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Report CopyRight/DMCA Form For : Service Manual Frank S Hospital Workshop
SERVICE MANUAL,TESE00005 11 ING,July 2009, TABLE OF CONTENTS. 1 INTRODUCTION 8, 1 1 GENERAL DESCRIPTION OF THE ANALYZER 8. 1 1 1 Operating arm 9, 1 1 2 Dispensing system 9, 1 1 3 Reactions rotor and reading 10. 1 1 4 Electronic system 11, 1 1 5 Application program 11. 1 2 FUNCTIONING OF THE ANALYSER 11, 1 3 TRANSPORT AND RESHIPMENT OF THE ANALYZER 12. 2 MECHANICAL ELEMENTS 14, 2 1 Instrument breakdown 14. 2 2 Description of the mechanical elements 14, 2 2 1 Operating arm 14. 2 2 1 1 X Guide 15, 2 2 1 2 X Carriage 16, 2 2 1 3 Y Carriage 16. 2 2 1 4 Needle unit 18, 2 2 2 Dispensing system 19. 2 2 2 1 Thermostated probe 19, 2 2 2 2 Dispensing pump 19. 2 2 2 3 Tubes and containers 21, 2 2 2 4 Container level control sensors 22. 2 2 2 5 Racks tray with integrated washing station 23. 2 2 2 6 Washing pumps 23, 2 2 3 Reaction rotor with integrated optical system 24. 2 2 3 1 Thermostated rotor and photometric system 24. 2 2 3 2 Lighting system 26, 2 2 4 Electronics cover 27. 2 2 5 Main cover hinges 28, 2 2 6 Base 29, 2 2 7 Casings 30. 3 Electronic system 31, 3 1 CPU Board CIIM00026 31. 3 2 Power Supply Board CIIM00015 36, 3 3 Needle Board CIIM00017 38. 3 4 Photometry Board CIIM00027 40, 3 5 XYZ Interconnection Board CIIM00018 41. 3 6 Communications Board CIIM00036 42, 3 7 Rotor interconnection board CIIM00029 43. 3 9 Pump interconnection board CIIM00028 45, 3 10 Component relation 47. 3 11 Auxiliar channel information 47, 3 12 Interconnection between boards 51. 3 13 Schematic liquid circuit 57,4 SERVICE PROGRAM 58. 4 1 Initialising the analyser 58, 4 2 ADJUSTMENTS 60. 4 2 1 Adjustment of the needle thermostatation system 60. 4 2 2 Adjustment of the rotor thermostation system 61. 4 2 3 Adjustment of the positioning of the operating arm 62. 4 2 3 1 Adjustment of X Y and Z position for reagent and pediatric racks 62. Service manual, 4 2 4 Adjustment of the positioning of the rotor 65. 4 2 4 1 Centering of the rotor with regard to the dispensing point 65. 4 2 4 2 Centering of the rotor with regard to the optical system 65. 4 2 5 Adjustment of the positioning of the filter wheel 66. 4 2 6 Adjustment of the level control scales 67, 4 2 7 Adjustment of the level detection sensitivity 68. 4 3 TESTS 68, 4 3 1 Motor tests 68, 4 3 1 1 Initialization test 69. 4 3 1 2 Movement test 69, 4 3 1 3 Loss step test 70. 4 3 1 4 Stress mode test 70, 4 3 1 5 Z axis secu ri ty systems test 70. 4 3 1 6 Maximum Z verification test 71, 4 3 2 Diaphragm pumps and electrovalves test 71. 4 3 2 1 Functioning test 72, 4 3 2 2 Stress mode test 72. 4 3 3 Needle self centering system test 72, 4 3 4 Needle level detection system test 72. 4 3 5 Needle thermostatation system test 73, 4 3 6 Needle rotor thermostatation system test 74. 4 3 7 Photometry tests 74, 4 3 7 1 Base line and integration times 74. 4 3 7 2 Darkness counts 76, 4 3 7 3 Repeatability without moving the filter wheel 76. 4 3 7 4 Stability 77, 4 3 7 5 Repeatability moving filter wheel 77. 4 3 7 6 Absorbance measurement 78, 4 3 7 7 Reactions rotor check 78. 4 3 8 Level control scales test 79, 4 3 9 Covers detection test 79. 4 3 10 PC Analyzer communications channel test 80. 4 3 11 Global stress mode of the analyzer 80, 4 3 12 Photometry tool 81. 4 4 UTILITIES 82, 4 4 1 Disassembly of the dispensing needle 82. 4 4 2 Fluid system supply 83, 4 4 3 Cleaning of the dispensing system 84. 4 4 4 Changing the lamp 84, 4 4 5 Configuration of the filter wheel 85. 4 4 6 Demonstration mode 85, 4 4 7 Read load adjustments and cycles 86. 4 4 8 Change the rotor type 87, 4 5 REGISTER 88, 4 5 1 Introducing the analyzer serial number 88. 4 5 2 Service Reports 89, 4 5 3 Language change 89. 4 5 4 Users 90, 4 6 MONITOR 90, 4 7 User s program 91. 4 7 1 Configuration of the level of access to the analyser 91. 4 7 2 Reagent Consumption 92,5 MAINTENANCE AND CLEANING 94. 5 1 MAINTENANCE OPERATIONS 94, 5 1 1 Housings and covers 94. 5 1 1 1 Removing the needle unit casing 94, 5 1 1 2 Removing the front housing 94. 5 1 1 3 Removing the main cover 95, 5 1 1 4 Removing the upper casing 96. 5 1 1 5 Removing the spring protector 98, 5 1 2 Operating arm 98. 5 1 2 1 Fully removing the operating arm 98, 5 1 2 2 Changing the arm hose 99. 5 1 2 3 Changing the X motor 100, 5 1 2 4 Changing the Y motor 102. 5 1 2 5 Changing the Z motor 102, 5 1 2 6 Changing the Y motor belt 103. 5 1 2 7 Changing the spring 103, 5 1 3 Dispensing system 104. 5 1 3 1 Changing the thermostated pipe 104, 5 1 3 2 Changing the dispensing pump seal 105. 5 1 3 3 Changing the dispensing pump motor 106, 5 1 3 4 Changing the dispensing electrovalve 107. 5 1 3 5 Changing the container tube unit 107, 5 1 3 6 Changing the distilled water container filters 107. 5 1 4 Reactions rotor and reading 108, 5 1 4 1 Changing the rotor temperature probe 108. 5 1 4 2 Fully removing the rotor 109, 5 1 4 3 Changing the rotor Peltier cells 109. 5 1 4 4 Changing the rotor cover detector 110, 5 1 4 5 Changing the rotor start photosensor 110. 5 1 4 6 Changing the rotor motor 111, 5 1 4 8 Changing the lamp 112. 5 1 4 9 Changing an optical filter 113, 5 1 4 10 Configuration of the filter wheel 113. 5 1 4 11 Changing the filter wheel start photosensor 113. 5 1 4 12 Changing the filter wheel motor 114, 5 1 5 Electronic Systems 114. 5 1 5 1 Changing the X Y and encoder start photosensor 114. 5 1 5 2 Changing the microprocessor board 115, 5 1 5 3 Changing the power supply board 115. 5 1 5 4 Changing the main power supply source 116. 5 1 5 5 Changing the photometric system board 116. 5 1 5 6 Changing the front indicator 117, 5 1 5 7 Changing the firmware program 118. 5 2 RECOMMENDED PREVENTIVE MAINTENANCE 118, 5 3 CARE AND CLEANING 119. 5 3 1 General care of the analyzer 119, 5 3 2 Cleaning the optical system 119. 5 3 3 Cleaning the dispensing system 120, 5 3 4 General cleaning of the interior of the apparatus 120. A I TECHNICAL SPECIFICATIONS 121,A II ADJUSTMENT MARGINS TABLES 125. A III LIST OF CONSUMABLES ACCESSORIES AND SPARES 126. A IV LIST OF REQUIRED TOOLS 128,A V SOFTWARE VERSIONS 128. Service manual,1 INTRODUCTION, The A15 analyzer is an automatic random access analyser specially designed for performing biochemical and turbi . dimetric clinical analyses The instrument is controlled on line in real time from an external dedicated PC . In each of the elements of the A15 analyser BioSystems has used leading edge tech nology to obtain optimum ana . lytical performance as well as taking into account eco no my robustness easy use and maintenance A three axis. Cartesian operating arm prepares the reactions Dispensing is performed by means of a pump with a ceramic piston. via a detachable thermostated needle A washing station guarantees that the needle is kept perfectly clean through . out the process The reactions take place in a thermostated rotor in which absorbance readings are taken directly by. means of an integrated optical system , This manual contains the information required for learning about maintaining and repairing the A15 automatic ana . lyzer It should be used by the Technical Service as a learning and consultation docu ment for the maintenance and. repair of the instru ment Chapter 2 describes the different mechanical elements that form the analyzer together with. their functionality and chapter 3 describes the electronic system Chapter 4 describes the Service Program All the. adjustments and checks of the analy zer are carried out through this program which is independent from the appli cation. program User Program The separation of both programs enable it to be maintai ned separately and the extensions. and improvements of one do not affect the other The user does not have the service program The Technical Service. must install it on the user s computer in order to carry out the service requirements Once said tasks have been car . ried out the Technical Service must uninstall the program Chapter 5 offers instructions for the different mainte nance . rep air and cleaning operations that can be carried out by the Technical Service The annexes contain a summary of. the technical specifications of the analyzer the adjustment margin tables the lists of accessories and spares a list. of software versions and their compatibility and a software troubleshooting guide . 1 1 GENERAL DESCRIPTION OF THE ANALYZER, The A15 analyser is made up of three basic elements the operating arm the dispensing system and the reading and. reactions rotor The electronic system of the instrument controls said elements and communicates with the external. computer containing the application program Through this program the user can control all the operations of the. 1 1 1 Operating arm, This is a three axis XYZ Cartesian mechanism The X and Y axes move the dis pens ing needle over the analyser. horizontally and the Z axis moves it vertically It is operated by three step by step motors In each 24 second prepara . tion cycle the operating arm performs the following actions first of all it sucks in the reagent from the corresponding. bottle Next the needle is washed externally in the washing station and sucks in the sample from the corresponding. tube It is washed externally again and dispenses the sample and the reagent into the reactions rotor Finally it is. exhaustively washed internally and externally before proceeding with the next preparation The arm has a system. for controlling vertical movement to detect whether or not the needle has collided into anything on descending If a. collision occurs as may be the case if for example a lid has been left on a bottle of reagent the arm automatically. restarts verifies the straightness of the needle and continues working issuing the corresponding alert to the user . A vertical axis retention system prevents the needle from falling in the case of a power cut avoiding injury from the. needle to the user or the needle being bent by an attempt to move the arm manually The operating arm only makes. the preparations if the general cover of the analyser is closed If the cover is raised while it is functioning the arm. automati cally aborts the task in progress and returns to its parked position to avoid injury to the user . 1 1 2 Dispensing system, This system consists of a thermostated needle supported and displaced by an operating arm and conne ct ed to a. dispensing pump The needle is detachable to enable cleaning and replacement The analyser has capacity level. detection to control the level of the bottles and tubes and prevent the needle from penetrating too far into the corre . sponding liquids thus minimising contamination An automatic adjustment system informs the user if the needle is not. mounted or if it is too bent The needle has a sophisticated Peltier thermos tatation system with PID control capable. of thermostating the preparations at approximately 37 in less than 15 seconds Dispensing is carried out by means. of a low maintenance ceramic piston pump driven by a step by step motor It is capable of dispensing between 3 and. 1250 ml The exterior of the needle is kept cons tantly clean by a wash station included in the base A membrane pump. transports the waste to the corresponding container . The A15 analyser has a tray with 4 free positions for racks of reag e nts or samples Each reagents rack can carry up. to 10 reagents in 20 ml or 50 ml bottles Each samples rack can contain up to 24 tubes of samples The samples can. be patients calibrators or controls The analyser can be configured to work with 13 mm or 15 mm diameter tubes of. samples with a length of up to 100 mm or with paediatric wells Any possible configuration of racks can be mounted. from 1 rack of reagents 10 reagents and 3 racks of samples 72 samples to 3 racks of reagents 30 reagents and. 1 rack of samples 24 samples , On the left of the analyser are the waste and distilled water containers The analyser constantly controls the level of. these containers and issues the appropriate alerts if the distilled water is nearly empty or if the waste container is full . Service manual,1 1 3 Reactions rotor and reading, The preparations are dispensed in an optical quality methacrylate reactions rotor thermos tated at 37 C The optical. absorbance readings are taken directly on this rotor Each reaction can be read for 10 minutes The readings are. taken as they are programmed in each measurement procedure The reaction wells have been designed to enable. the mixture of the sample and the reagent during the dispensing Each rotor has 120 reaction wells The length of the. light path is 6 mm The minimum volume required to take the optical reading is 200 uL The wells have a maximum. useful capacity of 800 uL When the reactions rotor is completely full the user must change it for one that is empty . clean and dry The reactions rotors can be reused up to 5 times if they are carefully cleaned immediately after use . The Cleaning the semi disposable reactions rotor section in the Installation and maintenance manual describes how. to cle an the rotors The us er has a test in the computer programme which he or she may use to check the condition. of the rotor The rotor is driv en by a step by step motor with a transmission A Peltier system with PID control ther . mostates the rotor at 37 C , An optical system integrated in the rotor takes the readings directly on the reaction wells The light source is a 10 W. halogen lamp The detector is a silicon photodiode The wavelength is selected by a drum with 9 positions available. for optic filters The filters are easily ch an ged by the user from the exterior of the analyser without the need for disas . sembling the filter drum A step by step motor positions the drum The optical system is capable of taking 1 25 readings. per second with or without a filter change in between The light beam from the lamp passes through a compensated. interferential filter to select the desired wavelength It then passes through the rotor well and finally reaches the pho . todiode where the light signal is turned into an electric signal A sophisticated analogical digital integrator converter. system converts the electric signal into a digital value with which the analyser obtains the absorbance values The. optical system continues to work when the general cover of the ana lyser is open whereby the analyser can continue. to take readings while the user handles for example the sample tubes or the reagent bottles The rotor cover must. be in place for the optical system to work correctly . A detector tells the analyser of the presence of the cover The analyser aborts the readi ngs if the user removes the. rotor cover while the optical system is taking photometric measurements If the rotor is not covered the analyser. informs the user so that he or she places the rotor cover when it sends samples to be analyzed . 1 1 4 Electronic system, The described elements are controlled by an electronic system based on a micropro cessor The microprocessor has. two exter nal communication channels to connect the instrument to the computer containing the application pro gram . The electronic system is made up of the following independent boards . Microprocessor board, Photometric system board, Needle conditioning board. Fluid system interconnection board, Arm interconnection board. Rotor interconnection board, Power supply board,1 1 5 Application program. The application program makes it possible to control all the operations of the analy zer Fro m this program the user. can monitor the state of the analyzer and the work session program parameters e g technique parameters prepare. the work session prepare results reports configure different analyzer options activate various test utilities prepare. and maintain the instrument and carry out internal quality control processes The purpose of this manual is not to. explain the fun ction ing of the user program For detailed information to this re gard please con sult the User Manual. included with the analyzer ,1 2 FUNCTIONING OF THE ANALYSER. The A15 analyser is an automatic random access analyser specially designed for performing biochemical and turbi . dimetric clinical analyses The analyser performs patient by patient analyses and enables the continual introduction. of samples The analyser is controlled from a dedicated PC that is permanently com muni cated to the instrument . The programme installed on the computer keeps the user constantly informed of the status of the analyser and the. progress of the analyses As results are obtained the com pu ter shows them to the user immediately . When a Work Session is begun the ana ly ser proposes performing the blanks calibra tors and controls programmed. Service manual, for the measurement procedures it is to carry out The user may choose between performing the blanks and the. calibra tors or not If they are not performed the analyser uses the last available memorised data The controls can. also be activated or not During a session while the analyser is working the user can introduce new normal or urgent. samples to be analyzed Each time a new sample is added the analyser automa tical ly proposes the possible new. blanks calibrators or controls to be performed A work session can remain open for one or more days When a session. is closed and another new session is opened Reset Session the analyser again proposes performing the blanks . calibrators and controls It is recommended that the session is reset each working day . The analyser determines the concentrations of the analytes based on optical absorbance measurements To measure. the concentration of a certain analyte in a sample the analyser uses a pipette to take a specific volume of the sample. and the corresponding reagent quickly thermostates them in the needle itself and dispenses them into the reactions. rotor The very dispensing speed together with the geometry of the reaction well causes the mixture to be shaken and. the chemical reaction begins In the bireagent modes the reaction begins when the analyser later dispenses a second. reagent in the same reaction well The reactions can be biochemical or turbidimetric In both cases the reaction or. the chain of reactions produced generate substances that attenuate certain wave len gths either by absorption or by. dispersion Comparing the light in ten sity of a certain wavelength that crosses a well when there is a reaction and when. there is not a reaction can determine the concentration of the corresponding analyte This comparison is quantified. with the physical magnitude called absorbance In some cases the concentration is a direct function of the absorb . ance and in other cases it is a function of the variation of the absorbance over time depending on the analysis mode . 1 3 TRANSPORT AND RESHIPMENT OF THE ANALYZER, If the analyser is to be reshipped or moved using a transport vehicle it is important to block the operating arm and. use the original packaging to ensure that the apparatus is not damaged To package the instrument we recommend. you follow the following instructions on the unpackaging instruc tions sheet . Service manual,2 MECHANICAL ELEMENTS,2 1 Instrument breakdown. The physical structure of the analyzer can be broken down as follows . Operating arm, X carriage, Y carriage, Needle unit. Dispensing system, Thermostated probe, Dispensing pump. Tubes and containers, Container level control sensors. Racks tray with integrated washing station, Waste pump. Reactions rotor with integrated optical system, Thermostated rotor and photometric system This contains the electronic photo metric system board. Lighting system, Electronics box This houses the electronic boards of the microprocessor the power sup ply and the front indicator. Main cover hinges, Upper casing, Front housing, Arm casing. Main cover, The following is a brief description of each of the mechanical elements that make up the analyzer . 2 2 Description of the mechanical elements,2 2 1 Operating arm. This mechanism positions the dis pen sing needle appropriately during the prepara tion of the analyses An encoder. checks the vertical movement of the needle and a spring automatically stops it from falling in the case of a power cut . The dispen sing pipe and the electrical hoses of the arm pass through the front casing. 1 X GUIDE, 2 X CARRIAGE, 3 Y CARRIAGE, 4 Y GUIDE, 5 NEEDLE UNIT. 6 CONTROL AND DISPENSING PIPE HOSE, The needle unit 5 supports the thermostated needle and can move on the Y carriage 3 which can move on the. Y axes 4 The Y axes are supported by the X carriage which moves on the X axes 1 In this way the needle can. be moved in the three Cartesian directions of X Y and Z The hose 6 houses the Teflon dispensing tube and all the. electrical ho se s of the arm , 1 2,2 2 1 1 X Guide . 1 UPPER X TOOTHED AXIS, 2 LOWER X AXIS, 3 X START PHOTOSENSOR. 4 BEARING X AXIS, 5 X MOTOR, 6 X START PHOTOSENSOR TAB. 7 AXIS SUPPORTS, This consists of two supports 7 that hold the steel axes 1 and 2 on which the X carriage moves The photosensor. 3 indicates the start position of the X carriage movement The motor X 5 is moved by a rack 2 The X carriage is. supported by the second axis 2 by means of a bearing 4 .
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