Humastar 80 Service Manual

Service Manual
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Cat.-No.: 16880/2
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1. INTRODUCTION 3
2. INSTRUMENT’S DEVICES DESCRIPTION 4
2.1 Liquid Processing System 4
2.1.1 Well Selector 4
2.1.2 Pipetting System 4
2.2 Reading Group 5
2.4 Application Program 5
3. DESCRIPTION OF THE ELEMENTS 6
3.1 Well Selector 6
3.1.2 Rotor Gear 6
3.1.3 Pre - Warming Of The Reaction Well 7
3.2 Diluter 8
3.3 Transfer Arm 9
3.3.1 Arm 10
3.3.2 Rotor 11
3.4 Sipping System 12
3.5 Optical System 13
4. ELECTRONIC CIRCUIT 15
5. LAYOUT AND CALIBRATIONS 24
5.1 Ordinary / Occasional Maintenance 24
5.2 Extraordinary Maintenance 25
5.2.1 Service 25
5.2.2 Layout And Calibration Menu 26
6. MAINTENANCE 37
6.1 Disconnecting Suction and Dispensing Flexible Tubes 37
6.2 Disassembling the transfer arm 38
6.3 Changing the Casing 39
6.4 Changing the Main Board 40
6.5 Changing the Optical Group 40
6.6 Changing the Filter Wheel 41
6.7 Changing the Filter 41
6.8 Changing the Filter Wheel Motor 41
6.9 Changing the Peristaltic Pump 42
6.10 Changing the Peltier Cell 42
6.11 Changing the Photodiode 42
6.12 Changing the Fan 42
6.13 Changing the Temperature Sensor 42
6.14 Changing the Lamp 43
6.15 Changing the Lens 43
6.16 Changing the Transfer Arm Vertical Motor 43
6.17 Changing the Transfer Arm Rotation Motor 45
6.18 Changing the Rotor Motor 45
6.19 Changing the Diluter Motor 46
6.20 Changing the Pre-warming Device of the Reaction Well 46
6.21 Changing the Safety Spring 47
6.22 Changing the Needle Set 47
6.23 Changing the Pre-warming Device of the Reagent 47
6.24 Lubrication 47
7. CARE AND CLEANING 48
7.1 Cleaning of the Optical Components (Lamp, Lens, Filters And Photodiode) 48
7.2 Cleaning of the Filters 48
7.3 Cleaning of the Lens 48
7.4 Cleaning of the Photodiode 48
7.5 Cleaning the Flow-thru Cuvette 48
7.6 General Cleaning of the Instrument 49
7.7 Preventive Maintenance 49
APPENDIX 1 50
APPENDIX 2 52
APPENDIX 3 53
2/63 Service Manual HumaStar 80

/012,-3+45*-2+,
This manual contains all the information about the automatic analyzer HUMASTAR 80 and it could be
considered a training document for the Technical Assistance Service and a reference guide for repair and
maintenance.
This manual is divided in three parts: the first one is about the description of mechanical groups, the second one
is about the configuration of the instrument and the third one is about the electronic circuits.
HUMASTAR 80 is an instrument that automatically performs clinical chemistry tests, by mixing samples and
reagents and then measuring their absorbance. It has been designed as a processing and reading unit,
connected to an external computer where the application runs.
The functioning of HUMASTAR 80 lays on two separate sections:
1. Physical part. It contains the mechanisms needed to handle the samples and reagents, make the reaction
mixtures, thermostat them and read their absorbances.
2. Application program. The user first prepares the work and then receives and processes the results.
HUMASTAR 80 consists in a liquid processing systems that pipettes the reagents from their bottles and the
samples from their wells, and mixes them up in the reaction wells where the reaction takes place. The reaction
wells are warmed up in order to have the reaction mixtures at the temperature near to that of the reading cell.
The system is made up of in some groups: peristaltic pump, diluter, transfer arm, optical group, rotor gear,
reagent plate.
All of these groups (except reagent plate that is fixed) are controlled by an electronic system with a
microprocessor, by means of the corresponding power circuits. The microprocessor is linked with the external
pc that contains the application program with all the needed tools (programming of tests, working lists….)
It is not the aim of this manual to describe the way this program works (for detailed information about the
program operation, refer to the User’s Manual), but only the parts required for the maintenance of the instrument
will be considered.
As shown in the diagram, HUMASTAR 80 has four main systems that will be explained in the follow chapters:
1. Liquid processing system

2. Reading group
3. Electronic and communications control
4. Application Program
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Service Manual HumaStar 80 3/63

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This system takes charge of all the liquid elements needed for a working session: samples, calibrators, controls,
reagents, water, washing solutions etc.
It is designed in order to aspirate and dispense liquid (water, reagent, etc.) into reaction well, cuvette or washing
box.
It consists in two mains elements:
1. Well selector
2. Pipetting system
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This system is designed in order to place the sample or the reaction well directly under the needle of the transfer
arm to let it take the sample, dispense the reagent/sample mixture or sip it to read.
It consists of a rotative tray (rotor) with 54 round hollow positions (from 1 to 54) and with 12 segment hollow
position. A sample well can be placed in each round position, either containing a sample, a calibrator or a
control. The reaction rack contains 12 reaction wells and it can be placed in the segment hollow position, making
a total of 144 wells.
The useful capacity of the reaction well is 1ml. This is the top limit that should not be surpassed in order to avoid
the cross- contamination between wells during the turning movements of the rotor.
It is formed by two elements:
Rotor gear
Pre-warming device
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The system allows to take in a programmed amount of a liquid (sample or reagent) and deliver it wherever is
required. It consists of a rotary arm that, when needed, can place itself over a reagent, a sample or a reaction
well, and a diluter that takes care of aspirating and dispensing the amount of liquid requested.
On the transfer arm there are two needles:

one for dispensing, connected with the diluter and thus belonging to the pipetting system
one for aspirating, connected to the peristaltic pump and thus belonging to the sipping system of the reading
group.
The transfer arm is doubly protected against both horizontal and vertical accidental blocking.
The pipetting system is depicts in the following picture.

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The reading group consists of a suction needle, peristaltic pump, flow cell, Peltier thermostatic system, a linear
optical group (halogen lamp, interference filters and photodiode).
This system is in charge of carrying the reaction mixture from the reaction well into the flow- thru cuvette, where
it is precisely thermostated and its absorbance read.
The reaction mixture is removed from its well by means of the suction needle and, through the peristaltic pump,
delivered into the cuvette. For kinetic measurements where readings take place at programmed time intervals in
which temperature should be kept stable, the cuvette is thermo- regulated by means of the Peltier cell.
In order to avoid the presence of bubbles inside the cuvette, that could interfere with reading, the optical block is
assembled with a 10° angle, so that any eventual bubbles produced along the circuit and retained by the cell, are
quickly removed.
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The diverse mechanisms that perform the analyzer functions are actioned by stepping motors and synchronized
by detectors that indicate the starting position of their mobile parts.
The thermostatic systems are formed either by heating resistors or Peltier cells and the corresponding
temperatures are measured by the appropriate sensors.
All these elements are controlled by means of electronic boards, including a microprocessor with a program able
to handle them. This program receives from the software running in external PC detailed instructions of the
diverse steps to be performed.
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The detailed description of the application program is beyond the scope of this manual. Please refer to the User
Manual enclosed with the instrument or with the latest updated release.
Software upgrade are available at:
http:\\www.human.de
refer to our website for latest software upgrade.

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It consists of two parts: rotor gear and pre-warming group
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The rotor gear allows the positioning of the sample and reaction wells below the arm needle.
1. Rotor support
2. Base
3. Axle pulley
4. Driving belt
5. Driving pulley
6. Stepping motor
7. Home sensor
8. Stirrup
9. Rotor axle
10. Centering support
11. Dowel pins
12. Knob
The centering support is moved by a stepping motor that steers the movement of driving pulley, driving belt, axle
pulley and rotor axle. All the systems is fixed on the base and the base is fixed on the rotor support. Inside of the
support the are two bearings that allow the rotor axle rotation.
On the centering support there are two dowel pins that allow a correct positioning of the sample/reaction plate.
The centering support is fixed on the rotor axle through a screw and the sample/reaction plate is fixed on the
centering support by a knob.
In order to monitoring the position of the rotor, there is an home sensor fixed on the base and a stirrup fixed on
the axle pulley. Using this reference, the mechanism moves forward a definite number of steps till reaching the
established position.

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The reaction well must be pre-warm before reading the reaction, in order to reach the temperature close to that
of the flow cuvette (37°C).
1. Pre-warming box
2. Box support
3. Sample/ handling plate
4. Temperature sensor
5. Box cover
6. Reaction well
7. Sample well
8. Resistor wire
9. Bimetallic thermostat
Around the anodized-aluminum pre-warming box there is a resistor wire that warms up the walls of the box. The
reaction wells are positioned inside of the box and they reach the temperature close to that of the walls.
Under the pre-warming box there is a box cover that protects the rotor gear from the dusty and the liquid
leakage.
This group is fixed to the rotor gear base by four box support.
The temperature is controlled by a temperature sensor and there is a safety bimetallic thermostat that switches
off the current intensity only if the temperature achieve 50°C.

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The diluter allows to aspirate and dispense samples and reagents into the reaction wells.
1. Syringe
2. Valve
3. Inlet hole
4. Outlet hole
5. Special screw
6. Guide axle
7. Revolving screw
8. Plunger displacer
9. Home sensor
10. Position plate
11. Supporting plate
12. Motor
13. Belt
14. Axle pulley
15. Driving pulley

The syringe and the e-valve are connected to the dispensing needle and to the washing bottle by tubing
attached to the corresponding connector. The right connector is different from the left one.
The syringe is connected to the plunger displacer by a special screw, and the plunger displacer is moved by the
system driving pulley- belt- axle pulley, moved by a stepping motor.
The maximum volume in the syringe is controlled by the position plate that stops the syringe when it goes
through the home sensor.
The diluter is fixed directly on the vertical diaphragm and it is in vertical position in order to avoid the presence of
bubbles inside the syringe. In this way, any eventual bubbles produced and retained by syringe, are quickly
removed.
NOTE:
The join that are screwed to e-valve are weak. So excessive strength on
fixing the plastic join to e-valve will damage the e-valve permanently. Note
that you should fix these joints QE1 P$C?6, or if you are using tools pay
attention on doing this.
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Although it only holds the needles and the reagent warming device,
it is the most complex mechanism of the analyzer.
The transfer arm must position itself precisely above the sample
wells, the reaction wells and reagent bottles. Once there, it moves
up or down in order to pipette or to sip the volume required.
It consists of two parts: the arm and the rotor.

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1. Arm support
2. Centering box
3. Arm screw
4. Tube in
5. Tube out
6. CS
7. Reagent warming case
8. Reagent warming box
9. Spacer
10. Home sensor stirrup
11. Spring fixation plate
12. Home sensor
13. Spring
14. Needles holder
15. Suction needle
16. Dispensing needle
17. Level sensor connector
18. Arm axle

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19. Support block
20. Guides
21. Safety Spring
22. Arm displacer
23. Stepping Motor for the arm rotation
24. Motor pulley for the arm rotation
25. Encoder plate
26. Axle pulley for the arm rotation
27. Belt for the arm rotation
28. Axle bearings
29. Belt block
30. Belt for the up and down movement
31. Axle pulley for the up and down movement
32. Motor pulley for the up and down movement
33. Stepping motor for the up and down movement
34. Bearings group
35. Vertical Home sensor stirrup
36. Home sensor for the up and down movement
37. Rotation Home sensor stirrup
38. Home sensor for the arm rotation
All this group is assembled on a support block that consists in 2 parts: a principal holder part and two guides.
The arm displacer is moved along these guide by a pulley- belt- motor system. The belt is fixed to the arm
displacer by a belt block. With this movement, the arm can introduce the needles in the wells.
To regulate the highness of the arm, on the arm displacer there is a home sensor that allows to stop the group
when vertical home sensor stirrup pass trough the home sensor (upper position).
To preserve the needles and to avoid the downwards displacement when you disconnect the instrument, there
is a safety spring around the left guide.

The arm can rotate because of pulley- belt- motor system that it is on the arm displacer. There is a double tree
motor that moves the pulley on the back side and it moves the encoder plate on the up side. The encoder picks
the movement impulses corresponding to the number of the steps of the motor.
In case of blocking of the rotation, there will be a discrepancy in this number and the system alerts on a possible
obstacle.
On the right side of the arm displacer, there is a home sensor that stops the rotation of the arm when the
Rotation Home sensor stirrup pass trough the home sensor. There is a mechanical stop on the home sensor
stirrup that allows to stop the rotation even if there is an error. On the other side, the right guide is the other
mechanical stop.
On the arm support there is a centering box that is fixed on the arm axle by an arm screw.
On the arm support there is a Printed circuit and, on this one, there is a Reagent warming box that allows to pre-
warm the reagent inside of the tube because inside of this box there are two heating resistor. Inside of this box
there is also a temperature sensor to keep the temperature stable.
The Reagent warming box with the tube turned around, is covered by a Reagent warming case.
There are two tubes: one, connected to flow cell, is connected into the suction needle, the other one, connected
to the diluter and turned around the reagent warming box, is connected into the dispensing needle. Both of
needle are fixed on the Needles holder and tightened by two screws. They are connected to the sensor level by
a wire. The needles holder is mobile and is fixed into a conical lodging by a spring. The spring fixation plate and
the spacers fix the spring by its upper side. The home sensor stirrup, that works together with the some sensor is
fixed to the holder. If when lowering the arm the needles find any obstacle, the plate moves out from the center
of the home sensor and this sends the blocking signal.
The needles, made of stainless steel, are parallel and have same length.
The arm circuit is connected to the electronic board by the socked.
The cover is fixed on the arm displacer by three screws.
On the cover there are two led, the red one on the left side for the impact, and the green one on the right side for
the level sensor.
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The sipping system allows to carry the reaction mixture from the wells and to delivery the mixture to the flow–
cell cuvette.
1. Washing bottle
2. Diluter
3. Transfer arm
4. Needles
5. Flow- cell cuvette
6. Peristaltic pump
7. Waste bottle
The sample is sipped by the suction needle and delivered to the cuvette. The tubes between needle and cuvette
is made by teflon and it is covered and protected by a silicon tube. It has a specified length on which the
instrument is calibrated. Each time this tube is changed, the corresponding adjustment of the pump must be
performed.
When the sample is inside of the cuvette, the reading is performed.
After the reading, the peristaltic pump aspirate the sample through a tefllon tube covered by a silicon tube and it
delivers the sample into the waste bottle through a tygon tube.

The peristaltic pump consists in six- roller rotor and it is moved by a stepping motor. The peristaltic pump tube is
a special rubber tube and it is fixed instead to be parallel each other.
If you prefer to use a external tank, there is a connector on the vertical plate of the instrument. The waste tygon
tube has to be fixed on this connector and on the back side of the instrument there is another blue connector on
which the external tank tube is to be fixed.
On the two bottles, washing and waste, there is a level sensor that alert the operator when the washing bottle is
empty and when the waste bottle is full. When you have to extract the bottles, you have to take off the gold
connector in order to switch off the level sensor.
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1. Incubator block
2. Conductor pad
3. Peltier cell
4. Dissipator
5. Tilt base
6. Fixing screw
7. Temperature sensor
8. Isolator
9. Halogen lamp
10. Lamp support
11. Filter wheel
12. Filter wheel support
13. Stepping motor
14. Photodetector
15. Photodetector protection
16. Incubator fan
17. Incubator fan support
18. Lent
19. Lents holder
The optical system is in charge of performing the photometric readings.
The incubator is a thermostating system, it is designed in order to keep the temperature inside the flow- cell at
the programmed value and inside a precision range (+/- 0.2°C).
The cuvette is positioned into the cuvette holder that is covered with a conductor pad, in order to guarantee a
homogeneous temperature distribution along the cuvette. A special screw fixes the cuvette inside of the
incubator.
The incubator block is in contact with one of the sides of the Peltier Cell and it is connected with the dissipator by
four insulated screw. The other side of the Peltier Cell is in contact with the dissipator. The Peltier Cell pumps
heat from one side to the other according to the direction of the current flow.
A power control circuit is in charge of guiding this current flow in the proper direction in order to warm or cool
according to the instructions coming from the microprocessor through Peltier unit. The optical block is equipped
with a dissipator and a fan in order to dissipate the heat coming from the cuvette holder.
There is a temperature sensor that measures the temperature in the cuvette holder and the signal is sent to the
microprocessor through the amplifier. The thermostatic program is located in the microprocessor and, according
to the programmed temperature and to the current value, it switches the power control on, warming or cooling as
required.
The light source is an halogen lamp. The light goes first trough the optical lent and through the diaphragm that
limits the amount of light and directs the beam towards the flow cell. After the flow cell, the light goes towards the
interferential filter located in the filter wheel that is moved by a stepping motor and behind the filter there is the
photodetector plus preamplifier, protected by a cover, that convert the light into a electric signal that will be used
by the electronic circuits to perform the measurement.

Filter Equalisation
This is the filter wheel as you can see when you open the filter wheel support.
The magnet is on the back side and the filter are numbered in the picture. When the magnet is on the sensor ,
the filter number 1 (340nm) is on the reading position.
magnet
Position Filter Equalisation

1 340nm No gel
2 405nm 1 gel of 1 + 3 gel of 5
3 492nm 2 gel of 2 + 1 gel of 5
4 505nm 1 gel of 4 + 1 gel of 5
5 546nm 1 gel of 4 + 1 gel of 1 + 1 gel of 5
8 Free position -------

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Block Diagram

PICTURE SHOWING BOARD CONNECTIONS and FUNCTION
Speaker
External
PC Peltier for optical
group
Lamp: Preamplifier Activity LED
termostating board
~ 11V
110704 110703 110702

(ID: 0) (ID: 2) (ID: 1)
Prehetaer
termostating Syringe Electrovalve Filter wheel Optical group
motor motor 12V DC FAN
(60x60)
Level
sensing
110700 110700 110700

(ID: 6) (ID: 3) (ID: 7)
Up/Down Needle impact
motor detection
External 12V
DC FAN (80x80)
110700 110700 110700

(ID: 4) (ID: 5) (ID: 8)
Sample
Arm polar motor Encoder board for rotor motor
arm Peristaltic pump Level sensor for
motor Washing and
Waste tank
Sample rotor
termostating

TABLES INDICATING BOARD ID and FUNCTION
ID BOARD CODE Function
0 110704 RS232 to RS485 Interface board

Power supply generation
36V (motor)
1 110702 Photometer board
Activity led
2 110703 Optical group termostating (Peltier driver)
Lamp voltage generation (around 11V)
Speaker control
3 110700 Diluiter syringe
Electrovalve handling
4 110700 Horizontal arm movement
Encoder for horizontal arm impact
5 110700 Sample rotor movement
Sample rotor termostating
6 110700 Up/Down arm movement
Level sensor
Needles impact detection
Preheater circuit termostating
7 110700 Filter wheel selection
Fan output for optical group (60 x 60 FAN 12 VDC)
8 110700 Peristaltic pump motor
General fan output for instrument (80x80 FAN 12V DC) Connection for
WASTE and WASHING TANK

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RX TX LED
Liquid detector LED

Preheater RED (ON = LIQUID
Heater LED PRESENT)

READING BOARD
COD. 110702
T40
TO BOARD
COD. 110703
PRE-AMPLIFIER
CONNECTOR

RED On: heating
GREEN ON:

Power Supply LED for
diagnostic. Check D3, D2,
D7, D5, D4

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The software is assisting the user for all the layout settings and calibration parts.
There are 2 types of maintenance that can be done on the instrument.
! Ordinary or occasional maintenance (RECOMMENDED supervision of service engineer)

! Extraordinary maintenance (NEEDS service engineer)
The following operations belong to ordinary / occasional maintenance:
! Priming diluter
! Wash cuvette and needles
! Peristaltic pump auto - calibration
! Volume calibration.
The following calibrations needs to be performed on the instrument only as extraordinary service is required:
! Reagents layout calibration

! Washing well layout calibration
! Reaction well centering
! Sample wheel centering
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You can access to this menu by clicking on “utility” button on main menu.
Explanation:
! Initialise: Basic alignment and homing. Will perform all the motors on the start right position.
! Prime diluter: will perform 3 cycles of diluter priming. Useful to fill up all the hydraulics, for checking
hydraulics, to remove air bubbles from syringe. Perform this at the first installation of analyzer.

! Wash cuvette: will perform an aspiration with peristaltic pump through cuvette. Can be used if the peristaltic
pump needle is dirty or blocked and the instrument do not have good aspiration from peristaltic pump.
Sodium hypoclorite (10% solution in water) can be a good washing solution.
! Volume calibration: only perform this kind of calibration if you are experiencing too high dead volume in
reagents bottle or if a washing cycle is not efficient (because of the too high residual volume left in the
washing well), or too high residual solution inside the reaction cuvette, or too high carry over.
! Photometer check: manual functioning of photometer.
! Pump calibration: to compensate the loose of the peristaltic pump rubber, an auto calibration of peristaltic
pump is recommended as occasional service operation. Good value should be inside: 0.8 – 3.5. Use this too
decrease carry over.
! Service: by pressing this button you will access to service menu (extraordinary maintenance). This operation
needs password and is for authorized person only.
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THIS MENU IS PASSWORD PROTECTED BECAUSE AN INCORRECT OPERATION AT THIS
LEVEL MAY DAMAGE SERIOUSLY THE INSTRUMENT. IF YOU DO NOT KNOW WHAT YOU
ARE DOING NEVER ENTER TO SERVICE MENU AND EXTRAORDINARY MANTEINANCE.
R070/1%B'X=AB
This is the maintenance to be done every time you disassemble the instrument for changing some of its
hardware parts.
When you click !"#$#"%&button on the '(#) menu, you enter in *+,-#.+/
Execute menu:
! STOP button: reserved for internal use
! Execute buffer button: reserved for internal use
Board version menu:

! Is reporting the board version.
Temperature menu:
! Quick view to temperatures.
Action menu:

! Refresh: Is refreshing board version and temperature status in board menu and temp menu.
! Macro: Single command parametric execution.
! Reset board: reset all boards.
! Layout: Will give you access to layout and calibration menu (see later)
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LAYOUT MENU:
! Reagent layout: reagent position centering.
! Sample tray: sample tray centering
! Reaction tray: reaction well centering
! Washer: washing well centering
TEST MENU:
! Volume: volume adjustment, do not use. Use Utility -> volume calibration instead (from Main
menu). Menu)
! Sensor: to test the status of the sensors.
! Temperatures: to test the status of the temperatures.
! Photometer: to check the photometer
CALIBRATION:
! Pump: peristaltic calibration, do not use. Use Utility-> Pump calibration instead (from main menu).
! Diluter: needs non adjustment. Do not use.
SPECIAL:
Burn In: Performs randomic movement cycles.

5.2.2.1 Reagent Layout
The instrument will select the 1st reagent (the one that is marked “1” on the reagent tray). Adjust it to its position
using the steps arrow (left and right).
When reagent 1 is centered, press “Last” button.
The instrument will select the last reagent.
Center in the same way the last reagent.
When finished click on “Save” button to save.

Note that if you exit without saving you will loose your changes.
Click “cancel “ in every moment to exit.

5.2.2.2 Sample Layout
The instrument will select the 1st sample (the one that is marked “1” on the sample tray). Adjust it to its position
using the steps arrow (left and right) for horizontal arm.
Use also left and right for rotor centering if needed.
When sample 1 is centered, press “NEXT >” button.
The instrument will select the sample at position 25 (second row).

Center it in the same way as done with sample 1.
The instrument will select the sample at position 43 (third row).

Center it in the same way as done with sample 1.
The save button will become active.

Now is possible to save your changes (click save button) or exit without saving (press cancel).
Note that you can go up/down through the UP/DOWN key.

5.2.2.3 Reaction Tray Layout
The instrument will select the 1st reaction well (the one that is marked “R1” on the reaction well tray). Adjust it to
its position using the steps arrow (left and right) for horizontal arm.
Use also left and right for rotor centering if needed.
When the position 1 is centered, press “NEXT >” button.
The instrument will calculated all the other values, and will select “R7” (second row).
Center it in the same way as done with “R1”.
When sample “R7” is centered, press “NEXT >” button.
The save button will become active.


5.2.2.4 Washing Well Layout
The instrument will select the washing well.

Adjust it to its position using the steps arrow (left and right) for horizontal arm.
The save button is always active.


5.2.2.5 Sensor Testing
The instrument has a special mode that lets you to know if the sensor are working properly or not.
! H2O: Level sensor of the washing solution.
Washing solution is OK
Not enough washing solution
! Waste capacity: Level sensor of the waste tank.
Waste is full.
Waste is not full
! Liquid sensor: Test with wet fingers.
No Liquid
Liquid is detected.
! Impact sensor: Test by pulling on the 2 needles.
Impact has not been detected
Impact has been detected

5.2.2.6 Temperature Adjusting
COARSE ADJUSTMENT
Open the instrument as explained in section 6.3. You have to work on Temperature board, on the left side of the
instrument, shown in the figure below.
Put the tester metal point in order to read the voltage between test – point TP2 (TEMP) (marked in yellow in the
figure below) and the ground marked GNDA (marked in red). Move the trimmer RV1 (marked in orange) in order
to read the voltage J0YR:. This will set temperature to 37°C.
FINE TUNING
Without opening the instrument, switch it on. The '(#) windows appears.
Click on !"#$#"% bottom
Now, on the Utility window, click on the *+,-#.+ button

(“service” is password required)

On the Service window, click on 0(%12" button
Click on the 3+4" button next to 3+56+,("2,+
Click on the button with the number 37° on the “Flow cell “ square
Put the thermocouple in the cuvette lodging. Take care that the thermocouple touches the bottom of the lodging.
Wait 15 minutes in order to reach the temperature homogeneously.

Click on “Calibration” button.
Adjust the temperature until the temperature displayed

match the thermocouple temperature around 37°C.
When you change the value, you can see on the screen
the changed temperature after 1 minute, in order to reach
the new stability.
The adjustment is finished when the thermocouple

temperature and displayed temperature MATCH and are
EQUAL to 37°C (+/- 0.3 °C).
NOTE:
Calibration is no needed for Preheater and reaction well rotor (first incubation). This temperatures
are digitally controlled by microprocessor.
SAMPLE ROTOR Target temperature is: 40°C

PREHEATER Target temperature is: 50°C

5.2.2.7 Pre-Amplifier Board Calibration
Without opening the instrument, switch it on. The '(#) windows appears on the monitor.
Click on !"#$#"% button and then on the *+,-#.+ button (“service” is password required)
Click on the 0(%12" button and than click on 3+4" next to 781"15+"+,.
Take the cuvette out of the incubator.

In the section “Filter”, select “340nm” and verify that the value on T1 window is between 1600 and 8000. If the
value is out of range, you have to adjust the trimmer RV2 that is on the optical group. In order to work on the
trimmer RV2, you have to open the instrument as explained in section 6.3. The RV2 trimmer is marked in red in
the figure below.
T2 is not important and not used by this instrument.
Verify that all the value on the others wave length are between 1600 and 8000.
IMPORTANT:
The trimmer RV2 acts as a general GAIN. Increasing or decreasing the GAIN will affect all the wavelength
transmittance value (T1).
T1 is a parameter that is related to the opposite of the filter transmittance.
The BIGGER is the value of T1, the LOWER is the filter transmittance.
The T1 value is printed each time you perform a test with the instrument as INITIAL BASELINE.
The instrument has autodiagnosys on startup to check if this value exceeds the maximum treshold allowed. If so
the instrument will give you a warning:
Blank Filter 340: 02018 (old = 1915)

Blank Filter 405: 02318 (old = 2215)
Blank Filter 492: 00991 (old = 912) *WARNING: UNDER LIMIT*
Blank Filter 505: 13018 (old = 13915) *WARNING: OVER LIMIT*
Blank Filter 546: 03058 (old = 3001)
Blank Filter 578: 03028 (old = 2992)
Blank Filter 630: 03518 (old = 3415)
This is warning on energy level:

This means that filter 492 has too much energy.
While filter 505 has too few.
Solution:
1. Add gelatine (coating) to filter 492 in order to decrease the energy on photodetector.
2. Remove gelatine from filter 505 in order to increase its trasnmittance (and so the energy on p.d.)
3. Adjust sligltly the gain (with RV2) if needed.

Z018K2,-.,K,*.
Be careful in the case you open the instrument for operation because of possible electric shocks
Z0/14=6A@CCBA&=CD1%"A&=@C1$C?14=6HBC6=CD1MGBV=QGB1-"QB6
1. Disconnect the bottle’s connectors from the vertical wall (C1 and C2 in fig).
2. Disconnect the suction and dispensing flexible tubes. In order to avoid the leakage, you have to follow these
steps
! You have to rotate the peristaltic pump by hand counterclockwise in order to make the tube empty.
! Take off the tubes in this order: n°1, n°2
! Move the arm in order to have the needles above the rotor gear plate, and then, take off the tube n°3.
! Take off the tube n°4 from the connection.

Z07114=6$66B#QG=CD1&PB1&'$C6OB'1$'#
WARNING: the calibration of the reaction wells and needles centering is lost when the transfer
arm is disassembled, thus is necessary to re-calibrate both afterwards.
! Disconnect the suction and dispensing flexible tubes as shown in section 6.1.
! Remove the 3 screws fixing the arm case (A).
! Remove the screw that is on the back of the arm (B).
! Detach the connector that links the two led with the main board.
! Detach the connector that comes from the axle from the main board.
! Remove the four screws that are under the arm, around the axle.
! Reverse this steps to reassemble, taking into account to perform the new calibration of the reaction well and
needle centering. When you fix the arm on the axle, you have to rotate the axle anti clockwise until you have
the mechanical stop. Than you can fix the arm in order to have the needles in front of the syringe.
A A B

Z0J1*P$CD=CD1&PB1*$6=CD
The casing consists in 2 principal parts: the upper part that contains the round plexiglas protection and the base,
on which there is the reagent plate.
This two parts are fixed together by 6 screws and they are fixed to the aluminum base by two screws on the front
side and two on the back side.
1. Take off the arm case, unscrewing the 3 screws on the top and detaching the connectors that link the two
led with the main board
2. Disconnect the suction and dispensing flexible tubes as shown in section 6.1.
3. Remove two screws on the front side and two on the back side of the instrument
4. Lift the little case cover that is under the arm (in picture below, it is indicated with the big black arrow).
5. Detach the connector that links the plate led with the main board that is on the left back side of the rotor gear
group.
6. Reverse this steps to reassemble, taking into account to perform the calibration of the reaction well and
needle centering.

Z0L1*P$CD=CD1&PB18$=C1S@$'?
There are 6 kind of main board:
! MOTOR CONTROLLER BOARD/ RS485 / TEMPERATURE AND LAMP BOARD
1. Remove the nuts and the washers that fix the dissipator to the instrument.
2. Remove the dissipator.
3. Remove the screws fixing the main board to the base.
4. Remove the faulty board and reverse the process to reassemble with the new one.
! READING MAIN BOARD
1. Remove the screws fixing the main board to the base.

2. Remove the faulty board and reverse the process to reassemble with the new one.
Z0R1*P$CD=CD1&PB1+H&=A$G1I'@"H
1. Remove the casing as explained in section 6.3.
2. To remove the bath that is positioned under the optical group, remove the
four nuts that are on the back side of the vertical wall.
3. Disconnect the motor and led connectors from the motor board on the
back of the vertical wall.
4. Disconnect the lamp and the Peltier connector from the board
cod.110703.
5. Disconnect the pre-amp from the reading board cod. 110702.
6. Remove the 2 screws that fix the Resistance.
7. Remove the 4 screws that fix the optical group to the base, marked with a
circle in the picture.
8. Reverse this steps to reassemble.

Z0Z1*P$CD=CD1&PB1M=G&B'1FPBBG
WARNING! Proceed very carefully when handling the filter wheel in order to avoid to scratch or soil the
filters.
1. Remove the optical group, following the instruction of section 6.5.

2. Remove the screws that fix the filter wheel support to the optical group.
3. Remove the screw that is on the side of the wheel.
4. Remove the filter wheel from the support using a special group composed by two screws.
5. Reverse the process to reassemble the new filter wheel.
Z0[1*P$CD=CD1&PB1M=G&B'
There is a free position in order to install a filter with a wavelength different from that of the filters installed in the
instrument.
1. Remove the filter wheel.

2. Remove the screws that fix the ring.
3. Remove the ring and the spring.
4. Replace the filter paying attention that the mirror face is turned downwards, furthermore pay attention to the
gelatins under the filter. AVOID to touch the 2 optical surfaces of the filter and the gelatins by hands not to
soil them.
Z0(1*P$CD=CD1&PB1M=G&B'1FPBBG18@&@'
1. Remove the optical group as explained in section 6.5.
2. Remove the filter wheel as explained in section 6.6.
3. Remove the four screws that fix the motors to the motor support.
4. Remove the faulty motor and reverse the process to reassemble the
group.

Z0Y1*P$CD=CD1&PB1;B'=6&$G&=A1;"#H
1. Disconnect the gray tube.
2. Remove the screw that fixes the peristaltic pump rotor to the motor.
3. Disconnect the motor connector from the motor board
4. Remove the 4 screws that fix the motor to the peristaltic pump support and to the vertical wall.
5. Remove the faulty motor/rotor/support and reverse the process to reassemble the group.
Z0/)1*P$CD=CD1&PB1;BG&=B'1*BGG
2. Remove the four screws that fix the motors to the motor
support.
3. Remove the screws that fix the incubator to the dissipator.
4. Remove the faulty Peltier cell and place the new one taking care
of the position.
Z0//1*P$CD=CD1&PB1;P@&@?=@?B
2. The photodiode is under the case. Remove the screw with the ground wire.
3. Remove the faulty photodiode and place the new one taking care of the
position. It must be on the center of the hole.
Z0/71*P$CD=CD1&PB1M$C
2. Detach the corresponding connector from the main board.
3. Remove the 4 screws and nuts.
4. Remove the grid.
5. Remove the fan.
6. Insert a new fan in order to have the label visible from the outside. The air
flux is outwards.
7. Place the grid and set with 4 screws and nuts.
8. Attach the connector to the main board.
Z0/J1*P$CD=CD1&PB1-B#HB'$&"'B1%BC6@'
2. Remove the screw that fix the temperature sensor board to the
incubator.
3. Detach the corresponding connector from the main board.
4. Insert a new temperature (with heating compound) sensor and
reverse the process to reassemble the group.

Z0/L1*P$CD=CD1&PB1<$#H
The group is equipped with a 12V/20W halogen lamp, with an
estimated shelf life of 2000 hours.
1. Switch the instrument off and wait until it is cool, about 15

minutes. Disconnect the power supply.
3. Disconnect the lamp cables from the board.
4. Remove the screws that fix the lamp support to the
incubator.
5. Unscrew the screws which sustain the ceramic lamp
holder on the bracket
6. Replace the lamp paying attention not to touch with
fingers the lamp bulb
7. To center the lamp, loosen the screws which fix the
bracket of the lamp to the incubator as much as sufficient
to be able to shift it. The light passes through the lent in
the incubator and the light must cover completely the little hole that is inside of the incubator.
8. Screw again the screws and connect the lamp cables to terminal board.
Z0/R1*P$CD=CD1&PB1<BC6
2. Remove the lamp support, unscrewing the screws.
3. Remove the brown insulator.
4. Remove the screwed ring.
5. Remove the lens from its holder taking care not to touch it with
the fingers.
6. Insert the new lens and fix it to the holder with the screwed ring.
7. Remount the parts.
Z0/Z1*P$CD=CD1&PB1-'$C6OB'1K'#1:B'&=A$G18@&@'
The transfer arm is an independent module that can be taken apart by removing the 4 nuts that fix it to the
supporting base.

2. Detach the transfer arm set from the supporting base, disconnecting the connectors from the main board
and removing the 4 nuts.
3. Remove the 4 screws and nuts fixing the vertical motor.
4. Position the new motor, place the screws and nuts back, tense the belt by slightly displacing the motor and
then fasten the screws to fix the motor.
5. Place the transfer arm back on the supporting base \=&P@"&1 O=V=CD1=&1\=&P1&PB1 6A'B\6. Check the correct
position of the transfer arm putting the casing on the instrument.
You have to verify that the needles are exactly above the center of the reagent bottle. If the needle are up or
down, you have to move the transfer arm group.

Take off the case taking care not to move the transfer arm group. Now you can fasten the screws.
6. Attach the connectors to the main board as shown in the following pictures.
This is the board on the

vertical wall, on the right side
of the transfer arm group Attach here the
connector coming from
the new motor
Attach here the connector

coming from the arm
Attach here the

This is the board on connector coming from
the base the encoder and
rotation motor

Z0/[1*P$CD=CD1&PB1-'$C6OB'1K'#13@&$&=@C18@&@'
2. Detach the transfer arm set from the supporting base, disconnecting
the connectors from the main board and removing the 4 nuts.
3. Detach the photodetector holder removing the screws that fix it to the
arm displacer.
4. Loosen the threaded pin and remove the slitted disk.
5. Remove the special screws that fix the motor to the displacer and
detach the connector from the main board.
6. Place the motor into displacer, insert the special screws, tense the
belt and fix the position by fastening the screws.
7. Attach the connector to the main board as shown in the section 6.15.
8. Put the slitted disk into position, placing it at 1mm from the motor
surface and fix it with the threaded pin.
9. Assemble the photodetector holder and check that the slitted disk
does not interferes with the photodetector.
10. Place the transfer arm back on the supporting base and fix it with the screws. Check the correct position of
the transfer arm putting the casing on the instrument (see the pictures and the instruction in section 6.15)
Fasten the screws only after verifying the correct position.
Z0/(1*P$CD=CD1&PB13@&@'18@&@'
The change or the rotor motor should be performed without disassembling the pre-warming device, in order to
avoid it further.

2. Remove the screws and nuts fixing the motor.
3. Detach the connectors from the main board as shown in the picture below.
4. Insert the new motor in its holder and place the screws and nuts.
5. Tense the belt and fasten the screws to fix the position.
6. Attach the connectors to the main board.

Z0/Y1*P$CD=CD1&PB14=G"&B'18@&@'
2. Remove the screws and nuts that fix the motor to the holder.
3. Detach the connector from the main board.
4. Insert the new motor in its holder and place the screws and nuts.
5. Tense the belt and fasten the screws to fix the position.
Z07)1*P$CD=CD1&PB1;'BN\$'#=CD14BX=AB1@O1&PB13B$A&=@C1FBGG
2. Remove the pre-warming device loosening the screws that fix the assembly
supports to the supporting base.
3. Detach the connectors from the main board.
4. Remove the screws that fix the wire to the pre-warming channel.
5. Remove the wire and disconnect the wire from the button.
6. Coil the new resistor wire around the pre-warming channel.
7. Fix the extreme parts of the wire fastening the screws.
8. Connect the wire to the button.
9. Place the pre-warming channel on the tray. The wire block and the button
must be on the right side, near the transfer arm.
To detect if the reaction well warmer is working properly, the metal should reach the target temperature of 40°C,
this to ensure 37°C in the reaction well itself.

The resistance between the connector to the resistance that HEATS the plate is approximately 4.5 Ohm.
4.5 Ohm
Wired into the

reaction well
BOARD ID:5, heater
Safe themostate
Z07/1*P$CD=CD1&PB1%$OB&E1%H'=CD
2. Loosen the 2 threaded pins that fix the column to the support. Move the column away from its lodging to
permit the extraction of the faulty spring.
3. Insert the spare spring and re-assemble the arm by reversing the former steps.
Z0771*P$CD=CD1&PB1,BB?GB1%B&
1. Remove the arm casing unfastening the screws fixing it.
3. Unscrew the connectors and detach the teflon tubing
from the needles.
4. Remove the screws fixing the spring retention piece.
5. Remove the set formed by the spring retention piece,
the spring and the needles.
6. Insert a new set and fix it with the screws taking care
that the detection plate remains inside the detector.
7. Attach the connector on the main board.
8. Attach the teflon tubing to the needles, fully introducing
them, and screw the connectors again.
9. Re-assembling the arm casing.
Z07J1*P$CD=CD1&PB1;'BN\$'#=CD14BX=AB1@O1&PB13B$DBC&
1. Remove the arm casing unfastening the screws.
2. Detach the teflon tubing from the dispensing needle.
4. Remove the teflon tubing from the outlet.
5. Detach the connector coming from the axle.
6. Remove the four screws fixing the pre-warming device supporting plate and disassemble the plate.
7. Re-assemble the arm reversing the former steps, taking care that the detection plate remains in the inside of
the detector.
Z07L1<"Q'=A$&=@C
In order to have a fluently movement of the arm (vertical and horizontal), of the rotor gear and of the diluter, you
have to lubricate the following components one time in a year. If the instrument works in a dusty ambient, you
have to lubricate two times in a year.
! Up/Down movement: you have to lubricate the belt using grease and the two columns using oil
! Rotation arm movement: you have to lubricate the belt using grease
! Rotor gear movement: you have to lubricate the belt using grease
! Diluter: you have to lubricate the belt and the revolving screw using grease

[01*K3.1K,41*<.K,2,I
In order to get an optimal operation of this instrument, it is necessary to follow some minimal maintenance rules.
1. Never use detergents or abrasive products for cleaning the outside of the instrument. Use only a cloth with
water and neutral soap.
2. Avoid the penetration of liquid into the inner part of the instrument. If liquid is spilled into the instrument,
clean it with damp paper or cloth.
3. Close the plexiglas protection when not in use in order to avoid dusty.
[0/1*GB$C=CD1@O1&PB1+H&=A$G1*@#H@CBC&61]<$#H^1<BC6^1M=G&B'61KC?1;P@&@?=@?B_
! Recommended material:
non abrasive, lint free paper
alcohol + ether (50/50) solution
cotton ear picks
lens cleaner (blower type)
! For a proper manipulation of the optical components, the following general precautions should be taken into
account:
" The working area should be clean and in order
" As the components are fragile, they should be treated carefully; a fall could result in breakage
" Avoid touching the operative surfaces with the fingers. Lenses, filters and photodiode should be held by
their sides and the lamp by its connecting terminals.
" To clean the components, first undust with the rubber bulb to avoid the scratches caused by small
particles on the surface when rubbing with the paper.
" In case of persistent or greasy dirt, slightly rub with a paper moisten with the alcohol/ether solution and
then with a dry paper. Sometimes, when cleaning the filters or the photodiode window, the use of the
cotton hear picks may be helpful together with the paper to clean the most delicate parts.
" Once the cleaning is finished it is convenient to go over with the rubber bulb in order to remove any
residual paper or cotton lint left on the surface.
" When assembling or disassembling any component take care to use the corresponding tools and follow
the written procedures, since they have been devised to avoid manipulation problems.
[071*GB$C=CD1@O1&PB1M=G&B'6
1. Remove the filter ring and the filter spring from the wheel and dislodge the filters as indicated in the section
6.5 and 6.13.
2. Clean as indicated in the section 7.1.
3. Reassemble as indicated in the section 6.5.
[0J1*GB$C=CD1@O1&PB1<BC6
1. Remove the screwed ring and the lens from the support as indicated in the section 6.14.
3. Reassemble as indicated in the section 6.14.
[0L1*GB$C=CD1@O1&PB1;P@&@?=@?B
1. Remove the photodiode as indicated in the section 6.9
[0R1*GB$C=CD1&PB1MG@\N&P'"1*"XB&&B
Cleanness of the flow-thru cuvette is a must. For a proper maintenance proceed as follows:
" to clean the inner part, refer to the User’s Manual
" to clean the external part, use alcohol and then dry with a soft paper.

[0Z1IBCB'$G1*GB$C=CD1@O1&PB12C6&'"#BC&
It is important to keep the instrument free of dust, that in great extent affects the optical system. Carefully
remove dust from the inside of the instrument specially from the fan vanes, using a dump cloth or a small
vacuum cleaner.
[0[1;'BXBC&=XB18$=C&BC$CAB
It is recommended to carry out the following yearly or after each 2000 hours of operation.
ROTOR MECHANISM
1. Verify the belt tension. By rotating the driving pulley, its movement be fully transmitted to the
pulley axle.
2. Verify the centering of the reaction wells in the heating channel.
PRE-HEATER
1. Its maintenance consists only on checking the proper status of the pre-warming channel and
the tray.
ARM MECHANISM
1. Verify the tension of the belt in charge of the horizontal and vertical movements.
2. Lubricate the displacer guides (use oil S.A.E.:30 or similar)
DILUTER MECHANISM
1. Verify the tension of the driving belt.
2. Clean and lubricate the revolving screw (use oil S.A.E.:30 or similar)
OPTICAL SYSTEM
1. Clean the optical components.
2. Clean the filters.
3. Clean the lens.
4. Clean the photodiode.
5. Wash the flow-thru cuvette.
6. Calibrate the photometric system.
PIPETTING SYSTEM
1. Check the water-tightness of the syringe piston. Verify that there is no leakage or formation
of micro bubbles. Substitute in that case.
2. Change the sipping circuit tubes.
3. Change the silicone tubing of the syringe valve.
4. Check the needles. Verify that they are properly aligned. Change if they are damage.
5. Check the priming tube. Check there are no obstructions or change in its diameter. Change
in that case.
6. Clean the washing station.
SIPPING SYSTEM
1. Change the teflon tubing.
2. Change the peristaltic tubing.
3. Check the waste tubing. Change it in case of cracking or obstruction.

K;;.,42`1/
SUMMARY OF TECHNICAL SPECIFICATIONS
IBCB'$G1*P$'$A&B'=6&=A6
Processing capacity: up to 54 positions (including samples, calibrators and controls) per tray in a work plan.
Incubation 1: 21 to 9999 s
Incubation 2: 0 to 180 s
Unlimited replicates for blanks, calibrators and samples
Calibration storing
Patient data (name, age, sex, etc. ) files – demography data base
QC
%$#HGB1-'$E
Sample cup capacity: 1.2 ml maximum
Tray capacity: 54 cups for samples, calibrators and controls
3B$DBC&1-'$E
Tray capacity: 20 reagent bottles of about 45 ml
3B$A&=@C1FBGG6
12 rows with 12 wells each
Reaction well capacity: 1 ml maximum
3B6B'X@='6
Wash bottle: 0.5 l
Waste bottle: 0.5 l
There is also the possibility to connect to external waste tank.
;'@D'$##=CD
Tests: unlimited
Profiles: Up to 9 with an unlimited number of tests
Calibrators
Controls
Filters
Reagents
KC$GE6=618@?B6
End point: 1 or 2 reagents
Differential
Fixed time
Kinetic
Multi Standard
a=CB&=A1KC$GE6=6
Absorbance measurements during the programmed interval
Linearity evaluation
Use of factor or calibrator
*$G=Q'$&=@C1-EHB6
Factor
Single calibrator: for one test (specific) or common to several test (multiple)
Calibration curve
*$G=Q'$&=@C1*"'XB
Up to 8 standards
Axes: Linear and Logarithmic
Calculation functions: Spline, Linear Regression, Square Regression, Polygonal

b"$G=&E1*@C&'@G
Analytical limits Control: Blank, Linearity, Factor
Up to 3 control materials per test
Levey- Jennings charts/shewart
%$#HGB1KC?13B$DBC&14=6HBC6=CD
One single syringe pipetting up to 1000 #l (positive displacement), 1/16 #l steps
Sample volume range: 2 to 200 #l in 1/16 #l steps
Reagent 1 volume range: 30 to 1000 #l in 1/16 #l steps
Reagent 2 volume range: 0 to 1000 #l in 1/16 #l steps
Liquid detection: ohmic Sensor
-B#HB'$&"'B1*@C&'@G
3 thermostated areas
Reagent pre-warmed in the transfer arm (+/-1°C)
Reaction mixture thermostated in the reaction wells to 37°C $ 2°C
Reaction mixture thermostated in the flow cuvette to 37°C $ 0.2°C
+H&=A$G1%E6&B#
Principle: interference filter
Readings: monochromatic or dichromatic
Filters wheel with up to 8 filters and automatic filter selection
Light source: halogen lamp (12 V and 20 W)
Detector: Silicon Photodiode
Absorbance range: -0.200 to 2.500 O. D.
Spectral range: 320 to 690 nm
Wavelength error: $ 2 nm
Bandwidth: 8 $ 2 nm
Resolution: 0.0001 O. D.
-'$C6OB'1%E6&B#
Continuous flow system, with peristaltic pump
Capacity of the cuvette flow: 18 #l
Automatic calibration
;PE6=A$G14=#BC6=@C6
680 (wide) x 720 (large) x 530 (high) mm
Weight: 55 kg
.GBA&'=A$G13B>"='B#BC&6
115/230 VAC ($ 15%) (autosense)
50/60 Hz
350 VA
K66=6&$CAB1&@156B'6
Automatic selection of the calibrators and controls required for a work plan
Automatic selection of the reagents required for a work plan
Dialogue screens (Windows) for programming, preparing work plans, presenting reports, etc.
Automatic alert messages on the screen
I'$HP=A6
Calibration and Kinetic curves
Quality Control (Levey-Jennings)

K;;.,42`17
TUBING

K;;.,42`1J
TROUBLESHOOTING
SECTION A:
Operational and maintenance error (no need of opening the instrument cover)
Aspiration needle
!"#$$
Dispensing

.33+318%I *K5%.1c1%+<5-2+,
Pump calibration value > 1.6 % Aspiration needle is obstructed (clean necessary from top
to bottom)
% Tube disconnected (check)
Too long time depleting washing cup > 20 sec. % Aspiration needle obstructed
% Volume calibration required
Air bubbles into the cuvette % Flow cell is dirty (need washing with deproteinizer agent)
% Check tube size (110 to 125) and air gap value
% Peristaltic pump calibration needed
% Aspiration needle obstructed
Volume calibration % R1 not present (put R1 in the carousel)
Error: R1 not present or air into the dispensing circuit % Air inside dispensing circuit (make diluiter prime)
% Dispening needle obstructed (clean from top to bottom)
Prime diluiter % Perform volume calibration
Needles bump into the washing well % Make diluiter prime without washing cup, then put again
the washing cup and make volume calibration
High CV (low precision / repetibility) % Dispening needle obstructed (clean from top to bottom)
Diluiter drift observed for same sample % Use washing solution (perchloric acid 50% diluited) or
pepsine based solution for clean dispensing needle (use
special “clean dispening needle” program, in MAIN-
>utility)
Linearity test out of 3% max error % Adjust offset of preamplifier board through “Dark current
setting procedure”
% Check for obstruction in the needles
Too much residual solution IN ALL reaction well % Volume calibration is needed to adjust minimum volume
Too much residual solution IN SOME reaction well % Aspiration needle is obstructed. Need to be cleaned.
First sample underestimation in kinetic test (GOT, GPT) % Reagent is too cold (wait more before performing test)
% The cuvette is cold due to the previous washing: increase
st
the 1 incubation time
% Washing solution is too cold?
Leakage from ASPIRATION needle. % Check the connection of (B) tube with flow cell and
aspiration needle
% Check the peristaltic pump rubber grey tube
% Check the connection of (A) tube
% Check integrity of tube (A) and (B)
Leakage from DISPENSING needle. % Check the connection of (C) tube with (D) tube. Screw the
joining to seal it.
% Check the tube (D) connection to electrovalve. Replace
the O-ring if necessary.
% No need to thight excessive! O-Ring is present. Excessive
strenght will damage permanently the Electrovalve.
% Check integrity of tube (C) and (D)
No aspiration from WASH BOTTLE % Check the O-Ring presence and integrity on the left side
of electrovalve (E-tube)
% Check the connection of E tube
The probe is not connected properly
The probe does not aspirate sample and/or reagent If the module works correctly, check if there are problems in
the tubing and if there is enough washing solution in the
container.
Check the diluter valve
The probe does not dispense the solution into the sampling Check if there is enough wash solution in the container

well Check all the tubing.
Check the sampling probe. If it is dirty, clean it. If there are
The test using a 3 #l sample size is not reproducible some scratches on it, change it.
Check the flow cell; clean it if it is necessary.
Check if the aspiration probe may be dirty or blocked.
Bad aspiration into the flow cell. Check the tubing.
Check the movement of the aspiration arm.
Check if the probe is positioned correctly
Check the tubing from the well to the valve.
The peristaltic pump works correctly but the washing well is Check the valve.
not emptied. The silicon tube inside the peristaltic pump may be damaged
or badly set.
Check the tubing of the peristaltic pump.
Check if the micro-flow cell is empty, in case fill it with water.
The analyser cannot perform reference values. Check the peristaltic pump tubing and change them if
necessary.
Air bubbles in to the cuvette. Recalibrate peristaltic pump.
Check the aspiration probe and its connection with cell. There
may be some leakage or air bubbles in the cell or the probe
could be dirty.
The sampling of distilled water could not be correctly executed
during the resetting.
Check if the wash solution container is empty.
Check the peristaltic pump valve.
Check if the photometer lamp is burnout.
Adjust the aspiration volume; it could be too big or too little.
Check if the controls are analysed following the manufacturer
The results of the controls are out of range. methods.
Check if the parameters settings (wavelengths, temperature,
sample volume, reagent volume, and factor) are correct.
Check if the water used for the controls is bi-distilled or
deionised.
Check if the reagents, controls and standards are prepared
following the manufacturer instructions.
Check if you have used the recommended wash solution.
It could be that the cell or the reagent is contaminated and
Kinetics tests (in particular GOT and GPT) give bacteria may inhibit the reaction. Clean the cell or change the
underestimated results. reagent container.
Check if you have used the correct factor. Check the
temperature and the volume you have set.
Check which water, reagents, control serum and wash
solution you have used.
Check the filter.
Check if the reagent is expired, not fresh or not correctly
stored.

SECTION B:
Hardware error (need of opening the instrument cover and full board access)
.''@' %@G"&=@C
% Check the connector of the sample rotor motor and home sensor
Arm bump due to rotor misaligment to the sample rotor board (ID 5).
% Check for false or bad contact of the connectors to the motor and
Error msg to the home sensor. Plug the connector properly and check the
HOME ERROR: ID 6 continuity of the wiring with a “beeping” multimeter.
HOME ERROR: ID 5 % Clean the home sensor by blowing pressured air from the dust.
NEEDLE IMPACT ERROR: ID 6 % The home sensor is not working properly and causing spike.
Change the home sensor board (Generally this cause wide
misaligment).
% Lubricate the belt and the gear of the motor.
% Check the dissipator of the board that is assembled properly.
% Cuvette friction: switch off the instrument and check that the
sample rotor wheel is running without friction (some cuvette are
causing excessive friction in to the rotor).
% Replace the motor control board (ID 5).
Arm bump due to horizonatal arm misaligment % Switch off the instrument and check if tha arm is running free
without friction when moving it by hand.
Error msg % Check the connector of the horizontal arm home sensor to the
HOME ERROR: ID 6 horizontal arm motor board (ID 4).
NEEDLE IMPACT ERROR: ID 6 % Check for false or bad contact of the connectors to the motor and
to the home sensor. Plug the connector properly and check the
continuity of the wiring with a “beeping” multimeter.
% Clean the home sensor by blowing pressured air from the dust.
% The home sensor is not working properly and causing spike.
misaligment).
Vertical movement of the arm malfunctioning % Switch off the instrument and check if the vertical movement is
running free without friction when moving it by hand, without
Error msg loosing position.
HOME ERROR: ID 6 % Check for the belt assembly (there is a block that fix the belt to the
NEEDLE IMPACT ERROR: ID 6 arm for motion transmission, fixed with screws. Check if this
screws are loose).
to the home sensor. Plug the connector properly and check the
% Clean the home sensor by blowing pressured air from the dust.
% The home sensor is not working properly and causing spike.
misaligment).

Encoder error % Switch off the instrument and check if the horizontal movement of
Error msg the amr is running free without friction when moving it by hand,
Encoder error: ID 4 without loosing position.
to the encoder board. Plug the connector properly and check the
% Check if the encoder board leds are active when moving the
horizontal arm by hand (Be sure that the instrument is reset or not
initialized!, otherwise you can damage the horizontal arm if it stay
in tension).
% The encoder board needs to be replaced if the activity leds are
not blinking when moving by hand the arm in horizontal way.
Timeout error on finding home % The home sensor is not connected or not working. Check
Error msg connections.
TIMEOUT ON FINDING HOME. ID (all) % The motor is not moving: check motor connection to its moving
board.
% Check if the flag of the home is correclty entering into the home
sensor.
% Check the continutiy of the home sensor with the motor board.
Diluiter and syringe error % Check SW version: install latest release.
Error msg % Check if no cable are interfering with the motor or the flag that fit
HOME ERROR: ID 3 into the home sensor.
TIMEOUT ON FINDING HOME. ID 3

4=$DC@6&=A1@O1.CA@?B'1S@$'?
Digital output.
Connected to board number 4.
Code number: 110700
Rules:
The encoder board works properly when turning the horizontal arm by hands the signal changes form 0 to 5V
continuosly approximately every 10 steps.
The 3 LEDs on the encoder board must change their state when changing the positioning of horizontal arm.
Example:
Arm position sensor : Output = 5V
Different arm position : Output = 0V
7 /
FILTER MOTOR CONNECTOR:
red
4 MOTOR PHASES yellow
blue
orange
.CA@?B'1+"&H"&1])1@'1R:_ +"&H"&1])1@'1R:_
IC? IC?
dR: dR:

4=$DC@6&=A1@O18$DCB&=A1%BC6@'1]!$GG1%BC6@'_.
Digital output.
Connected to BOARD number 7.
Code number: 110700
Rules:
The sensor board works properly when turning the filter wheel by hands there is a point where the output goes
low (0V). This is the home position for the filter wheel.
Example:
Magnet is far from sensor : Output = 5V
Magnet is on the sensor : Output = 0V
7 /
FILTER MOTOR CONNECTOR:
red
4 MOTOR PHASES yellow
blue
orange
!@#B1+"&H"&1])1@'1R:_
IC?
dR:

4=$DC@6&=A1@O1%BC6@'1<8JR1-B#HB'$&"'B1%BC6@'.
Analogue output.
BOARD number 2.
Code number: 110703
Rules:
The sensor board works properly if output is related to temperature with the following equation:
-B#HB'$&"'B1e1+"&H"&1]#:_U/)
Example:
Output = 235 mV means temperature detected by sensor board is 23.5 °C.
d(:
%BC6@'1Q@$'?
IC? +"&H"&

4=$DC@6&=A1@O1+H&=A$G1%BC6@'
Digital output.
Connected to BOARD number 4, 5, 6, 3.
Code number: 110700
Rules:
The sensor board works properly when moving the motor by hands when the optical sensor is obstructed the
output goes low (0V). This is the home position for the motor.
You can also use a paper to obstruct the path of the optic sensor to diagnostic the sensor.
Example:
Optic obstructed : Output = 5V
Optic free : Output = 0.5V
%BC6@'1Q@$'?
7 /
MOTOR CONNECTOR:
red
4 MOTOR PHASES
yellow
blue
orange
!@#B1+"&H"&1])1@'1R:_
IC?
dR:

AUTODIAGNOSYS PARAMETER AND MEANINGS
This is an example of the printout of the instrument during autodiagnosys.
-----------------------------
Computer info
-----------------------------
Family : 6
Model : 6
Speed : 1469 MHz ;!K%.1/W
Information regarding external computer and its
OS : Microsoft Windows 98 SE
operative system.
Total memory : 128 MB
IP Address: : 10.0.0.1
Total disk space: 38160 MB
Free disk space : 31398 MB
-----------------------------
Initializing diagnostic.
2003-10-17 16:10:52 :Resetting hardware :OK!
2003-10-17 16:10:54 :Checking hardware :
Board number 1 version: 1.04
Board number 3 version: 1.13 ;!K%.17
OK!
2003-10-17 16:11:06 :Checking tank level :OK! (;!K%.1J)
2003-10-17 16:11:08 :Initializing motors :OK! (;!K%.1L_
2003-10-17 16:11:34 :Checking temperature sensors :OK! (;!K%.1R_
PCB : actual= 29.0 Set=24.0
Incubat: actual= 39.6 Set=37.0
Rotor : actual= 23.7
Preheat: actual= 34.8
2003-10-17 16:11:36 :Checking filter wheel : (;!K%.1Z_
Checking position 2 / 8: ...OK!
OK!
2003-10-17 16:12:05 :Now priming diluiter....OK! (;!K%.1[_
2003-10-17 16:12:42 :Testing level sensors....OK! (;!K%.1(_
Start volume: 3106 uL
2003-10-17 16:12:44 :Aspirating in flow cell....OK!
2003-10-17 16:12:55 :Testing level sensors....OK!
End volume: 1362 uL
Estimated error: 12 % (;!K%.1Y_
Pump calibration value: 1.506900
2003-10-17 16:12:58 :
------------------------------
Energy levels:
Filter 1 --> 26823 (Old=5326) *WARNING: Energy level under LOW LIMIT*
Filter 3 --> 7518 (Old=274)
Filter 4 --> 16406 (Old=6070) *WARNING: Energy level under LOW LIMIT* &;!K%.1!"#
Filter 5 --> 16036 (Old=5998) *WARNING: Energy level under LOW LIMIT* Filter energy values
------------------------------
2003-10-17 16:13:15 :Today calibration: 14620 (;!K%.1//_
Factory calibration: 11469
2003-10-17 16:13:19 :Compensation values: 14640
Factory calibration: 11469 (;!K%.1/7_
6 warning(s)
SUCCESS!

8.K,2,I%
The instrument may fail in one of this phase of autodiagnosys. This is useful to understand the problems.
PHASE 1: Problem on the external computer.

PHASE 2: Generally timeout error. A Board is not connected or (if connected) the board is not working properly. Identification
number may be corrupted.
PHASE 3: Tank sensor not working properly or the washing tank sensor is disconnected. Check if the sensor are working with a
multimeter (valid state are 0 or 5 V). If the sensor are working properly, the problem is inside the board number 8 (the
board to which is connected tanks sensor)
PHASE 4: The motor cannot initialize. Generally home error. Cause may be motor disconnected (in this case the motor is not
moving) or the home sensor not working properly (Timeout on finding home ). Refer to the ID of the defective board, and
check its connection to the motor and if the home sensor is working properly or not (see procedure above).
PHASE 5: Temperatures:
;*S1111W11$A&"$Ge17Y0)1%B&e7L0) fN12C&B'C$G1@C1&PB1=C6&'"#BC&
2CA"Q$&W11$A&"$Ge1JY0Z1%B&eJ[0) fN-$'DB&1=61J[g*
3@&@'11W11$A&"$Ge17J0[ fN-$'DB&1=61DBCB'$GGE1L)g*
;'BPB$&W11$A&"$Ge1JL0( fN-$'DB&1=61$'@"C?1R)g*
If there is a reading error, may be a cable disconnect or a temperature sensor not working properly.
Check with procedure relative.
PHASE 6: Filter positioning check. If error in this phase, there is too much distance between the filter wheel magnet and sensor in
its housing. You should disassesmble the filter wheel and assemble it properly. You can also align the hall sensor.
PHASE 7: If error in this phase you may need to perform a volume calibration, or you have the dispensing needle (the one on the
left, connected with the syringe) obstructed. Use the cleaning needle to clean it.
PHASE 8: Error on level sensor. Touch the needles with the finger and see if the LED GREEN is on (should be ON when inside
water, OFF when outside). If problem check connection of predosifing board with board number 6.
PHASE 9: If error or warning in this phase, recalibrate peristaltic pump through utility menu.
Good calibration value are between 0.8 to 1.8.
If value is bigger, you probably have the aspiration needle obstructed. Use the cleaning needle to clean it.
PHASE 10: If error or warning in this phase are due to filter energy level.
Energy too high. Decrease the gain of the preamplifier board (see page 34).
Energy too low. Increase the gain of the preamplifier board (see page 34).
THE GAIN WILL ACT IN ALL THE FILTER, DECREASING/INCREASING ALL FILTERS ENERGY VALUES.
Pay attention, all the filter must be inside the range, without warnings printed out. If you have to act on a single filter,
please disassemble the filter wheel and add or remove some gelatine (type 5, the lighter, is corrresponding to 1000).
PHASE 11: Calibration value. Check if is inside (9000 to 18000). If outside, there may be problem on preamplifier board or reading
board.
PHASE 12: Compensation values. Factory calibration.

Human
Gesellschaft für Biochemica
und Diagnostica mbH
Max-Planck-Ring 21 ! D-65205 Wiesbaden
Germany
Telefon: +49 6122 9988 0
Telefax: +49 6122 9988 100
eMail: human@human.de
Internet: http://www.human.de
01/2005-01

Humastar 80 Service Manual

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Service Manual

2/63 Service Manual HumaStar 80

1. Liquid processing system

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On the transfer arm there are two needles:

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refer to our website for latest software upgrade.

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The optical system is in charge of performing the photometric readings.

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Position Filter Equalisation

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110704 110703 110702

110700 110700 110700

110700 110700 110700

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ID BOARD CODE Function

0 110704 RS232 to RS485 Interface board

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Liquid detector LED

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! Ordinary or occasional maintenance (RECOMMENDED supervision of service engineer)

The following operations belong to ordinary / occasional maintenance:

! Reagents layout calibration

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Board version menu:

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When finished click on “Save” button to save.

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The instrument will select the sample at position 25 (second row).

The instrument will select the sample at position 43 (third row).

The save button will become active.

Note that you can go up/down through the UP/DOWN key.

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The save button will become active.

Note that you can go up/down through the UP/DOWN key.

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The instrument will select the washing well.

The save button is always active.

Note that you can go up/down through the UP/DOWN key.

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! H2O: Level sensor of the washing solution.

Not enough washing solution

! Waste capacity: Level sensor of the waste tank.

Waste is not full

! Liquid sensor: Test with wet fingers.

! Impact sensor: Test by pulling on the 2 needles.

Impact has not been detected

Impact has been detected

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