Chem 5X - Service Manual
Chem 5X - Service Manual
REVISION RECORD
REV DATE AUTHOR REVIEWER REVISION MADE (Page No. refers to Operator
NO. Manual Page)
Version 1st October Ajay Niranjan First Release
1.0 2006 Yadav Ambikar
TABLE OF CONTENTS
CHAPTER PAGE No.
1. INTRODUCTION……………………………………………………….…………………5
2. SAFETY PRECAUTIONS.………………………………………………………………..7
3. SPECIFICATIONS…………………………………………………………………………9
4. INSTALLATION……………………………………………………………………………13
5. BLOCK DIAGRAM………………………………………………………………………...17
8. MAINTENANCE…………………………………………………………………………...44
9. TROUBLESHOOTING GUIDE…………………………………………………………..54
11.SPARE PARTS.…………………………………………………………………………...62
CHAPTER 1
INTRODUCTION
There are 9 modes of operation. Programming, reading and reporting operations are user
friendly.
The analyzer is provided with memory for storage of Quality Control Data, Reagent Blank
Absorbance, Factor, Non-linear Calibration Data and up to last 1000 results with Patient ID.
Operation is through a soft-touch keyboard with quick shift from one function to another
without going through complex sequential operations.
The analyzer is provided with a 240X64 dots backlit liquid crystal display with alphanumeric
and graphic capabilities.
A Patient ID wise or Date wise or Patient ID with Date wise collated report can be generated
upon request. Exhaustive Quality Control Data at 2 levels, for any of the tests can be stored
and printed.
The software is complete with the device diagnostic self test function capable of providing
timely flag / error messages related to Test results or analyzer malfunctioning.
The State-of-the-Art features, advanced optics, versatile analytical capabilities and economy
of 33 µl flowcell makes it the analyzer of choice for all laboratories.
This analyzer is intended to be used -for In-vitro quantitative and qualitative determination of
wide range of analytes in body fluids as mentioned above. -by the trained personnel in
controlled environment and continuously monitored operation.
CHAPTER 2
SAFETY PRECAUTIONS
Operator’s / service personnel safety is a primary concern. This section provides safety
information about analyzer. Use this product properly and safely to prevent injuries and or
damage to property. User must read this safety precaution before installation and follow the
directions.
GENERAL SAFETY:
¾ While operating, maintaining, servicing or repairing the analyzer, follow all the
procedures described in this manual.
¾ Always ensure that mains switch is off while connecting, removing or servicing the
analyser.
¾ Observe all WARNINGS and CAUTIONS posted on the system or described in this
manual.
¾ Avoid contact with all electrical circuits of analyzer. Observe CAUTIONS posted on the
analyser.
¾ During the operation photometric lamp becomes extremely hot. DO NOT look directly
into the light path of the lamp when it is ON. DO NOT touch the lamp when it is ON.
If the lamp needs to be changed, always switch off the lamp by switching of the
instrument and then wait until lamp has cooled down.
¾ Avoid using dangerous flammable material around the instrument. Fire or explosion may
be caused by ignition.
¾ Operator is responsible for taking all necessary precautions against hazards associated
with the use of clinical laboratory chemicals. Specific recommendations for each reagent
used with the analyzer are normally found on the manufacturer’s package inserts or on
product information sheets for each chemical. Wipe up any reagent spillage on the
instrument immediately.
CHAPTER 3
SPECIFICATIONS
A. HARDWARE SPECIFICATIONS
4. SETUP : Benchtop.
B. SOFTWARE SPECIFICATIONS
• Facility to memorize Reagent Blank ABS., Sample Blank ABS., Standard ABS.,
Factor, Non-linear curve.
• Report: Report generation for last 1000 samples are stored and obtained by
- Date.
- I.D.
- Both by date and I.D.
• Automatic zeroing.
• On-line help.
• Self-diagnostics.
CHAPTER 4
INSTALLATION
INSPECTION:
The analyzer is tested before shipment and is packed carefully to prevent any shipping
damage. It is user responsibility to inspect all cartons upon arrival and notify the carrier of
any apparent damage. Follow the steps described in the paragraphs below to install the
analyzer.
UNPACKING:
The main unit and accessories are packed in single cartons. Reagents and other additional
accessories such as power adapter, power cord may be packed in another carton. The
representative is responsible for unpacking, installing and initial setting up of the analyzer.
INSTALLATION REQUIREMENTS:
The proper location is an important consideration, a poor location can lead to malfunction of
the analyzer. Please follow our environmental and electrical suggestions to ensure the
accuracy and precision of the analyzer and to maintain a high level of safety for your
personnel.
Remember that a minimum 30cm. space is maintained between the rear panel and the wall
to allow for heat dissipation. The waste bottle should be placed on the same or below the
level as the analyzer.
NOTE:
PROBLEM resulting from the relocation of the analyzer done by unauthorised service
representative are not covered under warranty.
ELECTRICAL REQUIREMENTS:
Voltage & Frequency : Single phase continuous stabilized AC 230/115 V
± 10%, 50 / 60 Hz.
Grounding : Perfect earthing must be provided at power source
with all applicable local requirement (A grounded,
3 pin power plug only should be used The Voltage
between earth and neutral should not exceed
more than 5 V )
Plug Points : 1 No. of 15 amps outlet and 2 No. of 5 amps. sockets
should be available near the mounting desks.
(Normally only one socket is required per analyzer and 2
extra sockets are recommended for using any measuring
equipment and engineering tool if required while servicing.
Failure to properly ground the analyzer bypasses
important safety features and may result in an electrical
hazard. Heavy duty electrical devices like Air conditioners,
refrigerators, oven’s etc., should not be operated on the
same electrical lines as the analyzer). The analyser must
not be used on generators).
Please ensure while taking any electrical measurement the multimeter used must have valid
calibration identification. The AC power adapter supplied with the analyser will withstand
sudden/momentary variation in voltage between 90 – 260 V AC, 50/60 Hz, it is advised to
use analyser at 230V/115 V stabilized supply voltage. The analyser should not be used on
generators.
Also ensure that the power supply should be placed at a distance easily accessible to the
user. This will help the user to switch OFF the instrument immediately during any
emergency.
INSTALLATION PROCEDURE:
It is thermal printer housed inside chassis. It is extremely low noise printer. The non-
presence /improper installation (printer lever is not pressed downward) of paper is detected
and it is alarmed by two beeps and probable cause of beeps, message is displayed on the
screen.
To replace the paper roll, release lever and remove the old roll spindle, which is anchored
inside the paper-holder housing. Cut out the end of the new paper roll in a ‘V’ shape, and
slip the point of the “V” under the black rubber roller so that the paper comes out of the
upper part and close the lock lever. Refer below Figure 1 for proper routing and installation.
The thermal paper used must match the specification of the original one,
since the calibration of the working temperature is optimized for that kind of
NOTE: paper. Failure to use proper quality of paper may permanently damage the
printer.
CHAPTER 5
BLOCK DIAGRAM
LCD
THERMAL JUNCTION
PRINTER BOARD MAIN BOARD
KEYPAD
PHOTOMETER
The major blocks of the analyzer consist of Main board, thermal printer,Photometer, Keypad
and liquid crystal display (LCD). Keypad and thermal printer is interfaced to main board
using a junction PCB.
The LCD is a 240x64 dots backlit display with alphanumeric and graphic capabilities with
backlit feature which enables the user to read in case of less ambient light. This is most
sensitive device to get damaged, which require careful handling, is interfaced with keypad
using a interface card.
Photometer is a device to measure the intensity or power of a beam of radiation. When the
absorption of the radiation by colored substance is made by means of photometer. It can
serve 6 different wavelengths. The filter defines the wavelengths.
Main board as the name suggest is the heart of the analyser, which controls all the
hardware/software functions of the analyser. Refer the details of main board in chapter six.
CHAPTER 6
FUNCTIONAL DESCRIPTION OF PCB
MAIN BOARD
As shown in block diagram analyzer mainboard is the heart of this analyzer. This mainboard
gives necessary commands and controls the operation of other peripheral such as
Keyboard, LCD, Printer and Photometer. Major blocks are explained below.
RTC
12c887
A/D CONVER TEMP
5460A SENSR
EEPROM1
24c512
MUX 4051
PELTIER
DRIVER
EEPROM
WATCHDOG
ADM1232
Power supply
5 v /12 v /18v
COMPONENT LAYOUT
Instrument can be operated at 110-230 V AC +/- 10% universal power supply with the use
of AC to DC adaptor which gives 18 V DC required as input for the internal devices.
This instrument uses three power supply sections designed to provide power to electronic
circuit, lamp & photometer and the thermal printer.
Power Supply Æ External Adaptor provides it and the adaptor output 18 v is given as input
to the analyzer 18 V DC supply is further converted to +5 V DC, +12 V DC and +5 V DC
isolated supply by mainboard power section, and its outputs are
¾ Any defect in the section will lead to any of the following problem(s)
¾ Action to be taken
1. Replace mainboard.
The operations for controlling the instrument are performed by the mainboard. This section
is provided with ST10F168Q6 microcontroller and 89c51RD2 microcontroller, 64K of
EEPROMs. also a timer, a serial interface RS 232C, and a 24 bit parallel interface are
present on the card itself. The logic is all in CMOS technology to guarantee low
consumption and high reliability. The RTC is provided with inbuilt battery.
¾ Any defect in the section will lead to any of the following problem(s)
¾ Action to be taken
This section of the mainboard selects one among different analog signals at a time, such as
input voltage, lamp voltage, Vcc and photometer reading etc. converts these signals into
digital equivalent number. This number is further processed by controller.
The IC5460 performs the control of the measurement operations. It contains a 24-bit A/D
converter, the reference voltage, and the necessary I/O ports for talking with the
microcontroller, as well as the serial interface to the outside, and the circuit for the cuvette
temperature control.
¾ Any defect in the section will lead to any of the following problem(s)
¾ Action to be taken
This section controls the motion of motor using IC L6208. It is a DMOS Fully Integrated
Stepper Motor driver features a non-dissipative overcurrent protection on the high side
Power MOSFETs and thermal realized in Multipower-BCD technology. It includes a constant
off time PWM current controller. When the voltage drop across the sense resistor becomes
greater than the voltage at the reference input (VREFA or VREFB) the sense comparator
triggers the monostable switching the motor off. When the monostable times out the motor
will again turn on.
To store different types of data IC three 64 K bytes IC 24c512 are used to store. IC U4 is
used for chemistry parameters, U5 is for patient reports and values of standards and blank
for non-linear chemistry and U6 is used for quality control data.
IC 12c887 is a Real Time Clock plus RAM. The function includes a nonvolatile time of day,
calendar. The time of day and memory are maintained even in the absence of power.
¾ Any defect in the section will lead to any of the following problem(s)
1. Water, standard, solution is not getting aspirated after pressing ASP switch.
2. Motor is not running or not stopping.
3. Chemistry parameters are not stored.
4. Patient report or quality control data is not stored.
5. Date and time is not correct.
¾ Action to be taken
PHOTOMETRIC UNIT:
It is one of the major blocks of the instrument & it contains 6 different narrowband optical
interference filters of wavelengths 340, 405, 505, 546, 578 & 630 nm for specific chemistry
tests. When ray of light is passed through the reaction cell it gets splited into different
wavelength, which passes through the filter. This filtered light is detected by photodiodes
which is amplified and send to the multiplexer CD 4051 which select the one signal and
communicated to processor for further processing.
COMPNENT LAYOUT
¾ Any defect in the section will lead to any of the following problem(s)
¾ Action to be taken
JUNCTION PCB:
It is the basic interface between the keyboard and CPU PCB assembly for passing the key
press signals. It also passes the data to the display assembly. Aspiration switch and thermal
printer signals are also conveyed through this PCB.
COMPONENT LAYOUT
¾ Any defect in the section will lead to any of the following problem(s)
¾ Action to be taken
INVERTER PCB
The basic function of this assembly is providing the backlight to the display. Input voltage to
the inverter is +5V dc (+/-0.25V). The output of the inverter is 110 V AC (+/- 0.5 V AC) which
is given to back light display. This PCB is fixed beside the LCD PCB on the inner face of
chassis top.
¾ Any defect in the section will lead to any of the following problem(s)
¾ Action to be taken
PRINTER:
The printer is 40 column graphic printer, able to give a very high printing quality, high speed
and a considerable noiselessness on thermal paper without having to move the printing
head.
The liquid crystal graphic with 240x64 dots, with alphanumeric and graphic capability.
A 25 key membrane tactile keyboard is provided.
CHAPTER 7
TESTING AND CALIBRATION
The instrument assemblies are factory adjusted and does not require any field-testing,
adjustment or settings. It is advisable not to change setting unless necessary.
If it is necessary, the testing, adjustment or setting must be carried out by trained and
authorized personnel only.
TESTING OF MAINBOARD
1. Give 18 VDC supply at J11 connector and measure voltages at various test
points with respect to common ground point using a calibrated Multimeter.
** HARDWARE CHECK **
LAMP VOLTAGE :O.K.
LOGIC VOLTAGE :O.K.
SMPS VOLTAGE :O.K.
CALIBRATION DATA :O.K.
MEMORY :O.K.
PHOTOMETER :O.K.
HARDWARE TEST
1. Press numeric key < 4 > and go to maintenance in the Home screen and the
following screen is displayed.
2. Check the temperature of the flowcell press any of the numeric keys < 0-3 >
and corresponding temperature is attained in the flowcell.
3. Temp. of the flowcell will be displayed.
SETTING PARAMETERS
SYSTEM SETUP
The system setup option allows the user to view, edit and print the system date, time and
the data output mode.
1. SET DATE.
2. SET TIME.
3. SET OUTPUT MODE.
4. SET LAB INFORMATION.
5. BLANK DEDUCTION
The numeric keys 1, 2, 3, 4 and 5 are used to set the date, time, data output mode,
laboratory information and Blank Deduction respectively.
2. Press numeric key ‘< 1 >’ and the following screen appears:
3. The cursor is positioned on the DATE field on the SYSTEM SETUP-DATE screen.
5. After appropriate entry is made, press the <FN> key to save date and return to the
System Setup screen or press < PREV. > to quit without saving and return to the
System Setup screen.
1. Choose the option ‘2’ from the System Setup menu and SET TIME. The display
appears
2. The cursor is positioned on the TIME field on the SYSTEM SETUP-TIME screen.
Enter an appropriate time in the format as stated below
3. Each entry is separated by a ‘ : ’ sign, which appears automatically after the entry of
the 2nd digit.
4. After appropriate entry is made, press the < FN > key to save and return to the
System Setup screen or press <PREV.> to quit without saving and go back to the
System Setup screen. User will be prompted if the date and or time is entered wrong.
1. Choose numeric key <3 >on the system Setup menu to select the data output mode
3. Press <YES> or <NO> to select or deselect the printing of results on the Analyzer’s
Thermal and External printer automatically. Similarly press <YES> or <NO> to select
or deselect Transmission.
4. Press <PRINT> to select printing of results on the Analyzer’s Thermal and External
Printer when Print key is pressed in the respective screens.
RESULT TRANSMISSION
*12G6 ALB 2.63 g/dl L (*12G7 ALB 4.20 g/dl L'*12G8 GLU 133.3 mg/dlHÂ
4. LAB INFORMATION:
1. The user can enter laboratory information, (25 characters each on 5 lines) with
keyboard. This is stored in the memory.
LABORATORY INFORMATION
The result print out will have the header of Laboratory Information as fed in this menu. Thus
number of lines printed as the header will be matching with the number of lines fed in the
lab information screen.
1. Open the front cover and rotate preset P1 provided on the Junction PCB
TEMP CALIBRATION (IN NORMAL CONDITION – WITH PRINTER AND RD2 JUMPERS)
a. Milivolt Calibration
b. Actual Temperature Calibration
Note: The Resistance R61 (680 ohm) should be of 0.1% Tolerance SMD type.
Service engineer has to carry Thermister Jig to ensure the set temperature.
5. Press <ENTER> to confirm. This temperature will be stored in memory and when
temperature 37°C is selected, actual temperature will be 37.5°C. (This may take 5-7 min.)
6. Press <PREV.> to come out of calibration procedure.
PUMP CALIBRATION
1. Go to Maintenance mode.
2. Press < → > right arrow key display will show pump calibration key & default
parameter screen.
3. Take 1000 micro liters of distilled water in test tube.
4. Press ASP switch & aspirate distilled water. Aspirate till the last drop of water is
aspirated and again press ASP switch to stop aspiration.
5. The count will be displayed on the screen. Now the peristaltic pump is
calibrated to aspirate any volume from 300 µl upto 999 µl.
1. Go to maintenance menu.
2. Press key sequence <4> <7> <5>
3. A screen will display current lamp voltage.
4. Increase lamp voltage by pressing <UP> key and decrease using <DOWN> key. If
the voltage is 12v or above, further increase in voltage is not possible. Similarly if
voltage is 11.5v, further decrease in voltage is not possible.
5. Press <PREV.> for self test menu again.
Note:
Setting of Default Parameters for Dry Powder/Liquid stable Reagents and Product
Name for Local or Export order.
CHAPTER 8
MAINTENANCE
The analyzer is designed for trouble free operation and requires minimum maintenance. For
good functioning of the analyzer it is advisable to follow the instructions given below
2. When not in use, cover the analyzer with the dust cover to avoid accumulation of
dust.
3. Though air conditioning is not a must, it is advisable to keep the analyzer in a dust
free, cool atmosphere, away from direct sunlight.
A. DAILY MAINTENANCE
2. After every chemistry run, wash the flowcell thoroughly with good quality distilled
water using the “ASP” switch.
3. Always leave the flowcell filled with distilled water. Never leave any reaction mixture
in it.
4. At the end of each day, aspirate about 5 ml of ERBA wash solution into the flowcell
and allow it to remain in the flowcell for 5-10 minutes then wash the flowcell
thoroughly with distilled water. Leave the flowcell filled with distilled water.
CAUTION:
C. QUARTERLY MAINTENANCE
Replace the aspiration tubing and peristaltic pump tubing once every THREE months (as
explained below) or earlier if it shows signs of wear and tear.
NOTE: Failure to change the peristaltic pump tubing in time can cause serious
errors of aspiration volumes and can also damage the analyzer due to
the leakage of corrosive reagents through torn tubings.
Besides the above, certain other simple maintenance operations have to be performed as
and when required.
These are :
- Replacement of the paper roll
- Replacement of tubings
D. REPLACEMENT OF TUBING
The replacement has to be carried out once in THREE months, or whenever an alteration in
the aspiration volume occurs. Disconnect the tubing from the peristaltic pump if the
analyzer is not going to be operated for a few days or longer.
4. Slide out the washer and ‘O’ ring of the old aspiration tubing.
Note: Take care to see the side of the flowcell with the arrow mark is in light path & to
your left. & Always leave it filled with distilled water whenever not in use.
2. Before the old tube is removed, note the exact manner in which it is positioned
around the pump.
4. Detach both the ends of the tubing from Aspiration tubing and Waste tubing
respectively.
5. Insert the one end of new peristaltic tubing assembly into the tubing coming from
flowcell.
6. Position the new tubing around the rotor.
7. Insert the other end of peristaltic tubing into the waste tube and direct the waste
tube towards waste bottle.
8. Perform pump calibration with 1 ml distilled water.
9. Put the cover of the peristaltic pump housing.
3. Before the old lamp is removed, note the exact manner in which it is positioned.
4. Unscrew the two lamp terminals using (--) screw driver.
7. Place a new lamp and connect the lamp terminals and fix thumbscrews.
8. Refit the lamp cover.
NOTE: Due to the aging effect the lamp intensity may get reduced and results
may be improper, it is advisable to replace the lamp after every six month.
Before starting the instrument make sure that enough printer paper is on the roll. The
paper roll is located under the printer cover. To check and/or replacing the paper roll
lift off the printer cover. For inserting a new paper roll do as follows.
1. Lift off the printer cover and take the roll out of the paper roll housing.
2. Then take a new paper roll and lay down into the paper roll housing.
4. Cut the paper in ‘V’ shape and feed this paper tongue into the slot of the paper
feeder. Smoother side should face up.
6. Close the printer lever by pressing it down and close the printer cover.
CHAPTER 9
TROUBLE SHOOTING GUIDE
The following list is an extension of the troubleshooting section outlined in the operator’s
manual. The reader should familiarize with the setup, operation and troubleshooting section
of the operators manual before attempting to service the unit.
In all cases of problem that are not described in this chapter and that cannot be solved by
yourself according to the given remedies, it is strongly recommended to contact your
technical product specialist.
Note: It is very important while diagnosing problem to look at the non-instrumental aspects
of troubleshooting. This will save time and efforts for reaching to the correct solution.
¾ While re-programming new/old tests for instrument, ensure the parameters entered are
as per the reagents brands used.
a. +5 VDC at inverter PCB assembly not Possible loose connection of the connector
present on main board assembly and inverter
assembly.
b. Defective inverter PCB Assembly Replace inverter PCB assembly.
c. Defective main board Replace main board.
5. Liquid is not aspirated when the Dynamic key “WASH” switch is pressed
a. Check all the above mentioned points Check the all above mentioned points.
a. Peristaltic tube reversed. Fix the peristaltic tube in the correct position
b. Hole in tubing before peristaltic pump. Replace tubing.
c. Flowcell damaged Replace flowcell.
a. Printer lever is open (release position) Push the printer lever down to lock paper.
b. Loose or poor contact Check for any loose connections to printer
cables & connectors
c. Defective keypad assembly Replace keypad
d. Defective printer assembly Replace printer PCB assembly.
11. NO Printout
15. The result printout is accompanied by the warning “RX ABS LIM OVER” in all
Chemistries.
POSSIBLE CAUSE CORRECTIVE ACTION
a. The initial absorbance of reaction Check the “RX. ABSLIM.” value has been
mixture is more than the ABS MIN. correctly entered.
value in test parameters. Prepare fresh reagent and check the value.
Service Manual (Rev 1.0– 01 Oct 06) - 55 -
TRANSASIA
16. The result printout is accompanied by the warning “RX ABS LIM UNDER” in all
Chemistries.
a. The initial absorbance of reaction Check the “RX. ABSLIM.” value has been
mixture is less than the ABS MIN. correctly entered.
value in test parameters. Prepare fresh reagent and check the value.
a. Analyzer is not switched ON for more Set date and time by going through the
than 3 to 4 weeks. system setup option.
Replace IC U3 i.e. 12c887.
a. One or multiple signals on the main Check voltage at test point TP1 to Tp12.
board is not OK.
Replace main board.
25. The temperature attained in the flow cell is not within ± 0.1º C of the selected
temperature
POSSIBLE CAUSE CORRECTIVE ACTION
a. Flowcell is not completely inserted. Insert flowcell completely in proper way.
b. Refrigerated reagent is used. Bring the temp. of reagent to room temp.
and then use it.
Replace thermister still persists, replace
peltier.
CHAPTER 10
WIRING DIAGRAM
CHAPTER 11
SPARE PARTS
SPARES DETAILS AND ORDERING INFORMATION
It is recommended that all the spares and accessories used in or along with the equipment
are critical and original, supplied by the manufacturer. In case of requirement of these parts
for trouble free working of analyser. Kindly mention below details while ordering spares.