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 distributed 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 2.4.2 2.4.3 2.4.4
Process Management Liquid Handling Carousels, Temperature Control and Cooling Measurement System
3 ELECTRONICS
13 14 17 20 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 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7
Reagent Rotor Cuvette Rotor Belt Pipettor Liquid Detection Liquid Flood Communication
7 REPLACEMENT
39 40 42 44 45 47 48 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 Introduction This 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 procedures. Please contact your HUMAN authorised local Technical Service in the event of instrument failure or other difficulties with the instrument.
1.2 User Warranty HUMAN 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 Instrument The 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]
6
1.4 General Safety Warnings Use 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 materials 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 Concept The 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.
HumaStar 180 | Service manual
SAFETY INSTRUCTIONS
7
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 Warning Analytical 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!
FIGURE 1 Biological Hazard Symbol
1.7 Instrument Disinfection Before 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 welltrained personnel, and in observance of all necessary safety precautions.
8
HumaStar 180 | Service manual
SAFETY INSTRUCTIONS
Notes:
9
10
HumaStar 180 | Service manual
SYSTEM INTRODUCTION
11
2 SYSTEM INTRODUCTION -
Characteristics, Specifications & Performance Functional Description
2.1 Introduction HumaStar 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: Processing Modes: Analysis Modes:
-
Random Access Stat (immediate access and execution) Patient by Patient Test by Test 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 TABLE 1
Throughput:
-
Carousel:
-
Liquid Handling:
Measurement System:
Temperature Control:
HumaStar 180 | Service manual
-
-
around 150 Tests/hr under speed – optimised conditions 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 ! 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 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: “Serial Settings”.
4.4 Script A script consists of a string of commands, which are explained in this section of the Service manual.
25
26
The menucommand “EulyService” -> “Script” launches displays the following screen. FIGURE 12 EuLy Service Script Screen
List of prede-
Contents of
Result window of
fined saved
predefined
tests performed
scripts, if
saved scripts,
there is any
if there is any
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. When processing commands, Euly Service does not check
Script requires command strings that determine the module, the subfunction and the actual command for the respective function.
for sensors ! It is the responsibility of the Service engineer to make sure, that only command strings are being entered, that can not damage mechanical parts.
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 !)
HumaStar 180 | Service manual
SERVICE SOFTWARE “EULY SERVICE”
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
27
HumaStar 180 | Service manual
Mod. Code
0 (zero)
Module
Master
w
d1
Washer Pumps
Sample Pipettor
d2
These steps always require initialisation first !
Reagent Pipettor
WP off WP off WP ON WP ON WP off WP off WP ON WP ON
MV off MV off MV off MV ON MV ON MV ON MV ON Initialise Move Valve to Input position Move Valve to Output position
0w1 0w2 0w3 0w4 0w5 0w6 0w7 0d1ZR 0d1IR 0d1OR
1 2 3 4 5 6 7 ZR IR OR
Move Valve to Bypass position Move syringe to position xxxx (0-1000) Move syringe down for xxxx steps Move syringe up for xxxx steps start syringe prime cycle
0d2AxxxxR 0d2PxxxxR 0d2DxxxxR 0d2pR
AxxxxR PxxxxR DxxxxR pR
Move Valve to Output position
0d2OR
OR
0d2BR
Move Valve to Input position
0d2IR
IR
BR
start syringe prime cycle
pR
Initialise
Move syringe up for xxxx steps
0d1DxxxxR
DxxxxR
0d2ZR
Move syringe down for xxxx steps
0d1PxxxxR
PxxxxR
ZR
Move syringe to position xxxx (0-1000)
0d1AxxxxR
AxxxxR
0d1pR
Move Valve to Bypass position
0d1BR
BR
AP ON
AP off
AP ON
AP off
AP ON
AP off
AP ON
AP off (*)
system "Rest" for xxxxx milliseconds MV off
0w0
gives status of all sensors
0s
0 (zero)
gives status of module gives firmware version of module
0v
performs a reset on all modules
Effect
0g
0r
Command String:
Wxxxxx
xxxxx
Parameter
(*)
MV = Magnetic Valve WP = Wash Pump AP = Aspiration Pump
FIGURE 13
These steps always require initialisation first !
s W
v
Get Version
Wait
g
Get Sensors
r
Get State
Command
Reset all modules
Module Function
28
X
Pipettor X drive
Z
C
R
Cuvette rotor
Reagent Tray
These steps require initialisation of the respective module first
Probe Z drive
This step requires initialisation first
M
Mod. Code
Photometer drive
Module
v p x
Get Position
Goto Position
x
Goto Position
Get Version
p
Get Position
g
v
Get Version
Get State
g
Get State
r
Z-position right Probe
m
Left Probe to liquid
l
j
Initialise Right Probe
Z-position left Probe
i
Initialise Left Probe
n
v
Get Version
Right Probe to liquid
g
Get State
n
i
Initialise X-drive
X-position
v
x
Position
Get Version
i
Initialise
g
v
Get Version
Get State
g
move cuvette to a (0-6) from b (0-5) (*)
Mxa,b
Initialises X - drive to wash position
Xi
Initialises right probe to top position
Zj
a
a
gives firmware version of module gives position of ReagTray (1 - 25) moves ReagTray to pos a (1 - 25)
Rv Rp Rxa
moves Cuvette Rotor to pos a (1 - 75)
Cxa
gives status of module
gives position of Cuvette Rotor (1 - 75)
Cp
Rg
gives firmware version of module
Cv
move rigth probe to pos. xxxx (0 - 1200) gives status of module
Zrxxxx
xxxx
move left probe to pos. xxxx (0 - 1200)
right probe to liquid, a steps into liquid, but max b steps (1mm = 10 steps)
Cg
Zlxxxx
xxxx
(with comma !)
Initialises left probe to top position
Zi
left probe to liquid, a steps into liquid, but max b steps (1mm = 10 steps)
gives firmware version of module
Zv
Zma,b
gives status of module
Zg
move arm to X-Position (0 - 10) (*)
gives firmware version of module
Xv
Xna
gives status of module
Xg
(with comma !)
position belt in valid position
Mi
Zna,b
a,b
gives firmware version of module
Mv
(with comma !)
gives status of module
Effect
Mg
a,b
a
a,b
Command Parameter Command String:
Get State
Module Function
3= 2= 1= 0=
(*) 10 = 9= 8= 7= 6= 5= 4=
Spl probe at serum cup pos. Reag probe at Reag bttle Spl probe at prim. tube Reag probe at CuvPos 4 Reag probe at CuvPos 3 Reag probe at CuvPos 2 Reag probe at CuvPos 1 Spl probe at CuvPos 4 Spl probe at CuvPos 3 Spl probe at CuvPos 2 Spl probe at CuvPos 1 both probes at Washpos
(*) 0 = Rotor 1 = Photometer 1 2 = Photometer 2 3 = Photometer 3 4 = Photometer 4 5 = Photometer 5 6 = Waste disposal Before cuvettes can be moved / positioned within the photometer, the LED's must be turned on: -> See following page
SERVICE SOFTWARE “EULY SERVICE” 29
FIGURE 14
HumaStar 180 | Service manual
In this table, the module is determined by a number from 1 - 5, which stand for Photometer 1 to Photometer 5 The table shows an "X" for the respective photometer number
1-5
Mod. Code
h m a d
LED power on Read OD Get OD values LED power off
xxxxx wait for xxxxx millisec
Wxxxxx (NO module code !!)
Read and store dark value of Photom X (1-5) turns on LED's of Photometer X (1-5) read OD in Photometer X (1-5) gives reading of all 4 channels of Photometer X (1-5) turns off LED's of Photometer X (1-5)
Xc Xh Xm Xa Xd
Offset Photometer X (1-5)
gives firmware ver. of Photometer X (1-5)
Xv
Xo
gives status of Photometer X (1-5)
Effect
Xg
Parameter Command String:
To repeat a reading, only steps 8 and 9 need to be repeated.
1. LED power off 2. Sleep for 500 milliseconds (this is required to ensure there is no more light emitted) 3. Photometer Offset 4. Dark Reading 5. Sleep for 300 ms (required to finish dark reading) 6. LED power on 7. Sleep for 60000 milliseconds (this is required to make sure the LED's are stable) 8. Read OD 9. Get OD values
This command set allows to make readings "manually". In order to make a reading, the following steps must be perormed in exactly this order (for each photometer individually):
c
Dark Reading
W
Wait o
v
Get Version
Photometer Offset
g
Command
Get State
Module Function
FIGURE 15
Photometer 1 - 5
Module
30
SERVICE SOFTWARE “EULY SERVICE”
31
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: FIGURE 16 Commandset for reading with Photometer 1.
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 ReagentRotor Menucommand for adjusting and testing the Reagent Rotor.
4.6 CuvetteRotor Menucommand for adjusting and testing the Cuvette Rotor.
4.7 Belt Menucommand for adjusting and testing the Belt.
32
4.8 Pipettor Menucommand for adjusting and testing the Pipettor.
4.9 EulyTest Menucommand for testing the liquid detection.
4.10 Endurance Test Menucommand for testing the instrument.
4.11 Device Data Menucommand for reading and saving the Device Data.
4.12 FW Update Menucommand for updating the firmware.
4.13 Photo Menucommand for testing the Photometer.
4.14 Pumps-Valves Menucommand for testing the Pumps and Valves.
4.15 Info Menucommand for displaying program information.
HumaStar 180 | Service manual
MAINTENANCE
5 MAINTENANCE
5.1 Introduction This chapter gives information on maintenance procedures for the Eurolyser system. The required maintenance varies with usage of the Eurolyser system. Therefore the following recommendations are only general guidelines and should be adapted according to the needs.
5.2 Syringes Reasons 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 Valves Reasons to change the part: - Leakage of the Syringe Valve. - Continued formation of drops on the corresponding probe.
5.4 Tubings Reasons to change the part: - The Tubings look worn. - Leakage of the Tubings.
33
34
5.5 Photometer Reasons 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-Drive Reasons for maintenance of the part: - The X-Positioning is not accurate (e.g. small (unwanted) movements on a certain position). - At least once every 6 months. 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-Drives Reasons for maintenance of the part: - The Z-Positioning is not accurate (e.g. small (unwanted) movements on a certain position). - At least once every 6 months. 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).
HumaStar 180 | Service manual
MAINTENANCE
5.8 Liquid Detection Reasons for maintenance of the part: - The Liquid Detection is not accurate (e.g. sometimes aspiration of air due to a too high position). - At least once every 6 months. 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 Valves Reasons to change the part: - Leakage of the Magnetic Valve. - Magnetic Valve does not open. - Preventive Maintenance. - At least every second year.
5.10 Probes Reasons for maintenance of the part: - Probe is blocked. Instructions: 1. Use the Cleaning Set Reagent & Sample Probe.
5.11 Membrane Pumps Reasons 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.
35
36
HumaStar 180 | Service manual
TESTS/TROUBLESHOOTING
6 TESTS/TROUBLESHOOTING
6.1 Introduction This chapter gives information on testing components of the Human system.
6.2 Functional Tests General 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“. Start EulyService-Script „ReagRotorTest2“. Insert full tray on the reagentrotor. Start EulyService-Script „ReagRotorTest1“. Start EulyService-Script „ReagRotorTest2“. 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“.
37
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“.
HumaStar 180 | Service manual
TESTS/TROUBLESHOOTING
39
6.3 Troubleshooting
6.3.1 REAGENT ROTOR Step Check 1 Is the green LED on?
Result No No No
Action Switch on the instrument. Control the mains cable. Control the mains voltage.
No No Yes
Control the mains fuses. Control the master board fuses. Proceed with step 2. Start EulyService-Script AllState. Go to Communication Troubleshooting Table
2
3
4
Is the message displayed on Yes Result: „Error occured processing 0g: Timeout...“? No Is the message displayed on Yes Result: „... R: State: BUSY ...“? Yes Is the message displayed on Yes Result: „... R: State: READY ...“? Yes Is manual movement possible? No No Yes
5 Does the rotor move in clockwise No direction? No Yes Does the rotor move in No counter-clockwise direction? No Yes Does the rotor move in No counter-clockwise direction? No Yes
Proceed with step 3. Replace reagent-flat-cable. Replace reagent rotor control board. Proceed with step 4. Start EulyService-Script Reset. Try to move the rotor manually. Remove possible blocking. Replace carousel unit. Proceed with step 5. Start EulyService-Script ReagFastCW. Replace reagent rotor control board. Replace carousel unit. Start EulyService-Script ReagSlowCW. Replace reagent rotor control board. Replace carousel unit. Start EulyService-Script ReagSlowCCW. Replace reagent rotor control board. Replace carousel unit. Proceed with step 6.
TABLE 2 Switch off the power before changing any electronicmodule or connecting or disconnecting any cable. Wait 5 seconds after switching on the power before starting any command.
40
Step Check 6
Result
Is the test ok?
No Yes
Does the adjustment fail?
Yes No
Does the adjustment fail?
Yes No
Result: "R: State: READY RTimeout"
Yes
7
8
9
No
Action Select menucommand EulyService>ReagentRotor and click Test Digital. Replace carousel unit. Proceed with step 7. Select menucommand EulyService>ReagentRotor and click Adjust. (not required with new Reagentrotorsensor) Replace carousel unit. Proceed with step 8. Select menucommand EulyService>ReagentRotor and click Adjust Digital. Replace carousel unit. Proceed with step 9. Start EulyService-Script ReagRotorTest1. Replace carousel unit. If the error occurs from time to time replace carousel unit.
6.3.2 CUVETTE ROTOR TABLE 3
Step Check 1 Is the green LED on?
Result No No No No No Yes
2 Is the message displayed on Result: Yes „Error occured processing 0g: Timeout...“? No
HumaStar 180 | Service manual
Action Switch on the instrument. Control the mains cable. Control the mains voltage. Control the mains fuses. Control the master board fuses. Proceed with step 2. Start EulyService-Script AllState. Goto Communication Troubleshooting Table Proceed with step 3.
TESTS/TROUBLESHOOTING
41
Step Check Result 3 Is the message displayed on Result: "... C: Yes State: BUSY ..."? Yes Is the message displayed on Yes Result: "... C: State: READY ..."? 4
Yes Is manual movement possible?
Yes No No
Is manual movement possible?
No No Yes
5 Does the rotor move in clockwise direcNo tion? No No Yes Does the rotor move in clockwise direction?
No No No Yes
Does the rotor move in counter-clockwise direction?
No No No Yes
Does the rotor move in counter-clockwise direction?
Action Replace cuvette-flat-cable. Replace cuvette rotor board. Proceed with step 4. Start EulyService-Script Reset. Try to move the rotor manually. Proceed with step 5. Remove possible blocking. Put the cuvette rotor motor 2 mm away from the rotor. Remove possible blocking. Replace carousel unit. Replace cuvette drive motor assembley. Start EulyService-Script CuvFastCW. Replace cuvette rotor board. Replace cuvette drive motor assembley. Replace carousel unit. Start EulyService-Script CuvSlowCW. Replace cuvette rotor board. Replace cuvette drive motor assembley. Replace carousel unit. Start EulyService-Script CuvFastCCW. Replace cuvette rotor board. Replace cuvette drive motor assembley. Replace carousel unit. Start EulyService-Script CuvSlowCCW.
No
Replace cuvette rotor board.
No
Replace cuvette drive motor assembley.
No
Replace carousel unit.
42
Step Check 6
Is the test ok?
Result Action Yes Proceed with step 6. Select menucommand EulyService->CuvetteRotor and click Test Digital. No Replace cuvette rotor board. No Yes
7
Does the adjustment fail?
Yes Yes No
Result: „C: State: READY C-Timeout“
Yes
8
No
Replace carousel unit. Proceed with step 7. Select menucommand EulyService ->CuvetteRotor and click Adjust. Replace cuvette rotor board. Replace carousel unit. Proceed with step 8. Start EulyService-Script CuvRotorTest1. Replace carousel unit. If the error occurs from time to time replace carousel unit.
6.3.3 BELT Step Check 1 Is the green LED on? TABLE 4
2
3
HumaStar 180 | Service manual
Result Action 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. Start EulyService-Script AllState. Is the message displayed on Yes Goto Communication Result: „Error occured processing 0g: TimeTroubleshooting Table out...“? No Proceed with step 3. Is the message displayed on Yes Replace photometer-flat-cable. Result: „... M: State: BUSY ...“?
TESTS/TROUBLESHOOTING
43
Yes Is the message displayed on Result: „... M: Yes State: READY ...“? 4 Does the belt move in clockwise direction?
No No Yes
Does the belt move in clockwise direction? No No Yes Does the belt move in counter-clockwise direction?
No No Yes
Does the belt move in counter-clockwise direction?
No No No
5
Does the adjustment fail?
Yes No
Result: „M: State: READY M-Timeout“
Yes No
6
Replace photometer. Proceed with step 4. Start EulyService-Script BeltFastCW. Remove possible blocking. Replace photometer. Start EulyService-Script BeltSlowCW. Remove possible blocking. Replace photometer. Start EulyService-Script BeltFastCCW. Remove possible blocking. Replace photometer. Start EulyService-Script BeltSlowCCW. Remove possible blocking. Replace photometer. Proceed with step 5. Select menucommand EulyService->Belt and click Adjust and check results on sheets Belt1 and Belt2. Replace photometer. Proceed with step 6. Insert cuvette in outer carussel position 1. Start EulyServiceScript BeltTest1. Replace photometer. If the error occurs from time to time replace photometer.
44
6.3.4 PIPETTOR Step 1 TABLE 5
Check Is the green LED on?
Result No No No No No Yes
2
3
4
Is the message displayed Yes on Result: "Error occured processing 0g: Timeout..."? No Is the message displayed Yes on Result: "... Z: State: BUSY X: State: BUSY ..."? Yes Is the message displayed Yes on Result: "... Z: State: BUSY X: State: READY ..."? Yes Is the message displayed Yes on Result: "... Z: State: READY X: State: BUSY ..."? Is the message displayed Yes on Result: "... Z: State: READY X: State: READY..."? Yes
Is manual movement easily Yes possible? No No
No
HumaStar 180 | Service manual
Action Switch on the instrument. Control the mains cable. Control the mains voltage. Control the mains fuses. Control the master board fuses. Proceed with step 2. Start EulyService-Script AllState. Goto Communication Troubleshooting Table Proceed with step 3. Replace x-flat-cable.
Replace pipettor arm. Replace z-flat-cable.
Replace pipettor arm. Replace pipettor arm.
Proceed with step 4.
Start EulyService-Script Reset. Try to move the needles manually. Proceed with step 5. Remove possible blocking. Clean the spindles (use only alcohol) with a cotton wool stick and lubricate the spindles with a small drop of thin oil. Replace pipettor arm.
TESTS/TROUBLESHOOTING
Step
Check
45
Result
5
Is the message displayed on Result: "... Z: State: READY Zx-Timeout"?
6 Is manual movement possible?
Yes
Yes No Yes Yes No No
No 7 Is the message displayed on Result: "... Z: State: READY X-Timeout"?
Yes
Yes No
Action Be sure to have the arm in the frontmost position. Start EulyService-Script PipettorTest1. Clean the spindles (use only alcohol) with a cotton wool stick and lubricate the spindles with a small drop of thin oil. Replace pipettor arm. Proceed with step 6. Try to move the z-carriage manually. Proceed with step 7. Remove possible blocking. 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. Replace pipettor arm. Start EulyService-Script PipettorTest2. 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. Replace pipettor arm. If the error occurs from time to time replace pipettor arm.
6.3.5 LIQUID DETECTION Step Check 1 Is the green LED on?
Result No No No No No Yes
Action Switch on the instrument. Control the mains cable. Control the mains voltage. Control the mains fuses. Control the master board fuses. Proceed with step 2.
TABLE 6
46
Step Check Result 2 Is the message displayed on Yes Result: "Error occured processing 0g: Timeout..."? No 3 Is the message displayed on Yes Result: "... Z: State: BUSY X: State: BUSY ..."? Yes Is the message displayed on Yes Result: "... Z: State: BUSY X: State: READY ..."? Yes Is the message displayed on Yes Result: "... Z: State: READY ..."? 4
5
Is the adjustment successful?
No Yes
Are the results ok?
No Yes
6
HumaStar 180 | Service manual
Action Start EulyService-Script AllState. Goto Communication Troubleshooting Table Proceed with step 3. Replace x-flat-cable.
Replace pipettor arm. Replace z-flat-cable.
Replace pipettor arm. Proceed with step 4. Make sure to have a low resistant contact of the probe-cables (clean the leads and use a electronic contact spray). Select menucommand EulyService ->Pipettor and click Adjust Liquidsensor.... Replace pipettor arm. Proceed with step 5. Start menucommand EulyService ->EulyTest. Select Liquid Detection. Click Start and check the results on sheet EulyTest. Replace pipettor arm. If the error occurs from time to time replace pipettor arm.
TESTS/TROUBLESHOOTING
47
6.3.6 LIQUID FLOOD Step Check Result Action 1 Are there any traces of leakage No Proceed with step 2. obvious from outside? Syringe or valve leakage? Yes Replace the syringe with piston or the whole syringe pump. Did a wrong pipettor position Yes Goto Pipettor Arm Troubleshooting cause the liquid flood? Table. 2 Disassemble the cover. Are there any obvious leakages Yes Replace the particular tube or whole in the tubes? tubing system. Are there any obvious leakages Yes Replace the washing pumps. in the washing pumps? No Proceed with step 3. 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 Yes Try to clean the tubes inside with a some time? 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 TABLE 8
Step Check 1 Is the green LED on?
Result No No No No No Yes
2 Is an error message displayed: „...Dll-Error: 5...“?
3
Is the message displayed on Result: „Error occured processing 0g: Timeout...“?
Yes
No Yes
Yes Yes Yes
HumaStar 180 | Service manual
Action Switch on the instrument. Control the mains cable. Control the mains voltage. Control the mains fuses. Control the master board fuses. Proceed with step 2. Start EulyService-Script AllState. The serial port is opened by another application. Close all applications. Restart the computer and try again. Proceed with step 3. Control the serial or USB cable.
Control the serial port settings. Close all applications. Restart the computer and try again. Replace master board.
REPLACEMENT
49
7 REPLACEMENT
7.1 Introduction This chapter gives information on replacing components of the Human system.
7.2 Carousel Unit with new Reagentrotorsensor Disassembling the Carousel Unit 1. Disassemble the cover (see “Disassembling the Cover”). 2. Disconnect the tubing for cooling from the liquid connection block.
FIGURE 17
Tubing for cooling
Liquid connection block
3. Disconnect the reagent-code-flat-cable from the reagent control board.
50
4. Disconnect the reagent-position-cable from the reagent control board FIGURE 18
Reagent-code-flat-cable
Reagent-position-cable
5. Disconnect the cuvette-temperature-cable (white and brown) from the master board. FIGURE 19
Cuvettetemperature-cable
6. Disassemble the cuvette rotor board (see “Disassembling the Cuvette Rotor Board”).
HumaStar 180 | Service manual
REPLACEMENT
51
7. Remove the 5 screws on the bottom of the instrument fixing the carousel unit. FIGURE 20
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“.
52
6. Adjust the cuvette rotor board until the cuvette rotor position is aligned with the photometer. FIGURE 21
Open screws for adjusting cuvette rotor position
Centering-magnetcable
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).
HumaStar 180 | Service manual
REPLACEMENT
53
FIGURE 22
13. Execute functional test for reagent rotor.
54
7.3 Carousel Unit with old Reagentrotorsensor (Potentiometer) Disassembling the Carousel Unit 1. Disassemble the cover (see “Disassembling the Cover”). 2. Disconnect the tubing for cooling from the liquid connection block.
FIGURE 23
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. FIGURE 24
Reagent-code-flat-cable
Reagent-position-
cable
HumaStar 180 | Service manual
REPLACEMENT
55
5. Disconnect the cuvette-temperature-cable (white and brown) from the master board. Cuvette-temperature-cable
FIGURE 25
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. FIGURE 26
Screws for carousel
unit
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”). 9. 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“.
FIGURE 27
Centering-magnetcable
4. Disconnect the centering-magnet-cable. 5. Start EulyService-Script „CuvRotorTest1“.
HumaStar 180 | Service manual
REPLACEMENT
57
6. Adjust the cuvette rotor board until the cuvette rotor position is aligned with the photometer. FIGURE 28
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.
58
12. Insert tray and align border between position 1 and 25 with photometer.
FIGURE 29
13. Remove tray. 14. Adjust the centerring until the position shown by EulyService-Script “ReagRotorPosition” is on the threshold between 1 and
FIGURE 30
HumaStar 180 | Service manual
REPLACEMENT
59
15. Tighten the screws. 16. Insert the tray and test position 1 and 25. 17. Select menucommand „EulyService“ -> „ReagentRotor“. 18. Click “Adjust Digital” and follow the instructions. 19. Remove the tray. 20. Select menucommand „EulyService“ -> „ReagentRotor“. 21. Click “Adjust” and follow the instructions. 22. Execute functional test for reagent rotor.
7.4 Centering Magnet Adjusting 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.
FIGURE 31
> 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.
60
FIGURE 32
Top of cuvette ring
0.3mm
Top of photometer
HumaStar 180 | Service manual
REPLACEMENT
61
FIGURE 33
Open screws for adjusting the height of the cuvette ring
62
FIGURE 34
Spacing bolts for adjusting the height of the cuvette ring
HumaStar 180 | Service manual
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.
FIGURE 37
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.
FIGURE 38
HumaStar 180 | Service manual
Inlet tubing sample syringe
Inlet tubing reagent syringe
REPLACEMENT
65
4. Remove the 6 screws on the bottom of the instrument fixing the main cover.
FIGURE 39
Screws for main cover
5. Lift the main cover. 6. Disconnect the doorlock-cable (yellow-brown). FIGURE 40
Doorlock-cable
7. Disconnect the syringe-pump-cable from the master board.
66
8. Disconnect the doorsensor-LED-key-flat-cable from the master board. FIGURE 41
Syringe-pump-
cable
Doorsensor-LED-key-
flat-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”).
HumaStar 180 | Service manual
REPLACEMENT
67
7.6 Cuvette Drive Motor Assembly Disassembling the Cuvette Drive Motor Assembly 1. Disassemble the cover (see “Disassembling the Cover”). 2. Disconnect the cuvette-motor-cable from the cuvette rotor board.
FIGURE 42
Cuvette-motorcable
68
3. Unscrew the slug.
FIGURE 43
Slug
HumaStar 180 | Service manual
REPLACEMENT
69
4. Disassemble the cuvette drive motor assembly (1 screw on the bottom of the instrument).
FIGURE 44
Screw for cuvette drive motor assembley
Assembling the Cuvette Drive Motor Assembly 1. Assemble the cuvette drive motor assembly.
70
2. Adjust the cuvette drive motor assembly to a pressure of 8N by rotating.
FIGURE 45
Pressure = 8N
3. Tighten the slug. 4. Connect the cuvette-motor-cable to the cuvette rotor board.
HumaStar 180 | Service manual
REPLACEMENT
71
7.7 Cuvette Rotor Board Disassembling the Cuvette Rotor Board 1. Disassemble the cover (see “Disassembling the Cover”). FIGURE 46
Cuvette-flat-cable
Screws for cuvette rotor board
Cuvette-motor-cable
2. 3. 4. 5.
Centering-magnetcable
Disconnect the cuvette- flat-cable from the cuvette rotor board. Disconnect the cuvette-motor-cable from the cuvette rotor board. Disconnect the centering-magnet-cable from the cuvette rotor board. 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”). 6. Assemble the cover (see “Assembling the Cover”).
72
7.8 Master Board Disassembling the Master Board 1. Disassemble the cover (see “Disassembling the Cover”). 24V-cable
FIGURE 47
Outer-temperaturecable
Washingpumps-cable
Doorlockvalves-cable X-flat-cable X-15V-cable
Cuvette-temperature-cable
Photometer-temperature-cable
Z-24V-cable Cuvettesensor-cable Photometerflat-cable
Reagent-flat-cable
Cuvette-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.
HumaStar 180 | Service manual
REPLACEMENT
73
FIGURE 48
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. 15. Assemble the cover (see “Assembling the Cover”).
74
7.9 Photometer Disassembling the Photometer 1. Disassemble the cover (see “Disassembling the Cover”). FIGURE 49
Photometer-temperature-cable
Photometer-flat-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.
HumaStar 180 | Service manual
REPLACEMENT
75
FIGURE 50
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. 4. Adjust the centering magnet (see “Adjusting 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. 7. Assemble the cover (see “Assembling the Cover”). 8. Execute functional test for photometer.
76
7.10 Pipettor Arm Disassembling the Pipettor Arm 1. Remove the top cover (5 screws below the top cover). FIGURE 51
Screws for top cover
2. Disassemble the outlet tubing from the sample syringe pump. 3. Disassemble the outlet tubing from the reagent syringe pump. FIGURE 52
HumaStar 180 | Service manual
Outlet tubing sample syringe
Outlet tubing reagent syringe
REPLACEMENT
77
4. Remove the safety ring. Cable driller for
FIGURE 53
Z-24V-cable
Saftey ring
5. 6. 7. 8.
Disconnect the Z-24V-cable (red and black) from the Z–drive board. Open the cable driller fixing the Z-24V-cable behind the X-drive board. Disconnect the X-15V-cable (yellow and black) from the X-drive board. Disconnect the X-flat-cable from the X-drive board.
FIGURE 54
Z-24V-cable
X-flat-cable
X-15V-cable
9. Remove the pipettor arm.
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 washingdevice).
FIGURE 55
Needles
Holes in washingdevice
HumaStar 180 | Service manual
REPLACEMENT
79
3. Press „Adjust Z“ (adjust the needles just above the cuvette rotor). FIGURE 56
Needles
Top of cuvette rotor
4. Execute functional test for the pipettor.
80
7.11 Probes Disassembling the Probe 1. Remove the top cover (5 screws below the top cover). FIGURE 57
Screws for top cover
2. Disconnect the Z-24V-cable (red and black) from the Z–drive board. FIGURE 58
Reagent-probe-cable
Sample-probe-cable
3. Disconnect the probe-cable. 4. Open the screws fixing the probe and remove the probe.
HumaStar 180 | Service manual
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. FIGURE 59
Shield (middle) Liquidsensor-sampleprobe-potentiometer Liquidsensor-reagentprobe-potentiometer Temperature-sampleprobe-potentiometer Temperature-reagentprobe-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”.
82
7.12 Reagent Rotor Control Board Disassembling the Reagent Rotor Control Board 1. Disassemble the cover (see “Disassembling the Cover”).
FIGURE 60
Reagent-flat-cable
Reagent-code-flatcable
Screws for reagent rotor control board
Reagent-positioncable (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 present). 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”). 6. Assemble the cover (see “Assembling the Cover”).
HumaStar 180 | Service manual
REPLACEMENT
83
7.13 Reagent Rotor Potentiometer Disassembling the Reagent Rotor Potentiometer 1. Remove the cover from the centerring. FIGURE 61
2. Remove the 4 screws from the centerring.
84
FIGURE 62
Screws
Centerring
3. Disassemble the centerring.
FIGURE 63
Coupler
4. Disassemble the coupler.
HumaStar 180 | Service manual
REPLACEMENT
85
Reagent rotor potentiometer ring
FIGURE 64
Slug
5. Disassemble the reagent rotor potentiometer ring (fixed with a slug).
FIGURE 65
Reagent rotor potentiometer
86
6. Disassemble the reagent rotor potentiometer (by removing the silicon). Assembling the Reagent Rotor Potentiometer New reagent rotor potentiometer
FIGURE 66
Wires Old 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.
HumaStar 180 | Service manual
REPLACEMENT
87
FIGURE 67
3. Remove tray. 4. Adjust the centerring until the position shown by EulyService-Script “ReagRotorPosition” is on the threshold between 1 and 25. FIGURE 68
5. 6. 7. 8.
Tighten the screws. Insert the tray and test position 1 and 25. Assemble the cover of the centerring. Select menucommand „EulyService“ -> „ReagentRotor“.
88
9. Click “Adjust Digital” and follow the instructions. 10. Remove the tray. 11. Select menucommand „EulyService“ -> „ReagentRotor“. 12. Click “Adjust” and follow the instructions. 13. Execute functional test for reagent rotor.
HumaStar 180 | Service manual
REPLACEMENT
89
7.14 Syringe Pumps Disassembling the Syringe Pump
Tubings
FIGURE 69
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).
90
FIGURE 70
Syringe-pumpscable
3. Disconnect the syringe-pumps-cable from the syringe pump.
HumaStar 180 | Service manual
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 Pumps Disassembling the Washing Pumps 1. Disassemble the cover (see “Disassembling the Cover”). 2. Disconnect the washing-pumps-cable from the master board.
FIGURE 72
Washing-pumpscable
3. Disconnect the tubings from the washing pumps.
FIGURE 73
Tubings
HumaStar 180 | Service manual
REPLACEMENT
93
4. Disassemble the washing pumps (4 screws on the bottom of the instrument).
FIGURE 74
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. 5. Assemble the cover (see “Assembling the Cover”).
ADDITIONAL INFORMATIONS
8 ADDITIONAL INFORMATIONS
8.1 Introduction This chapter gives additional information on the components of the Human system.
8.2 Pipettor Arm 1. 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
95
96
HumaStar 180 | Service manual
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
