06 Servicemanual Rev03 Pdf

HumaStar 100/200 | Service Manual

Cat. No. 168902

REVISION LIST OF THE MANUAL Rev. /DATE.

REVISION DESCRIPTION

01/2013-02

First edition

02/2013-10

Review of first edition

03/2014/01

Revised version

SYSTEM VERSION VERSION

DESCRIPTION

0.44.2.15

HI Application software

1.34G

HumaStar 100 Firmware

1.34K

HumaStar 200 Firmware

COPYRIGHT Copyright 2013, Human Gesellschaft für Biochemica und Diagnostica mbH, Wiesbaden, Germany. All rights reserved. No part of this documentation may be reproduced in any form, nor processed, copied or distributed by means of electronic systems, without prior permission of HUMAN in writing. Since all precautionary measures were taken into account in producing these operating instructions, the manufacturer accepts no responsibility for any errors or omissions. This includes any liability for damage that could arise from possible incorrect operation based on this information. Subject to changes without notice as result of technical development.

SERVICE UND SUPPORT

CONTENTS

TABLE OF CONTENTS 1 SAFETY INSTRUCTIONS

9

1.1 INTRODUCTION

9

1.2 USER WARRANTY

9

1.3 INTENDED USE OF THE INSTRUMENT

9

1.4 GENERAL SAFETY WARNINGS

10

1.5 DISPOSAL MANAGEMENT CONCEPT

10

1.6 BIOHAZARD WARNING

11

1.7 INSTRUMENT DISINFECTION

11

2 THE ANALYZER HUMASTAR 100/200

13

2.1 GENERAL DESCRIPTION

13

2.2 MAIN CHARACTERISTICS

13

2.3 INSTALLATION

13

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6

Shipping and delivery Packaging Responsibilities Prior to setting-up Installation Moving

2.4 ANALYZER COMPONENTS

2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9

Function group identification Mechanical functions Sampling arm Needle wash station Reagent tray Sample tray and cuvette rotor Optical group Cuvette wash station Hydraulic system

3 COMPONENT PARTS

13 13 14 14 16 21 21 21 22 22 23 24 24 25 26 28 31

3.1 CPU BOARD

31

3.2 POWER SUPPLY BOARD

31

3.3 LEVEL AND SHOCK SENSOR BOARD

32

3.4 POWER SUPPLIES 24 V AND 12 V

32

3.5 GROUND CONNECTIONS

33

3.6 OPTICAL LAMP

34

3.7 HYDRAULICS PANEL

34

3.7.1 3.7.2 3.7.3 3.7.4

Front side Rear side Diluter and valve tubing Manifold

34 35 36 37

3.8 WASH STATION

37

3.9 EXTERNAL TANKS

39

4 TERMINAL PROGRAM

41

4.1 HOW TO USE THE TERMINAL PROGRAM

41

4.2 SERVICE MENU

42

5 HARDWARE TEST MENU (F1)

43

5.1 COLUMNS OF THE HARDWARE TEST TABLE

44

5.2 LOGICAL POSITIONS

45

5.3 PUMPS, VALVE AND LAMP TEST (F4)

47

5.4 CONTINUOUS INPUTS DISPLAY (F5)

47

6 MECHANICAL CALIBRATIONS MENU (F2)

49

6.1 OPERATIONS

49

6.2 CALIBRATION ROWS

50

7 MECHANICAL CHECKS MENU (F3)

55

7.1 RN/IP CHECK (F1)

55

7.2 SN/OP CHECK (F2)

55

7.3 AN/SN/OP CHECK (F3)

56

7.4 OP+FS HOME CHECK (F4)

56

7.5 ALL CHECK (F5)

56

7.6 OP READING CHECK (F6)

57

7.7 DS CHECK (F7)

57

8 OPTICAL READING TEST MENU (F4)

59

8.1 SET O.D. REFERENCE (F1)

60

8.2 SELECT CUVETTE (F2)

60

8.3 CHANGE CUVETTE F3)

61

8.4 READ ALL FILTERS (F4)

61

8.5 AUTOZERO (F5)

62

8.5.1 Autozero (F5-1) 8.5.2 Test (F5-2) 8.6 OUTER PLATE READING OFFSET (F6)

8.6.1 Search fine reading offset (F6-1)

62 64 65 65

CONTENTS

8.6.2 Adjust cuvette rough offset (F6-2) 8.7 FILTER WHEEL TEST (F7)

8.7.1 Test FS home repeatability (F7-1) 8.7.2 Test filter wheel offset + peak (F7-2)

66 67 67 68

8.8 CLEAR ERRORS (F8)

70

8.9 STATUS OF CUVETTES (F9)

70

8.10 G AND Z CUVETTES SELECTION SHORTCUTS

71

9 WASHINGS (F5)

73

9.1 WASHINGS MENU

73

9.2 WASH POSITION (F1)

74

9.3 EXECUTE WASHES (F2)

74

9.4 FILL WASH CUVETTE (F3)

75

9.5 STARTUP (F4)

75

9.6 SPECIAL PUMP TESTS (F5)

75

9.6.1 9.6.2 9.6.3 9.6.4 9.6.5

Pumps test (F5-1) Fill hydraulic tubes + Pumps self test (F5-2) Empty tubes (F5-3) Check residues (F5-4) Adjust pumps (F5-5)

76 77 78 78 79

9.7 WASH NEEDLE (F6)

80

9.8 WASH STATION TEST (F7)

80

9.9 CLEAR ERRORS (F8)

80

9.10 RINSE CUVETTES (F9)

80

10 SYSTEM PARAMETERS

81

10.1 EDIT PARAMETERS (F7)

81

10.2 PARAMETERS PAGES

82

10.3 FIND PARAMETER (F5)

83

10.4 BACKUP PARAMETERS (F6)

83

10.5 RESTORE PARAMETERS (F7)

83

10.6 SAVE THE PARAMETERS LIST AS A TEXT FILE

84

11 ADJUSTMENTS

85

11.1 A/D VOLTAGE REFERENCES ADJUSTMENT

85

11.2 REACTION PLATE TEMPERATURE ADJUSTMENT

86

11.3 OPTICAL OFFSET AND GAIN ADJUSTMENT

87

11.3.1 Necessary tools 11.3.2 Offset adjustment 11.3.3 Gain adjustment

88 88 88

11.3.4 Cuvettes selection shortcut 11.3.5 Interference filters 11.3.6 Readings out of range 11.4 FILTER WHEEL ADJUSTMENT

11.4.1 11.4.2 11.4.3 11.4.4

Necessary tools Optical home switch adjustment FS belt adjustment Offset adjustment

11.5 REACTION PLATE BELT ADJUSTMENT

11.5.1 Necessary tools 11.5.2 OP belt tightening 11.5.3 Access to the OP motor screws

89 89 89 90 90 90 91 91 91 91 91 92

11.6 NEEDLE VERTICAL ADJUSTMENT IN THE WASH WELL

93

11.7 WASH STATION DOWN ADJUSTMENT

94

11.7.1 Rough automatic calibration 11.7.2 Fine calibration 11.8 ADJUSTMENT OF THE COVER DETECTION SWITCH

12 SERVICING

94 94 94 95

12.1 LAMP REPLACEMENT

95

12.2 SAMPLE TRAY REPLACEMENT

96

12.3 SINGLE REACTION CELL REPLACEMENT

98

12.4 REACTION ROTOR REPLACEMENT

99

12.5 NEEDLE REPLACEMENT

101

12.6 INTERFERENCE FILTERS REPLACEMENT AND EQUALIZATION

103

12.7 VACUUM PUMP REPLACEMENT

105

12.8 VACUUM PUMP WEARING PARTS REPLACEMENT

106

12.8.1 HumaStar 100 12.8.2 HumaStar 200

106 107

12.9 PERISTALTIC PUMP HEAD REPLACEMENT

108

12.10 DILUTER REPLACEMENT

108

12.11 DILUTER SEALING GASKET REPLACEMENT

111

12.12 SAMPLING ARM REPLACEMENT

111

12.13 LEVEL SENSOR WIRING REPLACEMENT

112

12.14 EXTERNAL TANKS FLOATS REPLACEMENT

113

12.15 OPTICAL PREAMPLIFIER REPLACEMENT

114

12.16 CPU BOARD REPLACEMENT

118

13 FIRMWARE UPDATING – EPROMS REPLACEMENT

119

13.1 EPROMS REPLACEMENT – COMPILATION CHANGE

119

CONTENTS

13.2 EPROMS REPLACEMENT – VERSION CHANGE

120

13.3 REPLACEMENT OF VERY OLD EPROMS – DATA SYNCHRONIZATION 121

14 TROUBLESHOOTING

123

14.1 ANALYZER DOESN'T CONNECT

123

14.2 BAD PRECISION OF OPTICAL READINGS

124

14.2.1 14.2.2 14.2.3 14.2.4 14.2.5

Noise on the optical signal Imprecision of the reaction plate positioning Imprecision of the filter wheel positioning Dispensation problems Incorrect vertical positioning of the needle

125 125 125 125 125

14.3 BAD REPEATABILITY OF AUTOZERO, UNSTABLE OPTICAL SIGNAL

126

14.4 REACTION PLATE TEMPERATURE OUT OF CONTROL

126

14.5 DIRTY AND QUICKLY EXCLUDED REACTION CUVETTES

128

14.5.1 14.5.2 14.5.3 14.5.4 14.5.5

First checks Check the reaction cuvettes Check the cause of the high absorbances Execute the pump test Execute the cuvettes special wash

14.6 DROPLET FORMS ON NEEDLE TIP

14.6.1 Droplet formes at the end of the needle tip 14.6.2 Droplet hangs at the side of the needle

128 128 128 129 130 130 130 131

14.7 ABERRANT/NULL RESULTS, REAGENT BOTTLES WRONGLY DETECTED FULL 131 14.8 ERROR "NEEDLE SHOCK DETECTOR IS STUCK"

131

15 PERIODICAL CHECK-UP, SERVICE PROCEDURE

133

15.1 TWELVE MONTHS PROGRAMMED MAINTENANCE

133

15.1.1 Update firmware and software 15.1.2 Cover 15.1.3 Lamp 15.1.4 Sampling needle 15.1.5 Wash station needles 15.1.6 Wiring, connectors 15.1.7 Hydraulic tubes, floats 15.1.8 Diluter 15.1.9 Pumps 15.1.10 Reagents cooling 15.1.11 Sample plate 15.1.12 Reaction plate cuvettes

133 133 133 133 133 134 134 134 134 135 135 135

15.1.13 Test and adjustment procedures in the service menu 15.1.14 Diluter and pipetting

16 SYSTEM PARAMETERS LIST 16.1 EPROM PARAMETERS TABLE

16.1.1 Inner plate (IP) motor 16.1.2 Outer plate (OP) motor 16.1.3 Filters selection (FS) motor 16.1.4 Sampling needle (SN) motor 16.1.5 Diluter syringe (DS) motor 16.1.6 Needle rotation (RN) Motor 16.1.7 Wash station (AN) motor 16.1.8 Motor speeds, home tolerances 16.1.9 Pumps 16.1.10 Various parameters 16.1.11 Barcode 16.1.12 Level sensor, floats 16.1.13 Temperatures 16.1.14 Dilutions, pipetting 16.1.15 Reading

17 ERROR CODES

135 136 137 137 137 138 138 138 139 140 140 141 142 143 144 144 146 146 147 149

17.1 HI SOFTWARE ERROR CODES

149

17.2 FIRMWARE EXECUTION ERROR CODES

154

17.2.1 17.2.2 17.2.3 17.2.4

Execution errors Resources errors Off-line predilutions errors Errors caused by firmware/software mistakes

18 HI SOFTWARE INSTALLATION/UPDATE

155 155 155 156 157

18.1 SETTINGS

157

18.2 HI SOFTWARE UPDATING – RELEASE 0.4X

157

18.2.1 18.2.2 18.2.3 18.2.4

Logging on Creation of a backup copy of the data folder Installation of the new software Installation steps

157 158 158 158

18.3 HI DATA FOLDER

159

18.4 COMPATIBILITY WITH WINDOWS 7

160

18.5 DEVICE DRIVERS

160

CONTENTS

19 LIS ASTM INTERFACE SOFTWARE

161

20 SERVICE SCHEMATICS

163

20.1 INSTRUMENT BLOCK DIAGRAM

163

20.2 CPU BOARD LAYOUT

164

20.3 POWER BOARD LAYOUT

165

20.4 SAMPLING ARM BOARD LAYOUT

166

20.5 HIGH VOLTAGE WIRING

167

20.6 LOW VOLTAGE WIRING

168

20.7 INTERNAL RS232 SERIAL CABLE

174

20.8 OPTICAL PREAMPLIFIER CABLE

174

20.9 SAMPLING ARM CABLE

174

20.10 SAMPLING ARM CABLE CONSTRUCTIVE SCHEMA

175

20.11 HYDRAULICS DIAGRAM HUMASTAR 100

176

20.12 HYDRAULICS DIAGRAM HUMASTAR 200

177

20.13 HYDRAULICS PANEL LAYOUT (FRONT SIDE)

178

20.14 HYDRAULICS PANEL LAYOUT (REAR SIDE)

179

20.15 PUMPS PLATE HYDRAULICS MANIFOLD

180

20.16 WASH STATION

181

20.17 WASH STATION HYDRAULICS MANIFOLD HUMASTAR 100

182

20.18 WASH STATION HYDRAULICS MANIFOLD HUMASTAR 200

183

20.19 FLOATS AND TUBES CONNECTION ASSEMBLY

184

20.20 FLOATS AND TUBES ELECTRICAL CONNECTIONS

185

20.21 REFRIGERATION PLATE

186

20.22 MAIN POWER INPUT PANEL

187

20.23 CENTRAL MECHANICAL ASSEMBLY

188

20.24 MECHANICAL DESIGN – INTERNAL VIEW

191

20.25 FRAME BASE

192

SAFETY INSTRUCTIONS

1 SAFETY INSTRUCTIONS

1.1 Introduction This manual must be available to the service personnel. For accurate service, use and maintenance, please read the following instructions carefully. In order to avoid damage to the instrument or personal injury, carefully read the ”GENERAL SAFETY WARNINGS”, describing the appropriate operating procedures. Please contact your HUMAN authorised local Technical Service in the event of instrument failure or other difficulties with the instrument.

1.2 User Warranty HUMAN warrants that instruments sold by one of its authorised representatives shall be free of any defect in material or workmanship, provided that this warranty shall apply only to defects which become apparent within one year from the date of delivery of the new instrument to the purchaser. The HUMAN representative shall replace or repair any defective item within this warranty period at no charge, except for transportation expenses to the point of repair. This warranty excludes the HUMAN representative from liability to replace any item considered as expendable in the course of normal usage, e.g.: lamps, valves, syringes, glassware, fuses, tubing etc. The HUMAN representative shall be relieved of any liability under this warranty if the product is not used in accordance with the manufacturer‘s instructions, altered in any way not specified by HUMAN, not regularly maintained, used with equipment not approved by HUMAN or used for purposes for which it was not designed.

1.3 Intended Use of the Instrument The instrument is intended for laboratory application by professional users. It must be operated in perfect technical conditions, by qualified personnel, in such working conditions and maintained as described in this manual, in the GENERAL SAFETY WARNINGS. This manual contains instructions for qualified professional operators.

9

10

1.4 General Safety Warnings Use only chemical reagents and accessories specified and supplied by HUMAN and/or mentioned in this manual. Place the product so that it has proper ventilation. The instrument should be installed on a flat, stationary working surface, that is free of vibrations. Do not operate in area with excessive dust. Operate at temperature and at a humidity level in accordance with the specifications listed in the User Manual. Do not operate this instrument with covers and panels removed. Use only the power cord specified for this product, with the grounding conductor of the power cord connected to earth ground. Use only the fuse type and rating specified by the manufacturer for this instrument. The use of fuses with improper ratings may pose electrical and fire hazards. To avoid fire or shock hazard, observe all ratings and markings on the instrument. Do not power the instrument in environments that are potentially explosive or at risk of fire. Prior to cleaning and/or performing maintenance on the instrument, switch off the instrument and remove the power cord. Only cleaning materials described in this manual may be used, as other materials may damage parts. It is recommended to always wear protective clothing and eye protection while using this instrument. All warning symbols that appear in this manual must be carefully observed.

1.5 Disposal Management Concept The applicable local regulations governing disposal must be observed. It is the user‘s responsibility to arrange for proper disposal of the individual components. All parts which may contain potentially infectious materials must be disinfected by suitable, validated procedures (autoclaving, chemical treatment) prior to disposal. Applicable local regulations for disposal must be carefully observed. The instruments and electronic accessories (without batteries, power packs etc.) must be disposed of according to the applicable local regulations for the disposal of electronic components. Batteries, power packs and similar power sources must be removed from electric/electronic parts and disposed of in accordance with applicable local regulations.

HumaStar 100/200 | Service manual

SAFETY INSTRUCTIONS

11

1.6 Biohazard Warning Analytical instruments for in vitro diagnostic application involve the handling of human samples and controls which should be considered at least potentially infectious. Therefore every part and accessory of the respective instrument which may have come into contact with such samples must equally be considered as potentially infectious. The „BIOHAZARD“ warning label must be affixed to the instrument prior to first use with biological material!

FIGURE 1 Biological Hazard Symbol

1.7 Instrument Disinfection Before performing any servicing on the instrument it is very important to thoroughly disinfect all possibly contaminated parts. Before the instrument is removed from the laboratory for disposal or servicing, it must be decontaminated. Decontamination must be performed by authorised well-trained personnel, and in observance of all necessary safety precautions.

12

HumaStar 100/200 | Service manual

THE ANALYZER HUMASTAR 100/200

2 THE ANALYZER HUMASTAR 100/200

2.1 General description HumaStar 100/200 performs both clinical chemistry and turbidimetric immunochemistry tests. The compact and fully random automated analyzer is especially suited for medium- and small-size laboratories.

2.2 Main characteristics Small desktop space, 680 x 760 x 550 mm (width x depth x height). 940 mm height with open top cover. Light weight, 51 kg. 127 tests per hour, typical reagent mix. Method, needle and cuvette management of incompatible tests. Easy PAUSE request to add samples and reagents. Automatic recovery from empty reagent bottles. Multiple reagent bottles management. Extends range of kinetic tests through a dynamic processing of the readings. Simple access to hydraulic pumps system for easy maintenance. Run-time sample predilution in reaction well. Automatic standards predilution.

2.3 Installation

2.3.1 SHIPPING AND DELIVERY The new analyzer and its accompanying accessories have been shipped in two separate containers designed to provide adequate protection during transport under normal conditions.

2.3.2 PACKAGING The analyzer is wrapped in stretch-plastic and securely fixed within a strong wooden container mounted on a lift-pallet. The required accessories are placed in a well-packed, heavy cardboard carton.

13

14

2.3.3 RESPONSIBILITIES The shipment of the analyzer generally is the responsibility of the distributor and delivery is often made in person by an agent of the distributor. FIGURE 2 Shipment damages

If the shipment arrives by private or commercial carrier, immediately inspect the condition and if there is any damage to either containers report it immediately to both transporter and distributor. If the damage is extensive, it may be best to refuse the shipment to avoid any doubt in the attribution of responsabilties.

2.3.4 PRIOR TO SETTING-UP Prepare a location for your analyzer based on maximum laboratory efficiency and adequate work space. Keep in mind the patterns of work and staff circulation to ensure a trouble-free lab operation. 2.3.4.1 Site The laboratory bench for the analyzer work-station should be a level surface of solid construction to avoid vibration. A space of 15 cm on both sides and behind the instrument is the minimum requirement to allow adequate ventilation. An additional work area on one or both sides of the instrument will contribute greatly to the work efficiency of the technician during operation. FIGURE 3 Workbench

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15

If sufficient space is available a surface 90 cm deep by 200 cm in working width will allow a generous surface for the analyzer and the necessities of work (e.g. tubes, reagents, samples, calibrators, controls, pipettes, user manuals but also monitor, keyboard, mouse and printer – if necessary). 2.3.4.2 Environment The location of the analyzer should be dust-free, away from drafts, heat sources and direct sunlight. Satisfactory operations may be conducted with temperature ranges from 16°C to 30°C and with a variation during the testing process not to exceed ±2°C. Temperatures outside this range may cause erroneous operation. Air conditioning may be required to ensure result quality if temperatures exceed these limits. Relative humidity should not fall below 10% or rise above 80% with no condensation. Ensure that the electromagnetic standards are met. Refer to European directive on electromagnetic compatibility (see Document 89/336/CEE of 03/05/89). 2.3.4.3 Storage If for any reason the instrument has been subjected to prolonged storage under unfavorable conditions a revision by specialized technicians may be required before proceeding with installation. 2.3.4.4 Unpacking The analyzer arrives in a wooden container, the top of which is secured with screws. The four walls are fixed to the lift-pallet with screws at the bottom line. Taking off the bottom line screws allows to lift up the complete box to get easy access to the analyzer inside.

The top cover should be lifted up by two persons.

FIGURE 4 Wooden container

16

As you have already been told, and as HUMAN suggests, it is best to wait for the arrival of a representative of the distributor to remove the analyzer from the container (keep the wooden container in case you need to return the analyzer for adjustment or repairs).

FIGURE 5 Shipment contents

However, the cardboard carton of miscellaneous items and accessories may be opened and checked for the following: - User manual, - Software installation CD, - Water tank, - Waste tank, - Cleaning solution tank, - Tank connections group (boxed), - Accessories kit (boxed). See also complete "Shipment list" provided.

2.3.5 INSTALLATION After selecting an appropriate site for the instrument and for the PC (inclusive monitor, keyboard and mouse), you can proceed with the necessary connections. Connections required are located in two points on the sides of each instrument.

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2.3.5.1 Left side FIGURE 6 Left side connections

Liquid sensors connection plug snap-on connectors for water tank, cleaning solution tank and waste tank. 2.3.5.2 Right side

FIGURE 7 Right side connections

USB port type B; power cord fitting (incuding fuses compartment).

18

2.3.5.3 PC connections

FIGURE 8 USB connections type A

Connect the USB mouse to a PC port (1). Connect the USB touch-screen (optional) to a PC port (1). Connect the USB keyboard to a PC port (1). FIGURE 9 VGA connection

Connect the monitor to PC with a VGA cable (2). FIGURE 10 Power connection

Connect a power cord to the monitor (3) and to the power outlet (4). Connect a power cord to the PC (3) and to the power outlet (4).

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FIGURE 11 Schuko connection

Adaptors may be required for local power outlets.

Typically instruments are delivered with 'Schuko' connections (4). 2.3.5.4 Instrument connections

FIGURE 12 USB cord

FIGURE 13 USB connection type B

Connect a USB cord (5) to the PC port (1) and to the analyzer port (6). Connect a power cord to the instrument (3) and to the power outlet (4).

20

2.3.5.5 Hydraulic connections FIGURE 14 Tank positions

FIGURE 15 Connection tubes

FIGURE 16 Hydraulic connections Hydraulic tubes have easy-touse snap-on connectors each with a special valve to prevent liquid loss when disconnecting tubes. Ensure that the metal tab of each connector is released and ready to be snapped in place to ensure a safe attachment. The presence of bubbles in the system may be caused by liquid leakages. Check that the connectors are correctly snapped in place.

HumaStar 100/200 | Service manual

Place the three tanks below the work surface. Water and cleaning should be positioned as high as possible under the work surface. Waste should be positioned as low as possible.

Position connecting tubes as straight as possible to avoid the creation of air bubbles.

Insert and rotate the BLACK connector to secure the three liquid level sensors (2). Connect the three tanks to the corresponding hydraulic tube connections on the analyzer. Hydraulic connections are color coded as follows: - BLUE: Water (3). - GREEN: Cleaning solution (4). - RED: Waste (5).

THE ANALYZER HUMASTAR 100/200

21

2.3.6 MOVING The movement of an instrument after it has been put into operation should be handled with extreme care. One person should never try to move an analyzer alone. If the instrument needs to be moved over a large distance in or out of the laboratory please follow the instructions in the sequence below: -

-

-

Execute the "Empty entire system" procedure (see User Manual / Maintenance). Switch-off the analyzer, the computer and the reagent refrigeration, and disconnect all lines and tubes connected to the instrument. Be sure to avoid contact with potentially infectious liquid waste when disconnecting tubes. Fix the sampling arm in the uppermost position using the foam protection tube provided with the shipment. At least two persons are now required for moving the analyzer. Lift the instrument slowly holding the metal base and in such a way that the cover remains in the closed position. When the analyzer has been located in its new position, reconnect all lines and tubes according to the installation procedure contained in this manual.

2.4 Analyzer Components

2.4.1 FUNCTION GROUP IDENTIFICATION 1. 2. 3. 4. 5.

Sampling arm. Needle wash station. Reagent tray. Sample tray. Cuvette rotor with opening for cuvette access. 6. Optical group. 7. Cuvette wash station (shown for HumaStar 200).

FIGURE 17 Function groups 1

22

8. Diluter syringe. 9. Peristaltic pumps (shown for HumaStar 200). 10. Pinch valve

FIGURE 18 Function groups 2

2.4.2 MECHANICAL FUNCTIONS The principal mechanical movements of HumaStar 100/200 are powered by stepper motors which are activated when the analyzer is switched on and remain on until power-off or stand-by. The liquid movements are controlled by peristaltic pumps and vacuum pumps powered by direct current motors and activated when required.

2.4.3 SAMPLING ARM FIGURE 19 Sampling arm

Rapid action sampling arm. (Up, down and rotational movement, controlled by stepper motors with optical limit switches.)

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High-precision coated sampling needle. Liquid level sensor. Vertical needle shock sensor. A single arm is positioned to serve all sampling functions (reagents, samples and dilutions). The needle stroke permitted by the vertical movement of the sampling arm allows the use of sample tubes of up to 100 mm in height. The arm rotates 360° beginning and ending at the midpoint of the reagent tray. During this cycle the needle passes over all reagent bottles, the reaction cells and the sample tubes or cups. Test mix preparation begins first with the selection of the reagent (R1) to be used. Then, depending on the type of test to be performed, a sample (S) or a second reagent (R2) is collected in the sequence required for that test. Reagent(s) and samples are deposited in a reaction cell in reverse order. This action mixes the liquids as they are deposited. The sampling needle is washed after each individual pipetting.

2.4.4 NEEDLE WASH STATION FIGURE 20 Needle wash station

Following each sampling operation the needle is washed internally and externally to remove reagent and sample residues.

24

2.4.5 REAGENT TRAY FIGURE 21 Reagent tray

Removable tray (29 bottle positions for reagents and 1 for diluent). Power independent refrigeration. Refrigerated plate.

The removable tray is suitable

Independent refrigeration permits reagents to remain on-board when the analyzer is switched off. Multiple assortments of reagents can be prepared in advance of testing needs using additional trays. This section consists of a recessed semicircular compartment adjacent to the rotating sample arm. The bottom of the compartment is lined with a continuous refrigerated plate. When in position the tray permits bottles to rest directly on the plate. Refrigeration is provided by three 30W Peltier cells mounted directly under and in contact with the plate. A heat sink and fans located below cool the lower heated surfaces of the Peltier cells.

for bottles of either 50 ml or 20 ml.

2.4.6 SAMPLE TRAY AND CUVETTE ROTOR FIGURE 22 Sample tray and cuvette rotor

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Sample tray (inner plate) Removable 60 position sample tray (tubes of 12-13 mm or cups of 0.5-1.5 ml). Optional: Tray with 20 small and 20 large diameter positions to accommodate 20 tubes of 12-16 mm (using adjustable clips) or 20 cups of 3.5 ml. Cuvette rotor (outer plate) 80 reaction cells. Plastic rotor. Rotor safety cover. High quality reaction cells permit the execution of 30.000 tests before replacement is required. The rotational movements of both components are controlled by stepper motors with optical limit switches. The cuvette rotor aligns a reaction cell to receive the collected test mix for incubation. Needle access to individual cells is through an opening in the rotor cover. The rotor safety cover ensures safe management of dangerous liquids, protects the near environment and lessens the chance of contamination. During the ongoing testing process results are read as individual cells align with the optical group. Test readings are taken over the entire reaction process. As the testing process continues, programmed wash procedures are performed to the cells just under the wash station. The incubation temperature is controlled at 37 °C by the means of a heating strip, a temperature sensor and a thermostate.

2.4.7 OPTICAL GROUP FIGURE 23 Optical group

26

Halogen lamp assembly with heat sink. Rotating filter disk. 8/9 interferential filters of various wavelengths. 2 focusing lenses. Photoelectric detector. Signal amplifier. The execution of 20 readings for each test ensures full monitoring of test results. A self contained unit with a rotating disk positioned to enable an interferential filter of the wavelength required to be placed in the optical path between the halogen light source, the aligned reaction cell and the photoelectric detector for the test reading. Optical group diagram FIGURE 24 Optical group diagram

2.4.8 CUVETTE WASH STATION 2.4.8.1 Needle mounting FIGURE 25 Needle mounting HumaStar 100

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FIGURE 26 Needle mounting HumaStar 200

2.4.8.2 Wash station FIGURE 27 Wash station HumaStar 200

Shown for HumaStar 200 (safety cover removed). For HumaStar 100 the needles and tubes in position 3 and 6 (right to left) are not installed. HumaStar 100 10 wash needles (4 dispensation, 5 aspiration, 1 drying) HumaStar 200 13 wash needles (5 dispensation, 7 aspiration, 1 drying)

28

2.4.9 HYDRAULIC SYSTEM 2.4.9.1 Syringe assembly FIGURE 28 Diluter and pinch valve

These elements provide aspiration and dispensation functions central to the entire hydraulic system. During operation the sampling needle is immersed in the liquid (reagent, sample, diluent) to be collected and the plunger in the diluter moves backward to aspirate the specified amount of liquid. The sampling needle then moves to its destination (tube, cup, reaction cell) and the plunger moves forward to dispense that volume of liquid. Following completion of each liquid movement the sampling needle is rinsed internally by water diverted through the diluter and externally by water diverted through the needle wash station. Vacuum pumps: Diluter syringe: Pinch valve:

HumaStar 100/200 | Service manual

Located in the rear of the panel behind the manifold. Self-contained micro-metering pump with long-life plunger, stepper motor and optical limit switch. To divert the flow of water for either the internal or the external needle wash.

THE ANALYZER HUMASTAR 100/200

29

2.4.9.2 Pump set FIGURE 29

FIGURE 30

Peristaltic pump

Vacuum pump

The pump set provides the power for all washing functions. 6 (HumaStar 100) / 8 (HumaStar 200) self-priming peristaltic pumps are located in the hydraulic panel. (The peristaltic pumps provided with this analyzer have replaceable cassettes with neoprene tubes that ensure long life.) Two high-efficiency vacuum pumps are located inside the analyzer. 2.4.9.3 Liquid flow FIGURE 31 Manifold

This element collects and channels all the ingoing flow of water and cleaning solution and the outgoing flow of waste between the analyzer and the external liquid tanks. Snap-on connectors and release buttons permit easy and rapid attachment and removal. Safety valves are provided to avoid liquid loss during the operations.

30

HumaStar 100 does not have washing needles / peristaltic pumps 3 and 6.

FIGURE 32 Hydraulic system

HumaStar 100/200 | Service manual

2.4.9.4 Schematic diagram of the hydraulic system The diagram on the following page shows how the elements of the hydraulic system link to perform the liquid functions required (i. e. sampling needle wash, cuvette wash, waste disposal and the control of liquid flow).

COMPONENT PARTS

31

3 COMPONENT PARTS

3.1 CPU board FIGURE 33 CPU board

A: B: C: D: E: F:

Firmware EPROM1. Firmware EPROM2. J10, Reaction plate temperature sensor connector. J6, Optical signal connector. J1, Serial communication flat cable connector. Instrument parameters EPROM.

3.2 Power supply board FIGURE 34 Power board

OP-IP: FS-RN: SN==: DS-AN:

Outer plate – Inner plate motor control. Filters selection – Needle rotation motor control. Sampling needle – Not used motor control. Diluter syringe – Wash station motor control.

32

3.3 Level and shock sensor board FIGURE 35 Level and shock sensor board

A (Red): B (Black):

Level sensor connection Ground connection

3.4 Power supplies 24 V and 12 V FIGURE 36 Power supplies

A: B:

HumaStar 100/200 | Service manual

Instrument power supply. Input 100-240 Vac, 50-60 Hz. Output 24Vcc – 500W. Refrigerated plate power supply. Input 100-240 Vac, 50-60 Hz. Output 12Vcc – 40W. Output voltage to be adjusted from 12.1 Vcc to 12.2 Vcc.

COMPONENT PARTS

33

3.5 Ground connections FIGURE 37 Ground connection 1

Ground terminal The ground terminal combines: - Connection to main plug. - Connection to central mechanical assembly. FIGURE 38 Ground connection 2

The proper grounding is very important for the correct operation of the photometer preamplifier and the liquid level sensing.

Central mechanical assembly ground connection

34

3.6 Optical lamp FIGURE 39 Optical lamp

A: B: C:

Lamp fastening knob. Lamp connector. Lamp holder.

3.7 Hydraulics Panel

3.7.1 FRONT SIDE FIGURE 40 Hydraulics panel, front side

HumaStar 100/200 | Service manual

COMPONENT PARTS

35

D1-D6: Dispensing pumps for wash station needles 1-6. (HumaStar 100 is not having D3 and D6.) AW: Aspiration pump to wash needles mounting. DW: Dispensing pump to wash needles mounting. DS: Complete diluter assembly. EV: Valve switching internal (ON) / external (OFF) needle wash, using DW. Spare head for peristaltic pump: Peristaltic pump head.

3.7.2 REAR SIDE FIGURE 41 Wiring and tubing

FIGURE 42 Wiring

FIGURE 43 Electrical connections

36

Electrical connector PM2B

Description

Device destination EV

PM1 MDS SDS

Valve switching internal (ON) / external (OFF) needle wash. Needle wash dispensing pump. Diluter syringe stepper motor. Diluter syringe limit switch.

PM2 EV1 – EV6

Needle wash aspiration pump. Wash station dispensing pump 1-6.

DW DS motor DS limit switch interface board AW D1-D6 (HumaStar 100 doesn't have D3 and D6.)

FIGURE 44 Diluter and valve tubing

3.7.3 DILUTER AND VALVE TUBING A Input from the needle wash dispensing pump. B Outout to the external needle wash nozzle. C Wash input to the diluter. D Wash output from the diluter to the sampling needle. E Output to the sampling needle. EV Valve switching internal (ON) / external (OFF) needle wash.

HumaStar 100/200 | Service manual

COMPONENT PARTS

37

3.7.4 MANIFOLD FIGURE 45 Hydraulic panel manifold

The hydraulic connections are feeding the pumps with the system solution.

3.8 Wash station Wash station figures 46 to 50 show HumaStar 200 wash station. FIGURE 46 Wash station unit

38

FIGURE 47 Wash station wiring

FIGURE 48 Needles manifold and needles assembly, top view

FIGURE 49 Needles assembly

FIGURE 50 Manifold to hydraulics panel tubing

A = Aspiration B = Dispensation

HumaStar 100/200 | Service manual

COMPONENT PARTS

39

Wash station up/down limit switches U = UP limit switch. D = DOWN limit switch. FIGURE 51 Wash station up/down limit switches

3.9 External tanks

FIGURE 52 External tanks

A B C

Floats and tubes connection assembly Wash solution tank, 2 liters Waste tank, 20 liters System solution tank, 20 liters

40

The hydraulic tubes have snap-in connectors. They can be unplugged pressing on the lateral metal button. FIGURE 53 Floats and hydraulic tubes connectors

FIGURE 54 Snap-in connector

1.

2. 3. 4.

HumaStar 100/200 | Service manual

Floats connector Waste float (open = full) System and wash solution floats (open = empty) BLUE System solution tube GREEN Wash solution tube RED Waste tube

TERMINAL PROGRAM

41

4 TERMINAL PROGRAM

4.1 How to use the terminal program You can have direct access to the HumaStar 100/200 for service or diagnostic purposes, using the TERMINAL program. FIGURE 55 TERMINAL main screen

To access to the service TERMINAL you must be logged on to the HI software as a Service or Installer user. in the lower middle part of the screen and select Press the CLOUD icon to open it. TERMINAL The tab Log can be used to save a parameters list (see 10.6 Save the parameters list as a text file). The tabs Printer Buffer and Settings ar not active. To operate the TERMINAL, touch the TERMINAL window or click with the mouse inside the TERMINAL window to focus on it. When the TERMINAL window is focused, it is framed by a thin black line. With the right mouse key, or touching the screen for two seconds, the SCREENSHOT/PRINTSCREEN window will be opened: -

Select

to save the current screen as a JPG

-

file. Select

to print the current screen or to Press the CAPS LOCK key to

show a preview first. A printer has to be installed before.

set the upper case on the keyboard. This is mandatory for the TERMINAL operation.

42

4.2 Service menu The command OS allows to access to the SERVICE MENU. All submenus are accessible from here, pressing the appropriate function key on the keyboard (the mouse pointer is visible but deactivated). FIGURE 56 Service menu

HumaStar 100/200 | Service manual

HARDWARE TEST MENU (F1)

43

5 HARDWARE TEST MENU (F1) TERMINAL  OS  F1 HARDWARE TEST. Each line in the table in the middle of the screen represents a particular stepper motor. Use the UP and DOWN arrow keys to select a motor. FIGURE 57 Hardware test menu

44

F1 MOTOR ZERO

F2 MOTOR FWD F3 MOTOR BWD

F4 PUMP,VALVE,LAMP F5 DISPLAY INPUTS M ...

To reach the home position of the selected motor. Shows an "H" followed by the number of lost steps (ideally "0") on the right side of the motor line. When the home position is reached, the appropriate green LED above the connectors J10 and J11 on the power supply board switches on. To move the selected motor forward. To move the selected motor backward. If F1, F2 or F3 causes an error of the motor movement, "S.Err" is shown on the right side of the motor line. To go to the pumps, valve and lamp test. To activate the continuous display of the inputs. To continuously move the selected motor forward and backward, for stress test. To edit system parameters, press the "." key three times.

5.1 Columns of the hardware test table MOT DESCRIPTION ENAB SPEED

IX.STEPS LOG.POS. ABS.POS.

HumaStar 100/200 | Service manual

Motor number. Motor description. To enable/disable the motor current (0 = current off, FREE / 1 = current on, HOLD). Motor speed, in steps/second. This value is read, by default, from the motor speed system parameter and can be changed in the hardware test, only for diagnostics, without affecting the normal work of the analyzer. The lower the speed, the stronger the motor. Number of steps that will be executed with the F2 (forward) and F3 (backward) commands. To go to a logical position (see "5.2. Logical positions"). Absolute motor position in steps. (-32768 = motor not initialized.) Every stepper motor needs 200 steps for one complete revolution. The diluter syringe can perform 2.600 step max.

HARDWARE TEST MENU (F1)

45

5.2 Logical positions INNER PLATE OUTER PLATE

NEEDLE ROTATION

1-60 or 1-40 to move the corresponding sample tube under the sampling needle. 1-80 To move the reaction cell 1-80 in the reading position. 101-180 To move the reaction cell 1-80 under the wash station needle 1 (the rightmost needle). 201-280 To move the reaction cell under the sampling needle. 1-29 (depending on the bottles configuration) to rotate the needle over the corresponding reagent bottle. The other logical positions are the corresponding system parameter numbers: RNWASH RN1_OP RN_IP0 RN_IP1 RNDILC RNWRAP

FILTER SELECTION

86 92 90 91 95 85

Wash needle well position. Reaction plate dispensing hole. External ring of sample plate. Internal ring of sample plate. Diluent position. Wrap position. It is a position, close to the anticlockwise stroke and outside of a reagent bottle opening. It is used by the software to decide how to access to a reagent bottle, clockwise or anti-clockwise. Logical positions 0-9 move to the corresponding filter.

46

SAMPLING NEEDLE

WASH STATION

DILUTER SYRINGE

HumaStar 100/200 | Service manual

The logical positions are the corresponding system parameter numbers: SN1HIG 44 Needle high, 5mm over the reagents bottles. SN1MID 43 Needle 5mm over the sample tubes. SN1LOW 42 Needle 5mm over the reaction cells. SN1REA 49 Needle at the bottom of the reagent bottles. SN1WEL 46 Needle inside the wash well for internal needle wash. SN1PTU 51 Needle at the bottom of sample primary tubes. SN1CUP 50 Needle at the bottom of sample cups inserted on the cups adapter. SN1CU2 54 Needle at the bottom of sample cups on the inner ring of the 20+20 sample tray. SN1DS2 53 Needle inside the reaction cell for the second dispensation. SN1DLC 57 Needle at the bottom of the diluent bottle. The logical positions are the corresponding system parameter numbers: ANHOME 0/111 Home position. ANHIGH 0/112 Under the home position for fast home search. ANTUBE 1 Low immediately over the OP reaction tube ANWA2D 2 Down: quote for second pause in aspiration. ANWA1D 3/113 Down: quote for first pause in aspiration. Up: quote for restart of aspiration. ANWASP 4/115 Needle at the bottom of the reaction cells for aspiration. The logical position indicates the microliters (μl) to dispense.

HARDWARE TEST MENU (F1)

47

5.3 Pumps, valve and lamp test (F4) FIGURE 58 Pumps, valve and lamp test

For testing the peristaltic pumps, unmount the wash arm and place the needles in a be-

Go with the cursor to the pump or valve to be activated and type the number of hundredths of second it must remain activated. The valve that switches the needle wash between the internal wash and the external wash is parallel to the wash well aspiration pump. So the well dispensation pump dispenses internally or externally according to the state of the aspiration pump. Activation of the wash well aspiration pump empties the wash well only. Activation of the needle wash dispensing pump performs an external wash only. The optical lamp is ON with 0 and OFF with 1.

aker. This is to avoid flooding the reaction tray because the vacuum aspiration pumps are not working. When peristaltic pumps or vacuum pumps are activated, the appropriate red LEDs above the connectors J3 or J5 on the power supply board are switching on.

5.4 Continuous inputs display (F5) FIGURE 59 Display inputs

48

Mot.L.Sw. Level Sw.

OP temp. Reading PWM

HumaStar 100/200 | Service manual

Indicates the status of the eight home position sensors (1=engaged, 0=free). Indicates the status of the level sensor (1=no sense, 0=sense level). Level switches (left to right): 1 Liquid level sensing. 0 Vertical shock. 1 Not used. 1 Not used. 0 Waste tank (red). 0 System wash tank (blue). 0 Special wash tank (green). 1 Cover safety switch. Temperature of the OP reaction plate, in tenths of degrees Celsius. Instant A/D reading of the optical group. R indicates the percent voltage supplying the heating resistance of the outer plate temperature control (0-70 %).

MECHANICAL CALIBRATIONS MENU (F2)

49

6 MECHANICAL CALIBRATIONS MENU (F2)

6.1 Operations The mechanical calibration allows to adjust the group of quotes that define all the main operative points of the analyzer. In the table the system parameters are listed that are affected in every calibration point. The calibration points can be selected by direct address, typing the two digits of the row, or with the PAGE UP and PAGE DOWN keys, for sequential access. When one quote of the calibration point is temporary modified, it is shown in reverse. With F2 SAVE POSITION, the new value is recorded and the quote value returns normal. When a calibration point has been saved with F2, on the far right a "v" character appears. Before access, the names of the involved parameters are shown in the table (see FIGURE 60). After the access to the calibration point, the values of the involved parameters are displayed in the table. FIGURE 60 Mechanical calibrations

50

--IP---OP---RN---SN---AN---F6--

Column for inner plate parameter names and values. Column for outer plate parameter names and values. Column for needle rotation parameter names and values. Column for needle vertical parameter names and values. Column for aspiration needle parameter names and values. Column for special functions parameter names and values.

F1 CHECK POSITION F2 SAVE POSITION F3 CALIB. BAR CODE F4 EDIT PARAMETERS F5 MOTORS HOME F6 SPECIAL FUNCT.

Special functions are helpful in case of remote access to the instrument.

UP, DOWN IP/OP MOVE LEFT, RIGHT RN MOVE + - SN/AN MOVE M MOTORS OFF

Return home and check position. Record positions in the system parameters. Not active (for future use). Cell parameters edit. Search home for all the motors and return to position. Allow to check relative movements, levels, water flow, etc. Enabled only if the column F6 is not void. Calling F4 EDIT PARAMETERS, the cursor is positioned on the parameter listed in the F6 column. UP and DOWN arrows move IP or OP motors step by step. LEFT and RIGHT arrows move RN motor step by step. + and – move SN or AN motors down and up. Turns motors OFF. It is recovered with F5 MOTORS HOME.

6.2 Calibration rows The sample needle needs ap-

21 calibration rows are defined, each one calibrating a specific mechanical positioning.

prox. 7 steps to move 1 mm. The vertical collision flag in the sample arm starts moving 5 to 10 steps before SHOCK is displayed.

HumaStar 100/200 | Service manual

REAGENT BOTTLES 01 Sampling needle high, 4 mm over reagent position 1, large bottle. F6 checks the liquid level in the large reagent bottle. 02 Sampling needle low at the bottom of reagent position 1. When touching the bottom (SHOCK displayed), move 10 steps up. 03 Sampling needle high, 4 mm over the last reagent position 29, small bottle. F6 checks the liquid level in the small reagent bottle.

MECHANICAL CALIBRATIONS MENU (F2)

04 05

Sampling needle low at the bottom of reagent position 29. When touching the bottom (SHOCK displayed), move 10 steps up. Sampling needle low at the bottom of reagent position 1, cup. When touching the bottom (SHOCK displayed), move 10 steps up.

DILUENT BOTTLE 06 Sampling needle high, 4 mm over diluent bottle. F6 checks the liquid level in the large diluent bottle. 07 Sampling needle low at the bottom of diluent bottle. When touching the bottom (SHOCK displayed), move 10 steps up. NEEDLE WASH WELL 08 Sampling needle 5 mm over the wash well for vertical sampling needle 1 access. F6 checks the needle rotation position over the wash well nipple and the side position for the needle flush. 09 Sampling needle inside the wash well. F6 checks: - The needle internal wash inside the white nipple. - The needle position over the nipple, inside the water drop (needle must enter inside the drop down to the top of the white nipple). - The external wash of the needle (the water jet has to hit the needle). - The up movement to check if a droplet remains on the tip of the needle. Important for tests using low sample volume (max. 4 μl). SAMPLE TUBES AND CUPS 10 Sample inner plate barcode offset. F6 checks sample inner plate barcode offset. Adjustment for sample position 1: The beam must meet the middle of the tray handle. Adjustment for inner ring: The beam must be in the middle between positions 31 and 60. 11 Sampling needle 5 mm over sample primary tube 1. F6 checks the liquid level in the primary tube 1. 12 Sampling needle at the bottom of the sample primary tube 1. When touching the bottom (SHOCK displayed), move 20 steps up.

51

52

13

14

15

Sampling needle 5 mm over sample position 21 or 31 (first tube of inner circle, depending on tray type). When touching the bottom (SHOCK displayed), move 20 steps up. F6 checks the liquid level in the sample cup in position 21 or 31. Sampling needle at the bottom of sample cup 1 (cup placed on the adapter). When touching the bottom (SHOCK displayed), move 10 steps up. Sampling needle at the bottom of the cup 21 (only for the 20+20 samples tray).

READING POSITION 16 Reaction cell 1 of the outer plate in the reading position. Place cuvette 41 at the center of the cuvettes window. In this way, cuvette 1 is placed in front of the reading position. This position is roughly calibrated. The accurate calibration is made by F6 SPECIAL FUNCTION. F6 finds the fine offset of the reading (same as OS  F4 READING TEST  F6-1 OP READING OFFSET-Fine offset). WASH STATION, NEEDLE DISPENSATION 17 Wash needle 1 (the rightmost) over reaction cell 1. F6 moves the needles down just over the reaction cells. Used to calibrate precisely the reaction cells offset so that the cleaning needle can descend in the next step inside the reaction cells. In this position also the sampling needle must be just over the dispensing position. See also the description in "11.7. Wash station down adjustment". 18 Wash needles down, at the bottom of the reaction cells (ANWASP, one step over the bottom contact). In this calibration row the outer plate position cannot be calibrated. F6 is a calibration procedure that finds out approximately the ANWASP quote for correct aspiration. After auto-search of quote ANWASP with the F6 key, on the right of row 18 the suggested value of ANWASP is displayed. Use the lowest value (i. e. 208 as shown in FIGURE 61). FIGURE 61 Wash needle down test result

HumaStar 100/200 | Service manual

MECHANICAL CALIBRATIONS MENU (F2)

19

53

Sampling needle down at the bottom of the reaction cell, inside the dispensing hole, used by the 2nd dispensation. F6 checks with the shock sensor the vertical position for the 1st dispensation, to give a rough adjustment of the SN1DDS parameter. - If there is shock within 5 steps from SN1DDS, the message "ErLow" is displayed. - If there is no shock within 20 steps, the message "NoShk" is displayed. - Otherwise the message "SHOCK:nn" with the number of nn steps to the shock is displayed. FIGURE 62 Wash needle bottom test result

20

21

Sampling needle over the rotation wrap position. It is a position close to the anti-clockwise stroke and outside of a reagent bottle opening (between 15 and 16). It is used by the software to decide how to access to a reagent bottle: clockwise or anti-clockwise. F6 does the following in three steps: - Move the sampling needle to reagent bottle 15. - Move the sampling needle clockwise to reagent bottle 16. - Move the sampling needle counter-clockwise to the position between 15 and 16. Sampling needle low at the bottom of reagent bottle 1, tube. When touching the bottom (SHOCK displayed), move 10 steps up.

54

HumaStar 100/200 | Service manual

MECHANICAL CHECKS MENU (F3)

55

7 MECHANICAL CHECKS MENU (F3) FIGURE 63 Mechanical check

Some precision and stress tests are executed, using one or more motors at the time. The duration of test in seconds is predefined but changeable. (The tests are partially long lasting.) At the end of the test or when aborting the test by pressing ESC, a report of the errors is displayed.

7.1 RN/IP check (F1) Moves forward and backward the motors of the needle rotation and the inner plate. FIGURE 64 Correct example FIGURE 65 Erroneous example

A loss of 1-2 steps is acceptable while bigger losses of steps are critical and erroneous (see FIGURE 65 above).

7.2 SN/OP check (F2) Moves forward and backward the motors of the sample needle and the outer plate. A loss of 1-2 steps is acceptable while bigger losses of steps are critical and erroneous (see FIGURE 65 above).

56

7.3 AN/SN/OP check (F3) Moves forward and backward the motors of the aspiration and sample needle, and the outer plate. At the end displays the difference between the nominal position and the real position. A loss of 1-2 steps is acceptable while bigger losses of steps are critical and erroneous (see FIGURE 65 above).

7.4 OP+FS home check (F4) This is an important check for the co-operation of components.

Executes the home search of the outer plate and filter selection motors starting from all their positions. After positioning of the outer plate, before starting the home search, the test moves the wash station down and up. 800 cycles = 80 cycles of the outer plate * 10 filters.

7.5 ALL check (F5) Executes the sequence of the F1, F2, F3 and F4 tests. At the beginning requests the duration of the F1 to F3 tests (in seconds). FIGURE 66 Report of the ALL function with the results of the tests F1, F2, F3 and F4

①

Number of tests.  Number of total errors.  Total number of lossed steps for the filter wheel.  Number of AN (wash station up/down movement) errors.  Pre-home position (reduce speed to approach the outer plate home sensor).  Position limit switch.  Number of lossed steps of every filter.

HumaStar 100/200 | Service manual

MECHANICAL CHECKS MENU (F3)

57

FIGURE 67 Speed reduction in the reference zone

Losses of steps are not allowed in the reference zone (positions 61 to 67).

7.6 OP reading check (F6) Test of the outer plate reading movement for all 80 cuvettes. FIGURE 68 Outer plate reading test result

7.7 DS check (F7) Stress test of the diluter syringe movement for 10 μl, 20 μl, …, 990 μl and 1000 μl. A variation of 1 step for each different movement is acceptable, 4 steps are erroneous. FIGURE 69 Diluter syringe test result

58

HumaStar 100/200 | Service manual

OPTICAL READING TEST MENU (F4)

59

8 OPTICAL READING TEST MENU (F4) FIGURE 70 Optical reading test

Filter (0–9) Type 0 to 9 to select the operating filter. ... To edit system parameters, press the "." key three times. ① A/D in mV*10. ② Real time display.  From last fixing with F1 (Set O.D. reference). Column Description 1 Filter number 2 3 4 5 6

7

Filter wavelength in nm Previous reading of the filter in Abs. Current reading of the filter in Abs. Difference in Abs. between the previous and the current readings V = valid value, Err = error, value out of valid range, Dif = error, non repetitive, Ovf = reading overflow. Ratio between current autozero and factory initial value of the autozero. It helps to evaluate the filters downgrade. The factory initial autozero value is stored in TERMINAL with the command OZ9.

60

8.1 Set O.D. reference (F1) FIGURE 71 O.D. reference

Stores the current A/D reading value in the reference value. The O.D. value is the optical density calculated between the current A/D value and the stored reference value. The column in parentesis shows following values for an autozero after a lamp replacement: F0: 25 F1-F8: 1000

8.2 Select cuvette (F2) FIGURE 72 Cuvette selection

Type in the Reading Cuvette field the reaction cell number (1 to 80) which must be used for the reading test. The default value is 32. In this position, the two holes for the adjustment of the GAIN and the OFFSET of the optical preamplifier are placed over the two trimmers to allow the access with a screwdriver.

HumaStar 100/200 | Service manual

OPTICAL READING TEST MENU (F4)

61

8.3 Change cuvette F3) Position the selected cuvette at the center of the cuvette replacement hole, for cuvette inspection or replacement.

8.4 Read all filters (F4) FIGURE 73 Reading of selected cuvette for all filters

Read and display only all the autozero values of the filters, measured in empty cuvettes (i. e. not real autozero, because measured in air). Allows getting the reading of the selected cuvette for all filters. Filter and cuvette = 0 performs a simulation of autozero (reading between the cuvettes to eliminate the influence of cleanness of the cuvettes). It is faster then F5 AUTOZERO because of 10 consecutive gap readings. FIGURE 74 Reading of cuvette 32

62

If a cuvette 1 to 80 is selected, the reading is executed through the cuvette, so the A/D value is lower because of the cuvette absorbance. Then, the reading through cuvette 0 is higher.

8.5 Autozero (F5) FIGURE 75 Autozero menu

Execute the autozero of the optical group. At the end of the autozero processing, a confirmation is requested. 1 stores the current values in the old values, 0 restores the old values. Acceptable range for autozero values: 12.000 to 18.000.

8.5.1 AUTOZERO (F5-1) FIGURE 76 Autozero

HumaStar 100/200 | Service manual

OPTICAL READING TEST MENU (F4)

Column 1 2 3 4 5 6

7

63

Description Filter number Filter wavelength in nm Previous reading of the filter in Abs. Current reading of the filter in Abs. Difference in Abs. between the previous and the current readings V = valid value, Err = error, value out of valid range, Dif = error, non repetitive, Ovf = reading overflow. Ratio between current autozero and factory initial value of the autozero. It helps to evaluate the filters downgrade. The factory initial autozero value is stored in TERMINAL with the command OZ9.

Example of autozero with Dif error:

FIGURE 77 Autozero with Dif error

The analyzer could not obtain two autozero readings with the same value. In case of Dif error, it is necessary to find out the origin of the unreliability: 1. Defective lamp, loose lamp screw. 2. Lamp connections. 3. Defective or broken or loose interference filter. 4. Filter wheel offset (Reading test F7–2). 5. Reaction plate offset (Reading test F6–1). 6. Filter wheel belt (7. Mechanical check F4). 7. Reaction plate belt (7. Mechanical check F4).

64

The test to be performed for checking is noted inside the parentesis. If only filter 1 has the Dif Error, check points 1 and 3. If generally only one filter has the Dif Error, check point 3. Point 3 can also be verified with the autozero repeatability test (F5–2).

8.5.2 TEST (F5-2) FIGURE 78 Autozero repeatability

Repeats 10 times the autozero, calculates the average and the CV% for every filter. FSOP Should always be zero. Home sensor stops at different positions (±1 step).  Unscrew/screw the stirrup to fix the problem. Dark Offset should be 20-30. Even an offset of 100 requires no trimming. O.D. Lamp stability. Maximum variation = 0.001 mAbs. CV% Good values are lower then 0.1000 for all the filters (manufacturing and refurbishing) and lower then 0.2000 for filter 1. If the CV% value is higher, check the following points: 1. Filter wheel FS offset (F7–2): If the filters are not centered on the light beam the light variation increases and the CV% increases. 2. Reaction plate OP offset (F6-1): If the cuvettes are not centered, the light variation and the CV% increases. 3. Defective lamp, loose lamp screw. 4. Lamp connections. 5. Defective or broken or loose interference filter. 6. Filter wheel belt (7. Mechanical check, F4). 7. Reaction plate belt (7. Mechanical check, F4).

HumaStar 100/200 | Service manual

OPTICAL READING TEST MENU (F4)

65

8.6 Outer plate reading offset (F6) FIGURE 79 Reaction plate reading offset

To center the cuvettes for best optical reading in two steps: Rough and fine. A/D: Value stable  OK. Value increasing  wait for finishing warm-up. Value oszillating  problem. 1 - Fine offset The procedure verifies if the current reaction plate reading offset is correct or must be modified. It verifies only the fine tuning and it is supposed that the offset is already set within the range of the reaction cell (cuvette) 1 (see next procedure "Rough offset"). 2 – Cuvette 1 rough offset It is used to find the rough reading offset of cuvette 1. The purpose is to adjust the reaction cuvette 1 position in the center of the small opening of the reaction plate cover.

8.6.1 SEARCH FINE READING OFFSET (F6-1) FIGURE 80 Current reading offset

The test shows the current value of the reading offset (parameter 022 OPOFRD) and the value suggested, supposing that the rough offset of the reaction cell 1 is matched.

The +1/2 step is just to show the exact offset. It must of course be ignored when updating the 022 OPOFRD parameter.

66

FIGURE 81 Different reading offset

If the value is different, the operator can type Y to store the new value or N to keep the old value. FIGURE 82 Fine reading offset finding

8.6.2 ADJUST CUVETTE ROUGH OFFSET (F6-2) FIGURE 83 Rough cuvette offset adjustment

The distance between two cuvettes is 20 steps.

HumaStar 100/200 | Service manual

It is used to find the rough reading offset of cuvette 1. The purpose it to adjust the reaction cuvette 1 position in the center of the small opening of the reaction plate cover.

OPTICAL READING TEST MENU (F4)

67

With the LEFT and RIGHT keys, move the reaction cuvette 1 to the center of the opening. With the F2 key, save the adjusted offset. This positioning is a rough adjustment. The fine adjustment has a scope of +/half cuvette. So the rough adjustment is used to be sure that the cuvette 1 will be employed by the fine adjustment procedure.

8.7 Filter wheel test (F7) FIGURE 84 Filter wheel test

To test the filter wheel home repeatability and also the offset + peak settings.

8.7.1 TEST FS HOME REPEATABILITY (F7-1) FIGURE 85 FS home repeatability

The home positioning is repeated a 100 times and a correlation check is performed. The first two numbers are only for reference and must not be considered. All the numbers in the rows with eight columns must be higher than 0.9990. In this case the result is marked as -OK-.

68

If the result is lower than 0.9990, the result is failing. In the example two values are failing. The final result is then FAIL.

8.7.2 TEST FILTER WHEEL OFFSET + PEAK (F7-2) FIGURE 86 Filter wheel offset+peak test

The first row shows the current value of the filter wheel (FS) offset value FSOFFS. For each filter it is displayed if there is a correction to apply to the offset parameter FSOFFS: FSOFFS: +1 / -1 This message indicates that the peak for this filter should be incremented by 1 / decremented by 1. The suggested FSOFFS correction is based on the calculated average of the detected corrections. It any correction of FSOFFS is suggested, enter in the EDIT PARAMETERS procedure, typing three times the "." key. The FSOFFS parameter is already selected. Press F4 to unlock the parameters and insert the new value. Press ESC and then confirm the variation with the F2 key.

HumaStar 100/200 | Service manual

OPTICAL READING TEST MENU (F4)

69

Run again the FS OFFSET + PEAK test to match the mechanical middle with the absorbance peak. FIGURE 87 Filter wheel offset+peak test repeated

Now, if everything is right, there is no suggested FSOFFS variation. In this case it is possible to make a fine correction of the filter 1, which is the more sensitive to the beam centering. It is possible to add a specific offset only to the filter 1. Set the filter 1 correction value to parameter FSDOF1. In the picture example, set FSDOF1 = 2. Finally repeat "Search fine reading offset (F6-1)". FIGURE 88 Alignment of filter wheel and cuvette for best reading

70

Summary To achieve the best optical condition for precise readings perform following steps in given order: - Search fine reading offset (F6-1) - 2 x Test filter wheel offset + peak (F7-2) - Search fine reading offset (F6-1)

8.8 Clear Errors (F8) To delete error messages.

8.9 Status of cuvettes (F9) FIGURE 89 Cuvettes status

The first table is the current reading (unit 0.1 mAbs) of the 80 cuvettes at the filter 1 wavelength of 340 nm. The second table is the difference of the current reading to the start-up reference reading (unit 0.1 mAbs) of the 80 cuvettes at the filter 1 wavelength. At the bottom are some statistics on the 80 cuvettes: - Minimum reading. - Average reading. - Difference between minimum and average. - Standard deviation.

HumaStar 100/200 | Service manual

OPTICAL READING TEST MENU (F4)

8.10 G and Z cuvettes selection shortcuts In the Reading test menu the "G", "Z" and "S" keys can be used to shortcut the operations for the optical gain and offset adjustments (see "11.3. Optical offset and gain adjustment"). Press the "G" key to select cuvette 32 for the trimmer's adjustment with a screwdriver. Press the "Z" key to select cuvette 0 to check the reading at the true range. Cuvette 0 means reading between two cuvettes for a real autozero. Press the "S" key to set the optical gain to 30.

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HumaStar 100/200 | Service manual

WASHINGS (F5)

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9 WASHINGS (F5)

9.1 Washings menu FIGURE 90 Washings menu, shown for HumaStar 100

Press the "." key 3 times to edit system parameters. 1. The wash position is the position of the reaction carousel that is assigned to operate under the first needle (from the right) of the wash station. It ranges from 1 to 80. 2. On the upper right corner temperature, floats and cover door are continuously monitored. 3. The reaction cells wash status bar displays the status of the 80 reaction cells: 0 Clean cell. 1 Dirty cell. 2-9 Cell passed wash station 1-8 wash cycle. F Wash failed 1 or 2 times (cell didn’t pass the reading test after fill in position 6). W Cell in warning to be excluded (wash failed 3 or 4 times). X Cell excluded (wash failed 5 times). The white-on-blue-background group of eight cells represents the eight positions of the wash station. The first on the right is position 1 of the wash station, the last on the left is position 8 of the wash station. 4. The pumps and lamp work hours. 5. The pumps dispensation in μl (last, average, flow rate, timers, pump status).

74

9.2 Wash position (F1) To select the current wash position, enter its number.

9.3 Execute washes (F2) FIGURE 91 Execution of continuous washings

To activate the continuous wash function. Press Esc to stop the washing function. The reaction cells of the rotor are washed in sequence. For each reaction cell the new reading value of water at 340 nm after the wash cycles is displayed ("Tubes zero filter 0" table). Unit: 0.1 mAbs. Press a number (1-80) to set a number of reaction cells as dirty. When the cell passes under the wash station and if is dirty (status 1) the wash procedure is activated. If the cell is already clean (status 0), the wash station operations are skipped.

HumaStar 100/200 | Service manual

WASHINGS (F5)

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9.4 Fill wash cuvette (F3) Fill the reaction cuvette selected by the wash position with water through the sampling needle.

9.5 Startup (F4) To execute the start-up procedure. Useful for remote access to the instrument.

9.6 Special pump tests (F5) FIGURE 92 Special pump tests

Special tests: 1. Pumps test. 2. Fill tubes + pumps self test. 3. Empty tubes. 4. Check residue. 5. Adjust pumps.

76

9.6.1 PUMPS TEST (F5-1) FIGURE 93 Pump test

For the pumps test a primary tube filled with 5 ml of water is required in sample position or in the diluent bottle. If it is missing, the procedure is halted. The pumps test performs a precise measure of the flow of the six dispensing pumps of the wash station and the needle wash dispensing pump. It checks also the wash station vacuum pump. The results of the test can be verified in the monitoring section of the HI software Maintenance panel. The test is performed in four steps: 1. It calibrates the level sensor in the reaction cuvettes. 2. Test the wash station needles aspiration evaluating the vacuum pump flow. If the reaction cuvettes are not empty at the second step, the test fails. 3. Test the water dispensation from the needle. 4. Test the dispensation of the six pumps of the wash station.

The parameter 278 OPL150 is

According to the new calibration of the level sensor in the reaction cells, (parameters 278 OPL150 and 279 OPL450), the analyzer asks (if it is necessary) if you want to adjust the SN1 dispensing quote 053 SN1DS2.

a reference value for mixing and must be fixed. It corresponds to 100 μl mixing volume. Therefore the samle needle goes 21 steps into the liquid in the cuvette.

HumaStar 100/200 | Service manual

Type Y to adjust, else to keep the old value. If Y was selected, repeat F5-1 Pumps test. The parameter 278 OPL150 should be 150.

WASHINGS (F5)

9.6.2 FILL HYDRAULIC TUBES + PUMPS SELF TEST (F5-2) This procedure is used to fill all the hydraulic tubes after tank replacement or for the initial fill-up. In the HI software, MAINTENANCE panel, there are three options: - Fill water tubes after water tank replacement. - Fill wash tubes after wash tank replacement. - Fill all hydraulic system. In the SERVICE/WASHINGS menu only the Fill ALL option is possible. To avoid dangerous water overflow caused by aspiration pumps malfunctioning or unpredictable results caused by wash dispensing failure, during the fill hydraulics procedure a self-test of the pumps is performed. The self-test is performed mainly to check if the aspiration and vacuum pumps are performing. It also checks the flow rate of the needle wash dispensation, both internally and externally. The self-test is based on the use of the level sensor. So the first step of the selftest is to check the level sensor in the diluent bottle. If the diluent bottle is empty, the procedure is halted. The fill hydraulics procedure then performs the following steps: - Well tubes filling using the external needle wash flow, stop when water is flowing. - Well tubes filling using the internal needle wash flow, stop when water is flowing. - Check and measure the flow of the well pumps (external needle, internal needle, aspiration). - Fill seven reaction cells with 350 μl. - Check the wash station vacuum pump with a double-step aspiration, evaluate the vacuum flow-rate and a final test result PASS/FAIL. - Wash solution tubes filling, using the pump 2 and needle 2 of the wash station. Every 5 cycles, check with the level sensor if the wash solution is flowing. - Internal tubes filling. Repeat several cuvette washes to complete the filling of the wash station tubes with the system solution (needles 1, 3, 4, 5, 6). Every 5 cycles, check if water is flowing from needle 6. When the water is flowing regularly from needle 6, the procedure stops.

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FIGURE 94 Fill hydraulic tubes – pumps self-test

Fill the tubes of the needle wash. Measure the flow rate of the needle wash (internal, external, aspiration). Fill reaction tubes with 350 μl. Test vacuum pump for wash station aspiration (PASS / FAIL). Fill wash solution tubes through wash station needle 2. Fill system solution tubes.

9.6.3 EMPTY TUBES (F5-3) To perform the same procedure as fill hydraulic tubes, except that its duration is fixed and it doesn’t check when the tubes are filled. Extract the floats from the tanks before executing the empty tubes procedure. Do not unplug the external tubes from the analyzer until the procedure is completed.

9.6.4 CHECK RESIDUES (F5-4) This procedure can be performed to verify the liquid residues left by the wash station inside the reaction cells.

HumaStar 100/200 | Service manual

WASHINGS (F5)

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9.6.5 ADJUST PUMPS (F5-5) This test measures precisely the volume dispensed by the six wash station peristaltic pumps and allows eventually adjusting the pump timer values to obtain the specified dispensation volume. FIGURE 95 Adjust pumps 1

The measuring is repeated six times, and then a report is displayed: - Minimum volume dispensed. - Difference between minimum and maximum volume dispensed. - Average volume dispensed. - Old pumps timers. - Suggested adjusted pumps timers, to correct the dispensed volumes to reach the 177 WSHVOL parameter value (default: 400 μl). ① Values of the parameters 165 DIWSH6 to 160 DIWSH1 (from left to right).

The volume of pump 1 is lower then the volumes of all other pumps. This avoids the ascent of dirt at the inner walls of the cuvettes.

FIGURE 96 Adjust pumps 2

80

The pumps timers range from a minimum of 45 to a maximum of 80. Values outside this range will be clipped to the minimum and maximum values. Press Y to adjust the pumps timers, else to keep the old values. The analyzer processes the six pumps. If the new value is accepted, ok is displayed, else if the volume is too low, low is displayed.

9.7 Wash needle (F6) To execute a needle wash cycle in the well.

9.8 Wash station test (F7) To execute a single cycle of the wash station and move the wash position to the next cell.

9.9 Clear errors (F8) FIGURE 97 Washings error message

A system error is eventually displayed in reverse blue. It can be acknowledged and cleared with F8.

9.10 Rinse cuvettes (F9) To execute the Rinse cuvettes procedure.

HumaStar 100/200 | Service manual

SYSTEM PARAMETERS

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10 SYSTEM PARAMETERS

10.1 Edit parameters (F7) FIGURE 98 Edit system parameters

Parameters shown in red are

The system parameters edit function is called from Terminal by the OP command, from the service menu with F7 Edit Parameters or from the Hardware test, Reading test and Washings menus by pressing three times the dot "." key.

critical to the instrument and therefore protected by a password. For password handling, refer to the appropriate Human Ser-

Exit the Edit Parameters menu by pressing the Esc key. F1 SELECT PARAM. F2/PG UP NEXT PAGE F3/PG DN PREVIOUS PAGE F4 LOCK / UNLOCK F5 FIND PARAMETER F6 BACKUP PARAMETERS F7 RESTORE BACKUP

Locate a parameter by its number. Next page. Previous page. Lock/unlock parameters for editing. Locate a parameter by its name. Backup all the parameters. Restore all the parameters from the last backup.

vice Bulletin (HSB).

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10.2 Parameters pages In the upper right corner the name of one of the 9 parameter pages is displayed: 1. 2. 3. 4. 5. 6. 7. 8. 9.

IP, OP, FS SN Needle, DS REAG, WASH STATION SPEEDS WASH PUMPS MISCELLANEOUS LEVELS, FLOATS TEMP., DILs, PIPETTING READINGS

Parameters table description: Parameter number. 1st column nd Parameter name. 2 column Parameter type (P, U, I, O, R, S, A, V, C, F, D, c, m, s). 3rd column P = Integer (-32000 to +32000) U = Unsigned integer 0 to 65535) I = Inner plate O = Outer plate R = Needle rotation S = Sampling needle A = Wash station V = Speed C = Check sum F = Filters selection D = Diluter syringe c = 10th of milimeters m = Milimeters s = Seconds Parameter value. 4th column 5th column Default parameter value in parenthesis. If the parameter value in the 4th column equals to the default value, this column is empty. Trying to input a value outside the parameter range causes a beep, the new value is rejected and the old value is kept.

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SYSTEM PARAMETERS

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10.3 Find parameter (F5) FIGURE 99 Find system parameter

Type the name of the parameter to be found. The cursor will move on the selected parameter.

10.4 Backup parameters (F6) Press F6 to backup all the current values of the system parameters. A confirmation (Y/N) will be requested: Backup all parameters (Y/N)?

10.5 Restore parameters (F7) FIGURE 100 Restore system parameter

84

Press F7 to restore the parameters values recorded during the last backup. A confirmation (Y/N) will be requested: Restore parameters from backup (Y/N)?

10.6 Save the parameters list as a text file To create a parameters list file: -

HumaStar 100/200 | Service manual

Go to the Service Terminal. Select the LOG tab and tick the LOGS check box. Select the TERMINAL tab. Enter the PL command. Wait for the end of the parameters list (last parameter: CODCHK). Select again the LOG tab. The list of all the parameters must be there. Save the parameters list file as .TXT file by a right mouse click. CLOSE the Service Terminal. Open the created parameters list file with WORDPAD or with WORD.

ADJUSTMENTS

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11 ADJUSTMENTS

11.1 A/D voltage references adjustment FIGURE 101 A/D voltage adjustment

The voltage reference of the A/D converter for the photometer signal is adjusted on the CPU board with trimmer P1 and must be 1.000 Vcc on pin 2 of U26. The voltage reference for temperature A/D converter is adjusted on the CPU board with trimmer P2 and must be 2.731 Vcc on pin 6 of U30. Check the two reference voltages VREF1 and VREF2 on the CPU board as follows: VREF1

Connect the negative probe of the voltmeter on the analog ground (e. g. the board fixing screw in the lower left corner) and the positive probe on the pin 2 of the U26 and then adjust the trimmer P1 to obtain a value of voltage equal to 1.000 Vcc ± 0.005 Vcc.

Trimmers P1 and P2 are fixed by screw securing lacquer to

VREF2

Connect the negative probe of the voltmeter on the analog ground and the positive probe on the pin 6 of the U30 and then adjust the trimmer P2 to obtain a value of voltage equal to 2.731 Vcc ± 0.005 Vcc.

the factory settings. Under normal circumstances they never must be changed.

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11.2 Reaction plate temperature adjustment The procedure is to calibrate the temperature sensors so to match an external thermometer. FIGURE 102 Reaction plate temperature adjustment

The reaction outer plate temperature is calibrated with trimmer P3 on CPU board (see FIGURE 101). The calibration requires a thermometer with a 3 mm probe to measure the temperature inside a reaction cuvette of the outer plate. Fill the reaction cuvette at the center of the access hole to the reaction cuvettes with 0.5 ml of water. Insert then the thermometer probe in this reaction cuvette. There are two variants of temperature adjustment available:

HumaStar 100/200 | Service manual

A)

TERMINAL  OS SERVICE MENU  F1 HARDWARE TEST  F5 DISPLAY INPUTS In the upper right corner a window is displayed with the values of all the inputs. The row OP temp indicates the outer plate temperature in tens of degrees Celsius in continuous reading.

B)

TERMINAL  OS SERVICE MENU  F5 WASHINGS The reaction plate temperature is displayed in degrees Celsius in the upper right corner.

ADJUSTMENTS

87

The sensor is in a feed-back loop for temperature control, so the system will always slowly drive the temperature to the same (apparent) reference. If the measured temperature is higher than the set-point, turn the trimmer up (so that the displayed temperature goes close to the measured temperature) and wait for stabilization. If the measured temperature is lower than the set-point, turn the trimmer down (so that the displayed temperature goes close to the measured temperature) and wait for stabilization. The procedure must be repeated some times until the displayed value is identical to the measured value. Adjust the P3 trimmer on the CPU board until getting the same indication on the displayed temperature in variant A) or B) and an external thermometer placed in the outer plate. To achieve a temperature of 37 °C in the cuvettes the displayed temperature should be approx. 38 °C.

11.3 Optical offset and gain adjustment FIGURE 103 Optical offset and gain adjustment

88

The optical preamplifier board is located in the inner side of the reaction plate. The left hole (seen from the front) is to adjust the gain trimmer. The right hole (seen from the front) is to adjust the offset trimmer. The two trimmers GAIN and OFFSET are accessible in two ways: A) B)

TERMINAL  OS SERVICE MENU  F4 READING TEST  F2 SELECT CUVETTE  32. TERMINAL  OS SERVICE MENU  F4 READING TEST  G.

OFFSET and GAIN adjustment must be made after the thermal stabilization of the optical group, the reaction plate and the optical preamplifier.

11.3.1 NECESSARY TOOLS Flat screwsriver (1.5 mm) for the trimmers with minimum 22 mm length.

11.3.2 OFFSET ADJUSTMENT Select filter 0 (black) by pressing the 0 (zero) key. Check the reading and adjust the offset with trimmer (right) so that the value is approximately 15.

11.3.3 GAIN ADJUSTMENT During the reading test you can select all the filters with the keys 0-9 and get the corresponding reading. Check on the AUTOZERO readings list which is the filter with the highest reading and select this filter pressing the numeric key corresponding to the filter number. Adjust the GAIN with the trimmer (left) so that the maximum reading of the highest (most transparent) filter is close to 16,000 and the lowest one (less transparent) is higher than 12,500 (note that the maximum reading of the A/D converter is 19,999).

HumaStar 100/200 | Service manual

ADJUSTMENTS

Since cuvette 32 is selected, the current reading is obtained with the light beam through it. Depending on the absorbance of this cuvette, the A/D reading during the adjustment of the trimmers is 10 % lower (or even less) than the real AUTOZERO value. To check the true A/D reading, take the screwdriver off the holes and select cuvette 0 with F2 SELECT CUVETTE. Press F4 READ ALL FILT. to get a quick reading of all the wavelengths. In the A/D reading of the bare beam (cuvette 0 selected) it is preferable not to go beyond 18000, because it is needed some margin of tolerance to avoid reading overflow when changing the lamp. Lamps can have an emission tolerance, mainly in the low wavelength range (340-400 nm). When all A/D reading values are satisfactory, press F5 AUTOZERO and then 1 for a single AUTOZERO. Wait for the end of the procedure and eventually confirm (1) or reject (0) the values.

11.3.4 CUVETTES SELECTION SHORTCUT In the F4 Reading Test menu: - Press the G key to select cuvette 32 for the trimmers adjustment with the screwdriver. - Press the Z key to select cuvette 0 to check the reading at the true range.

11.3.5 INTERFERENCE FILTERS The interference filters are factory equalized, so that the maximum difference in the A/D readings is typically lower than 20 %. Anyway, to reduce the difference between the final transmittances, it is possible that a light quartz grey filter has been mounted on some interference filters for finer matching. Interference filters have a very high stability and are mechanically protected. It is very unlikely that they must be replaced. But it is eventually possible that a quartz grey filter has cracked if it has been locked too tight.

11.3.6 READINGS OUT OF RANGE If a filter has an AUTOZERO reading out of range, all the methods employing this filter will be marked with "AUTOZERO ERROR" and these methods cannot be executed.

89

90

The filter 1 (340 nm) is used also for the check of the cuvettes washing. An AUTOZERO error on this filter will give an "AUTOZERO ERROR" during the washings.

11.4 Filter wheel adjustment

11.4.1 NECESSARY TOOLS Allen key #2, #3 and #4 screwdrivers for M3, M4 and M5 Allen screws.

11.4.2 OPTICAL HOME SWITCH ADJUSTMENT Attention The optical switch must never be touched. Only if it is broken it will be necessary to replace it. Else all the adjustments will be done without touching the optical switch. To check if the filter wheel is operating properly there are two basic tests to be executed: - F4 READING TEST  F7  1: TEST FS HOME REPEATABILITY (see 8.7.1.). - F3 MECHANICAL CHECK  F4: OP-FS HOME CHECK (see 7.4.). F4 READING TEST  F7  1: TEST FS HOME REPEATABILITY The first test checks if the mechanics are working properly and if the stepper motor is well phased on the limit switch. If all the results are not OK (excluding the first row with two numbers), once a big problem in the mechanics has been excluded, it is possible that the home positioning is not repeatable because the optical switch position is phased in the middle of two mechanical steps. In this case the cogwheel of the FS motor must be shifted a bit. This is a blind operation, because you can check the result only later, repeating the FS HOME REPEATABILITY test. Procedure: 1. Open the filter wheel cover (one Allen screw M5 placed over the FS motor). 2. Release with a #2 Allen key screwdriver the two M3 Allen screws on the cogwheel of the FS motor.

HumaStar 100/200 | Service manual

ADJUSTMENTS

3. 4. 5. 6.

Rotate the cogwheel just a bit on the motor axle. Tighten the two Allen screws of the motor's cogwheel. Repeat the FS HOME REPEATABILITY test. If it fails, repeat from step 2. At the end, close the filter wheel cover (one M5 Allen screw).

11.4.3 FS BELT ADJUSTMENT The second test, F4 OP-FS HOME CHECK, will check the home search from all the filter positions. When the filter wheel is operating perfectly, it must give all null values. If it gives non-null values higher than 2, the filter wheel belt must be tightened. To tighten the belt, release the four M4 Allen screws of the motor, pull with one hand the motor, sliding outward, to tighten the belt and then tighten the four motor screws with the other hand.

11.4.4 OFFSET ADJUSTMENT Once the FS positioning is accurate and repeatable, the offsets of the single filters must be detected. This operation is done automatically by the analyzer running the F4 READING TEST  F7  2: ADJUST FS OFFSETS (see 8.7.2.).

11.5 Reaction plate belt adjustment

11.5.1 NECESSARY TOOLS Allen key #3 screwdriver for M4 Allen screws.

11.5.2 OP BELT TIGHTENING To tighten the OP belt, follow the procedure: 1. Take off the sample tray and the upper cover of the analyzer. 2. Move the reaction rotor by hand to identify the OP motor. 3. Using the 3 mm Allen key screwdriver, loosen the four M4 Allen screws that hold the OP motor. 4. While keeping the belt well tightened, pulling the OP motor, tighten the four motor's screws.

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11.5.3 ACCESS TO THE OP MOTOR SCREWS The four screws are placed on a square of approx. 50 mm. FIGURE 104 First screw

FIGURE 105 Second screw

The two outer screws are accessible by rotating the reaction rotor in such a way that the hole placed on the bottom of the rotor will be, in sequence, over the two screw's head. FIGURE 106 Third screw

HumaStar 100/200 | Service manual

ADJUSTMENTS

93

FIGURE 107 Fourth screw

The two inner screws are accessible by rotating first the sample rotor in such a way that the hole on the IP plate will be overlying on the vertical of a second hole of the reaction rotor (the IP hole and the OP hole must be then on the same radius). Move then the IP and OP rotors over the heads of the inner screws of the OP motor.

11.6 Needle vertical adjustment in the wash well Go to SERVICE  F2 MECHANICAL CALIBRATION, select row 09: WASH / SN L. The needle goes down in the wash needle position. Press F6 SPECIAL FUNCTION to enter the special check function and then press the space bar to step through the check: -

The water springs out the needle and washes the needle internally and externally. Check if the water flows well (INWELV = pump speed). - The flow stops and the needle moves up to the drip position. The needle must stay about 1 mm inside the water drop (the bottom of the needle must be at the same level of the top of the white well nipple (adjust SN1WSH). - The water flows from the lateral nozzle and washes the needle externally. The water jet must hit the needle gently with a downward parabola and not hit horizontally. In this way the drops will not remain attached on the needle side (adjust EXWELV). When completed, you can adjust with the "+" / "-" keys the vertical position of the needle inside the well so that, when it goes up to the drip position, the needle remains 1 mm inside the water drop.

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11.7 Wash station down adjustment

11.7.1 ROUGH AUTOMATIC CALIBRATION To be used only by operators not able to execute the FINE CALIBRATION procedure. Go to SERVICE  F2 MECHANICAL CALIBRATION, select row 18 and press F6 SPECIAL FUNCTION. See "6.2. Calibration rows", row 18.

11.7.2 FINE CALIBRATION Go to SERVICE  F2 MECHANICAL CALIBRATION, select row 18 and press F6 SPECIAL FUNCTION. See "6.2. Calibration rows", row 18. Use the "+" / "-" keys to move the wash station up and down one step. Go down until the wash station white swab touches the bottom of the reaction cuvettes. Then go up two steps and press F2 SAVE POSITION to store the new calibration.

11.8 Adjustment of the cover detection switch Use the two screws (A) to adjust the position of the cover detection switch. FIGURE 108 Cover detection switch adjustment

When the instrument is open, pull the button of the detector (B) up, to simulate the cover closed and enable the sampling operations

HumaStar 100/200 | Service manual

SERVICING

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12 SERVICING

12.1 Lamp replacement FIGURE 109 Lamp replacement

To execute when the lamp is burnt off. Lamp life has a wide distribution, can range from 500 to 2000 hours, with a typical life of 1000 hours. 1. Switch the instrument off. 2. Open the lamp window in the back side of the instrument. 3. Unplug the lamp connector (A). 4. Unscrew the lamp knob (B). 5. Remove the old lamp. 6. Insert the knob in the new lamp holder. 7. Insert the new lamp and fasten the knob (A). 8. Plug in the connector. 9. Close the lamp window. 10. Switch on the instrument. 11. Wait 20 minutes for warm-up. If you are not in TERMINAL > OS: 12. Put the instrument in RUN to execute an autozero and then go to MAINTENANCE / OPTICAL GROUP to check the lamp emission. 13. If lamp has a correct emission (all the wavelengths readings are between 11,000 and 19,000), execute the instrument start-up. Else go to the TERMINAL > OS.

96

If you are in TERMINAL > OS (the procedure is more strictive to allow the operator to have a longer autonomy):

Do not touch the glass part of the lamp with your fingers. Fat, dust and humidity shorten the life of the lamp and limit the lamp emission. The AUTOZERO procedure is used to store in memory the

12. Go to F4 READING TEST and execute the F5 AUTOZERO procedure to check the lamp emission. 13. If the lamp is not having a correct emission (all the wavelengths readings between 13,000 and 18,000), you have to adjust these values within this range trimming the optical preamplifier gain. See "11.3. Optical offset and gain adjustment". 14. In F4 READING TEST, verify the filters offset with the F7-2 function and eventually adjust the filters offset. See "8. OPTICAL READING TEST". 15. In F4 READING TEST, verify the reaction plate offset with the F6-1 function and eventually adjust the reaction plate reading offset. See "8. OPTICAL READING TEST". 16. Execute the instrument START-UP.

AUTOZERO values, which are the optical reading values of the lamp for all the filters.

12.2 Sample tray replacement There are two versions of the sample tray: FIGURE 110 Sample tray 30+30

The first (default) sample tray holds 60 samples: 60 primary tubes, diameter 12-13 mm, height 55-100 mm.

HumaStar 100/200 | Service manual

SERVICING

97

FIGURE 111 Sample tray 20+20

The second (to be extra ordered) holds 40 samples: 20 primary tubes, diameter 12-16 mm, height 55-100 mm, 20 "Hitachi" cups. When installing a sample tray, the operator must configure the following system parameters, using the F7 EDIT PARAMETERS function: System parameters for sample tray with 60 samples: IPNPS0: 30 N. POSITIONS ON EXTERNAL RING IPNPS1: 30 N. POSITIONS ON INNER RING IPTYPE: 2 System parameters for sample tray with 40 samples: IPNPS0: 20 N. POSITIONS ON EXTERNAL RING IPNPS1: 20 N. POSITIONS ON INNER RING IPTYPE: 1 Then the operator must go to F2 MECHANICAL CALIBRATION and calibrate the high and low position of the first tube of the internal and the external tubes rows: - PTU is the low position of primary tubes. - CUP is the low position of the cups mounted on the adapter. The adapter is necessary to allow level detection with the cups. - CU2 is the low position of the Hitachi cups of the inner row of the 40 positions tray. The inner row of this tray can hold only these cups, without adapter.

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Sampling needle high, 5 mm over sample primary tube 1 (follow the affected parameters): 11 IP01/SN H IPOFF0 RN_IP0 SN1MID Sampling needle low, at the bottom of the sample primary tube 1: 12 IP01/SN PTU IPOFF0 RN_IP0 SN1PTU Sampling needle high, 5 mm over sample primary tube 21 or 31 (first tube of inner circle, depending on tray): 13 IPx1/SN H IPOFF1 RN_IP1 SN1MID Sampling needle low, at the bottom of sample cup 1 (cup placed on the adapter): 14 IP01/SN CUP IPOFF0 RN_IP0 SN1CUP Sampling needle low, at the bottom of the cup 21 (only for the 40 samples tray): 11 IPx1/SN CU2 IPOFF1 RN_IP1 SN1CU2 On exit from the mechanical calibration, the instrument automatically evaluates the IPPHOM parameter that is the IP tube for fast pre-positioning during the home procedure.

12.3 Single reaction cell replacement See also the HumaStar 100/200 User Manual. -

HumaStar 100/200 | Service manual

With the analyzer switched on and connected, from the HI software press the lower-left MAINTENANCE button. Press the REACTION CUVETTES button. The excluded cuvettes are displayed in RED color. Press on the cuvette to be replaced. The rotor will move and bring the selected cuvette to the center of the opening. Verify that the engraved number corresponds to the selected one.

SERVICING

99

FIGURE 112 Cuvette position number

-

-

With the specific cell extraction pliers ES07017A (from the HumaStar100/200 accessories) extract the cuvette placed at the center of the opening. Insert the new cuvette. The cuvette has a rectangular foot. It must be inserted, oriented so that the marks (one or two) on the bottom face are situated on the external side of the rotor ring. Confirm on the screen that the cuvette has been changed. This will reset all the cuvette references and AUTOZEROs and mark the cuvette as dirty, to enable its washing before it can be used in a reaction.

12.4 Reaction rotor replacement FIGURE 113 HumaStar 200 wash station cover

HumaStar 100: Loosen the 3 screws of the black wash station cover to extract it. HumaStar 200 (see picture): Extract the wash station cover (A). Lift upwards.

100

' FIGURE 114 Needles group

Disassemble the needles group of the wash station (two screws (B) and (C)).

FIGURE 115 Reaction plate cover

Disassemble the reaction plate cover: - Unscrew the screws (D), (E) and (F). - Extract the reaction plate cover (G).

FIGURE 116 Reaction plate

HumaStar 100/200 | Service manual

SERVICING

-

101

Unscrew the six screws (A), (B), (C), etc., holding the reaction carousel. Insert the new carousel taking care to keep the orientation (six screws and one pin). Tighten the six screws progressively, taking care the rotor is in the correct flat position. Reassemble the reaction plate cover, the wash station and its cover.

12.5 Needle replacement FIGURE 117 Needle holder cap

Take off the needle cover. Unscrew the needle holder cap. FIGURE 118 Level sensor connector

Disconnect the level sensor connector (A). Unscrew the four screws that hold the level sensor board.

102

FIGURE 119 Needle guide

Unscrew the needle guide (B). FIGURE 120 Needle detachment

Detach the Teflon tube from the needle (C). Take off the needle group (D): Needle + brass needle contact + needle screw. FIGURE 121 Needle group components

The needle screw (E), the needle (F), the brass needle contact (G).

HumaStar 100/200 | Service manual

SERVICING

After re-assembling, check that the needle slides correctly in the needle guide without friction, so that the spring holds the needle in the lower position and the shock sensor is correctly activated in the upper position (the red LED goes on). If the needle doesn’t slide freely, try to loosen the white needle holder cap.

12.6 Interference filters replacement and equalization Eight or nine interference filters are mounted in the instrument. Their wavelength is defined in the system parameters FILTR1 to FILTR9. The wavelength defined in the system parameters is detected by the software when the instrument is connected. The filter’s rotor has ten positions. Position zero is for the dark offset reading. Every interference filter is marked, with the corresponding number engraved, on the filter’s rotor. The filters are equalized (matched) so that the reading of each filter is within a ± 20 % difference to the reference 340 nm filter. Typical final adjustment of the autozero of the filters is a minimum of 13,000 and a maximum of 18,000. The filters supplied belong to a set of 8 or 9 factory matched filters. This means, the filters don’t need a strong equalization with dark gray filters or pinhole disks. It can happen that a light gray quartz filter of 38 mAbs or 100 mAbs is added to the filters with a higher transmittance to reduce the emission and to have a better equalization. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Remove the instrument cover. Open the filters cover. Rotate the wheel to reach the filter with the requested number. To extract the old filter, unscrew the filter locking ring with the special tool. Replace the filter without mounting any gray quartz filter and the rubber O-ring. Screw the locking ring with the special tool. Close the filter cover. In F4 READING TEST check the filter equalization. If the A/D reading of the new filter is higher than the others, you must open again the filter and add a gray quartz filter.

103

104

10. If the A/D reading of the new filter is lower than the others, you must check if you can increase the gain of the optical preamplifier (if no readings reach 18,000). If not, you can leave it at its low level if its reading is higher than 13,000. Else you must add a gray filter to the readings with the highest levels and then increase the preamplifier gain. Cuvette 0: Cuvette 32:

-

Position to get filter reading value. Position for screwdriver holes alignment to adjust GAIN and OFFSET.

Select the DARK position on the filter wheel with the 0 key and cuvette 32 with the F2 key. Adjust the optical preamplifier OFFSET in the range 15 to 30. Select cuvette 0 with the F2 command. One by one, adjust all the mounted filters (select filters with the 1–9 keys). Adjust the readings with gray filters (38 mAbs or 100 mAbs) assembled together with the interference filters. Adjust the optical preamplifier GAIN selecting cuvette 32 with the F2 key, then go back to cuvette 0 with the F2 key.

The order of the pack must be: -

gray filter, O-ring, interference filter, locking ring.

The reading of all the filters must be in the range 14,000 to 17,000. -

HumaStar 100/200 | Service manual

Execute the AUTOZERO (F5-1) to verify the final readings (they can be slightly different from those obtained from the immediate reading) and eventually repeat the matching.

SERVICING

105

12.7 Vacuum pump replacement FIGURE 122 Vacuum pumps

Seen from rear, on the left is the vacuum pump (A) aspirating from the wash station cleaning nozzle. On the right is the vacuum pump (B) aspirating from the 6 wash station aspiration needles.

FIGURE 123 Vacuum tubing Y nipple

The two outputs of the vacuum pumps are connected together through a Y nipple (E) and the hydraulics panel manifold (C) to the waste output (D). For (C) and (D) see FIGURE 122 above. To remove the vacuum pump from the base plate, unscrew the four ALLEN screws underneath the motor (F).

106

12.8 Vacuum pump wearing parts replacement

12.8.1 HUMASTAR 100 FIGURE 124 Vacuum pump

Unscrew the pump head's four corner screws.

FIGURE 125 Vacuum pump head opened

Open the upper part of the pump head. Replace the two O-rings if they are worn. Also replace any solid particles eventually assembled inside the unit. FIGURE 126 Vacuum pump rubber membranes level

After removing the part with the two O-rings there's access to the two rubber membranes.

HumaStar 100/200 | Service manual

SERVICING

107

Replace them if they are worn. Also replace any solid particles eventually assembled inside the unit.

12.8.2 HUMASTAR 200 Unscrew the pump head's four corner screws.

FIGURE 127

Open the upper part of the pump head.

FIGURE 128

Vacuum pump

Vacuum pump head opened

The two membrane valves are inserted in two pins.

FIGURE 129

Take off the two disks. Center the two new membrane valves on the two pins and carefully position them. Close the pump head and screw it back.

FIGURE 130

Membrane valves

Membrane valves opened

108

12.9 Peristaltic pump head replacement FIGURE 131 Peristaltic pumps D1 to D6, AW and DW

Open the wicket of the hydraulic unit placed on the left side of the instrument. Find the pump that has to be replaced. Extract the two tubes of the pump head from the barbed fitting. Extract the pump head clenching the two clips placed on the opposit sides of the pump head.

12.10 Diluter replacement FIGURE 132 Diluter

To replace the diluter the following three parts are needed: (A) (B) (C)

EE0101A Diluter. ES05111B Teflon tube with two fittings (diluter to panel). ES05114B Teflon tube with one fitting and silicone adapter (diluter to pinch valve).

The fitting size is ¼-28 UNF.

HumaStar 100/200 | Service manual

SERVICING

109

FIGURE 133 Tubing connectors

Unconnect the motor connector (MDS) and the limit switch connector (SDS) and take them off the hydraulic panel frame. Unconnect the hydraulic fittings (B) and (C). Unscrew the four screws at the base of the diluter head to remove the diluter from the hydraulic panel. Place the new diluter and fix it with the four screws. Connect the new (B) and (C) fittings. Insert the new (MDS) and (SDS) connectors on the hydraulic panel frame and connect them to the wiring. FIGURE 134 Electrical connectors

FIGURE 135 Power board connectors

110

Check in F1 Hardware Test if the diluter executes the home sequence correctly. If it moves in the opposite direction, it is necessary to swap two wires on the motor’s diluter wiring to exchange the movement’s direction of the new diluter. Unconnect the DS-AN connector. On the left are the four DS wires (diluter syringe), on the right the four AN wires (wash station). FIGURE 136 Power board connector DS-AN

Extract the WHITE and the BLUE wires of the DS diluter motor (3rd and 4th from the left) and swap them to exchange the motor’s directions. Go to the EDIT PARAMETERS procedure. It is possible to set two options: - Set DSTYPE to 3 to run the diluter at the maximum speed, - Set DSTYPE to 4 to run the diluter at a bit slower speed (1,400 steps/sec). The DSTYPE is normally set to 3. If, due to hydraulic narrowings, the diluter is not working properly, set DSTYPE to 4 and the DSVELD to 1,500 or 1,400 to have higher torque margins. The system parameters whose values are constrained are: DSTROK = 368 DSTEPS = 2,600 DSOFFS = 0 DSGAPH = -2 DSVELD = 1,400 to 1,700 DSVELA = 1,400 DSVELZ = 1,200

HumaStar 100/200 | Service manual

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111

These values are automatically updated on exit of the EDIT PARAMETERS procedure, after having changed the DSTYPE parameter. On exit, press the F2 key to accept the modifications.

12.11 Diluter sealing gasket replacement This procedure applies to diluter type 3 or 4 (EE0101A) to replace the sealing gasket (orange O-ring inside the diluter head). The gasket must be replaced when it doesn’t seal any more and there is a water leakage from the back of the head or from the optical switch opening. - Remove the water hydraulic connector to avoid completely emptying the tubes. - Unscrew the diluter head with an Allen key and extract the head. - Remove the orange sealing gasket. - Place the new sealing gasket, oriented with the engraved letters on the outer side. - Insert gently the head on the piston, avoiding to damage the new gasket. - Tighten gently the two screws. - Reconnect the water hydraulic connector. - Execute a filling of the water tubes in MAINTENANCE of the HI software.

12.12 Sampling arm replacement FIGURE 137 Sampling arm replacement

-

Disconnect the wiring connectors and the needle tube blue fitting. Unscrew the two screws on the two lower ① spacers.

112

-

-

-

Unscrew the two screws on the two upper ② spacers. One of the two screws will remain trapped under the reaction plate incubator, but the sampling arm can be anyway disengaged. This screw is the last to be unscrewed. Replace the sampling arm, tighten first the two screws of the upper spacers, then the two screws of the lower spacers, re-connect the electrical connectors and the needle tube fitting. Go to SERVICE  F2 MECHANICAL CALIBRATION and adjust all the quotes related to the needle position.

12.13 Level sensor wiring replacement FIGURE 138 Level sensor wiring replacement (1 and 2)

Refer to the sampling arm replacement procedure for the disassembly and reassembly of the arm. The level sensor wiring ES02006A is routed and fastened to reduce the stress of the wires, with a larger size of the white plastic holder. FIGURE 139 Level sensor connector

HumaStar 100/200 | Service manual

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113

The wiring is composed of six ultra-flexible wires. They are supplied, on the level sensor board side, already crimped but not yet inserted in the Molex 8 pins connector case. The wires must be passed through the rectangular duct without the connector case. They must be routed carefully and inserted into the MOLEX connector. Molex MX254 8 pins F (top) 1 2 3 4 5 6 7 8

Black Yellow Red

Red Yellow Black

Minifit 8 pins 4x2 M (bottom) 1 2 3 4 5 6 7 8

Swapping the wires can da-

GND Level out 12 Vcc 12 Vcc Shock out

mage the CPU board. Shortcircuiting the red wire with the yellow wire will damage the CPU board.

GND

FIGURE 140 Connector pin layout

Pin 1 of the Molex MX254 8 pins, on the drawing, is on the upper side. On the 8 pins 4x2 minifit connectors, pin numbers are printed on the back of the connectors. 5 1

6 2

7 3

8 4

12.14 External tanks floats replacement To check if the float of an external tank is out of work, go to SERVICE  F5 WASHINGS. In the upper right corner of the screen the status of the floats is displayed. Extract the float from the tank and rotate it upside down and up slowly (5 seconds). You must see the displayed status of the float toggle on the screen.

114

If it is not toggling, it must be replaced. The contact of each float is closed in the normal status. This means that the water and wash tanks are closed in the up position (FULL) and the waste tank is closed in the lower position (EMPTY).

Each float contains a toroidal magnet in one side. The ma-

To replace the wiring, it is necessary to employ the specific TRIM-TRIO extractor to extract the two pins of its cable from the connector: Trim-Trio/Mate-n-lok pins extraction tool, P/N: CON-TRIO-ESTR.

gnet must be mounted in the opposite position when it belongs to a water/wash tank (normally

Open the connector shield, insert the extractor into the pin to close its harpoons and pull gently the wire out.

open) or to a waste tank (normal-

Then insert the replacement pin from the back of the connector and push it until the harpoons click. Pull gently the wire to verify that it doesn’t come out.

ly closed).

The single float with the wiring is P/N ES02013A. ES02013A

W

ES01009A

PW

ES01009AV1

PW

CON-TRIO-ESTR

Tanks float with cable (for floats replacement) Floats and tubes connection assembly (HumaStar 200) Floats and tubes connection assembly (HumaStar 100) Trim-Trio/Mate-n-lok pins extraction tool

12.15 Optical preamplifier replacement FIGURE 141 Replacement step 1

Remove the sample tray.

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115

FIGURE 142 Replacement step 2

Unscrew the wash station needles holder (2 screws). FIGURE 143 Replacement step 3

Take off the wash station needles holder. FIGURE 144 Replacement step 4

Unscrew the reaction rotor cover (2 + 1 screws).

116

FIGURE 145 Replacement step 5

Unscrew the reaction rotor (6 screws).

FIGURE 146 Replacement step 6

Extract the reaction rotor. FIGURE 147 Replacement step 7

Rotate the reaction rotor support until the notch is positioned over the preamplifier cover, then unscrew the preamplifier cover (2 screws) from the incubator.

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117

FIGURE 148 Replacement step 8

Push up the preamplifer cable (red wires with black sleeve) by hand in such a way that the preamplifier board is lifted up out of the incubator. FIGURE 149 Replacement step 9

Unscrew the preamplifier board. FIGURE 150 Replacement step 10

Replace the preamplifier board.

118

FIGURE 151 Replacement step 11

Reassemble everything. Adjust eventually GAIN and OFFSET (see "11.3. Optical offset and gain adjustment").

12.16 CPU board replacement If the CPU board has to be replaced, take the two firmware EPROMs (U2 and U3) and the parameters EPROM (U4) from the old CPU board and place them on the new one.

HumaStar 100/200 | Service manual

FIRMWARE UPDATING – EPROMS REPLACEMENT

119

13 FIRMWARE UPDATING – EPROMS REPLACEMENT The operator’s interface is programmed in the PC. The software is a .NET program written in C# and running under .NET Framework. All the instrument’s operations are programmed in the two EPROMs, mounted on the CPU board. This part of the software is called the firmware. The two EPROMs must always be changed together. The EPROMs are labeled with the firmware version, e. g. 1.34B. If the reason for updating is a change of the compilation (indicated by the trailing character), e. g. 1.34B to 1.34F, the EPROMs must be simply exchanged (see "13.1 EPROMs replacement – compilation change"). If the version changes, e. g. 1.22 to 1.34, it has to be done by the help of the TERMINAL program (see "13.2 EPROMs replacement – version change").

The HI software works best with the most recent firmware version available but it also works with all older firmware version. It detects the firmware version of the installed EPROMs and does not activate the HI features

13.1 EPROMs replacement – compilation change

which require newer firmware

To replace the two EPROMs: - Shut the instrument off. - Remove the cover of the instrument. - Open the boards cover (3 plastic nails to extract). - Extract the two EPROMs. - Insert EPROM 1 in the upper position, with the notch on the right. - Insert EPROM 2 in the lower position, with the notch on the right.

versions.

FIGURE 152 EPROM positions on CPU board

-

Switch the analyzer on.

120

13.2 EPROMs replacement – version change To replace the two EPROMs: - Enter the TERMINAL program and verifiy that the instrument is answering to the commands, e. g. OS. - Shut the instrument off. - Remove the cover of the instrument. - Open the boards cover (3 plastic nails to extract). - Extract the two EPROMs. - Insert EPROM 1 in the upper position, with the notch on the right. - Insert EPROM 2 in the lower position, with the notch on the right. (See FIGURE 152 above.) - Switch the analyzer on. - The @ symbol appears on the screen. - Press ENTER twice. - The following message is displayed on the screen: FIGURE 153 EPROM menu

-

-

While it is waiting for the keyboard confirmation, the analyzer shakes continuously the sample plate with two short moves forwards and one longer backwards. This is to remind the service operator that he has to confirm the EPROM change on the TERMINAL, else the software will not connect to the analyzer. Press 1 (Load new parameters defaults + check). A list of new or moved parameters will be displayed, e. g.:

FIGURE 154 New or moved parameters

-

HumaStar 100/200 | Service manual

Confirm with 1 (Load = yes) to all the parameters to initialize to the new value introduced with this release, e. g.:

FIRMWARE UPDATING – EPROMS REPLACEMENT

121

FIGURE 155 New parameter

FIGURE 156 Changed parameter

-

After the final parameter confirmation will be displayed, e. g.: FIGURE 157 Final parameter

-

Exit the terminal function (press the X button in the upper right corner of the TERMINAL window).

If you are using the HumaStar 100/200 TERMINAL software, do not exit from it because the HumaStar 100/200 HI software

13.3 Replacement of very old EPROMs – data synchronization

cannot connect when the instru-

If the software doesn’t connect after the EPROMs update procedure, it is possible that there is an incompatibility between the old data structures inside the instrument and those in the PC. In this case it is simply necessary to delete the old data inside the instrument.

ment is in the "Load+Check" confirm status. In this case you need to use a special program to confirm the EPROMs update. When you are in TERMINAL,

From the Service TERMINAL, type the following commands: MK<enter> to delete the old methods, SK<enter> to delete the old samples, WK<enter> to delete the old worklists. Then exit the Service TERMINAL, return to the HI software and run the Methods upload procedure to reload the methods into the instrument.

you can shut off and on the instrument without any connection problem.

122

HumaStar 100/200 | Service manual

TROUBLESHOOTING

14 TROUBLESHOOTING

14.1 Analyzer doesn't connect Press CONNECT. If it doesn’t connect: 1. Check if power is ON (red lamp on the main switch and orange lamp on the reagents cooling switch). 2. Switch the instrument OFF, wait five seconds, and switch ON again. At poweron, the instrument must shake the sample plate three times to show it is working. In addition to the 3rd shake the wash well aspiration pump (peristaltic pump 7) has to turn for a short time. If it doesn’t shake or shake only twice, contact the service. No shake means that the CPU or EPROM 1 or the power supply bord are not working. Only two shakes means that EPROM 2 is not working. Try again to connect. If it doesn’t connect, continue with step 3. 3. Verify if the USB cable between the computer and the instrument is correctly inserted. Try again to connect. If it doesn’t connect, continue with step 4. 4. Verify the USB port. Exit from the software. Enter the Windows CONTROL PANEL  SYSTEM  HARDWARE  PERIPHERALS DEVICE MANAGER. Unplug and plug-in again the USB cable from/at the instrument. Verify that the computer detects correctly the COM port (Ports COM & LPT section, USB serial port COMx). If not, check the USB cable and the USB port on the computer. Replace the analyzers USB-to-RS232 converter to check if the problem is in the internal converter board. If the USB port is detected correctly by the PC, note which is the detected COM port and continue with step 5. 5. Check the internal serial port. Start the EdifTerminalX86.exe program. Select in the upper left corner the COM port detected in the previous step. Click at the center of the window to focus on it. Shut the instrument OFF and then ON. Wait for the three shakings of the sample plate. The instrument motors are OFF and a @ character is displayed on the screen. Press ENTER three times. The instrument motors go ON (hold) and a must appear on the screen. If the @ doesn’t appear, the instrument is not transmitting on its internal RS232 output .

123

124

Notes on the USB-to-RS232 adapter: Every USB controller has

its

own

internal

serial

If it doesn’t answer to the ENTER (the motors remain OFF), the instrument is not receiving on its internal RS232 input. It is then necessary to check the internal USB-to-RS232 adapter ES03004A, the internal serial cable ES02008B and the serial port in the CPU board EI0302B1V1 (ICL232 driver IC). Continue with step 6. 6. Check the CPU on-board serial port. Remove the cover of the instrument and the CPU board carter. Unplug the CPU serial port cable (16 pins connector on the left side of the board). Short-circuit on the CPU connector pin 3 to pin 5 and pin 9 to pin 14. Switch the instrument OFF, wait five seconds and then ON. The sample tray must begin to shake continuously once a second. When you open the short-circuit, the sample tray will shake three more times. If not, the problem is on the CPU board, otherwise continue with step 7. 7. Check the internal serial cable and the serial port on the USB-to-RS232 converter. Short-circuit on the 16 pins female flat-cable connector pin 3 to pin 5 and on the CPU serial port connector pin 9 to pin 14. Go to TERMINAL operation. Press the terminal window to focus on the terminal. Type some letters on the keyboard. The letters must be displayed on the terminal screen. If the check fails, the problem is on the internal USB-to-RS232 internal adapter ES03004A or on the internal serial cable ES02008B.

number. This means that every USB controller corresponds for the PC to a different COM serial port. Once it has been detected for the first time, the same COM port number is assigned to that

EdifTerminalX86 lists on the upper left corner all the detected COM ports and allows to check the correct detection of the USB adapter. Do not unplug the USB cable when the software or the EdifTerminal are running – it will not reconnect. The software will not find the USB port anymore and it could crash.

USB controller. For this reason, if you connect two instruments to the same PC, every instrument will have its own COM port assigned.

HumaStar 100/200 | Service manual

14.2 Bad precision of optical readings There can be several reasons causing bad precision in readings: - Noise on the optical signal, - Imprecision in the reaction plate positioning, - Imprecision in the filter wheel positioning, - Dispensation problems, - Incorrect vertical positioning of the needle dispensation in the outer plate.

TROUBLESHOOTING

14.2.1 NOISE ON THE OPTICAL SIGNAL It can be checked in the reading test. Selecting filter 0 (dark), the signal must be stable and the maximum oscillation range is 1 unit. Selecting filter 1 and cuvette 0, the signal must be in the range of 15,000 to 18,500 and the maximum oscillation range must be lower than 10 units. If not, check in this order: 1. Spray a contact cleaner on all the lamp contacts, in the front and in the back. 2. Possible defective or close to end-of-life lamp. 3. The optical signal cable from the preamplifier to the CPU. 4. The optical preamplifier. 5. The reading section of the CPU board. See next chapter 14.3. for more detailed troubleshooting.

14.2.2 IMPRECISION OF THE REACTION PLATE POSITIONING It can be checked with the mechanical check F4. If the positioning is unstable, the belt must be tightened correctly.

14.2.3 IMPRECISION OF THE FILTER WHEEL POSITIONING It can be checked with the mechanical check F4. If the positioning is unstable, the belt must be tightened correctly. The imprecision in a single filter can be caused by a loose filter locking ring.

14.2.4 DISPENSATION PROBLEMS Check if the silicone tube is well inserted in the pinch valve and that it is not worn. Check that all the pipetting Teflon fittings are well tight. Check the diluter gasket (white+orange). Eventually replace it. Check the diluter mechanics (Mechanical Check, F7 DILUTER TEST). Check if the needle is clogged.

14.2.5 INCORRECT VERTICAL POSITIONING OF THE NEEDLE Incorrect vertical positioning of the needle during dispensation and mixing in the reaction plate (SN1DS2 quote). Execute in the WASHINGS MENU the PUMPS TEST F5-1. At the end of the test the program will suggest eventually to update the SN1DS2 quote.

125

126

14.3 Bad repeatability of autozero, unstable optical signal Go to READING TEST, wait that the instrument is warmed-up and do the following tests: 1. Select filter 0 (dark), unconnect the optical cable from the CPU board. The A/D signal on the screen must be close to 0 and stable. If not, there is a problem on the CPU A/D converter or the CPU analog preamplifier/multiplexer. 2. Re-connect the optical cable on the CPU and disconnect the optical preamplifier. The A/D signal must be close to 0 and stable. If not, there is a problem on the optical cable. There is a second optical cable in the wiring, used only for double-cuvette analyzers. Swap the defective optical cable with the second one. 3. Re-connect the optical preamplifier. The A/D signal must be in the range 1.5 mV to 5.0 mV (15-50 A/D units) and stable ± 0.2 mV (± 2 A/D units). If not, there is a problem in the optical preamplifier. 4. In READING TEST, select filter 1 (340 nm). The A/D signal must not oscillate more than 1.0 mV (10 A/D units). If not, there could be a problem of the lamp or the lamp contacts. Clean the lamp contacts with a contact cleaner. If the contacts are old tinned contacts, replace the lamp contacts (lamp and power board), if possible, with the new golden contacts. 5. Select filter 2 and then again filter 1. Then filter 3 and again filter 1, etc. Wait for 10 seconds. The A/D signal on filter 1 must come back to the original value within 2 mV (20 A/D units). If not, there is a problem in the filters wheel positioning. Check the filter wheel offset (F7-2), if the filter wheel belt is well tightened and it is not damaged (Test in MECHANICAL CHECK F4-1). It can happen that the belt doesn't look damaged but it doesn't work well anyway. If you are in doubt, replace the filter wheel belt.

14.4 Reaction plate temperature out of control Involved devices: - ± 5 Vcc analog power supply. - Reaction plate temperature sensor and wiring. - AD844 temperature A/D converter on CPU board. - 2.731 Vcc voltage reference on CPU board. - Reaction plate etched coil heating resistance and wiring. - Reaction plate thermostat. - Heating resistance driver MOSFET transistor on power board.

HumaStar 100/200 | Service manual

TROUBLESHOOTING

127

Go to HARDWARE TEST. Press F5 for continuous inputs display. Observe the inputs window in the upper right corner: 1. The displayed temperature is higher than 500 (tenths of °C) and PWM R = 0. - The reaction plate is at room temperature: The temperature sensor is broken or unconnected or the 2.731 Vcc voltage reference is broken. - The reaction plate is really at 50 °C: The driver MOSFET transistor is shortcircuited. 2. The displayed temperature is correctly 38.0 °C ± 0.2 °C, but the reaction plate temperature is wrong. - The temperature measurement is unadjusted. 3. The displayed temperature and the reaction plate are at room temperature and PWM R = 70. - The heating is not working. Check the voltage on the resistance connector: - The voltage on the resistance is close to 24 Vcc: The resistance is broken. - The voltage on the resistance is close to zero: Check the voltage on the power board connector J4, pin 3 - pin 4: - The voltage on the board connector is close to 24 Vcc: Check the wiring and the thermostat. - The voltage on the board connector is close to zero: The driver MOSFET transistor is broken. 4. The displayed temperature is close to zero and the reaction plate temperature is high: - The AD844 A/D converter is not working or the temperature sensor is shortcircuited. FIGURE 158 Temperature display

128

14.5 Dirty and quickly excluded reaction cuvettes

14.5.1 FIRST CHECKS Check if the specified systemic solution is used. It is possible that some reagents can create problems in the washing. Verify that all the employed reagents are well tested for the wash purposes. Check if all the reaction volumes are limited to 310 μl. Verify that the user never shuts the instrument off before the washings have been completed (in run or in shut-down).

14.5.2 CHECK THE REACTION CUVETTES It is important to check and find out in which way the cuvettes are dirty, because it is very important to understand the cause. The absorbance threshold for the cuvette to be considered clean is 120.0 mAbs at 340 nm. Typical absorbance for a new cuvette at 340 nm is lower than 60.0 mAbs, and for the other wavelengths is lower than 35.0 mAbs. In MAINTENANCE  Reaction Cuvettes, check the spectrum of the excluded cuvettes. The deposits that absorb at 340 nm cannot be seen by the human eye, so the cuvette seems clean. If the spectrum is very high at 340 nm and low at the other wavelengths, the cuvette looks clean to the eye, but it is anyway excluded. High absorbances on all the wavelengths, are typical for scratches or uncoloured (white/grey) deposits.

14.5.3 CHECK THE CAUSE OF THE HIGH ABSORBANCES There are internal deposits, i. e. the washing is poor. If the deposit is coloured, you can try to understand which reagents cannot be washed. There are internal vertical scratches, i. e. the stub touches the inner side of the reaction cuvette.

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129

There are external horizontal scratches, i.e. the reaction cuvette touches somewhere and is scratched during the rotation. There are external "clouds", i.e. the vacuum pump is not working well or the operator made some mistake and water poured outside. The "cloud" is the solid deposit that remained on the outer side of the cuvettes after the water was evaporated. In this case the two external sides of the cuvettes can be cleaned with a soft glass cloth. If the area is highly humid, the two external optical faces of the cuvettes can become dirty after some months. Take off the cuvettes rotor (see "12.4. Reaction rotor replacement") and pass a soft optical cloth on the two optical faces of the 80 cuvettes mounted on the rotor.

14.5.4 EXECUTE THE PUMP TEST Put a 5 ml tube filled with tap water in sample position 1. Go to SERVICE MENU  F5 WASHINGS  F5 TEST PUMPS DISP  1 TEST PUMPS. Verify that the aspiration flow in the aspiration test is higher than 1,500 μl and that the final result is Asp. PASS (not Asp. FAIL). The wash station dispensation must have the values higher than 350 μl. If the Aspiration test failed, the membrane valves of the vacuum pump or the entire pump must be replaced. If the Wash station dispensation is low, the peristaltic pumps timers must be increased. This can be done manually, increasing the DIWSH1 to DIWSH6 parameters in the following way:

The DIWSHx parameters range is between 45 and 80. If

Example:

Pump dispensation = 300. Old value of DIWSH1 = 50. New value of DIWSH1 = 50 x 400 / 300 = 67.

the parameter has to be set higher than 80, the pump’s head must be replaced.

130

The pumps timer correction can also be made automatically executing the ADJUST PUMPS procedure: SERVICE MENU  F5 WASHINGS  F5 TEST PUMPS DISP  1 ADJUST PUMPS.

14.5.5 EXECUTE THE CUVETTES SPECIAL WASH To eliminate protein and lipid deposits in the reaction cuvettes, put a reagent bottle with 26 ml of NaOH solution at 4 % in reagent position 1 and start the Special Wash Procedure. At the end, a Startup procedure is executed. To eliminate salt deposits in the reaction cuvettes, put a reagent bottle with 26 ml of HCl solution at 5 % in reagent position 1 and start the Special Wash Procedure. At the end, a Startup procedure is executed.

14.6 Droplet forms on needle tip

14.6.1 DROPLET FORMES AT THE END OF THE NEEDLE TIP If the drop is formed at the end of the needle tip, there can be several causes. The most common causes are: -

-

HumaStar 100/200 | Service manual

The silicone tube inside the pinch valve is damaged, not correctly inserted or too long out of the pinch valve toward the diluter (max. 1 cm). Check the silicone tube and eventually replace it. For the 368 μl diluter (DSTYPE 3 or 4), the parameter DSGAPH (μl of gap after diluter home) must be at -2. If necessary, increase it to -3. There are air bubbles in the diluter or the needle tubing. There can be a leakage in the fitting under the level sensor board or between the Teflon tube and the sampling needle. There can be a narrowing somewhere in the needle tubing so that the tubes blow up and the water flow is delayed. The needle vertical position SN1WSH in the wash well is not well calibrated and the needle tip does not pause on the white nipple 1 mm inside the water drop to let the droplets be captured.

TROUBLESHOOTING

14.6.2 DROPLET HANGS AT THE SIDE OF THE NEEDLE If the drop is hung in a higher position, on the side of the needle, it has probably been left there by the jet of the external wash nozzle. Clean the needle with alcohol to ease the drop fall. The water jet speed can be reduced with the parameter EXWELD, so that the jet hits the needle in a descending parabola, allowing a better leaching of the droplet. Try to reduce the EXWELD parameter by 5 or 10 units. If the external wash nozzle splashes the needle at the end of the internal needle wash, it means that the delay for the valve commutation ASWELD is too low (increase it by 10 to 30 units) or the Y tubing connected to the well dispensation pump, placed on the back side of the hydraulic panel, is too resilient and balloons. Actually it is used a silicone tube 1 x 3 mm to eliminate this problem.

14.7 Aberrant/null results, reagent bottles wrongly detected full It happens more or less frequently that some reagent bottles are detected as completely full (green color) even if they are not. At the same time it happens, that the needle sometimes fails to pipet the sample or reagent 2 (the results are null) or fails to pipet the reagent 1 (the results are aberrant). The cause most probably is the wiring of the sampling arm that is broken. Open the sampling arm cover and check the red level sensor LED during the execution. If the red LED blinks when the arm is still in a higher position, before having detected the liquid level, the level sensor board wiring is broken and must be replaced. See "12.12. Sampling arm replacement".

14.8 Error "Needle shock detector is stuck" The "Needle shock detector is stuck" message is issued when the needle is in an upper position and begins to move down. If a shock signal is detected before starting the movement, it means that the shock sensor is not working properly and the error message is issued.

131

132

There can be three causes: - The needle is bent or the white cap over the needle is too tight. In this case the needle doesn't slide well and it can remain in the upper "shock" position. - The optical sensor of the needle shock is broken: Replace the level sensor board or replace the opto-coupler on the level sensor board. - If the level sensor wiring is broken and the yellow wire of the shock signal is open, the system detects this as a shock situation and the alarm is issued: Replace the level sensor board wiring.

HumaStar 100/200 | Service manual

PERIODICAL CHECK-UP, SERVICE PROCEDURE

15 PERIODICAL CHECK-UP, SERVICE PROCEDURE

15.1 Twelve months programmed maintenance

15.1.1 UPDATE FIRMWARE AND SOFTWARE If the firmware or the software of the analyser is significantly old, proceed to update the EPROMs and the PC software (check the release on the info button on the lower left corner of the software screen).

15.1.2 COVER Check if the instrument is correctly levelled. Check if the top cover shuts correctly the cover switch.

15.1.3 LAMP Check the lamp life. Lamp life ranges between 1,000 and 2,000 hours. If the lamp has more than 1,000 hours of work and a new maintenance checkup is not scheduled, you can consider the lamp to change (remember to reset the lamp timer).

15.1.4 SAMPLING NEEDLE Check the sampling needle (coating, shape). Check if the needle slides correctly in the needle holder, otherwise take off the holder and clean it from eventual deposits. Check if the needle holder is not broken or worn. Check the shock sensor (in Mechanical calibration menu). Check if the sampling needle is clogged. Clean it in the special wash solution.

15.1.5 WASH STATION NEEDLES Check if the wash station needles are clogged, especially the first needle on the right. Eventually unclog them with a probe or a copper wire. The deposit on the needles depends on the type of reagents employed. Clean them with the special wash solution (basic) to remove protein or lipids deposits. Use an acid solution to remove salt deposits.

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134

Check if all the needles are not bent and are well centered in the cuvettes (MECHANICAL CALIBRATION procedure). Check if the dryer needle tip is not worn or broken or rotated. Replace all the damaged needles.

15.1.6 WIRING, CONNECTORS Check the lamp connectors (in the back and on the power board) and spray the contacts with a contact cleaner. In READING TEST, filter 1 selected, move the lamp wires and connectors. The reading value must not change for more than a few A/D units. Otherwise, check the lamp wires. Check the arm wiring: Wires can be stressed or, inside the isolation, the copper could be broken. The continuity of the signal is then precarious. Press, on the CPU board, all the connectors and the integrated circuits mounted on sockets.

15.1.7 HYDRAULIC TUBES, FLOATS Replace old tubes, dirty or with algae. Check if there is air leakage from the hydraulic connectors of the tanks. Check the tubes collars. Check if the three floats work correctly (check the floats in the WASHINGS MENU).

15.1.8 DILUTER Replace the sealing gasket (orange O-ring inside the diluter head).

15.1.9 PUMPS Run the pumps test (WASHINGS F5-1) and print the report. Adjust the SN1DS2 quote if requested by the pumps test. Check the peristaltic pumps life and flow-rate. If the flow-rate of any pump is lower than 500 μl/s or if the pump head work-time is higher than 30-50 hours, replace the pump’s head, reset the pump’s work timer and then execute the pumps adjustment procedure (WASHINGS F5-5). On the pumps test report (WASHINGS F5-1), check the vacuum pump flow rate. If lower than 2,000 μl/s for analyzers with 7 aspiration needles or else if lower than 1,100 μl/s for analyzers with 5 aspiration needles, then:

HumaStar 100/200 | Service manual

PERIODICAL CHECK-UP, SERVICE PROCEDURE

-

First check if any aspiration needle (the longer ones) is clogged and eventually unclog them. Else replace the pumps membrane valves or the vacuum pumps (see "12.8. Vacuum pump wearing parts replacement").

15.1.10 REAGENTS COOLING Check the power supply voltage (14.1 Vcc to 14.2 Vcc). Check if the cold plate is correctly cooled (3 Peltiers positions). If not, check the supply current. It must be in the range 2.3 A to 2.6 A. Clean the cold plate, remove eventual mildew. Check if there is mildew between the warm and the cold plate.

15.1.11 SAMPLE PLATE If necessary, clean it with a sterilising solution and then rinse abundantly, wipe and dry. If it is a 20+20 sample plate, check if the external tubes clips are well inserted and not damaged.

15.1.12 REACTION PLATE CUVETTES Check the cuvettes absorbances on the reaction plate. If absorbances are typically higher than 800, take the reaction rotor off and clean gently the two external faces of the cuvettes, wiping them with a lens cleaning cloth. Pay attention to avoid dust deposits on the two faces. After the cleaning, execute a wash of all the cuvettes (WASHINGS, F2, 80 cuvettes). Replace cuvettes which show an OD higher than 1,000 units (= 100 mAbs). Follow software MAINTENANCE  Reaction cuvettes  Cuvettes replacement procedure. After these two operations it is necessary to execute the start-up. There is a fast version of the start-up in the Washings menu.

15.1.13 TEST AND ADJUSTMENT PROCEDURES IN THE SERVICE MENU The following menus must be called from the service menu to execute the test procedures.

135

136

F2 Mechanical calibration

F3 Mechanical check

F5 Washings menu

Check all the mechanical calibrations, especially the sampling needle dispensation quote (SN1DS2), the wash station down quote (ANWASP), the sampling needle wash in the well drop (SN1WSH), the sampling needle in the reagent bottles and in the sample tubes and cups. To verify the belts and the mechanics. Execute the mechanical check tests, especially the F4. If FS or OP fails, eventually tighten the belt. F5-2 Fill the hydraulics if the tubes are empty, otherwise the following tests will be faulty: -

F4 Reading test menu

F5-1 Pumps test: Adjustment of the reaction cuvettes level check and of the needle dispensation quote. - F5-5 Adjust pumps. F6-1 OP Reading Offset check. F7-2 FS Filter wheel check. F5-2 AUTOZERO test: The CV% must be lower than 0.1500 for filters 1 and 2 and lower than 0.1000 for the other filters. In the first column FSOP, there must be only zero values (It is a signal of good FS and OP positioning). If the CV% are anyway high with zero FSOP values, check the lamp, its connectors and its wiring.

15.1.14 DILUTER AND PIPETTING Run the 2 μl pipetting test procedure with E124 (OD at 505 nm: 30 - 50 abs, 1 ml in sample tube 1). Commands to start the run: OK1,1 XM6 Commands to report: WS1 XM0 The CV% must be lower than 2.5 - 3 %. Factory value is lower than 2 %.

HumaStar 100/200 | Service manual

SYSTEM PARAMETERS LIST

137

16 SYSTEM PARAMETERS LIST

16.1 EPROM parameters table There are 361 parameters, consecutively numbered. Parameters, named "Qnnn", are unassigned. Parameters printed in red are critical to the instrument and therefore protected by a password. For password handling refer to the appropriate Human Service Bulletin (HSB). Do not change the parame-

Table columns: 1st column 2nd column 3rd column

ters described in this chapter,

Parameter name Parameter ID Parameter description

16.1.1 INNER PLATE (IP) MOTOR IPNPS0 IPNPS1 IPOFF0 IPOFF1 IPDDIL IPMODE IPPHOM IPOPER IPTYPE

000 001 002 003 004 005 006 007 008

IPHOME IPOFBC IPSHFT

009 010 011

Q12 Q13 Q14 Q15 Q16 Q17 Q18 Q19

012 013 014 015 016 017 018 019

IP N. positions on external ring. IP N. positions on inner ring. IP/SN needle offset for external ring. IP/SN needle offset for inner ring. IP Rotation for tube-side dilution dispensation. 1: Enable reverse rotation for small movements of IP. IP Pre-position for fast home. IP Delta steps for tube in front of operator. IP Type: 0: Free, PTU; 1: 20 ext=PTU, int=CUP2; 2: 30+30 PTU. Enable IP home after every sample. Samples barcode IP offset. Numbering shift between inner and external ring. (0=Inner follows with half step) – For barcode use.

as long as it is not expressively recommended by Human.

138

16.1.2 OUTER PLATE (OP) MOTOR OPOFAN Q21 OPOFRD OPPHOM OPMODE OPCHTU OPANSN OPR1R2

020 021 022 023 024 025 026 027

OPR2R3

028

Q29 OPOFGO

029 030

OP Offset AN side. OP Offset reading side. OP Pre-positioning for home speed-up. 3: No home during run. OP Offset between AN and tube change (in tube positions). OP Offset between AN and SN (in tube positions). N. of R1/R2 incubation cycles = OP offset between R1 and R2. N. of R2/R3 incubation cycles = OP offset between R2 and R3. OP tube for reading gain + offset.

16.1.3 FILTERS SELECTION (FS) MOTOR FSOFFS Q32 Q33 Q34 Q35 Q36 Q37 Q38 Q39

031 032 033 034 035 036 037 038 039

Filter wheel offset.

16.1.4 SAMPLING NEEDLE (SN) MOTOR SNOFFS SN1HOM SN1LOW SN1MID SN1HIG SN1WSH SN1WEL SNDWEL SN1DWU SN1REA SN1CUP

HumaStar 100/200 | Service manual

040 041 042 043 044 045 046 047 048 049 050

SN Offset. SN1 High out of FC for fast home search. SN1 Low position over the reaction tubes. SN1 Mid position over the sample tubes. SN1 High, for rotation over reagent bottles. SN1 For wash needle 1 in wash well. SN1 Low position over the wash well. Delta to SN1WEL for dispensation in wash well. SN1 Delta SN1 up for drop. SN1 At the bottom of reagent bottles. SN1 For sampling on IP: Cups.

SYSTEM PARAMETERS LIST

SN1PTU SN1DDS SN1DS2

051 052 053

SN1CU2 SN1RET SN1REC SN1DLC SNDLWE

054 055 056 057 058

SNDXWN Q60 SNDMOD

059 060 061

Q62 Q63 Q64 Q65

062 063 064 065

SN1 For sampling on IP: Primary tubes. SN1 Upside delta/SN1DS2 for 1st dispensation on OP. SN1 For 2nd dispensation in OP, with mixing, corresponding to ± 100 μl in OP. SN1 For internal row cups for IP 20 + 20. SN1 At the bottom of reagent bottle type: Tube. SN1 At the bottom of reagent bottle type: Cup. SN1 At the bottom of diluent bottle. Delta to SN1WSH for level sensing in needle wash well test. Delta to SN1WSH-SN1DWU for external needle wash. Enable dispensation from SN1DDS and then down to SN1DS2 with level check.

16.1.5 DILUTER SYRINGE (DS) MOTOR DSKADD MIXVO1 DSTYPE

066 067 068

DSOFFS DSTROK DSTEPS MIXVO2 MIXRP1 MIXRP2 DLYMIX DSGAP1 DSGAP3 DSGAPH MIXRPD

069 070 071 072 073 074 075 076 077 078 079

DS Steps correction. DS Reaction mixing volume 1st dispensation. 0: Free parameters, 1=Sanwa 530 μl, 2=Sanwa 354 μl, 3=Edif 368 μl. Syringe home offset. Diluter syringe volume (full stroke). DS Steps/stroke. DS Reaction mixing volume 2nd dispensation. DS Reaction mixing repetitions DISP.1. DS Reaction mixing repetitions DISP.2. Delay in needle mixing in csec. Diluter syringe first GAP. Diluter syringe third GAP. Diluter GAP after home: Diluter type 3-4: -2, else 0. DS Predilution in OP mixing repetitions.

139

140

16.1.6 NEEDLE ROTATION (RN) MOTOR NREAG Q81 RNREA1 RNREAN Q84 RNWRAP RNWASH RN1DWN RNDWEL Q89 RN_IP0 RN_IP1 RN1_OP Q93 Q94 RNDILC Q96 Q97 Q98 Q99 Q100 Q101 Q102 Q103 Q104 Q105 Q106 Q107 Q108 Q109

080 081 082 083 084 085 086 087 088 089 090 091 092 093 094 095 096 097 098 099 100 101 102 103 104 105 106 107 108 109

N. of reagents on RN plate (last position is for diluent). RN Position of 1st reagent bottle. RN Position of last reagent bottle. RN Wrap position. RN On wash well. RN Delta for wash on well SN1 side. RN Delta for check WN pumps. RN Needle 1 on IP external ring. RN Needle 1 on IP inner ring. RN Needle 1 on outer plate tubes.

RN On clinical chemistry diluent bottle.

16.1.7 WASH STATION (AN) MOTOR

HumaStar 100/200 | Service manual

ANOFFS ANHOME ANHIGH ANWA1D

110 111 112 113

ANWA2D ANWASP ANZMOD

114 115 116

AN Offset. AN Home position. AN High position under home. AN 1st pause during wash aspiration / Rising start vacuum aspiration. AN 2nd pause during wash aspiration. AN Bottom wash aspiration. AN Home search mode.

SYSTEM PARAMETERS LIST

ANTUBE Q118 Q119

117 118 119

AN Low immediately over the OP reaction tubes.

16.1.8 MOTOR SPEEDS, HOME TOLERANCES IPVEL IPVELZ IPDYBC Q123 Q124 OPVEL OPVELZ OPVELR Q128 Q129 FSVEL FSVELZ DLYFLT DSVELD DSVELA DSVLOW Q136 DSVELZ RNVEL RNVELZ Q140 Q141 Q142 Q143 SNVELU SNVELD SNVELZ Q147 Q148 ANVELH ANVELL ANVELZ Q152 IPZERR RNZERR OPZERR

120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155

IP Normal speed. IP Home speed. IP Delay in barcode scanning.

OP Normal speed. OP Home speed. OP Reading speed.

FS Speed. FS Home speed. Delay for filter rotation in reading. DS Dispensation speed. DS Aspiration speed. DS Speed low (GAP + sample aspiration). DS Home speed. RN Speed. RN Home speed.

SN Up speed. SN Down speed. SN Home speed.

AN Speed high. AN Speed low. AN Home speed. Steps limit for IP home step error. Steps limit for RN home step error. Steps limit for OP home step error.

141

142

SNZERR FSZERR ANZERR DSZERR

156 157 158 159

Steps limit for SN home step error. Steps limit for FS home step error. Steps limit for AN home step error. Steps limit for DS home step error.

16.1.9 PUMPS DIWSH1 DIWSH2 DIWSH3 DIWSH4 DIWSH5 DIWSH6 ASVAC4 ASVAC1 ASVAC2 ASVAC3 DLYPMP FILLWS

160 161 162 163 164 165 166 167 168 169 170 171

NRIPWS ENANDN EPM6ER

172 173 174

FILCHK

175

EPMDER

176

WSHVOL Q178 Q179 THMCNV

177 178 179 180

NDWMOD 181 NDWSHO 182 NDWSHS

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183

Water dispensation 1 time (csec). Wash dispensation 2 time (csec). Water dispensation 3 time (csec). Water dispensation 4 time (csec). Water dispensation 5 time (csec). Water dispensation 6 time (csec). Fourth vacuum aspiration (csec). First Vacuum aspiration (csec). Second vacuum aspiration (csec). Third vacuum aspiration (csec). Delay after pump stop, before VAC2 2 low digits=repetition for wash (wash prime on 2nd needle), 2 high digits=repetition for water prime. N. repetitions of filling/aspiration cycles in wash station. Enable check AN down limit switch. Enable PUMP 6 WASH DISPENSATION ERROR in test wash station dispensation. Enable pumps check in fill hydraulics, 1: Dispensation well, 2: Aspiration well, 4: Test well, 8: Wash station aspiration. Enable PUMPS WASH DISPENSATION ERROR in test wash station dispensation. Target volume (μl) for wash station.

THOMAS peristaltic pump dispensation μl per second conv. factor, over evaluated, to calculate water and waste variations (measured range: 700 to 1,050). Wash needle in well mode 0=center / 1=side+center. Wash dispensation, SN in OP tube (csec for 400 μl) SN_Wash(). Wash dispensation, SN in well / samples 1st + 2nd dispensation (csec).

SYSTEM PARAMETERS LIST

NDWSHR

184

NDWSHX ASWELD DIWELD EXWELD Q189 Q190 Q191 ASVAV1 ASVAV2 ASVAV3 EXWELV INWELV PERILF VAC1LF VAC2LF

185 186 187 188 189 190 191 192 193 194 195 196 197 198 199

Wash dispensation, SN in well / reagents check level, R3, R4 (csec). Wash dispensation, SN in well / external wash (csec). Well aspiration extension after well dispensation. Well Dispensation delay after pump stop, to avoid drop. Well external wash delay after pump stop, to avoid drop.

Peristaltic pump expected life (hours). Vacuum pump 1 expected life (hours). Vacuum pump 2 expected life (hours).

16.1.10 VARIOUS PARAMETERS RELEAS Q201 ENASIC Q203 ENALOG SVSCRN SPAUSE DISPLV EXECOD ENVACS

200 201 202 203 204 205 206 207 208 209

ENAWY EEXCHK ESWR12 Q213 Q214 RDSTEP NDISP PHASD3

210 211 212 213 214 215 216 217

Current software release for automatic parameter update. Enable door security limit-switch. Enable LOG prints. Enable automatic Save Screen with Terminal 2.2. 1=Sstep, >1: breakpoint at SStatus=SPAUSE - RESERVED. Local printer test mode – reserved. Enable full execution status codes (SW >= 0.38). Enable Vacuum ERROR: 1=needles aspiration test with SN, 2=swap aspiration test with SN, 4=vacuum sensor. Enable WY command. Enable execution flag check. Enable reagents swap in R1+R2 dispensation.

Optical reading step (1 or 2 cycles). N. of dispensations per cycle. Beginning of 2nd dispensation (sec), 0: No second dispensation.

143

144

MCYCLE PHASD2

218 219

EWNREA EWNSMP

220 221

ENWSHS NWPRIM NSPWSH Q225 Q226 Q227 LMPSAV LMPLIF

222 223 224 225 226 227 228 229

Machine cycle (sec) clinical chemistry. Beginning of 2nd dispensation (sec), 0: No second dispensation. Enable needle external wash after REAG. Enable needle external wash after SMP if volume <= EWNSMP. Enable wash station in run (0 for diagnostics only). N. of wash prime at run start (0=disable). N. of special cuvettes special washes (1/2).

Lamp saver - delay after switch on (sec). Optical lamp expected life (hours).

16.1.11 BARCODE BARCOD Q231 Q232 Q233 Q234 Q235 Q235 Q237 Q238 Q239

230 231 232 233 234 235 236 237 238 239

Barcode installed 0 or 1.

16.1.12 LEVEL SENSOR, FLOATS

HumaStar 100/200 | Service manual

LEVPTU

240

LEVCUP

241

LEVREA LEVDIL

242 243

LEVCUV

244

KLVPTU

245

Primary tube sample level check: -1=no, else steps before needle stops. Cups sample level check: -1=no, else steps before needle stops. Reagent level check: -1=no, else steps before needle stops. Sample dilution level check: -1=no, else steps before needle stops. Sample dilution in OP level check: -1=no, else steps before needle stops. SN: 0.151 mm/step. Coefficient: Primary tubes, μL/10 per SN needle step.

SYSTEM PARAMETERS LIST

KLVCUP KLVREL

246 247

KLVRES

248

KLVDLC LMXPTU

249 250

LMXCUP

251

LMXREA

252

LMXDLC

253

Q254 RELVOL

254 255

RESVOL

256

LVERWN

257

LEVWEL

258

Q259 WSTFUL WSTRES WATFUL WATRES WATRS2 WSHFUL WSHRES WSHRS2 Q268 Q269 DELREA

259 260 261 262 263 264 265 266 267 268 269 270

Q271 DSMPLV

271 272

EFLOAT ESHOCK Q275 Q276 REF150 OPL150

273 274 275 276 277 278

145

Coefficient: Cups, μL/10 per SN needle step. Coefficient: Reagent bottles, large, μL/10 per SN needle step. Coefficient: Reagent bottles, small, μL/10 per SN needle step. Coefficient: Diluent bottles, μL/10 per SN needle step. Primary tube sample maximum level (steps) above which detection is disabled. Cup sample maximum level (steps) above which detection is disabled. Reagent maximum level (steps) above which detection is disabled. Diluent maximum level (steps) above which detection is disabled. Reagent large bottle maximum level (ml) to which sured level is clipped. Reagent small bottle maximum level (ml) to which sured level is clipped. Reagent tube bottle maximum level (ml) to which sured level is clipped. Reagent cup bottle maximum level (ml) to which sured level is clipped.

meameameamea-

Full volume of waste (ml) = fatal alarm. Reserve volume of waste full (ml). Float commutation. Full volume of water (ml). Reserve volume of Water (ml). Float commutation. Reserve alarm volume of water (ml). Full volume of wash (ml). Reserve volume of wash (ml). Float commutation. Reserve alarm volume of wash (ml).

1=Delete reagents at power-on, 0=Don't delete, -1=Keep also levels. Maximum difference error in sample level double check (μl). Enable waste and wash floats alarm. Enable shock sensor.

OP level calibration 150 μl.

146

OPL450

279

OP level calibration 450 μl.

16.1.13 TEMPERATURES OP1TMP MAXRS1 PR1PWM OPTMPO OPTSBY Q285 Q286 Q287 TMPERR TMPTOU Q290 Q291 Q292 Q293 Q294 Q295 Q296 Q297 Q298 Q299

280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299

Normal OP temperature (0.1 °C). Maximum PWM for RS1 OP heating. Fixed reagent pre-heating % PWM. OP Temperature offset (0.1 °C). Standby OP temperature (0.1 °C).

Temperature error for alarm (0.1 °C). Temperature timeout for alarm (sec).

16.1.14 DILUTIONS, PIPETTING DLYASR DLYASS DLYDSP Q303 VOLDIL DILSHK MIXDIL Q307 MXDIL2 MINSMP Q310 Q311 Q312

HumaStar 100/200 | Service manual

300 301 302 303 304 305 306 307 308 309 310 311 312

CC: Delay aspiration reagent. CC: Delay aspiration sample. CC: Delay dispensation diluent / reagent / sample. Pre-dilutions base (dead) volume (μl). Pre-dilutions shake time (sec). Pre-dilution needle mixing repetitions. Maximum in-needle dilution rate. Minimum sample volume.

SYSTEM PARAMETERS LIST

16.1.15 READING Q313 Q314 SLFMOD NRSLFB Q317 INISTU Q319 FILTR1 FILTR2 FILTR3 FILTR4 FILTR5 FILTR6 FILTR7 FILTR8 FILTR9 FILAUX ZIF0 Q331 Q332 Q333 Q334 Q335 Q336 Q337 Q338 Q339 FITMIN OPGAIN OPRDER CLCMOD ENALIN SHRTRD ENTUBZ

313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346

ADJKIN Q348 RDGDOD DIFAUZ

347 348 349 350

DIFAZ2

351

Self blank mode: 1 check bubble. N. of readings employed in the self blank. Initial sampling tube in run (for diagnostics), 0=Auto. Filter 1 wavelength (nm). Filter 2 wavelength (nm). Filter 3 wavelength (nm). Filter 4 wavelength (nm). Filter 5 wavelength (nm). Filter 6 wavelength (nm). Filter 7 wavelength (nm). Filter 8 wavelength (nm). Filter 9 wavelength (nm), optional. Auxiliary filter for colorimetric tests. F0 Factory initial autozero value.

Minimum fit for kinetics (/1000). Current optical gain. Enable CancelLastReading() in OP home != 0. Internal use: 0=No calculations. Enable linearity in WF: 0=No, 1=Abs. value, 2=Alg. Value. Enable short reading. &1: Enable sub. tube zero in KINE/FIXT. &2: Enable sub. tube zero in BICR+COLOR. Enable kinetic adjustment of the number of readings. Threshold Dod1 x Dod2 for reading elimination. Maximum autozero difference in 1/1000 / previous autozero (50 = 21 mAbs). Maximum autozero difference /1000 in 2nd repetition (12 = 5 mAbs).

147

148

HumaStar 100/200 | Service manual

MINAUZ MAXZER

352 353

MAXDZE

354

MAXZE2

355

Q356 MXDIRT

356 357

ELSNGP CODCHK NPARAM

358 359 360

Minimum A/D value for autozero. Maximum zero value at FILTER1 (UV) for a reaction cuvette (0.1 mAbs). Maximum zero absolute difference between Startup 340 nm and current 340 nm (0.1 mAbs). Maximum zero value at visible filters for a reaction cuvette (0.1 mAbs). Maximum number of excluded tubes for error cuvette rotor dirty. Enable singular points elimination. Weighted parameters checksum. N. of elements in the parameter table.

ERROR CODES

149

17 ERROR CODES

17.1 HI software error codes Table columns: 1st column 2nd column 3rd column e0001 e0002 e0003 e0004 e0005

e0006 e0007 e0008 e0009 e0010 e0011 e0012 e0013 e0014 e0015 e0016 e0017 e0018

e0019

e0020

Error code Error mnemonics (first 15 characters) Error description

INSTR_CLOSE

You are not connected to an instrument! The program will be closed now. UNABLE_TO_READ_ Unable to read firmware version from instrument. CONN_BF_PROC Connect the instrument before proceeding. ERROR_REMOVING_ Error removing the selected method. METHOD_UPLOAD_P Method upload procedure cannot be executed when instrument is running or during check of reagent levels. PROBLEM_UPLOADI Problem uploading methods. Internal system error (error during test status update). AN_ERROR_OCCURE An error occurred while saving the settings. SAMP_POS_NV Not valid sample position. PATIENT_LINKERROR A linked patient should be defined to continue with the creation of the sample. INV_FIELD_BLANK Invalid field value for blank validity. INV_FIELD_OD1 Invalid field value for blank OD 1. INV_FIELD_STD Invalid field value for standards number. INV_FIELD_CALVA Invalid field value for calibration validity. INV_FIELD_FACT Invalid field value for calibration factor. INVALID_CORRELATION Invalid value for correlation factor. SU_FIN_INT Start-up procedure has been interrupted. It is recommended to repeat the procedure. NR_FIN_INT Needle rinse procedure has been interrupted. It is recommended to repeat the procedure. ET_FIN_INT Empty tubes procedure has been interrupted. It is recommended to repeat the procedure. PH_FIN_INT Prime hydraulics procedure has been interrupted. It is recommended to repeat the procedure.

150

e0021

e0022 e0023

e0024 e0025 e0026 e0027 e0028 e0029 e0030

e0031 e0032 e0033

e0034 e0035 e0036 e0037 e0038 e0039 e0040 e0041 e0042 e0043 e0044 e0045 e0046 e0047 e0048 e0049 e0050 e0051

HumaStar 100/200 | Service manual

WC_FIN_INT

Wash cuvettes procedure has been interrupted. It is recommended to repeat the procedure. SD_FIN_INT Shut-down procedure has been interrupted. It is recommended to repeat the procedure. MET_UP_PARTIAL Only the first 40 methods have been loaded on the instrument. Please check the number of methods and try again. ACCOUNT_LOG Internal system error (error in account login). METH_MAX_EXCEED The maximum number of methods has been reached. METH_ALR_EXIST The current method already exists in the method list. Operation aborted. METH_ERR_LOAD Error loading a method. SAMP_POS_ALR_EX This sample position is already used. SAMP_POS_INV Invalid position for current sample. SAMP_POS_NT_CHANG Sample position can be changed only if the sample doesn’t have executing or scheduled tests. SAMP_POS_VAL_INV Invalid sample position value. TO_REMOVE_AN_EX To remove an executing test the instrument must be connected. THE_INSTRUMENT_ The instrument is not responding. Check the cable connection. If the problem persists contact the assistance. ERR_MAIN_LOGS Error saving maintenance log. EXECUTION_STOPP Execution stopped. NON-VOLATILE_RA Non-volatile RAM error. LAMP_OUT-OF-WOR Lamp out-of-work. NO_CLEAN_REACTI No clean reaction tubes. REACTION_HIGH_T Reaction high temperature error. ERROR_ON_SAMPLI Error on sampling needle HOME search. ERROR_ON_WASH_S Error on wash station HOME search. ERROR_ON_NEEDLE Error on needle rotation HOME search. ERROR_ON_SAMPLE Error on sample plate HOME search. ERROR_ON_REACTI Error on reaction plate HOME search. ERROR_ON_DILUTE Error on diluter syringe HOME search. ERROR_ON_FILTER Error on filter wheel HOME search. REACTION_LOW_TE Reaction low temperature error. BARCODE_READER_ Barcode reader not ready. WELL_WASH_DISP. Well wash dispension pump error. WELL_WASH_ASP._ Well wash aspiration pump error. VACUUM_PUMP_1_E Vacuum pump 1 error.

ERROR CODES

e0052 e0053 e0054 e0055 e0056 e0057 e0058

VACUUM_PUMP_2_E WASH_DISP._1_PU WASH_DISP._2_PU WASH_DISP._3_PU WASH_DISP._4_PU WASH_DISP._5_PU WASH_DISP._6_PU2

e0059 e0060 e0061 e0062 e0063 e0064 e0065 e0066 e0067 e0068 e0069 e0070

DOOR_OPEN:_WAIT WASTE_FULL WATER_TANK_EMPT WASH_TANK_EMPTY SAMPLE_TUBE_EMP DILUENT_BOTTLE_ NEEDLE_SHOCK_ER REAGENT_POSITIO FILTER_POSITION FIRMWARE_ERROR READING_A/D_OVE READING_A/D_TIM

e0071 e0072 e0073 e0074 e0075

INVALID_AUTOZER REACTION_ROTOR_ WASH_STATION_DO ERROR_ON_REAGEN ERROR_IN_OUTER_

e0076 e0077 e0078

LOW_LIQUID_LEVE RINSE_BOTTLE_MI NEEDLE_SHOCK_DE

e0079

COMPOSED_ERROR

e0080 e0081 e0082 e0083

151

Vacuum pump 2 error. Wash dispension 1 pump error. Wash dispension 2 pump error. Wash dispension 3 pump error. Wash dispension 4 pump error. Wash dispension 5 pump error. Wash dispension 6 pump error. (Bubbles may be in the system. If problem persists after prime, the cause may be the malfunction of dispension pump 6.) Door open (waiting). Waste full. Water tank empty. Wash tank empty. Sample tube empty during predilutions. Diluent bottle empty during predilutions. Needle shock error. Reagent position request out-of-range. Filter position request out-of-range. Internal firmware error. Optical reading A/D overflow. Optical reading A/D time-out (A/D malfunction). Invalid autozero. Reaction rotor dirty (too many dirty tubes). Wash station down error. Error on reagent plate HOME search. Error in reaction plate OFFSET calibration. It is recommended to execute the optical calibration. Low liquid level in sample tube 1. Rinse bottle missing in reagent position 1. Needle shock detector is stuck (shock is detected in high needle position). Composed method error (formula of a composed method must not contain a cyclic reference). Internal system error (retrieving readings). Internal system error (RefreshTests). Internal system error (ElaborateTests Queue). Internal system error (UpdateMethods AvailableTests).

152

e0084 e0085 e0086 e0087 e0088 e0089 e0090 e0091 e0092 e0093 e0094 e0095 e0096 e0097 e0098 e0099 e0100 e0101 e0102 e0103 e0104 e0105 e0106 e0107 e0108 e0109 e0110 e0111 e0112 e0113 e0114 e0115 e0116 e0117 e0118 e0119 e0120 e0121 e0122

HumaStar 100/200 | Service manual

Internal system error (UpdateInstrumentStatus). Internal system error (RefreshTimeLeftFor Execution). Internal system error (UpdateWarmUp). Internal system error (not assigned). Internal system error (Core.TimerPollingCallBack). Internal system error (not assigned). Internal system error (loading calibrators and controls). Internal system error (saving calibrators and controls). Internal system error (saving quality control). Internal system error (SerializeQC). Internal system error (SerializeQC). Internal system error (loading QC log file). Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error. Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned).

ERROR CODES

e0123 e0124 e0125 e0126 e0127 e0128 e0129 e0130 e0131 e0132 e0133 e0134 e0135 e0136 e0137 e0138 e0139 e0140 e0141 e0142 e0143 e0144 e0145 e0146 e0147 e0148 e0149 e0150 e0151 e0152 e0153 e0154 e0155 e0156 e0157 e0158

153

Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (MainInterface. PrintSampleReportDirectly). Internal system error (SheetTabPage.InsertTests). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (PlaySound). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (assigned). Internal system error (PlaySound). Internal system error (AddTestToScheduler). Internal system error (RemoveTestFromScheduler). Internal system error (TestReportButton_ Click). Internal system error (unable to refresh sample). Internal system error (finding patient on RefreshSample). Internal system error (unable to clear fields). Internal system error (check test on a null test).

154

e0159 e0160 e0161 e0162 e0163 e0164 e0165 e0166 e0167 e0168 e0169 e0170 e0171

ERR_LOAD_BKP_WORK

e0172 e0173

ERR_CREA_MET

e0174 e0175 e0176 e0177 e0178 e0179 e0180

Internal system error (managing optical error). Internal system error (during autodilution process). Internal system error (during QC registration). Internal system error (trying to serialize method). Internal system error (trying to archive test). Internal system error (trying to remove test from instrument). Internal system error (color test). Internal system error (composed test). Internal system error (removing test from instrument). Internal system error (refreshing values for test and sample). Internal system error (InitSQC). Internal system error (loading xx QC item). Worklist backup was corrupted too. HI will make a copy of the file CurrentWorklist. sdw_corruptedBkp. Internal system error (CheckIfPrintAreNeeded). A method code must not contain spaces, commas and must not be longer than 6 characters. Internal system error (assigned). Internal system error (assigned). Internal system error (during sample sync). Internal system error (during sample creation). Internal system error (during sample selection on grid). Internal system error. Internal system error (QC print).

17.2 Firmware execution error codes Table columns: 1st column 2nd column

HumaStar 100/200 | Service manual

Error code Error description

ERROR CODES

17.2.1 EXECUTION ERRORS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Execution stopped. Non-volatile RAM error. Lamp out-of-work. No clean reaction tubes. Reaction high temperature error. ERROR ON SAMPLING NEEDLE. ERROR ON WASH STATION. ERROR ON NEEDLE ROTATION. ERROR ON SAMPLE PLATE. ERROR ON REACTION PLATE. ERROR ON DILUTER SYRINGE. ERROR ON FILTER WHEEL. Reaction low temperature error. Barcode reader not ready. Well wash disp. pump error. Well wash asp. pump error. Vacuum pump 1 error. Vacuum pump 2 error. Wash disp. 1 pump error. Wash disp. 2 pump error. Wash disp. 3 pump error. Wash disp. 4 pump error. Wash disp. 5 pump error. Wash disp. 6 pump error.

17.2.2 RESOURCES ERRORS 26 27 28

Waste full - Empty tank before start. Water bottle empty. Wash bottle empty.

17.2.3 OFF-LINE PREDILUTIONS ERRORS 29 30

Sample tube empty in predilutions. Diluent bottle empty in predilutions.

155

156

17.2.4 ERRORS CAUSED BY FIRMWARE/SOFTWARE MISTAKES 32 33 34 35 36 37 38 39 40 41 42 43 44

HumaStar 100/200 | Service manual

Reagent position request out of range. Filter position request out of range. Firmware error. Reading A/D Overflow. Reading A/D time-out. Invalid autozero. Reaction rotor dirty, more than MXDIRT excluded tubes. Wash station down error. ERROR ON REAGENT PLATE (LITHIA ONLY). OP Calibration error. Low level in sample tube IP-01. Low level Rinse bottle R1. SN needle shock detector is stuck.

HI SOFTWARE INSTALLATION/UPDATE

157

18 HI SOFTWARE INSTALLATION/UPDATE FIGURE 159 Human Interface icon

18.1 Settings The HI software is a Windows .Net application and runs under Microsoft Framework 4.0. It also requires some more Microsoft applications (Microsoft SQL Server Compact and Microsoft Report Viewer). All these Microsoft tools are already included in the installation CD and are installed automatically before the HI software will be installed. The program runs with almost any last generation CPUs. For slow cheap CPUs, like the Atom N270, it will be necessary to disable the fading effects in the HI software settings to reduce the graphics CPU load. The software auto-scales on the computer screen. It is anyway suggested to use the 1280 x 1024 screen resolution to get the best results. Minimum vertical resolution required is 900 dots.

18.2 HI software updating – release 0.4X

18.2.1 LOGGING ON To install the software you need to log-on to your computer as Windows Administrator.

158

18.2.2 CREATION OF A BACKUP COPY OF THE DATA FOLDER It is recommended to back-up the "Human" data folder. If you want to return to the old release, you have to replace the newly modified "Human" folder by the old backup data folder. See "18.3. HI data folder" to locate the "Human" data folder.

18.2.3 INSTALLATION OF THE NEW SOFTWARE If the new software has been downloaded: -

Unzip the installation software file (if it is compressed). Execute the SETUP.EXE program.

If the new software is on an installation disk, just insert the CD and the installation will start automatically (assuming the AUTORUN.INF feature is enabled). If AUTORUN.INF is disabled, execute the SETUP.EXE program.

18.2.4 INSTALLATION STEPS A: Only if the old installation has not been correctly uninstalled, a new window will ask you to remove the old installation. In this case confirm that the old installation must be removed, then press the CLOSE button and restart the installation. B: FTDI CDM - USB-RS232 driver installation: Press INSTALL – a DOS black window will open during this installation. C: MICROSOFT LICENSE AGREEMENT window (if the Microsoft Framework 4.0 tools are already present in your computer, this step can be skipped by the installer): Select the "I agree" option 3 times, first for Microsoft Framework, second for Microsoft Report Viewer and third for Microsoft SQL Server. In this case, the system will ask you to reboot the computer. Accept and wait while the computer restarts and enters again the installer. D: HI (HUMAN INTERFACE) LICENSE AGREEMENT window: Select the "I agree" option and press the NEXT button. E: Select the COMPLETE INSTALLATION option. F: CONFIRM INSTALLATION window: Press the NEXT button. The software is installed in a few seconds. G: INSTALLATION COMPLETE window: Press the CLOSE button.

HumaStar 100/200 | Service manual

HI SOFTWARE INSTALLATION/UPDATE

H:

I: J: K:

159

The installer creates a data folder named "Human" with only void files. If you want to keep your old data, you have to copy the old "Human" data folder. Follow the steps described in the next chapter. Otherwise contact your distributor for your default data folder. A reference default data folder is supplied in the Settings CD. A "HI" icon is now available on the desktop to start the program. When you start the program the first time, you must select the COM port that will be used for the communication with the instrument. Since the internal method structure could have been changed, log-on as ADMINISTRATOR or INSTALLER and execute the METHODS UPLOAD to synchronize the analyzer with the PC.

18.3 HI data folder The software installer initializes a void data folder. You can copy your own data folder or a default data folder, replacing the void folder created by the installer. The data folder path is: - For Windows XP: C:\Documents and Settings\All Users\Application Data\HI\Human. - For Windows Vista / Windows 7: C:\ProgramData\HI\Human The "Program Data" folder

To maintain the application data from an old installation, copy the old "Human" folder and paste it into the following folder: - For Windows XP: C:\Documents and Settings\All Users\Application Data\HI - For Windows Vista / Windows 7: C:\ProgramData\HI Once copied, rename your new data folder to "Human". To avoid the risk of data loss, it is anyway safe to back-up periodically the complete "Human" data folder. DEFAULT METHODS: There is a data folder in the Settings CD that can be used by beginners, replacing the void data folder that is created by the installation CD.

may be hidden. To show it, go to "Windows Control Panel  Folder Options  View" and set the "View Hidden Files" option.

160

18.4 Compatibility with Windows 7 There is full compatibility with Windows 7 when the Microsoft Framework 4.0 is installed.

18.5 Device drivers Make sure that the following drivers have been loaded (normally installed by the HI Software Installation CD): - Microsoft .Net Framework 4.0. - Microsoft SQL Server Compact 3.5 SP2 ENU. - Microsoft Report Viewer 2010 re-distributable. - FTDI CDM Driver package 17/02/2009 24.16 (this driver reinstalls at every installation). Optionally to be installed if using the recommended HUMAN touch screen monitor: - Device driver for RS-232 or USB controlled touch screen (comes on the CD with the monitor).

HumaStar 100/200 | Service manual

LIS ASTM INTERFACE SOFTWARE

19 LIS ASTM INTERFACE SOFTWARE Please refer to the most current version of the external documentation "LIS ASTM interface software for the HumaStar 100/200".

161

162

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SERVICE SCHEMATICS

163

20 SERVICE SCHEMATICS

20.1 Instrument block diagram FIGURE 160 Instrument block diagram

164

20.2 CPU board layout FIGURE 161 CPU board layout

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

165

20.3 Power board layout FIGURE 162 Power board layout

166

20.4 Sampling arm board layout

FIGURE 163 Sampling arm board layout

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

167

20.5 High voltage wiring

FIGURE 164 High voltage wiring

168

20.6 Low voltage wiring FIGURE 165 Low voltage wiring 1

Legend of colors BK BR BU GN GY

HumaStar 100/200 | Service manual

= black = brown = blue = green = gray

OG RD SH WH YE

= orange = red = shielding = white = yellow

SERVICE SCHEMATICS

169

FIGURE 166 Low voltage wiring 2

Legend of colors BK BR BU GN GY

= black = brown = blue = green = gray

OG RD SH WH YE

= orange = red = shielding = white = yellow

170

Wiring plan 1

FIGURE 167 Wiring plan 1

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

171

Wiring plan 2 FIGURE 168 Wiring plan 2

172

Wiring plan 3

FIGURE 169 Wiring plan 3

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

173

Wiring plan 4

FIGURE 170 Wiring plan 4

174

20.7 Internal RS232 serial cable FIGURE 171 Internal RS232 serial cable

20.8 Optical preamplifier cable

FIGURE 172 Optical preamplifier cable

20.9 Sampling arm cable FIGURE 173 Sampling arm cable

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

175

20.10 Sampling arm cable constructive schema FIGURE 174 Sampling arm cable constructive schema

176

20.11 Hydraulics diagram HumaStar 100 FIGURE 175 Hydraulics diagram HumaStar 100

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

177

20.12 Hydraulics diagram HumaStar 200 FIGURE 176 Hydraulics diagram HumaStar 200

178

20.13 Hydraulics panel layout (front side) FIGURE 177 Hydraulics panel layout (front side)

HumaStar 100/200 | Service manual

20.14 Hydraulics panel layout (rear side)

FIGURE 178 Hydraulics panel layout (rear side)

180

20.15 Pumps plate hydraulics manifold FIGURE 179 Pumps plate hydraulics manifold

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

181

20.16 Wash station

FIGURE 180 Wash station

182

20.17 Wash station hydraulics manifold HumaStar 100

FIGURE 181 Wash station hydraulics manifold HumaStar 100

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

183

20.18 Wash station hydraulics manifold HumaStar 200

FIGURE 182 Wash station hydraulics manifold HumaStar 200

184

20.19 Floats and tubes connection assembly

FIGURE 183 Floats and tubes connection assembly

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

185

20.20 Floats and tubes electrical connections FIGURE 184 Floats and tubes electrical connections

186

20.21 Refrigeration plate Electrical drawing

FIGURE 185 Electrical drawing

Electrical cabling FIGURE 186 Electrical cabling

HumaStar 100/200 | Service manual

SERVICE SCHEMATICS

187

20.22 Main power input panel FIGURE 187 Main power input panel

188

20.23 Central mechanical assembly View 1 FIGURE 188 Central mechanical assembly view 1

HumaStar 100/200 | Service manual

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189

View 2 FIGURE 189 Central mechanical assembly view 2

190

View 3 FIGURE 190 Central mechanical assembly view 3

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191

20.24 Mechanical design – internal view FIGURE 191 Mechanical design – internal view

192

20.25 Frame base FIGURE 192 Frame base

HumaStar 100/200 | Service manual

HUMAN Gesellschaft für Biochemica und Diagnostica mbH Max-Planck-Ring 21 • 65205 Wiesbaden • Germany Tel.: +49 6122/9988 0 • Fax: +49 6122/9988 100 eMail: [email protected] • www.human.de