Humastar 180 Service Manual

HumaStar 180| Service Manual

Cat No. 16900/200

REVISION LIST OF THE MANUAL

Rev. /DATE. REVISION DESCRIPTION

01/2004-07 First edition

02/2005-07 Addition of Chapter 8

03/2010-11 Adaption to new Corporate Design

04/2011-01 Addition of Chapter 5

SYSTEM VERSION

COPYRIGHT

Copyright 2010, Human GmbH, Wiesbaden, Germany. All rights reserved.

No part of this documentation may be reproduced in any form, nor processed, copied or distribut-

ed by means of electronic systems, without prior permission of Human GmbH in writing. Since all

precautionary measures were taken into account in producing these operating instructions, the

manufacturer accepts no responsibility for any errors or omissions. This includes any liability for

damage that could arise from possible incorrect operation based on this information. Subject to

changes without notice as result of technical development.

SERVICE UND SUPPORT

CONTENTS

TABLE OF CONTENTS

1 SAFETY INSTRUCTIONS 5

1.1 INTRODUCTION 5

1.2 USER WARRANTY 5

1.3 INTENDED USE OF THE INSTRUMENT 5

1.4 GENERAL SAFETY WARNINGS 6

1.5 DISPOSAL MANAGEMENT CONCEPT 6

1.6 BIOHAZARD WARNING 7

1.7 INSTRUMENT DISINFECTION 7

2 SYSTEM INTRODUCTION 11

2.1 INTRODUCTION 11

2.2 CHARACTERISTICS 11

2.3 SPECIFICATIONS 12

2.4 FUNCTIONAL DESCRIPTION 13

2.4.1 Process Management 13

2.4.2 Liquid Handling 14

2.4.3 Carousels, Temperature Control and Cooling 17

2.4.4 Measurement System 20

3 ELECTRONICS 23

3.1 INTRODUCTION 23

3.2 SCHEMATIC DIAGRAM OF ELECTRONICS 23

4 SERVICE SOFTWARE “EULY SERVICE” 25

4.1 INTRODUCTION 25

4.2 INSTALLATION OF EULY SERVICE 25

4.3 SERIAL SETTINGS 25

4.4 SCRIPT 25

4.4.1 Example for a reading through Euly Service Script 31

4.5 REAGENTROTOR 31

4.6 CUVETTEROTOR 31

4.7 BELT 31

4.8 PIPETTOR 32

4.9 EULYTEST 32

4.10 ENDURANCE TEST 32

4.11 DEVICE DATA 32

4.12 FW UPDATE 32

4.13 PHOTO 32

4.14 PUMPS-VALVES 32

4.15 INFO 32

5 MAINTENANCE 33

5.1 INTRODUCTION 33

5.2 SYRINGES 33

5.3 SYRINGE VALVES 33

5.4 TUBINGS 33

5.5 PHOTOMETER 34

5.6 X-DRIVE 34

5.7 Z-DRIVES 34

5.8 LIQUID DETECTION 35

5.9 MAGNETIC VALVES 35

5.10 PROBES 35

5.11 MEMBRANE PUMPS 35

6 TESTS/TROUBLESHOOTING 37

6.1 INTRODUCTION 37

6.2 FUNCTIONAL TESTS 37

6.3 TROUBLESHOOTING 39

6.3.1 Reagent Rotor 39

6.3.2 Cuvette Rotor 40

6.3.3 Belt 42

6.3.4 Pipettor 44

6.3.5 Liquid Detection 45

6.3.6 Liquid Flood 47

6.3.7 Communication 48

7 REPLACEMENT 49

7.1 INTRODUCTION 49

7.2 CAROUSEL UNIT WITH NEW REAGENTROTORSENSOR 49

7.3 CAROUSEL UNIT WITH OLD REAGENTROTORSENSOR

(POTENTIOMETER) 54

7.4 CENTERING MAGNET 59

7.5 COVER 64

7.6 CUVETTE DRIVE MOTOR ASSEMBLY 67

7.7 CUVETTE ROTOR BOARD 71

7.8 MASTER BOARD 72

7.9 PHOTOMETER 74

7.10 PIPETTOR ARM 76

CONTENTS

7.11 PROBES 80

7.12 REAGENT ROTOR CONTROL BOARD 82

7.13 REAGENT ROTOR POTENTIOMETER 83

7.14 SYRINGE PUMPS 89

7.15 WASHING PUMPS 92

8 ADDITIONAL INFORMATIONS 95

8.1 INTRODUCTION 95

8.2 PIPETTOR ARM 95

SAFETY INSTRUCTIONS 5

1 SAFETY INSTRUCTIONS

1.1 IntroductionThis manual is considered part of the instrument and must be available to the

operator and the maintenance personnel. For accurate installation, use and

maintenance, please read the following instructions carefully.

In order to avoid damage to the instrument or personal injury, carefully read

the ”GENERAL SAFETY WARNINGS”, describing the appropriate operating pro-

cedures. Please contact your HUMAN authorised local Technical Service in the

event of instrument failure or other difficulties with the instrument.

1.2 User WarrantyHUMAN warrants that instruments sold by one of its authorised

representatives shall be free of any defect in material or workmanship, provided

that this warranty shall apply only to defects which become apparent within

one year from the date of delivery of the new instrument to the purchaser.

The HUMAN representative shall replace or repair any defective item within this

warranty period at no charge, except for transportation expenses to the point

of repair.

This warranty excludes the HUMAN representative from liability to replace

any item considered as expendable in the course of normal usage, e.g.: lamps,

valves, syringes, glassware, fuses, tubing etc.

The HUMAN representative shall be relieved of any liability under this warranty

if the product is not used in accordance with the manufacturer‘s instructions,

altered in any way not specified by HUMAN, not regularly maintained, used with

equipment not approved by HUMAN or used for purposes for which it was not

designed.

1.3 Intended Use of the InstrumentThe instrument must be used for its intended purpose (see paragraph 2). It must

be operated in perfect technical conditions, by qualified personnel, in such

working conditions and maintained as described in this manual, in the GENERAL

SAFETY WARNINGS. This manual contains instructions for qualified professional

operators.

[IVD]

HumaStar 180 | Service manual

6

1.4 General Safety WarningsUse only chemical reagents and accessories specified and supplied by

HUMAN and/or mentioned in this manual. Place the product so that it has

proper ventilation.

The instrument should be installed on a flat, stationary working surface, that is

free of vibrations.

Do not operate in area with excessive dust.

Operate at temperature and at a humidity level in accordance with the

specifications listed in this manual.

Do not operate this instrument with covers and panels removed.

Use only the power cord specified for this product, with the grounding

conductor of the power cord connected to earth ground.

Use only the fuse type and rating specified by the manufacturer for this

instrument.

The use of fuses with improper ratings may pose electrical and fire

hazards.

To avoid fire or shock hazard, observe all ratings and markings on the

instrument.

Do not power the instrument in environments that are potentially explosive or

at risk of fire.

Prior to cleaning and/or performing maintenance on the instrument, switch off

the instrument and remove the power cord.

Only cleaning materials described in this manual may be used, as other mate-

rials may damage parts. It is recommended to always wear protective clothing

and eye protection while using this instrument.

All warning symbols that appear in this manual must be carefully observed.

1.5 Disposal Management ConceptThe applicable local regulations governing disposal must be observed. It

is the user‘s responsibility to arrange for proper disposal of the individual

components.

All parts which may contain potentially infectious materials must be

disinfected by suitable, validated procedures (autoclaving, chemical treatment)

prior to disposal. Applicable local regulations for disposal must be carefully

observed. The instruments and electronic accessories (without batteries, power

packs etc.) must be disposed of according to the applicable local regulations

for the disposal of electronic components.


Batteries, power packs and similar power sources must be removed from

electric/electronic parts and disposed of in accordance with applicable local

regulations.

1.6 Biohazard WarningAnalytical instruments for in vitro diagnostic application involve the handling

of human samples and controls which should be considered at least potentially

infectious. Therefore every part and accessory of the respective

instrument which may have come into contact with such samples must equally

be considered as potentially infectious.

The „BIOHAZARD“ warning label must be affixed to the instrument prior to first

use with biological material!

1.7 Instrument DisinfectionBefore performing any servicing on the instrument it is very important to

thoroughly disinfect all possibly contaminated parts. Before the instrument is

removed from the laboratory for disposal or servicing, it must be

decontaminated. Decontamination must be performed by authorised well-

trained personnel, and in observance of all necessary safety precautions.

FIGURE 1

Biological Hazard

Symbol


8


Notes:


10

SYSTEM INTRODUCTION 11

2 SYSTEM INTRODUCTION - Characteristics, Specifications & Performance

- Functional Description

2.1 IntroductionHumaStar 180 is a fully automated, random access Clinical Chemistry Analyser

for wet chemistry applications. It has an open structure, so that reagents from

most manufacturers can be used on the system.

HumaStar 180 is computer controlled and uses the Software Package „DETect“

for data reduction and result evaluation.

HumaStar 180 has been developed in a way as to maximise throughput at

maximum comfort, and at the same time to minimise maintenance efforts to be

taken by the user.

HumaStar 180 is fitted with a patented, maintenance free measuring street,

featuring 20 photometer channels for individual wavelength selection and

maximum flexibility.

2.2 Characteristics

Access Modes: - Random Access

- Stat (immediate access and execution)

Processing Modes: - Patient by Patient

- Test by Test

Analysis Modes: - Endpoint (Substrates)

- Kinetic (Enzymes)

- Initial Rate (fixed time kinetics)

- Serum Blank (differential)

- Turbidimetric (immunoturbidimetry)

- Multi Standard (quantitative)

- Bichromatic

- Multi Chemistry

- Intermethodes Calculation (mathematical)


12

2.3 Specifications

Throughput: - around 150 Tests/hr under speed – optimised

conditions

Carousel: - 25 reagent positions (with SW update up too

50 positions)

- 25 sample positions (random access)

- 25 serum cup positions (minimum 300μl

volume)

- 300 test positions (75x4 cuvettes)

- Customized carousels available !

Liquid Handling: - 2 independent Syringes:

Sample: 1 - 200μl in 1μl steps

Reagent: 1 - 900μl in 1μl steps

- CV less 2,0% for Volumes > 10μl

- High pressure washing

- Autocleaning

- Backflush function

- Easy maintenance

Measurement System: - Maintenance Free !

- Light sources: LED

- Detectors: Photodiodes

- Temperature controlled

- 5 inbuilt photometers, 4 channels each

- 20 independent channels

- up to 20 different wavelegths at a time

- Wavelength range: 340 – 900 nm

- Standard filters:

- 340, 405, 505, 546 & 620nm (4 each)

- Resolution: 0,0001 ABS

- Accuracy: <1% CV at 1ABS / 405nm

- Linearity: 0.0000 – 3.0000 OD better than +/- 1%

- Drift: less than 0.001 OD / hr

Temperature Control: - Reagent cooling (ambient minus 10°C)

- (water circulation w/ external cooler)

- Cuvette heating (electrical) in carousel and

- reading path: 37°C

- Liquid heating (electrical) in probes

TABLE 1


Power Requirements: - 85-264V, 50/60 Hz (autodetecting)

- Power Consumption: max 150 VA

- Mains Fuse: 2 x 2A T (slow blow)

Measures: - Dimensions: 810 x 550 x 550 (w x d x h)

- Weight: 28kg

Environmental: - Operation: 18 - 35°C, 10 - 90% rel. Hum.

- Storage: -40°C – 70°C, 5 – 95% rel. Hum.

Options: - External ISE module f. electrolytes

- Handheld Barcode Reader f. pos. Sample ID

Disposables: - Cuvette block for 4 tests each

(typical reading volume 200μl)

- Reagent bottles

- Serum Cups (1,5ml-minimum volume 300μl)

Overvoltage Cat.: II

Pollution Degree: 2

Method of Disposal: - Contaminated Waste

Usage: - Commercial

2.4 Functional DescriptionThe Clinical Chemistry Analyser “HumaStar 180” comprises the following main

functional units:

- Process Management

- Liquid Handling

- Carousels

- Temperature control

- Cooling (optional)

- Measurement System

- DETect Software package

The following explains the functions of all these units, as well as their

interference within eachother.

2.4.1 PROCESS MANAGEMENT

The working principal of HumaStar 180 is based on a

modular system, which is controlled by a PC via the Process Manager (inbuilt in

HumaStar 180).


14

Each module is fitted with it’s own “intelligence” and functions as a slave to the Process

Manager. The process manager is connected to a PC via RS 232 and receives his orders from DETect

Software package running on the PC. When a process is started on DETect (e.g.: testing a sample

for certain paramters), DETect cuts the complete process into the required steps:

- Washing the probes

- Pipetting the reagent(s)

- Pipetting the sample

- Mixing

- Incubating

- Reading

These process steps are sent to the process manager in the instrument, one at a time, exactly

whenappropriate. The process manager himself distributes the necessary commands to the

modules. The modules “fulfill the order” and report back to the process manager, which himself

provides DETect with the actual status accordingly.

2.4.2 LIQUID HANDLING

The functional unit “Liquid Handling” consists of two independent Liquid paths, one for Sample

pipetting and one for Reagent pipetting. All involved electrical components such as drive motors,

valves and syringes are connected to and controlled by the central Process Manager.

SystemLiquid

X Movement

Z Movement

Waste

Valve Positions:

VP a

VP b

VP c

1

3

2

4

5

6

78

109

11

12

14

13

FIGURE 2

Liquid Path


Explanation:

1 System Liquid Bottle 6 Probe w. liquid detection 11 Wash Station

2 Membrane Pump 7 Cuvette 12 Splitting Valve

3 Syringe 3-way Valve 8 Reagent Container 13 Waste Membrane Pump

4 Syringe Pump & Syringe 9 Primary Sample Tube 14 Waste Bottle

5 Syringe Pump Drive 10 Serum Cups

Both liquid paths are built up identical, with the only difference of the size of the

syringes and the probes:

Syringe: 1ml for Reagent path

250 μl for Sample path

Probe: 0.5 mm inner diameter for Reagent path

0.4 mm inner diameter for Sample path

X- and Z – movement are realised by the pipetting arm, which holds the

probes and the probes drives, together with all necessary motors, sensors and

electronics.

2.4.2.1 Pipetting cycle

The system is able to pippete reagents in either single- or multi pipetting mode.

Multipipetting mode means that, a multiple of the required reagent volume per

test of one reagent will be aspirated and then be distributed into the different

target containers (cuvettes) accordingly.

A complete pipetting cycle incorporates the following steps:

Single Pipetting (Sample or Reagent)

Wash probe

- move probe in Z direction into wash station

- flush with System liquid for a pre-defined time span

- lift probe in Z direction to top position

Pick up source liquid

- move probe in X direction to source container (reagent container, sample

tube or serum cup)

- move probe in Z direction into source container until liquid is detected

- aspirate the required test volume (driven by syringe pumps)



16

REAGENT Pipetting:

Pipette liquid into target container

- move probe in X direction to target container (Cuvette)

- move probe in Z direction into target container

- pipet required test volume into target container


SAMPLE Pipetting:

Pipette liquid into target container

- move probe in X direction to target container (Cuvette)

- move probe in Z direction into target container until liquid is detected

- pipet required test volume into target container

- mix by aspirating and re-pipetting


Move probe in X direction to home (Washstation)

Multi Pipetting (Reagent only)

Wash probe

- move probe in Z direction into wash station

- flush with System liquid for a pre-defined time span


Pick up source liquid

- move probe in X direction to source container (reagent container)

- Move probe in Z direction into source container until liquid is detected

- aspirate a multiple of the required test volume (driven by syringe pumps)


Pipet liquid into target container

- move probe in X direction to target container 1 (Cuvette)

- move probe in Z direction into target container 1

- pipet required test volume into target container 1


- move probe in X direction to target container 2 (Cuvette)

- Move probe in Z direction into target container 2

- pipet required volume into target container 2


- repeat for target containers 3 - n

Move probe to home (Washstation)


2.4.3 CAROUSELS, TEMPERATURE CONTROL AND COOLING

HumaStar 180 is using two Carousels, the Inner and the Outer Carousel. Both

carousels are directly connected to and controlled by the central Process

Manager.

- The INNER Carousel for carrying Samples, Reagents, Standards,

Calibrators and Controls. The inner carousel can optionally be cooled. This

option comprises an external cooling unit and cooled liquid is circulated

underneath the inner carousel.

- The OUTER Carousel for carrying the disposable Cuvettes. The outer carousel

is temperature controlled to 37° C (standard).

Outer

Inner

2.4.3.1 Inner Carousel

The inner carousel can easily be removed for loading.

1

2

3

*2 Controls, marked as C1 and C2

10 Standards / Calibrators marked as S1, S2 ... S10 (if less or no Std/Cal are used, these positions can be used for additional Samples)

13 free positions marked as 26, 27 ....... 48

FIGURE 3

Carousels, loaded, inside

Instrument

Please refer to Chapter 2 for

instructions on how to re-

move, load and replace the inner

carousel.

The Inner Carousel features:

1 25 Positions for Reagents,

marked as 1, 2 ... 25

2 25 Positions for Primary

Sample Tubes, marked as

1, 2 ... 25

3 25 Positions for Serum

Cups for:*

FIGURE 4

Inner Carousel


18

Empty Bottles can be ordered from Human:

Cat. number 16900/2

max 10,5 mm

1.5 ml Serum Cups can be ordered from Human:

Cat. number 16904

2.4.3.2 Outer Carousel

The outer carousel can not be removed for loading. Graph 1.17 just gives a better

impression of what the outer carousel is like.

The Outer Carousel features

75 Positions for Cuvette Blocks

Each Cuvette Block contains 4 Cuvettes, for

one test each.

Total loading volume: Cuvettes for 300

Tests. These Cuvette Blocks are unique

and can only be ordered from Human:

Cat number 16900/1

2.4.3.3 Functions of the Carousels

Temperature control of Outer Carousel

The temperature control of the outer carousel is effected by thermo resistors,

connected to an electronic regulating circuit. Together with temperature

sensitive sensors connected to the same regulating circuit, a stable temperature

is provided to the cuvettes throughout the whole test run.

FIGURE 5

Reagent bottle

FIGURE 6

Serum cup

FIGURE 7

Outer Carousel

FIGURE 8

Cuvette Block


Cooling Option of Inner Carousel

The cooling of the inner carousel is effected by cooled water circulating un-

derneath the inner carousel, within a closed spiral copper tube. This copper

tube is connected to an external cooling generator, the system is closed and

independent from a tap water connection.

Insulation

In order to prevent temperature – interferences between the (optionally) cooled

inner and the temp. controlled outer carousel, an insulation ring is dividing the

two carousels.

Rotation

Both Carousels are controlled and rotated independently, within a co-axial

mechanical system.

Besides keeping samples, reagents and test containers in stable temperature

environment, actually the main function of the carousels is to provide the

Y – movement of the source and target containers within the pipetting and

measuring system of HumaStar 180.

The carousels are rotated while other processes within the complete system are

being performed. By doing so, the time required for rotating and positioning the

carousels is not a critical factor in terms of process time and throughput.

The Inner Carousel is only to be rotated during pipetting steps, as described

under 2.4.3.

It is rotated in either clockwise or counter clockwise direction and provides the

source containers required for a specific pipetting step to be positioned precisely

underneath the probes.

The Outer Carousel is to be rotated during pipetting steps as described under

2.4.3.

Additionally, the outer carousel is to be rotated during measurement steps as

described under 2.4.4

For pipetting, it is rotated in either clockwise or counter clockwise direction

and provides the target containers required for a specific pipetting step to be

positioned precisely underneath the probes.

For measurement steps, it is rotated in either clockwise or counter clockwise

direction and provides the target containers required for the measurement step

to be positioned precisely at the entrance position of the Linear Photometer

street.


20

2.4.4 MEASUREMENT SYSTEM

HumaStar 180 is fitted with a unique Linear Photometer, featuring 20 independent measurement

channels for fast and accurate reading of test results in the cuvettes.

These 20 channels are organised in 5 groups of 4 channels each, whereas each group of 4 channels

is controlled by two electronic boards: One light emitting board and one detection board. These

are directly connected to the central Process Manager

Each of the 5 light emitting boards is fitted with 4 light sources (LED, light emitting diodes) and

the respective control electronics.

Each of the 5 detection boards is fitted with 4 detectors (Silicon Diodes) and the respective signal conver-

ter electronics, as well as with a RS 232 port which connects it with the Process Manager.

1 Cuvette block in Reading Position

Cuvettes in outer carousel

Cuvette Transport

Motor

Cuvette TransportBelt

Cuvette TransportNotch

Light emitting board

Detection board

Light source "LED"

Optics (lens)

Optics (lens)

Interference Filter

Detector

Cuvette Block

Light beam

FIGURE 9

Measurement

system


For reading, the cuvette block is transported from the outer carousel through the

linear photometer by a transport belt.

Depending on the wavelength required for the measurement, the cuvette block

will be positioned into the 4 light beams of the respective photometer block.

The light emitted by the LED’s is directed through a focusing lens. This lens

ensures a light beam, which is as parallel as required for having homogenous

measurement conditions.

While passing the cuvettes, respectively the liquid in the cuvettes, a part of the

light energy is being absorbed by the liquid in the cuvette. The remaining light

energy is now passing another lens and the respective interference filter and is

then being measured by the detectors.


22

ELECTRONICS 23

3 ELECTRONICS - Schematic Diagrams

3.1 IntroductionThis chapter gives information on the electrical and electronical components of

the Human system.

3.2 Schematic Diagram of ElectronicsFIGURE 10


24

FIGURE 11

SERVICE SOFTWARE “EULY SERVICE” 25

4 SERVICE SOFTWARE “EULY SERVICE”

4.1 IntroductionThis chapter gives the instructions on how to test functionality of all

independent modules of HumaStar 180 by using the Service Software

“EulyService”.

4.2 Installation of Euly ServiceEULY SERVICE REQUIRES EXCEL 2000 ™ and will not work with older versions !

Copy the Service-Software-Folder to your local harddrive.

Start Microsoft Excel ™.

Open the file “EulyService.xls”.

Activate macros (set the security-level accordingly).

Microsoft Excel ™ will display a new Menu point “EulyService”.

4.3 Serial SettingsSet the serial port by selecting the menucommand “EulyService” -> “Serial

Settings”.

4.4 ScriptA script consists of a string of commands, which are explained in this section of

the Service manual.


26

The menucommand “EulyService” -> “Script” launches displays the following

screen.

List of prede-

fined saved

scripts, if

there is any

Contents of

predefined

saved scripts,

if there is any

Result window of

tests performed

In the list „Scripts:“ a script can be selected.

In the field „Scripttext:“ the text of the selected script is shown.

In the field „Iterations:“ the number of iterations can be entered.

By clicking „Start“ the selected script is started.

In the field „Result:“ the results are shown.

By clicking „Stop“ the script is stopped.

Script features a command set that allows service personnel to check and

confirm functionality of modules of HumaStar 180. Every single module and it’s

sub-functions can be checked independently.

Script requires command strings that determine the module, the subfunction

and the actual command for the respective function.

A command – string consists of:

- Module Code

- Command

- Parameter

The Module codes, Commands and Parameters are explained on the following

pages (all letters are case sensitive !)

When processing commands,

Euly Service does not check

for sensors ! It is the responsibili-

ty of the Service engineer to make

sure, that only command strings

are being entered, that can not

damage mechanical parts.

FIGURE 12

EuLy Service Script

Screen


IMPORTANT NOTES:

Before starting X-movement of the pipetting arm, both probes must be in top

position !

Commands: “ Zi “ (initialises left Probe) and “ Zj “ (initialises right Probe)

Before starting Cuvette Rotor movements, make sure the Belt drive is

initialised! Command: “ Mi ”

Photometer Belt Movements: positioning within the photometer is only

possible after switching all LED’s on, and initialise Belt.

Command: Xh (where X here stands for the photometer number 1 – 5)

Command: Mi to initialise Belt


28

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ps a

lway

sre

quir

e in

itia

lisa

tion

first

!

FIGURE 13


Photo

meter

drive

M

Get V

ersio

nv

gives

firmw

are v

ersio

n of m

odule

Mv

Get S

tate

ggiv

es st

atus o

f mod

uleMg

Initia

lise

ipo

sition

belt i

n vali

d pos

ition

Mi

Posit

ionx

move

cuve

tte to

a (0

-6) fr

om b

(0-5

) (*)

Mxa ,b

(*)

Modu

leMo

d. Co

deMo

dule

Func

tion

Comm

and

Para

meter

Effec

tCo

mman

d Strin

g:

0 = R

otor

1 = P

hotom

eter 1

2 = P

hotom

eter 2

3 = P

hotom

eter 3

4 = P

hotom

eter 4

5 = P

hotom

eter 5

6 = W

aste

dispo

sal

Pipe

ttor X

drive

X

Get V

ersio

nv

gives

firmw

are v

ersio

n of m

odule

Xv

Get S

tate

ggiv

es st

atus o

f mod

uleXg

Initia

lise X

-driv

ei

Initia

lises

X -

drive

to w

ash p

ositio

nXi

(with

comm

a !)

a ,b

X-po

sition

n

move

arm

to X-

Posit

ion (0

- 10

) (*)

Xna

a(*)

10 = 9 =

8 = 7 =

6 =

5 =

4 =

3 =

2 = 1 = 0 =

Spl p

robe

at se

rum

cup p

os.

Spl p

robe

at pr

im. tu

beRe

ag pr

obe a

t Rea

g bttle

Reag

prob

e at C

uvPo

s 4Re

ag pr

obe a

t Cuv

Pos 3

Reag

prob

e at C

uvPo

s 2Re

ag pr

obe a

t Cuv

Pos 1

Spl p

robe

at C

uvPo

s 4Sp

l pro

be at

Cuv

Pos 3

Spl p

robe

at C

uvPo

s 2Sp

l pro

be at

Cuv

Pos 1

both

probe

s at W

ashp

os

Cuve

tte ro

torC

Get V

ersio

nv

gives

firmw

are v

ersio

n of m

odule

Cv

Get S

tate

ggiv

es st

atus o

f mod

uleCg

Get P

ositio

np

gives

posit

ion of

Cuv

ette R

otor (

1 - 75

)Cp

Goto

Posit

ionx

move

s Cuv

ette R

otor t

o pos

a (1

- 75

)Cx

aa

Reag

ent T

ray

R

Get V

ersio

nv

gives

firmw

are v

ersio

n of m

odule

Rv

Get S

tate

ggiv

es st

atus o

f mod

uleRg

Get P

ositio

np

gives

posit

ion of

Rea

gTra

y (1 -

25)

Rp

Goto

Posit

ionx

move

s Rea

gTra

y to p

os a

(1 -

25)

Rxa

a

Befor

e cuv

ettes

can b

e mo

ved /

posit

ioned

with

in the

photo

meter

, the L

ED's

must

be tu

rned o

n:->

See

follo

wing

page

This

step r

equir

esini

tialis

ation

first

Prob

e Z dr

iveZ

Get V

ersio

nv

gives

firmw

are v

ersio

n of m

odule

Zv

Get S

tate

ggiv

es st

atus o

f mod

uleZg

Initia

lise L

eft P

robe

iIni

tialis

es le

ft pro

be to

top p

ositio

nZi

Initia

lise R

ight P

robe

jIni

tialis

es rig

ht pr

obe t

o top

posit

ionZj

Z-po

sition

left P

robe

lmo

ve le

ft pro

be to

pos.

xxxx

(0 -

1200

)Zlx

xxx

Z-po

sition

right

Prob

er

move

rigth

prob

e to p

os. x

xxx (

0 - 12

00)

Zrxx

xx

xxxx

xxxx

Left P

robe

to liq

uidm

left p

robe

to liq

uid, a

step

s into

liquid

, bu

t max

b ste

ps (1

mm =

10 st

eps)

Zma,b

a ,b(w

ith co

mma !

)

Righ

t Pro

be to

liquid

nrig

ht pr

obe t

o liqu

id, a

steps

into

liquid

, bu

t max

b ste

ps (1

mm =

10 st

eps)

Zna,b

a ,b(w

ith co

mma !

)Th

ese s

teps r

equir

eini

tialis

ation

of th

e re

spec

tive m

odule

first

FIGURE 14


30

Phot

omet

er 1

- 5

1 - 5

Get V

ersio

nv

gives

firm

ware

ver.

of P

hoto

met

er X

(1-5

)Xv

Get S

tate

ggiv

es st

atus

of P

hoto

met

er X

(1-5

)Xg

Mod

uleM

od. C

ode

Mod

ule F

uncti

onCo

mm

and

Para

met

erEf

fect

Com

man

d St

ring:

Get O

D va

lues

agiv

es re

ading

of a

ll 4 c

hann

els o

fPh

otom

eter

X (1

-5)

Xa

LED

powe

r on

htu

rns o

n LE

D's o

f Pho

tom

eter

X (1

-5)

Xh

LED

powe

r off

dtu

rns o

ff LE

D's o

f Pho

tom

eter

X (1

-5)

Xd

Phot

omet

er O

ffset

oOf

fset P

hoto

met

er X

(1-5

)Xo

Dark

Rea

ding

cRe

ad a

nd st

ore

dark

value

of P

hoto

m X

(1-5

)Xc

Read

OD

mre

ad O

D in

Phot

omet

er X

(1-5

)Xm

This

com

man

d se

t allo

ws to

mak

e re

ading

s "m

anua

lly".

In o

rder

to m

ake

a re

ading

, the

follo

wing

step

s mus

t be

pero

rmed

in e

xactl

y this

ord

er (f

or e

ach

phot

omet

er in

dividu

ally)

:

1.

LED

pow

er o

ff

2. S

leep

for 5

00 m

illise

cond

s (th

is is

requ

ired

to e

nsur

e th

ere

is no

mor

e lig

ht e

mitte

d)

3. P

hoto

met

er O

ffset

4.

Dar

k Rea

ding

5.

Slee

p fo

r 300

ms (

requ

ired

to fin

ish d

ark r

eadin

g)

6. L

ED p

ower

on

7.

Slee

p fo

r 600

00 m

illise

cond

s (th

is is

requ

ired

to m

ake

sure

the

LED'

s are

stab

le)

8.

Rea

d OD

9.

Get

OD

value

s To

repe

at a

read

ing, o

nly st

eps 8

and

9 n

eed

to b

e re

peat

ed.

Wait

Wwa

it for

xxxx

x m

illise

cW

xxxx

x (

NO m

odule

code

!!)

xxxx

x

In th

is ta

ble,

the

mod

ule

is d

eter

min

ed b

y a

num

ber

from

1 -

5, w

hich

sta

nd fo

r Ph

otom

eter

1 to

Pho

tom

eter

5Th

e ta

ble s

hows

an

"X" f

or

the

resp

ectiv

e ph

otom

eter

nu

mbe

r

FIGURE 15


4.4.1 EXAMPLE FOR A READING THROUGH EULY SERVICE SCRIPT

The following commandset can be entered line after line, before starting the

actual reading. When saving the commandset as a script, this commandset will

be available for later tests as well:

After the command set has been entered and maybe stored as a script, select the

“Start”, button and one command after the other will be sent to the instrument.

During processing all steps, the feedback from the instrument will be displayed

in the Result Window of Euly Service.

4.5 ReagentRotorMenucommand for adjusting and testing the Reagent Rotor.

4.6 CuvetteRotorMenucommand for adjusting and testing the Cuvette Rotor.

4.7 BeltMenucommand for adjusting and testing the Belt.

FIGURE 16

Commandset for reading

with Photometer 1.


32

4.8 PipettorMenucommand for adjusting and testing the Pipettor.

4.9 EulyTestMenucommand for testing the liquid detection.

4.10 Endurance TestMenucommand for testing the instrument.

4.11 Device DataMenucommand for reading and saving the Device Data.

4.12 FW UpdateMenucommand for updating the firmware.

4.13 PhotoMenucommand for testing the Photometer.

4.14 Pumps-ValvesMenucommand for testing the Pumps and Valves.

4.15 InfoMenucommand for displaying program information.

MAINTENANCE 33

5 MAINTENANCE

5.1 IntroductionThis chapter gives information on maintenance procedures for the Eurolyser sy-

stem. The required maintenance varies with usage of the Eurolyser system. The-

refore the following recommendations are only general guidelines and should

be adapted according to the needs.

5.2 SyringesReasons to change the part:

- The Syringe Seal looks worn.

- Leakage of the Syringe.

- At least once a year.

Remarks:

You can either change the Syringe Seal or the complete Syringe. If you change

only the Syringe Seal change the whole Syringe every forth time.

5.3 Syringe ValvesReasons to change the part:

- Leakage of the Syringe Valve.

- Continued formation of drops on the corresponding probe.

5.4 TubingsReasons to change the part:

- The Tubings look worn.

- Leakage of the Tubings.


34

5.5 PhotometerReasons for maintenance of the part:

- The Photometer is dirty.

- At least once every 6 months.

Instructions:

1. Clean the wall of the photometer with a small amount of glass cleaner on a

cotton wool stick.

2. Perform a Belt Adjust (either with the Service Software or with the

Application Software).

5.6 X-DriveReasons for maintenance of the part:

- The X-Positioning is not accurate (e.g. small (unwanted) movements on a

certain position).


Instructions:

1. Clean the spindle and the two axis (use only alcohol) with a cotton wool stick.

2. Lubricate spindle and axis with a small amount of the Special Lubricant

(BE1072).

5.7 Z-DrivesReasons for maintenance of the part:

- The Z-Positioning is not accurate (e.g. small (unwanted) movements on a

certain position).


Instructions:

1. Clean the spindle (use only alcohol) with a cotton wool stick.

2. Lubricate spindle and axis with a small amount of the Special Lubricant

(BE1072).

MAINTENANCE 35

5.8 Liquid DetectionReasons for maintenance of the part:

- The Liquid Detection is not accurate (e.g. sometimes aspiration of air due to

a too high position).


Instructions:

1. Clean the leads of the probe cables and use an electronic contact spray in

order to have a low resistant contact.

2. Perform a Liquid Detection Adjust with the Service Software.

5.9 Magnetic ValvesReasons to change the part:

- Leakage of the Magnetic Valve.

- Magnetic Valve does not open.

- Preventive Maintenance.

- At least every second year.

5.10 ProbesReasons for maintenance of the part:

- Probe is blocked.

Instructions:

1. Use the Cleaning Set Reagent & Sample Probe.

5.11 Membrane PumpsReasons for maintenance of the part:

- Leakage of Membrane Pump .

- Bad performance of Membrane Pump.

- Preventive Maintenance.

Instructions:

1. Disassemble the pump header.

2. Replace the Membrane.

3. Clean the parts of the pump header.

4. Assemble the pump header.


36

TESTS/TROUBLESHOOTING 37

6 TESTS/TROUBLESHOOTING

6.1 IntroductionThis chapter gives information on testing components of the Human system.

6.2 Functional TestsGeneral EulyService-Scripts for Testing:

- AllState: Shows the State of all moduls.

- AllVersion: Shows the firmware-version of all moduls.

- Reset: Resets the instrument / stops all movements.

Sensors:

Start EulyService-Script “SensorTest” with 1000 iterations. Check the state of the

doorsensor, cuevettesensor, button and liquidsensors.

Reagentrotor:

Insert empty tray on the reagentrotor.

Select menucommand „EulyService“ -> „ReagentRotor“ and click „Test Digital“.

Start EulyService-Script „ReagRotorTest1“.


Insert full tray on the reagentrotor.



Cuevtterotor:

Select menucommand „EulyService“ -> „CuevetteRotor“ and click “Test Digital”.

Start EulyService-Script „CuvRotorTest1“. All positions are positioned in both

directions.

Select menucommand „EulyService“ -> „CuevetteRotor“ and click „Test Sensor“.

Cuevettesensor is tested with and without cuevettes.

Insert a cuvette on position 1 (marked with 2 dots) and remove all other cuvettes.

Start EulyService-Script „CuvRotorTest5“.


38

Pipettor:

Start EulyService-Script „PipettorSensorTest“ with 1000 Iterations. Open and

close the pipettor and check the results.

Start EulyService-Script „PipettorXTest“. Positions the X-drive.

Fill traypositions R2 and S2 with water (traypositions R1 and S1 have to be

empty). Select menucommand „EulyService“ -> „EulyTest”.

Enable “LiquidDetection”.

Click „Start“.

Check results on sheet „EulyTest“.

Dispenser:

Start EulyService-Script „DispenserTest“. Initalizes the dispenser.

Pumps and Valves:

Select menucommand “EulyService” -> “Pumps-Valves”.

Switch the pumps and valves on and off.

Photometerstreet:

Start EulyService-Script „PhotoLEDsOn“. Switches on the photometer-LEDs.

Insert a cuvette on position 1 (marked with 2 dots).

Start EulyService-Script „BeltTest1“. The cuevette is positioned to all

photometer-modules.

Endurance Test:

Fill traypositions R2 and S2 with water. Empty all other sample-positions and R1.

Insert a cuvette filled with water to position 1 (marked with 2 dots) of the

cuvette rotor.

Select menucommand „EulyService“ -> „EnduranceTest“.

Click „Start“.

Check results on sheet „EnduranceTest“.


6.3 Troubleshooting

6.3.1 REAGENT ROTOR

Step Check Result Action

1 Is the green LED on? No Switch on the instrument.No Control the mains cable.No Control the mains voltage.

No Control the mains fuses.No Control the master board fuses.Yes Proceed with step 2.

2 Start EulyService-Script AllState.

Is the message displayed on Result: „Error occured processing 0g: Timeout...“?

Yes Go to Communication Trouble-shooting Table

No Proceed with step 3.3 Is the message displayed on

Result: „... R: State: BUSY ...“?Yes Replace reagent-flat-cable.

Yes Replace reagent rotor control board.Is the message displayed on Result: „... R: State: READY ...“?

Yes Proceed with step 4.

4 Yes Start EulyService-Script Reset. Try to move the rotor manually.

Is manual movement possible? No Remove possible blocking.No Replace carousel unit.Yes Proceed with step 5.

5 Start EulyService-Script ReagFastCW.Does the rotor move in clockwise direction?

No Replace reagent rotor control board.

No Replace carousel unit.Yes Start EulyService-Script ReagSlowCW.

Does the rotor move in counter-clockwise direction?


No Replace carousel unit.Yes Start EulyService-Script ReagSlowCCW.

Does the rotor move in counter-clockwise direction?


No Replace carousel unit.Yes Proceed with step 6.

Switch off the power before

changing any electronicmo-

dule or connecting or disconnec-

ting any cable. Wait 5 seconds

after switching on the power

before starting any command.

TABLE 2


40

Step Check Result Action6 Select menucommand EulyService-

>ReagentRotor and click Test Digital.Is the test ok? No Replace carousel unit. Yes Proceed with step 7.

7 Select menucommand EulyService->ReagentRotor and click Adjust. (not required with new Reagentrotorsensor)

Does the adjustment fail? Yes Replace carousel unit. No Proceed with step 8.

8 Select menucommand EulyService->ReagentRotor and click Adjust Digital.

Does the adjustment fail? Yes Replace carousel unit. No Proceed with step 9.

9 Start EulyService-Script ReagRotorTest1.Result: "R: State: READY R-Timeout"

Yes Replace carousel unit.

No If the error occurs from time to time replace carousel unit.

6.3.2 CUVETTE ROTOR


1 Is the green LED on? No Switch on the instrument.

No Control the mains cable.

No Control the mains voltage.

No Control the mains fuses.No Control the master board fuses.Yes Proceed with step 2.

2 Start EulyService-Script AllState.Is the message displayed on Result:

„Error occured processing 0g: Timeout...“?Yes Goto Communication

Troubleshooting Table

No Proceed with step 3.

TABLE 3


Step Check Result Action3 Is the message displayed on Result: "... C:

State: BUSY ..."?Yes Replace cuvette-flat-cable.

Yes Replace cuvette rotor board.Is the message displayed onResult: "... C: State: READY ..."?


4 YesStart EulyService-Script Reset. Try to move the rotor manually.

Is manual movement possible? Yes Proceed with step 5. No Remove possible blocking.

NoPut the cuvette rotor motor 2 mm away from the rotor.

Is manual movement possible? No Remove possible blocking. No Replace carousel unit.

YesReplace cuvette drive motor assembley.

5 Start EulyService-Script CuvFast-CW.

Does the rotor move in clockwise direc-tion?

No Replace cuvette rotor board.

NoReplace cuvette drive motor assembley.

No Replace carousel unit.

YesStart EulyService-Script CuvSlow-CW.

Does the rotor move in clockwise direction?




YesStart EulyService-Script Cuv-FastCCW.

Does the rotor move in counter-clock-wise direction?




YesStart EulyService-Script CuvSlowCCW.

Does the rotor move in counter-clock-wise direction?





42



6 Select menucommand EulySer-

vice->CuvetteRotor and click Test

Digital.

Is the test ok? No Replace cuvette rotor board.



7 Select menucommand EulySer-

vice

->CuvetteRotor and click Adjust.

Does the adjustment fail? Yes Replace cuvette rotor board.



8 Start EulyService-Script Cu-

vRotorTest1.

Result:

„C: State: READY C-Timeout“


No If the error occurs from time to

time replace carousel unit.

6.3.3 BELT





No Control the mains fuses.

No Control the master board fuses.



Is the message displayed on

Result: „Error occured processing 0g: Time-

out...“?

Yes Goto Communication

Troubleshooting Table


3 Is the message displayed on

Result: „... M: State: BUSY ...“?

Yes Replace photometer-flat-cable.

TABLE 4


Yes Replace photometer.

Is the message displayed on Result: „... M:

State: READY ...“?


4 Start EulyService-Script BeltFast-

CW.

Does the belt move in clockwise

direction?

No Remove possible blocking.

No Replace photometer.

Yes Start EulyService-Script BeltSlow-

CW.

Does the belt move in clockwise direction? No Remove possible blocking.


Yes Start EulyService-Script

BeltFastCCW.

Does the belt move in counter-clockwise

direction?



Yes Start EulyService-Script

BeltSlowCCW.

Does the belt move in counter-clockwise

direction?




5 Select menucommand

EulyService->Belt and click Adjust

and check results on sheets Belt1

and Belt2.

Does the adjustment fail? Yes Replace photometer.


6 Insert cuvette in outer carussel

position 1. Start EulyService-

Script BeltTest1.

Result: „M: State: READY M-Timeout“ Yes Replace photometer.

No If the error occurs from time to

time replace photometer.


44

6.3.4 PIPETTOR

Step Check Result Action1 Is the green LED on? No Switch on the instrument. No Control the mains cable. No Control the mains voltage. No Control the mains fuses. No Control the master board fuses. Yes Proceed with step 2.2 Start EulyService-Script AllState. Is the message displayed

on Result: "Error occured processing 0g: Timeout..."?

Yes Goto Communication Troubleshooting Table

No Proceed with step 3.3 Is the message displayed

on Result: "... Z: State: BUSY X: State: BUSY ..."?

Yes Replace x-flat-cable.

Yes Replace pipettor arm. Is the message displayed

on Result: "... Z: State: BUSY X: State: READY ..."?

Yes Replace z-flat-cable.

Yes Replace pipettor arm. Is the message displayed

on Result: "... Z: State: READY X: State: BUSY ..."?

Yes Replace pipettor arm.

Is the message displayed on Result: "... Z: State: READY X: State: READY..."?


4 Yes Start EulyService-Script Reset. Try to move the needles manually.

Is manual movement easily possible?


No Remove possible blocking. No Clean the spindles (use only alcohol)

with a cotton wool stick and lubricate the spindles with a small drop of thin oil.

No Replace pipettor arm.

TABLE 5



5 Be sure to have the arm in the front-most position. Start EulyService-Script PipettorTest1.

Is the message displayed on Result: "... Z: State: READY Zx-Timeout"?

Yes Clean the spindles (use only alcohol) with a cotton wool stick and lubricate the spindles with a small drop of thin oil.

Yes Replace pipettor arm. No Proceed with step 6.6 Yes Try to move the z-carriage manually. Is manual movement

possible?Yes Proceed with step 7.

No Remove possible blocking. No Clean the spindle and the two axis (use

only alcohol) with a cotton wool stick and lubricate spindle and axis with a small drop of thin oil.

No Replace pipettor arm.7 Start EulyService-Script PipettorTest2. Is the message displayed

on Result: "... Z: State: READY X-Timeout"?

Yes Clean the spindle and the two axis (use only alcohol) with a cotton wool stick and lubricate spindle and axis with a small drop of thin oil.

Yes Replace pipettor arm. No If the error occurs from time to time

replace pipettor arm.

6.3.5 LIQUID DETECTION








TABLE 6


46




Result: "Error occured processing

0g: Timeout..."?

Yes Goto Communication Troubleshooting

Table



Result: "... Z: State: BUSY X:

State: BUSY ..."?

Yes Replace x-flat-cable.



Result: "... Z: State: BUSY X:

State: READY ..."?

Yes Replace z-flat-cable.



Result: "... Z: State: READY ..."?


4 Make sure to have a low resistant contact

of the probe-cables (clean the leads and

use a electronic contact spray).

5 Select menucommand EulyService

->Pipettor and click Adjust

Liquidsensor....

Is the adjustment successful? No Replace pipettor arm.


6 Start menucommand EulyService ->Euly-

Test. Select Liquid Detection. Click Start

and check the results on sheet EulyTest.

Are the results ok? No Replace pipettor arm.

Yes If the error occurs from time to time

replace pipettor arm.


6.3.6 LIQUID FLOOD


1 Are there any traces of leakage

obvious from outside?


Syringe or valve leakage? Yes Replace the syringe with piston or the

whole syringe pump.

Did a wrong pipettor position

cause the liquid flood?

Yes Goto Pipettor Arm Troubleshooting

Table.

2 Disassemble the cover.

Are there any obvious leakages

in the tubes?

Yes Replace the particular tube or whole

tubing system.

Are there any obvious leakages

in the washing pumps?

Yes Replace the washing pumps.


3 Select menucommand EulyService-

>Pumps-Valves and test the pumps

and valves.

Any obvious leakage? Yes Replace the involved part(s) (tube or

tube system, connector,...).

Overflow at wash station after

some time?

Yes Try to clean the tubes inside with a

longer wash cycle (some minutes) and

cleaning solution.

Yes Replace the whole tubing system.

Yes Replace the washing pumps.

No

TABLE 7


48

6.3.7 COMMUNICATION









Is an error message displayed:

„...Dll-Error: 5...“?

Yes The serial port is opened by another

application. Close all applications.

Restart the computer and try again.



Result:

„Error occured processing 0g:

Timeout...“?

Yes Control the serial or USB cable.

Yes Control the serial port settings.

Yes Close all applications. Restart the

computer and try again.

Yes Replace master board.

TABLE 8

REPLACEMENT 49

7 REPLACEMENT

7.1 IntroductionThis chapter gives information on replacing components of the Human system.

7.2 Carousel Unit with new ReagentrotorsensorDisassembling the Carousel Unit

1. Disassemble the cover (see “Disassembling the Cover”).

2. Disconnect the tubing for cooling from the liquid connection block.

Tubing for cooling

Liquid connection

block

3. Disconnect the reagent-code-flat-cable from the reagent control board.

FIGURE 17


50

4. Disconnect the reagent-position-cable from the reagent control board

Reagent-code-flat-cable

Reagent-position-cable

5. Disconnect the cuvette-temperature-cable (white and brown) from the

master board.

Cuvette-

temperature-cable

6. Disassemble the cuvette rotor board (see “Disassembling the Cuvette Rotor

Board”).

FIGURE 18

FIGURE 19

REPLACEMENT 51

7. Remove the 5 screws on the bottom of the instrument fixing the carousel

unit.

Screws for

carousel unit

8. Remove the carousel unit.

Assembling the Carousel Unit

1. Assemble the carousel unit (tubing for cooling right, all cables back).

2. Fix the carousel unit with 5 screws.

3. Assemble the cuvette rotor board (see “Assembling the Cuvette Rotor Board”).

4. Connect the cuvette-temperature-cable (white and brown) to the master

board.

5. Connect the reagent-position-flat-cable to the reagent control board.

6. Connect the tubing for cooling to the liquid connection block.

7. Adjust the carousel unit (see “Adjusting the Carousel Unit”).

8. Assemble the cover (see “Assembling the Cover”).

Adjusting the Carousel Unit

1. Adjust the centering magnet (see “Adjusting the Centering Magnet”).

2. Select menucommand „EulyService“ -> „CuevetteRotor“.

3. Click „Adjust“.

4. Disconnect the centering-magnet-cable.

5. Start EulyService-Script „CuvRotorTest1“.

FIGURE 20


52

6. Adjust the cuvette rotor board until the cuvette rotor position is aligned with

the photometer.

Open screws for

adjusting cuvette

rotor position

Centering-magnet-

cable

7. Tighten the 2 screws.

8. Connect the centering-magnet-cable.

9. Execute functional test for cuvette rotor.

10. Make sure the Reagentrotor-FW-Version is 22 or higher (check with

EulyService-Script “AllVersion”). If not update the firmware and start the

EulyService-Script “ReagRotor_V2x_EEPROM”.

11. Select menucommand „EulyService“ -> „ReagentRotor“.

12. Click “Adjust Digital” and follow the instructions. See picture for alignment

(e.g. position 1).

FIGURE 21

REPLACEMENT 53

13. Execute functional test for reagent rotor.

FIGURE 22


54

7.3 Carousel Unit with old Reagentrotorsensor (Potentiometer)

Disassembling the Carousel Unit


2. Disconnect the tubing for cooling from the liquid connection block.

Tubing for cooling

Liquid connection

block

3. Disconnect the reagent-code-flat-cable from the reagent control board.

4. Disconnect the reagent-position-cable from the reagent control board.

Reagent-code-flat-cable

Reagent-position-

cable

FIGURE 23

FIGURE 24

REPLACEMENT 55

5. Disconnect the cuvette-temperature-cable (white and brown) from the

master board.

Cuvette-tempera-

ture-cable

6. Disassemble the cuvette rotor board (see “Disassembling the Cuvette Rotor

Board”).

7. Remove the 5 screws on the bottom of the instrument fixing the carousel

unit.

Screws for carousel

unit

FIGURE 25

FIGURE 26


56

8. Remove the carousel unit.

Assembling the Carousel Unit

1. Assemble the carousel unit (tubing for cooling right, all cables back).

2. Fix the carousel unit with 5 screws.

3. Assemble the cuvette rotor board (see “Assembling the Cuvette Rotor Board”).

4. Connect the cuvette-temperature-cable (white and brown) to the master

board.

5. Connect the reagent-position-cable to the reagent control board.

6. Connect the reagent-position-flat-cable to the reagent control board.

7. Connect the tubing for cooling to the liquid connection block.

8. Adjust the carousel unit (see “Adjusting the Carousel Unit”).


Adjusting the Carousel Unit


2. Select menucommand „EulyService“ -> „CuevetteRotor“.

3. Click „Adjust“.

Centering-magnet-

cable

4. Disconnect the centering-magnet-cable.

5. Start EulyService-Script „CuvRotorTest1“.

FIGURE 27

REPLACEMENT 57

6. Adjust the cuvette rotor board until the cuvette rotor position is aligned with

the photometer.

Open screws for

adjusting cuvette rotor

position

7. Tighten the 2 screws.

8. Connect the centering-magnet-cable.

9. Execute functional test for cuvette rotor.

10. Make sure the Reagentrotor-FW-Version is 11 (check with EulyService-Script

“AllVersion”). If not update the firmware (select the file “R25_V11_Adr22.

hex”) and start the EulyService-Script “ReagRotor_V11_EEPROM”.

11. Start EulyService-Script “ReagRotorPosition“ with 1000 Iterations.

FIGURE 28


58

12. Insert tray and align border between position 1 and 25 with photometer.

13. Remove tray.

14. Adjust the centerring until the position shown by EulyService-Script

“ReagRotorPosition” is on the threshold between 1 and

FIGURE 29

FIGURE 30

REPLACEMENT 59

15. Tighten the screws.

16. Insert the tray and test position 1 and 25.


18. Click “Adjust Digital” and follow the instructions.

19. Remove the tray.


21. Click “Adjust” and follow the instructions.


7.4 Centering MagnetAdjusting the Centering Magnet

1. Adjust the distance between the carousel unit and the photometer to a

minimum of 0.3mm. The distance can be varied by moving the carousel unit

and/or by moving the photometer within the holes for the corresponding

screws.

> 0.3mm

2. Adjust the height of the cuvette ring to 0.3mm above the photometer. To

change the height open all 6 screws, rotate the spacing bolts 1/6-rotation

each and tighten the screws. Repeat this until the height is as desired.

FIGURE 31


60

Top of photometer

0.3mm

Top of cuvette ring

FIGURE 32

REPLACEMENT 61

Open screws for adjusting

the height of the cuvette

ring

FIGURE 33


62

Spacing bolts for adjusting

the height of the cuvette

ring

FIGURE 34

REPLACEMENT 63

3. Adjust the height of the centering magnet to the centre of the fixing area on

the cuvette rotor.

FIGURE 35

FIGURE 36


64

Adjust the position of the centering magnet so that the cuvette rotor position is

aligned with the photometer.

Alignment

7.5 Cover

Disassembling the Cover

1. Disassemble the pipettor arm (see “Disassembling the Pipettor Arm”).

2. Disassemble the inlet tubing from the sample syringe pump.

3. Disassemble the inlet tubing from the reagent syringe pump.

Inlet tubing sample

syringe

Inlet tubing reagent

syringe

FIGURE 37

FIGURE 38

REPLACEMENT 65

4. Remove the 6 screws on the bottom of the instrument fixing the main cover.

Screws for main

cover

5. Lift the main cover.

6. Disconnect the doorlock-cable (yellow-brown).

Doorlock-cable

7. Disconnect the syringe-pump-cable from the master board.

FIGURE 39

FIGURE 40


66

8. Disconnect the doorsensor-LED-key-flat-cable from the master board.

Doorsensor-LED-key-

flat-cable

Syringe-pump-

cable

9. Remove the inlet tubings from the main cover.

10. Remove the main cover.

Assembling the Cover

1. Lead the inlet tubings through the main cover.

2. Connect the doorsensor-LED-key-flat-cable to the master board.

3. Connect the syringe-pump-cable to the master board.

4. Connect the doorlock-cable (yellow-brown).

5. Put the main cover on the instrument.

6. Fix the main cover with 6 screws.

7. Assemble the inlet tubing to the reagent syringe pump.

8. Assemble the inlet tubing to the sample syringe pump.

9. Assemble the pipettor arm (see “Assembling the Pipettor Arm”).

FIGURE 41

REPLACEMENT 67

7.6 Cuvette Drive Motor AssemblyDisassembling the Cuvette Drive Motor Assembly


2. Disconnect the cuvette-motor-cable from the cuvette rotor board.

Cuvette-motor-

cable

FIGURE 42


68

3. Unscrew the slug.

Slug

FIGURE 43

REPLACEMENT 69

4. Disassemble the cuvette drive motor assembly (1 screw on the bottom of the instrument).

Screw for cuvette drive

motor assembley

Assembling the Cuvette Drive Motor Assembly

1. Assemble the cuvette drive motor assembly.

FIGURE 44


70

2. Adjust the cuvette drive motor assembly to a pressure of 8N by rotating.

Pressure = 8N

3. Tighten the slug.

4. Connect the cuvette-motor-cable to the cuvette rotor board.

FIGURE 45

REPLACEMENT 71

7.7 Cuvette Rotor BoardDisassembling the Cuvette Rotor Board


Cuvette-flat-cable

Screws for cuvette

rotor board

Cuvette-motor-cable

Centering-magnet-

cable

2. Disconnect the cuvette- flat-cable from the cuvette rotor board.

3. Disconnect the cuvette-motor-cable from the cuvette rotor board.

4. Disconnect the centering-magnet-cable from the cuvette rotor board.

5. Remove the cuvette rotor board (2 screws). Avoid scratching the bottom

surface of the carousel unit.

Assembling the Cuvette Rotor Board

1. Assemble the cuvette rotor board (2 screws).

2. Connect the centering-magnet-cable to the cuvette rotor board.

3. Connect the cuvette-motor-cable to the cuvette rotor board.

4. Connect the cuvette-flat-cable to the cuvette rotor board.

5. Adjust the cuvette rotor (see “Adjusting the Carousel Unit”).


FIGURE 46


72

7.8 Master BoardDisassembling the Master Board


24V-cable Outer-temperature-

cable

Washing-

pumps-cable

Doorlock-

valves-cable

Cuvette-tempera-

ture-cable

Photometer-tem-

perature-cable

Z-24V-cable

Reagent-flat-cable Cuvette-flat-cable

X-flat-cable

X-15V-cable

Cuvette-

sensor-cable

Photometer-

flat-cable

2. Disconnect the 24V-cable from the master board.

3. Disconnect the cuvette-temperature-cable from the master board.

4. Disconnect the outer-temperature-cable from the master board.

5. Disconnect the photometer-temperature-cable from the master board.

6. Disconnect the washing-pumps-cable from the master board.

7. Disconnect the doorlock-valves-cable from the master board.

8. Disconnect the Z-24V-cable from the master board.

9. Disconnect the x-flat-cable from the master board.

10. Disconnect the X-15V-cable from the master board.

11. Disconnect the cuvette-sensor-cable from the master board.

12. Disconnect the photometer-flat-cable from the master board.

13. Disconnect the cuvette-flat-cable from the master board.

14. Disconnect the reagent-flat-cable from the master board.

FIGURE 47

REPLACEMENT 73

Screws for master

board

15. Remove the master board (4 screws on the bottom of the instrument).

Assembling the Master Board

1. Assemble the master board (4 screws on the bottom of the instrument).

2. Connect the reagent-flat-cable to the master board.

3. Connect the cuvette-flat-cable to the master board.

4. Connect the photometer-flat-cable to the master board.

5. Connect the cuvette-sensor-cable to the master board.

6. Connect the X-15V-cable to the master board.

7. Connect the x-flat-cable to the master board.

8. Connect the Z-24V-cable to the master board.

9. Connect the doorlock-valves-cable to the master board.

10. Connect the washing-pumps-cable to the master board.

11. Connect the photometer-temperature-cable to the master board.

12. Connect the outer-temperature-cable to the master board.

13. Connect the cuvette-temperature-cable to the master board.

14. Connect the 24V-cable to the master board.


FIGURE 48


74

7.9 PhotometerDisassembling the Photometer


Photometer-flat-cable

Photometer-tempe-

rature-cable

2. Disconnect the photometer-flat-cable from the master board.

3. Disconnect the photometer-temperature-cable (red and black) from the

master board.

4. Remove the centering magnet.

FIGURE 49

REPLACEMENT 75

Screws for photometer

5. Remove the 8 screws on the bottom of the instrument fixing the photometer.

6. Remove the photometer.

Assembling the Photometer

1. Assemble the photometer.

2. Fix the photometer with 8 screws.

3. Assemble the centering magnet.


5. Connect the photometer-temperature-cable (red and black) to the master

board.

6. Connect the photometer-flat-cable to the master board.


8. Execute functional test for photometer.

FIGURE 50


76

7.10 Pipettor ArmDisassembling the Pipettor Arm

1. Remove the top cover (5 screws below the top cover).

Screws for top cover

2. Disassemble the outlet tubing from the sample syringe pump.

3. Disassemble the outlet tubing from the reagent syringe pump.

Outlet tubing sample

syringe

Outlet tubing reagent

syringe

FIGURE 51

FIGURE 52

REPLACEMENT 77

4. Remove the safety ring.

Cable driller for

Z-24V-cable

Saftey ring

5. Disconnect the Z-24V-cable (red and black) from the Z–drive board.

6. Open the cable driller fixing the Z-24V-cable behind the X-drive board.

7. Disconnect the X-15V-cable (yellow and black) from the X-drive board.

8. Disconnect the X-flat-cable from the X-drive board.

Z-24V-cable

X-flat-cable

X-15V-cable

9. Remove the pipettor arm.

FIGURE 53

FIGURE 54


78

Assembling the Pipettor Arm

1. Assemble the pipettor arm.

2. Connect the X-flat-cable to the X-drive board.

3. Connect the X-15V-cable (yellow and black) to the X-drive board.

4. Lead the Z-24V-cable behind the X-drive board to the Z-drive board and

connect the Z-24V-cable (red and black) to the Z–drive board.

5. Fix the Z-24V-cable with a cable driller behind the X-drive board.

6. Assemble the safety ring.

7. Assemble the outlet tubing to the sample syringe pump.

8. Assemble the outlet tubing to the reagent syringe pump.

9. Assemble the top cover (5 screws).

Adjusting the Pipettor Arm

1. Select menucomand „EulyService“ -> „Pipettor“.

2. Press „Adjust X“ (adjust the needles centred above the holes in the washing-

device).

Needles

Holes in washing-

device

FIGURE 55

REPLACEMENT 79

3. Press „Adjust Z“ (adjust the needles just above the cuvette rotor).

Needles

Top of cuvette

rotor

4. Execute functional test for the pipettor.

FIGURE 56


80

7.11 ProbesDisassembling the Probe

1. Remove the top cover (5 screws below the top cover).

Screws for top cover

2. Disconnect the Z-24V-cable (red and black) from the Z–drive board.

Reagent-probe-cable Sample-probe-cable

3. Disconnect the probe-cable.

4. Open the screws fixing the probe and remove the probe.

FIGURE 57

FIGURE 58

REPLACEMENT 81

Assembling and Adjusting the Probe

1. Connect the probe-cable (shield is middle-connector).

2. Insert the probe into a water-bath with 39°.

3. Switch on power-supply.

4. Select menucomand „EulyService“ -> „Pipettor“.

5. Click „Switch off Temperaturecontrol“.

6. Connect the Z-24V-cable (red and black) to the Z-drive board.

7. Wait 2 minutes.

Shield (middle)

Liquidsensor-sample-

probe-potentiometer

Temperature-reagent-

probe-potentiometer

Liquidsensor-reagent-

probe-potentiometer

Temperature-sample-

probe-potentiometer

8. Click “Adjust Temperature Sample/Reagent Probe”.

9. Switch off power-supply.

10. Take the probe out of the water-bath and assemble on the Pipettor Arm.

11. Switch on power-supply.

12. Click “Adjust Liquidsensor Sample/Reagent Probe”.

13. Assemble the top cover (5 screws).

14. Select menucomand „EulyService“ -> „EulyTest“.

15. Enable “LiquidDetection”.

16. Click “Start”.

17. Check results on sheet “EulyTest”.

FIGURE 59


82

7.12 Reagent Rotor Control BoardDisassembling the Reagent Rotor Control Board


Reagent-flat-cable Reagent-code-flat-

cable

Screws for reagent

rotor control board

Reagent-position-

cable (not present on

all instruments)

2. Disconnect the reagent-flat-cable from the reagent rotor control board.

3. Disconnect the reagent-code-flat-cable from the reagent rotor control board.

4. Disconnect the reagent-position-cable from the reagent rotor control board

(if present).

5. Remove the reagent rotor control board (4 screws). unit.

Assembling the Reagent Rotor Control Board

1. Assemble the reagent rotor control board (4 screws).

2. Connect the reagent-position-cable to the reagent rotor control board (if pre-

sent).

3. Connect the reagent-position-flat-cable to the reagent rotor control board.

4. Connect the reagent-flat-cable to the reagent rotor control board.

5. Adjust the reagent rotor (see “Adjusting the Carousel Unit”).


FIGURE 60

REPLACEMENT 83

7.13 Reagent Rotor PotentiometerDisassembling the Reagent Rotor Potentiometer

1. Remove the cover from the centerring.

2. Remove the 4 screws from the centerring.

FIGURE 61


84

Screws

Centerring

3. Disassemble the centerring.

Coupler

4. Disassemble the coupler.

FIGURE 62

FIGURE 63

REPLACEMENT 85

Reagent rotor potentio-

meter ring

Slug

5. Disassemble the reagent rotor potentiometer ring (fixed with a slug).

Reagent rotor poten-

tiometer

FIGURE 64

FIGURE 65


86

6. Disassemble the reagent rotor potentiometer (by removing the silicon).

Assembling the Reagent Rotor Potentiometer

Wires

Old reagent rotor

potentiometer

New reagent rotor

potentiometer

1. Disconnect the wires from the old reagent rotor potentiometer and connect

to the new reagent rotor potentiometer one by one.

2. Assemble the reagent rotor potentiometer and fix it with silicon.

3. Assemble the reagent rotor potentiometer ring (as low as possible).

4. Assemble the coupler.

5. Assemble the centerring.

Adjusting the Reagent Rotor

1. Start EulyService-Script “ReagRotorPosition“ with 1000 Iterations.

2. Insert tray and align border between position 1 and 25 with photometer.

FIGURE 66

REPLACEMENT 87

3. Remove tray.

4. Adjust the centerring until the position shown by EulyService-Script

“ReagRotorPosition” is on the threshold between 1 and 25.

5. Tighten the screws.

6. Insert the tray and test position 1 and 25.

7. Assemble the cover of the centerring.


FIGURE 67

FIGURE 68


88

9. Click “Adjust Digital” and follow the instructions.

10. Remove the tray.


12. Click “Adjust” and follow the instructions.


REPLACEMENT 89

7.14 Syringe PumpsDisassembling the Syringe Pump

Tubings

Screws for syringe

pumps

Sample syringe

pump

Reagent syringe

pump

1. Disassemble the tubings from the syringe pump.

2. Disassemble the syringe pump (2 screws each).

FIGURE 69


90

Syringe-pumps-

cable

3. Disconnect the syringe-pumps-cable from the syringe pump.

FIGURE 70

REPLACEMENT 91

Assembling the Syringe Pump

Reagent syringe

pump

Sample syringe

pump

Jumper

1. Install the jumpers on the syringe pump according the figure.Connect the

syringe-pumps-cable to the syringe pump.

2. Assemble the syringe pump (2 screws).

3. Assemble the tubings to the syringe pump.

FIGURE 71


92

7.15 Washing PumpsDisassembling the Washing Pumps


2. Disconnect the washing-pumps-cable from the master board.

Washing-pumps-

cable

3. Disconnect the tubings from the washing pumps.

Tubings

FIGURE 72

FIGURE 73

REPLACEMENT 93

4. Disassemble the washing pumps (4 screws on the bottom of the instrument).

Screws for

washing pumps

Assembling the Washing Pumps

1. Assemble the washing pumps (4 screws).

2. Connect the tubings to the washing pumps.

3. Secure the tubings with cable drillers.

4. Connect the washing-pumps-cable to the master board.


FIGURE 74

ADDITIONAL INFORMATIONS 95

8 ADDITIONAL INFORMATIONS

8.1 IntroductionThis chapter gives additional information on the components of the Human

system.

8.2 Pipettor Arm1. Z-Motors:

There are two types of Z-motors, which are from different manufacturers (escap

and maxon)

- Both motors have to be from the same manufacturer

- After either changing the Z-drive-board or the Z-motors start one of the

following EulyService-Script:

- “Z_Enc16_EEPROM” for motor from manufacturer escap

- “Z_Enc32_EEPROM” for motor from manufacturer maxon

2. X-Motor:

There are two types of X-motors, which are from different manufacturers (escap

and maxon)

- After either changing the X-drive-board or the X-motor start one of the

following EulyService-Script:

- “X_Enc16_EEPROM” for motor from manufacturer escap

- “X_Enc32_EEPROM” for motor from manufacturer maxon

There are two types of sensor systems for the reagent rotor:

- No hardware-change of the Reagent Rotor Control Board

1. Potentiometer and reflective sensors:

- Firmware has to be V11

2. Magnet and hallsensors:

- Firmware has to be V22 or higher


96

97

HUMAN

Gesellschaft für Biochemica und Diagnostica mbH

Max-Planck-Ring 21 • 65205 Wiesbaden • Germany

Tel.: +49 6122/9988 0 • Fax: +49 6122/9988 100

eMail: [email protected] • www.human.de

Humastar 180 Service Manual

Documents

select menucommand

applicable

cotton wool

fill traypositions

execute functional

predefined

select menucommand

select menucomand