Dimension® Systems
Advanced Hardware Diagnostics
& Troubleshooting
Local Area Training Workbook
Siemens Healthineers
Dimension Systems
Advanced Hardware Diagnostics & Troubleshooting
Local Area Training Workbook
Dimension Systems
T01008.095
Effective Date: 10/11/2021
© 2021 Siemens Healthineers Inc. All rights reserved.
This manual, and the software described in this manual, are copyrighted. No part of this may
be copied, reproduced, translated or reduced to any electronic medium or machinereadable form without the prior written consent of Siemens Healthineers.
Dimension, EXL, Flex, LOCI, QCC PowerPak, and QuikLYTE are trademarks of Siemens
Healthineers.
All other trademarks are the property of their respective owners.
ii
Dimension Systems
Table of Contents
Dimension Systems
1:
Welcome
2:
System Check Troubleshooting
3:
Electrical Cabinet
4:
Photometer
5:
Cuvette Manufacturing
6:
Reagent Delivery System
iii
iv
Dimension Systems
Welcome
1 Welcome
Welcome to Training
Siemens Healthineers would like to welcome you to the Local Area training on
the Dimension Systems.
This course is designed to teach you the advanced skills needed to operate, maintain,
and troubleshoot the Dimension Systems.
Our staff welcomes the opportunity to present this training program to you.
Dimension Systems
1-1
Welcome
Training Center Safety Information
While you are at the Training Center, please follow these safety practices:
•
Please wear your name badge at all times.
•
In the event of a fire alarm, Stop work immediately and leave the building
through the nearest exit. Instructors will discuss the evacuation route.
•
Note the location of the fire extinguisher.
•
Use the eyewash located near the sink if you should happen to get anything
in your eye(s).Report any injury to the instructor.
•
Carefully read the warnings, cautions, and notes in the guides and manuals.
•
Eating and drinking are not allowed in the instrument area of the
classroom.
•
You must wear laboratory coats and gloves which are provided. Do not wear
these garments outside the classroom.
•
Use safety glasses when operating the instrument or preparing samples.
•
Dispose of waste materials appropriately:
•
1-2
o
Biohazard Waste: Wastebaskets with red plastic liners
o
Paper Waste: Wastebaskets with clear plastic liners
o
Use sharps containers for the disposal of glass or sharp objects.
Wash your hands before leaving the classroom and after removing your
gloves.
Dimension Systems
Welcome
Course Objectives
Upon completion of this course, you will be able to:
Dimension Systems
•
Describe the process and components involved in a System Check.
•
Demonstrate troubleshooting failed system checks.
•
Identify components of the Electrical cabinet, Photometer, Cuvette
manufacturing and the Reagent Delivery System.
•
Identify error messages associated with the Electrical cabinet, Photometer,
Cuvette manufacturing and the Reagent Delivery System.
•
Demonstrate troubleshooting the Electrical cabinet, Photometer, Cuvette
manufacturing and the Reagent Delivery System.
1-3
Welcome
Training Agenda
Morning
Afternoon
Welcome
System Check Troubleshooting
1-4
Lunch
Cuvette Manufacturing
Electrical Cabinet
Reagent Delivery System
Photometer
Hands on Troubleshooting
Dimension Systems
Welcome
Dimension® Systems
Advanced Hardware Diagnostics & Troubleshooting
Operator Training
Course Validation Checklist
The participant places a checkmark beside the competency when it is completed. When all
competencies are checked, the instructor and participant sign and date below as record of
completion.
Topics
Competencies
System Check
Troubleshooting
Configure Supplies Alert and Auto Setup for
system check
Completed
Describe the process and components involved
in a System Check
Demonstrate troubleshooting failed system
checks
Electrical Cabinet
Identify electrical cabinet components
Use the Power Diagnostics screen
Perform the Instrument Power Shutdown and
Startup Procedure
Demonstrate replacement of a fuse
Photometer
Demonstrate replacement of the source lamp
Demonstrate troubleshooting the photometer
Cuvette
Manufacturing
Identify cuvette manufacturing components
Demonstrate troubleshooting the cuvette
manufacturing module
Perform rethreading of cuvette film
Reagent Delivery
Identify reagent delivery components and error
messages
Demonstrate troubleshooting reagent delivery
systems
Demonstrate troubleshooting RMS associated
error messages (EXL with LM only)
Dimension Systems
1-5
Welcome
Instructor:
__________________________________________________
Student:
__________________________________________________
Date:
__________________________________________________
What was most helpful to you during this program?
How can we improve this program to make it more meaningful to you?
1-6
Dimension Systems
System Check Troubleshooting
2 System Check Troubleshooting
Dimension Systems
2-1
System Check Troubleshooting
System Check Troubleshooting
Resources
•
Dimension EXL 200 / Dimension EXL with LM Operator’s Guide
Objectives
Upon completion of this exercise, you will be able to:
2- 2
•
Configure Supplies Alert and Auto Setup for system check.
•
Describe the process and components involved in a System Check.
•
Demonstrate troubleshooting failed System Checks.
Dimension Systems
System Check Troubleshooting
System Check Configuration
Supplies Alert
1. Display the Reagent Cartridge Alert screen by pressing:
Supplies.
2.
F1: Config Alerts.
3. Cursor to the CHK reagent and enter 10.
4. Press F1: Store Alerts.
Note: Entering 10 ensures that there will be enough tests present onboard the
instrument to run automated system check as scheduled.
Automated System Check
1. From the Operating menu, display the Daily Maintenance Routine screen, press:
F4: System Prep
2.
F8: Daily Maintenance.
3. To configure system check to run automatically press:
4.
F8: Auto Setup.
5. Use the left and right arrow keys or the touch screen to toggle between fields.
6.
To select the Start Day, use the Enter key to toggle through the days of the
week. For this exercise set the start and END day to today.
7. Toggle to the Start Time field and enter the appropriate time. For this exercise
enter 5 minutes from the current time using a 24 hour clock.
8. Toggle between OFF/ON to set Activate to ON.
9. Press F1: Save Changes.
10. Press Home to return to the main menu.
Tips:
1. The automated system check will not run as programmed if the instrument
remains on the Daily Maintenance or the Daily Maintenance Auto Run screens.
2. A series of warning screens appear prior to automated System Check starting.
3. The warnings appear in three time intervals: 5 minutes, 1 minute, and a final ten
seconds prior to the scheduled start time of the routine.
4.
Dimension Systems
The instrument will also beep 5 times when the ten second warning is
displayed.
2-3
System Check Troubleshooting
System Check Process
System Check Printout
CHK
Processing Steps
Modules Checked
None
(blank
cuvette)
Photometer takes 2 readings,
of blank cuvette, 43 seconds
apart
Photometer alignment
Cuvette windows
Source lamp
Optical filters
Photometer
Wavelength
293 nm
340 nm
383 nm
405 nm
454 nm
510 nm
540 nm
577 nm
600 nm
700 nm
Maximum
0.35
-0.21
-0.23
-0.23
-0.24
-0.23
-0.26
-0.23
-0.26
-0.21
Reagent #1
Results
Mean: 395.67
SD: 0.40
1st 395.53
2nd 395.89
3rd 395.74
4th 396.11
5th 395.07
Reagent #2
Results
Mean: 393.22
SD: 1.26
1st 394.25
2nd 394.51
3rd 393.29
4th 392.63
5th 391.41
Sampler
Mean: 38.33
SD: 0.26
Results
1st 38.22
2nd 38.16
3rd 38.11
4th 38.39
5th 38.76
2- 4
Read 2 subtracted from Read
1 for the result
Flex
reagent
cartridge
R1 probe adds 60 µL of CHK
and 420 µL of water to 5
different cuvettes
R1 arm
R1 probe
R1 pump/syringe
R1 alignments
Flex
reagent
cartridge
R2 probe adds 60 µL of CHK
and 420 µL of water to 5
different cuvettes
R2 arm
R2 probe
R2 pump/syringe
R2 alignments
Reaction
Vessel
R2 adds 50 µL CHK solution to
5 Reaction Vessel
R1 adds 345 µL water to 5
cuvettes
Sampler aliquots 10 µL CHK
solution from Reaction Vessel
followed by 45 µL to cuvettes
R1 arm, probe
R2 arm, probe
Sample probe
Sample pump panel/
syringe
Dimension Systems
System Check Troubleshooting
System Check Printout
HM Wash
Results
Mean: 38.53
SD: 0.09
1st 38.61 W1
2nd 38.47 W1
3rd 38.54 W2
4th 38.62 W2
5th 38.42 W2
Sample Probe
Cleaner
CHK
Flex
reagent
cartridge
Processing Steps
1. R2 adds water to 5 reaction
vessels.
2. Wash probes 1 and 2
aspirate and dispense
fluids from Reaction Vessel.
3. R1 adds water to cuvettes.
4. R2 adds CHK and water to
Reaction Vessel.
5. Sampler aliquots 5
replicates of CHK from
reaction vessels to 5
cuvettes.
Modules Checked
R1 system
R2 system
Sampler system
HM wash probe 1
HM wash probe 2
HM wash pump tubing
and cassette
Cleaners are delivered to
cuvette. Presence checked
photometrically.
Reagent and sample
probe cleaner delivery
systems
None
(blank
reaction
vessel)
1. Sampler appears to deliver
to reaction vessel but no
fluid is added.
2. LOCI arm transfers an
empty vessel to the read
chamber.
3. LOCI reader performs a
standard assay read.
4. LOCI arm transfer 4 more
vessels for a total of 5
reads.
LOCI module
Flex
reagent
cartridge
1. R3 probe adds CHK from
well 3 or 6 and water to
well 7 or 8 of CHK reagent
cartridge.
2. R1 probe aliquots 5
replicates of CHK from
diluted well to 5 cuvettes.
R3 arm
R3 pump/syringe
R1 arm
R1 pump/syringe
None
Reagent Probe
Cleaner
LOCI module
Results
<0.144
1st 0.025
2nd 0.020
3rd 0.030
4th 0.023
5th 0.033
RMS
Results
Mean: 398.32
SD: 0.68
1st 398.41
2nd 397.73
3rd 399.21
4th 398.70
5th 397.56
Dimension Systems
2-5
System Check Troubleshooting
System Check Troubleshooting
Failed Module
Resolution
Photometer
Perform Photometer Alignment
Clean Cuvette Windows
Check Cuvette Film
Replace Source Lamp
Replace Optical Filter
Reagent
R1, R2 or R3 (RMS)
Confirm Correct Carton Value
Replace / Align Reagent Probe
Investigate Reagent Pump Panel for leaks or crimped tubing
Perform Reagent Probe Ultrasonics test
Sampler
Confirm Correct Carton Value
R1 or R2 precision or accuracy (resolve R1 or R2 issue first)
Replace / Align Sample Probe
Investigate Sample Pump Panel
Perform Sample Probe Ultrasonics test
HM
Confirm Correct Carton Value
R1, R2 or Sampler precision or accuracy (resolve failed Probe issue first)
Replace/ align W1 or W2 probes
Replace pump cassette or tubing
Sample or Reagent Probe
Cleaners
Check Probe Cleaner solution or bottle
Check Tubing or connectors for leaks
Replace Pump Cassette
LOCI
Reset Statistics
Replace/align Transfer arm vacuum cup
Replace LOCI insert and rubber seal
2- 6
Dimension Systems
System Check Troubleshooting
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Dimension Training
*
10:25 Nov 15 20XX
*
SYSTEM CHECK
*
Entered:
10:15
Nov 15 20XX
*
Status:
FAIL
*
CHK Flex Lot # DR0095
*
PHOTOMETER
Wavelength
293nm
340nm
383nm
405nm
452nm
510nm
540nm
577nm
600nm
700nm
REAGENT #1
Mean:
393.87
SD:
0.87
REAGENT #2
Mean:
393.42
SD:
0.97
Maximum
4.90
3.02
2.00
1.57
0.64
0.55
0.58
0.55
0.50
0.41
1st
2nd
3rd
4th
5th
Results
394.08
392.97
393.22
393.90
395.19
1st
2nd
3rd
4th
5th
Results
391.70
393.90
393.70
393.91
393.90
SAMPLER
Mean:
39.08
SD:
0.11
Results
1st 39.05
2nd 38.96
3rd 38.99
4th 39.20
5th 39.18
* * * * * * * * * * * * * * * * *
HM WASH
Results
Mean:
39.05
1st 39.15
SD:
0.18
2nd 39.02
3rd 38.99
4th 39.29
5th 38.80
Sample Probe Cleaner
PASS
Reagent Probe Cleaner
PASS
* *
W1
W1
W2
W2
W2
* * * * * * * * * * * * * * * * * * *
LOCI Results
1st
0.025
2nd
0.020
3rd
0.030
4th
0.023
5th
0.033
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Dimension Systems
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POSSIBLE CAUSES
Scenario 1
RESOLUTION
2-7
System Check Troubleshooting
POSSIBLE CAUSES
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2- 8
* * * * * * * * * * * * * * * * * * * * * *
Dimension Training
10:25 Nov 15 20XX
SYSTEM CHECK
Entered:
10:15
Nov 15 20XX
Status:
FAIL
CHK Flex Lot # DR0095
PHOTOMETER
Wavelength
293nm
340nm
383nm
405nm
452nm
510nm
540nm
577nm
600nm
700nm
*
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Maximum
0.84
0.61
0.53
0.53
0.64
0.55
0.58
0.55
0.50
0.41
REAGENT #1
Mean:
SD:
393.87
0.87
1st
2nd
3rd
4th
5th
Results
394.08
392.97
393.22
393.90
395.19
REAGENT #2
Mean:
SD:
391.04
7.26
1st
2nd
3rd
4th
5th
Results
395.76
394.70
393.68
378.19
392.86
SAMPLER
Mean:
SD:
* *
*
Results
1st 39.05
2nd 38.96
3rd
38.99
4th
39.20
5th
39.18
* * * * * * * * * * * * * * * * * * * * *
HM WASH
Results
Mean:
39.05
1st 39.15 W1
SD:
0.18
2nd 39.02 W1
3rd
38.99 W2
4th
39.29 W2
5th
38.80 W2
39.08
0.11
Sample Probe Cleaner
PASS
Reagent Probe Cleaner
PASS
* * * * * * * * * * * * * * * * * * * * *
LOCI Results
1st
0.025
2nd
0.020
3rd
0.030
4th
0.023
5th
0.033
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Scenario 2
RESOLUTION
Dimension Systems
System Check Troubleshooting
POSSIBLE CAUSES
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* * * * * * * * * * * * * * * * * * * ** *
Dimension Training
10:25 Nov 15 20XX
SYSTEM CHECK
Entered:
10:15
Nov 15 20XX
Status:
FAIL
CHK Flex Lot # DR0095
PHOTOMETER
Wavelength
293nm
340nm
383nm
405nm
452nm
510nm
540nm
577nm
600nm
700nm
REAGENT #1
Mean:
393.87
SD:
0.87
REAGENT #2
Mean:
393.42
SD:
0.97
Maximum
0.84
0.61
0.53
0.53
0.64
0.55
0.58
0.55
0.50
0.41
1st
2nd
3rd
4th
5th
Results
394.08
392.97
393.22
393.90
395.19
1st
2nd
3rd
4th
5th
Results
391.70
393.90
393.70
393.91
393.90
SAMPLER
Mean:
39.08
SD:
0.11
Results
1st 39.05
2nd 38.96
3rd 38.99
4th 39.20
5th 39.18
* * * * * * * * * * * * * * * * * *
HM WASH
Results
Mean:
39.05
1st 39.15 W1
SD:
0.18
2nd 39.02 W1
3rd 38.99 W2
4th 39.29 W2
5th 38.80 W2
Sample Probe Cleaner PASS
Reagent Probe Cleaner PASS
* * * * * * * * * * * * * * * * * *
LOCI Results
1st 1.025
2nd 1.030
3rd 1.028
4th 1.032
5th 1.040
* * * * * * * * * * * * * * * * * *
Dimension Systems
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Scenario 3
RESOLUTION
2-9
System Check Troubleshooting
POSSIBLE CAUSES
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2- 10
* * * * * * * * * * * * * * * * * * * * * *
Dimension Training
10:25 Nov 15 20XX
SYSTEM CHECK
Entered:
10:15
Nov 15 20XX
Status:
*****
CHK Flex Lot # DR0095
PHOTOMETER
Wavelength
293nm
340nm
383nm
405nm
452nm
510nm
540nm
577nm
600nm
700nm
REAGENT #1
Mean:
***
SD:
***
REAGENT #2
Mean:
***
SD:
***
Maximum
***
***
***
***
***
***
***
***
***
***
1st
2nd
3rd
4th
5th
Results
394.08
392.97
393.22
393.90
395.19
1st
2nd
3rd
4th
5th
Results
391.70
393.90
393.70
393.91
393.90
SAMPLER
Mean:
***
SD:
***
1st
2nd
3rd
4th
5th
* * * * * * * * * * * * * * *
HM WASH
Mean:
***
1st
SD:
***
2nd
3rd
4th
5th
Sample Probe Cleaner
PASS
Reagent Probe Cleaner
PASS
Results
***
***
38.99
39.20
39.18
* * * * * *
Results
39.15 W1
39.02 W1
38.99 W2
39.29 W2
38.80 W2
* * * * * * * * * * * * * * * * * * * * *
LOCI Results
1st
0.025
2nd
0.020
3rd
0.030
4th
0.023
5th
0.033
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Scenario 4
RESOLUTION
Dimension Systems
System Check Troubleshooting
POSSIBLE CAUSES
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Dimension Training
*
10:25 Nov 15 20XX
*
SYSTEM CHECK
*
Entered:
10:15
Nov 15 20XX
*
Status:
FAIL
*
CHK Flex Lot # DR0095
*
PHOTOMETER
Wavelength
293nm
340nm
383nm
405nm
452nm
510nm
540nm
577nm
600nm
700nm
REAGENT #1
Mean:
393.87
SD:
0.87
REAGENT #2
Mean:
393.42
SD:
0.97
SAMPLER
Mean:
SD:
Maximum
0.84
0.61
0.53
0.53
0.64
0.55
0.58
0.55
0.50
0.41
1st
2nd
3rd
4th
5th
Results
394.08
392.97
393.22
393.90
395.19
1st
2nd
3rd
4th
5th
Results
391.70
393.90
393.70
393.91
393.90
Results
1st 0.45
2nd 0.87
3rd 0.63
4th 0.59
5th 0.64
* * * * * * * * * * * * * * * * * * * * *
HM WASH
Results
Mean:
1.67
1st 1.24 W1
SD:
0.3
2nd 1.54 W1
3rd 1.81 W2
4th 2.05 W2
5th 1.69 W2
0.64
0.15
Sample Probe Cleaner
PASS
Reagent Probe Cleaner
PASS
* * * * * * * * * * * * * * * * * * * * *
LOCI Results
1st
0.025
2nd
0.020
3rd
0.030
4th
0.023
5th
0.033
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Dimension Systems
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Scenario 5
RESOLUTION
2-11
System Check Troubleshooting
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2- 12
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Dimension Training
10:25 Nov 15 20XX
SYSTEM CHECK
Entered:
10:15
Nov 15 20XX
Status:
FAIL
CHK Flex Lot # DR0095
PHOTOMETER
Wavelength
293nm
340nm
383nm
405nm
452nm
510nm
540nm
577nm
600nm
700nm
REAGENT #1
Mean:
393.87
SD:
0.87
REAGENT #2
Mean:
393.42
SD:
0.97
SAMPLER
Mean:
SD:
39.08
0.11
Maximum
0.84
0.61
0.53
0.53
0.64
0.55
0.58
0.55
0.50
0.41
1st
2nd
3rd
4th
5th
Results
394.08
392.97
393.22
393.90
395.19
1st
2nd
3rd
4th
5th
Results
391.70
393.90
393.70
393.91
393.90
1st
2nd
3rd
4th
5th
* * * * * * * * * * * * * * * * * *
HM WASH
Mean:
24.85
1st
SD:
13.58
2nd
3rd
4th
5th
Results
39.05
38.96
38.99
39.20
39.18
* * *
Results
38.98
39.02
14.72
9.85
21.67
Sample Probe Cleaner
PASS
Reagent Probe Cleaner
PASS
* * * * * * * * * * * * * * * * * * * * *
LOCI Results
1st
0.025
2nd
0.020
3rd
0.030
4th
0.023
5th
0.033
* * * * * * * * * * * * * * * * * * * * *
W1
W1
W2
W2
W2
POSSIBLE CAUSES
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Scenario 6
RESOLUTION
Dimension Systems
Electrical Cabinet
3 Electrical Cabinet
Dimension Systems
3-1
Electrical Cabinet
Electrical Cabinet
Resources
•
Dimension EXL 200 / Dimension EXL with LM Operator’s Guide
Objectives
Upon completion of this exercise, you will be able to:
3-2
•
Identify Electrical Cabinet components.
•
Use the Power Diagnostics screen.
•
Perform the Instrument Power Shutdown and Startup Procedure.
•
Demonstrate replacement of a fuse.
Dimension Systems
Electrical Cabinet
Electrical Cabinet
Component
Reminders/Tips
Fuse Board A
5V, ±15V fuses (red LEDs) and +24V fuses
(green LEDS)
Fuse Board B
+24V fuses (all green LEDs)
Notes
CR- Current Resistor
PC Boards
Photometer
Cuvette
Empty or QCC
Motor Control Board 1
Motor Control Board 2
Motor Control Board 3
Auxiliary
Ultrasonics
Note: The digital display on the board is 1 to indicate all is OK. Any other number or letter
suggests a problem. Always use the ground wrist strap when working with PC boards. Static
electricity transferred to a board can damage it.
To Confirm a Blown Fuse
From the Operating Menu:
1. Select F7: DIAGNOSTICS.
2. Select F1: ELECTRO/MECH.
3. Select F7: POWER SYSTEM.
Note: Before you replace any fuse, the instrument must be turned off via the
Controlled Power Shutdown procedure.
Dimension Systems
3-3
Electrical Cabinet
Performing a Controlled Power Shutdown
From the Operating Menu
1. Select the sign out icon.
2.
Select Shutdown
3. When prompted: “If you really want to shut down the application, type y” select
Yes to confirm.
4. At the console menu, select option 4. Shutdown.
5. At the Shutdown Menu, select option 2. Shutdown.
6. When the message “Do you really want to shut down the computer? Select OK.
7. When the screen turns black, turn off the instrument power switch.
Replacing a Fuse
Using a flat head screwdriver remove the fuse holder from the correct fuse board.
Replace the damaged fuse with a new one of the same amperage/voltage found in
the Dimension spare parts kit.
Restoring Power after a Controlled Shutdown
1.
Push the instrument power switch to its up position.
2. At the console menu, select option 1 to start the Dimension System.
3. Sign out of GuestUser by selecting the sign out icon.
4. Select Change Operator.
5. Sign in using your Operator ID and password.
6. When the Operating Menu appears, run a System Check and QC to ensure that
all instrument systems are operating properly.
Toggling between the Gray Screen and Black Screen
Select ALT 1: Gray screen
Select ALT 2: Black screen
3-4
Dimension Systems
Photometer
4 Photometer
Dimension Systems
4-1
Photometer
Photometer
Resources
•
Dimension EXL 200 / Dimension EXL with LM Operator’s Guide
•
Dimension EXL Systems Quick Reference Guide
Objectives
Upon completion of this exercise, you will be able to:
4-2
•
Demonstrate replacement of the source lamp.
•
Demonstrate troubleshooting the photometer.
Dimension Systems
Photometer
Photometric Measurement System
Photometer Diagnostics Screen
F7: Diagnostics > F1: Electro/Mech > F5: Photometer
Acceptable Limits:
Lamp voltage: >6.0 and < 8.0 volts
When troubleshooting with technical support, it may be recommended to replace
lamp if voltage reading is below 6.8
Measure frequency: >30,000 and <135,000 Hz (lamp on high) at blank cuvette for all
filters except 293
Dimension Systems
4-3
Photometer
Photometer Module Troubleshooting
Error Message
Steps to Resolve
Notes
Photometer Source Lamp
Problem
The computer did not receive a
signal that the source lamp was
on.
(278 ) Photometer Source Lamp Off Detected
Check if LED CR3B on the photometer board is lit
and check Photometer Diagnostic screen. If CR3B
is out and/or lamp amps <0.1 Amp and lamp
voltage >20 Volts: Lamp problem
- Perform controlled power shutdown and
lower the thermal chamber.
- Check that the source lamp connector (P/J
72B) is connected
- Replace the source lamp, perform
Photometer alignments and all steps in
Replacing Source Lamp procedure
If lamp voltage is 0, it is not the lamp:
- Check the source lamp fuse 24 1D
If error message reappears, call CCC-TS. Other
probable causes could be a photometer board
problem or bad fuse 24 1C.
Photometer Diagnostics:
Photometer gross (276) and fine (277)
positioning error
1. If the photometer does not move through its
The photometer did not move
complete initialization cycle: Check for
the proper distance as verified
interference (film, wiring, and tubing). The
by the encoder. If the
most typical cause of this is the photometer
disagreement between the
hitting bunched up film or the thermal
motor and the encoder is 3 to 7
chamber. Perform controlled power shut
steps, it is considered a fine
down, lower the thermal chamber, ensure all
error. If 8 or more, a gross error.
cables and tubing are out of the way, and
reseat it.
2. If the photometer moves without stopping:
- Cycle the photometer
- If the Home field does not change to On
and then Off during this cycle or if the
photometer gets to -11 and makes a loud
noise, the sensor has failed.
- Change the photometer home sensor.
After restoring power perform
photometer alignments, System Check
and Daily QC
3. If the photometer does not move at all: The
fuse may have opened. Check fuse 24 1C on
Fuse board A; if not lit, replace the fuse.
F7:DIAGNOSTICS
F1:ELECTRO/MECH
F5:PHOTOMETER
Photometer Mispositioned
4-4
F7:DIAGNOSTICS
F1:ELECTRO/MECH
F5:PHOTOMETER
F8:CYCLE
Dimension Systems
Photometer
Replace and Align Photometer Source Lamp
Use the Dimension EXL Systems Resource Guide.
List the required steps after replacing the source lamp and restoring power to the
system.
1.
2.
3.
4.
5.
Dimension Systems
4-5
Cuvette Manufacturing
5 Cuvette Manufacturing
Dimension Systems
5-1
Cuvette Manufacturing
Cuvette Manufacturing
Resources
•
Dimension EXL 200 / Dimension EXL with LM Operator’s Guide
Objectives
Upon completion of this exercise, you will be able to:
5-2
•
Identify cuvette manufacturing components.
•
Demonstrate troubleshooting the cuvette manufacturing module.
•
Perform rethreading of cuvette film.
Dimension Systems
Cuvette Manufacturing
Cuvette Manufacturing on the Dimension System
Dimension Systems
5-3
Cuvette Manufacturing
Digital Gauge Panel on the Dimension System
Pressure Gauge*
20 psi ±2.0
(min. 15 psi)
Flow meter*
(4.0 lpm to 9.0 lpm)
Vacuum Gauge**
(>3.0 Hg)
*Digital pressure gauge has pressure switch built in.
**Vacuum gauge reading for instrument waste system
5-4
Dimension Systems
Cuvette Manufacturing
Error Message
Steps to Resolve
Notes
Bad Cuvette
(261) Heat Torch Timed Out
- Check that the solenoid arms are locked in place.
- Check the heat torch connector P/J 13K is
connected
- If CR3B is not on (at all), check fuse 24 2B on fuse
board “A”.
- Check that LED CR3B on cuvette board is pulsing
in standby, but comes full on at the start of a
cuvette formation, then begins to blink on and
off.
Press ALT/M
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F4: CUVETTE
Failed heat torch.
-Using the Operator’s Guide replace heat torch
Bad Cuvette
(260) Cuvette Not Sealed
- Check that cuvette manufacturing U-seal
solenoid arm is locked in place
- U-seal connector is plugged in
- Clean and lubricate the U seal solenoid
Press ALT/M
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F4: CUVETTE
Failed U-seal
- Using the Operator’s Guide replace U-seal
Bad Cuvette
(259) Cuvette Air Pressure too low
- Check cuvette diaphragm to ensure it is seated
properly and it doesn’t have a hole. Replace if
necessary
- Check that nozzle solenoid bracket is positioned
properly behind plunger
Press ALT/M
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F4: CUVETTE
- Check to ensure the rubber tip is still positioned
on the plunger
- Clean and lubricate the nozzle solenoid
- In Cuvette diagnostics, cycle cuvettes and
Monitor air flow and pressure:
Air Flow 4.0 – 9.0 lpm
Air Pressure 20 ± 2 psi
Dimension Systems
5-5
Cuvette Manufacturing
Bad Cuvettes Repeatedly
Formed
(508) Three bad cuvettes sequentially formed
If the system generates three sequential bad
cuvette error messages, it will generate this error
Check the Error Log for the first “Bad Cuvette”
error that appeared.
Troubleshoot the minor error associated with the
first “Bad Cuvette” error.
Cuvette Wheel Can Not
Find Position
061, 062 Cuvette wheel sensor problem or wheel
did not move
257 Cuvette wheel index error
- Capstan lever not locked into place
- Look for obstructions: anything inhibiting the
movement of the cuvette wheel, for example
cuvette film jam in idler (nip) roller latch area,
alignment gauges or thermometer adapter left
in cuvette hole, cuvette window not seated
properly
- Clear the obstruction.
- Film slack, tension film or cycle cuvettes.
- Failed cuvette ring position sensor.
- Using Operator’s Guide, replace sensor.
F7: DIAGNOSTICS
F6: ERROR LOG
F5: MORE INFO
Press ALT/M
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F4: CUVETTE
If cuvette wheel does not move at all,
- Check fuse LED indicator on (Fuse Board A 242A).
Cuvette Failed Photometric
QC Check
5-6
(262) Bad cuvette QC
- Check to ensure film has not run out
- Dirty windows
- Source lamp weak (old)
Use Operator’s Guide to replace source lamp
Dimension Systems
Cuvette Manufacturing
Rethread Cuvette Film
Before performing each step, read the entire step to be aware of any requirements,
warnings, or cautions. Only trained operators should perform this procedure.
1. With the instrument in Standby, raise the reagent lid.
2. From the Operating Menu, press
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F4: CUVETTE
F4: U-SEAL SOLENOID twice
3. Raise the barcode reader to the left.
4. Loosen the alignment bar thumbscrew and lift the alignment bar up and out of
the way.
WARNING: When doing the next step, do not touch the u-seal
solenoid. It is hot
5. Pull the curved locking bar on the u-seal solenoid assembly to the right. Move
the assembly to the left.
6. Pull the cuvette formation assembly away from the cuvette wheel. A rubber
band can be used to hold the cuvette formation assembly back and out of the
way.
7. Locate the Top Seal assembly. Disconnect the J2 black cable, which is the top
connector from the control board. This will remove the heat from the top seal
element. The red and yellow indicator lights will turn off when element
temperature is cool.
8. Open the cabinet door. Remove the cuvette waste container.
Dimension Systems
5-7
Cuvette Manufacturing
9. Unhook the latch of the capstan lever located directly above the cuvette waste
container area and remove any film left around the cuvette wheel.
10. Pull approximately 4 feet of the right side film strip from the film cartridge. This
allows you to rethread completely around the cuvette wheel. This helps with
keeping the correct tension on the film while threading.
11. Feed the right film strip from the bottom of the film guide into the right film
guide until you see the end come out the left side of the self-feeding guide at a
45-degree angle.
12. Attach a 2-inch piece of tape to the end of the right film strip. Line up the film
with the cuvette wheel. Press firmly on the tape to secure the right film strip to
the wheel.
13. Advance the cuvette wheel in a clockwise direction, by grasping the wheel left
of the capstan motor, until you see the taped film appear to the left of the
capstan. There is only about 1 inch of access left of the capstan motor. Once you
see the film appear to the left of the capstan, stop moving the wheel and hold it
stationary.
Do not move the cuvette wheel counterclockwise or you will lose tension.
14. Keep tension on the film as you peel the taped strip from the wheel. Use a small
screw drive to help detach the tape.
5-8
Dimension Systems
Cuvette Manufacturing
15. While pulling the film, 10 inches, towards yourself (not down), wrap the film
around the capstan and hook the latch of the capstan lever into place.
16. Insert the left film strip into the left film self-feeding guide until you see it come
out the left side of the guide, pass 3 cuvette positions, pass where the u-seal will
seal.
17. Place all components back into place.
18. Confirm that the position of the left film is far enough for the u-seal to seal the
left film to the right film.
19. Reconnect the J2 black cable to control board, confirm all 3 lights are ON,
indicating heat has been restored to the top seal element.
20. On the Cuvette Diagnostic screen, type 50 in the Cycle Count box and press the
Enter key.
To advance both sides of film completely off of the cuvette wheel, type in 110
cuvettes (15min).
21. Press F1: Cycle. The instrument will make cuvettes.
Watch to confirm cuvettes are advancing and no error messages occur. Lower
the reagent lid, close cabinet door.
Dimension Systems
5-9
Reagent Delivery Systems
6 Reagent Delivery Systems
Dimension Systems
6-1
Reagent Delivery Systems
Reagent Delivery Systems
Resources
•
Dimension EXL 200 / Dimension EXL with LM Operator’s Guide
Objectives
Upon completion of this exercise, you will be able to:
6-2
•
Identify reagent delivery system components.
•
Demonstrate troubleshooting the reagent delivery systems.
•
Demonstrate troubleshooting RMS associated error messages (EXL with LM
only).
Dimension Systems
Reagent Delivery Systems
Reagent Module Movements and Sensors
Module
Movement
Sensor Name
Probe
Up/Down
R1, R2 or R3 vertical home sensor
Carriage
In/Out
R1, R2 or R3 radial home sensor
Arm (R2 only)
CW/CCW
R2 angular home sensor
Error Message
Steps to Resolve
Notes
Cannot Find Home
May be caused by:
cfh=cannot find home
- Drains overflowing onto sensor or tubing leaking onto sensor
To test
motor/sensor:
soh=stuck on home
- Defective sensor
- Loose or unplugged connectors or defective cables or connectors
- Blown fuse
- Defective motor or motor control board
To resolve:
Press Reset to initialize the module and observe movement.
If it MOVES through a complete initialization cycle without
stopping:
- Locate the sensor LED on the appropriate board using fuse/PC
board label on instrument door.
- If possible, move the module into and out of its home position,
checking for the LED to turn on and off.
- If it does not turn on and off, clean or replace the sensor.
If it DOES NOT MOVE through its complete initialization cycle:
- Suspect interference, i.e. tubing or cabling restricting movement
If it does not move at all:
- Check fuse boards for blown fuses (fuse LED off), or verify in
power diagnostics screen.
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F1: REAGENT
F1: REAGENT 1
F2: REAGENT 2
F2: TEST MTR ONLY
(View HOME column
for Pass or Fail)
OR
To Cycle Arm:
F8: ADVANCED DIAG
F7: CYCLE ARM
View “Sensors”
status field. Verify
status changes state
(ON/OFF).
- If fuse LED is off or DC voltage is in red, use the Operator’s Guide
to replace fuse with the same type.
If failure persists, suspect motor or motor control board
Lost Steps
- Interference (i.e., reagent tray lid latch, HM tubing)
Reagent Diagnostics
mfh=moving from
home
- Use F7: Cycle Arm function in Reagent Diagnostics to visually
check for mechanical interference.
mth=moving to home
- Clean with alcohol then lubricate silver guide rod, and brass
splined shaft with TufOil. DO NOT lubricate “top” silver splined
shaft.
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F1: REAGENT
F8: ADVANCED DIAG
F7: CYCLE ARM
- Check alignments
Dimension Systems
6-3
Reagent Delivery Systems
R1, R2, R3 Metering
or Flush Pump Lost
Steps
- Use Reagent Diagnostics or Pump Prime to cycle pumps.
Reagent Diagnostics
- Investigate syringe in question for breaks, leaks, etc.; replace if
necessary
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F1: REAGENT
F8: ADVANCED DIAG
F7: CYCLE PUMP
- Clean/lubricate silver guide rod with TufOil and lead screw with
grease lubricant.
- Check syringe gap setting specs (.005 - .010 inches or printer
paper folded to four equal thicknesses) using the Operator’s
Guide.
R1, R2, or R3
Metering or Flush
Pump Cannot Find
Home
OR
- Replace the probe or tubing
Pump Prime:
F4: SYSTEM PREP
F7: PUMP PRIME
- Verify syringe home sensor operation by viewing sensor status in
Reagent Diagnostics.
View Sensors status
field Meter: ON or
Flush: ON status.
Verify status changes
- Check syringe gap setting specs (0.005 – 0.010 inches or printer
paper folded to four equal thicknesses) using the Operator’s
Guide.
- Replace pump optical sensor using the Operator’s Guide.
R1, R2, or R3
- Check tightness of probe tip.
Ultrasonics Unable to
Mix
- Check R1/R2/R3 probe alignments.
- Confirm probe body is aligned (centered).
- Use Ultrasonics Diagnostic screen to verify lock status is > 98 100%
Ultrasonics
Diagnostics:
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F8: ULTRASONICS
F1: SELECT PROBE
(If probe selected is
Sample, press F5: Fill
Sample Cup first)
F2: ENABLE ON/OFF
Reagent Preparation
Error
(381) Process error during preparation
(382) Prepared reagent failed quality assurance
- Never press reset.
Press Alt/M or go to Error Log. Find Reagent Preparation error
and look at the Time column to determine if previous message
listed in log is related. If time is the same, troubleshoot the
previous message, not the Reagent Preparation error.
Error Log:
F5: PROCESS CTRL
F6: ERROR LOG
OR
F7: DIAGNOSTICS
F6: ERROR LOG
6-4
Dimension Systems
Reagent Delivery Systems
Aligned Probe Body
Misaligned Probe Body
Dimension Systems
6-5
Reagent Delivery Systems
Reagent Management System (RMS)
Reagent Management System Overview
The RMS functions to allow the Dimension system to process samples without
interruption by:
6-6
•
Providing the capacity for 44 additional refrigerated Flex® reagent cartridges.
•
Providing the capacity to load 18 Flex reagent cartridges at one time
•
Hydrating Flex reagent cartridges.
•
Automatically transferring Flex reagent cartridges to the Dimension system.
•
Automatically removing any empty or expired Flex reagent cartridges.
Dimension Systems
Reagent Delivery Systems
Major Components of the RMS Module
1.
Load tray
2.
Elevator
3.
Turntable
4.
RMS reagent tray
5.
Hydration station
6.
R3 reagent probe
7.
Bar code reader
8.
Laser bar code reader
9.
Hydration Station Sensor Assembly
These four components are located inside the RMS cabinet.
Dimension Systems
•
Card cage boards
•
R3 reagent pump/syringe
•
Main power switch
•
Waste container
6-7
Reagent Delivery Systems
RMS Error Messages
RMS Shuttle Lost Steps
- Clean shuttle rails
F7: DIAGNOSTICS
- Perform RMS shuttle and turntable alignments
F1: ELECTRO/MECH
- Cycle the shuttle in diagnostics
F1: REAGENT
- Belt cracked/frayed. Call CCC-TS.
F7: RMS
F5: FLEX TURNTABLE
F2: TEST MTR ONLY
RMS Hydration Station
Sensor Error
If reagent cartridge is located in hydration station:
Fix Inventory:
- Use the verify slot on the Fix Inventory screen to remove
(slot 88)
F4: SYSTEM PREP
- Check for bent R3 probe
F6: FIX INVENTORY
If NO reagent cartridge is located in hydration station:
Cartridge Position Sensor.
- Check LED CR2B on RMS Motor Control board – should be
OFF. Use finger to push in metal wire in hydration station to
raise flag gently, LED should turn ON and sensor will change
status
RMS barcode error
F1: INVENTORY
RMS Diagnostics
F7: DIAGNOSTICS
F1: ELECTRO/MECH
F1: REAGENT
F7: RMS
- Replace the RMS hydration station sensor using the RMS
Operator’s Guide
F1: REAGENT R3
Barcode mismatches occur when the laser barcode reader
either cannot read or reads the wrong barcode. The
cartridge will be put in the reagent hold inventory area for
further investigation.
Fix Inventory:
- Enter reagent hold area of inventory
- If the system cannot verify the reagent, remove from the
system.
- Inspect reagent cartridge for mismatch or defective label.
- Clean laser barcode reader
Cartridge present
No→Yes
F4: SYSTEM PREP
F1: INVENTORY
F1: SHOW HOLD
F2: SHOW MISMATCH
Select Method
F3: VERIFY SLOT
F2: REMOVE DATA
- Align laser barcode reader
6-8
Dimension Systems