MEDONIC
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0
CONTENTS
0 CONTENTS ................................................................................................................. 1
0.1 COPYRIGHT () NOTICE ........................................................................... 4
0.2 SERVICEMANUAL CHANGES/UPDATES.................................................. 5
1 FUNCTIONAL DESCR. DILUTING STAGES............................................................. 6
1.1 INTRODUCTION........................................................................................... 6
1.2 WHOLE BLOOD ASPIRATION .................................................................... 6
1.3 FIRST DILUTION .......................................................................................... 8
1.4 DILUTING THE WBC & HGB ...................................................................... 10
1.5 DILUTING THE RBC/PLT ............................................................................ 13
1.6 ASPIRATION PIPETTE CLEANING ............................................................ 15
1.7 AUXILIARY VALVES................................................................................... 16
2 FUNCTION DESCR. ANALYSING PROCESS............................................................ 18
2.1 INTRODUCTION........................................................................................... 18
2.2 FUNCTIONAL FLOW DIAGRAM ANALYSER PART................................ 18
2.3 CREATING THE VACUUM .......................................................................... 20
2.4 FILLING THE METERING UNIT ................................................................. 21
2.5 START ANALYSING PROCESS................................................................... 22
2.6 COUNTING THE WBC SAMPLE.................................................................. 23
2.7 CLEANING THE ORIFICE BEFORE THE RBC COUNT............................. 24
2.8 ANALYSING THE RBC SAMPLE ................................................................ 27
2.9 ENDING THE COUNTING PROCEDURES.................................................. 28
2.10 MEASURING THE HGB.............................................................................. 28
3 SPECIAL SERVICE PROCEDURES (DILUTER)........................................................ 30
3.1 DILUTER PUSH BUTTONS.......................................................................... 30
3.2 SPECIAL FUNCTIONS HEX-SWITCH CPU BOARD ................................ 30
3.3 THE TURNING VALVE POSITIONING SYSTEM ...................................... 31
3.4 ADJUSTMENT POSITIONING TURNING VALVE V1 ............................... 33
3.5 ADJUSTMENT POSITIONING TURNING VALVE V2 ............................... 35
3.6 BLOOD DETECTOR ADJUSTMENT ........................................................... 36
3.7 MIXING CUP DETECTOR CHECK .............................................................. 38
3.8 FILLING THE TURNING VALVES WITH DETERGENT ........................... 38
3.9 DILUTER VALVE TEST ............................................................................... 39
4 SPECIAL SERVICE PROCEDURES (ANALYSER).................................................... 41
4.1 PRINT SAMPLE-STATUS............................................................................. 41
4.2 COUNT ONLY ............................................................................................... 44
4.3 PHOTOMETER ADJUSTMENT.................................................................... 45
4.4 START / STOP DETECTOR ADJUSTMENT ................................................ 47
4.5 CALIBRATE PRESSURE .............................................................................. 50
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---------------------------------------------------------------------------------------------------------------------4.6 SCREEN-DUMP............................................................................................. 51
4.7 SHOW INPUT SIGNALS ............................................................................... 52
5 ERROR MESSAGES .................................................................................................... 53
5.1 ERROR NUMBERS / ANALYSING UNIT ................................................... 54
5.2 ERROR NUMBERS / DILUTING PART ....................................................... 57
6 CHANGING/INSTALLING PARTS , PC-BOARDS etc. .............................................. 64
6.1 CHANGING DILUTER PC-BOARDS............................................................ 64
6.2 CHANGING ANALYSER PC-BOARDS........................................................ 65
6.3 CHANGING PARTS / TURNING VALVES .................................................. 65
6.4 CHANGING THE SYRINGE/PISTON........................................................... 66
6.5 CHANGING VALVES & TUBES .................................................................. 67
6.6 CHANGING THE ORIFICE TRANSDUCER................................................. 68
6.7 CHANGING THE VIEWING ANGLE (LCD DISPLAY)............................... 69
7 TUBING SYSTEM LAY-OUT .................................................................................... 70
7.1 LEGENDS ...................................................................................................... 70
8 INSTALLING AUXILIARY DEVICES ........................................................................ 72
8.1 INSTALLING THE PRINTER AND SERIAL OUTPUT................................ 72
8.2 INSTALLING THE BAR-CODE PEN............................................................ 73
9 DESCRIPTION ELECTRONICS ( DILUTER SECTION )........................................... 78
9.1 POWER SUPPLY BOARD ( DRAWING 581-4113 / 4114 / 4115 -1 ) ........... 78
9.2 CPU uP DILUTER ( DRAWING 581-3008 ) .................................................. 80
9.3 AC-MOTOR DRIVERS ( DRAWING 581-3009 ) .......................................... 81
9.4 DC-MOTOR DRIVERS ( DRAWING 581-4106 ) .......................................... 81
9.5 VALVE DRIVERS ( DRAWING 581-4104 ).................................................. 82
9.6 DETECTOR/INDICATOR OUTPUTS ( DRAWING 581-4105 ) ................... 82
9.7 INPUT SIGNALS ( DRAWING 581-4107 ).................................................... 82
9.8 BOTTLE DETECTORS ( DRAWING 581-4108 ) .......................................... 82
9.9 COMMUNICATION ( DRAWING 581-4109 )............................................... 83
9.10 TURNING VALVE POSITIONING SYSTEM ( DRAWING 581-4116 ) ..... 83
10 DESCRIPTION ELECTRONICS (ANALYSER SECTION) ..................................... 84
10.1 POWER SUPPLY CPU BOARD (DRAWING 570-860A) ............................ 84
10.1 ANALOGUE AMPLIFIER ( DRAWING 570-855B) .................................... 84
10.3 DISCRIMINATOR CIRCUIT ( DRAWING 570-855C)................................ 85
10.4 HGB LAMP DRIVER CIRCUIT ( DRAWING 570-859A) ........................... 85
10.5 STATE MACHINE (DRAWING 570-855A)................................................. 86
10.6 METERING UNIT DETECTORS ( DRAWING 570-852B) ......................... 86
10.7 PRINTER DRIVER (DRAWING 570-854A) ................................................ 87
10.8 CPU SYSTEM ( DRAWING 570-851A)....................................................... 87
10.9 SERIAL OUTPUT ( DRAWING 570-856A )................................................ 87
10.10 HGB & PRESS. TRANSDUCER AMPL: ( DRAWING 570-858A ) ........... 88
10.11 DISPLAY PCB ( DRAWING 570-870 )...................................................... 88
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---------------------------------------------------------------------------------------------------------------------10.12 MAINS FILTER ( DRAWING/PCB 570-9040).......................................... 89
11 SERVICE SCHEDULE ............................................................................................... 90
11.1 SERVICE POINTS ....................................................................................... 91
12 APPENDIX / TECHNICAL BULLETINS................................................................... 96
13 REPORTING SERVICE QUESTIONS ....................................................................... 97
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0.1
COPYRIGHT (
 ) NOTICE
PLEASE NOTE :
All rights strictly reserved. Reproduction or issue of
this manual or parts of it to third parties in any form
whatever is not permitted without written authority
from the proprietors MEDONIC in Sweden.
This copy issued by :
Date
:
MEDONIC
CELLANALYZER CA570
5
Sweden

Date :
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SERVICEMANUAL CHANGES/UPDATES
This manual has been updated from revision 0.0 in the following chapters:
Section 1.5 Text : ' To mix the final dilution carefully, the airpump is switched on and
Changed to : ..... valve 7 is pulsed
2.
3.
New text in section 4.1
Error # 80,81,82 and 130-139 added in section 5.1
Text added in section 6.7
6.
7.
Section 10.12 added
Warning text and servicesheet added in section 11
9.
10.
Appendix section 12
letins added. (
important )
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1
FUNCTIONAL DESCR. DILUTING STAGES
1.1
INTRODUCTION
The CA570 performs two dilutions, 1:400 and 1:40.000 . The 1:400 dilution is used for the
WBC and HGB determination and the 1:40.000 dilution is used to perform the RBC and PLT
measurements. These dilutions are done in 2 separate stages. The first and second dilution
stages are completely separated from each other . Two separate turning valves are used . To
understand the functions of the CA570, please study the descriptions below. To simplify the
description; each main part of the diluting stage is reduced to its necessary parts, several
secondary valve functions are excluded, however they are discussed in other sections.
1.2
WHOLE BLOOD ASPIRATION
The turning valve V1 is used to dilute the whole blood 1:200 ( N.B. the 1:400 dilution is later
performed). The figure below explains the basic principle .
figure 1
V1
Turning valve. The turning valve is drawn in its number 1 position. This position is used
to aspirate whole blood from an open vial. The turning valve has an internal volume of 30
microlitres
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1,2,3 Tube valves, controlled by the software of the CA570 diluting part.
B3
Vacuum buffer container. ( small size )
DOT Blood detector BEFORE the turning valve
DAV Blood detector AFTER the turning valve.
R1
Air-restrictor ( certain length/diameter tube)
If the whole blood inlet is activated ; the following cycle is performed .
Valve 1 is opened and the waste pump is started. Therefore a vacuum is created in B3 . The
level of the vacuum is not controlled, in other words this might be rather high and completely
depending on the condition of the waste pump. To reduce this vacuum to a more usable level;
valve2 is opened during short intervals. ( pulsing) . Some air is now aspirated in to B3 and
reducing the vacuum. How much the vacuum is reduced, is depending on the air restrictor R1
and the time that valve2 is opened. As R1 is a constant, the vacuum can be changed by
changing the duty cycle of valve2.
Valve3 is now opened and the blood is aspirated through turning valve V1 position 1.
As there are 2 blood detectors present, which are sensed by the (diluter) microprocessor;
Valve3 will close if both blood-detectors are detecting blood. and the aspiration will stop
immediately.
A question might arise : ' What is detected as being blood ?' .The definition of blood is purely
defined by the sensitivity of the two blood detectors. The blood-detectors are designed around
a LED ( green-colour) and a photocell. The optical path goes through a fibre optic and lights
through the aspiration tube made of Teflon material. The sensitivity of these detectors can be
set within a SPECIAL PROCEDURE program as described in the user manual of the CA570
section 'SPECIAL PROCEDURES' or as in section 3.6 of this service manual.
As the software in the diluting part will wait until BOTH detectors see 'blood' ; it is important
that BOTH detector sensitivities are set at about the same level. It is advisable that the
detection level of both detectors is around a blood level with an HGB of 1.5 to 3 g/dl. Usually
this level will remain stable for long periods, however in the case of a protein built-up within
the aspiration tube, this level might change. It is therefore advisable to clean the aspiration tube
with a hypo chlorite solution ( ca. 3-5%) or an enzymatic cleaner whenever service is
performed on the CA570 and/or the blood detection level is (re) adjusted.
Note that the LED is only switched on during the aspiration sequence of blood or during
the BLOOD-DETECTOR ADJUSTMENT procedure as described in the user manual of
the CA570 section ' Special procedures' or refer to section 3.6 in this manual.
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Figure 2 below illustrates the construction of a blood-detector.
figure 2
If the whole blood aspiration is activated and NO blood is ever detected, the aspiration
will stop after 10 seconds and a BEEP signal will be heard as a warning that no blood is
detected. However the diluter will continue its 'diluting' process anyhow to make
blank/check cycles possible. Also during long aspiration sequences, valve2 will be closed
during longer intervals to increase the vacuum in B3 and in the inlet tip. The diluter
software 'thinks' that the blood has a high viscosity or that the capacity of the waste
pump is low and therefore compensate the vacuum automatically to a higher level . (
more vacuum).
1.3 FIRST DILUTION
The first dilution is made by positioning the turning valve V1 to its second position. The second
position is on one end connected to a syringe filled with the diluent and the other end to an inlet
of the mixing cup. The syringe has a mechanical fixed volume of 6 ml. As the turning valve has
an internal volume of 30 uL ; the dilution in the mixing cup will have a ratio of 1: 200 ( 30 ul
into 6 ml of diluent ).
The first dilution in the mixing cup is not enough mixed after the dilution is made. To achieve a
correct mixing of the sample, the air pump is started and valve5 is pulsed ( ON/OFF with
certain intervals) and large air bubbles are pushed into the sample. This creates a good mixed
sample which is of great importance for the reproducibility of all counted parameters .
Therefore the following parameters are direct dependent on a correct mixing procedure in the
mixing-cup :
RBC,PLT,WBC and HGB. Of course, the MCV,RDW,MPV parameters are LESS dependent
on the mixing cycle as they are NOT related to a concentration of cells.
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To avoid that the sample is contaminated with dust etc., the air passes an airfilter with an
opening size (diameter) which should be smaller than the diameter of the smallest PLT. The
size of the filter ( diameter ) is therefore ca. 1.5 micrometer.
It is obvious that this filter should be changed with regular intervals to prevent blocking
due to local dust environments.
figure 3
Legends:
S1
V1
B1
F1
Diluent syringe, fixed at 6 ml volume.
Turning valve 1 , drawn in position 2
Mixing cup for the first dilution
Airfilter with hole diameter of ca. 1.5 micrometer.
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1.4
DILUTING THE WBC & HGB
As described in section 1.3 above, the first dilution in the mixing cup is 1:200. To achieve the
final 1:400 dilution for the WBC & HGB determination , the following sequence is performed.
Please study the figure 4 below which contains the necessary parts :
figure 4
Legends:
S2
Lyser syringe. volume is fixed to 5.2 ml . Valve 11 is switched to an open position to
the lyser container (A) whenever it moves downwards, in the upwards direction valve 11 (B)
opens to point AC1
Coil made of a Teflon tube. The total volume from A to B is 2.6 ml
B1
The mixing cup for the first dilution 1:200
E1
Electrode ( metal tube) . This tube is used as the mixing tube as described in section 1.3
and as an electrode during the transfer of the sample to the WBC/HGB cup.
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E2
Electrode (metal tube). This tube is used to transfer the sample to the turning valve
It is also used as an electrode to check for liquid during the transfer of the sample to the
WBC/HGB cup.
V2
Turning valve 2 (position 3). This turning valve is basically the same as V1. However
there are only 2 positions called 3 and 4. The internal volume is the same as for V1 , 30 ul.
F1
Air filter . Opening size 1.5 um diameter
BV1 One-way valve. This passive one-way valve is used to prevent that liquid from B5 can
travel backwards into the 'air-tube'. It is located as close as possible to B5.
B5
Measuring cup WBC/HGB
The centre electrode/metal-tube in the mixing cup is connected to position 3 of turning valve 2.
The other side of position 3 is connected via valve15B and the coil C1 to the WBC/HGB
measuring cup at point B. The volume of the coil C1 from A to B is 2.6 ml.
The waste pump is switched on and valve18 is opened, the WBC/HGB cup is drained. The
mixing cup B1 is pressurised by switching on the air pump and opening valve6B . Valve 15B is
also opened and the 1:200 dilution from the mixing cup is now flowing through the coil C1
towards the WBC/HGB cup. NOTE that the drain pump is still on and valve18 as well, so the
WBC/HGB is drained continuously during this process.
During this 'sample-transfer' process the two electrodes E1 and E2 (metal tubes) in the mixing
cup B1 are sensed by the diluter uP for liquid. ( As the diluent has a certain conductivity ). The
level of 1:200 diluted sample in the mixing cup B2 will now slowly decrease and finally reach
the bottom of electrode E1. At this moment the diluter uP will sense no liquid and valve15B is
closed. Valve18 and the drain pump will still be in the same position, therefore the WBC/HGB
will be EMPTY but the 1:200 dilution is now trapped in the coil C1 ( between point A and B )
Finally valve18 is closed, ending the draining process of the WBC/HGB cup.
Now the syringe S2, which is filled with 5.2 ml lyser, is moved upwards with valve 11B open,
giving 5.2 ml in the WBC/HGB measuring cup. This solution contains 2.6 ml 1:200 sample and
2.6 ml lyser. The sample is therefore diluted by a factor 2 giving a total dilution of 1:400 in the
WBC/HGB cup.
As the final 1:400 is not mixed enough, the sample is mixed by switching on the air pump and
opening valve7 by short intervals, introducing large air bubbles into the measuring cup B5 The
one-way valve BV1 secures that no liquid can travel backwards through the air tube connected
to valve7 .
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IMPORTANT POINTS
The following points are important to understand in case of any service around the parts of
above figure 4.
As soon as the mixing cup B1 is pressurised and the sample will flow to B5, a timer starts to
check that the time from the start of the transfer to the position where the sample has reached
the bottom of electrode E1 is within certain limits. If there should be an air leakage in B1 or an
obstruction in the coil C1 or any other part connected to it; this time could be too long. In such
a case the system will stop and display :
TOO LONG TRANSFER TIME
A typical case occurs if the system is used mainly for prediluted samples. As these
samples often are contaminated or contains hairs,fibres and other particles not related to
the sample, these particles are usually stucked in the electrode E2 which is one of the
narrowest 'tubes' of the system. This electrode should be cleaned on the inside with a
needle to be sure that no obstructions are present.
Another possibility of the above warning could be liquid on top of the mixing cup B1 between
the electrodes E1 and E2. In that case the uP 'thinks' that there is liquid at all time inside the
mixing cup.
The maximum transfer time is 10 seconds for a whole blood sample and 18 seconds if the
predilute entry is used. A normal transfer time is 3-6 seconds.
Also, if the time should be unreasonable short, a similar warning is given. If the transfer time is
less than 2 seconds, on the whole blood inlet, the following is displayed :
NO DILUENT IN DILUTER
In this case the volume in the mixing cup is too small, due to a lack of diluent ( diluted
sample).
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In both cases the system will not measure any parameters . However by pressing the
diluter-reset switch C and the <MENU> key, the CA570 will be operational again.
See figure below :
In case the transfer time is less than 2 seconds on the prediluted inlet, a warning :
ERROR 863 is displayed. In that case ONLY press MENU to continue.
Resetting the diluter with switch C, as explained above, is NOT necessary.
1.5
DILUTING THE RBC/PLT
As the turning valve V2 contains a micro volume of 30 ul from the 1:200 sample during the
sample transfer as described in section 1.4 above ; V2 is now turned to its position 4. Hereby
connecting one side of position 4 to the diluent syringe 1 and the other side to the RBC/PLT
cup via a tube.
Note that this tube is already (always) filled with diluent . When the syringe S1 moves upwards,
the final volume in B4 (RBC/PLT cup) will be 6 ml as well, but containing 30 ul of the 1:200
sample. As this is again a dilution of 1:200, the final dilution will be 1:40.000 in the measuring
cup B4 (RBC/PLT).
To mix the final dilution carefully, the air pump is switched on and valve7 is pulsed during
certain intervals; introducing large air bubbles in B4. The passive one-way valve BV2 prevents
that liquid flows backwards into the 'airtube' to valve7 .
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figure 5
Legends:
B4 RBC/PLT measuring cup
F1
Air filter ( 1.5 um diameter)
S1 Diluent syringe
V2 Turning valve 2. Drawn in its position 4
BV2 One-way valve ( passive )
IMPORTANT
As both syringes are driven by the same motor system; both dilution's ( WBC and RBC)
are performed simultaneously. In case syringe S1 moves upwards like in section 1.3 figure
3, no lyser is 'needed' by the system. However the lyser syringe S2 will move upwards
anyhow. In such a case valve11 is opened towards the lyser container (position A) and the
lyser is just flushed backwards into the lyser container
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1.6
ASPIRATION PIPETTE CLEANING
The aspiration pipette for whole blood is cleaned on the in- and outside with diluent when the
sample is diluted and analysed. A cleaning cup is moved by a motor to the inlet of the aspiration
pipette and clean diluent is flushed around the pipette and drained through the pipette. An
excessive 'draining' of the pipette with air is also used to dry the inside of the pipette.
figure 6
Legends:
P3
Membrane pump. This 'pump' is just a chamber divided by a membrane 'wall'. One side
contains diluent and the opposite side only air.
B2
Washing device. This device is turned by a motor either in the shown position or
downwards after the cleaning cycle is finished.
BV3
Passive one-way valve
AP1 Whole blood aspiration pipette. The blood is aspirated through the inside which is a
Teflon tube fitted in a stainless steel tube.
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SL1 Whole blood start-lever. The lever is pushed backwards by B2 whenever in its
horizontal position. NOTE that this is the indication if the cleaning cycle should start. If
the lever is NOT pushed backwards, the cleaning cycle is inhibited and the operator will
be warned with a series of 'beep' signals.
The flush pump is a separate pump only used for several cleaning cycles in the CA570.
Whenever started, a pressure is applied in the tubes connected to the flush pump. Therefore the
membrane pump P3 will be filled with diluent on one side. As valve14 is still closed, P3 will
have a buffer of diluent available anytime during the diluting process. The one-way valve BV3
prevents that diluent might flush backwards.
When the air pump is started and valve6B is opened a high pressure is built-up inside P3. By
pulsing valve14 , the diluent can now be supplied to the aspiration needle AP1.
The cup B2 is drained by opening valve 13 with the drain pump switched on.
IMPORTANT
The above cleaning cycle is only performed if the start lever is pushed backwards
whenever the cleaning cup B2 is in a horizontal position. The pin TP1 can be adjusted to
assure that the start-lever SL1 is activated .
This means that whenever the cleaning device is removed ( e.g. to check the valves
behind) , NO cleaning is performed as the start-lever SL1 will not be activated.
1.7
AUXILIARY VALVES
In the previous sections, several valves are not mentioned as they mainly have secondary
functions like cleaning.
Below follows a description of these valves :
VALVE 4
This valve is activated at the end of a cycle for ca. 1 second and flushes detergent through the
turning valve systems. This is necessary to assure that the turning valves never dry-up in their
closed compartments.
VALVE 6A
The main function of this valve is to enable the aspiration of a prediluted sample. In that case
the mixing cup will have a vacuum created by the waste pump and an open valve 8.
VALVE 9B
This valve, together with valve 15B and the flush pump, enables the cleaning ( with diluent ) of
the WBC counting cup B5.
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VALVE 12
This valve gives the flush pump a possibility to flush either with diluent or detergent. If valve
12B is open, the flush pump will flush detergent into the system.
VALVE 15A
This valve, together with valve 9A, and with the waste pump switched on, empties the mixing
cup B1 from excessive sample or clean diluent which is applied during the cleaning process of
the diluting part.
VALVE 16B
This valve is used to flush the RBC cup , B4 with clean diluent during the autocleaning cycle
between each sample.
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2
FUNCTION DESCR. ANALYSING PROCESS
2.1
INTRODUCTION
The analysing process of the sample is basically separated from the diluting stages.. As 2
separate micro processors are used for the diluter and the analysing part, these processors are
communicating by means of an excessive communication protocol. However the analysis of
cells is only performed by the CPU of the analysing part. Certain valves that are directly
involved in the analysing procedure are also controlled from the analyser CPU.
This section 2 describes the necessary functions.
2.2
FUNCTIONAL FLOW DIAGRAM ANALYSER PART
The below figure contains the parts of the analyser system.
figure 7
Legends:
B6
Vacuum bottle. This bottle is hermetically closed and is always empty. Only traces of
liquid should be observed in the bottle and waste tube through valve19.
PT
Pressure transducer. This is an electronical pressure transducer connected to the CPU
board of the analysing part. This transducer can handle ( linear ) a vacuum up to c. -500 hPa
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R2
Air restrictor. Teflon tube of a certain length/diameter.
R3
Liquid restrictor. Tygon tube of a certain length/diameter.
STOP Stop detector. This is an optical detector consisting of an IR LED and a photocell.
Whenever the glass tube ( metering unit ) is filled with liquid (diluent) a high light intensity is
measured at the photocell. If the metering unit is empty, the light intensity is low.
START Start detector. This is an optical detector consisting of an IR LED and a photocell.
Whenever the glass tube ( metering unit ) is filled with liquid (diluent) a high light intensity is
measured at the photocell. If the metering unit is empty, the light intensity is low.
METERING UNIT This is a glass tube. The volume between the start and stop detector is
the actual measured (diluted) sample volume. The volume between the start and stop detector
is fixed at 300 micro litre.
T1
Transducer. The transducer consist of a chamber with point 1 and 2 on one side and a
chamber at point 3 and 4 on the other side divided by an orifice of 80um. The sample is drawn
through the orifice from 3-4 to 1-2.
Connection points 1-2 are platinum tubes as well 3-4. These platinum tubes are used as
electrodes. Point 3-4 being the 'cold' side (ground) and 1-2 the 'hot' side
B5 The WBC/HGB counting cup.
19
Tube valve 19 is driven by the diluter CPU but controlled by the analysing CPU
system.
25,26,27,28,29,30,31 Tube valves, controlled by the analyser CPU.
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2.3
CREATING THE VACUUM
The vacuum bottle is used to enable the sample to be drawn through the orifice in the
transducer T1. The metering unit should always be filled with diluent before this process is
started. To fill the metering unit ( up to the stop detector), the vacuum bottle is put at ca. 400hPa by starting the waste pump and opening valve 19. The pressure transducer is sensed
and valve 19 is closed at the desired -400hPa level. A maximum time of 20 seconds is allowed
to reach this vacuum level. Also the vacuum bottle is drained during this process. If this level
cannot be reached within this time limit; an error code 20 will be displayed. Indicating a
defect waste pump or a leakage at the vacuum bottle. Note that this vacuum level of 400hPa is only used to fill the metering unit. The actual vacuum during the analysing
process is 163-137 hPa. ( See section 2.5)
figure 8
Creating vacuum to fill the metering unit.
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2.4
FILLING THE METERING UNIT
To fill the metering unit with diluent, after performing the sequence as described in 2.3 above;
valve 26,30 and 28 are opened . The diluent is drawn through the flush pump ( which is OFF)
and the STOP detector is sensed for liquid. As soon as the stop detector detects liquid, these
valves are closed.
figure 9
Fill metering unit with diluent
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2.5
START ANALYSING PROCESS
To start the analysing of cells in the counting cups B4 or B5, first the liquid column in the
metering unit is moved downwards below the start detector. The vacuum in the bottle B6 is
first regulated to - 163 hPa. If the vacuum was too high, valve 25 and 26 are opened until the
correct vacuum is reached. If the vacuum was too low, valve 19 is opened and the waste pump
is switched on until the correct vacuum is reached. ( - 163 hPa ).
To move the column downwards, valve 31,30 and 25 are opened and the START detector is
sensed for air. This process should end within 3 seconds, if no air is detected within this time
limit ; error-code 30 will be displayed.
The column will stop below the start detector as a time delay is added to assure that the
meniscus is a few mm below the start detector before the valves are closed.
If during the time that the column moves downwards an airbubble is detected at the start
detector; the software will take care of this situation as long as the time for this bubble to pass
the start detector is less than 0.1 second. If the time is longer, the column will not stop at a
correct position and the counting process will end with the warning Tl ( Time-out lower
detector).
figure 10
Moving the column downwards
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2.6
COUNTING THE WBC SAMPLE
After the sequence in above section 2.5 is performed, the WBC sample is analysed by opening
valve 26, 30 and 29A ( which is normally open ).
The sample is aspirated through the transducer orifice from section 3-4 to section 1-2 towards
the metering unit glass tube. As the volume from point 2 of the orifice unit ( T1) to the lower
end of the metering unit is larger than the actual volume of the metering unit; the sample is
never drawn into the glasstube which therefore always will be clean.
As a timer starts as soon as the liquid passes the start detector, a maximum time of 17.5
seconds is allowed for the column to reach the stop detector. If there should be a time-out, the
valves are closed and the warning Tu will be displayed, indicating a clogging in the orifice.
figure 11
Counting the WBC sample
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2.7
CLEANING THE ORIFICE BEFORE THE RBC COUNT
After the WBC analysing process is ended as described in section 2.6 above, the orifice
transducer T1 is cleaned to prevent that traces of haemolyser can enter the RBC sample. ( In
case this happens, the MCV parameter will be greatly effected).
The orifice cleaning is done in 3 steps. First valve 31 and valve 29B are opened. Valve 27 is
now pulsed with 0.3 seconds intervals 3 times. The RBC sample is used to clean the transducer
T1 in chamber 3-4 from haemolyser traces. Note that only a small portion of the RBC dilution
is used for this purpose. See figure below.
figure 12
Cleaning step 1
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CLEANING STEP 2
To be sure that no traces of haemolyser are left around the transducer T1, the chamber 1-2 is
now flushed with a high pressure supplied by the flush pump and with valves 28 and 31 open.
Valve 29B will be open as well, therefore some of the flushing liquid ( clean diluent ) will also
enter the chamber 3-4 of the transducer T1 via the orifice. This cycle is performed within 0.6
seconds.
figure 13
Step 2 , cleaning cycle
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CLEANING STEP 3
Before the RBC sample is analysed, valve 25 and 30 is opened and 29 is released leaving 29A
open.. Due to gravity, the column will move downwards slowly and clean diluent will flow
from chamber 1-2 of the transducer T1 through the orifice to chamber 3-4 into the WBC cup.,
this cleans any tube connection between point 4 of T1 and the entry of valve 29A..This action
will last for ca. 3 seconds.
figure 14
Step 3 of the cleaning process.
As a second step in the RBC counting procedure, the chamber 3-4 is filled with the RBC
sample by opening valve 29B and 27. for ca. 0.8 seconds. This will fill the transducer chamber
3-4 completely with the RBC sample.
NOTE: The above cleaning steps are all done to prevent any trace of haemolyser
entering the RBC sample. Tests have shown that even if the flush pump should not work
correctly ( out of order). Step 1 and 3 are still enough to ensure that the RBC
measurement is performed correctly. This makes the cleaning process not dependent on
production and/or field tolerances.
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2.8
ANALYSING THE RBC SAMPLE
The analyse process of the RBC/PLT sample is done analogue to the previous described WBC
counting. The column in the metering unit is moved downwards below the start detector as
described in above section 2.5 , however the vacuum in the bottle B6 is not regulated back to 163 hPa .
As a second step in the RBC counting procedure, the chamber 3-4 is filled with the RBC
sample by opening valve 29B and 27. for ca. 0.8 seconds. This will fill the transducer chamber
3-4 completely with the RBC sample.
See figure below.
figure 15
Filling the transducer with the RBC sample
The RBC sample is now analysed by opening valve 26,30 and 29B. Please refer to section 2.6
for further details as the RBC analysing process is the same as described for the WBC
measurement..
Note that after the RBC count is finished, the liquid has arrived at the stop detector, the
vacuum in the bottle B6 is at ca. - 137 hPa.
So, the vacuum during the RBC counting process is always lower compared to the WBC
measurement. Giving always a somewhat longer counting time on the RBC 'channel'.
( The counting time is defined as being the time needed for the liquid column to move from the
start detector to the stop detector.)
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The counting time for the RBC process is therefore ca. 0.7 to 1.2 seconds longer than for the
WBC measuring cycle.
2.9
ENDING THE COUNTING PROCEDURES
At the end of the sample analyse cycle, the orifice will be cleaned in several steps.
STEP 1
Valve 29 is released ( leaving 29A open ) and 25 is opened. This reduces the vacuum left in the
metering unit to zero. At the same time a high voltage ( ca 50-100 volt) is supplied over the
orifice between chamber 1-2 and 3-4. ( note that the connections 1 to 4 are made of platinum
tubes acting as electrodes). This will clean the orifice from possible protein layers built up
during the WBC analysing process.
STEP2
Valves 31 and 28 are opened and the flush pump is started. This will clean chamber 1-2 of the
orifice transducer T1 and remove air bubbles introduced by the high voltage cleaning process.
This lasts for ca. 1 second.
STEP3
Finally valve 27 and 29B are opened for ca. 3 seconds. This cleans the chamber 3-4 of the
orifice transducer T1 as the RBC counting cup B4 was flushed with clean diluent.
The end of a complete cycle will therefore leave the analysing part cleaned from all blood
traces around the orifice transducer T1.
2.10
MEASURING THE HGB
The HGB parameter is determined from the WBC dilution. The WBC cup has a built in
photometer system. For explanations concerning the adjustment and functions, please refer to
section ' Special service procedures'
The HGB determination is done in 3 steps. The 'offset' , sample and blank is measured. These
3 parameters are necessary to determine the HGB. The photometer lamp is always switched off
if no sample is processed by the CA570. As soon as a sample is processed, first the offset is
measured, than the lamp is switched on. After the sample is diluted and transferred to the WBC
cup, the light transmission is measured. This is done 20 times during ca. 1 second. The mean
value is stored and used by the analyser uP to calculate the HGB. If the Variance of these
measurements is too high, the HGB will be displayed with an SE mark, indicating an unstable
measurement.
As soon as the WBC counting is finished, the WBC cup is emptied by opening valve 18 and the
waste pump P5 is switched on.
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After ca. 1 second, the lyser syringe will move upwards with valve 11B open and 15B closed,
this means that the liquid in the coil (diluent) is flushed into the WBC cup and immediately
drained as valve 18 is still open. The lyser syringe will stop at about 2.5 ml but valve 18
remains open. The WBC cup will therefore be empty.
Finally valve 18 is closed and the syringe continues to move upwards, flushing lyser into the
WBC cup B5.
This liquid (lyser) is used to measure the HGB blank of the sample.
See figure below.
figure 18
Filling the WBC cup with 'blank'
Note that this procedure is done simultaneously with the RBC analysis of the sample.
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3
SPECIAL SERVICE PROCEDURES (DILUTER)
The diluter part has several built-in test procedures. These are functioning even if the analysing
part is disconnected ( or should be out of order by some reason)
This chapter explains how to use these functions for test/service or adjustment purposes.
3.1
DILUTER PUSH BUTTONS
Please locate four push button switches at the upper left corner behind the front cover (door) of
the diluting part. Called A,B,C, and D from left to right.
figure 19
A Empty counting cups. ( B4 and B5)
B Flush counting cups. (B4 and B5)
C Reset diluter CPU. This switch may be disabled/enabled
through a jumper on the CPU board in the diluter.
D Not implemented.
3.2
SPECIAL FUNCTIONS HEX-SWITCH CPU BOARD
On the diluter CPU board, in the upper part on the right-hand side, you will find a turnable
switch marked 0 to F. The switch is marked as SW1. Just beside this switch you will
find a push button switch marked SW2.
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---------------------------------------------------------------------------------------------------------------------By turning SW1 into a certain position and pressing SW2 certain pre-defined test programs can
be activated. Please refer to the list below.
SW1 position
Action when pressing SW2
6
Automatic clean operation. Same as performed
every fourth hour when the system has not been operated.
Turning valve V1 adjustment
Turning valve V2 adjustment
Detector test/calibration function.
Fill turning valve system with detergent. Used at first time
installation.
Activates the valve test program
8
9
D
E
F
Function 6 is obvious. It simulates the automatic cleaning cycle performed every 4-th hour
when the CA570 enters the standby mode.
Please refer to the sections below for detailed explanations concerning functions 8 to F.
3.3
THE TURNING VALVE POSITIONING SYSTEM
The turning valve valves ( V1 and V2 ) in the diluting part are positioned in a purely
electronical way.
The positions are stored as digital data in a separate memory chip IC6 on the CPU board. The
positioning is done in the following way :
1. The required position of the valve is captured by the software from the positioning memory
chip IC6 and transmitted in serial form to the D/A converter.
2. The motor that drives the turning valve is started in the correct direction
3. The CPU. is checking for an abrupt change which indicates that the turning valve has
reached the required position.
Note : The reference voltage to the ( high precision ) potentiometer and the D/A converter are
from the same source, making the positioning system 'independent' on voltages changes of V
ref.
As there always will be some hysteresis ( backlash) between the potentiometer and the actual
position of the turning valve, each position is retrieved always from the same direction. This
will cancel possible backlash in mechanical parts. See figure 20 below.
The resolution of the electronical positioning system is 0.07 degrees.
In practice, a tolerance of 0.1 mm is allowed on the positioning accuracy between the inlet and
the turning valve itself.
This means that in any position of the turning valve, a 1.0mm diameter calibrator pin can be
inserted in the front seat as a check that the positioning is correct. This is correct except for
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---------------------------------------------------------------------------------------------------------------------the blood inlet position 1 in turning valve V1, the inlet at the front seat has a diameter of 0.7
mm.
See figure 21 below.
IMPORTANT
Whenever the diluter CPU board is changed for whatever reason, the positioning chip
IC6 from the 'old' board should be inserted in the 'new' board otherwise a new turning
valve calibration should be carried out!
So :
There is no reason to perform any turning-valve adjustment except if the diluter CPUboard has been changed WITHOUT exchanging the CPU memory chip IC6.
However :
If the gearbox or the potentiometer (or the position of the potentiometer) is changed, a
turning valve calibration MUST also be performed.
figure 20
Electronical lay-out of the turning valve system.
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figure 21
Maximum tolerance positioning system turning valve V1 and V2
3.4
ADJUSTMENT POSITIONING TURNING VALVE V1
Please refer to section 3.3 first before proceeding !
Procedure to adjust turning valve V1 :
If available, mount the perspex adapter ( supplied by Medonic ) at the front of the turning
valve. To do this , first remove the front seat ( 3 screws) and mount the adapter instead.
Be careful not to scratch the surface of either the 'front seat' or the turning valve itself!
1. Select the HEX-switch SW1 ( CPU board) position 8 and press SW2.
2. Select HEX-switch SW1 position 1 and press SW2
The turning valve will now rotate to position number 1
3. The valve can be turned CCW with the WHOLE BLOOD (E) lever in 0.7 degree steps and
CW with the PREDIL-BLOOD (F) lever in 0.7 degree steps.
The push-button A and B is the fine adjustment, A will turn the valve CCW in 0.07 degree
steps and B will turn the valve CW in 0.07 degree steps.
4. Align the valve with a pin calibrator of 1.0 mm diameter so that the pin goes smoothly into
position 1.
5. Proceed to calibrate position 2 by turning the HEX-switch SW1 to position 2 and press
SW2. The turning valve will now rotate to position 2. Repeat step 3 above for this position.
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---------------------------------------------------------------------------------------------------------------------6. Repeat this for position 3 and 4 . Position 3 is the closed tube position and position 4 is the
same as position 2 both retrieved from the opposite direction..
So, there are 3 physical positions but 4 'electronical' positions as position 2 and 4 are physically
the same.
Note: During the adjustment procedure, SW2 can be pressed, the turning valve will
repositioning itself to the current position. This makes hysteresis (backlash) checking
possible.
7. When all positional adjustments are done, turn the HEX-switch SW1 to position 0 and press
SW2. This will store the new positions into the memory chip IC6 and calculate the new
checksum.
NOTE : Do not forget point 7 above ! Otherwise the system will not 'remember' the new
positions after a reset or power down !
See figure 22 and 23 below
figure 22
Push-button , turning valve adjustment, definitions
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figure 23
Turning valve V1 position definitions
3.5
ADJUSTMENT POSITIONING TURNING VALVE V2
Please refer to section 3.3 first before proceeding !
Procedure to adjust turning valve V2 :
If available, mount the perspex adapter ( supplied by Medonic ) at the front of the turning
valve. To do this , first remove the front seat ( 3 screws) and mount the adapter instead.
Be careful not to scratch the surface of either the 'front seat' or the turning valve itself!
1. Select the HEX-switch SW1 ( CPU board) position 9 and press SW2.
2. Select HEX-switch SW1 position 3 and press SW2
The turning valve will now rotate to position number 3
3. The valve can be turned CCW with the WHOLE BLOOD (E) lever in 0.7 degree steps and
CW with the PREDIL-BLOOD (F) lever in 0.7 degree steps.
The push-button A and B is the fine adjustment, A will turn the valve CCW in 0.07 degree
steps and B will turn the valve CW in 0.07 degree steps.
4. Align the valve with a pin calibrator of 1.0 mm diameter so that the pin goes smoothly into
position 3
5. Proceed to calibrate position 4 by turning the HEX-switch SW1 to position 4 and press
SW2. The turning valve will now rotate to position 4. Repeat step 3 above for this position.
6. When both positional adjustments are done, turn the HEX-switch SW1 to position 0 and
press SW2. This will store the new positions into the memory chip IC6 and calculate the new
checksum.
NOTE : Do not forget point 6 above ! Otherwise the system will not 'remember' the new
positions after a reset or power down !
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See figure 22 and 24 below
figure 22
Push-button , turning valve adjustment, definitions
figure 24
Turning valve 2 position definitions
3.6
BLOOD DETECTOR ADJUSTMENT
Please refer also to section 1 for explanations.
Within the diluter there are minimum 2 optical blood detectors, one directly on the open tube
inlet pipette and the other on the output of the turning valve system (V1).
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If an auto sampler or closed tube adapter is used a third detector is found on that inlet pipette.
The blood detectors are optical devices using LED's (green colour), fibre optics and photocells.
The path is formed by a Teflon tube. Whenever this tube is changed it is recommended that the
sensitivity of the blood detectors is checked and,
if necessary, adjusted.
On the main diluter PC board you will find a 7-segment display. This display is used in the test
procedure described below.
Before running this test procedure, please locate also the three trim potentiometers placed
between the 7-segment display and the switch SW1. Marked OT,AV and CT.
Test Procedure
1 Dilute a blood sample manually so that a HGB value of about 0.7-1.0 g/dl is achieved.
2 Put SW1 (diluter, CPU board) in position D.
3 Press SW2 (diluter, CPU board). Now the waste pump in the diluter is started.
4 Enter the sample (HGB ca. 0.7-1.0 g/dl) and press manually valve 3. Observe that blood is
entering the inlet pipette fast.
Release valve 3. The blood stops in the inlet pipette.
5 Observe the 7-segment display.
a) The UPPER segment reflects the status of the upper blood detector (DAV). When lit,
light is passing through the blood detector and indicates NO BLOOD.
To adjust, turn the trim potentiometer DAV into such a position that the UPPER
segment just changes from ON to OFF.
b) The lower left hand side segment of the display reflects the status of the open tube
inlet pipette.
When lit, light is passing through the blood detector and indicates NO BLOOD.
To adjust, turn the trim potentiometer DOT into such a position that this segment
just changes from ON to OFF.
c) If an auto-sampler or closed tube adapter is used the segment on the lower right
hand side reflects the status of the closed tube blood detector. When lit, light is
passing through the blood detector and indicates NO BLOOD.
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To adjust, turn the trim potentiometer DCT in such a position that this segment just
changes from ON to OFF and than 1 turn towards the on position.
N.B. After the above adjustment is done it is IMPORTANT that SW2 is pressed again to
switch off the waste pump and valves.
figure 25
7 segment display definitions
3.7
MIXING CUP DETECTOR CHECK
To check that the mixing cup detectors are working correct, proceed as follows :
Turn the HEX-switch SW1 in position D and press SW2.
Note that this is the same position as for the adjustment test as described in section 3.6.
Remove the mixing cup B1 and fill it with diluent.
Put the mixing cup back so that both electrodes are covered with diluent.
Observe the decimal point at the 7- segment display ( see figure 25 ) on the diluter CPU board.
The decimal point should be ON with diluent covering the electrodes and OFF with
no diluent.
3.8
FILLING THE TURNING VALVES WITH DETERGENT
Both turning valves are in a hermetically closed compartment surrounded by detergent.
At installation, these chambers are empty. To speed up the filling process of these chambers ; a
special procedure can be followed.
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---------------------------------------------------------------------------------------------------------------------Turn the HEX-switch SW1 in position E and press SW2. As soon as SW2 is pressed, the
Waste-pump P5 is started and valve 4 is opened. The turning valve compartments are therefore
quickly filled with detergent. Proceed by pressing SW2 until no large air bubbles are observed
at the detergent output of turning valve 2.
figure 26
Filling the turning valves with detergent
3.9
DILUTER VALVE TEST
To activate the built-in valve test, turn the HEX switch SW1 to position F and press SW2.
The built-in 7 segment display will show 10 by first displaying 1 and half a second later the
digit 0.
Locate the 4 buttons located on the upper left hand side of the diluter front. See figure 27. The
2 left switches (A and B) are now used to select a valve number that has to be tested. See
figure 27. Pressing the left switch (A) will decrease the number, pressing the right button (B)
will increase the number.
By pressing the whole-blood start lever (E), the corresponding valve is now activated.
Test a valve by pressing the whole blood start lever and check by hand that the proper valve is
activated in a correct way.
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Note :
The whole-blood start lever will activate the valve in the 'normal' way. This means that
whenever a valve is closed, the voltage over the valve is increased to 27Volts during ca.
200 msec. After this time, the voltage is reduced to 22 Volt. ( The 'hold' voltage over the
valve). This is the way a valve is closed within the software of the diluting system.
Pressing the PREDIL. start lever (F) will activate the chosen valve with only 22 Volts. This is
not used within the software but can be used by the service technician to determine if a valve
should operate in a doubtful way.
figure 27
Locating push buttons A and B
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4
SPECIAL SERVICE PROCEDURES (ANALYSER)
4.1
PRINT SAMPLE-STATUS
Within the service menu a support is found that might help the user or the service technician to
analyse a sample- or an instrument failure.
Whenever a sample is analysed, the system keeps track of all important data during the
analysing process. This data can be printed out so that a failure analysis is greatly simplified.
Some of the printed values are instrument constants and individual for the instrument. It is
therefore wise to run a sample and perform a ' PRINT SAMPLE STATUS' as found in the
´'SERVICE MENU' of the CA570. And save this data for comparison purposes later.
The following data is printed whenever 'PRINT SAMPLE STATUS' is performed.
Note that each printout is different as most of the values are mainly related to the actual sample
and not the instrument.
Program versions:
Cellcnt= 2.3 Dec 22 1994
Diluter= 2.3/50Hz Dec 14 1994
Counting times :
PLT/RBC= 13.30
WBC
= 12.60
Pressure sensor :
cal
= 962
offset = 164
Photometer data :
lamp = 3.90
offset = 0.55 (0)
sample= 2.00 (2)
zero = 3.88 (1)
RDW correlation:
threshold-C = 68.25
threshold-Bl = 69.50
threshold-Pd = 72.20
PLT/RBC ratemeter
12:
250 270 250 260 274 265
260 270 247 251 254 262
WBC ratemeter :
10
100 95 105 88 93 102 100
99 98 103
Cellcounter status :
L0V5.95D0F503FI0E0OT
Diluter status :
L0-*X3.65F0E0B0
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An explanation of the above follows :
Pressure sensor
The cal and offset values are instrument constants and NOT related to the sample .
Photometer data
The lamp value is the actual lamp voltage of the photometer
The offset value is an instrument constant and should be stable within 1%
The sample value is individual and represents the output voltage of the photometer on the
actual sample.
The zero value represents the HGB blank voltage.
The digits printed bewteen ( ) signs, repesent the variance of the values. As the lamp,offset and
sample voltages are measured several times; a variance is calculated on this data.
A (0) (zero) represent a perfect stable parameter.
Any value up to (10) an be tolerated as having an acceptable stability. Values higher than (10)
indicates an instable measuring cycle. In case of variances higher than (10) printed on sample
or zero, a bad mixing or airbubbles might be expected or a too low sample / blank level in the
WBC/HGB cup.
A high variance value on one of these measured voltages means in other words an instability
and will trigger the SE flag on the HGB parameter.
Note that the 'offset' must always be (0) or not more than (5). If excessive noise from an
external power source should occur, the variance on the offset will be greatly influenced
as well as background on the PLT ( and/or RBC-WBC ) parameter.
Note:
To calculate the extinction of a sample proceed as follows :
Subtract the OFFSET value from both the SAMPLE and the ZERO value.
Calculate than the extinction by : EXT = LOG ( ZERO / SAMPLE ). The HGB factor is ca.
45 ( if HGB is in g/dl ) . In that case the HGB should be close to : HGB = EXT. x 45
Note that this is approximated, any additional HGB calibration factor will not influence the
extinction value.
RDW correlation
The first value is the coarse calibration threshold as done in the service menu 2
( Appendix 1 in user manual)
threshold Bl is the threshold value inclusive the calibration factor for RDW for whole blood
threshold Pd is the threshold value inclusive the calibration factor for RDW for prediluted
samples.
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RBC and WBC ratemeter
For the calculation of the SE flagging, the CA570 performs a ratemeter analysis during each
count. The Sd is calculated for a group of values, if outside a reasonable limit, the SE flag is
set. Note that the values should vary but not drop or rise suddenly. This might indicate an
instrument (valve 29) failure.
Cellcounter status
L0
Program information , no user info
V5.95 The actual time, in seconds, to create the correct vacuum. Note that this is an
instrument constant but might vary due to local circumstances. It also might vary from sample
to sample.
D0
Diff. status D0 means WBC diff. switched off , D- no diff performed, D2 2 part diff
and D3 means that a successful 3 part diff. is available.
F503F Internal flags, no user information
I0
Internal error codes, no user information
In case this error-code is not zero. Fax this 'status' printout immediately to Medonic
E0
Error codes ( see chapter 'errors')
OT
Sample inlet status . OT = opentube,CT=closed tube,PD=predilute,SA= sampler
Diluter status
L0
Programinfo, no user information
-
No blood detected . ( * means : blood detected)
*
Vacuum level is OK . A dash -- means that the vacuum could not reach the desired
level
X3.65 Transfer time of the first dilution of the sample from the diluter to the analyser
( seconds) See section 1 for detailed explanation.
F0
Fatal error ( see chapter 'errors' )
E0
Non fatal errors (see chapter 'errors')
B0
Bottle status ( 0 means all bottles full, all other values, bottle(s) empty)
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4.2
COUNT ONLY
Within the SERVICE-MENU a routine is available that allows the CA570 to simulate a semiautomatic analyser for test purposes. The sample has to be prepared manually and entered into
the 2 counting cups B4 and B5 ( RBC and WBC ). This allows the service technician to check
the analysing part separate from the diluting part.
Proceed as follows to use the 'COUNT-ONLY' sequence :
1.
Locate the 4 push buttons on the diluter front Switch A is used to empty the counting cups B4
and B5. Push switch A to empty both cups.
figure 29
Locating push-button A
2.
Prepare the RBC dilution 1:40.000 and the lysed WBC dilution 1:400 externally. Minimum 6
ml of volume.
For WBC e.g. 20 ul into 8 ml diluent + a few drops lyser ( concentrated type)
For RBC e.g. 100 ul from the WBC dilution ( before it is lysed) into 10ml diluent.
3.
Remove to two lids from the RBC and WBC ( B4 and B5 ) counting cups and pour both
dilution's in the proper cups.
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4.
Activate the 'COUNT-ONLY' program from the service menu.
The CA570 will now perform a count of all parameters except the HGB parameters as there is
no blank reference available during this routine. Results can be printed out as well as a second
'COUNT-ONLY' can be done from the same sample to check the reproducibility.
As the sample is not washed out after the count is finished, several 'COUNT-ONLY'
analysis can be done on the same sample.
Note: Run at least one blank-sample before returning to routine operation.
4.3
PHOTOMETER ADJUSTMENT
Within the service menu a 'PHOTOMETER ADJUSTMENT' menu is found. This is used to
test and/or adjust the photometer system.
To understand the function of the HGB photometer please refer to the figure below :
figure 30
Electronical lay-out HGB photometer system.
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Physical lay-out WBC/HGB cup
The photometer system consists of a tungsten lamp /cuvette / 540nm filter and photocell.
Whenever the 'PHOTOMETER ADJUSTMENT' menu is entered, the lamp is switched on to
its nominal value. The current lamp-voltage and the output voltage from the photometer are
displayed.
As the photometer needs a correct working range, the lamp intensity should be within a certain
limit.
Within this menu the lamp voltage can be changed with the ↓ and ↑ keys. The output voltage
will follow the lamp voltage in the same direction, however not in a linear way of course.
As the lamp is only switched on if a sample is processed, the uP needs to know which lamp
voltage should be provided to the lamp to obtain a correct light intensity within the working
range of the photometer.
This setting can be done automatically. Proceed as follows :
1. Be sure that the lamp is OK and that the photometer cuvette ( = the WBC cup ) is clean
2. Enter the PHOTOMETER ADJUSTMENT menu and press digit 1 on the keyboard.
The following auto-procedure is done :
a. The lamp is switched off and the offset is measured and stored.
b. A blank solution ( lyser) is flushed from the diluting part into the cuvette ( = WBC cup )
c. The lamp voltage will slowly rise and stop when the output voltage reaches ca. 4 Volt
d. The actual lamp-voltage will be stored and used during each sample.
e. The storage is confirmed with a short beep
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Whenever the lamp is changed or any form of service is done on the cuvette, e.g. cleaning or
replacing components; the above procedure should be carried out.
On the analyser CPU board a trimpotentiometer is found marked PHOTOM. GAIN. This is the
gain setting of the photocell amplifier and should normally not be changed. However in case of
replacing the complete cuvette ( = WBC cup, B5) , the following should be checked before the
above auto-adjustment is performed.
a. Be sure that the cuvette ( = WBC cup ) is absolutely clean on the inside. Clean if necessary
with hypo chlorite or any other protein remover . ( NO alcohol!). Use switch A on the diluter
front to empty the cup. And fill finally the WBC cup (B5) with clean diluent.
b. Be sure that the lamp is OK in any respect. Remove the lamp and check that the bulb is clear
and not dirty or grey/black.
c. Enter the PHOTOMETER ADJUSTMENT menu and use the ↓ and/or ↑ keys to put the
LAMP-voltage at 4.3 volt.
d. Turn the trimpotentiometer PHOTOM. GAIN so that the photometer-output voltage is 4
Volt.
(This is not critical , tolerances are +/- 0.5 volt )
e. Now perform the auto-adjustment procedure by pressing digit 1 on the keyboard
The actual values of the offset/lamp voltage and photometer-output voltage are given on a
printout of the 'PRINT SAMPLE STATUS' menu, see section 4.1 .
The printed ZERO value corresponds to the photometer output voltage whenever the blank is
measured and should always be within 3.5 to 4.2 volts.
4.4
START / STOP DETECTOR ADJUSTMENT
One of the most essential points in the analyser section are the start and stop indicators located
on the metering unit glass-tube.
These detectors should detect differences between air and liquid ( diluent ). If , by some reason,
these detectors should not work correctly, several error numbers might occur.
The figure below describes the physical lay-out of a start or stop detector.
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figure 31
Start/stop detector
The IR-LED is ONLY switched on if a sample is processed. To check the start/stop functions
however, use the menu 'SHOW INPUT SIGNALS' (which switches on the LED's) as found in
the service-menu and connect a syringe filled with dist.water as in the figure below.
N.B. The display 'SHOW INPUT SIGNALS' will also display the current status of the 2
detectors.
figure 32
Connection to glass tube
Be sure that the glass tube is open at the upper end so that the dist. water can be moved up and
downwards in the glass tube.
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---------------------------------------------------------------------------------------------------------------------Proceed as follows :
1. Empty the glass tube and observe the LED lamps on the analyser CPU board, see figure
below
2. LE4 (STOP) and LE6 (START) should lit
3. Fill the glass tube with dist.water and observe LE5 and LE7, they should both lit.
Under no circumstances both LED's LE4/LE5 and/or LE6/LE7 should be off.
To adjust the STOP detector :Fill the glass tube with dist.water and adjust RV4 in such a
way that LE5 is just between ON/OFF and than turn 'RV4 just about a 1/4 to 1/2 turn towards
the ON position. ( LE4 should be off)
Empty the tube and check that LE4 is on and LE5 off.
To adjust the START detector :Fill the glass tube with dist.water and adjust RV5 in such a
way that LE7 is just between ON/OFF and than turn 'RV5 just about a 1/4 to 1/2 turn towards
the ON position. ( LE6 should be off)
Empty the tube and check that LE6 is on and LE7 off.
figure 32
START/STOP LED lay-out CPU board
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CALIBRATE PRESSURE
The analyser section has a built-in vacuum bottle which is used during the counting procedure
to aspirate the diluted sample through the orifice. The vacuum bottle is pressurised by opening
valve 19 and the waste-pump P5 switched on. The vacuum in the bottle B6 is sensed by the
electronic pressure transducer PT and processed by the analyser CPU.
As the pressure transducer has to be calibrated concerning its offset and gain settings, these
factors are stored in the memory chip U19 on the analyser CPU board.
This calibration is done at the factory and there is no reason that an additional
calibration should ever be necessary, except if :
1. The CPU board is changed
2. The pressure transducer (PT) is changed
If the CPU board is changed for whatever reason and the pressure transducer calibration should
be avoided, remove the memory chip U19 from the 'old' CPU board and put it in the same
position in the 'new' CPU board. This procedure will in most cases avoid the calibration
procedure as described below.
To calibrate the pressure transducer to the current analyser CPU board, proceed as follows :
1. A high precision manometer is needed ( analogue or , preferably, digital) which handles a
vacuum up to (minimum) -500 mBar (- 500 hPa)
( the manometer should have a maximum tolerance at -150mBar of +/- 5 mBar)
2. Connect the manometer (-P) as shown in figure 34 below. ( parallel to the bottle B6)
3. Enter the menu ' CALIBR. PRESSURE' as found in the service menu.
The system will first release all vacuum from the bottle during ca. 10 seconds.
Than the actual pressure is displayed which is, on a calibrated transducer, close to zero.
4. Use the ↑ and ↓ keys to select the units that corresponds to the reference manometer scale. (
usually mBar)
5. Use the → key to increase the vacuum, read on the reference manometer, to ca. 150 mBar . (
use the ← key to decrease) and wait until the pressure is stable after a few seconds.
6. Read the vacuum at the reference manometer and key in this value at the chosen units
position and press <ENTER>.
7. A next menu will ask you to enter a code. Enter 910624 <ENTER> to confirm the
calibration. or press MENU to cancel the calibration.
After the above procedure is done the calibration factors are automatically stored in U19 on
the analyser CPU board.
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Be sure that the above procedure is done correctly ! Any significant error in the
reference manometer will put the CA570 out of order !
figure 34
Calibration of pressure transducer PT
4.6
SCREEN-DUMP
Within the 'service menu2' a routine is found 'SCREEN DUMP' . This is only used if by some
reason ( education/translation) the actual screen display has to be printed just as it is shown at
the LCD display.
If ON, use the normal PRINT button to print the screen image to the selected printer.
If SCREEN_DUMP is on, no data can be transmitted to the serial output.
Note : In all cases during normal operation of the CA570; SCREEN-DUMP should be
OFF !
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4.7
SHOW INPUT SIGNALS
Within the service menu, a sub menu is found 'SHOW INPUT SIGNALS'. This menu is used
whenever the START/STOP detectors has to be checked or adjusted. See section 4.4 for
detailed information.
As this menu shows the input signals in 'real-time' , which means that the shown parameters are
continuously updated, it can also be used to check other in-signals like :
1. Each individual bottle ( Diluent-I, Detergent, Haemolyser)
2. Ready/Busy from the serial and printer ports.
3. The photometer output voltage with the lamp OFF. ( = offset)
4. The current output voltage from the pressure transducer (which will vary dependent on the
previous position of the CA570)
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5
ERROR MESSAGES
The CA570 has an advanced error handling system, which is based on time-out situations either
in the diluting or in the analyser part of the system.
An error situation is ( in most cases ) defined as being a time-out error. As soon as a certain
action is started by the software, the time needed to perform this action is measured and
compared to the minimum and maximum allowed limits. If these limits are violated, an error
message number is displayed.
As a general rule : error numbers less than 800 are generated by the analyser CPU system.
Error numbers between 800 and 900 are generated by the diluter CPU and error numbers
over 900 are related to the auto sampler 210.
In case of a diluter error situation, the diluting part is stopped and put into a save
position with the READY and ASP lamps blinking. The internal display on the diluter
CPU board will display the error number until switch C is pressed.
The only way to enable the diluting part is to reset the diluter by pressing switch C on the
diluter front panel.
See figure below :
figure 35
Locating the diluter reset switch C
Any error number generated by the analyser or diluter part will be displayed as a number on the
LCD. Press the key <MENU> to cancel the error code. In case the error number is related to
the diluting part; the reset switch C has to be pressed as well, to put the CA570 back into an
operational mode.
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5.1
ERROR NUMBERS / ANALYSING UNIT
Note : Please check also the Appendix in this manual for any additional Error codes !
ERROR 10
If the battery backuped RAM contents AND the EEPROM contents were corrupt; this error
number will be displayed. All instrument settings like calibration factors, pressure transducer
calibration, language etc.. are set to factory settings.
The instrument MUST be fully calibrated including the pressure transducer ( see section 4.5).
ERROR 11
The contents of the memory chip U19 are copied into the battery backed-up RAM.
The RAM data was destroyed but 'repaired' by the EEPROM data. This error occurs if the
battery was disconnected.
Note that only the instrument settings were 'repaired', the sample memory data is lost but the
CA570 will be fully operational with all calibration constants intact.
ERROR 12
This error is related to the EEPROM U19 on the analyser CPU board. The EEPROM is
missing or faulty. This is only tested at a power-on of the CA570.
The EEPROM must be replaced. After the CA570 is powered on again, the calibration values
will be automatically restored into the EEPROM.
ERROR 13
The EEPROM U19 doesn't respond in a correct way during normal operation of the CA570. It
might be missing or faulty. The EEPROM must be replaced. After the CA570 is powered on
again, the calibration values will be automatically restored into the EEPROM.
ERROR 20
This error is related to a time-out situation when the vacuum is created in the bottle B6. The
time to create the vacuum to the desired level is too long. This error is typical during an
installation of the CA570. The waste-pump might have been dry and the capacity therefore too
low. Ignore this error by pressing MENU and continue the installation procedure.
If the CA570 has been in use for a longer time; this error might be caused by :
1. Bad capacity of the waste-pump ( change the membrane in the pump )
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---------------------------------------------------------------------------------------------------------------------2. Leakage in the connections to bottle B6. ( This can be checked within the menu 'CALIBR.
PRESSURE' )
3. Valve 19 is not working correct or the tube in the valve is sticking.
ERROR 21
The error 21 is generated by a time-out situation. The analyser is unable to shunt the vacuum
down to the desired level. This error can only be caused by a faulty valve/sticking-tube 26, 25
or a blockage in the air-restrictor R2.
ERROR 22
The analyser is unable to neutralise the vacuum in the bottle B6 down to a zero level. This can
only be caused by a faulty valve/sticking-tube 26, 25 or a blockage in the air-restrictor R2.
ERROR 30
This error is related to the metering unit ( glass-tube). The liquid is moving from the STOP to
the START detector but doesn't arrive within 3 seconds. Check for blockages in tubes or faulty
valves. ( e.g. 25, 26,30 and 31 )
ERROR 31
The upper detector (STOP) in the metering unit detects liquid AFTER that the column was
moved to the START detector. This might be caused by large air/liquid bubbles, e.g. during
installation. Perform the RINSE ORIFICE, FILL command from the main menu.
ERROR 32
The liquid in the metering unit doesn't arrive at the START detector (upwards) after the
maximum specified time. This might occur during the installation procedure. In that case ignore
this message. Otherwise look for a blockage around valve 26.
ERROR 33
The liquid in the metering unit doesn't arrive at the STOP detector (upwards) after the
maximum specified time. This might occur during the installation procedure. In that case ignore
this message. Otherwise look for a blockage around valve 26.
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ERROR 34
This error is related to the START detector. Bubbles were detected during the rise of the
column. Ignore this message by pressing ENTER during the installation of the CA570.
Otherwise a ' RINSE ORIFICE, FILL' should cancel this message.
This error number can only be displayed after a 'prime' cycle. During normal operation
of the CA570, this errornumber is replaced by a ‘Tb’ warning in the RBC or WBC
parameter field.
ERROR 80, 81, 82
This error number is related to the communication between the analyser CPU and the diluter
CPU. It might occur if the diluter was reset ( or fail ) during the analysing process.
This error might be caused by a ‘noisy’ power supply (+5V) in the diluter section ( PCB 5819073) or by a bad collector within the flush-pump that radiates H.F. into the communication
cable between the diluting - and the analyser part. Be sure that the connection wires of the
flush-pump are mounted through the ferrite-bread and that the communication cable from the
diluter to the analyser is not wrapped into the power cable of the flush-pump.
ERROR 90
This error occurs if the auto-sampler is operated with 2 consecutive blanks, showing the
message ' NO SAMPLE DETECTED' and the CA570 went into the standby-mode. After the
MENU button is pressed to exit the standby mode; this error number will be displayed. Cancel
by pressing MENU once more.
ERROR 100
The error 100 is related to the printer output. If the printer was in a time-out situation showing
' PRINTER TIME-OUT' on the LCD screen and the CA570 went into the standby mode.
When the user presses MENU to exit the stand-by mode, this error number will be displayed.
Cancel by pressing MENU once more.
ERROR 101
The source of this error is that the printer buffer was not empty before the next print was
performed. (The printer is too slow.)
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ERROR 110
See error 100 above, however this error is related to the serial output.
ERROR 111
See error 101 above, however this error is related to the serial output.
ERROR 120
The error 120 is related to the battery backup memory. The memory checksum was corrupt
and the sample memory will be deleted. All instrument calibrations will remain.
This error might occur if a new program version is inserted ( Just ignore this error in that
case).
A bad battery might be the reason as well.
ERROR 130-139
Error numbers within this range are generated if Valve 18, 27, 28, 29B or 31 should not work
correctly during the selftest of the CA570 before the 4 hour cleaning cycle is started. Probably
one of the tubes is sticking in one of these valves. This test is a safety procedure that will cancel
the 4 hour cleaning cycle if one if the involved valves should not work.
This error might happen after an tube-exchange in one of these valves but ‘never’ in an
instrument that has been performing well over a longer period of time. The latter, indicates a
defect valve.
5.2
ERROR NUMBERS / DILUTING PART
Note : Any error number related to AC driver motors , e.g. turningvalve motor and syringe
motor ; might be caused by a missing -5 Volts supply from the diluter power supply board.
See section 9.1
ERROR 817
The checksum in the EEPROM chip IC6 on the diluter CPU board was corrupt.
The turning valve 1 MUST be recalibrated ( see section 3.4)
If the EEPROM is changed, this error occurs at the start-up. Press SW2 on the diluter CPU
board to cancel this error and re calibrate the turning valve V1.
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ERROR 818
The error 818 is related to the turning valve V1. The valve couldn't turn CCW within the
defined time frame.
The reason might be :
1. An electronical fault in the driving circuit
2. A mechanical blockage.
ERROR 819
See error 818 above but for the CW direction instead.
ERROR 827
The checksum in the EEPROM chip IC6 on the diluter CPU board was corrupt.
The turning valve 2 MUST be recalibrated ( see section 3.5)
If the EEPROM IC6 is changed, this error occurs at the start-up. Press SW2 on the diluter
CPU board to cancel this error and recalibrate the turning valve V2
ERROR 828
The error 828 is related to the turning valve V2. The valve couldn't turn CCW within the
defined time frame.
The reason might be :
1. An electronical fault in the driving circuit ( check -5 V power supply )
2. A mechanical blockage.
ERROR 829
See error 828 above but for the CW direction instead. ( check -5 V power supply )
ERROR 830
This error number is related to a time-out situation on the bottom microswitch in the syringe
drive system and can only occur at a power on. The source might be :
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---------------------------------------------------------------------------------------------------------------------1. Power supply ( -5V) failure
2. Mechanical blockage
3. Bottom microswitch failure
ERROR 831
This error number is related to switch pattern failure at the power on of the diluting part
syringe drive system and can only occur at a power on. The source might be :
1. Defect micro switch ( one or more of the 3 switches)
2. Cable from microswitches to the PCB not proper connected.
ERROR 832
This error number is related to a time-out situation (too short time ) on the bottom microswitch
in the syringe drive system. The source might be :
1. Power supply ( -5V) failure
2. Mechanical blockage
3. Bottom microswitch failure
ERROR 833
This error number is related to a time-out situation on the bottom microswitch in the syringe
drive system. The source might be :
1. Power supply ( -5V) failure
2. Mechanical blockage
3. Bottom microswitch failure
ERROR 834
This error number is related to a time-out situation (too short time) on the 'home microswitch
in the syringe drive system. The source might be :
1. Power supply ( -5V) failure
2. Mechanical blockage
3. 'Home' microswitch failure
ERROR 835
This error number is related to a time-out situation on the 'home microswitch in the syringe
drive system. The source might be :
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1. Power supply ( -5V) failure
2. Mechanical blockage
3. 'Home' microswitch failure
ERROR 836
This error number is related to a time-out situation (too short time) on the top microswitch in
the syringe drive system. The source might be :
1. Power supply ( -5V) failure
2. Mechanical blockage
3. Top microswitch failure
ERROR 837
This error number is related to a time-out situation on the top microswitch in the syringe drive
system. The source might be :
1. Power supply ( -5V) failure
2. Mechanical blockage
3. Top microswitch failure
ERROR 840
This error is related to the closed tube adapter. The UPPER switch (retracted position) is
activated too late.
Note : This error can only occur after a reset of the diluter system or after a power on.
The source might be :
1. Switch failure
2. Motor failure ( or driving circuitry)
3. Mechanical blockage
4. Power supply -5V failure
ERROR 841
This error is related to the closed tube adapter. The LOWER switch (penetrated position) is
activated too early.
The source might be:
1. The lower switch.
2. Power supply -5V failure
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ERROR 842
This error is related to the closed tube adapter. The LOWER switch (penetrated position) is
activated too late
The source might be :
1. The lower switch.
2. Mechanical blockage
3. Motor or driving circuit error
4. Power supply -5V failure
ERROR 843
This error is related to the closed tube adapter. The UPPER switch (retracted position) is
activated too early.
The source might be:
1. Upper micro switch
2. Power supply -5V failure
ERROR 844
This error is related to the closed tube adapter. The UPPER switch (retracted position) is
activated too late.
The source might be :
1. Switch failure
2. Motor failure ( or driving circuitry)
3. Mechanical blockage
4. Power supply -5V failure
ERROR 861
This error is caused by a too short sample transfer time.( see section 1.4 for detailed
explanation) The analyser will show ' NO DILUENT' and the diluter will show this error
number on the diluter CPU board 7 segment display.
Both the ASP and READY lamp will flash and the diluter must be reset with switch C at the
diluter front.
The reason for this error might be :
1. There was not enough diluent in the mixing cup B1 ( might happen during the installation)
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---------------------------------------------------------------------------------------------------------------------2. Attempt to run the CA570 on dist. water or tap water. ( as water is not detected by the
electrodes E1 and E2 in the mixing cup B1 )
ERROR 862
This error is caused by a too long sample transfer time.( see section 1.4 for detailed
explanation) The analyser will show : TOO LONG TRANSFER TIME' and the diluter will
show this error number on the diluter CPU board 7 segment display.
Both the ASP and READY lamp will flash and the diluter must be reset with switch C at the
diluter front.
The reason for this error might be :
1. No air pressure in the first dilution cup B1
2. Blockage in the coil C1 or any part connected to it
3. Blockage inside the centre-needle in the mixingcup B1.
( Note : this is the most common of these error possibilities) In this case, clean the
centre needle with a 0.8 mm wire.
4. Blockage in valve 15B
5. Shortage between the electrodes E1/E2 caused by liquid on top of the lid.
NOTE : If this error occurs, the mixing cup B1 MUST be removed and emptied
BEFORE the CA570 is put back into the operational mode.
ERROR 863
This error is caused by a too small sample volume in the prediluted inlet. Press MENU to
cancel this error.
This error 863 is also possible if one of the electrodes in the mixing cup is durty; an electrical
isolation occurs and a time-out situation will occur. Clean the electrodes !
The sample transfer time was less than 2 seconds, which is the minimum limit. See section 1.4
for detailed explanations.
NOTE: The diluter will continue it's operation after the MENU key is pressed. Switch C
(reset) should NOT be activated.
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ERROR 880
This error is related to the communication between the analyser and diluter CPU.
There was a breakdown in the communication protocol during an analysing cycle.
The reason might be :
1. A temporary reset of the diluter CPU
2. Power failure
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6
CHANGING/INSTALLING PARTS , PC-BOARDS etc.
Changing components in the CA570 is in most cases obvious and doesn't need additional
information. This section gives hints on critical parts so that any service can be done without
introducing secondary errors in the system. Special attention should be given to the section
CHANGING PC BOARDS and any service around the turning valve systems.
6.1
CHANGING DILUTER PC-BOARDS
The only boards that need special attention, in the diluter unit, are the POWER SUPPLY board
and the CPU board.
To change the diluter power supply board in the CA570, please note the following :
1. ONLY versions 300-907-3 and higher can be used
No additional trimming is further necessary
To change the diluter CPU board in the CA570, please note the following :
1. Remove the EEPROM memory chip IC6 from the 'old' board and put this circuit in the same
position in the 'new' board.
By doing this, all turning valve ( V1 AND V2) calibrations are NOT necessary.
If this circuit is not exchanged, you MUST recalibrate the turning valves as described in section
3.4 and 3.5)
2. Perform the blood detector adjustment as described in section 3.6
This must always be done, regardless of exchanging IC6 on the CPU board.
3. Check that trimpotentiometer P4 is turned fully clockwise.
4. Check that jumper J3 is in position 1-2 ( external reset enabled)
5. Check that jumper J2 is in the 32 K position ( 1-2)
No other adjustments are necessary
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6.2
CHANGING ANALYSER PC-BOARDS
In the analyser part, 3 PC boards are found :
1. The CPU board
2. Valve board
3. Display PC board
Attention should be paid whenever changing the CPU board.
As the CPU board is calibrated to the pressure transducer as well as the start and stop detectors
and HGB, a direct replacement of the CPU board implements automatically a recalibration of
these connected 'transducers' . The pressure transducer calibration can be avoided by
exchanging the EEPROM memory chip U 19.
Proceed as follows whenever changing the analyser CPU board:
1. Remove U19 from the 'old' board and put this IC in the same position on the 'new' board
2. Perform the START/STOP adjustment procedure as described in section 4.4
3. Perform the HGB lamp/photocell adjustment as described in section 4.3
4. Recalibrate the MCV/MPV/RDW and HGB with a bloodcontrol
Note : If U19 is not exchanged, the pressure transducer calibration as described in section
4.5 must be performed.
6.3
CHANGING PARTS / TURNING VALVES
Parts within the turning valve system are critical. This is the most sensitive part of the CA570
and all parts within the turning valve compartment should be handled with care. For the internal
lay-out, please refer to the attached drawing 570-4035 & 570-4034.
The surfaces of part number 27 and 32 are critical. Avoid scratching or any other damages on
the surfaces of these parts.
Part number 101 (housing) can be removed by just pull this item backwards, it is NOT fitted to
the chassis but just guided over the 3 pins.
If the turning valve is not filled with detergent ( see section 3.8), a leakage might be
expected at the axis O-rings with partnumber 37 (drawing 570-4035)
These O-rings can be exchanged by dismantling the turning valve and by removing part 101.
In diluter (CA570) versions with serial number higher than 2000, this part is replaced by
1 sealing ring. marked 104 in drawing 570-4034.
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---------------------------------------------------------------------------------------------------------------------Note that part 99 should be well fitted into the 2 guiding pins 98 on both sides of the turning
valve 32.
When the turning valve is assembled, inspect that the surfaces of parts 27 and 32 are clean and
not damaged.
6.4
CHANGING THE SYRINGE/PISTON
The syringes in the diluting part do not need regular service. However in case the piston has to
be changed, observe the following :
The piston itself is on top of the cylinder/piston guiding and the easiest way of dismantling the
cylinder/piston is as follows :
See figure below:
1. Remove the Tygon tube on top of the cylinder, use a knife to cut the Tygon instead of trying
to pull it from the cylinder ( you might crack the glass !)
2. Remove the 2 screws A/B
3. Pull the cylinder upwards
4. Replace the piston by removing the PISTON_ADJUSTMENT screw.
5. Tighten the piston-adjustment screw in such a way that the cylinder goes smoothly over the
piston.
If the piston adjustment screw is tightened too strong, the system will not work correctly
with heavy variations on all counted parameters. The piston should be in the TOP or
BOTTOM position BEFORE the corresponding microswitch ( TOP & BOTTOM) is
activated.
After the piston is replaced this point MUST be checked.
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figure 36
Physical lay-out syringes S1/S2
The 2 stop rings should NOT be removed or adjusted.
6.5
CHANGING VALVES & TUBES
The valves used in the CA570 are silicon-tube pinch valves. Two different types are used, 1
way normally closed and 2 way valves. The tube used in these valves has narrow tolerances (
0.1mm) and has 1.5mm inside and 3.0 outside diameters. These silicon tubes must always be
original from Medonic, no other suppliers are allowed to assure trouble free operation of the
system.
Note that the normally closed section of the valve will clamp the silicon tube in such a way that
if the CA570 is removed from the mains-power supply during a longer period of time ( > 2
days); it will stick and has to be opened by hand BEFORE the system is powered on again.
The valves are divided into a mechanical and an electrical part. It can be separated into 2 parts
by removing the CLIP ( see drawing below ).
After the 2 screws are removed, the mechanical part can than be moved forward .
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---------------------------------------------------------------------------------------------------------------------Care must be taken that the valves are absolutely free from salt crystal traces as they can effect
the correct operation of the plunger.
In the ( 2-way) valve below, position A is normally open and position B normally closed.
Also note that, whenever changing/checking a tube, the tube must be put back perfectly in
place.
The coil has a different power rating for a 2-way and a single valve !
The mechanical part of a valve can be replaced separately from the coil, they don't have to be
matched to each other. This means that usually only the mechanical part has to be replaced in
case of a valve failure avoiding unnecessary soldering on PC boards..
figure 37
Physical lay-out of a 2-way valve
6.6
CHANGING THE ORIFICE TRANSDUCER
The orifice transducer T1 ( see section 2.2 figure 7 and the attached drawing 570-4036
).consists of 2 parts (chambers). marked 54 and 56 in drawing 570-4036 The orifice is mounted
in chamber 56.. The connection 'tubes' A-C to both chambers are made from platinum and act
as electrodes at the same time. As all liquid should travel ( between the chambers ) through the
orifice, it is of great importance that both compartments are completely separated from each
other, no leakage is allowed in any form. The sealing marked 55 in drawing 570-4036. should
also be in perfect condition to prevent leakage out of the chamber. Also from an electrical point
of view ( noise !) these 2 chambers should be well isolated from each other. Any form of
leakage around the chambers will introduce noise in the system that will be seen as a high PLT
background and/or dropping MCV values to the user.
Note that C and D are connected with a platinum wire and act as the 'hot' side of the transducer
( inside of the coaxial cable). The chamber 56 electrodes marked A-B are connected to the
ground shield of the coax-cable.
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6.7
CHANGING THE VIEWING ANGLE (LCD DISPLAY)
The LCD display has a certain range on the viewing angle. This angle can be adjusted in the
following way :
1. Remove the screws on the rear of the display unit that fits the metal shield ( stainless-steel).
( This is not necessary in instruments produced after 1993, a small hole is drilled in the shield
where the potentiometer can be reached easely)
2. On the PCB where the LCD is mounted a trimpotentiometer is found ( there is only one).
Use the setting of this trimpotm. to adjust the viewing angle.
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7
TUBING SYSTEM LAY-OUT
The attached drawing 570-3002 shows the principle diagram and drawing 570-3005 shows the
physical tube lay-out in the CA570.
The lengths/type and connectors are shown with legends. See section 7.1
Never cut tube lengths which might seem to be unnecessary long , they might be restrictors like
R1, R2 or R3 ( see section 1 and 2)
R1 is marked as 350PT2
R2 is marked as 55PT2
R3 is marked as 130T2
7.1
LEGENDS
Tubes are shown in the format AAA-B-C
Where :
AAA = Length in mm
B
= Tube material
C
= Size of tube (diameters)
A connection shown as a dash - means that 2 tubes are directly connected to each other
without any additional connector
A connection shown as = means that an additional connector is inserted between the
tubes
Tube legends :
S1
T1
T2
P1
PT1
PT2
PT3
PT4
Silicone ∅ 1.5/3.0 mm
Tygon ∅ 1/16" / 1/8" (inch) ( ∅ 1.6/3.2mm)
Tygon ∅ 0.8/2.4 mm
PVC ∅ 3/5 mm
PTFE (Teflon) ∅ 1.2/2.0 mm
PTFE (Teflon) ∅ 0.7/1.6 mm
PTFE (Teflon) ∅ 0.7/1.6 mm (same as PT2)
PTFE (Teflon) ∅ 1.6/3.2 mm
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Connector legends
T220
L20
Y220
AD
DD
DC
T connector 2.5mm Insidediam.
L connector 2.5mm Insidediam.
Y connector 2.5mm Insidediam.
Straight connector 1.5mm / 2.5mm insidediam.
Straight connector 2.5mm Insidediam.
Straight connector 2.5mm / 3.0mm insidediam.
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8
INSTALLING AUXILIARY DEVICES
This chapter will provide you with additional information concerning external devices
connected to the CA570
8.1
INSTALLING THE PRINTER AND SERIAL OUTPUT
Printer configurations ( see also Appendix 4 , program version 2.40 )
As long as the connected printer is of the DPU411 type, no additional settings are necessary.
Just select the DPU411 settings in the 'PRINT FORMAT´menu as found in the SETUP
MENU2.
An IBM compatible printer should be setup in a correct way.
The IBM comp. printer MUST have a speed that allows the printer to print a complete sample
WITH size distribution curves within 65 seconds. Violating this, will result in printer-output
error messages during the normal operating of the CA570.
Proceed as follows :
1. Check which paper format is used ( A4 , 11 or 12 inch are possible)
2. Set the dipswitch ( or software settings) in the printer to this format.
3. Select the PRINT FORMAT menu as found in the SETUP MENU 2 and select the
corresponding format.
4. If the printer protocol can be changed by means of dipswitch or software settings; choose
IBM format only. ( not EPSON or HP etc..)
In other words, the dipswitch/software protocol/paper format setting in the printer should be
the same as the setting in the CA570.
In case an IBM compatible printer is choosen without using tickets, please note :
The CA570 software ‘remembers’ the selected format during printing and always tries to use
the paperformat to its maximum. This means that whenever some samples are printed with and
other without curves, the software makes its own decision from which point to insert a
formfeed. As a result of this, the paperform must be synchronised to software.
To do this, perform some prints until the printer makes a formfeed. At this point manually
adjust the paper to the ‘top of form’ position. Please remember that to keep the paperform
synchronised to the software, the printer must always be switched on during operation.
Configuring the serial output
The serial output format/setup is described in the user manual. If any computer / network is
connected to the CA570; the following should be observed.
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---------------------------------------------------------------------------------------------------------------------In the SETUP MENU a submenu is found INSTRUMENT-CODE. This is used to give the
CA570 an unique identifier in case several CA570´s are connected to the computer network. (
called the instrument suffix) e.g. CA570-0 or CA570-1 etc..
The instrument suffix is only transmitted on the serial output, please refer to the user manual
for additional information. concerning the data-format
Before the receiving software on the host computer is developed; it is wise to dump a few
samples to a connected computer as a file to get familiar with the serial format even in case
patient and/or instrument abnormalities are included in the transmitted data.
On the hardware side of the serial output, please note the following :
The serial driver is a FULLY galvanic isolated RS232 driver. Groundloops etc. through the
CA570 are therefore not possible whenever an external computer is connected. Also the GND
output is only a RS232 ground and NOT an instrument ground connection. This will greatly
simplify the connected hardware configuration.
Don't use extreme baud-rate settings if they are not necessary. Usually 1200 Baud is enough
and this will not slow down the CA570 in any case due to the internal data buffering on the
RS232 output.
Note that the serial hardware driver on the RS232 is an option supplied by Medonic. All
software drivers are included in the standard software version. No additional software changes
are necessary to activate the serial output. After inserting the hardware driver ( which is an
additional IC , placed in a free socket U8) only the above described setup sequences are
necessary.
8.2
INSTALLING THE BAR-CODE PEN
The CA570 is , as standard, equipped with a bar-code input for the HP pentype HBCR-8300
and other equivalent types.
A sample label ID is automatically transfered to the ID field. Note that also alpha-numerical
signs can be read, however ( as the keyboard doesnot support these characters) some
limitations within the memory search menu will occur in programversions > 2.40 . Reading
alpha-numerical characters from an ID label should therefore be avoided.
This pen-type can be ordered from Medonic; in that case you must specify for which codes the
pen will be used for. Please note that Bar-Code pens are bought by Medonic from other
companies, therefore the type and specifications might change without notice.
Proceed as follows whenever you configure the HBCR-8300 yourself.
a. Order the user-manual for the HBCR-8300 ( book code-number : HBCR-8997 ) from HP.
b. In order to let the pen 'talk' to the CA570 proceed as follows:
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---------------------------------------------------------------------------------------------------------------------Connect the bar-code pen to the proper connector at the rear of the CA570. Press MENU to
enter the operational mode of the CA570 showing the parameter screen with the ID field in the
upper left corner.
Enter the bar code set-ups as below in the correct order. Read the proper code from the usermanual of the bar-code pen.
As the initial setup of the bar-code pen does not confirm an entry, it is important that
the setup is done in a correct way. Read each code only once in the order as shown
below.
The last entry (..... Miscellaneous ) will be confirmed with OK in the ID field.
After the below setup is done, the user codes can be entered as described in the HP manual.
During the user-code setup sequence, the ID field will show messages OK, CONTINUE or
SYNTAX-ERROR . This simplifies the final user setup of the bar-code pen.
Below follows the chapters in the correct order
CHAPTER
PAGE
Message buffers
B10/B25
1. CONFIGURATION MODE
a. ENTER
B10
2. MESSAGE BUFFERS
a. Header
B10
3. ....CHARACTER MENU
a. CR
b. End of characters
B25
4. MESSAGE BUFFERS
a. Trailer
B10
5. ....CHARACTER MENU
a. LF
b. End of Characters
B25
6. CONFIGURATION MODE
a. Exit
B10
Serial port
B11
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---------------------------------------------------------------------------------------------------------------------7. CONFIGURATION MODE
a. Enter
B11
8. BAUD RATE
B11
a. 1200 baud
9. PARITY
a. 0's
B11
10 CONFIGURATION MODE
B11
a. Exit
......Serial port
B12
11 CONFIGURATION MODE
a. Enter
B12
12. STOP BITS
a. 1 stop bit
B12
13.INTERCHARACTER DELAY
a. Disable
B12
14 CONFIGURATION MODE
a. Exit
B12
I/O pacing
B13
15 CONFIGURATION MODE
a. Enter
B13
16 SINGLE READ MODES
a Disable Single Read Modes
B13
17 DC1/DC3 PACING
a Disable
B13
18 OUTPUT BUFFER
a Enable
19 WAND INPUT BUFFER
a Disable
B13
B13
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20 CONFIGURATION MODE
a Exit
B13
Wand Emulation
B14
21 CONFIGURATION MODE
a Enter
B14
22 WAND EMULATION
B14
a Disable
23 CONFIGURATION MODE
a Exit
B14
Resets
B16
24 CONFIGURATION MODE
a Enter
B16
25 ROM,RAM SELF TEST
a Disable
B16
26 HARD RESET MESSAGE
a Disable
B16
27 CONFIGURATION MODE
a Exit
B16
Miscellaneous Options
B17
28 CONFIGURATION MODE
a Enter
B17
29 NO-READ RECOGNITION
a Disable
B17
30 CONFIGURATION MODE
a Exit
B17
....Miscellaneous Options
B18
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31 CONFIGURATION MODE
a Enter
B18
32 BAR CODE MENU SCAN RESPONSE
a Enable
B18
33 CONFIGURATION MODE
a Exit
B18
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9
DESCRIPTION ELECTRONICS ( DILUTER SECTION )
The diluter section of the CA570 analyser has several PC boards. Two main boards are found,
mounted on the rearside. The CPU board and , mounted as piggy back, the (switched) power
supply board that also is used to power the analyser section.
Another PCB board located at the front of the diluter section, with switches A to D as
described in section 3.1, has some additional logic for the positioning system of the turning
valves. All other boards are mainly valve-boards where no additional electronic components are
found.
Drawing number 581-4112 gives the drawing numbers related to the main (CPU) board PCB
300-901-x
9.1
POWER SUPPLY BOARD ( DRAWING 581-4113 / 4114 / 4115 -1 )
Drawing 581-4113-1
The power supply, mounted in the diluter section, is also used to power the analyser part.
The transformer in the CA570 has 2 secondary supplies, 24 and 26 Volts. The 24V is
connected to the ACV1 and ACV2 input ( drawing 581-4114-1), fused with F1 ( 4 Amps
Slow-burn) and the electronics are protected by a fast Transorb diode pair D14. A high power
spark on the mains (power-line) will put this diode into a short circuit mode, blow the fuse F1
and protect the main electronics. The 24V is rectified by D9/11/15 and D10 to a 32 Volt DC
level over capacitor C22. This voltage is used to switch and regulate it down to 5 Volt by the
switching regulator IC7 and L2. The output voltage at VCC is therefore 5 Volt. The 5Volt is
used by all logic circuits in the diluter AND analyser section.
IC2 is used to supply additional circuits with a +12V supply, the input voltage is reduced by a
zenerdiode Z1. The 12V is mainly used by the DC motor on the pipette cleaning circuit.
ACM1 / ACM2 is a 26V supply from the transformer used to drive the motors/pumps in the
system. This voltage is also used to supply power to the transformer on the analyser CPU
board ( see section 10 ). Fuse F2 is of a 6.3 Amp slow-burn type and the additional electronics
are protected against voltage/power sparks by the fast Transorb diode D8.
This voltage is also used to supply the triacs motor/pump switches with a -5Volt supply derived
from the rectifier D18 and the 2 stabilisers IC6 and IC3.
Two input zenerdiodes are used to reduce the input voltage on the first stabiliser IC6 to ca. 20
Volt. IC6 is a -12V stabiliser connected to IC3 which has an output voltage of - 5Volt at
ACDC ( in respect to ACM2)
Note that if this voltage (-5V) should fail, the CA570 will immediately show error codes
related to time-out situations from any of the motors driving the syringe or turning
valves.
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Drawing 581-4115-1
The voltage to the tube valves is derived from the above described 24V ACV1 /ACV2 supply.
A switched power supply is used to stabilise this voltage to 22Volt. The output voltage is
measured at point VV. Note that the output voltage can be switched between 22V and 28 Volt
by means of T3 which switches the feedback/amplification factor. The hardware jumper J1 can
be used to put either the VV output voltage at 22 or 28 Volts. This jumper is only for
production test purposes. It should always be in position 3-4 !
This position enables the diluter uP to switch the VV voltage between 22 and 28 Volts. Each
time a valve is activated ( closed ) the line HI/LO is put at a high level for ca. 200 msec. This
will 'pop' VV to 28 Volts ( 27 volt over the actual valve ) during this time period, securing a
correct valve operation.
IC4 is a current sense circuit. This circuit is used to sense the current through a valve coil. The
output is connected to 4 comparators driving 2 LED's. In the diluter test program 'F' as
described in section 3.9 the valves are tested on their mechanical behaviour. With the 2 LED's
also the current can be checked. A double valve has about twice the current of a single valve
which switches T4 and LED D12 will be on.
For a single valve, T5 is switched, putting LED D13 in an ON state.
The trimpotentiometer P1 is used to cancel any offset in the amplifier IC4; to set this
trimpotentiometer proceed as follows :
1. Connect a mV ( milliVolt) meter at testpoint NULL positive side and 'ground' to GND as
found in the lay-out of the PC-board 300-907-3
2. Turn trimpotm. P1 so that a voltage of 10 mV (positive) is found at testpoint NULL
( no valve should be ON during this OFFSET adjustment)
PCB lay-out 300-907-3
Reference point
Testpoint
Value
Tolerances
Used by
GND
GND
P5V
P24V
5.2 Volt
32 Volt
+ 0.2 / - 0.1
+3 /- 1V
GND
VV
22V
+1 V/-1V
GND
P12V
12V
+/- 0.7V
ACR
ACR
ACDC
ACAC
-5V∗
26V AC
+0.5/-0.3V
+/- 1.5 V
Logic /diluter/analyser
5V/12V and valve
supply (raw)
Valve supply voltage
(pops to 28V during
valve switching)
Powersupply/pipette
cleaning circuit
Motor drivers
Motor voltage
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---------------------------------------------------------------------------------------------------------------------* (this voltage must be measured with load, e.g. push switch A at the diluter front to start the
drain pump )
9.2
CPU uP DILUTER ( DRAWING 581-3008 )
On the diluter CPU board all main electronics are found that controls the complete diluting
system. The CPU board is controlled by a V25 uP and the software is in one chip IC8. Note
that there are 2 versions for 50 or 60 Hz operation of the CA570 !
The CPU uP system has a 32 K RAM circuit IC5 as working memory.
Jumper J2 must always be in position 1-2 to enable the uP memory.( marked as '32K')
A watch-dog circuit IC11 resets the uP during a power on in a correct way or whenever switch
C is pressed on the front of the diluter. Note that jumper J3 must be in position 1-2 to enable
this function.
IC6 ( EEPROM) contains the turning valve calibration factors and IC4 (GAL) is the memory
address decoding circuit.
The following test points are found on the CPU board :
Use the GND on the power supply board (300-907-3) as reference and use the BLOOD
DETECTOR adjustment testprocedure as described in section 3.6 to measure testpoints TP1
to TP4.
Testpoint
Value
Tolerances
Used by
RST
TP1
+5V
0-4V
+/- 0.3V
TP2
pulsed
TP3
0-4V
TP4
0-4V
Reset CPU
Photocell voltage from DAV (after
turning valve) blood detector.
Mixing cup electrodes/liquid
detector.
Photocell voltage from DCT (closed
tubes) blood detector.
Photocell voltage from DOT (open
tubes) blood detector.
The testpoints TP1/3 and 4 are actually the output voltages of the phototransistors that act as
the blood-detectors. The inputs of the V25 uP, at these points, are ANALOGUE inputs and the
uP acts here as a simple A/D converter.
Note that the gain settings of the blood-detectors are fixed with resistors RN11. The sensitivity
of the blood detector circuit is only adjusted with the current through the corresponding LED's
by P1 to P3 as found in drawing 581-4105.
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9.3
AC-MOTOR DRIVERS ( DRAWING 581-3009 )
The following motors are of an AC type in the diluter section of the CA570 :
1. Waste pump , 24V 3-4 Amp
2. Air-pump, 24V 0.5 Amp
3. Turning valve motors , 24V max. 0.5 Amp.
4. Syringe driving motor, 24 V max. 0.5 Amp
These motors are all controlled by triacs and opto-coupled devices to protect the main
electronics in case of a triac failure. Note that IC38 and IC39, which are the triac drivers, are
connected to the -5V (minus 5 V) in the power supply ( 300-907-3 PCB). If this voltage should
fail, NO motor can be operated; resulting in ERROR codes all related to an AC motor time-out
situation.
a. Turning valve 1 is controlled by Z5 and Z4
b. Turning valve 2 is controlled by Z3 and Z2
c. Air-pump, controlled by Z10
d. Waste pump, controlled by Z1 which is mounted on a heathsink H1.
e. Syringe motor, controlled by Z9 and Z8
9.4
DC-MOTOR DRIVERS ( DRAWING 581-4106 )
In the dilutersection of the CA570, there are 2 DC-motors.
1. Flush pump, operating at ca. 15 V 0.5 -1 Amp max.
2. Washing device motor , current controlled/limited.
The flush pump, which is used only for cleaning purposes during the dilution process, is
switched by a power FET T2. The voltage over the pump is adjusted with P4. This
trimpotentiometer should always be turned fully CW ( clock-wise) to put the flush-pump on a
15 Volt level. In most cases; increasing the voltage over the flush-pump, will not give the pump
a higher capacity. This is due to the fact that if the flush pump looses it's capacity, it is caused
by an internal leaking of the membrane and not the actual speed of the motor.
As this is a DC- motor, observe the + (red) and minus (-) indication on the board and motor
whenever changing this pump.
The washing device motor is current controlled by IC2. The motor can be turned in both
directions and with different currents as well; which enables the system to have different forces
on the washing device dependent on the current level.
Note that the washing device itself is NOT fixed to the motor axis, but mounted by means of a
friction coupling.
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9.5
VALVE DRIVERS ( DRAWING 581-4104 )
The valves in the diluting system are switched by IC19,20 and IC21. These circuit are powerdriver circuits. The latched input signals are derived from IC26-IC28. Note that the valves are
switched to GND (VV ground) level, which means that all valves has a VV ( 22V) voltage on
both ends of the valve coil in respect to the chassis of the diluting system even if all valves are
in a OFF position.
9.6
DETECTOR/INDICATOR OUTPUTS ( DRAWING 581-4105 )
The front panel indicators as well as the beeper are controlled by IC31. The LED's at the blood
detectors are only switched on if a sample is processed or if the diluter special function switch
(SW1) is put in position D and SW2 is pressed to activate the blood detector adjustment/test.
(section 3.6 ) The LED's are switched by T4 , marked LOLED which is the common cathode
of all blood detector LED's.
9.7
INPUT SIGNALS ( DRAWING 581-4107 )
The uP is sensing several inputs. In the CA570 diluter system only 3 mechanical switches are
used all found on the syringe unit. A top, bottom and home position. These switch inputs are
found at IC 16 which is an input latch circuit. In case a closed tube adapter is used, a
startswitch, top and bottom switches of this device are added ( SWVAHI & SWVALO).
Further, 2 inputs are used for the turning valve system to sense when the turning valve arrives
at the correct position. ( See drawing 581-4116 and section 3.3 & 9.10 for detailed explanation
)
All other inputs are not used.
9.8
BOTTLE DETECTORS ( DRAWING 581-4108 )
The external bottles, connected to the diluting system, are sensed for low level by a
synchronous detector circuit. A square wave is supplied to the liquids by means of a common
electrode found on the INSIDE of the diluter. The square wave is derived from IC17. (
0/5Volt)
The return voltage is measured by the return wires from the bottles and measured by means of
the analogue switches IC24 and capacitor pairs. The switches are controlled by IC17 ( and
software ) at the same frequency and phase as the common supply frequency. Therefore, the
capacitors pairs ( e.g. C25/24) are charged to the correct return level on both the 5V and 0V
portion of the square wave. Which makes the bottle detector system independent on possible
hum(50/60Hz) or external noise.
The leakage in the capacitor pairs should be low however to prevent unwanted unbalance in the
detector system.
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---------------------------------------------------------------------------------------------------------------------The capacitor pair voltages are connected to a precision comparator IC 12 and IC18 used to
switch the level indicators to the uP. The uP software controls the level indicator at the front
panel; this indicator is not directly switched by the bottle sensors itself.
9.9
COMMUNICATION ( DRAWING 581-4109 )
The communication between the 2 uP in the CA570 takes place via an opto coupled serial data
line. On connector K6 in this drawing ONLY the lines marked CTS / RXD / RTS / TXD are
used by the system. All other lines are not used. Jumper J4 is always in position 1-2 which
enables the serial communication. Note that J4 is on current PCB's replaced by a fixed strap. If
the communication between the 2 CPU systems should fail; the diluter uP will put itself in a
STANDBY state, the STBY LED will be lit on the front panel and the 4 hour cleaning cycles
will be performed anyhow.
9.10
TURNING VALVE POSITIONING SYSTEM ( DRAWING 581-4116 )
The basic detection circuit for the electronical positioning system is located at PCB 300-910-x .
Please refer to section 3.3 for the basic explanation of this system.
The PCB board is located at the front of the diluter section, switches A-D as shown in section
3.1 are also mounted on this board.
IC1 and IC2 are 2 serial-data to analogue converters and are loaded from the CPU uP with
data retrieved from the positioning memory chip IC6 on the CPU board. A current to voltage
converter is formed by IC3. The output of IC3 is connected to the comparator IC4.
The sensor potentiometers are connected to IC4 as well, which is comparing the sensor
potentiometer voltage with the voltage supplied by the serial D/A. A balance between these
voltages is detected at the output pins 4 and 15 of IC4.
The 2 LED's D1-A and D1-B are indicating the trig-point of the comparator and are connected
at the same point as the input to the main CPU -uP.
Note that whenever the turning valves are in a correct position ( the turning-valve driving
motor is off ), these LED's can be in any state e.g. ON, flashing or OFF.
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10
DESCRIPTION ELECTRONICS (ANALYSER SECTION)
In this section a brief explanation is given for the electronics in the analyser section of the
CA570 .In the analyser section there are 3 PC boards. One main board ( CPU ), a display PCB
and a connector board for the valves.
The CPU board is described below in certain sections as it consists of a power supply, CPU
and analogue circuits on the same board.
10.1
POWER SUPPLY CPU BOARD (DRAWING 570-860A)
The CPU board receives its power from a 24V AC line from the diluter section.
This 24V AC is transformed by TR1 into several voltages needed by the analyser section of the
CA570.
U45 and U46 are the stabilisers for +15 and -15 V , used by the analogue circuitry. U47 is used
to supply the voltage to the orifice transducer. CAPV is fixed at 22 V.
The following test points are of importance :
All voltages are in respect to GND , testpoint TP 11
Testpoint
Value
Tolerances
Used by
TP12
TP16
TP18
TP13
TP15
5V
145V
22V
15V
-15V
+ 0.2V -0.1V
+/- 20V
+/- 1V
+/- 0.7V
+/- 0.7V
Digital circuits
Orifice cleaning
Orifice meas. Voltage
Analogue circuits
Analogue circuits
Note : The additional watch-dog circuit in this drawing ( U17) is connected to the CPU and
I/O circuits. Please refer to section 10.8
10.1
ANALOGUE AMPLIFIER ( DRAWING 570-855B)
The analogue amplifier consists of U48 and U49 ( C and B).
The orifice electrodes are connected to P16. Pin 1 is the 'hot' side. The measuring voltage is
only connected to the orifice during an analysing process via relay RL1. As resistor R62 is 18
Kohm, the voltage over the transducer will be about half of the supplied voltage ( ca. 10V). At
the end of the analysing process , RL1 is switched off and RL2/RL3 are switched on for about
1 second, supplying a high voltage over the transducer for protein removal purposes.
Diodes D15,16,17,21,22 and 23 are input protection diodes ( low noise types). The total
overall gain is set by RV3. Note that the gain setting is basically the same as the MCV / MPV
calibration. RV3 should never be adjusted without instructions from Medonic.
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---------------------------------------------------------------------------------------------------------------------U49-C act as a low-pass filter and U49-D as the DC restoring circuit set by trimpotentiometer
RV2.
U49-B is the final stage of the amplifier.
Note that the total overall gain is ca. 10.000 x, therefore all components are critical. Care must
be taken that the shield around the amplifier is proper connected as well as the connections of
the coax cable attached to P16 ( coax connector) and the orifice transducer itself..
Any adjustment in the amplifier stage should never be done during a normal service without
approval of Medonic.
All signals are in respect to AN-GND , testpoint TP 20
10.3
Testpoint
Signal
Tolerances
TP19
positive pulses max 15V
Function
Output amplifier
DISCRIMINATOR CIRCUIT ( DRAWING 570-855C)
The input of U33-A marked 'cell' is connected to the output of the analogue amplifier as seen in
drawing 570-855B. U33-A is acting as a sample/hold detector, tracking the top ( peak value )
of each pulse generated by a cell that passes the orifice. U34-C is controlled by a 'statemachine' which switches U34-C to the 'open' state at the peak value of a pulse. This peak value
is digitised by the A/D converter U32 and read/processed by the CPU.
U38 is a serial-data to analogue converter which is used to set the discriminator voltage at the
comparator U40. Note that the discriminator setting voltage, measured at pin 14 of IC39-D, is
automatically changed by the software between a RBC/PLT and a WBC count.
The comparator has 2 outputs. One is controlled by the software (LOLEV) and the second is
fixed at a high level ( HILEV).
The reference voltage for the D/A serial converter is retrieved from Z2, which is a high
precision voltage reference of -5V.
10.4
HGB LAMP DRIVER CIRCUIT ( DRAWING 570-859A)
The HGB photometer lamp is only switched on during the time that a sample is processed by
the CA570 . The lamp voltage is variable and set by the software to the correct level. ( see
section 2 ). The PW ( pulse-width) modulator U34-A/D is used together with the low-pass
filter R22/C17 and R32/C to drive the lamp via the driver-circuit U39-A and Q1.
The PW- modulator is switched by the CPU (measured at TP3.)
All signals are in respect to AN-GND , testpoint TP 20
Testpoint
Signal
Tolerances
Function
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TP5
TP3
Lampvoltage 0 to5 Volt
Square-Wave 0/5 Volt
HGB lamp
Variable Voltage
Note that the lamp-voltage is between 4 and 4.7 volt whenever a sample is processed, else it is
0 V. At TP3 a Square-Wave can be measured only during the time a sample is processed. To
analyse this circuit, use the menu ' PHOTOMETER ADJUSTMENT' as found in the service
menu. Using the ↑↓ keys will change both the signal at TP3 and the output voltage at TP5.
10.5
STATE MACHINE (DRAWING 570-855A)
To reduce the number of components, several logic parts are included in the 2 GAL circuits
U37 and U35. Signal analysis at these circuits is not recommended except at the testpoints TP4
and TP5.
All signals are in respect to AN-GND , testpoint TP 20
10.6
Testpoint
Signal
Function
TP4
TP6
clock
Discriminator-output-pulses
Detection circuit/GAL
Filtered output of
comparator U40
METERING UNIT DETECTORS ( DRAWING 570-852B)
The function of the START/STOP detectors is explained in section 4.4 . if the glass tube is
filled with liquid, a high light intensity will be detected by the phototransistors connected at
P23/P32 ( STOP) and P31/P32 (START). The corresponding trimpotentiometer RV4 and
RV5 are adjusted in such a way that a logical 0 ( zero ) is seen at the input of U50-A / C. This
voltage is measured by the comparator U51 and the corresponding LED (LE5 and LE7) is lit if
the level is ok ( < 1 Volt ). The same is valid if the glass tube is empty. The light intensity will
be low and the input voltage at U50-A and C will be high. This is detected by the comparator
and the corresponding LED will be lit if > 4 Volts (LE4 and LE6)
A voltage measurement at the testpoints TP22 and TP 21 during the adjustment of RV4 and
RV5 is not necessary, just follow the instructions as found in chapter 4.4.
However, if these testpoints are measured, please note the following :
The LED's used as the light source to detect liquid/air in the glass-tube are only switched on if
a sample is processed or if the 'SHOW INPUT SIGNALS' menu is displayed. The LED's are
connected to R94 and R92 and LEVEX which is used to switch these 2 LED's on/off.
Any measurements at the following testpoints should be done by first activating the menu '
SHOW INPUT SIGNALS'
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All signals are in respect to GND, testpoint TP 11
10.7
Testpoint
Signal
Function
TP22
< 1V /liquid
> 4V /air
START
TP21
< 1V /liquid
> 4V /air
STOP
PRINTER DRIVER (DRAWING 570-854A)
The printer driver circuit is formed by U6 ( data ) and the printer 'busy' signal is connected to
P3-11 ( R6). A busy status from the printer will put P3-11 at a low level and LE2 on the CPU
board will be lit. A correct line-termination is used by RN4 / R15 , enabling high speed datatransfer at the printer output. P13 11/25 at R7 is a return GND from the printer. This resistor is
inserted to avoid groundloops in the system ( value is 2.7 ohm )
10.8
CPU SYSTEM ( DRAWING 570-851A)
The CPU used in the CA570 is a 186 uP using a DMA to process the incoming data. The
program is divided in 2 circuits as 16 Bit data is used. These circuits are marked as ODD and
EVEN. ( U23 and U25) on the CPU PCB. The working / sample-memory is formed by U24
and U26 which is (battery) backuped by U20 and the battery BAT1.
JMP1 is enabling the battery to the driver circuit U20. Note that if this jumper is removed, only
the sample-patient data is lost whenever the CA570 is powered down. All instrument settings
will remain as they are stored in the EEPROM U19..
The reset of the CPU system is performed by U17 as found in drawing 570-860A . A LED (
LE3) is connected to the reset line. This LED should only flash during a power-on or if the
manual reset-switch S1 is pressed. As U17 is a watch-dog IC, any failure in the uP system will
put the CPU in a reset state for ca. 0.5 second indicated by LE3.
Note : A flashing LED LE3 means that the uP system is out of order by any reason.
10.9
SERIAL OUTPUT ( DRAWING 570-856A )
The serial output (data) available at the output connector P2 driven by U8 which is an opto
isolated RS232 driver ( optional ). Note that at 9600 Baud a well balanced RS232 must be used
at a maximum length of 2.5 meter. Reducing the baud-rate to 1200 Baud will enable the driver
even to run on long lines without taking care of accurate line terminators.
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---------------------------------------------------------------------------------------------------------------------The LED LE1 will lit whenever the serial output will signal a 'busy' to the UART (U9) when
the CTS line is at a low level..
U7 and U4 are the opto-coupled drivers to the diluter CPU. Here the communication between
the 2 uP takes place. U19 is the EEPROM circuit where all instrument data is stored.
10.10 HGB & PRESS. TRANSDUCER AMPL: ( DRAWING 570-858A )
The photometer amplifier is formed by U41 and U42. The overall gain setting is done with the
trimpotentiometer RV1. Refer to section 4.3 for detailed information concerning the settings.
The output is measured at TP7. Note that even if the lamp is switched off, a voltage is
measured at this point ( offset ). This offset voltage is put at a positive level at all time by
R52/R56 before it is applied to the DAC ( serial) via R57 to U44. This enables the software to
measure and store the photometer offset and make corrections for it during the HGB
determination. Note that the HGB photometer amplifier has a high input sensitivity ( = high
gain).
The pressure transducer is connected to P12. A voltage converter is formed by U43. The
output at zero pressure will be slight negative at TP 8. This is put at a positive level by
R53/R54 before the output voltage of the transducer via R55 is measured by the DAC U44.
All signals are in respect to AN-GND , testpoint TP 20
Testpoint
Signal
Function
TP7
0 to 4.5 V
TP8
-1 to 3V
Photometer
output
Pressure transducer
output
10.11 DISPLAY PCB ( DRAWING 570-870 )
The LCD-display is adapted to the display/keyboard in the CA570. The keyboard has no extra
logic or any other IC's. The keys are directly connected to the connector K2 as seen in the
drawing 570-870. As the LCD display is a standard display unit, only the viewing angle
adjustment P1 is found. Please refer also to section 6.7 concerning the adjustment.
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10.12 MAINS FILTER ( DRAWING/PCB 570-9040)
To comply to the IEC 801 norms, all CA570 analysers shipped after the first half of 1994 are
equipt with this additional filter. This filter provides an excellent low frequency noise
suppression and is specially designed for mains supply filtering in the frequency range from 5 to
200 Khz. The transorb circuitry ( D1-D8) also protects the analyser electronics against extreme
mains power surges ( lightning).
Protective ground filtering is performed by L1/R5 and L4. If additional equipment is connected
to the CA570, please note that the mains protective ground is not directly connected to the
CA570 chassis but through this ground filtering circuit.
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11
SERVICE SCHEDULE
Several parts in the CA570 need regular service. As whole-blood is used, certain cleaning
procedures are obvious. Below follows a service schedule that is recommended to avoid
unplanned service visits to the enduser. The schedule assumes that the cleaning procedures as
described in the user manual of the CA570 are followed by the enduser. If this is not the case,
these 'service' points should be added to this list.
Assumed is ca. 50samples/day or less, if a higher load is used; adjust the time-frames in the
service schedule according to this.
Note that some parts might have a much longer lifetime than 'stated' in the service manual.
However the service sched's should be seen as a way to avoid unplanned service visits as much
as possible.
After the 24 month period, a service time-frame of 12 months is recommended
Below follows a short reference to the stated service points :
Note :
Be always aware of infection risks during service of the instrument. As whole blood is used,
care should be taken to minimise any infection risk.
Use disinfectionsolutions as supplied by the lab staff and follow the usage instructions of
qualified lab. personal. (Hypo-chlorite can be used as disinfectionsolution without any harm
to the instrument.)
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11.1
SERVICE POINTS
Service point
Installation
6 months
12 months
24 months
1. START/STOP
YES
YES
YES
YES
2. PHOTOM.
YES
YES
YES
YES
3. FILTER
NO
NO
YES
YES
4. MEMBRANE
NO
NO
YES
YES
5. PRESSURE
YES
YES
YES
YES
6.CHECK LEAK
YES
YES
YES
YES
7. FLUSH PMP
YES
YES
YES
YES
8. CLEANING
NO
NO
YES
YES
9. TUBES
NO
NO
NO
YES
10. PISTONS
NO
NO
NO
YES
11.BLOOD
NO
NO
YES
YES
See also attached service chart at the end of this section 11.
PNT 1
START/STOP
As the START/STOP detection is one of the most essential points in the CA570; these settings
should be checked during installation as well. An uncontrolled transport might move the
position of the glass tube in respect to the detector fittings. Check the START/STOP detector
as described in section 4.4
Note that an adjustment should not be necessary, only a check should be done to be sure that
the start/stop system was not effected by the transport of the instrument to the enduser.
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---------------------------------------------------------------------------------------------------------------------Proceed in the same way during the planned service intervals, check that the start/stop settings
are OK and don't adjust these detectors if not necessary.
Refer to section 4.4 for detailed information
PNT2
PHOTOMETER
An installation check should be done concerning the gain settings of the photometer system.
Please refer to section 4.3 for detailed information.
Note that an adjustment should not be necessary, only a check should be done to be sure that
the photometer system was not effected by the transport of the instrument to the enduser.
Proceed as follows during the installation/check:
1. Go to the menu 'PHOTOMETER ADJUSTMENT' as found in the service menu.
2. Enter this menu and observe the lampvoltage AND photometer-output voltage.
The lamp voltage should be 3.9 - 4.6 Volts
The photometer output voltage should be 3.8-4.1 volts
Proceed as follows during the 6/12 month service check
1. Empty the WBC/HGB cup by pressing switch A at the diluter front ( section 3.1 to locate
the push buttons )
2. Remove the cover of the WBC/HGB cup and fill it with either an enzymatic protein solver or
a 4-5% hypochlorite solution. Wait about 10 minutes.
3. Run a few blank samples
4. Enter the PHOTOMETER ADJUSTMENT menu again and press digit 1 on the keyboard.
The system will now perform an automatic blank adjustment/storage.
Check that the lamp-voltage is 3.9-4.7 Volts and the photometer output-voltage 3.8-4.1 Volts
after this adjustment is done.
Refer to section 4.3 for detailed information concerning photometer adjustments.
PNT3
FILTER
The air filter should be changed with regular intervals. Due to local environments, this could be
necessary more often. Check that a good mixing is performed in both the mixing-cup and the
RBC cup.
Sparepart/position number : 581-03-054
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PNT4
MEMBRANE
The membranes located in the waste-pump have to be changed. Remove the housing of the
pump section of the waste-pump and change the membrane/package.
If the capacity of the drainpump is too low, an error 20 might occur indicating that the used
400mBar level can't be reached within a specified time-interval. In most cases the CA570 will
work correct anyhow during normal sample operation, but might fail during the RINSE
ORIFICE,FILL or a ‘prime’ cycle.
To check the capacity ( on air ) of the waste pump, the menu 'CALIBR. PRESSURE' can be
used.
Enter this menu ( wait until zero vacuum is displayed ) and increase the vacuum with the →
key to 400 mBar. Measure the time that the system needs to reach this level. The normal time
to reach this vacuum level is ca. 10-15 seconds.
PNT5
PRESSURE
This point is done to check that the vacuum-bottle or connected tubes has no leakage AND
that the waste pump is able to create the correct vacuum.
Proceed as follows during installation/service :
1. Go to the menu CALIBR. PRESSURE as found in the service menu.
2. Increase the pressure with the → key to about 400mBar
3. Wait ca. 20 seconds, the pressure should now be stable and not drop.
4. Release the vacuum by pressing the ← key to 150 mBar
5. Wait 20 seconds, the pressure should now be stable.
6. Leave this menu by pressing <MENU>
Refer to section 4.5 for detailed information
PNT6
CHECK /LEAKAGE
Check that there are no leakage's within the CA570. Look for salt crystals. If found, remove
any salt crystals with dist.water only. Salt crystals that could fall on tube-valve plungers, might
introduce unstable functioning of these valves.
•
The CA570 should always be clean around the tube-valves to allow a trouble free
operation of the valve plungers.
PNT7
FLUSH PUMP
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---------------------------------------------------------------------------------------------------------------------The (shielded) flush pump in the CA570 is only used for cleaning purposes between the
samples. A low capacity of the flush pump will usually not effect the parameter results, but
mainly the pipette cleaning efficiency and the 4 hour cleaning cycle are effected.
To check that the flush-pump has a correct capacity, proceed as follows:
1. Turn the HEX Switch SW1 as found on the diluter CPU board in position 6 and press SW2
( refer also to section 3.2 )
2. The system will now perform a 4 hour cleaning cycle. After 1-2 minutes when the cycle is
finished, look at the level of the liquid in the RBC cup.
The level should be OVER the outlet connected to tube-valve 29.
PNT8
CLEANING
Cleaning sequences that are not mentioned in other service points, are mentioned below:
1. Remove the mixing-cup B1 and clean BOTH the cup/electrodes and lid with dist. water only.
Rinse the electrodes on the inside with a pin/wire of 0.8 mm on the inside.
Rinse all other connections at the lid as well with a 0.8mm wire to avoid salt crystal buildup
that might block one of the air-connections.
2. Clean the aspiration pipette with alcohol ONLY on the outside
3. Check the waste outlet tube, change if excessive bacterial grow is found at the waste
outlet/tubes or any other device that is connected at the waste of the CA570.
PNT9
TUBES
The silicon tubes used in the tube valves have a limited life-time. With the stated
number_of_samples/day ; they should be replaced each 2nd year.
Replace only the tubes that are actually going through the valves.
Replace tubes that are obvious damaged by any other reason. A cleaning or tube-exchange
might also be expected around the pressure-container B3 ( see section 1.2 )
Please refer to section 6.5 for detailed information
PNT10
PISTONS
The syringe pistons should be exchanged whenever excessive liquid is found on the cylinder
walls below the pistons.
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---------------------------------------------------------------------------------------------------------------------An adjustment as described in section 6.4 might stop a piston leakage temporary. A full piston
exchange is recommended each 2nd year.
Please refer to section 6.4 for detailed information
PNT11
BLOOD DET.
The blood detection level might change by time due to protein layers in the (Teflon) aspiration
tube. Also, a protein layer will decrease the drying efficiency of the aspiration pipette, resulting
in 'carry-over' tendencies.
Proceed as follows :
1. Enter an enzymatic cleaner or 4-5 % hypochlorite as a sample and run ca. 5 cycles.
2. Refer to section 3.6 to check/adjust the blood detectors.
Note that the actual 'trigger' level is not critical. As long as 'blood' with an HGB of 0.5 g/dL is
not detected as blood and 'blood' with an HGB of ca. 3 g/dL is detected as blood; the detectors
are correct and no further adjustments are necessary.
Please refer to section 3.6 for detailed information
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12
APPENDIX / TECHNICAL BULLETINS
Use this section to collect additional information send by Medonic as Appendix and/or
Technical bulletins / Document numbers 570-nn-xxx
Note that most info in these bulletins is not found in
any other section of this service manual !
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13
REPORTING SERVICE QUESTIONS
Please use a copy of the attached form whenever contacting Medonic for further service
information.
As the CA570 is equipped with an important service tracking system; enclose always the
printouts of:
a. 'PRINT ALL SETTINGS'
b. ´'PRINT SAMPLE STATUS' directly after running the sample where the problem was
found.
End Of File