.
3-22
TP0 (J1:4)
Ground
TP1 (J1:2)
Reflex detector signal
Service Manual
Revision 00
JOSTRA HL 20
3.6
3. Function
Console
The HL 20 Console contains:
the Power Supply
the Mains Transformer
the Backup Battery
the 19" Rack
The 19" Rack holds the Power Supply Module and all monitoring modules. All
interconnections between different modules are done through the console
(mainly through the Rear Panel board in the 19 rack).
1. Backup Batteries
2. Mains Transformer
3. Mains Transformer Jumpers
4. Mains Contactor
5. 19 Rack
6. Power Supply Board
The inside of the Console
Revision 00
Service Manual
3-23
3. Function
3.6.1
JOSTRA HL 20
The Mains Power Supply

The mains power distributing elements are:
the mains cable and plug,
the mains fuse,
the mains filter,
the contactor,
the transformer
the power supply board.
CCM
POWER
BCM
Power Supply Board
Mains Power Supply interconnection.
3-24
Service Manual
Revision 00
JOSTRA HL 20
3.6.2
3. Function
The Mains Transformer

The Mains Transformer isolates the HL 20 from the Mains Power as well as
transforms the voltage to three different outputs. Different input voltages can be
accepted via jumper configuration.
Jumpers at Main Transformer
Settings
Jumper
Jumper
Input Voltage
AG
F B
100 VAC IN
AH
F C
110 VAC IN
DI
230 VAC IN
EK
240 VAC IN
Test Points
Revision 00
Green/Yellow
terminal
Protective earth
U1/V1
AC OUT
2u3/2v3
3 VAC
2u2/2v2
29 VAC
2 pair black cables
19 VAC
Service Manual
3-25
3. Function
JOSTRA HL 20
Fuses
None
Wiring
Cable
Connected
Earth cable
between the transformer and the Fuse Panel.
Temperature probe
between the transformer and P11 on the RP
Mains Power In
between the transformer and the main relay.
19 VAC (Main Output) cable
between the transformer and the PSB.
29 VAC cable
between the transformer and P9 on the RP.
3 VAC cable
Input Voltages
One of the following:
NOTE
Input
From
100 VAC
Main Switch Contactor
110 VAC
230 VAC
240 VAC
The jumpers shall be set accordingly. See Setting above.
Output Voltages
3-26
Output
To
19 VAC
the PSB
29 VAC
the BCM
3 VAC
the CCM
Service Manual
Revision 00
JOSTRA HL 20
3.6.3
3. Function
The Power Supply Board

The Power Supply Board feeds the pumps and the 19" Rack with 24 VDC. The
PSB is built on a collection of identical circuits (groups) one for each pump and
one for the 19" Rack. Each group mainly consists of a rectifier, a capacitor and
relays. The number of groups depends on if the HL 20 is a 2, 4 or 5 pump
version.
The power supply board serves three purposes:
Convert the 19 V transformer AC to 24 VDC for each group.
Select power source (battery or transformer) for each group. The selection
is controlled via a signal from the CCM.
Select power ON / OFF for each group (power path is cut or closed).
Power Supply Board working principle
Settings
None
Test Points
Negative battery terminal
0 VDV
Positive battery terminal
24VDC
P55, 35, 39, 43, 47, 51
24VDC
P57, 56, 39, 36, 41, 40
0 VDC
P 45, 44, 49, 48, 53, 52
0 VDC
P58, 38, 42, 46, 50, 54, TP1
Earth Ground
Fuses
Revision 00
P9 - P10
Monitor circuit-breaker
P11 - P12
Monitor circuit-breaker
P13 - P14
Pump 1 circuit-breaker
P15 - P16
P17 - P18
P19 - P20
P21 - P22
P23 - P24
P25 - P26
P27 - P28
Service Manual
3-27
3. Function
JOSTRA HL 20
P29 - P30
P31 - P32
Wiring
Cable
Connected
19VAC
between AC IN and transformer Output.
Ribbon cable or flat cable
between the 19" Rack (P13) and the PSB (P8).

Note: Cable not keyed, PSB-brown wire right,
19" Rack brown wire down.
P59 and P60
to P17 on the 19" Rack.
Battery Connections
to the battery terminals.
P33 and P34
to the spot light output on Fuse Panel.
Fuse connections
all to Fuse Panel
P1-P6
to ON/OFF switches
TP1
to earth ground
ODU Power Harness
between the output and the ODU connectors of

each pump.
Inputs
3-28
Input
To
P1: 3-4
Monitoring on/off switch
P2: 3-4
Pump 1 on/off switch
P3: 3-4
P4: 3-4
P5: 3-4
P6: 3-4
P9-P10
Monitoring supply rectifier fuse.
P11-P12
Monitoring supply main fuse. The rectifier fuse and the main
fuse are fitted in the same physical housing.
P13-P32
Connect to the rectifier fuses /main fuses according to the

following table:
P. 1
P. 2
P. 3
P. 4
P. 5
Rectifier
P13-P14
P17-P18
P21-P22
P25-P26
P29-P30
Main
P15-P16
P19-P20
P23-P24
P27-P28
P31-P32
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Outputs
Output
To
P1: 1-2
Monitoring on/off switch indicator
P2: 1-2
Pump 1 on/off switch indicator
P3: 1-2
P4: 1-2
P5: 1-2
P6: 1-2
P8:1-8
(Not used)
P8:9-14
BATTERY/RECTIFIER selector wires for each of the pumps

and the monitoring supply.
P8:15-20
FUSE_SENSOR wires for each of the pumps and the

Monitoring supply.
P35-P58
Connect to the pumps (P.1 - P.5) and the monitoring supply

according to the following table:
P.1
P. 2
P. 3
P. 4
P. 5
Monitoring
+24 Vpower
P35
P39
P43
P47
P51
P55
0V power
P36
P40
P44
P48
P52
P56
0V s+l
P37
P41
P45
P49
P53
P57
Prot. gnd.
P38
P42
P46
P50
P54
P58
P59-P60
NOTE
Revision 00
Connect to the CCM 20 via the RP board in order to power the

CCM 20 as soon as the console Main Switch is pressed
irregardless of any other switches.
If tapping on a relay causes it to operate then the power supply board

must be replaced.
Service Manual
3-29
3. Function
3.6.4
JOSTRA HL 20
The Battery
To provide the HL 20 system with power at mains power failure two self
contained, maintenance free lead batteries are included in the system.
See Maintenance for information about charging and periods of replacement.
Battery interconnection cable
Settings
Interconnection cable connects the two batteries to each other.
NOTE
Disconnect the interconnection cable when work is performed inside the

console.
Test Points
Output
24 VDC
Fuses
None
Wiring
Cable
Connected
Two black cables
between the negative terminal of the battery

and the PSB and the BCM respectively.
Two red cables
between the positive terminal of the battery and

the PSB and the BCM respectively.
Interconnection cable
between the two batteries.
Inputs
3-30
Outputs
Input
From
Output
To
24 VDC
the PSB
24 VDC
the BCM
Service Manual
Revision 00
JOSTRA HL 20
3. Function
3.7
Modules
3.7.1
19" Rack and the Rear Panel Board

The 19" rack interconnects all the modules. All access to the modules, the
panel and the monitor is done through the 19" rack.
The 24 VDC is fed via the RP board to the PSM. The 12 and +5 V are fed via
the RP board to the modules, the panel and the monitor. On the RP board a
saw-tooth signal is generated and fed to the modules. The saw-tooth signal is
used to synchronize the PWM stop signals when more than one module is
breaking ('slowing down') the same pump.
M IM
The 19 Rack, older revision (top) and newer (bottom)
Communication
As the RP board is merely a interconnection board, all connectors are
described under the corresponding units.
The LEVEL/BUBBLE, DUAL PRESSURE, TEMPERATURE, ANALOG IN/OUT
and AUX connectors are also described under THE UNIVERSAL MODULE
INTERFACE.
Revision 00
Service Manual
3-31
3. Function
JOSTRA HL 20
Rear Panel Board 1
Jumper Settings
3-32
JMP1
open
JMP2
open
JMP3
open
JMP4
open
JMP5
closed
JMP6
closed
JMP7
closed
JMP8
open
JMP9
open
JMP10
open
JMP11
open
JMP12
open
JMP13
open
JMP14
open
JMP15
open
JMP16
open
JMP17
open
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Test Points
On Rear Panel Board
TP0
0Vl
TP1
0Vs
TP2
+5V DC (+5.1V from PSM)
TP3
+12V DC
TP4
-12V DC
TP5
24V DC
TP6
0V CCB
TP7
0V CCM
TP8
+5V CCB
TP9
Sawtooth
TP10
DB Ground
Fuses
None
Wiring
Cable
Connected
Main switch cable
to P4.
Ribbon cable, or flat cable
between the PSB and P13.

Note: This cable is not keyed.
Revision 00
PSB
to brown wire to the right.
RP
to brown wire down.
Interconnection board,
mounted on the RP
to P14
29 VAC IN
between the transformer and P9.
Battery terminals
to P7
Battery temperature sensor
to P6
Fan
to P15
Battery indicator lamp
to P3
Charge indicator lamp
to P2
Buzzer
to P5
HCU
to the SYSCOM interface.
19 VAC
between the PSB and P17
24VDC
between the PSB and P1
Transformer temperature
sensor
to P11.
3VAC
between the transformer and P8
SYSCOM
between the panel interface and P12
Panel LEMO
between the Panel interface and P10
PSM
to J1 interface.
ABD
to J10 interface.
AIO
to J9 interface.
Service Manual
3-33
3. Function
JOSTRA HL 20
QTM
to J8 interface.
DPMx
to J7 interface.
DPMx
to J6 interface.
CCM
to J3 interface.
BCM
to J2 interface.
MIM
to J4 interface.
DIO
to J5 interface.
SCP
to panel interface.
Inputs
3V AC
19V AC
29V AC
24V DC
Outputs
5V DC
+12V DC
-12V DC
Battery charger output
3-34
Service Manual
Revision 00
JOSTRA HL 20
3.7.2
3. Function
Power Supply Module (PSM)

The Power Supply Module is a DC/DC converter creating DC voltage for all
systems and modules in the HL 20.
The PSM panel with LEDs, trim potentiometers and test sockets.
An illuminated LED in each field shows that the voltage matches the preset.
Each voltage can be checked at the test socket. Below the test socket is a
potentiometers to precisely trim each voltage.
WARNING
Voltage adjustments should be made by MAQUET service personnel

only.
Improperly set voltages can result in unexpected performance, module
failure or complete system failure.
Settings
Test Points
None
-12V DC test
-12.1V
+12V DC test
+12.1V
+5V DC test
+5.1V
Fuses
SI1
4A
Wiring
Cable
Connected
Power cable
between the PSB an P1 on the RP.
Inputs
Revision 00
Output
Input
From
19.2 - 28 VDC
(typical 24 VDC)
PSB
Output
To
12.1 VDC Almost all modules
Service Manual
+5.1 VDC
Almost all modules
3-35
3. Function
3.7.3
JOSTRA HL 20
Console Control Module (CCM)

The CCM supervises the basic functions of the console. Inside the CCM the
Battery Charge Module (BCM) is located. To access the BCM it is necessary to
remove the CCM. See Battery Charge Module for more information.
Console Control Module (CCM) (and the Battery Charger Module (BCM))
Inside the CCM is one PCB, the Console Control Board (CCB). The CCB
contains an MPU which controls the CCM and transmits pump select and mode
select signals.
The CCM performes the following:
It switches to battery mode when the mains voltage goes below 85%.
It Displays Fuse Error on the SCP in case of a broken fuse on the Fuse
Panel.
It creates the PUMP_SELx and the x_MODE signals. These signals are
used when programming the pumps to different modes.
It sends the signals that handles the start, stop and monitoring of the battery
charging.
In case of mains voltage failure the signals POWER_FAIL and /POWER_FAIL

are generated. When the POWER_FAIL signal appears the CCM switches the
battery/rectifier relays on the PSB to battery operation.
3-36
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Console Control Board
Jumper Settings
assistance.
Test Points
TP7
Earth
TP0
0V CCB
TP2
+5V DC
TP3
+12V DC
TP5
5.000V 5mV. If POT1 is not fitted; just check.
TP6
+24V DC
TP8
2.6V via Pot 2 approximately
TP9
3V via Pot 3 tolerance = 10mV
Fuses
Fuse 1
1A
Fuse 2
4A
Fuse 3
4A
Fuse 4
63 mA
Revision 00
Service Manual
3-37
3. Function
JOSTRA HL 20
Wiring
Cable
Connected
Ribbon Cable
between the PSB and the RP used for sensing

blown fuses and for sending the B_x signals.
Main Switch
between the mains switch and P4 on the RP.
19V AC IN
between the PSB and P17 on the RP.
3V AC IN
between the transformer and PSB on the RP.
Battery Indicator
between the battery indicator and P3 on the

RP.
Charge Indicator
between the indicator and P2 on the RP.
Inputs
Input
from
P1:A7-A15
PSB receive the voltages after the main circuit-breakers.

Used to detect blown circuit-breakers.
P1:A16
Transformer temp. sensor receives the transformer

temperature.
P1:A22,A24
DINBUS receive the DINBUS communication.
P1:B12
BCM receives the battery voltage divided to suit the

analogue input of the MPU.
P1:B16
--- Not used
P1:B17
Battery temp. sensor receives the battery temperature.
P1:B24-B25
Transformer carry pulses from the transformer. Used to

detect line voltage.
P1:B30-B31
Transformer Powers the CCM as soon as transformer (line)

voltage is present.
P1:B32
back up battery powers the CCM when no line voltage is

present
Outputs
3-38
Output
To
P1:A17-A21
The pumps 5V 100 Hz sqw signals if the corresponding

mode is free. Pulled low when the corresponding mode is
selected by a pump.
P1:A23,A25
DINBUS transmit the DINBUS communication from the CCM

to the system DINBUS.
P1:A27-A30
PSB
P1:B26-B28
select battery or rectifier as power supply to monitoring and

pumps.
P1:B1
Main switch lights the main switch indicator.
P1:B3
Battery indicator lights the battery power indicator (on the

console's front).
P1:B5
Charge indicator lights the charging indicator (on the

console's front).
P1:B7
Console buzzer sounds the console buzzer (mounted on the

rear of the 19" rack).
Service Manual
Revision 00
JOSTRA HL 20
3. Function
P1:B9
BCM +5 VDC supply
P1:B10
BCM controls the relay connecting the 48 ohm resistor as

load.
P1:B11
Fan selects high/low speed of console mounted cooling fan

(mounted under the transformer).
P1:B13
BCM controls the relay connecting the battery to the battery

charger.
P1:B14
BCM disables the charging
P1:B15
BCM Adjusts the end of charge voltage according to the

battery temperature.
P1:B18-B23
the pumps 5V 50 Hz sqw pump select signals addressing

one pump at the time. A pump can select mode (except free
mode) only when selected.
P1:B32
Main switch powers the CCM from the battery as soon as

the main switch is pressed if no line (transformer) voltage is
present.
Self test and operation status output

The self test includes the BCM.
What is tested is evident from the Self test report on the terminal.
The operation status line contains
Ueff
FUSE's
Ubatt
BP-RE
T_HS
B_Hlim
T_BATT
B_Llim
T_TRAFO
ERROR
Ueff
displays the calculated line voltage in % of the nominal line

voltage
Ubatt
displays the measured battery voltage.
T_HS
is not used
T_BATT
displays the measured battery temperature.
T_TRAFO
displays the measured transformer temperature.
FUSES
Indicates the blown fuses.
The value must be converted to binary units:
Revision 00
Service Manual
3-39
3. Function
3.7.4
JOSTRA HL 20
Battery Charger Module (BCM)

The BCM controls the battery charging current and charging voltage. The
charger is a switch mode voltage regulator with current limit. The charging
voltage and current is adjusted to the ambient temperaure of the batteries.
NOTE
This module is always connected to the battery power. The BCM should
always be removed from its interface before any test probes are
connected or disconnected from it.
Battery Charger Module (BCM)
TP4
F2
POT1
F1
F3
JMP2
JMP1
POT2
TP3
TP1
POT3
TP2
Battery Charger Board
Settings
3-40
JMP1
closed (Test and adjustment jumper)
JMP2
open (Test and adjustment jumper)

Service Manual
Revision 00
JOSTRA HL 20
3. Function
Test Points
TP1
0V
P1-Z8 (fuse 3
interface side)
Battery voltage (fuse removed) Pot 3 adjusts reading on

SCP to match measurement read at this point.
TP2
Battery voltage - nominal +24V
TP3
26.4V DC 0.2V (JMP2 opened),

28.32V DC 0.01V (JMP2 closed) adjusted with Pot 1
Fuse 3
(removed)
2A + 0.1A - 0.2A adjusted with Pot 2.
TP4
40V DC
Fuses
F1
4 A glass fuse
F2
4 A glass fuse
F3
4 A glass fuse
Wiring
Cable
Connected
29V AC IN
BATT
between the battery terminals and P7 on the RP.
Inputs
Input
From
P1:Z4,
Transformer
P1:D6
29 VAC which is rectified on the board to approx. 40 VDC.
P1:Z12
CCM controls relay 2 connecting the 48 ohm resistor as load. Used

to check charger if battery is fully charged.
P1:D18
CCM controls relay 1 connecting the battery charger to the battery.
P1:Z20
CCM used to interrupt the charging process
P1:D22
CCM used to adjust the end of charge voltage according to the

battery temperature
Outputs
NOTE
Revision 00
Output
To
P1:Z8,
Back up battery
P1:D10
battery charging output.
P1:Z32
CCM carries the battery (or charging) voltage divided to suit the
MPU ADC window.
Replace the battery charger board if charging current cannot be

accurately adjusted.
Service Manual
3-41
3. Function
3.7.5
JOSTRA HL 20
Control Panel and HCU Interconnection Module (CHI)

The System Control Panel and the Heater/Cooler apparatus are connected to
this module.
System Extension Module (SEM) old version. On the newer Interconnection

Module, the SCP plug is connected on the RP and the SYS-COM is placed at
the CCM.
CAUTION
Danger of unexpected module failure.

The 9-pin Dsub socket is only for connection of JOSTRA external
devices.
Do not connect or disconnect any external device with the mains power
switched on.
3.7.6
Monitor Interface Module (MIM)

The MIM consists of a DC/DC converter with a universal interface. It
galvanically separates the SMU from the Rack and supplies the SMU with the
operating voltage of 15 V.
Monitor Interface Module (MIM) old version. On the newer Monitor Interface
Module, the MONITOR plug is connected on the RP.
CAUTION
Danger of unexpected module failure.

Do not plug or unplug the Display Monitor or SCP while the HL 20 is
switched on.
3-42
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Monitor Interface Board
Test Points
P1-31
Ground
Fuse 1
+5V DC
Fuse 2
+24V DC 4V
Fuse 3
+12V DC
P1-A8 as ground
Fuse 4
-12V DC
P1-A8 as ground
P1-A8 as ground
S1-19 and
S121 on LEMO
connector
15V DC 1.5V
Fuses
Fuse 1
4 A glass fuse
Fuse 2
4 A glass fuse
Fuse 3
250 mA glass fuse
Fuse 4
250 mA glass fuse
Wiring
Revision 00
Cable
Connected
SMU Cable
via LEMO contact between the SMU and MIM.
Service Manual
3-43
3. Function
JOSTRA HL 20
Inputs
Input
From
P1:A17
the arterial pump transmits the pump action signal.
P1:A21
the arterial pump transmits the calculated pump action signal.
P1:A22-A24
SCP/master transmits the system control messages to the SMU

via the DINBUS
P1:A27
AIO 20 transmits the ECG signal.
P1:A28
AIO 20 transmits the pressure signal.
Outputs
3-44
Output
To
P1:A23-A25
SCP/master transmit the system control messages from the

SMU via the DINBUS.
Service Manual
Revision 00
JOSTRA HL 20
3.7.7
3. Function
Air Bubble Detector Module (ABD)

The ABD is a STOP module and consists of two PCBs:
The Level/Bubble Controller Board (LBC)
The Bubble Detector Board (BUBO).

Also see section 3.7.11 Air Emboli Protection Module (AEP)
The LBC Board

The stop selector switch connects the stop signal to the corresponding
xxx_STOP line, and also connects one of 5 voltages from the voltage divider
R1-R2-R3-R4 to the MPU for soft stop address definition.
The BUBO
Voltage on TP7-8-9 is normally 1.1V DC. On P1:1 the voltage is normally 3.3V.
Other voltages mean that the module hasn't been able to adjust to tube size or
tube material (PVC/silicone)
On P1:2 pulses indicate air bubbles. Normally 0V
Revision 00
Service Manual
3-45
3. Function
JOSTRA HL 20
Level/bub Control Board
Jumper Settings
assistance.
Test Points
TP0
0Vl
TP1
0Vs
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
+5V DC 5mV
Fuses
F1
1A
F2
1A
F3
1A
3-46
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Bubble Detector Board
Jumper Settings
None
Test Points
TP0
0Vl
TP1
0Vs
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
5V DC adjusted with Pot 1 5mV
TP12
18V DC 10%
TP19
Protective earth
Fuses
F1
160 mA SMD fuse
Wiring
Revision 00
Cable
Connected
ABS or Air Bubble Sensors
to the front of the module.
LEMO
between the ULD and the front of the module.
Service Manual
3-47
3. Function
JOSTRA HL 20
Inputs
Input
From
P1:A17
the arterial pump carries the pump action signal.
P1:A21
the arterial pump carries the calculated pump action signal.
P1:A22-A24
SCP/master carry the system control messages to the SMU

via the DINBUS
P1:A27
AIO 20 carries the ECG signal.
P1:A28
AIO 20 carries the pressure signal.
P1:A11
the RP board is used to synchronise the pump stop signal

with other modules.
P1:A:22-A24
the SCP/master carry the messages to the module via the

DINBUS.
Outputs
3-48
Output
To
P1:A23-A25
SCP/master transmit the system control messages from the

SMU via the DINBUS.
P1:A12-A16
The pumps are used to stop the selected pump if air bubbles
or low level (ULD 20) is detected.
P1:A22-A24
the SCP/master transmit the messages to the master via the

DINBUS.
Service Manual
Revision 00
JOSTRA HL 20
3.7.8
3. Function
Ultrasonic Level Detector Module (ULD)

The ULD creates a high voltage that is used in the High Frequency Board. The
HF board uses this high voltage to make the ultrasonic signal that is sent to the
level sensor.
Ultrasonic Level Detector Module (ULD)

Also see section 3.7.11 Air Emboli Protection Module (AEP)
Revision 00
Service Manual
3-49
3. Function
JOSTRA HL 20
ULD Board (top view and bottom view)
Jumper Settings
assistance.
Test Points
3-50
TP1
Ground
TP3
400V DC adjusted with Pot 1 10V
TP4
Clock generator
TP10
+12V DC
TP11
+12V DC
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Fuses
F1
125 mA
F2
1A
Wiring
The level sensor with its cable is soldered directly to the ULD board.
The cable connection between the ABD and the ULD via LEMO connection
carries power and signals.
Inputs
Input
From
J1:4
ABD 20
Outputs
Revision 00
Output
To
J1:6
ABD carries the echo after a transmit pulse. Should carry a

voltage if an echo (=level) exists.
J1:7
ABD carries the echo without a previous transmit pulse. Should

be 0V else the sensor detects noise.
Service Manual
3-51
3. Function
3.7.9
JOSTRA HL 20
Quad Temperature Module (QTM)

The QTM is a standard size module equipped with an universal interface. It can
display four different temperature measurements on the SCP.
Quad Temperature Module (QTM)

Temperature limits can be set on the SCP to trigger an acoustic alarm when
exceeded.
WARNING
The QTM is not a stop module.

The acoustic alarm is a warning for the perfusionist to check the
temperature regulating system.
NOTE
NOTE
Temperature probes used must be Yellow Springs YSI 400 series.
Some countries requires the QTM to go through a special test to insure

the safety of the patient. The module is then sealed and accepted as long
the seal is not broken.
The four external inputs enters a multiplexer and are then fed to an A/D
converter via an amplifier. The amplification can be set to 8 or 24.3 by the line
HIGH_RES.
3-52
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Quad Temp. Board
Jumper Settings
assistance.
Test Points
TP0
0Vl
TP1
0Vs
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
Protective earth
TP6
5 V DC adjusted with Pot 1 5mV
TP7
7.88V DC adjusted with Pot 2 5mV
Fuses
F1
1A
F2
160 mA
F3
160 mA
Wiring
Temperature probes.
Inputs
Input
Outputs
Output
From
P1:A23, A25 The DINBUS.
P1:A22, A24 The DINBUS.

Revision 00
To
Service Manual
3-53
3. Function
3.7.10
JOSTRA HL 20
Dual Pressure Modules (DPM)

The DPM is a stop module of standard size equipped with an universal
interface. The HL 20 houses two identical pressure modules with two channels
each.
Dual Pressure Modules (DPM) Channel 1 to 4

The EPROM software in each pressure module determines whether the module
will monitor pressure 1 and 2 or pressure 3 and 4.
DPM 20-440
pressure 1 and 2
DPM 20-441
pressure 3 and 4
WARNING
It is not possible to change from DPM 20-440 to DPM 20-441 or the

other way around by just changing the software.
There is a modifiation on the DPM 20-441 board.
The DPM can stop as well as slow down a selected pump using the
corresponding xxx_STOP line. The stop line is selected by a stop selector
switch for each channel. The stopping channel reports its identity over the
DINBUS to the stopped pump.
To stop a pump the stop line is pulled low.
To slow down a pump the stop line is pwm.
To synchronise several channels slowing down the same pump the saw-tooth
signal is used.
3-54
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Dual Pressure Board 1 and Dual Pressure Board 3+4
Jumper Settings
assistance.
Test Points
TP0
0Vl
TP1
0Vs
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
TP6
TP7
Protective earth
Fuses
F1
1A
F2
160 mA
F3
160 mA
Wiring
Revision 00
Cable
Connected
Pressure transducer adapter
between the DPM and the pressure line.
Service Manual
3-55
3. Function
JOSTRA HL 20
Inputs
Input
From
P1:A11
RP board carries the saw-tooth signal. The signal is used to

synchronise the pump slow down (or stop) units.
P1:A22-A24
the SCP/master carry the messages to the module via the

DINBUS.
Outputs
3-56
Output
To
P1:A12-A16
the pumps are used to stop the selected pump by pulling the
corresponding line low or slowing down the pump by pwm the
corresponding line.
P1:A19
AIO transmits the channel one pressure as a pwm sqw signal if

the module is DPM 20-440. If the module is DPM 20-441 the
line is not affected
P1:A20
AIO transmits the channel two pressure as a pwm sqw signal if

the module is DPM 20-440. If the module is DPM 20-441 the
line is not affected.
P1:A23, A25
the SCP/master transmit the module messages via the

DINBUS.
Service Manual
Revision 00
JOSTRA HL 20
3.7.11
3. Function
Air Emboli Protection Module (AEP)

The Air Emboli Protection Module has the same function as the Air Bubble
Detector (ABD) Module and the Ultrasonic Level Detector (ULD) Module
together, but works through capacitive level detection.
In the 19-rack the ABD Module and the ULD Module is replaced by the AEP
Module and the space for the ULD Module is covered with a panel.

Also see section 3.7.7 Air Bubble Detector Module (ABD) and
3.7.8 Ultrasonic Level Detector Module (ULD)
Revision 00
Service Manual
3-57
3. Function
JOSTRA HL 20
Lev/bub Control Board
Jumper Settings
assistance.
Test Points
TP1
0Vs
TP7
4.5 0.1V
TP7
0.0 0.1V (with P8:3 connected to P8:4)
TP8
9.0 0.1V
TP9
< 0.5V
TP9
3.75 0.2V (with a resistor of 750R connected between P8:1

and P8:4 or use AEP test resistor
Fuses
Controller Board
F1
1A
F2
1A
F3
1A
Bubble Board
F1
160 mA
3-58
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Wiring
Cable
Connection
Air Bubble Sensor
to the front of the module
Capacitive Level Sensor
to the front of the module
Inputs
Input
From
P1:A17
the arterial pump transmits the pump action signal.
P1:A21
the arterial pump transmits the calculated pump action signal.
P1:A27
AIO 20 transmits the ECG signal.
P1:A28
AIO 20 transmits the pressure signal.
P1:A11
the RP board is used to synchronise the pump stop signal with

other modules.
P1:A22-A24
the SCP/master transmits the messages to the module via the

DINBUS.
Outputs
Revision 00
Output
To
P1:A23-A25
SCP/master receives the system control messages from the

DPM via the DINBUS.
P1:A12-A16
The pump stop signals are used to stop the selected pump if air
bubbles or low level (ULD 20) is detected.
P1:A22-A24
the SCP/master transmit the messages to the master via the

DINBUS.
Service Manual
3-59
3. Function
3.7.12
JOSTRA HL 20
Analog I/O Module (AIO)

The AIO is a standard size module equipped with an universal interface. The
two connectors on the panel are for connecting external signals to be displayed
on the SMU.
Analogue I/O Module (AIO)
NOTE
Do not connect the AIO directly to the patient. The AIO should only be
connected to a monitoring device that is of an accepted medical standard
that properly isolates between the patient and the monitoring device.
WARNING
Leakage current .
See warning in User Manual regarding leakage current.
Each external input to the module enters an op-amp where the amplification
can be adjusted from 1 to 10. Each amplified signal is added 2.5V DC to suit
the ADC window. The voltage is limited to 0-5 VDC. These voltages are read by
the MPU.
3-60
Service Manual
Revision 00
JOSTRA HL 20
3. Function
I/O Module Board (top view and bottom view)
Jumper Settings
assistance.
Revision 00
Service Manual
3-61
3. Function
JOSTRA HL 20
Test Points
TP0
0LI
TP1
0SF
TP2
+5V DC
TP3
+12V DC
TP4
-12V DC
TP5
Protective earth
TP6
+5V DC adjusted with pot 9 5mV
TP7
-2,5V DC adjusted with pot 10 5mV
Fuses
F1
1A
Wiring
Cable
Connected
D-sub connector
between the AIO board and the external

device (optional).
LEMO connector two connectors, one for ECG

and another for PRESSURE
between the AIO and the external device

(optional).
Inputs
Input
From
P1:A19
DPM 20-440, channel 1 is buffered, filtered and sent to the

external output connector.
P1:A20
DPM 20-440, channel 2 is buffered, filtered and sent to the

external output connector.
P1:A22, A24
DINBUS carry the DINBUS messages to the AIO.
Outputs
3-62
Output
To
P1:A23, A25
DINBUS transmit the AIO messages to the DINBUS.
P1:A27
SMU carries the ECG as a pwm sqw signal
P1:A28
SMU carries the pressure as a pwm sqw signal
Service Manual
Revision 00
JOSTRA HL 20
3.7.13
3. Function
Digital I/O Module (DIO)

The DIO is a standard size module with a universal interface. Four separate
channels can be used to connect external devices to the HL 20. External
signals are recorded on the JOCAP XL and can with a special program be
displayed on the SMU.
The DIO is divided into two separate boards:
DIO - controls channel 1 and 2.
DIE (extended) - controls channel 3 and 4
NOTE
See warning in User Manual regarding leakage current!
DIO Board
Revision 00
Service Manual
3-63
3. Function
JOSTRA HL 20
DIE Board
Jumper Settings
assistance.
Test Points
TP0
ground
TP2
+5V DC
TP4
ground
TP5
+5V DC
TP6
protective earth
Fuses
F1
1A
Wiring
Four LEMO connectors for connecting external device through RS232 serial
interafce
Inputs
P1:A22, A24
DINBUS carry messages to DIO.
Outputs
P1:A23, A25
3-64
DINBUS carry messages to the data collection system

(JOCAP XL).
Service Manual
Revision 00
JOSTRA HL 20
3.8
3. Function
Interconnection Overview
Three types of interconnections exist in the HL 20 consoles.
Power distribution
These cables supplies the modules with electrical power.
Single signals paths

These lines interconnect signals between the modules. A single signal only
distributes one signal, a pressure or a ECG signal for example, and gets its
name from the signal it distributes.
Digital communication path

The digital communication bus (DINBUS) distributes various signals in
digital form. All types of signals can be sent over the DINBUS, including
digital copies of the single signals.
3.8.1
Power Distribution
To supply the different units in the HL 20 the power distribution is split into
several paths on the Power Supply Board (PSB).
24 V
Battery
19 VAC
Trafo
19 Rack
BCM
MIM
3 VAC
CCM
29 VAC
HL 20 power distribution
The fuse panel is located next to the power supply board. For clarity these are
not shown in the power distribution path. See Detailed Description, Power
Supply Module.
Voltages in the HL 20
+24 V
+5 V
0 Vp
(0 V. pump)
+12 V
-12 V
PE
(Protective ground)
0 Vl
(0 V. logic)
+15 V
Revision 00
Service Manual
3-65
3. Function
3.8.2
JOSTRA HL 20
Single Signal Paths

The single signal paths carries only one signal each. They can connect from
two up to several connection points.
The signals are of analog, pwm, or sqw type.
The HL 20 Single Signal block diagram

The single signal paths in the HL 20. Signals residing only within the 19" rack
are not indicated.
3-66
Service Manual
Revision 00
JOSTRA HL 20
3. Function
Single Signal Paths in the HL 20

Signal name
Function
ART_STOP
Stop (pulled low) or 'slow down' (pwm) signals from a

module to stop the arterial pump. Normally high.
SUCKER_STOP
Stop signal for the suction pump
AUX_STOP
Stop signal for the auxiliary pump
CARD_STOP
Stop signal for the cardioplegia pump
0 Vm
Monitoring system 0 V.
ART_MODE
100 Hz sqw if the corresponding mode is free (not

selected by any pump). Low if mode is selected by any
pump.
CARDPL_MODE
Cardioplegia mode line
AUX_MODE
Auxiliary mode line
SUCKER_MODE
Suction mode line
R_TRIGGER
5V sqw created by the SMU, using the pwm signal

PWM_ECG.
CALC_PU_CURVE
Calculated pump action trace. Pwm signal.
PULS_PU_ACTN
Pulsatile pump action. Pwm signal of the pump's real

action.
PUMP_SEL_1
100 Hz sqw. signals addressing the indicated pump. A

pump can select/change mode only when addressed.
PUMP_SEL_2
PUMP_SEL_3
PUMP_SEL_4
PUMP_SEL_5
PWM_ECG
Pwm. sqw signal carrying the ECG signal.
/POWER_FAIL
Normally high. Low as soon as power fails.
SAWTOOTH
Saw-tooth signal. Approx. 2 kHz.
PWM_PRESS1
Pressure channel 1 and 2. Pwm sqw signals.
PWM_PRESS2
PWM_PRES
Revision 00
Pressure signal from the AIO module. Pwm sqw signal
Service Manual
3-67
3. Function
3.8.3
JOSTRA HL 20
Digital Communication Path

The digital serial communication bus (DINBUS) is a symmetric bus transferring
the different signals between the system units. The DINBUS consists of 5 wires:
TRANSM. A
TRANSM. B
RECEIVE A
RECEIVE B
DB GND
The bus is symmetric meaning that the wires A and B change their voltage
symmetrically. When A goes high (~5V), B goes low (~0V). The bus is
controlled by a master (located in the SCP) via which all communication
passes.
The DINBUS interconnection
3-68
Service Manual
Revision 00
JOSTRA HL 20
3. Function
BUS Communication
Over the DINBUS each unit is called by the master. When called, the unit
answers with a message (e.g. a value) and an address (value destination). The
answer is always built up of a fixed size data block. The data block from a
universal module consists of:
ERROR CODE
refer HEC
STATUS
high limit
exceeded, low
limit exceeded,
bypassed, ...
VALUE BLOCK
STOP ID
value 1, value 2,
trend 1, trend 2,
limit 1, limit 2,
reset, ...
which pump is
selected by the
stop select switch.
Call Up Structure
The DINBUS master calls all possible HL 20 modules. Answering modules are
listed as present and non answering modules are listed as non-present.
The DINBUS master then again calls all modules listed as present but only
the first module on the non-present list.
The present list and the non-present list are updated.
The DINBUS master again calls all present modules. This time the second
module on the non-present list is called.
The procedure continues until all non-present modules has been called
once.
The procedure then starts all over again continuously updating the present and
the non-present lists.
Revision 00
Service Manual
3-69
3. Function
3.9
JOSTRA HL 20
Interfaces
Seven different interfaces exist between the different units. These are:
Console - Pump interface
SCP interface
SMU interface
Console control module and battery charger interface
Power supply module interface
Universal module interface
Operation status monitor interface
Each interface is described in the following sections. "Signal origin" indicates

where the line originates. 0V lines and DINBUS lines are not commented, all
other signals originate in the described unit if nothing else is indicated in the
interface description.
3-70
Service Manual
Revision 00
JOSTRA HL 20
3.9.1
3. Function
The ConsolePump Interface

The ODU-connector between the console and the pump serves as a connector
between the pumps and the other units (including the other pumps when
working in master/slave mode).
The connector connects the supply voltage as well as the DINBUS, the single
signals, and the protection ground. The connector as seen from above (outside
the console or inside the pump) carries the following signals:
Pin
no
Signal name
Signal origin
Pin
no
Signal name
Signal origin
12
PUMP_SEL
CCM 20
13
R_TRIGGER
SMU 20
14
CALC_PU_CURV
E
(Arterial pump)
Ground
+24 V
0 Vp
ART_STOP
A module
15
PULS_PU_ACTN
(Arterial pump)
SLAVE_STOP
A module
16
ACT_VAL_ARTP
(Arterial pump)
SUCKER_STOP
A module
17
--- (Reserved 1)
AUX_STOP
A module
18
--- (Reserved 2)
CARD_STOP
A module
19
--- (Reserved 3)
0 Vm
20
0Vl, 0Vs
ART_MODE
CCM 20
21
DB_TRANSM_A
SLAVE_MODE
CCM 20
22
DB_RECEIVE_A
CARDPL_MODE
CCM 20
23
DB_TRANSM_B
10
AUX_MODE
CCM 20
24
DB_RECEIVE_B
11
SUCKER_MODE
CCM 20
25
DB_GND
Revision 00
PSB
Service Manual
3-71
3. Function
3.9.2
JOSTRA HL 20
The System Control Panel Interface

The system control panel interface carries the following signals:
Console mounted connector

Pin nr
Denom
Signal origin
+5 V
PSM 20
10
0 Vs
+5 V
PSM 20
11
/POWER_FAIL
CCM 20
+5 V
PSM 20
12
R_TRIGGER
SMU 20
+5 V
PSM 20
13
DB_TRANSM_B
DINBUS
0 Vl
14
DB_RECEIVE_B
DINBUS
0 Vl
15
DB_TRANSM_A
DINBUS
0 Vl
16
DB_RECEIVE_A
DINBUS
0 Vl
17
DB_GND
DINBUS
+12 V
18
PROTECTIVE
EARTH
Console
3-72
PSM 20
Pin nr
Service Manual
Denom.
Signal origin
Revision 00
JOSTRA HL 20
3.9.3
3. Function
The System Monitor Unit Interface

The SMU interface carries the following signals:
Console mounted connector

Pin
nr.
Denomination
Signal origin
Pin
nr.
Denomination
+5 V
PSM 20
13
DB_TRANSM_A
+5 V
PSM 20
14
DB_GND
+5 V
PSM 20
15
PULS_PU_CRV
(Arterial pump)
0 Vl
16
R_TRIGGER
SMU 20
0 Vl
17
CALC_PU_CRV
(Arterial pump)
0 Vl
18
+15_CRT
SMI 20
+12 V
19
+15_CRT
SMI 20
0 Vs
20
0 Vl
-12 V
21
0 Vl
10
DB_RECEIVE_B
22
PWM_ECG
AIO 20
11
DB_TRANSM_B
23
PWM_PRES
AIO 20
12
DB_RECEIVE_A
24
PROTECTIVE
EARTH
Console
Revision 00
PSM 20
PSM 20
Service Manual
Signal origin
3-73
3. Function
3.9.4
JOSTRA HL 20
The Console Control Module Interface

The console control board interconnects to the 19" rack through a 64 pin
connector which carries the following signals:
Pin #
Denomination
Signal origin
Pin #
Denomination
Signal origin
CCM 20
A1
(Reserved 1)
B1
LINE_LED1
A2
(Reserved 2)
B2
(Reserved 4)
A3
(Reserved 3)
B3
BATT_LED1
A4
+24 V.
B4
(Reserved 5)
A5
0 Vlm
B5
CHARGE_LED1
A6
0 Vlm
B6
(Reserved 6)
A7
/POWER_FAIL
CCM 20
B7
BUZ+
A8
S_F1
PSB
B8
0 Vccb
A9
S_F2
PSB
B9
+5 Vccb
PSM 20
A10
S_F3
PSB
B10
/CHECK
CCM 20
A11
S_F4
PSB
B11
FAN
CCM 20
A12
S_F5
PSB
B12
UBM
BCM 20
A13
S_F6
PSB
B13
/CHARGE
CCM 20
A14
S_F7
PSB
B14
/NOCHARGE
CCM 20
A15
S_F8
PSB
B15
EOCV
EOCV
A16
TEMP_TR
Trafo sensor
B16
TEMP_HTS
(Not used)
A17
ART_MODE
CCM /Arterial p.
B17
TEMP_B
Battery sensor
A18
SLAVE_MODE
CCM /Slave p.
B18
PUMP_SEL1
CCM 20/Pump 1
A19
CARDPL_MODE
CCM /Cardiopl. p.
B19
PUMP_SEL2
CCM 20/Pump 2
A20
AUX_MODE
CCM /Aux. p.
B20
PUMP_SEL3
CCM 20/Pump 3
A21
SUCKER_MODE
CCM /Sucker. p.
B21
PUMP_SEL4
CCM 20/Pump 4
A22
DB_RECEIVE_B
DINBUS
B22
PUMP_SEL5
CCM 20/Pump 5
A23
DB_TRANSM_B
DINBUS
B23
PUMP_SEL6
CCM 20/Pump 6
A24
DB_RECEIVE_A
DINBUS
B24
AC2_H
Main trafo
A25
DB_TRANSM_A
DINBUS
B25
AC1_H
Main trafo
A26
DB_GND
DINBUS
B26
/B_P2
CCM 20
A27
/B_P1
CCM 20
B27
/B_P4
CCM 20
A28
/B_P3
CCM 20
B28
/B_P6
CCM 20
A29
/B_P5
CCM 20
B29
0 Vcc
A30
/B_MONB
CCM 20
B30
AC1_CCB
Main trafo
A31
0 Vp
B31
AC2_CCB
Main trafo
A32
PROTECTIVE_GND
B32
UBATT
Main switch
3-74
CCM 20
Console
Service Manual
CCM 20
CCM 20
CCM 20
Revision 00
JOSTRA HL 20
3.9.5
3. Function
The Power Supply Module Interface

The PSM interconnects to the 19" rack and all other units through a 15 pin back
plane connector. The pins are:
Pin no
Denomination
Signal origin
Z4
+5 V
PSM 20
D6
SENSE +5V
RP board
Z8
0 Vl
D10
SENSE 0V
RP board
Z16
+12 V
PSM 20
D18
0 Vs
Z20
0 Vl
D22
-12 V
Z12
D14
PSM 20
Z24
D26
Revision 00
Z28
0 Vpu
D30
+24 V
PSB
Z32
PE
Console
Service Manual
3-75
3. Function
3.9.6
JOSTRA HL 20
The Universal Module Interface

The various monitoring modules all interconnect through an universal backplane connector. The pins of the back plane connector are described below:
Out means out of module - into console.
Pin no
3-76
Denomination
Signal origin
+5 V
PSM 20
+5 V
Denomination
Signal origin
17
PULS_PU_ACTN
Arterial pump
PSM 20
18
R_TRIGGER
SMU 20
PSM 20
19
PWM_PRESS1
DPM 20
PSM 20
20
PWM_PRESS2
DPM 20
0 Vl
21
CALC_PU_CURVE
Arterial pump
0 Vl
22
DB_RECEIVE_B
DINBUS
+12 V
23
DB_TRANSM_B
DINBUS
0 Vs
24
DB_RECEIVE_A
DINBUS
-12 V
PSM 20
25
DB_TRANSM_A
DINBUS
10
/POWER_FAIL
CCM 20
26
DB_GND
DINBUS
11
SAWTOOTH
RP board
27
PWM_ECG
AIO 20
12
ART_STOP
A module
28
PWM_PRES
AIO 20
13
SLAVE_STOP
A module
29
(Not used)
14
SUCKER_STOP
A module
30
+24 V
15
AUX_STOP
A module
31
0 Vp
16
CARD_STOP
A module
32
PE
PSM 20
Pin no
Service Manual
PSB
Protective
earth
Revision 00
JOSTRA HL 20
3.9.7
3. Function
The Self Test and Operation Status Outputs

On every 'intelligent' unit (units containing an MPU) there is an interconnection
for an external terminal. On this terminal self test result can be output. After the
self test operation status is continuously output. The pins of the connector are
described below:
Pin no
Denomination
Description
RXD
Serial data in
TXD
Serial data out
NOSERVICE
Normally high. Pull down to

signal ground to activate
interface.
GND
Signal ground
The terminal connected to the interface must have the following settings:
Speed:
9600 bps
Data length:
8 bits
Error detection:
No parity
Stop length:
2 bits
Others:
Control codes assume a WYSE 50 terminal.
Refer to each module description for detailed self test and operation status
output.
Revision 00
Service Manual
3-77
3. Function
JOSTRA HL 20
Notes
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________________________________________________________________________________
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3-78
Service Manual
Revision 00
JOSTRA HL 20
4. Troubleshooting
Troubleshooting
4.1
Alarm Response
Each alarm condition on the HL 20 causes the audible alarm to sound and the
affected area to blink. The correct response to each alarm therefore, is to
1. Silence the audible alarm with the override button (the button with the
speaker crossed out), and then,
2. Look for the area that is blinking. This will be either on the System Control
Panel or one of the pump modules.
Once the blinking segment is located, the cause of the alarm can be dealt with.
For convenience, a table of alarm conditions is included following in this
section.
WARNING
Emergency procedures.
Each operator should be familiar with emergency procedures so alarm
conditions can be dealt with rapidly.
NOTE
Revision 00
Each alarm condition creates a new alarm. If a first alarm is silenced and
is then followed by another, the audible alarm is released so each alarm
can be heard. The override switch must be used to silence each new
alarm.
Service Manual
4-1
4. Troubleshooting
JOSTRA HL 20
4.2
Alarm Tables
4.2.1
Console
Alarms are arranged in order of increasing concern
Visual1
Cause
Alarm2
Pump Stop
Correction
ERxx, EPxx or
EMxx3
Software
Error
possible
possible
reset4
system
FUS1, FUS2
Blown Fuse
possible
possible
reset circuitbreaker
EM2c
Blown Fuse
yes
possible
restore fuse
Battery voltage
and battery
LED blink
battery
voltage
< 22 V
double beep;
cannot be
shut OFF
approx. 2
minutes to
system
shutdown
restore line
power
System
shutdown
battery
voltage
< 19.2 V
steady tone
(Flatline)
all stop
restore line
power
1)
2)
3)
4)
4-2
Message in Status Window or Pump Status Window

Single beep, can be silenced
Error message numbers; see following list.
Switch OFF for five seconds, then back ON.
If resetting does not correct problem, refer problem to maintenance SCP =
Service Manual
Revision 00
JOSTRA HL 20
4.2.2
4. Troubleshooting
Pump and Twin Pump

Alarms are arranged in order of increasing concern.
Visual1
Cause
Alarm2
Pump Stop
Correction
ERxx
Hardware or
Software
Error
yes
yes
reset4 pump
Other error
message3
minor errors
possible
possible
reset4 pump
"TEMP"
Pump is
Overheating
no
no
"STOP BUB"
Bubble
detector
stopped
pump
yes
yes
correct
problem,
reset bubble
detector
"STOP LEV"
Fluid level
below
sensor
yes
yes
restore
reservoir
level
"STOP Prx"
Line
pressure out
of limits
yes
yes
restore line
pressure
"NO SEL"
Console
software
error
yes
yes
reset
system
"NO COMM"
Databus
communicati
on lost
yes
yes
switch pump
to FREE
mode
"RUNAWAY"
or RPM-DIFF
Pump head
speed >10%
of set speed
yes
yes
turn speed to
zero then
back up as
desired
ER12
"DIRECT"
Rotation
direction
error
yes
yes
4
reset pump
"!!!!"
2
RUNAWAY
alarms in 5
seconds
yes
yes
reset4 pump
1)
2)
3)
4)
Revision 00
Message in Pump Status Window.

Error message; see following list.
If resetting does not correct problem, send pump for service
Service Manual
4-3
4. Troubleshooting
4.2.3
JOSTRA HL 20
Bubble Module
Visual1
Cause
Alarm2
Pump Stop
Correction
"Sensor Fault"
lamp ON
sensor faulty
or
disconnecte
d
yes
yes
check
sensor,
cable and
connection
Both Bubble
and Level
Sensor Fault
lamps
illuminated
Bubble/Level
Module
failed selftest
yes
yes
reset4
system
"BUB" LED
blinks at pump
Pump mode
changed on
AEP or ABD
module.
yes
no
Several bubble
segments lit
on SCP
Bubble(s) <5
mm dia.
detected
no
no
look for
bubble
source
Bubble Alarm
Lamp ON
(All segments
lit)
Bubble(s) >5
mm dia.
detected
yes
yes
correct
problem,
press
RESET and
Safety Set
Button
1)
2)
3)
4)
4-4
Message in Status Window.

If resetting does not correct problem, refer problem to JOSTRA service.
Service Manual
Revision 00
JOSTRA HL 20
4.2.4
4. Troubleshooting
Level Module
Visual1
Cause
Alarm2
Pump Stop
Correction
"Sensor Fault"
lamp on
sensor faulty
or
disconnecte
d
yes
yes
check
sensor,
cable and
connection
Both Bubble
and Level
Sensor Fault
lamps
illuminated
Bubble/Level
Module
failed selftest
yes
yes
reset4
system
"LEV" LED
blinks at pump
Pump mode
changed on
AEP or ABD
module.
no
no
Several level
segments lit
on SCP
level
variation
detected
no
no
watch
reservoir
Level Alarm
Lamp ON
Level below
sensor
yes
yes
restore level
(selfresetting)
1)
2)
3)
4)
Revision 00
Message in Status Window.

Single beep, can be silenced.
If resetting does not correct problem, refer problem for maintenance
Service Manual
4-5
4. Troubleshooting
4.2.5
JOSTRA HL 20
Pressure Module
Visual1
Cause
Alarm2
Pump Stop
Correction
ERxx
Hardware or
Software
Error
possible
possible
reset4
system
Pressure
Display shows
"CAL"
system is
selfcalibrating
no
no
none, wait
"PRE" LED
blinks at pump
Pump mode
changed on
DPM
module.
no
no
Pressure
display shows
"----"
No
transducer
connected.
no
yes
Pressure
display shows
"-**-"
self-test
failed or
module is
missing
no
no
reset
system and
check
module(s)
Pressure in
window blinks
Pressure is
outside of
alarm limits
yes
yes
correct
pressure or
change limits
1)
2)
3)
4)
4-6
Message in upper Pressure Display.

Service Manual
Revision 00
JOSTRA HL 20
4.2.6
4. Troubleshooting
Temperature Module
Visual1
Cause
Alarm2
Pump
Stop
Correction
ERxx
Hardware
or Software
Error
possible
no
reset4
system
Temperature
Display
shows "----"
Sensor
faulty or
disconnect
ed
no
no
check
probe and
cables
Temperature
Display
shows "-**-"
Self-test
failed or
module is
missing
no
no
reset
system and
check
module(s)
Temperature
Display
shows
or
Temperatur
e is <0 C
,or >50 C
yes
no
check
temperatur
e
Temperature
in Display
blinks
Temperatur
e is outside
of alarm
limits
yes
no
correct
temperatur
e or
change
limits
1)
2)
3)
4)
Revision 00
Message in upper Temperature Display.

Single beep, can be silenced.
Service Manual
4-7
4. Troubleshooting
4.2.7
JOSTRA HL 20
"Pulsatile" Module
Visual1
Cause
Alarm2
Pump Stop
Pulse Display
shows "-**-"
No ART
PULS pump
selected.
no
no
Pulse Display
shows
External
frequency
not detected
no
no
check
incoming
ECG
Pulse Display
blinks
Heart rate is
outside of
alarm limits
yes
no
Monitor ECG
or change
limits
1)
2)
3)
4)
4-8
Correction
Message in Pulse Display.

Switch Main Switch OFF for five seconds, then back ON.
Service Manual
Revision 00
JOSTRA HL 20
4.3
4. Troubleshooting
Pumps
NOTE
The simplest solution to a faulty pump is to switch its function to another

pump, or to replace it with a spare pump module.
However, before replacing the pump, it is important to review the error
codes to make certain that a module has not stopped the pump.
If a module is stopping the pump, it will stop any pump dedicated with the
same name.
4.3.1
4.3.2
Revision 00
Reports on the Pump Flow Display

Display
Explanation
<=<=
Instruction to set the pump Speed Control Knob

potentiometer to zero
!!!!
More than one runaway alarm within 5 seconds.
ERR
See the Pump Status Window for error report
-OK-
Self test concluded without fault
HOUR.XXX
Display of hours of operation since last major service
NO COMM
No communication with the master computer
NO SEL
Fault in Console Control Module
RUNAWAY or
RPM-DIFF
The pump speed is exceeding the amount set at the Pump

Flow Adjustment Knob
V x.x
Software version number
Reports in the Pump Window

Display
Explanation
+5 V TEST
The +5 V supply differs from the set value by more than

5%
+12 V TEST
The +12 V supply differs from the set value by more than
10%
-12 V TEST
The -12 V supply differs from the set value by more than
+10 /-20%.
AD CONV
The analogue digital memory is faulty
ARITHMET
The pump's microprocessor is faulty
BELT!
Belt slip
DIRECT
The pump is turning in the opposite direction from what is

set on the pump front panel
EEPROM
The internal instruction code memory is faulty
HEAD
The tachometer at the pump head is faulty
ILL.ERR
Other error (illegal error code)
KEYSTUCK
A button is stuck or has been held down longer than 15

seconds
Service Manual
4-9
4. Troubleshooting
JOSTRA HL 20
Display
Explanation
LAMPTEST
One of the displays is faulty
MODEBLO
An error in the selection system for the modes of operation

has been discovered
MODE-REL
The mode selection relay is faulty
OFFSET
The offset voltage is too high
OVERLOAD
Overload at pump head
PUMP OK
Pump is ready for operation
RAM
The internal data memory is faulty
ROM
The internal program memory is faulty
RECIRC
The pump is in Cardioplegia Flush mode. Accumulators in

the Cardioplegia Window on the Display Monitor are
disabled.
REFERENC
The internal voltage reference differs from the set value by

more than 5%.
REV-REL
The pump reverse relay is faulty
SAFETY-S
The safety system has discovered a deviation from set

values
SET SIZE
The tube size has not been set
SPEED
The master is calling for a slave speed >250 RPM
STOP
The pump was stopped by an external module, but the

module itself could not be identified. This can occur if there
is an error in the communication system or if the
monitoring system was shut down.
STOP BUB
The pump has been stopped by the bubble detector.
STOP-INP
A stop intervention is faulty
STOP LEV
The pump has been stopped by the level sensor.
STOP PRx
The pump has been stopped by the pressure module

number x
STOP REL
The emergency stop relay is faulty
TEMP!!
The pump is overheating
UNEXPECT
Software error
If one of the above errors occurs the pump stops and an acoustic alarm
sounds.
4.3.3
In Case of Pump Error

If a pump does not operate as it should, or if warnings or errors are shown
during start-up or operation, call MAQUET Technical Support immediately.
Never try to operate a faulty pump or one you think may be faulty.
4-10
Service Manual
Revision 00
JOSTRA HL 20
4. Troubleshooting
4.4
Console
4.4.1
Mains Power Failure

In the event of a mains power failure, the HL 20 quickly and automatically
switches over to battery power. The entire HL 20 will run on battery power,
including all pumps, modules, monitoring and recording.
If the mains power failure may be lengthy, or the cause is unknown, it may be
wise to switch OFF unnecessary components.
The total length of battery operation of a new, fully charged battery is
approximately 1.5 hours, with the following systems operating:
Arterial pump, 4 LPM, 3/8" tube, 37C, 100 mm Hg
Three sucker pumps 50 RPM
Complete Monitoring and data recording
Shutting down unnecessary components will greatly extend the length of battery
operation. In general, the pumps consume about 4 times the amount of power
that the monitoring system does.
CAUTION
Set all pumps to FREE before switching OFF the Monitoring

System!
Switching the Monitoring System OFF will result in a NO COMM Error at
the pumps, stopping all pumps. If the Monitoring is switched OFF, set all
pumps to FREE mode and continue.
4.4.2
Error Reports
Error reports from each module are shown by a blinking display in the
uppermost window of the affected group. The form of the report is: ERxx, where
a number with two digits is shown for xx.
WARNING
An error code means that the corresponding module should no

longer be operated.
Continued use after an error report may create unexpected results.
If an error report concerns the System Control Panel itself it is shown in the
Status Window in place of the clock. On this display the form of report is EMxx
or EPxx, whereby here again xx is replaced by two digits.
While it is not usually possible for the user to correct these problems, the
number should be noted before calling MAQUET Technical Support. This will
enable the Service Technician to guide you to the quickest possible resolution
of a problem.
Revision 00
Service Manual
4-11
4. Troubleshooting
4.4.3
JOSTRA HL 20
Error Messages
Code Message
4-12
Code
Message
01
ROM error
02
RAM error
03
EEPROM error
04
A to D converter error
05
Offset test error
06
Reference voltage test error
07
+5 V test error
08
+12 V test error
09
-12 V test error
0a
Lamp test error
0b
Temperature error
0c
Reverse Relay test error
0d
Stop relay error
0e
Mode Relay test error
0f
Stop Input error
10
Safety system error: Can't

Stop
11
Safety system error: General
12
Direction error
13
-- not used --
14
Stuck button error
15
No PUMP_SEL received
16
No Optical Tacho Signal

detected
17
Unexpected error
18
Arithmetic-unit error
19
Illegal error code
1a
Overflow error
20
Mode block / console

interface PCB error
21
Bypass status error
22
Calibration error
23
No sawtooth signal detected
24
Clock error
25
Dual-port ram error
26
Real-time clock error
27
Monitor keyboard controller

error
28
No master acknowledge
error
29
No panel acknowledge error
2a
Illegal key code
2b
Fatal error
2c
Blown fuse
2d
Battery overvoltage
2e
Time out error
7f
EPROM Warning: Factory

Defaults loaded
81
Mode already selected
82
No PUMP_SEL detected
83
Mode line failure (Clock

transaction overflow)
84
Selection not OK (mode line

pulled low)
85
EEPROM error
86
Illegal Mode
87
Illegal Warning
Service Manual
Revision 00
JOSTRA HL 20
4.4.4
4. Troubleshooting
Error Report EM7f

The HL 20 EEPROM memory saves all user settings (limits, zero-adjustment
etc.) when switched off completely. These values are then loaded from memory
with every new start of the HL 20 and are used as the initial presets.
If the HL 20 is not switched OFF with the Main Switch (for example, the Monitor
System is switched off), these settings may not be correctly saved. Note that
the settings are saved correctly if the main power fails, however.
If the new values were incorrectly saved, this is detected by the electronics
when the machine is next switched on. All values are now replaced by factory
default settings. The control panel shows that the factory defaults have been
reloaded by displaying the error message EM7f.
If EM7f appears, the user has to switch the Monitoring System OFF (not the
complete machine!) and ON again to clear this error message.
If the error report EM7f appears, the master computer loads the following
Factory default settings:
Pressure:
Pressure limit
200 mm Hg (all channels)
Gain
1 (all channels)
Temperature:
Upper limit
41C (105F) - all channels
Lower limit
25C (77F) - all channels
Pulsatile
Start
20%
Stop
70%
Base flow
0%
Internal frequency
72 BPM
Upper limit frequency
120 BPM
Lower limit frequency
40 BPM
These are replaced with user set parameters by changing them to the desired
value and switching the machine OFF normally.
Revision 00
Service Manual
4-13
4. Troubleshooting
4.5
JOSTRA HL 20
Modules
All microprocessor controlled modules have two LEDs on the front:
The green LED (OK) lights up when all the module self-test has been
completed without error, and the module is ready for use.
The yellow LED (COM or BUS) blinks only when the module is exchanging data
with the master computer.
If you have a problem with any of the modules in your system it is always
advisable to start by checking the two LEDs on the front panel of the
corresponding module.
If the OK LED is out this may mean that there is a fault in the module.
If the COM LED is out it may mean that communication to or from that module
is faulty. The error is probably in the module if the other modules receive their
calls. Otherwise the error is probably in the DINBUS. If the diode flashes but not
at all as often as for the other modules it receives the calls from the master, but
the master does not receive the answer from the module. The error is probably
located in the module.
Note that the COM LED blinks only when the module is exchanging data.
4.5.1
Bubble and Level Detection Errors

As these modules do not have alpha-numerical displays, an error in one is
shown by both sensor fault displays lighting up simultaneously.
Should either of these modules fail, they will most likely fail to the OFF (no
intervention) condition.
If the selected pump stops, the following procedure should be followed:
1. Switch the HL 20 OFF with the Main Switch
2. Open the Module Access Door at the back of the Console.
3. Using a small screwdriver, select an unused pump mode for intervention
(AUX, for example)
4. Do not use that pump mode name until the problem is corrected.
CAUTION
Do not unplug a module while the machine is switched ON.

Damage to the DATABUS can be the result.
4-14
Service Manual
Revision 00
JOSTRA HL 20
4.5.2
4. Troubleshooting
Pressure Module Errors

Should these modules fail, they will most likely fail to the OFF (no intervention)
condition (error message on the system control panel).
If the selected pump stops, the following procedure should be followed:
1. Switch OFF the HL 20 with the Main Switch.
2. Open the Module Access Bay at the back of the Console.
3. Using a small screwdriver, select an unused pump mode for intervention
(AUX, for example)
4. Do not use that pump mode name until the problem is corrected.
CAUTION

4.5.3
Temperature Module Errors

Should this module fail, it will most likely fail to the OFF (no intervention)
condition (error message on the system control panel).
However; should the module fail and activate the alarm, the following procedure
should be followed:
1. Switch OFF the HL 20 with the Main Switch
2. Check that the channel reporting the error has correctly set limits.
3. Replace the probe on the malfunctioning channel.
4. If this does not correct the problem, remove the probe from that channel
and notify MAQUET Service.
CAUTION

Revision 00
Service Manual
4-15
4. Troubleshooting
JOSTRA HL 20
Notes
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________________________________________________________________________________
________________________________________________________________________________
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________________________________________________________________________________
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________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
4-16
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
Maintenance
5.1
Cleaning and Disinfection
5.1.1
General
Clean all surfaces of the whole system including the pump heads, rolls and tube
guides to remove any blood or spilled liquids.
Sponges should be wrung dry to prevent excess liquid from getting inside
components. Ordinary household dish washing liquid is recommended for
cleaning the front pump and control panels. Disinfectants may be used if
needed, but be certain to use only products and processes that are suitable for
plastic surfaces. Avoid excess water near control panels.
Chemical solvents, acids, bases and coarse abrasives should not be used as
these may damage polymer face plates. Chemical solvents such as ether,
acetone etc. should NOT be used in or on any part of the system as such
solvents could damage control panels, connectors, etc. Do not allow any
anesthetics to spill on any part of the system or spare parts. Chemicals such as
Foram (Isofluoran) can be very damaging.
If necessary, a stiff sponge (Scotchbrite or similar) can be used to remove
stubborn stains from the stainless steel and aluminum surfaces. Stainless steel
surfaces may also be polished with mild abrasive polishes made for this
purpose, if desired. Prevent cleaners or polishes from coming in contact with
the plastic panel face plates.
If rust spots develop on stainless steel from repeated exposure to liquids,
contact MAQUET for instructions on spot passivation.
5.1.2
Pumps
CAUTION
Do not remove a pump while the pump is switched on!

This will damage the pump and/or the Console.
Pumps may be lifted off and placed on any flat surface when necessary to clean
under them. Be certain the pump is turned off before removing it from the
Console. All electrical connections are automatically made when the pump is
replaced on the Console.
Revision 00
Service Manual
5-1
5. Maintenance
5.1.3
JOSTRA HL 20
Sensors
Wipe the ultrasound level sensor face with a clean, damp cloth to remove old
gel.
Open the bubble sensor and rinse the white silicone cushion with warm water
until all the gel has been removed.
5.1.4
Jamming ON/OFF Buttons

The ON/OFF buttons on the console front side may jam or get stuck due to dirt
on the inside.
To clean a button:
1. Put a sharp instrument (scalpel or similar) between the lens and the frame
around the lens and carefully prize a little on each side of the lens until it
comes loose.
2. Clean the lens and the frame.
3. Press the lens back on its place.
5-2
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
5.2
Preventive Maintenance
5.2.1
General
This section comprise a description of the Preventive Maintenance to be
performed on the HL 20.
Furthermore, there is an Extensive Preventive Maintenance for HL 20 as
described in section 5.3 Extensive Preventive Maintenance. The Extensive
Preventive Maintenance procedure is created for the US Service organization,
but can of course be used worldwide if required.
5.2.2
Preventive Maintenance interval

Perform the Preventive Maintenance every 500 hours of operation or at least
every 6 months.
Check the battery capacity at least every 6 months. Replace the batteries every
2 years or when they can no longer be fully charged within 15 hours or when
fully charged batteries cannot run the complete system longer than 60 minutes.
Replace belts in Single Pumps at least every 2 years.
Replace belts with pulley assembly in Twin Pumps at least every 5 years.
5.2.3
Console mechanics
Part
Action
Masts
Check that they are properly fastened in the chassis.
Infusion masts
Check that the infusion masts go up and down with

acceptable resistance.
Access panel
Check that the access panel does not close by itself.
Drawer
Check that the drawer opens and closes smoothly and

stops in the middle position.
Wheels and
brakes
Check that the locking mechanism is functioning

properly.
Monitor
Check that the SMU swivels and locks properly.
Control panel
Check that the SCP swivels and locks properly.
Halogen lamp
Check the function of the halogen lamp.
ODU connectors
with covers
Check that the ODU connectors are clean and

equipped with covers.
Rack connectors Check the LEMO connectors. Varify that the pins are
not backing out when pushed on.
Revision 00
Positioning
dowels
Check that the positioning dowel is tight.
Fan
Make sure that the fan works.
Service Manual
5-3
5. Maintenance
5.2.4
JOSTRA HL 20
Pump mechanics
Part
Action
Pump ID
Note the Pump type, Serial number and runtime on all

pumps on the system.
Tube locking,
inserts
Make sure the locking mechanism works.

Check that the tube holding mechanism works.
Occlusion
Check the occlusion of each pump using a tube and

water. See User Manual.
Guiding pins
Check that the guiding pins roll nicely.
Rollers
Check that the rollers roll nicely.
Pump lid
Check that the lid is not defective and that it is

equipped with a warning sticker.
ODU
connectors,
spring, pin fixing
Check that the connector works properly (springloaded) and that the pins are not defective.
Belt
Check that the belts are not worn out or twisted.

Check the belts tension.
Fan
5.2.5
Make sure that the fan works in each pump.
Pump electronics
Part
Action
Switches and
breakers
Check that the pumps can be powered ON and OFF

several times (approx. 5) and that no errors are shown
on the displays (self-test passed). Check with switches
and with circuit breakers.
Also check switches on the twin pumps.
Speed
Slowly increase/decrease the speed over the whole

range. Check that it runs smooth with no unexpected
noise.
Check the speed of the pump head at 250 RPM in
both forward and reverse direction with a tachometer.
See Pump Calibration section.
5-4
RPM/LPM switch
Check that the display toggles between RPM and

LPM.
Mode selection
Check that all pumps can be programmed to all

modes.
Calibration
mode
Check that the flow can be calibrated.
Master slave
Check that the master slave speed ratio can be

adjusted.
Stop lines and

communication
Check with one stop module that the pump stop in all
modes. Check all pumps.
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
Runaway
protection
Set pump speed to 0 and manually turn the pump

head in the same direction as indicated by the arrows
on the inserts. Check that Runaway alarm is activated
and reset the alarm.
Repeat the test as above (within 5 seconds) and
check that the !!!! alarm is activated.
Overload alarm
Set pump speed to 5 RPM and stall the pump head

using a wooden dowel.
WARNING
5.2.6
Keep fingers away from the pump

head!
Error direction
alarm

head in the opposite direction than indicated by the
arrows on the inserts.
Reset hour
counter
Reset the hour counter on each pump. Refer to Belt

replacement instructions in the Extensive Preventive
Maintenance.
System Control Panel and System Monitoring Unit

Part
Action
SCP
Check:
- Pressures, up to 4 pressures
- Temperatures, 4 temperatures
- Level indication, function
- Air bubble alarm, artificial air bubble 5 mm
generates air alarm.
SMU
Check:
- ECG trace
- Pressure trace
- MAP, SYS, DIA data
- Arterial pulsatile trace
- Cardioplegia windows
- Digital in/out function.
Revision 00
Service Manual
5-5
5. Maintenance
5.2.7
JOSTRA HL 20
Battery back-up
Part
Action
Battery mains
switch
Make sure that the batteries are fully charged.

Start the system (all pumps on 100 RPM) with tubing
installed.
Disconnect mains power supply and check that:
- The system switches to battery power supply and
continue to run during at least 60 minutes.
- The battery LED is lit and an audible alarm is
activated.
- The mains switch LED goes off.
Re-connect mains and check that the system returns
to mains power supply mode and that all battery
indications (see above) are switched off.
Charge circuit
5.2.8
5.2.9
Check that the Battery Charge LED is lit.
Others
Part
Action
Level Sensor
Check for any damage to the sensor or cable.
Bubble Sensor
Check for any damage to the sensor or cable and for

any gel built-up.
Electrical safety
Part
Action
Electrical safety
test
Perform Electrical safety tests according to standard

procedure regulated by IEC 60 601-1 or corresponding
national standards. Allowable values and test methods
are defined in the standard. The use of a leakage
tester, e. g. Bender Safety Tester 601/751 or
equivalent is recommended.
- Record the ground resistance value (protective
earthing continuity).
- Record the leakage current values.
The standard procedures may require 110% voltage.
During this test, 100% voltage should be used.
5-6
Service Manual
Revision 00
JOSTRA HL 20
5.2.10
5. Maintenance
Preventive Maintenance Checklist
Equipment:
Type:
Serial No:
Console Mechanics
OK
Masts .......................................................................
Infusion masts .........................................................
Access panel ...........................................................
Drawer .....................................................................
Wheels and brakes .................................................
Monitor ....................................................................
Control panel ...........................................................
Halogen lamp ..........................................................
ODU connectors with covers ..................................
Rack connectors .....................................................
Positioning dowels ..................................................
Fan ..........................................................................
Remarks:
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Pump mechanics
Type:
Serial number:
Runtime (highest value):
Tube locking, inserts
Occlusion
Guiding pins
Rollers
Pump lid
ODU connector
Belt
Fan
Pump electronics
Switches and breakers
Speed
RPM / LPM switch
Mode selection
Calibration mode, flow adjust
Master - slave, slave adjust
Stop lines and communication
Runaway protection
Overload alarm
Error direction alarm
Reset hour counter
Remarks on Pumps:
Revision 00
Service Manual
5-7
5. Maintenance
JOSTRA HL 20
SCP and SMU
OK
Remarks:
SCP:
- Pressures .............................................................
- Temperatures .......................................................
- Level indication......................................................
- Air bubble alarm ...................................................
________________________________
________________________________
________________________________
________________________________
SMU:
- ECG trace .............................................................
- Pressure trace ......................................................
- MAP, SYS, DIA values .........................................
- Arterial pulsatile trace ...........................................
- Cardioplegia windows ..........................................
- Digital in/out function ............................................
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Battery back-up
Automatic battery mains switch ...........................
Charge circuit ..........................................................
________________________________
________________________________
Others
Level sensor ...........................................................
Bubble sensor .........................................................
________________________________
________________________________
Electrical safety
Ground resistance ..................................................
Earth leakage current (normal condition) ...............
Enclosure leakage current (normal condition) ........
NOTE
Date:
____________________________ Ohm
______________________________ A
______________________________ A
During maintenance, the following settings may have been changed in order to test
their function: Flow Calibration, Occlusion, Tube settings, Mode settings, Pressure
limits, Stop lines, Pressure and Temp channels e.t.c.
Please check all settings and values carefully before use.
Signature:
File this form according to procedures defined by your office.
5-8
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
5.3
Extensive Preventive Maintenance
5.3.1
General
Scope
The Extensive Preventive Maintenance procedure to be performed on the
HL 20 as described below is created for the US Service organization, but can of
course also be used worldwide if required.
The Extensive Preventive Maintenance Checklist shall be completed during
this procedure.
Portions of Field Test Procedure: HL 20 are incorporated into the Extensive
Preventive Maintenance. Review these procedures before beginning.
Preventive Maintenance interval

Perform the Preventive Maintenance every 500 hours of operation or at least
every 6 months.
Check the battery capacity at least every 6 months. Replace the batteries every
2 years or when they can no longer be fully charged within 15 hours or when
fully charged batteries cannot run the complete system longer than 60 minutes.
Replace belts in Single Pumps at least every 2 years.
Replace belts with pulley assembly in Twin Pumps at least every 5 years.
Recommended Test Equipment & Supplies

Recommended tools: A complete tool kit shall be available to permit correct
disassembly of unit. Avoid using inappropriate or worn out tools. A partial list is
as follows - usage references ( ) are subject to change. Also refer to 6.9 Field
Test Procedure.
1. 5 mm Blade Screwdriver (Single & Twin pump bottom plate)
2. #2 Philips Screwdriver (RotaFlow bottom plate)
3. 7 mm Nut Driver (ground nuts, battery terminals)
4. 10 mm open end ignition wrench (Single pump belt tension)
5. Hex key wrench set, 1.5 mm and higher
6. Potentiometer adjustment tool - remove metal clip before use!
7. Twin pump extension boards - recommended
8. 4 pin extension cable - recommended
9. BCM extension board - recommended
10.Terminal Cable (all boards with capability)
11.Bottom Cabling Assembly - recommended
12.Sonic Tension Meter, Gates 507C or equivalent
13.Dual Channel Oscilloscope, Fluke 123 or equivalent
14.Test tubing 3/8 ID x 3/32 W (9/16 OD) Tygon formulation or similar
15.BlocLube tamper evident seal (to secure potentiometer adjustments)
16.Dow Corning 200, 100 cst or CRC Silicone Lubricant.
The lubricant must be of Electrical & Food Grade formula (no petroleum)
Revision 00
Service Manual
5-9
5. Maintenance
JOSTRA HL 20
Requirements
Completion of MAQUET service training is prerequisite to performing this
procedure.
WARNING
Danger of serious personal injury. Disconnect mains

voltage before opening equipment. Observe precautions
when operating pumps with cover removed. HL 20 may
tip over when opened. Review precautions in Users
Manual and Service Manual. Consult MAQUET Technical
Support if there are any questions regarding these
documents.
Service by unqualified individuals may result in serious
injury and equipment damage.
Cleaning
Clean all surfaces, rollers, and tubing guides to remove any blood or spilled
liquids. Always use personal protective equipment and observe precautions for
Blood Bourne Pathogens. Refer to User manual for further information.
5.3.2
Initial inspection
1. Perform the Initial Inspection portion of Field Test Procedure: HL 20 and
complete the User Settings Worksheet before starting the Extensive
Preventive Maintenance.
2. Briefly operate console and all pumps to determine system status.
Verify the console fan operates quietly.
3. Turn off Main and Monitoring system power.
5-10
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
ODU Connectors
NOTE
Assure Mains power is off. Only place pumps on flat surfaces to avoid
damage to connector. Skin oils can tarnish the pins avoid contact.
1. Test each HL 20 ODU Connector. Remove pumps individually and then

replace after inspection.
Verify ODU connector is secured and has a plastic cover.
Verify resistance is >20 MegaOhm between chassis and all pins except
pin A. If resistance is found low then isolate to pump or component inside
HL 20.
Verify resistance is less than 1 Ohm between chassis and pin A.
Verify all sockets are undamaged and not pushed in.
Note: Pin B is shorter on pump connector.
Figure 1. ODU Connector on HL 20

Pin #
A
B
C
1
2
3
4
5
6
7
8
9
10
11
Signal Name
GROUND
24 V
0 Vp
ART_STOP
SLAVE_STOP
SUCKER_STOP
AUX_STOP
CARD_STOP
0 Vm
ART_MODE
SLAVE_MODE
CARDPL_MODE
AUX_MODE
SUCKER_MODE
Signal Origin
CHASSIS
PSB
A Module
A Module
A Module
A Module
A Module
CCM20CCM20CCM20CCM20CCM20-
Pin #
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Signal Name
PUMP_SEL
R_TRIGGER
CLC_PU_CURVE
PULS_PU_ACTN
ACT_VAL_ARTP
(Reserved)
(Reserved)
(Reserved)
0 V1, 0 Vs
DB_TRANSM_A
DB_RECEIVE_A
DB_TRANSM_B
DB_RECEIVE_A
DB_GND
Signal Origin
CCM20SMU20(Art. Pump)
(Art. Pump)
(Art. Pump)
Figure 2. ODU Connector details Signal Descriptions
Revision 00
Service Manual
5-11
5. Maintenance
JOSTRA HL 20
Pumps
1. Pin resistance to ground was tested earlier when pump was attached to
HL 20. Measure pump connector resistance if this step was not performed.
2. Residue inside and outside the pump tubing guides may require cleaning as
follows:
Place unit on its side to avoid fluid ingress.
Use warm water and paper towel to remove any external residue.
Dab warm water on guide ends and rotate Teflon guide to free
movement.
Dispel liquid from inside the tubing guide using Silicone spray lubricant.
Always wear eye protection when spraying liquids!
Do not use any petroleum based products!
Wipe any pooled liquid from inside pump housing.
5-12
Service Manual
Revision 00
JOSTRA HL 20
5.3.3
5. Maintenance
HL 20 Console
The HL 20 contains circuit boards which are factory calibrated and
shall not be repaired or adjusted in the field except as outlined in
current service documents. Contact MAQUET Technical Support for
replacement information.
NOTE
The HL 20 Console contains modules and circuit boards as shown in Figure 3.
AEP
Power Supply Module DC/DC

Adjustment for 5.1, 12.1 V supplies
Air Emboli Protection Module
QTM
AIO
Analog I/O Module
DPM
Dual Pressure Module 1, 2
PSM 1
CHI
Dual Pressure Module 3, 4

Console Control Module
Adjustment for 100% Mains display
Battery Charger Module
Adjustment for Battery voltage display, charge current & voltage
Control Panel Module
MIM
DIO
Digital I/O Module
DPM
CCM
BCM 1
Rear Panel Board

Power Supply Board
1
Adjustments may be performed to these modules as outlined in this document.

Figure 3: HL 20 Modules and circuit boards
1. Configure the HL 20 as follows:

Turn on Main power and Monitoring system power.
Override the necessary interventions.
Turn on each pump and operate at typical settings.
2. Adjust the PSM to the voltages shown in Figure 4.
PSM Voltage
Adjustment
:
-12.10 0.01 V
12.10 0.01 V
5.10 0.01 V
Figure 4: PSM voltage adjustments
WARNING
Revision 00
The console is unstable when open and may fall over.

A suitable support is required when servicing the unit in
the open position.
Service Manual
5-13
5. Maintenance
JOSTRA HL 20
Battery Replacement
1. The HL 20 battery shall be replaced every 2 years as follows:
Follow the service manual instructions for opening the console.
Remove the cable connecting the two batteries.
Disconnect the (+) and () battery cables and remove the battery bracket.
Exercise care when handling the temperature sensor!
Replace the batteries and attach the (+) and () battery cables, bracket,
and sensor.
2. Perform internal inspection.
Blow out any dust that has accumulated inside console and around fan.
Verify cables are properly routed and secured.
3. Reassemble console following service manual instructions.
Attach the cable connecting the two batteries.
Test the new battery according to Field Test Procedure: HL 20.
Recycling: Worn-out batteries must be recycled or disposed of properly in
accordance with appropriate industrial and environmental standards.
Battery Adjustments
A battery which has failed operational testing and is within two years old may
indicate a problem with the battery charger. Verify Battery Charger Board
(BCB) adjustments if such a failure occurred.
1. A depleted battery is needed to set charging current. Run down the battery
to this state.
2. Verify Mains cable is disconnected and all power is turned off.
3. Remove the Console Control Module (CCM) for disassembly. The BCB and
Console Control Board (CCB) are located inside the CCM.
NOTE
Always remove the BCB before attaching or removing test leads.

Battery voltage is always present on this board when inserted into HL
20. Assure Mains power is off before removing board!
4. Remove JMP 1 and F3 (4 A glass fuse). Measure voltage between TP3 and
TP1 (0 volts) on BCB.
Verify 28.32 0.01 volts with JMP 2 closed (use Berg jumper).
Adjust POT1 if necessary.
Verify 26.4 0.2 volts with JMP 2 open.
5. Close JMP 1 and connect ammeter as F3 on the BCB.
Verify current is 1.8 to 2.1 amps.
Adjust POT2 to obtain reading within this range if necessary.
If charger current adjustment is unstable then replace BCB.
6. Measure voltage at F3 on the connector side (with fuse still removed).
Verify measurement equals Control Panel battery display 0.5 volts.
7. Replace JMP 1 and F3.
5-14
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
Mains Voltage Percentage

1. View Mains voltage percentage on control panel.
Verify display shows 100 to 105 percent of measured Mains voltage.
Adjust POT2 on the CCB if necessary (refer to Figure 5).
2. Apply BlocLube to all potentiometers that were adjusted.
3. Completely reassemble the console, remount on HL 20, and test pump
functions according to Field Test Procedure: HL 20.
Console Control board
JMP2
JMP1
Battery Charger board

Figure 5: Console circuit board test points and adjustments
Revision 00
Service Manual
5-15
5. Maintenance
5.3.4
JOSTRA HL 20
Single Pump
1. Remove the 6 screws securing the pump bottom plate and separate from
pump chassis.
Figure 6: Supplying power with Pump Servicing Cable

and spare Bottom Cabling assembly.
2. Clean the fan and inside of unit with compressed air (preferred) or ESD safe
brush.
3. Clean the tacho strobe label with cotton and alcohol while turning pump
head by hand.
4. Loosen the front panel by removing the 8 screws using a 2.5 mm hex key
wrench. Replace screws which are galled or have worn heads.
5. Use a flashlight and observe the belts for wear or twisting (see Belt
Replacement).
6. Check the belt tensions (see Belt Replacement).
7. Use the Terminal Cable to connect a Laptop to Display board (P6) or Pump
Control board serial connector. Run a terminal program with port settings
9600 8-N-2, Wyse 50 Emulation.
8. Supply power to the pump from the HL 20 through the Pump Servicing
Cable. Use a spare Bottom Cabling assembly to permit operating the unit as
shown in Figure 6.
Verify the fan operates quietly.
Verify the motor runs smooth and quietly at various speeds.
5-16
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
Figure 7: Typical terminal output

9. Observe the terminal program (similar to Figure 7) and confirm the following
values:
Measurement
Limits
Offset
Ref. Test
10
490-510
Label
RPM
LPM
POTI
475 to 525
-96 to -132
SETV
STOP
HEAD
T_MO
Description
RPM display
Flow display in L/min
Flow Pot. Set Value
Motor Tachometer
in RPM
Slave Mode Set Value
Stop Input Value
Head Tachometer
Motor Temperature
12V Test
108 to 132
ACTV
5V Test
-12V Test
HOURS
RUNNING
HOURS
TOTAL
0
5 of set
Varies
Since last
cleared
T_HS
Heatsink Temp.
ACTS
DELT
CORR
Head Tacho in
Pulsatile Mode
Pulsatile Mode Reg.
Deviation
Pulsatile Mode
Motor Reg.
Limits
Varies
Figure 8: Acceptance criteria for terminal output Single Pump

Note: The following board level adjustments may be required if limits shown in
Figure 8 are exceeded. Contact MAQUET Technical Support if board layout
differs from those shown.
10. Measure between TP5 (5 Vref) and TP1 (0 volts) on Pump Control board.
Verify 5.000 0.005 volts.
Revision 00
Service Manual
5-17
5. Maintenance
JOSTRA HL 20
11. Run pump in forward direction at maximum speed.

Verify POTI and SETV values are 2500 5.
Adjust POT101 on Motor Control board for a HEAD value of 2500 1.
12. Run pump in reverse direction at maximum speed.
13. Use Figures 9 and 10 to verify test point voltages if necessary.
Pump Control
TP1 (0 volts)
TP2 (5.0 0.1 VDC)
TP3 (12 0.5 VDC)
TP4 (-12 0.5 VDC)
TP5 (5.000 0.005 VDC)
Safety Board
TP1 (0 volts)
TP5 (5.000 0.005 Vdc)
Motor Control
TP1 (0 V)
TP2 (5 0.1 VDC)
TP3 (12 0.5 VDC)
TP4 (-12 0.5 VDC)
TP106 (5.0000.005 VDC)
Figure 9: Test point voltages Single Pump
Pump Control Board
Safety Board
Motor Control Board
Tacho Board
Figure 10: Single pump circuit board test points and adjustments
5-18
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
14. Attach oscilloscope to Tacho board test points and TP3 (0 volts) and run
pump at maximum speed. The traces shall look similar to Figure 11.
Verify both traces are centered near 2.5 volts with amplitudes > 2 volts
peak to peak.
Adjust Tacho board if necessary (refer to Figure 10).
POT1 adjusts the signal at TP1 and POT2 adjusts the signal at TP2.
Verify the phase relationship is 90 10 degrees.
Make slight adjustments to the Tacho board orientation if necessary.
NOTE
It will not be possible to operate the pump if Tacho board adjustments

are too far out of specification. In this case, turn the pump by hand
while adjusting the traces without clipping.
Figure 11: Typical oscilloscope display for calibrated (single pump) Tacho board
16. Completely reassemble the pump, remount on HL 20, and test pump
Revision 00
Service Manual
5-19
5. Maintenance
5.3.5
JOSTRA HL 20
Belt Replacement, Single Pump

1. Replace belts which are found twisted, have wear, cracking, or service life
over 2 years.
2. Loosen the belt tension by turning tensioning nuts until belts can be rolled off
the pulleys.
3. Cut the old belts to prevent their reuse.
4. Adjust the tensioning nuts to permit the lower belt to easily roll onto the
motor and head pulleys. Repeat this for the upper belt. Do not overstretch
the belts!
5. Rotate the pump head by hand a number of times to fully seat and equalize
tension in the belt. Increase the tension until finger deflection starts to
become tight.
6. Lightly pluck the belts while holding the Sonic Tension Meter 1 cm away
and read the measured frequency. Always take at least three measurements
to assure accuracy. Adjust to 320 32 Hz.
NOTE
A frequency filtering feature is available with the 507C Meter. Band

pass ranges are selectable for 10 to 600 Hz (standard) and 500 to
5000 Hz (high). Select the correct range when taking measurements.
7. When belts are tensioned properly they shall deflect approximately 3 mm

with moderate finger pressure. This takes experience to determine.
Figure 12: Lightly pluck the belt and measure with the Sonic Tension Meter
8. Run the pump at 250 RPM under load for at least 30 minutes and verify the
tension and orientation of belts.
9. Check the Tacho board signals as previously described.
10. Reset Hours Running by closing JP11 (use Berg jumper) on Pump Control
board and performing a cold start. A cold start occurs if power is reapplied
after being off for over 5 seconds.
Important: Resetting hours will also clear flow calibration values (which were
written on the User Settings Worksheet. You must restore these values before
returning pump to active service!
5-20
Service Manual
Revision 00
JOSTRA HL 20
5.3.6
5. Maintenance
Twin Pump
1. Remove the 6 screws securing the pump bottom plate and separate from
pump chassis.
2. Clean the fan and inside of unit with compressed air (preferred) or ESD safe
brush.
3. Use a flashlight and observe the belts. Replace belts which have wear,
cracking, or service life over 5 years (see Belts with Pulley Replacement).
4. Loosen the front panel by removing the 8 screws using a 2.5 mm hex key
wrench. Replace screws which are galled or have worn heads.
5. Use the Terminal Cable to connect a Laptop to one of the Control board
serial connectors (you must remove the 2-wire cable connecting the two
Control boards). Run a terminal program with port settings 9600 8-N-2,
Wyse 50 Emulation.
6. Supply power to the pump from the HL 20 through the Pump Servicing
Cable and operate the unit on its side.
Verify the fan operates quietly.
Verify the motors run smooth and quietly at various speeds.
7. Observe the terminal program (similar to Figure 7) and confirm the following
values. Repeat this procedure for the other Control board.
Measurement
Limits
Offset
Ref. Test
10
490-510
Label
RPM
LPM
POTI
12V Test
108 to 132
ACTV
5V Test
475 to 525
SETV
STOP
Description
RPM display
Flow display in L/min
Flow Pot. Set Value
Motor Tachometer in
RPM
Slave Mode Set Value
Stop Input Value
-12V Test
-96 to -132
HEAD
Head Tachometer
T_MO
Motor Temperature
0
5 of
set
Varies
Since last
cleared
T_HS
Heatsink Temp.
ACTS
HOURS
RUNNING
HOURS
TOTAL
DELT
CORR
Limits
Varies
Head Tacho in
Pulsatile Mode
Pulsatile Mode Reg.
Deviation
Pulsatile Mode Motor
Reg.
Figure 13: Acceptance criteria for terminal output Twin Pump
NOTE
Revision 00
The following board level adjustments may be required if

limits shown in Figure 13 are exceeded. Contact
MAQUET Technical Support if board layout differs from
those shown.
Service Manual
5-21
5. Maintenance
JOSTRA HL 20
8.
Measure between TP5 (5 Vref) and TP1 (0 volts) on Control board.

9. Measure between TP11 (5 Vref) and TP1 (0 volts) on Motor Control board.
10. Run pump in forward or reverse direction at maximum speed.
Verify POTI and SETV values are 2500 5
11. Use Figures 14 and 15 to verify test point voltages if necessary.
Control
Safety Board
Motor Control
TP1 (0 volts)
(see Figure 10)
TP1 (0 volts)
TP2 (5.0 0.1 Vdc)
TP1 (0 volts)
TP2 (5 0.1 Vdc)
TP3 (12 0.5 Vdc)
TP5 (5.000 0.005 Vdc)
TP3 (12 0.5 Vdc)
TP4 (-12 0.5 Vdc)
TP4 (-12 0.5 Vdc)

TP11 (5.000 0.005
Vdc)
TP5 (5.000 0.005 Vdc)

Figure 14: Test point voltages Twin Pump
Control Board
Motor Control Board
Figure 15: Twin pump circuit board test points and adjustments
12. Attach oscilloscope to Tacho board (use extension cable) and run pump at
maximum RPM.
Verify trace is centered near 2.5 volts with amplitude > 2 volts peak to
peak.
The waveform shall be similar to Figure 11 except single trace.
Adjust Tacho board POT1 if necessary.
5-22
Service Manual
Revision 00
JOSTRA HL 20
5.3.7
5. Maintenance
Belts with Pulley Replacement, Twin Pump

Note: The value in (mm) denotes hex key wrench size. Refer to Figure 16.
1. Remove the pump bottom plate as follows:
Remove the 6 screws securing the pump bottom plate and separate from
pump chassis.
Disconnect the two ground wires from the stud using a 7 mm nut driver.
Place both serrated washers and nut back on stud restore ground
connection after service!
Disconnect the Bottom Cabling from the Interconnection board and
remove bottom plate.
2. Remove the pump head as follows:
Remove the fasteners securing pump head cables and disconnect all
connectors from the Interconnect board.
Loosen the set screws on opposite sides of the pump head (2.5 mm).
Release the two outer tube inserts by removing the pins (1.5 mm).
Remove the two outer tube inserts, springs, seats, and screws (3 mm).
Gently lift the pump head straight up paying careful attention to the
cables. If the gasket sticks then work it free. Clean any residue under the
gasket.
Lay the pump head next to the chassis upside down.
NOTE
Work on one pump at a time so as to have a reference. Use caution

when working around the tacho strobe to avoid scratches. Clean the
tacho strobe label with cotton and alcohol while turning pump head by
hand if necessary.
3. Remove the tacho cable nylon fastener and the following screws which
secure the motor:
Single screw between the motors (6 mm).
Two locking screws along the edge (5 mm).
Tension adjustment screw (4mm).
4. Lift off the motor and set aside.
5. Remove the screws which secure the Belts with Pulley assembly:
Rotate the pulley to expose the locking screw (5 mm).
Tension adjustment screw (3 mm).
6. Remove the old Belts with Pulley assembly. Cut the old belts to prevent their
reuse.
7. Loop the new Rotor belt over the pulleys and lightly secure the locking screw
(5 mm). Hold the assembly while attaching the tension adjustment screw
(3 mm) and tension using the other pump as a reference. Do not over
tension final adjustment will be performed later.
8. Loop the new Motor belt over the pulleys and hold the motor in place while
attaching the tension adjustment screw (4 mm). Lightly secure the locking
screws and tension the Motor belt using the other pump as a reference. Do
not over tension.
Revision 00
Service Manual
5-23
5. Maintenance
JOSTRA HL 20
9. Rotate the pump head by hand a number of times to fully seat and equalize
tension in the belts.
10.Lightly pluck the belts while holding the Sonic Tension Meter 1 cm away
and read the measured frequency. Always take at least three measurements
to assure accuracy.
NOTE
A frequency filtering feature is available with the 507C Meter. Band

pass ranges are selectable for 10 to 600 Hz (standard) and 500 to
5000 Hz (high). Select the correct range when taking measurements.
11.Tension the belts to the following specification:

Rotor belt: 850 20 Hz adjust the tension screw on the pulley (3 mm).
Motor belt: 400 20 Hz adjust the tension screw on the motor (4 mm).
NOTE
The adjustments are interdependent and may require multiple

adjustment and measurements. Secure both pulley and motor locking
screws fully when tension is set and recheck frequencies.
12.Perform this procedure for the other pump. Operate pumps at 250 RPM
under load for at least 30 minutes and recheck the tension.
13.Reset Hours Running by closing JP11 (use Berg jumper) and performing a
cold start. A cold start occurs if power is reapplied after being off for over 5
seconds. Do this for both Control boards.
Important: Resetting hours will also clear flow calibration values (which were
written on the User Settings Worksheet. Restore these values before
returning pump to active service!
14.Completely reassemble the pump, remount on HL 20, and test pump
Twin Pump
Interconnection
Board
5-24
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
Figure 16a: Screws to remove in order to release the pump head
Figure 16b: Tension adjustment screws on pump head sides
Figure 16c: Locking screw on the pulley, motor removed, and tacho board and strobe
Figures 16: Various pictures of the Twin Pump, pump head assembly
Revision 00
Service Manual
5-25
5. Maintenance
5.3.8
JOSTRA HL 20
Extensive Preventive Maintenance Checklist

This checklist is completed as part of the Extensive Preventive Maintenance.
Confirm the following steps have been performed:
HL 20 Console
HL 20 Serial Number:
Step Performed:
Yes No
Yes No
ODU Connector Resistance:

External Inspection:
Cooling Fan Operational:
Power Supply Adjustments:
Battery Replaced:
Internal Inspection:
Cables Routed & Secured:
Circuit Board Adjustments:
Field Test Procedure:
Single Pump / Twin Pump

Pump 1
Pump 2
Pump 3
Pump 4
Pump 5
Pump 6
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Serial Number:
Single / Twin:
Step Performed:
ODU Connector Resistance:
Internal and External
I Strobe
ti 1:
Cleaned Tacho
Cables Routed & Secured:
Cooling Fan Operational:
Motor Runs Smooth:
Verified Terminal Data:
Inspected Belts1:
Replaced Belts:
Speed Adjustments Made:
Tacho Checked / Adjusted:
Field Test Procedure:
1
Single Pump only
5-26
Service Manual
Revision 00
JOSTRA HL 20
5. Maintenance
Notes
.Signature
.Date Performed
.Clarification of signature and title
Revision 00
Service Manual
5-27
5. Maintenance
JOSTRA HL 20
Notes
________________________________________________________________________________
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________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
5-28
Service Manual
Revision 00
JOSTRA HL 20
6. Service
Service
6.1
General
A repair procedure must normally be proceeded by a fault diagnosis procedure
as the complex structure of the system may indicate faults in other parts of the
machine than the fault origin. Always look up the error code presented on the
faulty module or somewhere else in the HL 20 system. See 4 Troubleshooting
and Appendix A Description of the HL 20 Self-test.
CAUTION
Switch off the main switch and unplug the mains cable before
attending service on the HL 20.
Before disconnecting cables, opening the console, removing pumps or
modules always switch the main switch OFF.
See 3 Function for detailed information about the different units and modules
of the HL 20.
Revision 00
Service Manual
6-1
6. Service
JOSTRA HL 20
6.2
Operations Prior to Adjustment
6.2.1
Open/Close SCP/SMU
Open
To open the SCP/SMU do as follows
Power the machine down.
Remove the screw in front (on SMU and on MPL, MPR, MRC or MLC
mounted SCP only) and in the rear.
Hold the SCP/SMU with one hand in case it falls out.
Push a small screwdriver in the middle hole onto the middle screw until the
board comes loose.
Pull the board out in a downward motion until you can reach the
connector(s) on the rear of the board.
Remove the cable from the connector.
Place the SCP/SMU on a cushioned surface so the display will not be

damaged.
Remove the three screws in the lower rear of the SCP housing (on ROC or
LOC).
Gently pull the lower part of the SCP front panel outwards approximately
10 mm.
In the same move then pull downwards approximately 10 mm until the

upper part comes out from the console housing.
Close
6-2
Check that the power connections are correct.
Connect the cable to the connector on the rear of the board.
Guide the SCP/SMU upward until the top edge is in place.
Check that the wires are not going to be crushed.
Push the SCP/SMU back in the housing and tighten the screws.
Service Manual
Revision 00
JOSTRA HL 20
6.2.2
6. Service
Install Pump
To install a pump:
1. Switch OFF the HL 20 with the Main Switch.
2. Open the cover over the electrical socket at the intended pump bay on top
of the Console.
3. Make sure that the pump position is turned OFF.
CAUTION
Switch off power to the pump before installing or removing it from

the Console.
Removing a pump while switched on will damage internal components.
4. Lower the pump straight down on the Console. Two large stainless pins
guide the pump into position, and provide grounding contact with the
Console.
All power connections to the pump are made through a socket on the Console,
and the pump is ready for immediate operation.
6.2.3
Remove Pump
To remove a pump:
1. Switch the Pump OFF.
CAUTION
Switch off power to the pump before installing or removing it from

the Console.
Removing a pump while switched on will damage internal components.
2. Lift the pump straight up off the Console.

After removing a pump, it may be placed on any flat surface without damage to
the electrical pins. Uneven surfaces could result in damage to the pins on the
pump base. If the rubber feet on the bottom side of the pump become
damaged, they should be replaced.
When handling the pump, be careful not to let the electrical pins on the
underside contact anything. Never touch the pins as skin oils and moisture may
subsequently degrade electrical connections.
If the pump will be removed for more than a few moments, or if the Console is
being cleaned, place the plastic cover over the electrical socket. This is
especially important to help prevent liquids from getting into the socket.
Revision 00
Service Manual
6-3
6. Service
6.2.4
JOSTRA HL 20
Open/Close Pump
Roller Pump Module (RPM)
Open
CAUTION
Do not open the pump on its operational place on the console.

The equipment might get damaged.
Place the pump on its side with the front to the left.
Remove the six screws holding the bottom plate.
Carefully pull the bottom plate towards you. Twist the inside of the plate
upwards and place the bottom plate on the table.
Close
Before closing check that all connections are in place an that all boards are
fastened.
Twin Pump Module (TPM)

Open
CAUTION
Do not open the pump on its operational place on the console.

Place the pump in its natural resting position with the front facing you.
Remove the eight screws holding the front panel.
Remove the front panel slightly and remove all connections.
Close
6-4
Before closing the front panel check that all connections are in place.
Service Manual
Revision 00
JOSTRA HL 20
6.2.5
6. Service
Open/Close Console
WARNING
Danger of electric shock

Always disconnect the mains plug before opening the console.
Open
Power down the machine by pressing the main switch to position OFF and
remove the mains cable.
Remove all pumps.
Disconnect the SCP, the SMU and the spotlight cablings and secure them
to the masts.
CAUTION
Remove the bubble sensor and make sure that the level sensor is out of the
way.
Lock the back wheels in an outwards position.
Lock the front wheels in a forward position.
Loosen the two lock screws. See following picture.
Be careful not to tilt over the console.
CAUTION
NOTE
When open the console might easily tilt.

Secure the console with a wooden box or similar.
Do not use a metal tool box or similar as this easily may scratch the
console housing. Sharp corners may even destroy the ON/OFF switches.
NOTE
Open the console housing by gently pulling the masts forward.
Check that the stop hinge is in its locked position.
Revision 00
Secure the SCP, the SMU and the spotlight cablings before opening
the console.
The cablings may fall down and short-circuit the battery poles.
Remove the battery cable connecting the two batteries together in order to
work safely in the machine.
Service Manual
6-5
6. Service
JOSTRA HL 20
1. Stop hinge
2. Battery cable connecting the two batteries together.
3. Lock screw (one on each side of the console)
Opening the console
Close
6.2.6
Check that no tools or hardware are left in the machine.
Check that all connections are in place.
Close the battery connection.
Lift the stop hinge and close the console by pulling the masts.
Connect the SCP, the SMU and the spot-light cablings.
Check that the console is properly locked by tightening the two lock screws.
Remove Module
Remove the straight screws on the corners of the module and gently pull the
module out of the 19-rack.
6.2.7
Open/Close Module
CAUTION
6-6
Electrostatic sensitive equipment.

Always work on an anti-static surface mat and use a wrist strap when
handling electrostatic sensitive equipment.
Service Manual
Revision 00
JOSTRA HL 20
6. Service
6.3
SCP Adjustments
6.3.1
SCP Time and Date Setting

To set the clock time:
1. Simultaneously press the Safety Set button (2) and the loudspeaker button
(3). The two left digits of the real-time clock (1) now blink. Turn the
Adjustment Knob (4) to set the hour. Set the hours in military (24 hour) time.
2. Press the Safety Set button (2) and the loudspeaker button (3) again. The
two right positions now blink. The minutes can be set by turning the
Adjustment Knob.
If you press the Safety Set and loudspeaker buttons again, you are in the
seconds mode. Set the seconds by turning the Adjustment Knob.
Continue in this manner and in the next four steps set the day of the week, the
month, the day of the month and the year.
Please note that the setting cycle must always be completed. Clock setting is
not complete until all of the positions have ceased to blink.
Revision 00
Service Manual
6-7
6. Service
JOSTRA HL 20
6.4
SMU Adjustments
6.4.1
SMU Display Adjustments
6-8
COMM LED
This LED blinks when data is being exchanged with the rest
of the system.
OK LED
This LED is illuminated when all self-tests of the monitor
unit have been completed without fault, and the monitor is
ready for use.
Screen Contrast adjustment
Screen Brightness adjustment
ECG Amplitude adjustment

This screwdriver-adjustable potentiometer adjusts the
displayed amplitude of the ECG signal.
Pressure Amplitude adjustment

displayed amplitude of the input pressure signal.
ECG Position adjustment

position of the ECG signal on the screen.
Pressure Position adjustment

position of the Pressure curve on the screen.
Service Manual
Revision 00
JOSTRA HL 20
6. Service
6.5
Pump Adjustments
6.5.1
Tube Installation
See User Manual.
6.5.2
Occlusion Setting
See User Manual.
6.5.3
Flow Rate Calibration

Each pump should have the flow display calibrated to actual output for each
tube size. This normally needs to be done infrequently, such as when a new
pump is installed, when switching to a new tube size, or as a periodic check.
NOTE
It is important that this is done accurately as the flow rates which are
recorded in the JOCAP data set when recording a case are based on this
calibration.
1. Select tube size
Press the Menu (page) button on the pump until SET TUBE is displayed.
Press the SET button. Press the Menu button until the correct tube size is
displayed. Then press and hold the SET button for three seconds until a
long beep is heard.
2. Insert the tube and set the occlusion as described in the User Manual.
(Record the micrometer occlusion setting on the pump head so this can be
quickly reset for the same type of tube in the future.)
3. Set the pump to CAL MODE
Press the Menu (page) button until CAL MODE is displayed. Then press
and hold the SET button for three seconds until a long beep is heard and
the display blinks.
4. Connect both ends of the tube to a static supply (bucket) holding at least 10
litres of water. Switch on the pump, and set to about 60 RPM for 1/2" ID or
larger tubes, or approximately 100 RPM for smaller tubes.
NOTE
Do not change the pump speed until the end of the calibration.
5. Move the outlet side of the tube to a collection container, and collect the
output for exactly one minute. Then move the outlet end back to the main
bucket. Measure the volume collected in litres.
Revision 00
Service Manual
6-9
6. Service
JOSTRA HL 20
6. Switch the display to LPM mode. Using the adjusting screwdriver, adjust the
potentiometer on the front channel of the pump so that the LPM reading in
the Display Window agrees with the amount collected in one minute.
7. When you have entered the correct flow in the display and want to
memorise it, press the SET button and hold for three seconds. A long beep
confirms that the programming procedure has been completed and the new
flow curve is memorised.
If you wish to leave the calibration mode without memorising the new value,
merely press any other button.
8. The pump speed may now be changed or the pump switched OFF. The
new flow-rate calibration curve for this tube size is linear, and will remain in
the pump memory even when the pump is switched off.
RPM
TPM
6-10
Service Manual
Revision 00
JOSTRA HL 20
6.5.4
6. Service
Belt replacement
Refer to section Belt Replacement, Single Pump or Belts with Pulley
Replacement, Twin Pump in the Maintenance chapter.
6.5.5
Optical Tachometer Board Adjustment

The tachometer must be adjusted to the pump it is going to operate in. If the
tachometer is installed in another pump it must be readjusted. (A special test
cable might be needed to access the test points)
Adjustment procedure
Refer to section Single Pump or Twin Pump in the Maintenance chapter.
6.6
Console Adjustments
6.6.1
Mast Angle
To adjust the mast angle do as follows
Revision 00
Open the console. See 6.2.5 Open/Close Console.
Loosen the screw (1).
Loosen the four screws (3) located under the mast block (2).
Adjust the mast angle as desired by hand.
Tighten the screws (3)
Service Manual
6-11
6. Service
JOSTRA HL 20
6.7
Module Adjustments
6.7.1
Power Percentage Adjustment CCM
1. Display showing line voltage as a

percentage of nominal voltage.
2. Battery check button
System Control Panel Console
Group
CCM Board
1. Disassemble the Console Control Module (CCM) and mount it together with
the extension board.
2. At nominal line voltage adjust the POT2 on the CCM Board until the
Console Group display (1) shows 100%.
6.7.2
Dual Pressure Module

Calibration of Pressure Control
See User Manual.
6-12
Service Manual
Revision 00
JOSTRA HL 20
6.8
6. Service
Check Procedures
This section comprise a check list to help complete an adjustment or service
session. It is important that a thorough check after service is performed to
prevent mistakes of any kind.
After the list some check procedures are described in detail.
Furthermore, there is an extensive test for HL 20 as described in section 6.9
Field Test Procedure. It is recommended this procedure be completed to verify
performance standards following major service intervention or periodic
maintenance of the HL 20. Parts of this procedure may also be used during
system installation. This Field Test Procedure is created for the US Service
organization, but can of course be used worldwide if required.
6.8.1
Checklist
The checklist includes information in two categories:
Replace
Perform these check points after an adjustment to the system or

replacement of a component, a module etc.
Service
These check points are used at the periodical maintenance

service.
SCP
Replace Service
Check
The entire Field Test Procedure.
SMU
Replace Service
Check
Check that all signal curves are displayed correctly.
Check that the JOCAP system works.
Pumps
Replace Service
Check
Outside Pump
CAUTION
Revision 00
Power OFF before touching the inside of the pump

house!
Check the inside of the pump house and the tube locking for
mechanical damage.
Check that the guiding rollers runs smooth, are tightened and
are not damaged.
Check that the rollers runs smooth and are secured in the
middle of the pin.
Check that the roller blocks runs smooth.
Check that the occlusion locking work and has a spring

function.
Service Manual
6-13
6. Service
JOSTRA HL 20
Replace Service
Check
Check that the tube locking runs smooth, on the insert system
check the spring function.
Check that the occlusion knob is tightened with the two stop
screws.
Occlusion check
(should be performed by MAQUET trained personal only).
Pump Front
Check that the front panel is tightened with eight screws.
Press all the buttons and make sure that they are distinct and
has a good sound.
Pump Bottom Plate
Check that the pins in the ODU connector are secured in the
housing.
Check that the bottom plate is tightened with six screws.
Inside the pump

NOTE
Must be performed by MAQUET trained personnel only.

Belt check
Dismount the front panel and make sure that the EMIprotection is secured to the chassis.
Check the belt tension (max. possible depression 3 mm) and

that the belt is not twisted.
Chassis
Dismount the bottom plate and make sure that the EMIProtection is secured to the plate.
Clean the fan and check the condition of the cables and their
isolation.
Roller Pump boards (RPM 20-310, RPM 20-320)

Front Panel Board
X
Check the board visually
Check jumper settings

Interconnection board

Control Board
Connect Ground to TP1 and check voltage at TP5

Safety System Board
6-14
Connect ground to TP1 and check voltage at TP5
Service Manual
Revision 00
JOSTRA HL 20
6. Service
Replace Service
Check
Motor Control Board

X
Connect 24V to TP2, ground to TP0 and check the voltage at

TP2, TP3 and TP4.
Connect ground to TP1 and check voltage at TP106 (only

pumps delivered after June 1996)
Motor Control Module 1 (only pumps delivered before
June 1996)

Optical Tacho Board
Check tachometer signals. See 6.5.5 Optical Tachometer

Board Adjustment.
Twin Pump boards (TPM 20-330)

Front Panel Board
X

Interconnection Board

Control Board
Connect Ground to TP1 and check voltage at TP5

Safety System Board
Connect ground to TP1 on the Control Board and check

voltage at TP5
Optical Tacho Board
Check tachometer signals. See 6.5.5 Optical Tachometer

Board Adjustment.
Motor Control Board
Revision 00
Connect ground to TP0 and check the voltage at TP2.
Connect ground to TP1 and check the voltage at TP3, TP4

and TP11.
Service Manual
6-15
6. Service
JOSTRA HL 20
Replace Service
Check
Pump function
X
Start the pump and check that it passes the self test.
Check that the pump are able to switch between LPM and
RPM.
Speed Check
Set the pump to max. speed and check that it shows 250 rpm
1 rpm.
Check the speed with a hand tachometer (1 rpm).
Check that it is not possible to set the pump in reverse mode

while running.
Set the pump in reverse mode.
Set the pump to max. speed and check that it shows 250 rpm
1 rpm.
Check the speed with a hand tachometer (1 rpm).

Calibration Check of the Tubes
Check that it is possible to calibrate the flow of the tubes and

that the value is stored.
Intensity Check
Check that the intensity can be adjusted to 25, 50 and 100%

and stored.
Alarms
See 6.8.2 Pump Alarm Check Procedure.
Check that the runaway / rpm-diff and repeated runaway /

rpm-diff alarm is functioning.
Check that the direction alarm is functioning.
Check that the beltslip alarm is functioning.
Mode function
X
Set the pump ARTERIAL mode, check that all the modules
with stop functions are stopping the pump.
Set the pump to SLAVE mode, check that all the modules
Set the pump to SUCKER mode, check that all the modules
Set the pump to AUX mode, check that all the modules with
stop functions are stopping the pump.
Set the pump to CARD mode, check that all the modules with
stop functions are stopping the pump.
The ART PULSE Mode
6-16
Set the pump to ART PULSE mode and check that the pump
can be controlled from the control panel.
Service Manual
Revision 00
JOSTRA HL 20
6. Service
Replace Service
Check
SLAVE 1 and 2 Mode

X
Set the pump to SLAVE 1, set another pump to ART mode

and check that the SLAVE pump can be adjusted within
20% of the value set on the ART pump.
Set the ART pump to 0. The slave pump must stop.
Set the pump to SLAVE 2, set another pump to ART mode

and check that the SLAVE pump can be adjusted within
20% of the value set on the ART pump.
Set the ART pump to 0. The SLAVE pump must stop.
In SLAVE 2 mode, set the ART pump to ART PULSE and

check that the pump runs without pulsating but is following
the flow from the art pump.
Check that the SLAVE 2 is delayed when the ART pump is

started and stopped.
Set the SLAVE pump to SLAVE 1 and check that the pump is
pulsating like the ART pump.
Console
Replace Service
Check
General
X
Check that the front wheels are secured to the body and have
total lock function.
Check that the rear wheels are secured to the body and have
a direction lock function.
Check that the drawer runs smooth.
Check that the power socket list are secured, works and have
a safety plate.
Check that the access panel is able to stay in its open

position.
Check that the switches lights up when pushed ON and do

not get stuck when pushed OFF.
Check that the charge and battery indicators light up when

charging or running on batteries.
Check that the position dowels are secured to the body and
not mechanical damaged.
Check that the ODU connectors are secured to the body and
have a cover.
ROC and LOC only
Revision 00
Check that the panel can be tightened in all positions.
Check that the panel locks in the three different positions.
Check that the panel can be locked to the mast.
Service Manual
6-17
6. Service
JOSTRA HL 20
Replace Service
Check
MRC and MLC only

X
Check that the panel runs smooth from side to side and can
be secured at any position.
Check that the monitor runs smooth from side to side and can
be secured at any position.
Check that the monitor arm are secured to the mast.
Check that all the masts and side guards are secured to the
console.
Check that the infusion masts run smooth and can be

secured with the grip.
Module Access Bay

X
Remove all LEMO plugs from the SCP and the SMU. Check
that both the male and female connector are intact and that
no pin are pushed in.
Remove the Air Bubble Sensor. Check that both the male and
female connector are intact and that no pin are pushed in.
Check the female LEMO connectors on the AIO, DPM, QTM

and DIO module and make sure that none of the pins are
pushed in.
Check all the fuses on the fuse panel by switching ON and

OFF at each position.
Check that the spot light works in both connectors.
Unscrew the modules one by one and make sure that the
EMI-protection is properly secured.
Do a total function check on the system according to User

Manual.
Mains Transformer
X
Check that the jumper configuration is correct.
Check that the outputs are correct.
Check that the power percent is between 100 and 105 %.
Check that the leakage current is acceptable. See User

Manual.
Power Supply Board
6-18
Check that the fuse panel cables are correctly mounted.
Check that all output cables are correctly mounted.
Check that all switches are correctly mounted.
Check that the correct pump positions receive power in

conjunction with the pump switches.
Check that the FUSE alarms are in conjunction with the

corresponding FUSE.
Check that the machine switches to BATTERY mode

normally.
Check that the spot light works.
Check that the screws on the PSB are tightened.

Service Manual
Revision 00
JOSTRA HL 20
6. Service
Replace Service
Check
Check that all connections are tight.
Check that the screws through the bridge rectifiers are tight.
Battery
X
Check that the batteries charge up normally.
Check that the battery back-up time is acceptable.
The 19" Rack and the RP Board

X
Since the RP board interconnects literally the entire system

together, it is without question that all the final test must be
performed.
Modules
Replace Service
Check
Power Supply Module (PSM)

X
Check that the voltage outputs are correct and stabile.
Check that the machine functions are normal.
Check that no errors occur on several cold starts.
Console Control Module (CCM)

X
Check that the power percentage is between 100 and 105%.

See 6.7.1 Power Percentage Adjustment CCM.
Check that all pumps, SCP and SMU function in Battery

mode.
Check that all pumps can be programmed to all possible

modes.
Check that the batteries charge up normally.
Check that the Stop Modules function in all selections.
Check jumper settings.
Battery Charge Module (BCM)

X
Check that P1-Z8 is the same voltage as displayed on the

SCP (fuse removed).
Check that 2 amperes are travelling through F3 when the

batteries are empty.
Check that the batteries are fully charged after 15 hours.
Check that the machine runs in battery mode for the

acceptable time limit.
Monitor Interface Module (MIM)
Revision 00
Check that the signals are displayed on the SMU.
Check that the external ECG can be displayed on the SCP

and a pump can trigger from it.
Service Manual
6-19
6. Service
JOSTRA HL 20
Replace Service
Check

X
Check that the bubble detection circuit detects micro-bubbles.
Check that the level detection circuit works properly.
Check that the ABD stops all pumps in different modes.
Check that the override function works.
Ultra Level Detector Module (ULD)

X
Check that the level displays proper number of bars on

display with phantom.
Check that an alarm sounds if sensor is below the liquid level.

Stop functions and override functions.
Quadruple Temperature Module (QTM)

X
Check that the temperature probe and what is displayed on

the SCP are the same value (use simulator).
Check that the leakage current is of acceptable value
Dual Pressure Module (DPM)

X
Check that the pressure transducers can be calibrated

correctly (with simulator).
Check that the pressure is displayed on the SCP.
Check that the DPM sends out an alarm when the pressure
exceeds the limit.
Check that the stop function works.
Check that the DPM can regulate a pump.

X
Check that the bubble detection circuit detects micro-bubbles.
Check that the AEP stops all pumps in different modes
Check that the level displays proper number of bars on

display.
Check that an alarm sounds if sensor is below the liquid level.
Analogue I/O Module (AIO)

X
Check that the external signals are displayed.
Check that the leakage current of the combined devices are

acceptable.
6-20
Check that the external signals are recorded on JOCAP.
Check that the external signals are displayed if programmed

to do so.
Check that the combined leak current is acceptable.

Service Manual
Revision 00
JOSTRA HL 20
6.8.2
6. Service
Pump Alarm Check Procedures

Runaway / RPM_DIFF Alarm RUNAWAY / RPM_DIFF
1. Adjust the pump speed to 0 rpm.
2. Turn the pump head in the arrow direction.
3. Check that the pump alarm starts indicating RUNAWAY / RPM-DIFF.
4. Reset the pump by turning the speed knob up and down.
Repeated Runaway Alarm !!!!

1. Make the runaway check twice within 5 seconds.
2. Check that the display shows !!!! or perhaps SAFETY-S.
3. Reset the alarm by turning the pump OFF.
Direction Alarm DIRECT

2. Turn the pump head in the opposite arrow direction.
3. Check that the pump alarm starts indicating DIRECT.
4. Reset the pump by turning the pump OFF.
Beltslip Alarm LOAD !!!

2. Put one hand on the pump head in order to prevent it from turning.
3. Increase the pump speed with your other hand.
WARNING
Danger of severe personal injury.

Only trained personnel may perform this test.
The pump is very powerful and can cause severe damage to the hand.
4. Check that the pump alarm starts indicating LOAD !!! or HEAD.
5. Reset the pump.
Reset the LOAD !!! alarm by turning the speed knob down.
Reset the HEAD alarm by turning the pump OFF.
Revision 00
Service Manual
6-21
6. Service
JOSTRA HL 20
6.9
Field Test Procedure
6.9.1
General
Scope
The Field Test Procedure described below is created for the US Service
organization, but can of course also be used worldwide if required.
It is recommended this procedure be completed to verify performance
standards following major service intervention or periodic maintenance of the
HL 20. Parts of this procedure may also be used during system installation.
Field Test Checklist

The Field Test Checklist shall be completed during this procedure.
Test Equipment
1. Test equipment specifications are listed to facilitate substitution. lternate
test equipment must meet or exceed the following recommendations.
2. Temperature References: YSI Series 400.
Specs: 1.5C, 20.1C, 34.5C, 43.3C, 0.1%.
3. Pressure Transducer Simulator: Fogg System Company BP-28 or
equivalent.
Specs: 0.5 mmHg 0.1% of setting @ 25C, 200/300/3000 Ohms, range
500 mmHg.
4. Photo-Tachometer: Extech 461895 or equivalent.
Specs: 0.05% + 1 digit, 0.1 RPM resolution.
5. Electrical Safety Analyzer: to meet local requirements and device
configuration.
Specs: AAMI or IEC (local requirements).
Recommended Test Equipment
Sonic Tension Meter
6-22
Pressure Transducer Simulator
Service Manual
Revision 00
JOSTRA HL 20
6. Service
Test Tubing
1. Test configuration consists of 1 section PVC tubing segmented with 15 cm
section of same dimension silicon, 3/8 inch ID x 3/32 inch W x length
suitable to reach water container, roughly 2 meter length total. Silicon
portion is to test Air Bubble Detector on both types of tubing. Can also use
separate tubing setups of same dimension and length.
2. Centrifugal pump with 50 cm 3/8 inch ID x 3/32 inch W PVC tubing
attached. Submerge into water to expel all air and loop. Attach adjustable
tubing clamp (miniature tubing cutter with blade removed works well or use
an adjustable flat wrench).
3. Polycarbonate flask for level sensor tests. Permanently attach Level Sensor
pad to flask (Back packers wide mouth water bottle).
4. Water container for 5 mm pellet test (1 liter water bottle).
Temperature References: YSI Series 400

1. IRC RC Precision Metal Film 0.1% resistors.
a.
1050 = 43.34C
b.
1500 = 34.52C
c.
2800 = 20.11C
d.
6810 = 1.51C
2. Switchcraft 2 conductor 1/4 Black Phone Plug.

External Signal Simulator:
1. Per customer installation or use signal generator.
2. Refer to service manual for analog i/o input specifications.
Tools
1. Potentiometer adjustment tool (for module switches, potentiometer
adjustments)
2. 10 mm diameter wooden dowel (for pump tests)
Requirements
Completion of MAQUET service training is prerequisite to performing this
procedure. If any portions of the following tests fail then a determination of
impact shall be performed and the decision to return equipment to clinical use
shall be made based on the severity of the non-conformance. Do not return
equipment to clinical use which has failed testing for critical functions. Correct
all non-conformances as soon as possible to maintain users performance
expectations.
WARNING
Revision 00
Danger of serious personal injury. Disconnect mains

voltage before opening equipment. Observe precautions
when operating pumps with cover removed. HL 20 may
tip over when opened. Review precautions in Users
Manual and Service Manual. Consult MAQUET Technical
Support if there are any questions regarding these
documents.
Service Manual
6-23
6. Service
6.9.2
JOSTRA HL 20
Initial Inspection
1. Check the unit for mechanical defects. Verify the following:
Drawer opens and closes smoothly
Masts go up and down smoothly
Support arm clamps are secure and tension adjustment operates
Front wheels are secured, run smoothly, and have total lock function
Rear wheels are secured, run smoothly, and have directional lock
function
Panel and Monitor can be secured at multiple positions
Panel and Monitor move side to side (as equipped)
Cables and connectors are in good shape
Confirm electronic module screws are secure
Verify hand crank(s) are available and in good shape
2. Check each pump for signs of damage. Verify the following:
Front panel is in good shape
Cover is in good shape
Tubing lock functions
Inserts can be moved and spring function operates
Rollers run freely and no play is detected
Tubing guides rotate smoothly
Occlusion locking mechanism operates (do not adjust).
3. Turn on Main power and Monitoring system power.
Verify audible alarm sounds.
Verify the Monitor (SMU) powers up and traces are displayed on the EL
panel.
Verify all Control Panel LEDs illuminate (in groups) followed by
initialization.
Verify the Control Panel displays Mains voltage (%).
4. Press and hold Mains / Battery.
Verify battery voltage is displayed.
5. Hold down safety switch and press Mains / Battery.
Verify display intensity scrolls through 25%, 50%, and 100% settings.
6. Turn on each pump.
Verify an audible beep sounds, self test is performed, all LEDs light, and
OK is shown.
7. Inspect the following switches & indicators:
Verify Halogen Lamp operates (if applicable).
Verify all on/off switches operate smoothly and lights illuminate.
Verify Charge C indicator illuminates when operated on Mains voltage.
Record the acceptance.
6-24
Service Manual
Revision 00
JOSTRA HL 20
NOTE
6.9.3
6. Service
Complete the User Settings Worksheet and return all equipment to

original settings after tests have been completed! Attach the worksheet
to service report.
Record occlusion scale settings (turns until fully closed or open) if this
adjustment will be altered (e.g., for cleaning). You must restore
occlusion adjustments to exactly the same settings!
Battery Capacity
1. Disconnect Mains voltage and continue with the test procedure while
running on batteries:
Verify audible alarm.
Verify Battery B indicator illuminates when operated on battery.
Verify battery life is 1.5 hour minimum when performing test procedure.
Reconnect to Mains voltage when necessary. Battery voltage shall be
>23 V.
Revision 00
Service Manual
6-25
6. Service
6.9.4
JOSTRA HL 20
Pressure Channels Calibration

NOTE
Calibrate pressure channels with a calibrated Pressure Transducer

Simulator (PTS) to maintain stated accuracy (see Technical Data
section of Users Manual). A customer operated Pressure Transducer
Calibration procedure is outlined in the Users Manual.
1. Set PTS to 0 mmHg and attach to channel I.

2. Zero channel I by holding safety switch and pressing 0.
3. Set PTS to 300 mmHg and verify the trend LED indicates increasing
pressure.
4. Press AMPLITUDE while turning Adjustment Knob to select
300 mmHg.
5. Set gain on channel I by holding safety switch and pressing Amplitude.
Verify 300 mmHg is displayed after switches are released.
Verify Trend LED indicates increasing pressure.
6. Press kPa and verify 39.9 is displayed. Press again for mmHg units.
7. Set PTS to 100 mmHg.
Verify display shows 100 1 mmHg.
Verify Trend LED indicates decreasing pressure.
8. Set PTS to 10 mmHg
Verify display shows 10 1 mmHg.
9. Repeat the Pressure Channels Calibration procedure verifying channel II.
10. Repeat the Pressure Channels Calibration procedure verifying channel III.
11. Repeat the Pressure Channels Calibration procedure verifying channel IV.
Dual Pressure Modules (DPM) connector pin-out
6-26
Service Manual
Revision 00
JOSTRA HL 20
6.9.5
6. Service
Stop Functions
Pressure and Level stop function tests are performed for each pump and all
modes. It is reasonable to test only the modes which are used at the facility
(refer to worksheet).
1. Set all Pressure Channel and Air-Bubble / Level Detector Stop switch
settings to ART.
2. Program the pumps with Soft Alarms enabled as follows:
Pump 1 ART
Pump 2 SLAVE 1
Pump 3 SUCKER
Pump 4 AUX
Pump 5 CARD
Pump 6 FREE (if applicable)
3. Program all Control Panel pressure alarm upper limits to 105 mmHg.
4. Attach simulators as follows:
PTS to channel I set to < 95 mmHg.
Level Sensor to a polycarbonate flask containing water behind the
sensor.
Water filled tubing in Air-Bubble Detector or override alarm.
5. Start all pumps at maximum RPM.
Verify normal operation.
Verify all 9 Level Detector LEDs are illuminated.
Verify the correct pump Monitoring LED(s) are illuminated (per module
switch settings).
6. Set PTS to 100 mmHg.
Verify Pump 1 reduces speed (it will eventually stop).
Verify Soft alarm activates.
7. Toggle PTS between < 95 and 100 mmHg.
Verify Pump 1 speed is controllable by pressure.
8. Set PTS to > 105 mmHg.
Verify Pump 1 immediately stops.
Verify STOP PR1 is displayed on Pump 1.
9. Decrease PTS to < 95 mmHg.
Verify Pump 1 resumes operation.
Repeat these tests after attaching PTS to Channels II, III, and IV.
PR2, PR3, and PR4 will be displayed accordingly on pump under test.
10. Tilt the bottle to slowly lower the water level.
Verify Bar LEDs gradually extinguish.
Verify Pump 1 speed reduces with water level.
Verify Pump 1 stops when no water is behind the sensor.
11. Enable override feature when no water is behind sensor.
Verify Pump 1 starts.
This completes Stop Functions testing for one stop mode.
Revision 00
Service Manual
6-27
6. Service
JOSTRA HL 20
The test will be repeated for all other modes as follows:

12. Set all Pressure Channel and Air-Bubble / Level Detector Stop switch
settings to SLA.
Repeat Stop Functions test procedure verifying Pump 2.
13. Change Air-Bubble Detector and all Pressure Channel Stop switch settings
to SUC.
to AUX.
to CPL.
16. Disconnect the sensor for the AEP module (leave disconnected).
Verify Sensor Fault is indicated.
Verify Pump 5 stops.
Verify audible alarm sounds.
17. Connect the RotaFlow (if applicable).
Repeat Stop Functions test procedure verifying RotaFlow.
6.9.6
Control Functions
1. Set Pressure Channel and Air-Bubble / Level Detector Stop switches with
no duplicates:
I = ART
II = SLA
III = SUC
IV = AUX
Air-Bubble / Level Detector = CPL
2. Remove PTS and Override all monitoring alarms.
3. Program the pumps with Soft Alarms disabled as follows:
Pump 1 ART
Pump 2 SLAVE 1
Pump 3 SUCKER
Pump 4 AUX
Pump 5 CARD
Pump 6 FREE
The modes shown here are for the first repetition of this test routine. All tests
are performed for each pump by sequentially changing modes and repeating
the following.
6-28
Service Manual
Revision 00
JOSTRA HL 20
6. Service
Master Slave
1. Adjust ART to 100 RPM. Adjust SLAVE ADJ. potentiometer on SLAVE 1.
Verify slave pump:
Increases with clockwise adjustment.
Decreases with counterclockwise adjustment.
Revolutions adjust from 80 to 120 5 RPM.
2. Adjust ART to 0 RPM.
Verify SLAVE 1 stops.
3. Program SLAVE 1 as SLAVE 2 and repeat Master Slave Tests.
Pulsatile Internal Operation

1. Program ART as ART PULS (Arterial-Pulsatile) and start the pump.
Verify the pump does not alarm RUNAWAY (RPM-DIFF in U.S.).
2. Set pump speed to maximum RPM.
3. Set internal frequency to 120 BPM (view BPM / % display) by holding down
Internal freq. switch while turning Adjustment Knob. The BPM LED shall
illuminate during this procedure.
4. Enable Internal Pulse feature.
Verify ART PULS operates 30 2 times within 15 seconds (use Timer 1).
Verify the lowest curve on the Monitor (flow amplitudes, pump duty) is
synchronized with the internal pulse.
5. Set pump speed to 50 RPM.
Verify the curve amplitude decreases to ~ 20% of maximum.
6. Connect the RotaFlow (if applicable).
Verify pulsatile pumping is possible.
Pulsatile External Operation (if applicable)

1. Attach External Signal Simulator to Analog I/O.
Verify simulated signals are displayed on the Monitor.
Verify Monitor displays values 10% of simulator output.
Verify frequency is displayed on the Control Panel.
2. Set ART PULS speed to ~ 100 RPM.
3. Set base flow to 0% (view BPM / % display) by holding down Base flow
switch while turning Adjustment Knob. The % LED shall illuminate during
this procedure.
4. Enable External Pulse feature.
Verify lockout i.e., must enter Continuous mode first.
Verify the trigger signal (dashed line) is displayed on the Monitor, bottom
trace.
Verify ART PULS operates in synchronization with the external signal.
5. Set Base flow to 50%.
Verify roughly a 50% increase in base flow by viewing pump trace (lower
part of signal).
Revision 00
Service Manual
6-29
6. Service
JOSTRA HL 20
6. Set Base flow to 100%.

Verify ART PULS runs continuously.
Verify the pump trace is a straight line.
7. Set Base flow to 0%, Start to 0%, and Stop to 20%.
Verify the pump starts with the trigger signal and stops at ~ 20% of
period.
8. Set Start to 60% and Stop to 80%.
Verify the pump starts at ~ 60% after trigger signal and stops at ~ 80% of
period.
9. Set Start to 20%.
Verify the pump starts at ~ 20% after trigger signal and stops at ~ 80% of
period.
Master Slave, Pulsatile Operation

1. Slave pump was programmed as SLAVE 2 from earlier test.
Verify SLAVE 2 runs with out pulsating.
Verify SLAVE 2 RPM rate follows ART PULS.
2. Lower Pump 1 to 0 RPM, wait for rotation to stop, and then increase speed.
Verify SLAVE 2 starts delayed from ART PULS.
3. Program SLAVE 2 as SLAVE 1.
Verify SLAVE 2 exactly follows ART PULS.
Cardioplegia Mode Accumulators Normal Mode

1. Set Pump 5 (Cardioplegia) at 0 RPM and view Monitor Cardioplegia
display.
Verify only Plegia Pause timer is accumulating.
2. Set pump speed to ~ 100 RPM
Verify Plegia Pause timer has stopped.
Verify all other values are increasing.
3. Adjust pump speed to 0 RPM and back to ~ 100 RPM and verify:
Verify act. VOL reset to 0.
Verify act. PL Time resets to 0.
Verify total VOL. resumes counting.
Cardioplegia Mode Accumulators Luxation Mode:

1. Hold Set switch while adjusting pump speed to 0 RPM. Continue holding
until LUXATION appears.
Verify pump flashes LUXATION.
Verify act. PL TIME continues to increase.
Adjust pump speed to ~ 100 RPM and then back to 0 RPM.
6-30
Service Manual
Revision 00
JOSTRA HL 20
6. Service
Recirculation Mode Accumulators Recirculation Mode:

1. Hold Set switch while adjusting pump speed to ~ 100 RPM.
Verify pump displays RECIRC.
Verify PLEGIA PAUSE timer is running.
Verify act. PL TIME is not running.
Verify act. VOL and total VOL are not changing.
2. Adjust pump speed to 0 RPM and then back to ~ 100 RPM.
Verify pump does not display RECIRC.
Verify act. VOL and act. PL Time reset and total VOL. resumes
counting (normal mode).
Stop Control Functions

1. Test the stop control functions with all pumps running normally.
2. Press Pressure I flashing Override switch to enable alarm.
Verify only ART PULS, SLAVE 1, and CARD stop.
Press safety switch and Override to resume pump operation.
3. Press Pressure II flashing Override switch to enable alarm.
Verify only SLAVE 1 stops.
4. Press Pressure III flashing Override switch to enable alarm.
Verify only SUCKER stops.
5. Press Pressure IV flashing Override switch to enable alarm.
Verify only AUX stops.
6. Press Level flashing Override switch to enable alarm.
Verify only CARD stops.
Record the acceptance (test 1).
This completes one repetition of Control Functions testing. The test will be
repeated for all other modes starting at Master Slave with pump modes
programmed as follows. It is reasonable to test only the modes which are used
at the facility (refer to worksheet).
7. Increment the pump modes as follows:
Pump 1 FREE
Pump 2 ART
Pump 3 SLAVE 1
Pump 4 SUCKER
Pump 5 AUX
Pump 6 CARD
8. Repeat the Control Functions test procedure.
Revision 00
Service Manual
6-31
6. Service
JOSTRA HL 20

Pump 1 CARD
Pump 2 FREE
Pump 3 ART
Pump 4 SLAVE 1
Pump 5 SUCKER
Pump 6 AUX
Pump 1 AUX
Pump 2 CARD
Pump 3 FREE
Pump 4 ART
Pump 5 SLAVE 1
Pump 6 SUCKER
Pump 1 SUCKER
Pump 2 AUX
Pump 3 CARD
Pump 4 FREE
Pump 5 ART
Pump 6 SLAVE 1
Pump 1 SLAVE 1
Pump 2 SUCKER
Pump 3 AUX
Pump 4 CARD
Pump 5 FREE
Pump 6 ART
6-32
Service Manual
Revision 00
JOSTRA HL 20
6.9.7
6. Service
Twin Pump Cardioplegia Slave Mode

1. Program the left side pump as CARD (master) and the right side pump as
CARD SL (slave).
2. Adjust master pump speed.
Verify CARD SL follows the master.
Verify Monitor displays BLOOD CARDIOPLEGIA.
3. Stop the pump and select SET RATIO on slave pump.
4. Vary the flow control.
Verify ratio adjusts from Off, 1:20 to 1:1.
5. Adjust to 1:4 and press Set for 3 seconds to select.
Verify Monitor displays Act. C/B ratio: 1:4.
6. Start master pump.
Verify CARD SL runs at of master flow.
7. Repeat Twin Pump Cardioplegia Slave Mode test reversing master and
slave mode.
6.9.8
Speed Accuracy
1. Program the pumps with Soft Alarms disabled as follows:
Pump 1 ART
Pump 2 SLAVE 1
Pump 3 SUCKER
Pump 4 AUX
Pump 5 CARD
Pump 6 FREE
2. Operate all pumps and press Monitoring system power switch to shut down
Console and Monitor.
Verify all pumps stop, alarm, and display NO COMM. error.
3. Set Pump 1 speed to 0 RPM.
Verify alarm cancels when speed is set to 0 RPM.
Repeat this for all pumps.
4. Press and hold Set until a beep is heard.
Verify pump changes to FREE mode.
Repeat this for all pumps.
5. Press the Monitoring system power switch to restore power and set all
pumps to maximum speed.
Verify Pump 1 operates at 250 1 RPM using tachometer.
Verify it is not possible to reverse the direction of Pump 1 when running.
6. Run Pump 1 in reverse direction at maximum speed.
Verify Pump 1 operates at 250 1 RPM using tachometer.
Verify the reverse indicator illuminates.
Return Pump 1 to normal counter clockwise direction.
7. Repeat Tachometer measurements for all other pumps.
Revision 00
Service Manual
6-33
6. Service
6.9.9
JOSTRA HL 20
Pump Alarms
Runaway (RPM-DIFF in U.S.)
1. Set Pump 1 speed to 0 RPM (clear <=<= display).
2. Turn the pump head by hand in the arrow direction.
Verify the pump alarms RUNAWAY (RPM-DIFF in U.S.).
Verify the audible alarm sounds.
3. Quickly reset the alarm by turning flow adjustment up and then back to 0
RPM.
4. Turn the pump head again by hand in the arrow direction within 5 seconds.
Verify either SAFETY-S (from safety system) or !!!! (from motor control)
is displayed.
Verify the alarm cannot be reset by turning the flow adjustment. Power
cycle Pump 1.
5. Repeat test for all other pumps.
Direction
1. Set Pump 1 speed to 0 RPM (clear <=<= display).
2. Turn the pump head by hand in the direction opposite to the arrows.
Verify the Pump 1 alarms ERR. DIRECT.
Verify the audible alarm sounds.
Power cycle Pump 1.
Overload
1. Set Pump 1 speed to 5 RPM.
2. Stall the pump head (use the wooden dowel).
Verify Pump 1 alarms OVERLOAD (BELT SLIP may also be indicated).
3. Turn the pump head slightly by hand in the arrow direction.
Verify Pump 1 alarms ERR. HEAD.
Power cycle Pump 1.
6-34
Service Manual
Revision 00
JOSTRA HL 20
6.9.10
6. Service
Timers
1. Press Start Stop for Timer 1.
Verify Timer 1 starts and stops.
Verify Monitor displays BYPASS ON (when running) and OFF when
stopped.
2. Press and hold Reset for Timer 1.
Verify the value clears and only a single dot on the right hand side is
illuminated.
3. Press Start Stop for Timer 2.
Verify Timer 2 starts and stops.
Verify Monitor displays AORTA CLOSED (when running) and OPEN
when stopped.
4. Press and hold Reset for Timer 2.
Verify the value clears and only a single dot on the right hand side is
illuminated.
5. Repeat the Timer test procedure for Timer 3 (no indicators on monitor
display).
6.9.11
Temperature Module
1. Attach temperature references to Temperature Probe Box (attached to
QTM).
Verify the displayed channel temperatures correspond to the reference
values:
Channel I = 1.5 0.1C.
Channel II = 20.1 0.1C.
Channel III = 34.5 0.1C.
Channel IV = 43.3 0.1C.
Verify Up and Down Trend LEDs illuminate accordingly.
Revision 00
Service Manual
6-35
6. Service
6.9.12
JOSTRA HL 20
Air Bubble Detector

5 mm Bubbles
1. Attach Air Bubble Tubing Test Set to a pump with both ends submerged
into a container of cold water. Silicon extension shall be oriented on outlet
side of pump.
NOTE
Record occlusion scale settings if change is required. Restore this

setting after test!
2. Program pump as ART and set Air-Bubble Detector Stop switch setting to
position ART.
3. Prime the tubing free of air and attached Air Bubble Detector to PVC portion
on output side of pump.
4. Operate the pump at 50 RPM and introduce a 5 mm test pellet.
Verify the unit causes an Air bubble alarm when pellet passes through
sensor.
Repeat test for a few pellets.
5. Repeat this test with pump operating at 200 RPM.
6. Attach sensor to Silicon portion of test set (if applicable) and repeat 5 mm
Bubbles test.
7. Verify alarm override by holding down safety switch and pressing Override.
Micro-bubbles
1. Operate the pump at 50 RPM
Verify normal operation.
2. Restrict the inlet side of the tubing to create micro-bubbles.
Verify micro-bubbles are detected.
3. Repeat this test with pump operating at 200 RPM.
4. Attach sensor to Silicon portion of test set (if applicable) and repeat Microbubbles test.
6-36
Service Manual
Revision 00
JOSTRA HL 20
6.9.13
6. Service
Electrical Safety Test

NOTE
Electrical safety tests shall be performed in accordance with

IEC 60 601-1 or corresponding national standards.
1. Perform Electrical safety tests according to standard procedure regulated

by IEC 60 601-1 or corresponding national standards. Allowable values and
test methods are defined in the standard. The use of a leakage tester, e. g.
Bender Safety Tester 601/751 or equivalent is recommended.
Record the ground resistance value (protective earthing continuity).
Record the leakage current values.
The standard procedures may require 110% voltage. During this test, 100%
voltage should be used.
Revision 00
Service Manual
6-37
6. Service
JOSTRA HL 20
6.9.14
User Settings Worksheet

Date:
Pump 1
Pump 2
Pump 3
Pump 4
Pump 5
Pump 6
Model
Serial No.
Mode
Flow1 @ 100
Brightness
Soft Alarm?
Hours
Tubing Size
Occlusion2
1
For Single & Twin pumps
Flow
(TYPICAL)
Pump 1
Pump 2
Pump 3
Pump 4
Single Pump @ 100 RPM
Pump 5
Pump 6
/2
/8
(2.6)
/4
(1.28)
3
/16
1
/8
(0.32)
(1.6)
Record occlusion settings if adjustments will be made
SIZE
(4.5)
(0.43)
4:1
Twin Pump @ 250 RPM
1
/4
(1.5)
Twin Pump @ 100 RPM

(0.32)
(0.15)
/16
1
/8
Record all flow calibration data if pump hours will be reset
Switch Setting
ART
SLV
SUC
AUX
CPL
I
DPM
Module
II
III
IV
AEP Module
Notify user that service was performed and settings may have been changed!
6-38
Service Manual
Revision 00
JOSTRA HL 20
6.9.14
6. Service
Field Test Checklist

This checklist is completed as part of Field Test Procedure.
Confirm the unit has passed the following tests:
Configuration:
Test Performed:
Initial Inspection:
Battery Capacity:
Pressure Channel Calibration:
Timers:
Temperature Module:
Yes No
Yes No
Yes No
Yes No
II
III
IV
Yes No
5 mm:
Micro:
Air Bubble Detector:
Pump 1
Pump 2
Pump 3
Pump 4
Pump 5
Pump 6
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Serial Number:
Single / Twin / RotaFlow:
Test Performed:
Stop Functions:
Master Slave:
Pulsatile Internal:
Pulsatile External:
Master Slave Pulsatile:
Accumulators:
Stop Control Functions:
Twin Pump Cardio Slave Mode:
Speed Accuracy Forward:
Speed Accuracy Revered:
Runaway (RPM-DIFF) Alarm:
Direction Alarm:
Overload Alarm:
Electrical Safety:
Record ground resistance:
Ohm
Record Earth leakage current (normal condition):
Record Enclosure leakage current (normal condition)
Signature
Date Performed
Clarification of signature and title

Revision 00
Service Manual
6-39
6. Service
JOSTRA HL 20
Notes
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6-40
Service Manual
Revision 00
JOSTRA HL 20
7. Installation
Installation
7.1
Unpacking
7.1.1
Transport Package
The HL 20 is delivered from factory in one package with the pumps separately
packaged inside.
Check all items according to the packing slip.
Before opening the shipping container, make a general inspection of the goods.
In case of visual damages or signs that the container has been subject to rough
handling, immediately report your findings to the freight carrier. If a concealed
shipping damage is discovered after acceptance, file a claim for this damage.
7.1.2
General Unpacking
When unpacking, check that the contents is according to the packing list
delivered with the package.
Inspect every detail for transport damages. In case of visual damages or signs
of rough handling, immediately report your findings to the freight carrier.
Remove all packing material. All packing material must be discarded in
accordance with appropriate industrial and environmental standards.
CAUTION
Take necessary precautions to prevent the equipment from tipping

during unpacking.
7.1.3
Cleaning
The equipment need no special cleaning after unpacking. Just remove dust
using a dry soft cloth or similar.
The machine is sold non-sterile. Refer to the Users Manual.
7.2
Check after Installation

Before starting-up or operating the equipment, study the User Manual and the
Service Manual carefully.
Perform the Check after Installation according to instructions below and fill in
the Installation Checklist.
WARNING
Check after Installation is to be performed before using the

equipment.
The equipment may cause injury to the technician, the patient or other
personnel if not properly checked after installation.
Revision 00
Service Manual
7-1
7. Installation
7.2.1
JOSTRA HL 20
Console mechanics
Part
Action
Masts
Check that they are properly fastened in the chassis.
Infusion masts
Check that the infusion masts go up and down with

acceptable resistance.
Access panel
Check that the access panel does not close by itself.
Drawer
Check that the drawer opens and closes smoothly and

stops in the middle position.
Wheels and
brakes
Check that the locking mechanism is functioning

properly.
Monitor
Check that the SMU swivels and locks properly.
Control panel
Check that the SCP swivels and locks properly.
Halogen lamp
Check the function of the halogen lamp.
ODU connectors
with covers
Check that the ODU connectors are clean and

equipped with covers.
Rack connectors Check the LEMO connectors. Verify that the pins are
not backing out when pushed on.
7.2.2
7.2.3
7-2
Positioning
dowels
Check that the positioning dowel is tight.
Fan
Make sure that the fan works.
Total assembly
Part
Action
All modules
installed
Install all modules.
Self-check
Check that all modules pass the startup self-check.
Pump mechanics
Part
Action
Pump ID
Note the Pump type and Serial number on all pumps

on the system.
Tube locking,
inserts
Make sure the locking mechanism works.

Check that the tube holding mechanism works.
Occlusion
Check the occlusion knob and lock on each pump.
Guiding pins
Check that the guiding pins roll nicely.
Rollers
Check that the rollers roll nicely.
Pump lid
Check that the lid is not defective and that it is

equipped with a warning sticker.
Service Manual
Revision 00
JOSTRA HL 20
7.2.4
7. Installation
ODU
connectors,
spring, pin fixing
Check that the connector works properly (springloaded) and that the pins are not defective.
Fan
Make sure that the fan works in each pump.
Pump electronics
Part
Action
Switches and
breakers
Check that the pumps can be powered ON and OFF

several times (approx. 5) and that no errors are shown
on the displays (self-test passed). Check with switches
and with circuit breakers.
Also check switches on the twin pumps.
Speed
Slowly increase/decrease the speed over the whole

range. Check that it runs smooth with no unexpected
noise.
Check the speed of the pump head at 250 RPM in
both forward and reverse direction with a tachometer.
See Pump Calibration section.
RPM/LPM switch
Check that the display toggles between RPM and

LPM.
Mode selection
Check that all pumps can be programmed to all

modes.
Calibration
mode
Check that the flow can be calibrated.
Master slave
Check that the master slave speed ratio can be

adjusted.
Stop lines and

communication
Check with one stop module that the pump stop in all
modes. Check all pumps.
Runaway
protection

head in the same direction as indicated by the arrows
on the inserts. Check that Runaway alarm is activated
and reset the alarm.
Repeat the test as above (within 5 seconds) and
check that the !!!! alarm is activated.
Overload alarm
Set pump speed to 5 RPM and stall the pump head

using a wooden dowel.
WARNING
Error direction
alarm
Revision 00
Keep fingers away from the pump

head!

head in the opposite direction than indicated by the
arrows on the inserts.
Service Manual
7-3
7. Installation
7.2.5
JOSTRA HL 20
System Control Panel and System Monitoring Unit

Part
Action
SCP
Check:
- Pressures, up to 4 pressures
- Temperatures, 4 temperatures
- Level indication, function
- Air bubble alarm, artificial air bubble 5 mm
generates air alarm.
SMU
Check:
- ECG trace
- Pressure trace
- MAP, SYS, DIA data
- Arterial pulsatile trace
- Cardioplegia windows
- Digital in/out function.
7.2.6
Battery back-up
Part
Action
Battery mains
switch
Make sure that the batteries are fully charged.

Start the system (all pumps on 100 RPM) with tubing
installed.
Disconnect mains power supply and check that:
- The system switches to battery power supply and
continue to run during at least 60 minutes.
- The battery LED is lit and an audible alarm is
activated.
- The mains switch LED goes off.
Re-connect mains and check that the system returns
to mains power supply mode and that all battery
indications (see above) are switched off.
Charge circuit
7.2.7
7-4
Check that the Battery Charge LED is lit.
Others
Part
Action
Level Sensor
Check for any damage to the sensor or cable.
Bubble Sensor
Check for any damage to the sensor or cable and for

any gel built-up.
Service Manual
Revision 00
JOSTRA HL 20
7.2.8
7. Installation
Electrical safety
Part
Action
Electrical safety
test
Perform Electrical safety tests according to standard

procedure regulated by IEC 60 601-1 or corresponding
national standards. Allowable values and test methods
are defined in the standard. The use of a leakage
tester, e. g. Bender Safety Tester 601/751 or
equivalent is recommended.
- Record the ground resistance value (protective
earthing continuity).
- Record the leakage current values.
The standard procedures may require 110% voltage.
During this test, 100% voltage should be used.
7.2.9
Formal handover
Part
Action
Handover to
customer
Fill in and sign the Installation Checklist and, if

applicable, other handing-over documents required by
local regulations or by the local service organization.
Installation documents must be archived by the local
service organization in accordance with procedures
defined by your office.
Report completion of the installation according to
procedures defined by your office.
Revision 00
Service Manual
7-5
7. Installation
7.2.10
JOSTRA HL 20
Installation Checklist
Equipment:
Type:
Serial No:
Console Mechanics
OK
Masts ......................................................................
Infusion masts .........................................................
Access panel ..........................................................
Drawer ....................................................................
Wheels and brakes .................................................
Monitor ....................................................................
Control panel ..........................................................
Halogen lamp ..........................................................
ODU connectors with covers ..................................
Rack connectors .....................................................
Positioning dowels ..................................................
Fan ..........................................................................
Total assembly
Remarks:
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
OK
All modules installed ...............................................

All modules passed startup self-test .......................
Remarks:
________________________________
________________________________
Pump mechanics
Type:
Serial number:
Tube locking, inserts
Occlusion
Guiding pins
Rollers
Pump lid
ODU connector
Fan
Pump electronics
Switches and breakers
Speed
RPM / LPM switch
Mode selection
Calibration mode, flow adjust
Master - slave, slave adjust
Stop lines and communication
Runaway protection
Overload alarm
Error direction alarm
Pump remarks:
7-6
Service Manual
Revision 00
JOSTRA HL 20
7. Installation
SCP and SMU
OK
Remarks:
SCP:
- Pressures ..............................................................
- Temperatures ........................................................
- Level indication ......................................................
- Air bubble alarm ....................................................
________________________________
________________________________
________________________________
________________________________
SMU:
- ECG trace .............................................................
- Pressure trace .......................................................
- MAP, SYS, DIA values ..........................................
- Arterial pulsatile trace ...........................................
- Cardioplegia windows ...........................................
- Digital in/out function .............................................
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Battery back-up
Automatic battery mains switch ............................
Charge circuit ..........................................................
________________________________
________________________________
Others
Level sensor ............................................................
Bubble sensor .........................................................
________________________________
________________________________
Electrical safety
Ground resistance ...................................................
Earth leakage current (normal condition) ................
Enclosure leakage current (normal condition) ........
____________________________ Ohm
_____________________________ A
_____________________________ A
Formal handover
Handover to customer .............................................
________________________________
Other remarks:
Date:
Hospital and
location :
FSE
Name:
FSE
Signature:
Customer
Name:
Customer
Signature:
Revision 00
Service Manual
7-7
7. Installation
JOSTRA HL 20
Notes
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7-8
Service Manual
Revision 00
JOSTRA HL 20
Appendix A Description of Self-test
Appendix A
Brief description of the HL 20 Self-test

This appendix contains a brief description of the HL 20 Self-test. A more extensive
description of the HL 20 Self-test is published in a separate document.
Revision 00
Service Manual
A-1
1.
JOSTRA HL 20
DESCRIPTION OF THE HL 20 SELF-TEST ......................................................4
1.1
General Self-tests ....................................................................................................................4
1.1.1
Internal RAM-Test...............................................................................................................4
1.1.2
ROM-Test ...........................................................................................................................4
1.1.3
External RAM-Test .............................................................................................................5
1.1.4
OFFSET-Test .....................................................................................................................5
1.1.5
+5V-Test .............................................................................................................................5
1.1.6
+12V-Test ...........................................................................................................................5
1.1.7
-12V-Test ............................................................................................................................5
MODULE SCP20-482 / SCP20-484 ......................................................................6

2.1
MASTER-processor .................................................................................................................6
2.1.1
Output on the service terminal:...........................................................................................6
2.1.2
Adjustments on the service terminal...................................................................................7
2.1.3
Error messages ..................................................................................................................8
2.2
PANEL-processor ....................................................................................................................9
2.2.1
Output on the service terminal............................................................................................9
2.2.2
Error messages ............................................................................................................... 10
2.2.3
Error messages of the lamp test on Module SCP20-482 ................................................ 10
2.2.4
Error messages of the lamp test of Module SCP20-484 ................................................. 11
3.
MODULE SMU20-490 ......................................................................................13
3.1
MASTER-processor .............................................................................................................. 13
3.1.1
Output on the service terminal:........................................................................................ 13
3.1.2
Error messages ............................................................................................................... 14
3.2
Display-processor................................................................................................................. 15
3.2.1
Output on the service terminal......................................................................................... 15
4.
MODUL CCM20-450 ........................................................................................16
4.1
Output on the service terminal ............................................................................................ 16
4.2
Error messages ..................................................................................................................... 18
5.
MODULE ABD20-410 ......................................................................................19
5.1
5.2
Error messages ..................................................................................................................... 21
6.
MODULE QTM20-430 ......................................................................................22
6.1
6.2
Error messages ..................................................................................................................... 23
7.
MODULE DPM20-440 ......................................................................................24
7.1
7.2
Error messages ..................................................................................................................... 25
8.
8.1
A-2
MODULE AIO20-425........................................................................................27
Service Manual
Revision 00
JOSTRA HL 20
8.2
Adjustments on the service terminal.................................................................................. 28
8.3
Error messages ..................................................................................................................... 30
9.
9.1
MODULE DIO20-470........................................................................................31
9.2
9.2.1
Interface test mode .......................................................................................................... 31
9.2.2
Output of the messages from external devices ............................................................... 32
9.3
10.
Error messages ..................................................................................................................... 32
MODULE RPM20-310 ......................................................................................33
10.1 Output on the service terminal ............................................................................................ 33

10.1.1 At COLDSTART............................................................................................................... 33
10.1.2 At WARMSTART ............................................................................................................. 34
10.2
10.3
Tests during operation ......................................................................................................... 38
10.4
Error messages ..................................................................................................................... 39
11.
MODULE TPM20-330 ......................................................................................41
11.1 Output on the service terminal ............................................................................................ 41

11.1.1 At COLDSTART............................................................................................................... 41
11.1.2 At WARMSTART ............................................................................................................. 42
11.2
11.3
Tests during operation ......................................................................................................... 46
11.4
Error messages ..................................................................................................................... 47
12.
MODULE AEP20-415.......................................................................................49
12.1
12.2
Error messages ..................................................................................................................... 51
Revision 00
Service Manual
A-3
1.
JOSTRA HL 20
Description of the HL 20 Self-test

When the HL 20 is switched on a self-test is started independently in each module.
This self test checks the function of the modules. If the self-test is faulty the module
stays in a safe condition and shows the user the error through an error report.
During operation the individual modules continuously monitor the most important
functions. If an error is found the module goes into the safe condition and shows
the user the error through an error report.
To put the circuit boards into operation and for service purposes each module is
equipped with a service interface. This service interface is a data connection to the
microcontroller of the module according to RS232 and the following interface
parameters:
Data rate
9600 Baud
Amount of data bits
Stop bits
Parity
None
When the module is switched on the result of the self-test is shown through this
interface. In addition this interface serves for special adjustments or for service
operations.
1.1
General Self-tests
As a microcontroller from the same family is used on all the modules the same or a
similar hardware core is to be found on all the modules, therefore some self-tests
are to be found on all the modules.
1.1.1
Internal RAM-Test
The microcontroller of the family SAB80C5XX have a processor-internal RAM with
256 byte. This processor-internal RAM is written with various data samples and
read back. If the comparison shows an error the processor is held in an endless
loop, which it can only leave through a RESET. Modules with their own display
show the error report ER02. Modules with no display of their own stay in the
endless loop and can no longer show the error.
1.1.2
ROM-Test
The program storage of the modules is an EPROM of the type 27C256 (32K * 8) or
27C512 (64K * 8). The contents of the EPROM are linked byte by byte during the
ROM test and the result must be 0. A result unequal to 0 leads to the error report
ERR-ROM. In the EPROM itself the necessary LRC byte was filed in the last
storage cell of the EPROM while creating the HEX file. An ERR-ROM error can be
caused either by a defect or insufficiently programmed EPROM or through defect
access logic to the EPROM.
A-4
Service Manual
Revision 00
JOSTRA HL 20
1.1.3
External RAM-Test
In addition to the internal data storage the modules have an external 32K * 8 static
RAM. This RAM is also checked through writing and control reading of various
data samples. A faulty RAM test is shown by the report ERR-RAM. The cause can
be hidden in the RAM itself or in the access logic to the RAM.
1.1.4
OFFSET-Test
The microcontrollers used have an internal 8- or 10-Bit A/D-converter before which
a multiplexer has been connected. With this A/D-converter the supply voltages on
the board are monitored and the analog signals are measured. This A/D-converter
needs an external 5V reference voltage, which must be aligned to 5,00V 0,01V.
The first check of the A/D-converter takes place in the offset test. Thereby the A/Dconverter input bound to GND is measured. If the measured value at the
SAB80C517A is larger than 10 digits the A/D converter is graded as defect. With
all the other microcontrollers the threshold lies at 8 digits.
In case of an error the error report ERR-OFFSET is given.
A faulty or non-aligned reference voltage can also lead to an OFFSET error. This is
to be expected when all the other voltage monitoring are faulty.
1.1.5
+5V-Test
Through an entry of the processor-internal A/D-converter the +5V supply voltage
that is divided through a voltage divider is measured. The voltage value measured
is output through the service interface. The supply voltage must lie between +5V
5%. When the tolerance range is left the error report ERR-p5V is given.
1.1.6
+12V-Test
Through an entry of the processor-internal A/D-converter the +12V supply voltage,
which is divided down through a voltage divider, is measured. The voltage value
measured is output at the service interface. The +12V supply must lie between
+12V 10%. When the tolerance range is left the error report ERR-p12V is given.
1.1.7
-12V-Test
Through an entry of the processor-internal A/D-converter the -12V supply voltage
that has been adapted to a positive voltage through a voltage divider is measured.
The voltage value measured is output at the service interface. The -12V supply
must lie between -12V +10% and -20%. When the tolerance range is left the error
report ERR-n12V is given.
Revision 00
Service Manual
A-5
JOSTRA HL 20
Module SCP20-482 / SCP20-484

The module SCP20482/4 consists of two processing units. The MASTERprocessor handles the communication in the whole HL-20. The PANEL-processor
handles the display unit and the key functions of the HL-20. The PANEL-processor
transmits the key codes via the MASTER-processor to the requested module of the
HL-20. The Display values were requested cyclic by the MASTER-processor from
the modules and transmitted to the PANEL-processor for displaying. Both
processors are supplied with a service interface.
2.1
MASTER-processor
2.1.1
Output on the service terminal:

After power on the MASTER-processor of the module SCP20482/4 displays the
results of the self-tests on the service terminal:
AFTER COLDSTART:
JNS MASTER Module

---------------------Software Revision V2.2
COLDSTART
Ramtest intern:
Romtest:
Ramtest:
DUALPORT-RAMtest:
EEPROM Test:
Offset8 :
+5V Test:
+12V Test:
PASSED
PASSED
PASSED
PASSED
PASSED
0
498
119
06
02
FD
02
Self-Test PASSED
CYCLE
43
A-6
PAGE
02 FD
ERROR
00
Service Manual
Revision 00
JOSTRA HL 20
After Warmstart (power supply switched off for a short time):
JNS MASTER Module

---------------------Software Revision V2.2
WARMSTART
Ramtest intern:
Romtest:
Offset8 :
+5V Test:
+12V Test:
PASSED
PASSED
0
504
120
Self-Test PASSED
CYCLE
43
PAGE
02 FD
ERROR
00
During the Warmstart long tests will not take place (RAM-Test, DualportRam-Test
und EEPROMTest).
2.1.2
Adjustments on the service terminal

Via the service terminal the following adjustments may be made:
Initialize the EEPROM of the board SCP20-482/4
Set the EEPROM-page
Display the contents of the EEPROM as HEX-Dump
Revision 00
Service Manual
A-7
2.1.3
JOSTRA HL 20
Error messages
Error code
A-8
Error description
Possible reasons
EM 01 ERR_ROM
Program memory defect;

A incorrect LRC has been
found
EPROM defect; access control of

the EPROM defect
EM 02 ERR_RAM
Data memory defect
SRAM defect; access control of

SRAM defect
EM 03 ERR_EEPROM
EEPROMtest failed
EEPROM defect; access control

of EEPROM defect or all 16
pages used
(EEPROM-page number >= 16)
EM 05 ERR_OFFSET
OFFSETtest of the
processor internal ADconverter failed
Reference voltage not adjusted;

AD-converter defect; AD-input
not connected
EM 07 ERR_5VTEST
+5V- supply voltage test

failed
5V-supply voltage out of

tolerance; reference voltage not
adjusted; AD-converter defect;
AD-input not connected; wrong
voltage distributor
EM 08 ERR_p12VTEST

failed
+12V-supply voltage out of

voltage distributor
EM 17
ERR_UNEXPECTED
Illegal software status
Fatal error!
EM 25 ERR_DPRAM
Dual-Port-RAM test failed
DPRAM defect; access control of

DPRAM defect
EM 29 ERR_PANEL
Panel doesnt
acknowledge
Panel defect; Panel-processor

break down; DP-RAM defect
EM 2B ERR_FATAL
Fatal error
EM 2A ERR_ILLKEY
Illegal key code from

PANEL
Fatal error or incompatible

software versions
EM 7F WARN_EEPROM
DEFAULT-settings copied
from EPROM into
EEPROM
HL-20 settings with wrong

Checksum stored in the
EEPROM by a sudden break
down of the power supply)
Service Manual
Revision 00
JOSTRA HL 20
2.2
PANEL-processor
2.2.1
Output on the service terminal

Coldstart
JNS PANEL-Modul
---------------------------Software Revision V2.4
Ramtest intern:
Romtest:
DUALPORT-RAMtest:
Offset8:
+5V Test:
+12V Test:
Ref. Test:
Lamptest:
PASSED
PASSED
PASSED
0
0
496
120
499
PASSED
Self-Test PASSED
Warmstart
The output on the service terminal is the same as during the COLDSTART. During
the WARMSTART there is no lamp test.
JNS PANEL-Modul
--------------------------Software Revision V2.4
Ramtest intern:
Romtest:
DUALPORT-RAMtest:
Offset8:
+5V Test:
+12V Test:
Ref. Test:
Lamptest:
PASSED
PASSED
PASSED
0
0
507
121
500
PASSED
Self-Test PASSED
Revision 00
Service Manual
A-9
2.2.2
JOSTRA HL 20
Error messages
Error code
2.2.3
Error description
Possible reasons
EP 01 ERR_ROM
Program memory defect;

An incorrect LRC has
been found.

the EPROM defect
EP 02 ERR_RAM
Processor internal RAM

defect
Microcontroller defect
EP 25 ERR_DPRAM
Dual-Port-RAM test failed

DPRAM defect
EP 05 ERR_OFFSET
Offset test of internal ADconverter defect

not connected
EP 06 ERR_REF
+5V-referencetest failed
5V-reference voltage of MASTER

out of tolerance; reference
voltage of PANEL not adjusted;
not connected; wrong voltage
distributor
EP 07 ERR_5VTEST

failed
5V-supply voltage out of

voltage distributor
EP 08 ERR_p12VTEST

failed

voltage distributor
EP 17 ERR_UNEXPECTED Illegal software status
Fatal error!
EP 26 ERR_RTC
REAL-TIME-CLOCK
doesnt acknowledge
REAL-TIME-CLOCK defect;
REAL-TIME-CLOCK not
accessible
EP 28 ERR_MASTER
Master doesnt
acknowledge
Master defect; Master-processor

break down; DP-RAM defect
EP 0A ERR_LAMP
Lamp test failed
LED or key-LED defector not

connected
EP 14 ERR_KEYSTUCK
Key is hanging
Key is hanging or key is pressed

to long.
Error messages of the lamp test on Module SCP20-482

The following connection between the error number of the lamp test and the defect
LED consists:
No.
1
3
5
7
9
11
13
15
17
A-10
Display
Ext. frequency BPM
pressure 1
pressure 2
console
hypo-water-temperature
temperature 2
temperature 4
timer 2
real time
Service Manual
No.
2
4
6
8
10
12
14
16
Display
BMP
delta-pressure
art. flow
hypo-set-temperature
temperature 1
temperature 3
timer 1
timer 3
Revision 00
JOSTRA HL 20
2.2.4
No.
LED
No.
LED
64
BUBBLE-BAR Bit 0
65
BUBBLE-BAR Bit 1
66
BUBBLE-BAR Bit 2
67
BUBBLE-BAR Bit 3
68
BUBBLE-BAR Bit 4
69
BUBBLE-BAR Bit 5
70
BUBBLE-BAR Bit 6
71
BUBBLE-BAR Bit 7
72
LEVEL-BAR Bit 8
73
LEVEL-BAR Bit 9
74
BUBBLE-BAR Bit 8
75
BUBBLE-BAR Bit 9
76
LEVEL-BAR Bit 0
77
LEVEL-BAR Bit 1
78
LEVEL-BAR Bit 2
79
LEVEL-BAR Bit 3
80
LEVEL-BAR Bit 4
81
LEVEL-BAR Bit 5
82
LEVEL-BAR Bit 6
83
LEVEL-BAR Bit 7
84
LEVEL-ALARM
85
LEVEL-SENSOR FAULT
86
BUBBLE-ALARM
87
BUBBLE-SENSOR FAULT
88
TEMP-TREND1-
89
TEMP-TREND1+
90
TEMP-TREND4-
91
TEMP-TREND4+
92
TEMP-TREND3-
93
TEMP-TREND3+
94
TEMP-TREND2-
95
TEMP-TREND2+
96
TEMP-CH-SEL1
97
TIM 3 H/M
98
TIM 2 H/M
99
TIM 1 H/M
100
HYP-SEL4
101
HYP-SEL3
102
HYP-SEL2
103
HYP-SEL1
104
TEMP-CH-SEL4
105
TEMP-CH-SEL3
106
TEMP-CH-SEL2
107
PR TREND 3-
108
PR TREND 3+
109
PR TREND 2-
110
PR TREND 2+
111
PR TREND 1-
112
PR TREND 1+
113
PULSE BPM
114
PULSE %
115
PULSE ASS.3
116
PULSE ASS.2
117
PULSE ASS.1
118
BATT.
119
LINE
120
HYP CIRC
121
HYP PAT MODE
122
TEMP TREND
123
PR KPA
124
PR ZERO2
125
PR ZERO1
126
PR OR2
127
PR OR1
128
BUBBLE OR
129
LEVEL OR
130
PR TREND
131
PULSE INT.
132
PULSE EXT.
133
AUDIO
134
PULSE CONT.
Error messages of the lamp test of Module SCP20-484

The following connection between the error number of the lamp test and the defect
LED consists:
No.
1
3
5
7
9
Revision 00
Display
ext. frequency (BPM)
pressure 1
pressure 2
console
hypo-water-temperature
Service Manual
No.
2
4
6
8
10
Display
BPM
delta-pressure
art. flow
hypo-set temperature
temperature 1
A-11
11
13
15
17
19
Nr.
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
A-12
JOSTRA HL 20
temperature 2
temperature 4
timer 2
pressure 3
real time
LED
BUBBLE-BAR Bit 0
BUBBLE-BAR Bit 2
BUBBLE-BAR Bit 4
BUBBLE-BAR Bit 6
LEVEL-BAR Bit 8
BUBBLE-BAR Bit 8
LEVEL-BAR Bit 0
LEVEL-BAR Bit 2
LEVEL-BAR Bit 4
LEVEL-BAR Bit 6
LEVEL-ALARM
BUBBLE-ALARM
TEMP-TREND1TEMP-TREND4TEMP-TREND3TEMP-TREND2TEMP-CH-SEL1
TIM 2 H/M
HYP-SEL4
HYP-SEL2
TEMP-CH-SEL4
TEMP-CH-SEL2
PR1 TRENDPR2 TRENDPR1/2 TRENDPULSE %
PULSE ASS.2
BATT.
PR4 TRENDPR3 TRENDHYP CIRC
TEMP TREND
PR2 ZERO
PR2 OVR
PR4 ZERO
PR4 OVR
PR1/2 TREND
PULSE INT.
BUBBLE OR
AUDIO
PR3/4 KPA
HYP HEAT
Service Manual
12
14
16
18
Nr.
65
67
69
71
73
75
77
79
81
83
85
87
89
91
93
95
97
99
101
103
105
107
109
111
113
115
117
119
121
123
125
127
129
131
133
135
137
139
141
143
145
temperature 3
timer 1
timer 3
pressure 4
LED
BUBBLE-BAR Bit 1
BUBBLE-BAR Bit 3
BUBBLE-BAR Bit 5
BUBBLE-BAR Bit 7
LEVEL-BAR Bit 9
BUBBLE-BAR Bit 9
LEVEL-BAR Bit 1
LEVEL-BAR Bit 3
LEVEL-BAR Bit 5
LEVEL-BAR Bit 7
LEVEL-SENSOR FAULT
BUBBLE-SENSOR FAULT
TEMP-TREND1+
TEMP-TREND4+
TEMP-TREND3+
TEMP-TREND2+
TIM 3 H/M
TIM 1 H/M
HYP-SEL3
HYP-SEL1
TEMP-CH-SEL3
PR1/2 TREND+
PR1 TREND+
PR2 TREND+
PULSE BPM
PULSE ASS.3
PULSE ASS.1
LINE
PR4 TREND+
PR3 TREND+
HYP PAT MODE
PR1/2 KPA
PR1 ZERO
PR1 OVR
PR3 ZERO
PR4 OVR
PULS CONT.
PULSE EXT.
LEVEL OR
PR3/4 TREND
HYP COOL
Revision 00
JOSTRA HL 20
3.
Module SMU20-490
The module SMU20-490 consists of two processing units. The MASTER-processor
handles the communication to the HL-20 and prepares the data for the display
processor. He also writes the HL-20 data and the events to the memory card. The
display processor controls the display of the HL-20. The DISPLAY processor also
handled the keys SPEED, HALT, PAGE SELECT and EVENTS.
All other keys were read by the Master-processor.
MASTER- and DISPLAY-processor are connected by a DUAL-Port-RAM.
3.1
MASTER-processor
3.1.1
Output on the service terminal:

After power on the MASTER processor of the Module SMU20-490 displays the
following results of the self-tests on the service terminal:
JNS ECG-MONITOR Master-Proc

---------------------------------------------Software Revision: V2.3
SELFTEST
Ramtest intern:
Romtest:
DUALPORT-RAMtest:
Ramtest:
Offset:
+5V Test:
+12V Test:
-12V Test:
PASSED
PASSED
PASSED
PASSED
0
506
120
121
Self-Test PASSED
Revision 00
Service Manual
A-13
3.1.2
JOSTRA HL 20
Error messages
Error code
ER 01 ERR_ROM
Error description
Program memory
defect; A incorrect
LRC has been found
Data memory defect
ER 02 ERR_RAM
ER 25 ERR_DPRAM
ER 05 ERR_OFFSET
ER 07 ERR_5VTEST
ER 08 ERR_p12VTEST
ER 09 ERR_n12VTEST
ER 17 ERR_UNEXPECTED
A-14
Possible reasons
EPROM defect

SRAM defect
Dual-Port-RAM
defect
DPRAM defect
Reference voltage not adjusted; ADOffset test of
input not connected; AD-Converter
processor internal
defect;
AD-converter failed
+5V- supply voltage
5V-supply voltage out of tolerance;
test failed
reference voltage not adjusted; ADinput not connected; wrong voltage
divider
+12V- supply voltage +12V-supply voltage out of tolerance;
test failed
reference voltage not adjusted; ADConverter defect; Ad-input not
connected; wrong voltage divider
-12V-supply voltage
-12V-supply voltage out of tolerance;
test failed
reference voltage not adjusted; ADconverter defect; AD-input not
Illegal software status Fatal error!
Service Manual
Revision 00
JOSTRA HL 20
3.2
Display-processor
3.2.1

After power on the DISPLAY processor of the module SMU20490 displays the
following screen on the service terminal:
ECG-Monitor Firmware Version T.1

******************************************
Ing.-Buero Heinze
Schondorferstr. 15a
86919 Utting
m
p
t
toggle MEMORY_CARD IN/OUT

toggle PULSATILE ON/OFF
Test Display
YOUR SELECTION: t
ATTENTION With the actual software version, there are no good results by
pressing any key.
Revision 00
Service Manual
A-15
JOSTRA HL 20
4.
Modul CCM20-450
4.1

After power on the module CCM20-450 displays the following results of the selftests on the service terminal:
JNS CONSOLE
----------------------Software Revision: V1.2
SELFTEST
Ramtest intern:
Ramtest:
Offset:
+12V Test:
TEMP- TEST
PASSED
PASSED
0
119
PASSED
Romtest:
PASSED
+5V Test:
507
Self-Test PASSED
Ueff Ubatt T_HS T_BATT T_TRAFO FUSE's BP-RE B_Hlim B_Llim ERROR
103
250
0
23
40
63
127
283
192
00
Self-Test PASSED
A-16
All self-tests passed successfully.
Ueff
Ubatt
T_HS
T_BAT
T
T_TRAF
O
FUSE's
BP-RE
103
250
23
40
63
127
B_Hlim
B_Llim
ERROR
283
192
00
Ueff
Line voltage in % (example above 103 %)
Ubatt
Battery voltage (example above 25.0 V)
T_HS
Temperature of the heat sink. This temperature will never be

measured. (always 0)
T_BATT
Temperature of battery (example above 23C)
T_TRAFO
Temperature of trafo (example above 40 C)
FUSEs
Status of the fuses. The microcontroller reads the control signals of

the fuses via Port 1 and P8.3 and shows the state of these signals
as FUSEs-Statusbyte. A 1 in this byte shows a closed fuse; a 0
shows a blown or open fuse.
Service Manual
Revision 00
JOSTRA HL 20
FUSESTATUSByte:
b7
Fuse pump 7 (not available)
b6
Fuse pump 6 (not available)
b5
Fuse pump 5 (only by 5-pump console)
b4
Fuse pump 4
b3
Fuse pump 3
b2
Fuse pump 2
b1
Fuse pump 1
b0
Fuse monitoring
Example above:
63 as 3F hexadecimal
b0 to b5 fuse closed
b6,b7 fuse open, blown or not available
For controlling the fuses the number of available pumps/fuses can

be adjusted by the signals PU0, PU1 and PU2.
BP-RE
Battery-Power-Relais-Status.
This byte shows the status of the battery-power-relais on the
power-supply board. A 1 in this byte shows this relais in line-mode;
a 0 shows a relais in battery-mode,
BP-StatusByte:
b7
not used
b6
Monitoring
b5
Pump 6
b4
Pump 5
b3
Pump 4
b2
Pump 3
b1
Pump 2
b0
Pump 1
Example above:
127 as 7F in hexadec. --> Relais of pumps and monitoring in line
mode.
Revision 00
B_Hlim
Limit of the battery voltage. By reaching this limit the loading of the
battery will be stopped and the error message ERR_BATLIM (ER
2D) will be displayed. The limit is 3% over the calculated maximal
loading voltage (depending on battery temperature: 0C 28,3V;
25C = 27,3 V; 50C = 26,4V)
B_Llim
Low limit of the battery voltage = 19,2V: By going deeper than this
battery voltage all battery-line-relais will be switched into line mode
and a further discharging avoided.
ERROR
Error status of the CCM-module
Service Manual
A-17
4.2
Error messages
Error code
ER 01 ERR_ROM
ER 02 ERR_RAM
ER 05 ERR_OFFSET
Error description
Possible reasons
Program memory defect; EPROM defect; access control to the
An incorrect LRC found. EPROM defect
Data memory defect
SRAM defect; access control to the
RAM defect, microcontroller defect
(internal RAM)
Offset test of internal
Not adjusted reference voltage; ADAD-Converter failed
converter defect; AD-input pin not
connected
ER 07 ERR_5VTEST

failed
ER 08 ERR_p12VTEST
+12V-supplyvoltage test
failed
ER 04 ERR_ADCONV

Timeout of the
processor internal ADConverter
Temperature too high
ER 0B ERR_TEMP
ER20 ERR_PSEL
ER2C ERR_FUSE
ER 2D ERR_BATLIM
A-18
JOSTRA HL 20
Error in the control

signals of the mode
selection of the pumps.
Fuse or fuses blown
The battery charge

voltage is greater than
the maximal allowed
voltage (3% above the
end of charging voltage)
Service Manual
5V-supply out of tolerance; reference

voltage not adjusted; AD-Converter
defect; AD-input pin not connected;
wrong voltage divider
+12V-supply out of tolerance;
reference voltage not adjusted; ADconverter defect; AD-input pin not
Fatal error!
Trafo temperature > 90C or battery

temperature > 70C; reference voltage
not in order; AD-converter defect or not
connected; temperature sensor not
connected or defect.
Error on board JNS_MDB0; error in the
console wiring
Fuses defect; size of pumps not
correct adjusted to actual number of
available fuses; defect control logic.
Battery charger defect; defect ADConverter or logic; defect reference
voltage.
Revision 00
JOSTRA HL 20
5.
Module ABD20-410
5.1

After power on the module ABD20-410 displays the results of the self-tests on the
service terminal:
JNS BUBBLE-LEVEL Module

------------------------------------------Software Revision V1.1
Ramtest intern:
Romtest:
Ramtest:
PASSED
PASSED
PASSED
Offset8:
+12V Test:
-12V Test:
Threshold:
SAWTOOTH:
STOP-Test:
LEVEL-TEST:
0
119
- 121
109
PASSED
PASSED
PASSED
Self-Test PASSED
LEVEL: Sig2: BUBBLE: MIKRO: BUB_INT: REGUL: SILIKON: ALARM: STOP: SB SBP ER
255
0
0
0
0
YES
YES
NO
01 321 0 00
Self-Test PASSED
Revision 00
LEVEL:
Sig2:
BUBBLE:
MIKRO:
BUB_INT:
REGUL:
SILIKON:
ALARM:
255
YES
YES
NO
STOP:
SB
SBP
ER
01
321
00
LEVEL
(Sig1)
8-bit AD-converter value of the LEVEL-SENSOR in digits (example

above 255)
Sig2
8-bit AD-converter value of the level reference signal (example

above 0). If there is no noise, this signal must be smaller than 0.5V
(SIG2 < 25).
BUBBLE
Bubble activity. (Counted bubble interrupts BI; example above 0 -->

no bubbles detected)
MIKRO
Counted Microbubbles (counted micro bubble interrupts UBI; ex.

above 0 --> no bubbles)
BUB_INT
Integral of bubble activity (example above 0)
REGUL
Regulation of the bubble detector is ready (YES / NO)
SILIKON
Tube of silicon detected (YES / NO)
ALARM
Alarm (YES / NO)
Service Manual
A-19
STOP
JOSTRA HL 20
Stop byte shows the stop identification and the status of the stop
lines.
Stop-Byte:
b7
b6
b5
b4
b3
b2
Stop
--
--
--
Stop
Stop-Identification
Level
Bubble-Level-Modul
Bubble
b1
b0
Stop identification:
A-20
b2
b1
b0
no stop function
Stop to the Arterial pump
Stop to the Slave pump
Stop to the Sucker pump
Stop to the Auxiliary pump
Stop to the Cardioplegia pump
illegal status
illegal status
SB
Measured voltage of the signal SB. This signal is the sum of the 3
channels of the detector logic (in the ready state: set value = 3 * 1,1
V = 3,3 V +- 10%; example above 3.21 V)
SBP
Measured voltage of the signal SBP. Input signal depends on the

size of the bubbles (0... 3,3 V; example above 0.00 V)
ERROR
Error byte of the ABD-module
Service Manual
Revision 00
JOSTRA HL 20
5.2
Error messages
Error code
ER 01 ERR_ROM
ER 02 ERR_RAM
ER 04 ERR_ADCONV
ER 05 ERR_OFFSET
ER 06 ERR_REF
ER 08 ERR_p12VTEST
ER 09 ERR_n12VTEST
ER 0D ERR_STOP
ER 21 ERR_OVERRIDE
ER 23 ERR_SAWTOOTH
Revision 00
Error description
Possible reasons
Program memory defect; EPROM defect; access control of the
EPROM defect
A incorrect LRC has
been found
Data memory defect
SRAM defect; microcontroller defect
(internal RAM)
Timeout of processor
internal AD-converter
Reference voltage not adjusted; ADOffset test of the
converter defect; AD-input not
processor internal ADconnected
converter
Threshold voltage test
Threshold voltage out of tolerance;
failed
AD-converter defect; reference
voltage not adjusted;
+12V-supply voltage test +12V-supply voltage out of tolerance;
failed
connected; wrong voltage distributor;
-12V-supply voltage test -12V-supply voltage out of tolerance;
failed
Stoprelais defect; stopcontrol logic
Stop logic test failed or
defect; PWM-output defect;
error of the stop
stopselection switch not o.k.; ADselection switch
converter defect; AD-logic defect;
stopselection switch tuned during
operation;
Fatal error!
Override status in the
The Override status is stored twice in
software not equal.
the software and is not equal. Data
transmission error from the MASTERmodule;
Synchronization voltage No saw tooth voltage available;
of the stoplogic not o.k.
reference voltage not adjusted; ADconverter defect
Service Manual
A-21
JOSTRA HL 20
6.
Module QTM20-430
6.1

After power on the module QTM20-430 displays the following results of the
selftests on the service terminal:
JNS Quad Temperature Module

-----------------------------------------Software Revision V1.1
Ramtest intern:
Romtest:
Ramtest:
PASSED
PASSED
PASSED
Offset8:
+5V Test:
+12V Test:
-12V Test:
Ref. Test:
Offset12
AD12 Test:
0
503
118
- 120
781
0
PASSED
Self-Test PASSED
Temp1: Temp2: Temp3: Temp4: R6800: R4700: R2200: R1355: R1200: OFFSET CORR: ER
10000 10000 10000 10000 156
904
2554 3700 4000
0
10028 00
2560 3707 4008
-1
10013
Self-Test PASSED
A-22
Temp1:
Temp2:
Temp3:
Temp4:
R6800:
R4700:
R2200:
R1355:
10000
10000
10000
10000
156
904
2554
3700
2560
3707
R1200:
OFFSE
T
CORR:
ER
4000
10028
00
4008
-1
10013
TEMP1
Temperature of channel 1. The temperature is displayed in C with

2 characters after the point. The value 10000 shows no sensor, the
value 9990 shows a positive overrun and 9980 a negative overrun.
(Example above 10000 --> no sensor)
TEMP2
Temperature of channel 2. (see TEMP1)
TEMP3
TEMP4
R6800
Measured temperature value of the high precision resistor 6800

(example above 1.56C)
R4700

(example above 9.04C)
Service Manual
Revision 00
JOSTRA HL 20
6.2

R2200

(example above 25.54C or 25.60 C with high gain)
R1355
Measured temperature value of the high precision resistor1355

R1200

OFFSET
Calculated offset value of the 12-Bit AD-converter (example above

0 or 1 Digit with high gain)
CORR
Calculated gradient of the 12-Bit AD-converter (example above

10028 or10013 with high gain)
ER
Error status of the QTM-Module
Error messages
Error code
ER 01 ERR_ROM
ER 02 ERR_RAM
ER 04 ERR_ADCONV
ER 04 ERR_ADCONV
ER 05 ERR_OFFSET
ER 05 ERR_OFFSET
ER 06 ERR_REF
ER 07 ERR_5VTEST
ER 08 ERR_p12VTEST
ER 09 ERR_n12VTEST
ER 22 ERR_CALIBRATION
Revision 00
Error description
Possible reasons
EPROM defect
a incorrect LRC has
been found
Data memory defect
SRAM defect; access control of the
(internal RAM)
Timeout of the
processor- internal ADconverter
AD12-Test failed
12-Bit-AD-converter defect; measure
circuit or test circuit defect
Reference voltage not adjusted; ADOFFSET test of the
processor- internal ADconnected
converter failed
OFFSET-Test of the12- Multiplexer DG506 defect; ADBit AD-converter failed
converter MX574 defect; access
control of MX574 defect;
Reference voltage test
failed
7.88V-Reference voltage out of

adjusted; AD-converter defect; ADinput not connected; wrong voltage
distributor;
failed
failed
failed
Fatal error!
Calibration error
High precision resistors wrong; AD-converter not good enough; ADconverter defect
Service Manual
A-23
JOSTRA HL 20
7.
Module DPM20-440
7.1

After power on the DPM20-440 displays the following results of the selftests on the
serviceterminal:
JNS Dual Pressure Module

----------------------------------Software Revision V1.5
Ramtest intern:
Romtest:
Ramtest:
PASSED
PASSED
PASSED
Offset8:
+12V Test:
-12V Test:
Ref. Test:
Offset12
AD12 Test:
SAWTOOTH:
STOP-Test:
0
116
- 118
500
- 1
PASSED
PASSED
PASSED
Self-Test PASSED
CH1
CH2
Prx_1:
10
0
Prx_2:
3
0
Limx:
200
200
Self-Test PASSED
A-24
Offsx:
0
0
Mx: STOP-ID ERROR

487
487
BC
00
Prx_1:
Prx_2:
Limx:
Offsx:
Mx:
CH1
10
200
487
CH2
200
487
Prx_1:
Pressure values; integrated over 1 seconds
Prx_2:
Pressure values; integrated over 5 seconds
Limx:
High limit
Offsx:
Offset of the pressure diagram
Mx:
Gradient of the pressure diagram
Service Manual
STOP-ID
ERROR
BC
00
Revision 00
JOSTRA HL 20
STOP-ID
Stop identification of the dual pressure module

b7
b6
b5
stop
stop-id ch2
b4
ch2
7.2
b2
b1
stop
stop-id ch1
b0
ch1
stop chx:
0 = no STOP;
stop-id:
000
no stop function
001
Stop to ARTERIAL pump
010
Stop to SLAVE pump
011
Stop to SUCKER pump
100
Stop to AUXILIARY pump
101
Stop to CARDIOPLEGIA pump
110
illegal stopid
111
illegal stopid
1 = STOP
ERROR
Error byte of the dual pressure module
CH1
Values of channel1
CH2
Values of channel2
Error messages
Error code
ER 01 ERR_ROM
ER 02 ERR_RAM
ER 04 ERR_ADCONV
ER 04 ERR_ADCONV
ER 05 ERR_OFFSET
ER 05 ERR_OFFSET
ER 06 ERR_REF
ER 08 ERR_p12VTEST
ER 09 ERR_n12VTEST
Revision 00
b3
Error description
Possible reasons
EPROM defect
A incorrect LRC has
been found
Data memory defect
(internal RAM)
Timeout of the
processor internal ADconverter
12-Bit AD-converter test AD-converter defect; Multiplexer
failed
defect; PWM-output defect;
Reference voltage not adjusted; ADOFFSET test of the
processor internal ADconnected
converter failed
OFFSET-test of the12Multiplexer defect; AD-converter
Bit AD-converter failed
MX574 defect; access control of
MX574 defect;
Reference voltage test
5.00V-referencevoltage out of
failed
tolerance or not adjusted; ADconverter defect; AD-input not
connected; wrong voltage distributor
failed
failed
Service Manual
A-25
ER 0D ERR_STOP
ER 18 ERR_ARIT
ER 21 ERR_OVERRIDE
ER 23 ERR_SAWTOOTH
ER 2E ERR_TIMEOUT
A-26
JOSTRA HL 20
Stoprelais defect; stopcontrol logic

defect; PWM-output defect; stop
selection switch not o.k. AD-converter
defect; AD-logic defect; stop selection
switch turned during operation;
Fatal error!
Arithmetic error
Division by 0; data transmission error
from MASTER to the module.
OVERRIDE status in the The OVERRIDE status is stored twice
software not equal
in the software and is not equal; data
transmission error from the MASTERmodule
Synchronization voltage No saw tooth voltage available;
of the stop logic not ok
reference voltage not adjusted; ADconverter defect;
TIMEOUT error
A internal watchdog of the software
has recognized an error;
Stoplogic test failed or
error of the stop
selection switch
Service Manual
Revision 00
JOSTRA HL 20
8.
Module AIO20-425
8.1

After power on the module AIO20-425 displays the following results of the selftests on the service terminal:
JNS Analog INPUT-OUTPUT Module

------------------------------------------------Software Revision V1.2
Ramtest intern:
Romtest:
Ramtest:
PASSED
PASSED
PASSED
Offset10:
+12V Test:
-12V Test:
0
125
- 126
Self-Test PASSED
SYS-PRES
- 3
DIAS_PRES
- 2
Self-Test PASSED
Revision 00
MEAN_PRES
0
AUX1:
3
AUX2:
-2
AUX3:
0
ERROR:
00
SYS-PRES
DIAS_PRES
MEAN_PRES
AUX1:
AUX2:
AUX3:
ERROR:
-3
-2
-2
00
SYS_PRES
Systolic pressure; voltage at the input SYS_PRES multiplicities

with the input-gain as 10-Bit value; Input voltage range from -2.5V
to + 2.5 V shown as -511 to+512. The Poti 3 can adjust the
displayed value to the input voltage.
DIAS_PRES
Diastolic pressure; voltage at the input DIAS_PRES multiplicities

with the input-gain as 10-Bit value; Input voltage range from -2.5V
to + 2.5 V shown as -511 to +512. The Poti 4 can adjust the
displayed value to the input voltage.
MEAN_PRE
S
Mean arterial pressure; voltage at the input MEAN_PRES

multiplicities with the input-gain as 10-Bit value; Input voltage
range from -2.5V to + 2.5 V shown as -511 to +512. By the Poti 5
the displayed value can be adjusted to input voltage.
AUX1
Voltage at the input AUX1 multiplicities with the input-gain as 10Bit value; input voltage range from -2.5V to + 2.5 V shown as -511
to +512. The Poti 6 can adjust the displayed value to the input
voltage.
AUX2
Voltage at the input AUX2 multiplicities with the input-gain as

10-Bit value; Input voltage range from -2.5V to + 2.5 V shown as 511 to +512. The Poti 7 can adjust the displayed value to the input
voltage.
Service Manual
A-27
8.2
JOSTRA HL 20
AUX3
Voltage at the input AUX3 multiplicities with the input-gain as 10Bit value; Input voltage range from -2.5V to + 2.5 V shown as 511 to +512. The Poti 8 can adjust the displayed value to the input
voltage.
ERROR
Error byte of the AIO-Module

Pressing <t> on the service terminal can activate a test mode. The following
screen is displayed on the service terminal:
TEST Analog INPUT-OUTPUT

--------l---------------------------------1
2
3
4
TEST OUTPUT
TEST INTERCONNECTION (need testconnector)
TEST INPUT-OUTPUT (need testconnector)
DISPLAY INPUT Voltage
<ESC>
END
RAMP on all output-channels
ESC
leaves the test mode
By pressing 1 the AIO-module outputs on all ANALOG-outputs a saw tooth voltage.

On Pin J2-16 und J2-17 the amplitude of the saw tooth voltage is from -5V to +5V.
On Pin J2-18 to Pin J2-23 the amplitude of the saw tooth voltage is 5 V, The period
of the saw tooth voltage is T= 6,2 seconds. The message RAMP on all output
channels shows the activated test mode.
By pressing <2> the analog outputs and inputs of the AIO-module can be checked
with a special test connector. The test connector must do the following
connections:
1-16; 2-17; 3-18; 4-19; 5-20; 6-21; 7-22 und 8-23.
A-28
Service Manual
Revision 00
JOSTRA HL 20

-----------------------------------------1
2
3
4
TEST OUTPUT
<ESC>
END
Check output <---> input connection

-----------------------------------------------98
305
530
616
697
775
860
943
105
320
530
612
695
780
858
944
The first line shows the 8 output values. The second line displays the measured
AD-values.
By a gain of 1 (adjusted with POT 1 to POT 8) the AD-values must show the output
values with a tolerance of +-10% (line 1 equal line 2).
By pressing <3> a test is activated to set every second a new analog value to
the outputs and read it back by the connected inputs. By pressing <ESC> the test
is stopped; each other key switches the test into the single step mode (one step
per received character from the service terminal) and by pressing <l> the cyclic
mode is restarted.

-----------------------------------------1
2
3
4
TEST OUTPUT
<ESC>
END
Test input:
<l> = loop; <ESC> = end
-----------------------------------------------ECG
PRES SYS-PRES DIAS_PRES MEAN_PRES AUX1:
AUX2:
AUX3:
-2466
-2417
The input values of ECG and PRES are going from -2500 to + 2500. The other
input values are going from 0 to 2500 according to the applied voltage (2500 ==
2.500V).
Revision 00
Service Manual
A-29
JOSTRA HL 20
By pressing <4> a display mode is activated to display the analog input voltage.

--------------------------------------------1
2
3
4
TEST OUTPUT
<ESC>
END
READ AD-VALUES FROM ANALOG-INPUTS

-----------------------------------------------------------------------ECG
0
PRES SYS-PRES DIAS_PRES MEAN_PRES AUX1:

19
- 10
- 5
AUX2:
AUX3:
- 10
The displayed values are showing the input voltage on the analog inputs (2500 =
2,500V).
8.3
Error messages
Error code
ER 01 ERR_ROM
ER 02 ERR_RAM
ER 04 ERR_ADCONV
ER 08 ERR_p12VTEST
Timeout of the processor

Offset test of the
processor internal
AD_converter failed
+12V-supply voltage failed
ER 09 ERR_n12VTEST
-12V-supply voltage failed
ER 05 ERR_OFFSET
A-30
Error description
Program memory defect.
A incorrect LRC has been
found.
Data memory defect
Service Manual
Possible reasons
the EPROM defect
SRAM defect, microcontroller defect
(internal RAM)
Reference voltage not adjusted; ADconverter defect; AD-input not
connected
distributor
-12V-supply voltage out of
distributor
Fatal error!
Revision 00
JOSTRA HL 20
9.
Module DIO20-470
9.1

After power on the module DIO20-470 displays the following results of the selftests on the service terminal:
JNS DIGITAL INPUT / OUTPUT

--------------------------------------------Software Revision V1.2
Ramtest intern:
Romtest:
Ramtest:
PASSED
PASSED
PASSED
Self-Test PASSED
HOST running
0
9.2
00
01
HOST running
The serial ports have been initialized.
The first value shows the errorbyte of the DIO-module as

decimal value.
The second value shows the same error as hexadecimal
value.
The third value shows the serial mode of the DIOmodule. (Example above: serial mode 1)
00
01

The following inputs via the service terminal are possible:
9.2.1
<Shift> <X>
Start of the interface test mode
<Shift> <A>
Output of the messages from external devices in ASCII
<Shift> <H>
Output of the messages from external devices in HEX
Interface test mode

With a special test connector (see adjustment procedure) the serial ports channel1
to channel 4 can be tested. On the screen of the service terminal the following
picture is displayed:
Revision 00
Service Manual
A-31
JOSTRA HL 20
TEST SERIAL INTERFACE CHANNEL0 ... CHANNEL3

--------------------------------------------------------------------TEST CHANNEL 0
TEST CHANNEL 1
TEST CHANNEL 2
TEST CHANNEL 3
0
1
2
3
YOUR SELECTION: _
<ESC> leaves the test mode. The test mode is described in the adjustment
procedure of the DIO-module.
9.2.2
Output of the messages from external devices

During the adaptation of external devices to HL-20 an output function is
implemented to send the received messages from the external device to the
service terminal. The message can bee send as ASCII-String or as HEX-Dump.
With the command <Shift><A> on the service terminal the ASCII-mode and with
the command <Shift><H> the HEX-mode is activated.
Example:
ASCII-mode:
BIOMEDICUS 540D: ID BIO-CON 012 0367
BIOMEDICUS 540D: ET 0000234 0019234 03B5
BIOMEDICUS 540D: DA +0234 -205 0000 0 0 1 0 0 050E
BIOMEDICUS 540D: DA +0234 -205 0000 0 0 1 0 0 050E
HEX-mode:
BIOMEDICUS 540D: 49 44 20 42 49 4F 2D 43 4F 4E 20 30 31 32 20 30 33 36 37 0D
BIOMEDICUS 540D: 45 54 20 30 30 30 30 32 33 34 20 30 30 31 39 32 33 34 20 30 33
42 35 0D
BIOMEDICUS 540D: 44 41 20 2B 30 32 33 34 20 2D 32 30 35 20 30 30 30 30 20 30
20 30 20 31 20 30 20 30 20 30 35 30 45 0D
BIOMEDICUS 540D: 44 41 20 2B 30 32 33 34 20 2D 32 30 35 20 30 30 30 30 20 30
20 30 20 31 20 30 20 30 20 30 35 30 45 0D
9.3
Error messages
Error code
ER 01 ERR_ROM
A-32
ER 02 ERR_RAM
Error description
Program memory defect
A incorrect LRC was
found
Data memory defect
Service Manual
Possible reasons
EPROM defect; access control of the
EPROM defect
SRAM defect, microcontroller defect
(internal RAM)
Fatal error!
Revision 00
JOSTRA HL 20
10.
Module RPM20-310
10.1

After power on, the main processor of the module RPM 20-310 displays the
following results of the self-test on the service terminal:
10.1.1
At COLDSTART
JNS PUMP
----------------------Software Revision V2.2
COLDSTART
Ramtest intern: PASSED
Ramtest:
PASSED
KEY-PORT TEST:
Offset:
Ref. Test:
+12V Test:
TEMP- TEST
SAFETY-SYS. Test:
SAFETY-STOP Test:
MODE RELAIS
HOURS RUNNING
0
Romtest:
PASSED
EEPROM Test:
PASSED 01 FE
PASSED
0
A/D Test:
PASSED
497
+5V Test:
504
120
-12V Test:
- 116
PASSED
LAMP TEST:
PASSED
PASSED
STOP RELAIS
PASSED
PASSED
REVERSE RELAIS
PASSED
PASSED
STOP-INPUT-TEST
PASSED
HOURS TOTAL * 6
0000FF37 hex
Self-Test PASSED
RPM LPM POTI ACTV SETV STOP HEAD T_MO T_HS ACTS DELT CORR
220 2.82 2191 2196 2189
0
2202
31
27
0
0
0
In the COLDSTART all displays and LEDs were switched on and the buzzer
sounds. After 1 second the software version number is displayed in the FLOWdisplay and the account of the operation hours since the last service is displayed in
the DIALOG-display. After second this information is overwritten by the
messages OK on the FLOW-display and PUMP OK on the DIALOG-display. A
detected error is displayed as ERR. on the FLOW-Display and an error message
on the DIALOG-display.
After the COLDSTART the software checks the pump mode, which is stored twice
(pump-mode and complemented pump-mode) in the EEPROM If the complement
shows the same pump-mode as the PUMP_MODE the pump switches into this
mode. In the other cases the pump will start as FREE pump.
After a coldstart the pump is always running in forward direction.
The tube size is read out of the EEPROM and displayed in the DIALOG-display
beside the pump-mode.
Revision 00
Service Manual
A-33
10.1.2
JOSTRA HL 20
At WARMSTART
JNS PUMP
WARMSTART
Ramtest intern:
KEY-PORT TEST:
Offset:
Ref. Test:
+12V Test:
TEMP- TEST
SAFETY-SYS. Test:
SAFETY-STOP Test:
REVERSE RELAIS
MODE RELAIS
STOP-INPUT-TEST
HOURS RUNNING
HOURS TOTAL * 6
PASSED
PASSED
0
A/D Test:
497
+5V Test:
120
-12V Test:
PASSED
PASSED
STOP RELAIS
PASSED
PASSED
PASSED
PASSED
0
0000FF37 hex
PASSED
504
- 116
PASSED
Self-Test PASSED
220 2.82 2191 2196 2189
0
2202
31
27
0
0
0
During a WARMSTART the release number of the software is displayed on the
FLOW-display and the running hours since the last service is displayed on the
DIALOG-display. After about 1 second this information is overwritten by the
message OK on the FLOW-display and PUMP OK on the DIALOG-display.
A detected error is displayed as ERR. on the FLOW-display and as error
message on the DIALOG-display (for example. ERR. EEPROM)
After the WARMSTART the software checks the pump mode, which is stored twice
The direction of the pump is read out of the EEPROM and selected.
Also the tube size and the pulsatile values as START, STOPP, BASE_FLOW,
PULSRATE, HIGH- and LOW-LIMIT as well as the ASSIST-mode were set after
reading out of the EEPROM. So after a WARMSTART the pump starts with the last
mode before power off.
A-34
KEY-PORT
TEST
The keys of the RPM read directly by the microcontroller. During

the self-test no input of the microcontroller is allowed to be
connected to GND (no key is pressed).
Offset : 0
The offset of the processor internal 10-Bit AD-converter is checked

(see 1.1.4). The measured AD-value is displayed in bits from 0 to
1023. An AD-offset value > 10 is estimated as an error.
A/D Test:
The 10-Bit A/D-converter of the microcontroller SAB80C517A is

checked by a linearity test. During this test 2 voltage values were
put via the PULS-PWM output as SET_VAL to the AD-converter
input. The straight through these 2 points is checked by 3 values,
which also were applied via the PULS_PWM-output as SET-VAL to
the AD-converter.
Service Manual
Revision 00
JOSTRA HL 20
Revision 00

Ref. Test:
497
The reference voltage of the motor-control-board is measured and

checked by the processor internal AD-converter. The measured
voltage is displayed, showing 4.97 V as 497. The tolerated value is
+5.0 V +- 5%.
+ 5V Test:
504
The + 5V supply voltage is measured (see 1.1.5). The measured

+5.0 V +- 5%.
+12V Test:
120
The +12V supply voltage is measured (see 1.1.6). The measured

+12,0 V +-10%.
-12V Test: 116
The -12V supply voltage is measured (see 1.1.7). The measured

voltage is displayed, showing -11.6 V as -116. The tolerated value
is -12,0 V +10%/-20%.
TEMP Test:
Measuring the analog voltages of the temperature sensors checked

the motor temperature and the heat sink temperature. The fan is
switched into the fast mode if the motor temperature is higher than
60C or the heat sink temperature is higher than 45C. If the motor
temperature reaches 70C or the heat sink reaches 60C the
warning TEMPERAT is displayed in the DIALOG-display. If the
motor temperature reaches the limit of 90C or the heat sink the
temperature of 70C the pump will be stopped and the error ERR.
TEMPERAT is displayed.
LAMP Test:
During the lamp test all LEDs and displays were switched on for
one second. The buzzer sounds for second. The user must
check this. The alphanumerical displays were checked by writing
and control reading of the display registers.
SAFETYSYS. Test:
The main processor checks the state of the status lines SS_OK1
and SS_OK2. On these lines the safety system shows the main
processor an error status. SS_OK1 must be HIGH and SS_OK2
must be LOW in the error free state. All other combinations are
showing an error.
STOPRELAIS:
Disabled motor driver tests the stoprelais. First the stoprelais is

activated and the control signal (STOPREL_CTRL) checked, which
is generated by a voltage divider. Then the stoprelais is released
and the control signal checked again. At the end of the test the
stoprelais is activated and checked again.
SAFETYSTOP Test:
In the SAFETY-STOP test the main processor makes the safety

system via the RA-Mode lines to activate the stop function of the
safety system. The main processor controls the function of the
safety system stop. The test is as follows:
-
The main processor switches the RA-MODE lines into the test
mode
the main processor waits 250 ms
safety system sets SS_OK1 to LOW and SS_OK2 to HIGH and

stops the pump via the stop input of the safety system.
The main processor checks the function of SS_OK1 and

SS_OK2
The main processor checks the function of the safety system

stop by reading the control signal of the stoprelais.
The main processor finishes the test modes by setting the RAmode lines into the normal mode.
The safety system checks the sate of the RA-mode-lines. The

test mode is only allowed for 5 seconds.
Service Manual
A-35
REVERSERELAIS:
JOSTRA HL 20
Disabled motor controller checks the REVERSE-relais. The

REVERSE-Relais is set by the signals REV1 and REV2. Only the
state REV1 = LOW and REV2 = HIGH switches the relais into the
reverse mode. The REVERSE-relais is tested according the
following table:
REV1
REV2
REVERSE-CTRL
OFF
OFF
LOW (forward)
ON
OFF
LOW
OFF
ON
HIGH (reverse)
ON
ON
LOW
ON
OFF
LOW
MODERELAIS:
Disabled motor controller tests the MODE-relais. The mode relais

were tested by activating one relais after the other and checking
the control signals of each relais. At the end all the relais were
released and reading the control signals again tests the function.
STOPINPUTTEST:
No current through the LED of the optocoupler activates a stop to

the pump. If there is a current through the LED of the optocoupler,
the pump will not be stopped. Therefore a defect stop line or a
defect module stops the pump.
The stop logic is tested as following:
A-36
The GND of the STOP-Logic is switched from monitoring-GND

to the pump-GND. So the external stop signals have no function
and the internal stop signals can stop the pump.
By setting the Stop-Latch one stop is selected. This function

can be checked by reading the EXT_STOP signal with the
processor internal AD-converter. If the relaise 1 is open, there
is no current through the optocoupler (stop input active). A
closed relais 1 causes a current through the optocoupler and
simulates an active stop line.
- So one stop input after the other is tested.
HOURS
RUNNING 0
The operating hours since the last service are displayed. A closed
Jumper RES_HOUR on the controller board may clear the
operating hours to 0 during the eeprom-test in the coldstart. Also
the parameters in the EEPROM were overwritten by the default
settings. So after a service it is necessary to calibrate the tube
sizes again.
HOURS
TOTAL * 6
The total amount of the operation hours since initialization of the

EEPROM is displayed as hexadecimal value. The displayed value
is a copy of the value stored in the EEPROM and must be divide by
6. The value 0000FF37 is 65335 in decimal. 65335 / 6 is 10889
operation hours.
Service Manual
Revision 00
JOSTRA HL 20

Self-Test PASSED
10.2
RPM
LPM
POTI
ACTV
SETV
STOP
HEAD
T_MO
220
2.82
2191
2196
2189
2202
31
T_HS
ACTS
DELT
CORR
27
RPM
Rotations of the pump head in RPM (example above 220 RPM)
LPM
Flow in liter / minute (example above 2.82 LPM)
POTI
Flowpoti value (= SET value; not in Slavemode; example above 219,1 RPM)
ACTV
Value of the motortacho (example above 219,6 RPM)
SETV
Set value for slave mode (example above 218,9 RPM)
STOP
Stopinput value (example above 0; that means no stop)
HEAD
Headtachovalue (example above 220,2 RPM)
T_MO
Motor temperature (example above 31 C)
T_HS
Heat sinks temperature (example above 27 C)
ACTS
Actual headtacho value in pulsatil mode
DELT
Deviation of the regulation in pulsatil mode
CORR
Correction of the motor regulation in pulsatil mode

The EEPROM can be initialized via the service terminal by typing <Shift><R>. The
jumper JMP11 must be closed (see service manual). The following functions were
made during the initialization:
- SET EEPROM-page to 0
- The operation hours since the last service were cleared to 0
- The total amount of operation hours is set to 0
- The not used EEPROM area is filled with 0
- The used EEPROM area is filled with the DEFAULT-settings
Revision 00
Service Manual
A-37
10.3
JOSTRA HL 20
Tests during operation

During normal operation the main processor of the RPM makes the following tests:
TEST
TOLERANCE
ERROR REACTION
Checking the processor

internal AD-converter offset
Offset10 <11 digits
ER 05
Checking the +5V supply

voltage
+5 V
+- 5%
ER 07

voltage
+12V
+- 10%
ER 08
Checking the -12V supply

voltage
- 12V
+- 20%
ER 09
Checking the motor

temperature:
Motor temperature
> 60C
FAN fast
Motor temperature
> 70C
Warning TEMP
Motor temperature
> 90C
Error message ERR
TEMPERAT:
ER 0B
Checking the heat sink

temperature:
Heat sink temperature
> 60C
FAN fast
> 70C
Warning TEMP
> 90C
Error message ERR
TEMPERAT:
Checking the pump mode
A-38
ER 0B
ER 85
Watching runaway
Headtacho
> Setvalue +10%
RUNAWAY
Watching the overload

situation
Headtacho
< Setvalue -10%
OVERLOAD
Watching the belt
Headtacho
< Motortacho -10%
BELT SLIP
Watching the max. speed
Headtacho
> 250 RPM.
OVERSPEED

in pulsatil operation
Headtacho
> 250 Umdr. /Min.
Watching the key
Key pressed longer than 15

seconds
KEY!
Watching the data

communication
No communication to the
MASTER for more than 5
seconds
NO COM
Watching the mode lines
The signal PSEL is lost
NO SEL
Checking the direction of

the pumphead
rotation against the

selected direction
ER 12
Service Manual
Revision 00
JOSTRA HL 20
10.4
Error messages
Error code
Revision 00
Error description
Possible reasons
ER 01 ERR_ROM
Program memory defect; A

EPROM defect; access
incorrect LRC has been found control of EPROM defect
ER 02 ERR_RAM
data memory defect
SRAM defect; access control

of SRAM defect;
microcontroller defect
(internal RAM)
ER 03 ERR_EEPROM
EEPROMtest failed
EEPROM defect; access

control of EEPROM defect;
max. writing cycles of the
EEPROM reached;
ER 04 ERR_ADCONV
Timeout of processor internal

AD-converter
ER 05 ERR_OFFSET
OFFSETtest of the processor

internal AD-converter failed
Reference voltage not

adjusted; AD-converter
defect; AD-input not
connected;
ER 06 ERR_REF
Reference voltage of the

motor controller not O.K.

motor controller out of
tolerance; AD-converter
defect; reference voltage not
adjusted;
ER 07 ERR_5VTEST
+5V supply voltage test failed
+5V supply voltage out of

adjusted; AD-input not
connected; wrong voltage
divider;
ER 08 ERR_p12VTEST
+12V-supply voltage test

failed
+12V- supply voltage out of

divider;
ER 09 ERR_n12VTEST
-12V-supply voltage test failed -12V- supply voltage out of

divider;
ER 0A ERR_LAMPTEST
Lamp test failed
ER 0B ERR_TEMP
Motortemperature or heat sink The temperature is too high;

temperature too high.
sensor not connected; ADconverter defect; reference
voltage not adjusted
ER 0C ERR_REV-REL
REVERSE-relais not O.K
Reverserelais defect; access

logic of the reverserelais or
controllogic defect.
ER 0D ERR_STOP-REL
STOP-relais not O.K.
Stoprelais defect; access

logic of the Stoprelais or
ER 0E ERR_MODE-REL
MODE-relais not O.K.
Moderelais defect; access

logic of mode relais or
controllogic defect
Service Manual
Displays defect; the access

control of the displays is
defect.
A-39
A-40
JOSTRA HL 20
ER 0F ERR_STOP-INP
Stopinput test failed
Connection between PUMPGND and MONITORINGGND; stopinputlogic defect;
ER 10 ERR_S-STOP
stopfunction of the safety

system not O.K.
The access logic of the

STOP-relais by the safety
system is defect;
ER 11 ERR_SCHUTZ-S
Safety system not O.K.
The status lines SS_OK1 and

SS_OK2 are showing an error
state;
ER 12 ERR_DIRECTION
pumphead moves in the

wrong direction
The pumphead was turned in

the wrong direction;
headtacho defect;
ER 13 ERR_ILLEGAL
illegal errorcode
This errorcode is not allowed;

illegal software status
ER 14 ERR_KEY
key is hanging
key is hanging; key pressed

during keyport test;
ER 15 ERR_MODEBLO
Mode selection not O.K.
The pump receives no PSELsignal from the CCM-module

or the PSEL-signal is wrong.
ER 16 ERR_HEAD
pump head error; The

motortacho shows an value
but the haedtacho shows 0.
headtacho not connected; belt

broken; motortacho defect;
ER 17
ERR_UNEXPECTED
illegal softwarestatus
Fatal error!
ER 18 ERR_ARITHMET
Arithmetic error
Division by 0 by calculating
the new pump parameters;
datatransmission error
between MASTER and pump;
ER 19 ERR_ILLEGAL
illegal errorcode in errorbyte
Fatal error!
ER 81 ERR_MODUSED
pump mode used
A not used pump mode is

recognized as used during
programming the new pump
mode.
ER 82 ERR_MODPSEL
The PSEL-signal was lost

during programming a new
pump mode
ER 83 ERR_MODCLK
During programming a new

pumpmode there is more than
one .clocktransitions on the
mode lines.
ER 84 ERR_MODSEL
The mode line is pulled to

LOW but the processor
doesntt see the LOW state;
ER 85 ERR_MODEEPROM
the pump-mode stored in the

EEPROM is not equal with
the complement of the pumpmode
EEPROM defect;
ER 87 ERR_MAXWARN
illegal warning in errorbyte
Fatal error!
Service Manual
Revision 00
JOSTRA HL 20
11.
Module TPM20-330
11.1

After power on the main processor of the module TPM 20-330 displays the
following results of the self-test on the service terminal:
11.1.1
At COLDSTART
JNS TWIN
COLDSTART
Ramtest intern: PASSED
Ramtest:
PASSED
KEY-PORT TEST:
Offset:
0
Ref. Test:
497
+12V Test:
120
TEMP- TEST
SAFETY-SYS. Test:
SAFETY-STOP Test:
MODE RELAIS
HOURS RUNNING
Romtest:
EEPROM Test:
PASSED
PASSED
PASSED
PASSED
PASSED
0
PASSED
PASSED 01 FE
A/D Test:
PASSED
+5V Test:
504
-12V Test:
- 116
LAMP TEST:
STOP RELAIS
REVERSE RELAIS
STOP-INPUT-TEST
HOURS TOTAL * 6
PASSED
PASSED
PASSED
PASSED
0000FF37 hex
Self-Test PASSED
220 2.82 2191 2196 2189
0 2202
31
27
0
0
0
In the COLDSTART all displays and LEDs were switched on and the buzzer
sounds. After 1 second the software version number is displayed in the FLOWdisplay and the account of the operation hours since the last service is displayed in
the DIALOG-display. After second this information is overwritten by the
messages OK on the FLOW-display and PUMP OK on the DIALOG-display. A
detected error is displayed as ERR. on the FLOW-Display and an error message
on the DIALOG-display.
After the COLDSTART the software checks the pump mode, which is stored twice
After a coldstart the pump is always running in forward direction.
The tube size is read out of the EEPROM and displayed in the DIALOG-display
beside the pump-mode.
Revision 00
Service Manual
A-41
11.1.2
JOSTRA HL 20
At WARMSTART
JNS TWIN
WARMSTART
Ramtest intern:
KEY-PORT TEST:
Offset:
Ref. Test:
+12V Test:
TEMP- TEST
SAFETY-SYS. Test:
SAFETY-STOP Test:
REVERSE RELAIS
MODE RELAIS
STOP-INPUT-TEST
HOURS RUNNING
PASSED
PASSED
0
497
120
PASSED
PASSED
PASSED
PASSED
PASSED
PASSED
0
A/D Test:
+5V Test:
-12V Test:
PASSED
504
- 116
STOP RELAIS PASSED
HOURS TOTAL * 6
0000FF37 hex
Self-Test PASSED
220 2.82 2191 2196 2189
0
2202
31
27
0
0
0
During a WARMSTART the release number of the software is displayed on the

FLOW-display and the running hours since the last service is displayed on the
DIALOG-display. After about 1 second this information is overwritten by the
message OK on the FLOW-display and PUMP OK on the DIALOG-display.
A detected error is displayed as ERR. on the FLOW-display and as error
message on the DIALOG-display (for example. ERR. EEPROM)
After the WARMSTART the software checks the pump mode, which is stored twice
The direction of the pump is read out of the EEPROM and selected.
Also the tube size and the pulsatile values as START, STOPP, BASE_FLOW,
PULSRATE, HIGH- and LOW-LIMIT as well as the ASSIST-mode were set after
reading out of the EEPROM. So after a WARMSTART the pump starts with the last
mode before power off.
A-42
KEY-PORT
TEST
The keys of the RPM read directly by the microcontroller. During

the self-test no input of the microcontroller is allowed to be
connected to GND (no key is pressed).
Offset : 0
The offset of the processor internal 10-Bit AD-converter is checked

(see 1.1.4). The measured AD-value is displayed in bits from 0 to
1023. An AD-offset value > 10 is estimated as an error.
A/D Test:
The 10-Bit A/D-converter of the microcontroller SAB80C517A is

checked by a linearity test. During this test 2 voltage values were
put via the PULS-PWM output as SET_VAL to the AD-converter
input. The straight through these 2 points is checked by 3 values,
which also were applied via the PULS_PWM-output as SET-VAL to
the AD-converter.
Service Manual
Revision 00
JOSTRA HL 20
Revision 00

Ref. Test:
497
The reference voltage of the motor-control-board is measured and

checked by the processor internal AD-converter. The measured
+5.0 V +- 5%.
+ 5V Test:
504
The + 5V supply voltage is measured (see 1.1.5). The measured

+5.0 V +- 5%.
+12V Test:
120
The +12V supply voltage is measured (see 1.1.6). The measured

+12,0 V +-10%.
-12V Test: 116
The -12V supply voltage is measured (see 1.1.7). The measured

voltage is displayed, showing -11.6 V as -116. The tolerated value
is -12,0 V +10%/-20%.
TEMP Test:
The motor temperature and the heat sink temperature were

checked by measuring the analog voltages of the temperature
sensors. The fan is switched into the fast mode if the motor
temperature is higher than 60C or the heat sink temperature is
higher than 45C. If the motor temperature reaches 70C or the
heat sink reaches 60C the warning TEMPERAT is displayed in
the DIALOG-display. If the motor temperature reaches the limit of
90C or the heat sink the temperature of 70C the pump will be
stopped and the error ERR. TEMPERAT is displayed.
LAMP Test:
During the lamp test all LEDs and displays were switched on for
one second. The buzzer sounds for second. The user must
check this. The alphanumerical displays were checked by writing
and control reading of the display registers.
SAFETYSYS. Test:
The main processor checks the state of the status lines SS_OK1
and SS_OK2. On these lines the safety system shows the main
processor an error status. SS_OK1 must be HIGH and SS_OK2
must be LOW in the error free state. All other combinations are
showing an error.
STOPRELAIS:
Disabled motor driver tests the stoprelais. First the stoprelais is

activated and the control signal (STOPREL_CTRL) checked, which
is generated by a voltage divider. Then the stoprelais is released
and the control signal checked again. At the end of the test the
stoprelais is activated and checked again.
SAFETYSTOP Test:
In the SAFETY-STOP test the main processor makes the safety

system via the RA-Mode lines to activate the stop function of the
safety system. The mainprocessor controls the function of the
safety system stop. The test is as follows:
-
The main processor switches the RA-MODE lines into the test
mode
The main processor waits 250ms
Safety system sets SS_OK1 to LOW and SS_OK2 to HIGH and

stops the pump via the stopinput of the safety system.
The main processor checks the function of SS_OK1 and

SS_OK2
The main processor checks the function of the safety system

stop by reading the control signal of the stoprelais.
The main processor finishes the test modes by setting the RAmode lines into the normal mode.
The safety system checks the sate of the RA-mode-lines. The

test mode is only allowed for 5 seconds.
Service Manual
A-43
REVERSERELAIS:
JOSTRA HL 20
The REVERSE-relais is checked by disabled motor controller. The

REVERSE-Relais is set by the signals REV1 and REV2. Only the
state REV1 = LOW and REV2 = HIGH switches the relais into the
reverse mode. The REVERSE-relais is tested according the
following table:
REV1
REV2
REVERSE-CTRL
OFF
OFF
LOW (forward)
ON
OFF
LOW
OFF
ON
HIGH (reverse)
ON
ON
LOW
ON
OFF
LOW
MODERELAIS:
Disabled motor controller tests the MODE-relais. The mode relais

were tested by activating one relais after the other and checking
the control signals of each relais. At the end all the relais were
released and reading the control signals again tests the function.
STOPINPUTTEST:
A stop to the pump is activated by no current through the LED of

the opt coupler. If there is a current through the LED of the opt
coupler, the pump will not be stopped. Therefore a defect stop line
or a defect module stops the pump.
The stop logic is tested as following:
A-44
The GND of the STOP-Logic is switched from monitoring-GND

to the pump-GND. So the external stop signals have no function
and the internal stop signals can stop the pump.
By setting the Stop-Latch one stop is selected. This function

can be checked by reading the EXT_STOP signal with the
processor internal AD-converter. If the relaise 1 is open, there
is no current through the opt coupler (stopinput active). A
closed relays 1 causes a current through the opt coupler and
simulates an active stop line.
So one stopinput after the other is tested.
HOURS
RUNNING 0
The operating hours since the last service are displayed. A closed
Jumper RES_HOUR on the controller board may clear the
operating hours to 0 during the eepromtest in the coldstart. Also the
parameters in the EEPROM were overwritten by the default
settings. So after a service it is necessary to calibrate the tube
sizes again.
HOURS
TOTAL * 6
The total amount of the operation hours since initialization of the

EEPROM is displayed as hexadecimal value. The displayed value
is a copy of the value stored in the EEPROM and must be divide by
6. The value 0000FF37 is 65335 in decimal. 65335 / 6 is 10889
operation hours.
Service Manual
Revision 00
JOSTRA HL 20

Self-Test PASSED
11.2
RPM
LPM
POTI
ACTV
SETV
STOP
HEAD
T_MO
220
2.82
2191
2196
2189
2202
31
T_HS
ACTS
DELT
CORR
27
RPM
Rotations of the pump head in RPM (example above 220 RPM)
LPM
Flow in liter / minute (example above 2.82 LPM)
POTI
Flowpoti value (= SET value; not in Slavemode; example above 219,1 RPM)
ACTV
value of the motortacho (example above 219,6 RPM)
SETV
Set value for slave mode (example above 218,9 RPM)
STOP
Stopinput value (example above 0; that means no stop)
HEAD
headtachovalue (example above 220,2 RPM)
T_MO
Motor temperature (example above 31 C)
T_HS
Heatsink temperature (example above 27 C)
ACTS
Actual headtacho value in pulsatil mode
DELT
Deviation of the regulation in pulsatil mode
CORR
Correction of the motor regulation in pulsatil mode

The EEPROM can be initialized via the service terminal by typing <Shift><R>. The
jumper JMP11 must be closed (see service manual). The following
- SET EEPROM page to 0
- The operation hours since the last service were cleared to 0
- The total amount of operation hours is set to 0
- The not used EEPROM area is filled with 0
- The used EEPROM area is filled with the DEFAULT-settings
Revision 00
Service Manual
A-45
11.3
JOSTRA HL 20
Tests during operation

During normal operation the main processor of the RPM makes the following tests:
TEST
TOLERANCE
ERRORREACTION
Checking the processor

internal AD-converter offset
Offset10 <11 digits
ER 05

voltage
+5 V +- 5%
ER 07

voltage
+12V +- 10%
ER 08
Checking the -12V supply

voltage
-12V +- 20%
ER 09
Checking the motor

temperature:
Motor temperature
> 60C
FAN fast
Motor temperature
> 70C
Warning TEMP
Motor temperature
> 90C Error message

ERR TEMPERAT:
ER 0B
Checking the heat sink

temperature:
> 60C
FAN fast
> 70C
Warning TEMP
> 90C
Error message ERR
TEMPERAT:
Checking the pump mode
A-46
ER 0B
ER 85
Watching runaway
Headtacho > Setvalue

+10%
RUNAWAY
Watching the overload

situation
Headtacho < Setvalue -10%
OVERLOAD
Watching the belt
Headtacho < Motortacho

-10%
BELT SLIP
Headtacho > 250 RPM
OVERSPEED
Watching the max. speed in

pulsatil operation
Headtacho
/Min
Watching the key
Key pressed longer than 15

seconds
KEY!
Watching the data

communication
No communication to the
MASTER for more than 5
seconds
NO COM
Watching the mode lines
The signal PSEL is lost
NO SEL
Checking the direction of

the pumphead
rotation against the

selected direction
ER 12
Service Manual
> 250 Umdr.
Revision 00
JOSTRA HL 20
11.4
Error messages
Error code
Revision 00
Error description
Possible reasons
ER 01 ERR_ROM
Program memory defect; A

EPROM defect; access control
incorrect LRC has been found of EPROM defect
ER 02 ERR_RAM
Data memory defect

SRAM defect; microcontroller
defect (internal RAM)
ER 03 ERR_EEPROM
EEPROM test failed
EEPROM defect; access

control of EEPROM defect;
max. writing cycles of the
EEPROM reached;
ER 04 ERR_ADCONV
Timeout of processor internal

AD-converter
ER 05 ERR_OFFSET
OFFSETtest of the processor

internal AD-converter failed

not connected;
ER 06 ERR_REF

motor controller not O.K.
Reference voltage of the motor

controller out of tolerance; ADconverter defect; reference
voltage not adjusted;
ER 07 ERR_5VTEST
+5V supply voltage test failed
+5V supply voltage out of

tolerance; AD-converter defect;
reference voltage not adjusted;
voltage divider;
ER 08 ERR_p12VTEST
+12V-supply voltage test

failed
+12V- supply voltage out of

voltage divider;
ER 09 ERR_n12VTEST
-12V-supply voltage test failed -12V- supply voltage out of

voltage divider;
ER 0A ERR_LAMPTEST
Lamp test failed
Displays defect; the access

control of the displays is defect.
ER 0B ERR_TEMP
Motor temperature or heat

sink temperature too high.
The temperature is too high;

sensor not connected; ADconverter defect; reference
voltage not adjusted
ER 0C ERR_REV-REL
REVERSE-relais not O.K
Reverserelais defect; access

logic of the reverserelais or
ER 0D ERR_STOP-REL
STOP-relais not O.K.
Stoprelais defect; access logic

of the Stoprelais or controllogic
defect.
ER 0E ERR_MODE-REL
MODE-relais not O.K.
Moderelais defect; access logic

of mode relais or controllogic
defect
ER 0F ERR_STOP-INP
Stop input test failed
Connection between PUMPGND and MONITORING-GND;

stopinputlogic defect;
ER 10 ERR_S-STOP
Stop function of the safety

system not O.K.
The access logic of the STOPrelais by the safety system is

defect;
Service Manual
A-47
A-48
JOSTRA HL 20
ER 11 ERR_SCHUTZ-S
Safety system not O.K.
The status lines SS_OK1 and

SS_OK2 are showing an error
state;
ER 12 ERR_DIRECTION
Pump head moves in the

wrong direction
The pumphead was turned in

the wrong direction; headtacho
defect;
ER 13 ERR_ILLEGAL
Illegal error code
This errorcode is not allowed;

illegal software status
ER 14 ERR_KEY
Key is hanging
key is hanging; key pressed

during keyport test;
ER 15 ERR_MODEBLO
Mode selection not O.K.
The pump receives no PSELsignal from the CCM-module or

the PSEL-signal is wrong.
ER 16 ERR_HEAD
Pump head error; The

motortacho shows an value
but the haedtacho shows 0.
headtacho not connected; belt

broken; motortacho defect;
ER 17 ERR_UNEXPECTED Illegal software status
Fatal error!
ER 18 ERR_ARITHMET
Arithmetic error
Division by 0 by calculating the

new pump parameters;
datatransmission error between
MASTER and pump;
ER 19 ERR_ILLEGAL
Illegal error code in error byte
Fatal error!
ER 81 ERR_MODUSED
Pump mode used
A not used pump mode is

recognized as used during
programming the new pump
mode.
ER 82 ERR_MODPSEL
The PSEL-signal was lost

during programming a new
pump mode
ER 83 ERR_MODCLK
During programming a new

pumpmode there is more than
one .clocktransitions on the
mode lines.
ER 84 ERR_MODSEL
The mode line is pulled to

LOW but the processor does
not see the LOW state;
ER 85
ERR_MODEEPROM
The pump-mode stored in the

EEPROM is not equal with
the complement of the pumpmode
EEPROM defect;
ER 87 ERR_MAXWARN
Illegal warning in error byte
Fatal error!
Service Manual
Revision 00
JOSTRA HL 20
12.
Module AEP20-415
12.1

After power on the module ABD20-410 displays the results of the selftests on
the servicterminal:
JNS AIR-EMBOLISM-PROTECTION Module

------------------------------------------Software Revision V1.1
Ramtest intern:
Romtest:
Ramtest:
PASSED
PASSED
PASSED
Offset8:
+12V Test:
-12V Test:
Threshold:
SAWTOOTH:
STOP-Test:
0
119
- 121
109
PASSED
PASSED
Self-Test PASSED
LEVEL: Curr: BUBBLE: MIKRO: BUB_INT: REGUL: SILIKON: ALARM: STOP: SB SBP ER
3
173
0
0
0
YES
YES
NO
01 321 0
00
Self-Test PASSED
Revision 00
LEVEL:
CURR:
BUBBLE:
MIKRO:
BUB_INT:
REGUL:
SILIKON:
ALARM:
173
YES
YES
NO
STOP:
SB
SBP
ER
01
321
00
LEVEL
8-bit AD-converter value of the CLS in digits (example 3). If the signal is >
100, the pump is stopped.
CURR
8-bit AD-converter value of the CLS current consumption. If the signal is <
128 or > 205, the pump is stopped and SENSOR FAULT lights up.
BUBBLE
Bubble activity. (counted bubble interrupts BI; example above 0 --> no

bubbles detected)
MIKRO
Counted Microbubbles (counted microbubble interrupts UBI;

ex. above 0 --> no bubbles)
BUB_INT
Integral of bubble activity (example above 0)
REGUL
Regulation of the bubbledetector is ready (YES / NO)
SILIKON
tube of silicon detected (YES / NO)
ALARM
Alarm (YES / NO)
Service Manual
A-49
STOP
JOSTRA HL 20
Stop byte shows the stop identification and the status of the stop lines.
Stop-Byte:
b7
b6
b5
b4
b3
b2
Stop
--
--
--
Stop
Stop-Identification
Bubble
Stop ID:
A-50
b1
b0
Level Bubble-Level-Modul
b2
b1
b0
No stop function
Stop to the Arterial pump
Stop to the Slave pump
Stop to the Sucker pump
Stop to the Auxiliary pump
Stop to the Cardioplegia pump
Illegal status
Illegal status
SB
Measured voltage of the signal SB. This signal is the sum of the 3 channels
of the detector logic
(in the ready state: set
value = 3 * 1,1 V = 3,3 V +- 10%; example above 3.21 V)
SBP
Measured voltage of the signal SBP. Input signal depends on the size of the
bubbles (0... 3,3 V; example above 0.00 V)
ERROR
Error byte of the AEP-module
Service Manual
Revision 00
JOSTRA HL 20
12.2
Error messages
Error code
Revision 00
Error description
Possible reasons
ER 01 ERR_ROM
Program memory defect; EPROM defect; access control

of the EPROM defect
A incorrect LRC has
been found
ER 02 ERR_RAM
Data memory defect

SRAM defect; microcontroller
defect (internal RAM)
ER 04 ERR_ADCONV
Timeout of processor
microcontroller defect
ER 05 ERR_OFFSET
Offset test of the

processor internal ADconverter

not connected
ER 06 ERR_REF
Threshold voltage test

failed
Threshold voltage Uth out of

ER 08 ERR_p12VTEST
+12V-supply voltage test +12V-supply voltage out of

failed
voltage distributor;
ER 09 ERR_n12VTEST
-12V-supply voltage test

failed
-12V-supply voltage out of

adjusted ; AD-converter defect;
voltage distributor;
ER 0D ERR_STOP
Stop logic test failed or

error of the stop
selection switch
Stoprelais defect; stop control

logic defect; PWM-output defect;
stop selection switch not o.k.;
AD-converter defect; AD-logic
defect; stop selection switch
tuned during operation;
Fatal error!
ER 21 ERR_OVERRIDE
Override status in the

software not equal.
The Override status is stored

twice in the software and is not
equal. datatransmission error
from the MASTER-module;
ER 23 ERR_SAWTOOTH
Synchronisation voltage
of the stop logic not o.k.
No sawtooth voltage available;

AD-converter defect
Service Manual
A-51
JOSTRA HL 20
Notes
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A-52
Service Manual
Revision 00
JOSTRA HL 20
Appendix B
Appendix B
Console Wiring Diagram
Revision 00
Service Manual
B-1
JOSTRA HL 20
Notes
Revision 00
Service Manual
Maquet Critical Care AB, 2006. All rights reserved. MAQUET reserves the right to modify the design and specifications contained herein without prior notice.
Order No.: 705371. Revision 00, March 2006. Price group: 7. Printed in Sweden.
Maquet Critical Care AB

SE-171 95 Solna, Sweden
Phone: +46 8 730 73 00
www.maquet.com/criticalcare
For local contact:

Please visit our website
www.maquet.com
GETINGE GROUP is a leading global provider of equipment and

systems that contribute to quality enhancement and cost efficiency
within healthcare and life sciences. Equipment, services and technologies are supplied under the brands ARJO for patient hygiene,
patient handling and wound care. GETINGE for infection control
and prevention within healthcare and life science and MAQUET for
Surgical Workplaces, Cardiopulmonary and Critical Care.

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JOSTRA HL 20

Purpose (Read this First) ....................................................... 1-1

Service ....................................................................................... 1-1

Hazard notices ..................................................................... 1-1

Preventive maintenance......................................................... 1-2

Functional check .................................................................... 1-2

To the responsible service personnel..................................... 1-2

Special Notes .......................................................................... 1-3

Manuals .................................................................................... 1-3

Definitions and Abbreviations ............................................... 1-4

Location of Signs and Labels ................................................ 1-6

Introduction ............................................................................. 2-1

Functional elements ............................................................... 2-2

Module Access Bay .............................................................. 2-3

System Control Panel ........................................................... 2-4

System Monitor Unit ............................................................. 2-5

Pump Front Panel ................................................................ 2-6

Technical Data ......................................................................... 2-7

Console ................................................................................ 2-7

Pumps .................................................................................. 2-9

System Control Panel ......................................................... 2-10

Display Monitor ................................................................... 2-10

Air Bubble Detection ........................................................... 2-11

Ultrasonic Level Detection .................................................. 2-11

Capacitive Level Detection.................................................. 2-11

Temperature Measurement ................................................ 2-12

Pressure Control ................................................................ 2-12

Input/Output devices .......................................................... 2-13

Heater Cooler Unit .............................................................. 2-13

JOCAP ............................................................................... 2-14

Principles of Operation .......................................................... 3-1

Mains and Battery Operation ................................................. 3-2

Voltage Display .................................................................... 3-3

Mains Operation ................................................................... 3-4

Battery Operation ................................................................. 3-4

Charging the Battery ............................................................ 3-6

System Control Panel (SCP) .................................................. 3-7

System Monitor Unit (SMU) .................................................. 3-10

Pumps .................................................................................... 3-13

Twin Head Pump (TPM) ..................................................... 3-19

Console .................................................................................. 3-23

The Main Transformer ........................................................ 3-25

The Power Supply Board ................................................... 3-27

The Battery ......................................................................... 3-30

Modules ................................................................................. 3-31

Power Supply Module (PSM) ............................................. 3-35

Console Control Module (CCM) ......................................... 3-36

Battery Charger Module (BCM) .......................................... 3-40

Control Panel and HCU Interconnection Module (CHI) ...... 3-42

Monitor Interface Module (MIM) ......................................... 3-42

Air Bubble Detector Module (ABD) ..................................... 3-45

Ultrasonic Level Detector Module (ULD) ............................ 3-49

Quad Temperature Module (QTM) ..................................... 3-52

Dual Pressure Modules (DPM) ........................................... 3-54

Air Emboli Protection Module (AEP) .................................. 3-57

Analog I/O Module (AIO) .................................................... 3-60

Digital I/O Module (DIO) ..................................................... 3-63

Interconnection Overview .................................................... 3-65

Single Signal Paths ............................................................ 3-66

Digital Communication Path ............................................... 3-68

Interfaces ............................................................................... 3-70

The System Control Panel interface ................................... 3-72

The System Monitor Unit interface ..................................... 3-73

The Console Control Module Interface ............................... 3-74