DxC 600 800 Basic Service Workbook Ver B

Introductions Dx C B as i c Ph as e 1

UNICEL DxC 600/800 Pro Basic Service, Introductions Version A 08282006

Page 1 of 12 Brea Training Center

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Ac A c r o n y m s an and d Def Defii n i t i o n s Unicel DxC ASCII

Am erican eri can Standar Stan dard d Code Co de f or Infor Inf ormat matio io n Inter In terch chan an e

ASTM

Am erican eri can Societ Soc iet for fo r Testi Tes ti n and Material Mater ial s

CAU

Chemis hemistr tr Ana Anal tica tical Unit nit

CC

Cartrid e Chemistries Chemistries also referred referred to as Random Random Access RA

CD

Com act Disk

DMD

Dual Motor Driver

GSM GSM

Generic Generic Smart Smart Module Refe Refers rs to softw are commo n to all smart

HC16 HC16

The DMD DMD Micro-cont Micro -cont rol ler

ICC ICC

Instrume Instrument nt Control Com uter uter

ICD

In-C n-Circuit ircuit Debu

ICS ICS

Instrument nstrument Control S stem stem

MC

Modular Chemist Chemist ries also referred referred to as Parallel Parallel Process PP

MPC MPC

Multi Product Console

MSMC MSMC

Multi le Smart Smart Module Controller Controller

OS

O er at i n S s t em

PARI ARISE

Paralle rallell roce rocessin cu and ISE chemist chemistrr softwa software re

PP

Parallel Parallel Process see MC

RA

Rando Random m Access Acc ess see CC

SM

Smart Modul e see DMD

SRS

Softwa oftware Re uireme uirements nts S ecifica cification tion

TS-CTS

Thick hick Sto

TCP/ TCP/IP IP

Transmis Transmis sion Control Protocol / Internet Internet Protocol

er Cable

er - Close losed d Tube ube Sam lin



Tools Parts List KIT, TOOLS – DxC 600/800 SYSTEM PART NUMBER A18396 A18397 A20658 389476 389524 450893 467731 471803 473100 473181 476211 756613 756934 756956 759473 891349 949109 970334 970531 970534 975561 977929 979071

P/N: A18779

AC

DESCRIPTION TOOL, ALIGN PROBE CAR, DXC TOOL, ALIGN, TWO CAR, DXC SCRIBER, POCKET STYLE, STEEL TOOL, STIRRER – REMOVAL WRENCH, RETAINER NUT SCD, PENLIGHT – CX3 SYSTEMS PLIERS, RETAINING RING – RWRK ALIGNMENT TOOL, REACTION WHEEL CUVETTE ALIGNMENT TOOL KIT, FLUSH – FLOWCELL TOOL, PROBE ALIGNMENT LX20 TUBING ASSY,PROBE CLEANER STANDARD, BARCODE – PKG/5 PLUG, WHEEL ALIGNMENT GAGE, FEELER – CUVETTE – WASH SENSOR SCREWDRIVER, 5” LG – 3/16” BLADE WRENCH, SPANNER WRIST STRAP, ESD – ADJUST SCREWDRIVER, PHILIPPS NO.1 – 3” LG WRENCH, 5/16 IGNITION – 15 & 80 DEG WRENCH SET, ALLEN – 0.05-5/16 PLUG MIRROR, INSPECTION Miscellaneous Tools

475865 474433

TOOL, ALIGNMENT, SAMPLE TUBE – (Cap Piercer ) Carbon Bridge Striking Tool

977655

Cable Kit; Diagnostic Tools


QTY 2 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1


DXC 600 / 800 BASIC SERVICE TRAINING COURSE AGENDA PHASE 1 Week 1 Day 1 Monday Time

08:00 – 09:30

09:30 – 11:30 11:30 – 12:30 12:30 – 5:00

Event Introduction – Student survey Load DXC IFU, REF, VER, HOST, CIM Manuals Load DXC In-Lab Training Manual Replicate DXC Databases, Application Repository. Check Diagnostic Tools, DxC 600 & 800 Simulator System Overview System Overview Software Overview System Parameters / Setup Enable Metering Exercise Lunch MC Reagent Preparation and Loading Exercise Reagent Calibration Exercise Read DxC Inst ructio ns For Use – Chapter 13: "Troubleshooting Calibration and Result Errors"

Location

Classroom

Laboratory

Laboratory

Day 2 Tuesday Time 08:00 – 08:30

Event Review: Questions & Answers

Location Classroom

08:30 – 09:00

QC / Customer Maintenance

Classroom

09:00 – 11:30

QC & Sample Programming / Processing Exercises

Laboratory

11:30 – 12:30

Lunch Event Logs, QNX, and Boot Sequence Instrument Control Subsystem Event Logs, QNX, Boot Sequence and Instrument Control Computer Exercises Troubleshooting Exercises

12:30 –

1:30

1:30 – 5:00

Day 3 Wednesday Time Event 08:00 – 08:30 Review: Questions & Answers 08:30 – 10:00 Power Subsystem, Smart Modules & Communications Subsystems 10:00 – 11:30 Power & Fans Exercises 11:30 – 12:30 Lunch 1:00 – 5:00 Smart Modules & Communications Exercises Troubleshooting Exercises


Laboratory

Location Classroom Classroom Laboratory Laboratory


DXC 600 / 800 BASIC SERVICE TRAINING COURSE COURS E AGENDA PHASE 1 Week 1 Continued Day Day 4 Thurs day Time 08:00 – 08:30 08:30 – 10:00 10:00 – 11:30 11:30 – 1:00 1:00 – 5:00

Day Day 5 Fri day Time 08:00 – 08:30 08:30 – 10:00

10:00 – 11:30 11:30 – 12:30 12:30 – 5:00

Event Event Review: Review : Questions & Answers Utilities – Hydro-pneumatics Subsystem Theory Hydro Exercises Lunch Hydro Exercises Troubleshooting Exercises

Location Classroom Classroom Laboratory

Event Event Review: Review : Questions & Answers Sample Rack Handling Subsystem Theory Reserved Racks TS-CTS Cap Piercer Sample Rack Handling Exercises Lunch Sample Rack Handling Exercises Troubleshooting Exercises

Location Classroom Classroom


Laboratory

Laboratory Laboratory


DXC 600 / 800 BASIC SERVICE TRAINING COURSE AGENDA PHASE 1 Week 2 Day Day 6 Mon day Time 08:00 – 08:30 08:30 – 10:00 10:00 – 11:30 11:30 – 12:30 12:30 – 5:00

Day 7 Tuesday Time 08:00 – 08:30 08:30 – 10:00 10:00 – 11:30 11:30 – 12:30 12:30 – 5:00

Event Event Review: Review : Questions & Answers MC Sample Handling, Level Sense, Obstruction Detection, MC Cups Theory Dual Syringe, Sample Probe Exercise MC Cups Exercises Lunch MC Cups Exercises Troubleshooting Exercises

Location Classroom

Event Event Review: Review : Questions & Answers ISE Theory Preventive Maintenance Minor (ISE/MC) Lunch PM continued


Day 8 Wednesday Time Event Eve nt 08:00 – 08:30 Review: Questions & Answers 08:30 – 11:30 PM completion Decontamination Procedure Overview Exercise Troubleshooting Exercises 11:30 – 12:30 Lunch 12:30 – 5:00 Troubleshooti ng Exercis Exercis es, Cont... Cont... Day Day 9 Thurs day Time 08:00 – 08:30 08:30 – 11:30 11:30 – 1:00 1:00 – 2:00 2:00 – 5:00

Event Event Review: Review : Questions & Answers Troubleshooting Exercises Lunch Lab Cleanup Student Survey Mentoring Period Requirements


Laboratory

Laboratory

Laboratory

Location Classroom Laboratory

Laboratory

Location Classroom Laboratory Laboratory Classroom


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Personal Progress Report Name: ____________________ Instructions

The Personal Progress Report is your way of monitoring your skill development. At the end of each exercise, monitor your progress by comparing your answers or reports to the Reference Key. Initial your Personal Progress Report and ask your Instructor to do the same. ITEMS PERTINENT TO INSTALLATION ARE IN BOLDFACE

Day 1 Monday Exercise System Overview

Objectives  Identify major system components

and locations Software Overview  Software operation, menus, ico ns and options System Set Up  Set up / review all System Parameters Metering  Acti vate Service Mode using Passwor d Generator pr ogram  Initialize Metering  Disable Service Mode  Accessing Metering Information  Utilize Meter-Use Manual MC Reagent Preparation & Loading MC Reagent Calibration

 Identif y preparation requirement  AUTO lo ad MC reagents  MANUAL l oad of MC reagents  Edit volumes

Student Initials

Instructor Initials

_______

_______

_______

_______

_______

_______

_______ _______

_______

_______

_______

_______

_______

_______

 Assi gn calib rator IDs  Calibrate MC and CC Reagents

With barcodes Without barcodes  Reprin t (recall) previous calibration reports  Read Chapter 13: Troubleshooting Calibration and Result Errors • •

DxC IFU



Day 2 Tuesday Exercise QC and Sample Programming / Processing

Customer Maintenance Software Boot Sequence

Objectives

QNX Procedures Event Logs

Instructor Initials

 Program & process QC  Program & process samples:

With bar code labels Without bar code labels  Requesting Load Lists  Clear rack assignm ents  Recall result s  Sample repli cates and chem r eplicates  Statistical summary report  Absorbance versus Time Plots/Tables • •

 Review customer maintenance procedures   

Instrument Control Subsystem

Student Initials

     

in the IFU Initiate Hyper Terminal session Observe boot process in the Hyper Terminal window Identify information provided in the Hyper Terminal window Remove & reinstall ICS components Perform ‘Console Only Boo t’ Enter hardware ethernet address and serial number Locate and review QNX procedures Understand when they may be applicable View and identify the information displayed in the Event Logs

_______

_______

_______

_______

_______

_______

_______

_______

_______

_______

_______

_______

Day 3 Wednesday Exercise Power Subsystem

Smart Modules Fiber Optics

Objectives

Student Initials

Instructor Initials

 Locate Power Subsystem components  Remove and reinstall power supply  Observe normal power up sequences  Identify LED display codes  Adjust power supplies  Power supply measurements Min Max

_______

_______

 Locate the Smart Modules on the DxC  Troubleshooting Fiber Optics

_______

_______



Day 4 Thur sday Exercise

Objectives  Identify Hydro components  Observe instrument & instrument status

Hydropneumatics

  

  

during routine operations Observe proper valve operation Remove and reinstall valves Perform Diagnostic tests  Vacuum and Air Pump test  Float Switch Tests  Hydro valves tests Pump Box access Review PMC Procedures Review decontamination procedure

Student Initials

_______

Instructor Initials

_______

Day 5 Friday Exercise Cap Piercer TS-CTS

Sample Rack Handling

Objectives  Remove and reinstall bar code reader  Remove and reinstall TS-CTS  Blade and wick removal and replacement  Auto gloss pump repair and replacement  One blade TS-CTS functional alignment

Student Initials

Instructor Initials

_______

_______

_______

_______

 Shuttle latch solenoid removal and      

replacement Remove and reinstall onload tray assembly Remove and reinstall offload tray assembly Remove and reinstall shuttle assembly Perform sample rack handling alignment procedures Verify alignments Review TS-CTS event log entries



Day 6 Monday Exercise Dual Sample Syringe Assy. MC Sample Crane

MC Cups

Objectives  Remove and reinstall the Dual Sample

Syringe Drive Assembly  Remove and reinstall MC crane  Remove covers from the Triple Crane Assembly and observe its function  Remove and reinstall MC probe  Perform MC Crane Alignments  Identify LED status/colors  Remove and reinstall MC cup module  Remove and reinstall pump and valves  Remove and reinstall stirrer motor  Adjust cup temperature via diagnostics  Remove and reinstall lamp via diagnostics  Perform lamp calibration

Student Initials

Instructor Initials

_______

_______

_______

_______

_______

_______

Day 7 Tuesday Exercise MC ISE Preventive Maintenance Procedure

Objectives  Replace Carbon Bridge  Strike the Carbon Bridge

Student Initials

Instructor Initials

_______

_______

_______

_______

 Perform PMC Minor (ISE/MC)

Day 8 Wednesday Exercise Decontamination Procedure

Objectives  Locate, review and understand the

system decontamination procedures.


Student Initials _______

Instructor Initials _______


Operations Exercises 1

UNICEL DxC 600/800 Pro Basic Service, Operations Version A 08272006


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Lab Exercise: System Overview Objectives

This exercise will guide you through the following: Identifying system components and locations Software overview • •

Why

Identify system components and locations in preparation for more detailed training. Overview the software to become familiar with the icons and menus for more detailed operation.

Reference Materials

DxC In-Lab Training Manual DxC Reference Manual

Please feel free to consu lt wit h an instr ucto r if you have any questions about the information in this exercise.



System Overview: Reference: DxC In-Lab Training Manual Chapter 1 – System Components

System Components

 Read the above chapter reference and identify all components and

locations on your instrument.  When you have completed the above move on to the next section.

References: DxC In-Lab Training Manual: Chapter 2 – Software Overview

Software Overview

 Read the above chapter reference and identify the sections of the

main screen on your instrument.

 Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and demonstrate what you

have learned.



Lab Exercise: Syst em Parameters/Set Up Objectives

Select options on the Setup Menu and review their purpose. 1) Auto Serum Index / ORDAC 2) Chem Config / Sample Type 3) Date/Time 4) Demographics Setup 5) Immediate Report 6) Panels 7) Replicates 8) Report Setup 9) Reportable Ranges 10) Reference / Critical Ranges 11) Sample Comments 12) Special Calculations 13) Setup Summary 14) Units / Precision 15) User-Defined Chemistries 16) Bar Code 17) Reserved Racks / Obstruction Detect 18) Disable Service Monitor 19) External Water Monitor 20) Host Communication 21) Language / Keyboard 22) Printer Setup 23) Service Setup (Password Generator Program) 24) System Configuration (password) 25) Version Upgrade 26) Status Alarm / Annunciator 27) Chem Update 28) Password Setup 29) Auto Generation of Control

Why

During an installation, you may be asked to define the instrument's system parameters based on your customer's needs. This exercise will also provide you with the opportunity to explore the software.

Reference Materials

DxC Instructions For Use Manual DxC Reference Manual




System Parameters Setup: References: DxC Reference Manual: Chapter 3 – Detailed System Setup DxC Information For Use Manual Chapter 4 – System Setup Operations

Auto Serum 1 Index / ORDAC

 Do not enable auto serum index on your training instrument.

Note: •

•

•

•

2 Chem Config/ Sampl e Type

3

Auto serum index checks for hemolysis, lipemia, and icterus on ALL samples! DIL1 reagent must be loaded on the instrument when testing for serum index. Auto serum index is intended for sample integrity assessment only, not for patient diagnosis! Numeric values (indices) are printed on the patient report. The corresponding relative concentration of each interfering substance may be found in the DxC Chemistry Information Manual – Serum Index Tab. It is also possible to enable/disable serum index via the ‘Samples’ Icon (see F3 Option).

 Using the information found in the table below, define the

Chemistry Print Names for the following chemistries.

Chemistr y

Print Name

Na

Sodium

K

Potassium

Cl

Chloride

Ca

Calcium

Date/Time

Demographics Setup Immediate 5 Report 4

6 Panels

 Set up the date and time information on your instrument

using PST.  Review menu with the references.  Set up Module Chemistries for ALL to Printer only and

Immediate Report of Reruns  Review this menu and take note of Default Panel feature. The Default Panel of tests is automatically run if the host fails to respond within the designed time period to a host query.



System Parameters Setup, c ont.… 7

Replicates

 Review menu with the references.

8

Report Setup


9

Reportable Ranges


10 Reference/ Critical Ranges


11 Sample Comments

 Review menu with the references.  Enable the following Special Calculations:

12 Special Calculations 13 Setup Summary

ANION GAP (1) BUN/CREA RATIO  Review – Should be the same information as on the HELP Icon.

14 Units / Precision


15 User-Defined Chemistries


16 Bar Code Reserved Racks / 17 Obstruction Detection

 Review menu with the references.  Enable the Obstruction Detection feature on

18 Disable Service Monitor

your training instrument.  Review menu with the references.

19 External Water Monitor


20 Host Communication


21 Language / Keyboard


22 Printer Setup


23 Servi ce Setup – This will be performed in the next exerci se. 24 System Configuration


25 Version Upgrade


26 Status Alarm / Annunc iator

 Test the alarm selections choose Alarm 1.

27 Chem Update


28 Passw ord Setup


29 Auto Generation of Contr ol


 Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and to demonstrate what you

have learned.






Lab Exercise: Metering Objective

•

• • • •

Why

Activate Service Mode using the Password Generator Program Initialize Metering Disable Service Mode Access the Metering Information Familiarize yourselves with the Metered-Use Manual that your customer receives

The metering function is used to keep track of reagent usage on the instrument for accounts that are on a reagent-metering program. Metering data is to be collected via modem; copying metering data to a floppy diskette can be used as a backup procedure. For this exercise, you will need the Password Generator Program, which allows you access to Service Mode. Once the metering feature has been initialized, contact Systems Technical Support with meter read day and modem phone number. When verifying an instrument repair or performing troubleshooting chemistry tests, the Service Mode should be enabled so that the customer is not charged for those tests.

Materials Needed

Service Password Generator Program on your laptop.

Reference Materials

DxC Service Manual DxC Metered Use Manual




Metering , cont… Reference: DxC Metered Use Manual: Operational Overview Enable Metering

 Read the Operational Overview.  To enable metering on your training instrument.  Main Menu  Select Setup on the Icon Menu Bar  Select [23] Service Setup  Obtain password using Service Password Generator  Enter password on Password Screen and select [OK}

If you have generated and entered the correct password, you will be in the Service Setup Screen, if not repeat the process.  On the Service Setup Menu select [5] Service Mode Active  Acknowledge the Service Mode Active pop-up  Select Utilities on the Icon Menu Bar  On the Utilities Menu select [9] Metering  Enter the following information: Facility Name: DxC Service Training Lab Facility Address: Beckman Coulter, Inc. 250 S. Kraemer Bl vd. Brea, CA 92822 Meter day-of-the Month: 25 Reference: DxC Metered Use Manual: Metering Data Transfer Procedure - Operating in Service Mode Disable Service Mode

 Read the above reference  Disable Service Mode:

Questions

What color distinguishes Service Mode from Normal Operations? __________________________



System Setup Menu - [18] Disable Service Monitor

Why disable the Service Mode?



Metering, cont… Reference: DxC Metered Use Manual: Metering Data Transfer Procedure Adjustments to Standard Replenishments Assume the DxC has alerted you with the message: METER DATA IS DUE. PROCEED TO UTILITIES SCREEN AND SELECT METERING.  Perform the following adjustments on your training instrument.

Part

Replenishment/Adjustment

472481 - CO2 Acid

[HOLD]

445865 - WASH CONCENTRATE

Decrease by 1 box

 Print a copy of a meter report and the Replenishment /Adjustment

screen. Review the information found in the print out.

Question

If your customer transmits their Metering Report via modem to BCI, how will they be informed that the transmission was successful? ___________________________________________ ___________________________________________


have learned.






Lab Exercise: MC Reagent Preparation and Lo ading Objective

This exercise will guide you through the following: Identify preparation requirements Loading of MC reagents Auto load of MC reagents Manual load of MC reagents Edit volumes • •

• •

•

Why:

When installing the DxC one of the first things you will need to do is place the MC reagents on the DxC. Some require preparation. Load Once placed on the DxC you will need to load them on the system. The term “loading reagents” on an DxC means that we are loading the following information into the system parameters’ memory: The test or reagent name The lot number The expiration date The serial number • • • •

Typically, reagent parameter information is automatically loaded using the hand-held barcode reader. If the barcode reader fails, however, reagents can still be loaded using manual load – typing the information in. The only way that you can be sure that the information has been loaded is to watch the Reagent Load Screen to see that the data changes. Edit When the bulk reagents are scanned the system assumes 100% Volume volume. This can cause serious problems with ISE results if it is not accurate. Reference Materials

DxC DxC DxC DxC

Reagent Preparation Quick Reference Card Instructions For Use Manual Reference Manual Chemistry Information Manual




MC Reagent Preparation

:

References: Reagent Preparation Quick Reference Card: Supplied with all DxC instruments. (P/N A18595) DxC Instructions For Use DxC Chemistry Information Manual MC Reagent  The MC reagents for your training instrument have already been Preparation prepared and placed on the CAU (Chemistry Analytical Unit).  Take special note of the numbers and letters that are on the tubing that is attached to the MC reagent straws.

MC Reagent Load: References: DxC Instructions For Use: Chapter 5 – Reagent Load / Calibration DxC In-Lab Training Manual: Chapter 3 – Procedures and Processes AUTO (Reagent) Load

 Using the bar code reader, load all of the MC reagents in the bulk

reagent compartment and the Wash Concentrate II. Load the No Foam and, if your DxC has a cap piercer installed, the CTS AutoGloss. They are located in the middle section of the instrument in the Hydropneumatics compartment. Note: If any of the reagents have unreadable barcodes, load them in the next step.

Manual (Reagent) Load

 Manually load CO 2 Alkaline Buffer reagent located on the ISE

Module and any bulk reagents that have bad barcodes.



MC Reagent Edit Volumes: References: DxC Instructions For Use Manual: Chapter 1- General Information - Precautions - Insufficient ISE Reagents DxC Instructions For Use Manual: Chapter 5 – Reagent Load/Calibration Edit Volume

 If the volume displayed does not match the actual reagent volume,

enter the correct % estimate for each reagent in the Vol field on the Reagent Status side of the Rgts/Cal screen.

Warning: This is an extremely important step for the ISE reagents! There is no other mechanism for the system to warn of insufficient ISE reagents – the system will report erroneous results. In some cases, results will be obtained without reagents.

Questions

1. Which of the bulk reagents require preparation before placing the reagent on the instrument? _________________________________________________ 2. The MC reagent tubes attached to the reagent straws have numbers and letters attached. What do the letters represent? _________________________________________________ 3. Can the Vol field be adjusted while in the Reagent Status Screen? _________________________________________________ 4. What chemistries are permanently configured on the DxC? _________________________________________________

 Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and to demonstrate where

the answers can be found.






Lab Exercise: MC Reagent Calibration: Objective

This exercise will guide you through the following: Assigning calibrator IDs Calibration of MC chemistries with and without bar code labels Reprint (recall) previous calibration reports • •

•

Why:

This exercise guides you through the steps that you will need on an installation to calibrate the instrument in preparation for precision and carry over tests. As with the other exercises some steps are slightly out of order so that you can see the pop up messages that indicate what you need to do first.

Reference Materials

DxC Instructions For Use Manual DxC Chemistry Information Manual




MC Reagent Calibratio n: References: DxC Chemistry Information Manual Chemistry Information Sheets -Specific Chemistry Tab -Calibration -Calibrator Required Cal Status

 Check the calibration status of all the reagents currently loaded.

Requesting Calibration

 Press the appropriate button in the Chemistry or Position column

on the Reagent Status side of the Rgts/Cal Screen to select the following chemistries for calibration: DxC 800 – Na, K, Cl, CO2, Calc, BUNm, CREm, GLUCm, PHOSm, TPm, ALBm and Mg DxC 600 – Na, K, Cl, CO2, Calc, GLUCm and Mg Note: Magnesium (Mg), a Cartridge Chemistry, has already been loaded on your instruments for the purpose of these exercises.  Press the Cal [F4] function button.

Question

What do the pop-up messages say? 1. ______________________________________________ 2. ______________________________________________

 Look up the calibrator(s) you will need in the Chemistry Information

Manual or the Tech Marketing Support Info database on Lotus Notes for those chemistries that still show Cal Required. List of Calibrators

You can find out which calibrator parameters have been loaded on the instrument by checking the List of Calibrators menu.  Press the Assi gn [F7] button.  On the Assign Barcode/Rack Menu press or click on the pull down arrow next to the Calibrator Name. If the calibrator(s) you need are not on this list, you will need to load the calibrator diskette.



MC Reagent Calibr ation, cont … Loading Calibrator Diskette

 Press Options [F6].  Press option button [1] Load calibrator diskette on the Cal

Options Menu  Load the calibrator diskettes you need. Verify that the lot numbers

of the calibrator you are using match the lot number on the diskette. Note: Protein Cal is not used on the DxC 600. Assi gn Calibrator ID

Now that the calibrator parameters have been loaded on the system, the instrument needs to know where the calibrator samples will be located when they are run. We can do that in three ways: 1. Assign a calibrator ID barcode. 2. Assign a rack number and position number to the calibrator. 3. Assign a barcode ID and a rack and position number.  Assign the calibrator ID for AQUA CAL (and PROTEIN CAL if your

instrument is a DxC 800). You will find the IDs on the sample container barcodes located in the labeled gray racks on your workstation. Assi gn Calibrator Rack

 Multi Calibrator does not have a barcode for this exercise, so

assign it a rack and position number .

Reserved Racks

Since barcodes labels are too long for the sample cups, we have to place them in a container long enough to accommodate them. These cups are referred to as “Nested Cups.” The details will be discussed later in the course, but for now, we need to reserve any racks that have nested cups.  Go to the setup menu.  Arrow down and select button [17] Reserved Racks / Obstr uctio n

Detect  Type in the rack numbers for the nested calibrators in the Reserved Racks text box.  Define the rack sizes as appropriate. Cal Status

 Recheck the calibration status of all the reagents currently loaded,

and select for calibration all those that require it.



MC Reagent Calibr ation, cont … List

 Press [F5] Lis t to identify the calibrators required for the selected

chemistries. Calibration using bar code labels

 Pour the calibrators into either a 0.5 ml sample cup or a 2.0 ml

Calibration without bar code labels

 Pour the calibrator for Mg into a 0.5 ml sample cup and place it in

sample cup and nest these cups into their respective bar code labeled containers.

position on the rack assigned for Multi Calibrator.  Initiate calibration!

Printing Calibration Reports

 While your instrument is calibrating, press [F6] Optio ns on the

Rgts / Cal screen and select option number 10 to familiarize yourself with printing of current and previous cal reports.  If your instrument is a DxC 600, obtain a calibration report for all of

the chemistries from one of the DxC 800s.


have learned.

 Review the DxC 800 calibration report obtained above while

reading: DxC Instructions For Use Manual: Chapter 13 – Troubleshooting Calibration and Result Errors – MC Calibration  Be prepared to answer any questions and demonstrate where the answers can be found in tomorrow's class session.



Operations Exercises 2

SYNCHRON, DxC 600 / 800 Pro Basic Service, Customer Maintenance Version A 08272006





Lab Exercise: QC and Sample Programming/Processing Objective

This laboratory exercise will guide you and your partner through: Define quality control files Assign control ids Programming and processing of qc Programming and processing patient samples with and without bar code labels Requesting load lists Clear rack assignments Recall results Sample replicates and test replicates Statistical summary report Absorbance versus time plots and tables. • • • •

• • • • • •

Why

You need to know how to program and process QC samples to be able to troubleshoot perceived QC problems in the field. In addition, knowing how the customer runs patient samples will assist you in deciding customer induced problems. Knowing how to request load lists and clearing rack assignments will help in determining whether there is a test still pending or the rack is unavailable for programming in some problem situations. Recalling results and statistical summary reports are easy ways to check precision results. Absorbance versus Time Plots can be very useful in troubleshooting particular chemistry problems, especially since the DxC Tech Marketing Support Info Database on Lotus Notes has examples of good plots for all chemistries in Section 17.

Reference Materials

DxC Instructions For Use Manual DxC In-Lab Training Manual




QC and Sample Prog rammi ng/Processing Reference: DxC Instructions For Use Manual: Chapter 6 – Quality Control -Defining a Control DxC In-Lab Training Manual: Chapter 3 – Procedures and Processes -Program / Process QC Define Quality Control Files

 Using the information found in the table below, define the following

quality control files:

Control Name: Unicel Level 1 Control Lot #: XX605330 Sampl e Type: Serum Chemistry

QC File Number

Target Value (Assigned Mean)

Standard Deviation (Assigned SD)

101

6.9

0.3

Calcium Carbon Dioxide Chloride

102

10.0

1.5

103

79

2.0

Potassium

106

2.5

0.15

Sodium

107

115

2.5

Control Name: Unicel Level 2 Control Lot #: XX605330 Sample Type: Serum Chemistry

QC File Number

Target Value (Assigned Mean)

Standard Deviation (Assigned SD)

201

10.2

0.45

Calcium Carbon Dioxide Chloride

202

20.0

1.5

203

101

2.5

Potassium

206

5.0

0.2

Sodium

207

144

3.0



QC and Sample Prog rammi ng/Processing, cont… Reference: DxC Instructions For Use Manual: Chapter 6 – Quality Control Control ID Assignments Assi gn Control ID

 Using the information found in the table below, assign bar code IDs

for the 2 QC files you had just defined. Control Name Unicel Level 1 Unicel Level 2

Control ID SYN1 SYN2

Reference: DxC Instructions For Use Manual: Chapter 6 – Quality Control - Running Control Samples -- Running Control Samples With Bar Code Labels and Auto Generation of Control Enabled Program and Process Quality Control WITH bar code labels

 Program and process Unicel Controls, Levels 1 and 2.

Reference: Chapter 3 – Preparing Samples for Analysis - How to Use Reserved Racks -- Processing Bar Coded Samples Patient Samples WITH Bar Code labels

 Using the information that is provided in the table below, process

simulated patient samples. NOTE: These samples have readable barcodes.  Using the Sampli ng Template, verify adequate sample volume!  Request a Load List and print it.

Sampl e ID

Sampl e Type

Patient Name

Chemistr ies

101264

Serum

Arthur Edwards

NA, K, Cl, CO2, CALC

101375

Serum

Mark West




QC and Sample Prog rammi ng/Processing, cont… Reference: DxC Instructions For Use Manual: Chapter 3 – Preparing Samples for Analysis - How to Use Reserved Racks -- Processing Unreadable Bar Coded Samples Chapter 7 – Sample Programming -Identifying Samples --Manually Assigning Rack and Position Patient Samples WITHOUT bar code labels

 Using the information that is provided in the table below, program

and process simulated patient samples. NOTE: These samples do not have readable bar code labels!  Request a Load List and print it.

Sample ID

Sampl e Type

Patient Name

Chemistr ies

101526

Serum

George Jetson


101638

Serum

June Cleaver


Reference: DxC Instructions For Use Manual Chapter 7 – Sample Programming - Prior to Programming -- Rack Status Clear Racks

 When all the results have printed, CLEAR racks of any manually

assigned samples!

Reference: DxC Instructions For Use Manual Chapter 9 – Results Recall Results Recall

 Recall and reprint the results for the following samples:

Arthur Edwards – Sample ID: 101264 George Jetson – Sample ID: 101526



QC and Sample Prog rammi ng/Processing, cont… Reference:  Select Sample Menu Icon  On the Program Sample Menu select [F3] Options

System Replicates and Test Replicates

 Program the following samples in the same rack choosing the

options listed: Sample ID – SYNC L1 Chemistries – K, CL Sample Replicates – 5 Reps – leave blank Sample ID – SYNC L2  Chemistries – K, CL Sample Replicates – 1 Reps – K – 5 CL – 5  Using Unicel Controls Levels 1 & 2 as samples, run them. 



QC and Sample Prog rammi ng/Processing, cont… Questions

 How many pages were printed out?

SYNC L1 __________ SYNC L2 __________ Answ er to your question

When running precision tests with 20 replicates as on an installation or for troubleshooting:  Selecting Sample Replicates will print out each sample on a separate page, 20 pages in all.  Selecting Reps (Test Replicates) will print out all 20 on one page.

Reference: DxC Instructions For Use Manual Chapter 9 – Results Recall - Results Recall -- Statistical Summary Report Recall Results and Print Statistical Summary Report

 Print a Statistical Summary report for the precision tests SYNC L1

and SYNC L2.  This feature provides all of the statistical results needed for the precision tests on an installation.

Reference: DxC Instructions For Use Manual Chapter 8 – Results Recall - Results Recall - Absorbance Versus Time Absorbance vs. Time

 Recall the Absorbance Plot and Table for one of the above results

and print the Plot.  Compare it to the plot for that chemistry on the next page.


have learned.



Genera ted by ABS vs Tim e Macro V1.0 JAD - June 1998 Patie nt ID: Last Name: First Name: Samp le ID: SYN 2 Rack: 30 Positio n: 2 Chem: K Lot#: Serial #: Resp: -1732.611328 Rslt: 4.774033 blank window

reacti on window

0 0

5

10

15

20

25

30

35

40

45

40

45

-1000

-2000 -3000 D A - -4000 E S I

-5000

-6000 -7000

-8000

t / sec

Generated b y ABS vs Time Macro V1.0 JAD - June 1998 Patie nt ID: Last Name: First Name: Samp le ID: SYN 2 Rack: 30 Position : 2 Chem: CL Lot#: Seri al#: Resp: 1508.083252 Rslt: 100.511436 blank window

reaction window

4000 3500 3000 2500 D A - 2000 E S I

1500 1000 500 0 0

5

10

15

20

25

30

35

t / sec SYNCHRON, DxC 600 / 800 Pro Basic Service, Customer Maintenance Version A 08272006





Lab Exercise: Customer Maintenance Objective

This laboratory exercise guides you through the following maintenance procedures: Review Customer Maintenance Procedures •

Why

It is important to know which procedures the customer is expected to perform for maintenance. The engineer must be able to identify when the root cause of an on-site service call is due to lack of customer maintenance. The customer can then be informed of the deficiency and prevent future work flow interruptions.

Reference Materials

DxC Instructions For Use Manual


UNICEL DxC 600/800 Pro Basic Service, Operations Continued Version AA Created on 08272006


Customer Maintenance Exercise Reference: DxC Instructions For Use Manual: Chapter 10 Maintenance - Maintenance Overview

Maintenance Acti on Log

 Review the above document

 Locate an instructor for sign off of this exercise.  Be prepared to answer any questions and demonstrate where the

answers can be found.

UNICEL DxC 600/800 Pro Basic Service, Operations Continued Version AA Created on 08272006


Software & ICS Exercises

UNICEL DxC 600/800 Pro Basic Service, Software and ICS Version A 08202006





Lab Exercise: Software Boot Sequence Objectives

This exercise will guide you and your partner through the following procedures: Proper power down and power up Initiate a Hyper Terminal session Observe boot process in Hyper Terminal window Identify the information in Hyper Terminal window • • • •

Why

The purpose of this exercise is to provide you with a better understanding of the boot sequence.

Materials Needed

RS232 AT Serial Modem Cable, DB 9-Pin Female to a DB 25-Pin Male, Belkin (P/N F2L088-06) or equivalent. Belkin USB Serial Bridge (P/N F5U109) or equivalent.

Reference Materials

DxC In-Lab Training Manual DxC Instructions For Use Manual Unicel DxC Service Manual on Lotus Notes

Please feel free to consu lt wit h an instr ucto r if you have any questions about the inf ormation in this exercise.



Software Boot Sequence Reference: DxC In-Lab Training Manual - Chapter 3: Procedures and Processes - Power Down and Power Up DxC Instructions For Use Manual - Chapter 11: System Status and Commands - Instrument Commands  Power down DxC CAU and console using proper shutdown

procedure.

Reference: Unicel DxC Service Manual on Lotus Notes - Chapter 20: Service Tools -ICC Hyperterminal - Items 1, 2 & 3 Hyper Terminal

 Install hardware connection for HyperTerminal.  Setup and configure a HyperTerminal Session.  Power on DxC CAU only .

Observing the ICC Boot

 Observe the ICC boot progress in the Hyper Terminal window on

Question

What event on the Hyper Terminal window indicates that the ICC is ready to communicate with the DxC? __________________________________________________

Observing the CAU Boot

Question

your laptop.

 Power on the DxC console.  Notice that new lines begin to appear in the HyperTerminal screen.

What happens when the line appears? __________________________________________________



Software Boot Sequence, Cont... Observing Shutdown

   

Power down the DxC through proper shutdown procedure. Observe the HyperTerminal Screen for new information. Disconnect your laptop from the DxC Verify the system boots to Standby.

Reference: Unicel DxC Service Manual on Lotus Notes - Chapter 20: Service Tools - CAU Boot Errors

Questions

 Refer to Item 3, Action #1.

If the instrument boots up using a crossover patch cable, what components are suspect? ______________________________________________  Refer to Action #5.

Where on the instrument can the Ethernet # (ICC Hardware Address) be found? ______________________________________________  Refer to the diagram on the next page.

When looking at an RJ45 cable as shown, what distinguishes a crossover cable from a straight-through cable? ______________________________________________ ______________________________________________ ______________________________________________


have learned.





Lab Exercise: Instrument Control Subsystem Objective

This lab exercise guides you and your partner through the following procedures: Removal and replacement of the ICS components Boot to "Console Only" Instrument serial number and Ethernet address entry • • •

Why

By performing the procedures in this lab exercise, you will familiarize yourself with the system's electronic architecture and how the components interact with one another. When installing a DxC or replacing the ICS or ICC, the QNX software on the Multi-Product Console (MPC) needs to know the Ethernet address of the new ICC in order to communicate with the Chemistry Acquisition Unit (CAU). It is a 12 digit hexadecimal number on the face of the ICC bracket. If this number is not entered into the console, the console will not be able to proceed beyond the Hardware Diagnostics Bar Graph. The system will continue trying to communicate for 10 minutes before popping a red Severe Error Message 0X13AC000B requiring a reboot or shutdown, which, of course will not help. To prevent this attempt to communicate with the CAU, the MPC must be booted into the 'Console Only Mode,' which will bypass the connection with the instrument (CAU). At this time, the address and serial number may be entered.

Reference Materials

Unicel DxC Service Manual on Lotus Notes




ICS Removal and Replacement Reference: Unicel DxC Service Manual on Lotus Notes on Lotus Notes - Chapter 10 – ICS/Dual Motor Drivers/Smart Modules - Removal and Replacement - Items 1 through 3 - Diagrams and Schematics - The ICS Expanded View  Power down the instrument.

You must follow proper electrostatic discharge safety pro cedures. The ESD Kit is provided in you r tool box.  The strap portion should be placed around the wrist.  The wire portion can be connected to the system in one of the

following ways:  Alligator Clipped: Wrist straps with an "alligator" clip should be clamped onto the unpainted metal frame of the system. To access, open either the left or center door. If desired, the doors may be closed after the clip is attached to the metal frame.  Banana Plug Insert: Wrist straps with a "banana" plug must be inserted into the jack found next to the Stop button on the front of the system.  Consult with an instructor if you have any questions concerning proper electrostatic safety procedures. FAILURE TO FOLLOW PROPER PROCEDURES WILL DAMAGE THE INSTRUMENT CONTROL COMPUTER

Instrument Control Subsystem

 Locate the ICS and remove it from the instrument.  Remove and reinstall the following ICS components:  ICC  MSMC #1  Fiber Optic Board  Power Contro ller Board  Reinstall the ICS.  Locate the UPS Battery  Power up the DxC.  Verify the system boots to standby.



ICS Removal and Replacement, Cont... Reference: Unicel DxC Service Manual on Lotus Notes - Chapter 18: Software Troubleshooting - Item 6 – Booting Into Console Only Mode

"Console Only" Boot

 Boot to "Console Only".

Note: In addition to the tones, there are also visual cues: As soon as “Starting QNX windows server on node 1…” • disappears the whole screen will be black. An instant later, it will turn gray. • It is at this point that shift-alt-c must be pressed. • If you are too early in the black screen, the normal boot will • continue and you have missed your opportunity. If you are too late after the gray screen appears, you will • have missed it.

Ethernet Address & Serial Number

 On the DxC monitor, select ‘SETUP’.  Select ‘SYSTEM CONFIGURATION’.  Enter the password beckman.       

- The password is case sensitive. Click on the [OK] button Hitting the [ENTER] key on the keyboard will not work. Verify that the hardware ethernet address and Serial Number on your training instrument matches the information on the console. Make changes as required Select [OK] Reboot the system. Verify that the system goes into standby.


have learned.






Lab Exercise: QNX Procedures Objectives

This exercise will direct you and your partner to the QNX procedures that can be useful in resolving corrupted database problems.

Why

Improper shutdown by an operator who did not follow proper procedures often results in corrupted databases. Upon boot, software tries to correct any problem detected in the databases. This process can be lengthy and, often times, results in a big clock on the screen. The larger the database, the longer the boot process will take. Abnormal shutdowns can also result in host communication problems. A host can transmit information to the DxC, but the DxC cannot transmit information to the host. If host communication problems are experienced after an abnormal termination, the hostcomm database should be initialized. If the DxC is in standby, it can be initialized by accessing QNX via Service Setup There are 3 ways to access QNX - the method used will depend on the status of the DxC console. The procedures are self explanatory and do not r equire practice as a laboratory exercise, but it is im portant to review the docum ent for futu re use in the unli kely event that you w ill need them.

Reference Materials

Unicel DxC 600/800 Service Manual on Lotus Notes




QNX Proc edures, cont … Reference: Unicel DxC Service Manual on Lotus Notes - Chapter 18: Software - Software Troubleshooting - Operating System & Network Communication SCENARIO 1 A power outage should not normally cause a corrupted database on the DxC console due to the presence of the Uninterruptible Power Supply. In the rare event that the UPS did not function correctly and the DxC was not shut down properly, the databases can become corrupted. If the Event Log Database is extremely full, it is possible that the system will not be able to repair the corruption before QNX Windows appears. In that case, a large clock indicating that the databases are being corrected will appear telling the operator to please wait and stating that the process can take up to two hours. SCENARIO 2 A more likely cause of corrupted databases is when someone in the lab has turned off the DxC improperly. This can happen when a pop-up error occurs in the middle of the night shift and a trained operator isn't there. The alarm constantly going off might cause untrained personnel to shut the console off in any way and at any cost. Next morning they have the clock. Resolution

It would be best to let the instrument finish its process if at all possible, since it might be finished in five minutes and often is before you even arrive at the account.

QNX

 If that is not an option, the databases can be re-initialized through

access to QNX.  The procedures in the above reference are self explanatory and do not require practice.  Review the document above to familiarize yourself with its contents.  Please feel free to consult with an instructor for clarification.

 Locate an instructor for sign off on this exercise.



Lab Exercise: Event Logs Objectives

This exercise will guide you and your partner through the following procedures: Viewing information displayed in the Event Log. Identifying information found in the Event Log • •

Why

Because the Event Log records both error and normal conditions that occur within the instrument, it is a valuable source of information while troubleshooting. Event Log Error Codes are referred to throughout the service manual for troubleshooting specific problems. Event Log troubleshooting will be used throughout this course and is an integral part of DxC Basic Training.

Reference Materials

Unicel DxC 600/800 Service Manual on Lotus Notes DxC Instructions For Use Manual




Event Lo gs Reference: Unicel DxC Service Manual on Lotus Notes Chapter 18: Software – Software Troubleshooting - Event Log Chapter 21: System Troubleshooting – Event Log Error Codes DxC Instructions For Use Manual Chapter 12 – Utilities- Event Codes Event Log s

 Read the above references while reviewing each event log on your

instrument.  Load an empty sample rack with the bar code label facing the wrong direction. Observe the information presented on the DxC monitor.

Questions

What message appeared on the DxC monitor ? ________________________________________________ What were the Event ID and Class Number (for the pop-up message on the DxC monitor)? ________________________________________________

Event Log s  Locate the error message in the Event Log. Print the screen that

displays the event log information regarding this event.  Program the following request on DxC. Since a barcode label will

not be provided for you, manually assign this sample to a rack and cup. Sample ID: Test Test: K  Place the assigned rack/pos on the autoloader tray without any

sample! Initiate the run and observe the DxC monitor.

Questions

What message appeared on the DxC monitor? ________________________________________________ What were the Event ID and Class Number? ________________________________________________



Event Logs , Cont… Event Log s

 Locate the error message in the Event Log. Print the screen that

displays the event log information regarding this event.

Questions Cont...

 In the table below, match the severity code with its correct

description.

Severity Code System Error

Descrip tion All significant events that are not errors are assigned this severity code.

Important Message

Recovery from this error can only be done by rebooting the instrument.

Message

An event with this severity code indicates a situation of which the operator needs to be informed, but no immediate action or acknowledgment is required.

Event

An event with this error code indicates a situation wherein the operator needs to be informed, but no immediate action or acknowledgment is required.

Which severity codes will cause a pop-up on the monitor? ________________________________________________


have learned.






Power Smart Modules Fiber Optics Exercises

UNICEL DxC 600/800 Pro Basic Service; Power, Smart Modules, Fiber Optics Version B 04162007





Lab Exercise: Power Subsystem Objectives

This lab exercise will guide you and your partner through the following: Location of Power Subsystem components Remove and replace power supply Observe normal power up sequence Identify LED display codes Power supply adjustments Power supply measurements • • • • • •

Why

Troubleshooting the power subsystem starts with a good understanding of the power up sequence, the components within the system, and how these components are integrated.

Materials

Fluke DMM provided.

Reference Materials

Unicel DxC Service Manual on Lotus Notes Fluke 187 & 189 Users Manual on the training CD




Power Subsystem Reference: Unicel DxC Service Manual on Lotus Notes Chapter 4: Installation Item 4 – Computer Setup Chapter 14: Power Subsystem Removal and Replacement  Power down the instrument.  Unplug the CAU input power from the UPS

Components

 Locate the following Power Subsystem Components:  Isolatran  220vac input J101  220vac outputs J100A, J100B & J100C  +24.5vdc Power Supply  +36.0vdc Power Supply  Power Distribution Board

Power Supplies

   

Remove and reinstall the +24.5vdc power supply. Check one more time to insure correct cabling. Plug the input power back into the UPS. Do not power up.

Reference: Unicel DxC Service Manual on Lotus Notes Chapter 14: Power Subsystem - Troubleshooting - Item #3 The diagnostic four digit display - Item #6 The Power Distribution Initialization / Startup LED Disp lay

 Review the above references.  Compare Item #3 to what is occurring on the instrument as you

power up the DxC.  Verify that the instrument goes into standby.



Power Subsy stem, Cont... Reference: Unicel DxC Service Manual on Lotus Notes Chapter 14: Power Subsystem Fluke 187 & 189 Users Manual Power Measurements

 Measure the inputs to the Isolatran and power supplies and the

outputs of each power supply and fill in the information below.

Inputs Supply

Ground (G/Y) to

Ground (G/Y) to

Neutral (BLU) to

Neutral (BLU)

Load (BRN)

Load (BRN)

Isolatran +24.5vdc +36.0vdc

Outputs +24.5vdc +36.0vdc



Power Subsy stem, Cont... Reference: Unicel DxC Service Manual on Lotus Notes Chapter 14: Power Subsystem - Adjustment Fluke 187 & 189 Users Manual Power Adju stments DC Power Measurements Under Various Load Conditions

 Perform power supply adjustments.

 Check the power supply outputs under load conditions.

1. Connect the DMM using alligator clips to the output of the 2. 3. 4. 5. 6. 7. 8.

+24vdc power supply. Enter the MIN MAX mode. Press the stop button on the DxC. Exit the MIN MAX mode. Enter the MIN MAX mode. Home the DxC. When the instrument reaches standby, record the minimum and maximum readings in the table below. Repeat steps 1 through 8 for the +36vdc power supply.

+24.5vdc Power Supply During Stop

MIN ____________

MAX ____________

During Home

MIN ____________

MAX ____________

+36.0vdc Power Supply During Stop

MIN ____________

MAX ____________

During Home

MIN ____________

MAX ____________



Power Subsy stem, Cont... Reference: Unicel DxC Service Manual on Lotus Notes Chapter 14: Power Subsystem - Electronics - Removal and Replacement Power Distribution Board

Power Distribution Board

Fans Loc ation

 Review the Electronics document in the above reference and

become familiar with component locations. 1. Power Distribution Board 2. On Board Power Supplies 3. Input Power 4. + 24.5 V Bus Voltage Interface 5. + 36 V Bus Voltage Interface 6. Peltier Status Interface (J15) 7. Refrigerator Temperature Interface (J34) 8. Fan Tachometer Interface (J29) 9. Fiber Optic Repeater Board Power Interface (J13) 10. Board/ICS Power and Fan Voltage Interface (J28) 11. RS232 Debug Interface (J43)  Locate the six system fans on the DxC.


have learned.



Lab Exercise: Smart Modules & Fiber Optics Objective

This lab exercise guides you and your partner through the following procedures: Location of the various smart modules in the DXC Troubleshooting Fiber Optics • •

Why

By performing the procedures in this lab exercise, you will familiarize yourself with the system's electronics components and how they communicate with one another.

Reference Materials


Please feel free to consu lt wit h an instr ucto r if you have any questions about the info rmation in this exercise.



Smart Modules & Fiber Optics: Reference: Unicel DxC Service Manual on Lotus Notes: Chapter 10: ICS/Dual Motor Drivers/Smart Modules - Diagrams and Schematics - Smart Module Locations DxC Basic Service Training CD - Fiber Optics Diagrams - Troubleshooting Fiber Optics Smart Module Identification

 Remove the covers and locate all the smart modules on your

Fiber Optic Checks

 Perform MSMC Loop-back Test located on Service Setup Menu.  Main Menu  Select Setup on the Icon Menu Bar  Select [23] Service Setup  Obtain password using Service Password Generator  Enter password on Password Screen and select [OK}

training instrument.  Identify the address switch locations on the smart modules.  Compare your instrument with the Fiber Optics Diagram.

If you have generated and entered the correct password, you will be in the Service Setup Screen, if not repeat the process.  On the Service Setup Menu select [8] MSMC Loopback Test  Follow the on-screen instructions.  Review the fiber optics troubleshooting procedure on the DxC

Basic Service Training CD  Feel free to consult an instructor for clarification or demonstration.


have learned.






Hydropneumatics Exercises

UNICEL DxC 600/800 Pro Basic Service, Hydropneumatics Version B 04162007





Lab Exercise: Hydropneumatics Objectives

This exercise will guide you and your partner through the following procedures: Component identification Observe instrument status during routine hydro operation Valves: Removal & replacement of valves Perform the following diagnostics tests: Vacuum and air pump test Float switch tests Hydro valves tests Pump Box access Review PMC procedures Review decontamination procedure • • •

•

•

• • •

• • •

Why

The hydropneumatics system is essentially the heart & lungs of the instrument. Diagnostics allows the operator the ability to test the functionality of a component (pump, float switch, etc.) without having to shut down the system. In addition, diagnostics provides the operator with real-time feedback while they are adjusting pressures.

Reference Materials





Hydropneumatics Reference: Unicel DXC Service Manual on Lotus Notes Chapter 9: Hydropneumatics

Component Identification

 Shutdown the DxC.  Locate the following hydropneumatic components on your training

instrument. Components Location – Rear of Instrument

 Remove the center section and the left section air ducts from the

Pump Box

 Locate the Pump Box Stop Bracket with pump on/off switch from

back of the DXC.  Unplug the center fan and both left fans.  Remove the fans to access the frame compartment s.  Inspect the following hydropneumatic components on your training instrument.  Gravity drain assembly  Restrictor Reservoir A19456  Waste connections  DI water connections

     

Components Location Hydro Drawer and System

front of the DxC. Pull out the Pump Box per procedure. Remove the cover and identify the components using the Pump Box Diagram provided. Reinstall the Pump Box and associated assemblies, Reinstall the fans. Reinstall the air ducts. Power up the DxC

 Observe the operation of the hydro drawer while the instrument is

homing, when the pumps come on, valve operation, etc.  On the DxC, locate all of the components depicted on the Master Hydropneumatic Schematic in the above reference.  Do the same with the major assemblies on DxC 600/800 HydroPneumatic Diagram P/N A18111.



Hydropneumatics, Cont… Routine Hydro Operation

 View instrument's Hydro Status on your instrument's monitor.  Home the instrument.  While the instrument is homing, observe the information displayed

on the Status screen. Pump Volume and Recovery

 Initiate 20 primes on the instrument:  While the instrument is priming:  Observe how low each of the pressure and vacuum gauges

dip during thi s process – it is an important indicator of the ability of th e pumps to provi de a const ant volume when under stress.  Record the values in the table below.

Volume Stress Test Vacuum - inHg

MIN ____________

MAX ____________

10psi

MIN ____________

MAX ____________

17psi

MIN ____________

MAX ____________

25psi

MIN ____________

MAX ____________

Questions

When the DI Water Reservoir float switch reaches the ' EMPTY' position, which valve and LED turns on to fill the canister? Valve(s) #: ___________________LED(s) #: ___________________ What is the responsibility of each valve? ___________________________________________ ___________________________________________ ___________________________________________



Hydropneumatics, Cont… Valves Operation

 If your instrument is still priming, STOP the prime.  Locate DI Water Inlet Valve, V0, and the gray valve override button .

Manually fill the DI Water Reservoir using this valve. FYI While manually fill ing the DI Water Reservoir, it is i mport ant NOT to turn the gray button while pushing in. Doing so will cause it to remain open.  Select Hydro Maintenance from the Utilities-Maintenance menu.  Remove the Wash Solution canister from the instrument. Empty out

its contents. Note: Do NOT lose the O-ring! This is required to ensure a tight s eal.  Replace the canister back on the instrument.  Exit out of Hydro Maintenance.  Observe the canister as it is being filled and answer the questions below. Questions

Which valve(s) and LED(s) are responsible for filling this canister? Valve(s) #: __________________LED(s) #: __________________ What is the responsibility of each valve? _________________________________________ _________________________________________ _________________________________________

Valves Removal and Replacement

    

Remove Valves V31 & V32. Disassemble and clean the valves. Place V31 & V32 back on the hydro. Exit out of maintenance. Prime as necessary to verify proper operation of the Valve 31,



Hydropneumatics, Cont… Reference: Unicel DXC Service Manual on Lotus Notes Chapter 9: Hydropneumatics - Troubleshooting

Note: Diagnostics

Vacuum and Ai r Pump Pu mp Test

Float Switc Switc h Test

Information displ ayed ayed u nder STATUS STATUS is updated every 9 seconds. To view "real-time" "real-time" in formation , perform adjustments in Diagnostics mo de.

the Vacuum and and Air Pump Tests  Access the  Select the Utilities Icon  [4] Diagnostics  Functional Area – Hydropneumatic System  [1] Vacuum and Air Pump Test  [Vacuum Pump] and then [Set] will turn the pumps on or off, the indicator on the button will be blue when the pumps are on. pressure relief relief valve to attain a 25psi 25psi reading reading on  Adjust the high pressure the gauge. the 10psi and and 17psi regulators regulators to attain the proper proper reading  Adjust the on the Vacuum and Air Pump Test Screen.  Exit Diagnostics  Verify your adjustments on the Hydro Status Screen. the Float Switch Tests.  Access the  Turn off the DI water inlet valve on the hydro drawer.  Disconnect the DI Water Reservoir float switch and connect the cable to the float switch provided at your work station.  Manipulate the test float switch and observe the changes on the test screen.  Perform the same steps while watching the LED display on the Hydro Control Board. Note which SR LED lights up when the float is at the top and which V LED lights with it, and do the same when the float is on the bottom.  Verify that they are working properly by comparing them with the designations in the service manual.  Reconnect the instrument's float switch.

UNICEL DxC 600/800 Pro Basic Service, Hydropneumatics Hydropneumatics Version B 04162007


Hydropneumatics, Cont… Questions

Why is it important to turn OFF DI water at V0 when exercising float switches even though the canisters are not under pressure? ______________ ______________________ _______________ ______________ ______________ ___________ ____ ______________ ______________________ _______________ ______________ ______________ ___________ ____ List the 3 possible readings/conditions that you may see for float switches: ______________ ______________________ _______________ ___________ ____ ______________ ______________________ _______________ ___________ ____ ______________ ______________________ _______________ ___________ ____

Hydro Valves Diagnostic

Valves Diagnostic Diagnostic  Access the Hydro Valves  Each button has an indicator that turns blue when the valve is          

Instrument Verification

ready to be turned on. The [Set] button will actually activate the selection. Once on it will not turn off until the button is selected again and the [Set] button is pressed. Select valve(s) by clicking on the check box to the left of the valve(s). One or more valves or all valves at the same time. Once the valve(s) is selected, click on . . Watch the selected valve light(s) come on and each valve clicks open and closed. Deselect the valve check box(s) and select . . If a valve light fails to come on, check the connection and harnesses. If the light continues to fail, replace the valve. Exit Diagnostics Turn the DI water inlet valve back on. Home the instrument.

 Verify that the instrument is in Standby mode and that all the

instrument status is within specifications.  Calibrate all Modular Chemistries



Hydropneumatics, Cont…  Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and to demonstrate what you

have learned.

Reference: DXC Service Manual on Lotus Notes Chapter 9: Hydropneumatics - System Decontamination Procedure (ISE/MC/HYDRO) Chapter 11: ISE Module - DxC 600/800 System Decontamination Procedure (MC/ISE/HYDRO)  Review the above reference to become familiar with the procedure.






Sample Rack Handling Subsystem Exercises

UNICEL DXC 600/800 Pro Basic Service, Sample Rack Handling, TS-CTS Version AA 08292006





Lab Exercise: Cap Piercer TS-CTS Objectives

This exercise will guide you and your partner through the following procedures: Bar-code reader removal and replacement TS-CTS removal and replacement Blade & wick removal and replacement Autogloss pump repair and replacement One blade TS-CTS functional alignment • • • • •

Why

We have discussed some of the problems you might see in the field regarding the cap piercer. Use this opportunity to become familiar with the operation, repair and alignment of the TS-CTS.

Reference Materials





Cap Piercer TS-CTS: Reference: Unicel DXC Service Manual on Lotus Notes Chapter 17: Sample Handling - Removal and Replacement - The Barcode Reader Barcode Reader Removal

 Remove the barcode reader as described in the above reference.  Do not replace it at this time.

Reference: Unicel DXC Service Manual on Lotus Notes Chapter 6: Cap Piercer - Removal and Replacement - The Blade, Wick removal and replacement Procedure -The Linear Pump Replacement and Alignment Blade & Wick Removal

 Perform the procedure as described in the above reference.

Linear Pump Removal and Replacement

 Perform the procedure as described in the above reference.

Reference: Unicel DXC Service Manual on Lotus Notes Chapter 6: Cap Piercer - Cap Piercer Removal and Replacement Procedure


have learned.



Lab Exercise: Sample Rack Handling Objectives

This exercise will guide you and your partner through the following procedures: Shuttle latch solenoid removal and replacement Onload tray assembly removal and replacement Offload tray assembly removal and replacement Shuttle assembly removal and replacement Sample rack handling alignment procedures • • • • •

Why

The Sample Rack Handling subsystem is one of the subsystems within the DXC. Its primary function is to introduce sample racks containing sample containers. The shuttle mechanism guides the sample rack to the bar code reader, the cap piercing stations (if present), and onto the sample wheel. Once the rack is on the sample wheel, the MC and CC sample probes can access the samples in order to process any requested test(s). At the completion of a run, the rack is off loaded from the sample wheel to the offload tray.

Reference Materials





Sampl e Rack Handl ing : Reference: Unicel DxC 600/800 Service Manual on Lotus Notes Chapter 17: Sample Handling - Arm/Latch Solenoid - Onload Tray - Offload Tray - Shuttle Assembly Arm/ Latch Solenoid

 Remove and reinstall the shuttle latch solenoid.

Onload Tray Removal

 Remove the Onload Tray and inspect the replaceable components.  Compare the DxC 600 Onload Tray with the DxC 800 Onload Tray.

Offload Tray Removal

 Remove the Offload Tray and inspect the replaceable components.

Shuttle Assembl y Removal Reinst all all SRH Components

Sampl e Rack Handling Alig nm ents

 Remove the Shuttle Assembly and inspect the replaceable

components.

 Reinstall all Sample Rack Handling Components on your training

instrument:  Shuttle Assembly  Offload Tray  Onload Tray  TS-CTS Cap Piercer  Barcode Reader.  Perform the following Functional Area alignment procedures  Sample Carousel  Sample Rack Handling  Cap Piercer



Sample Rack Handling, Cont... Al ignm ents Verification

To test the alignments you have just made:  Place an un-programmed 75mm or 100mm rack with four capped tubes in the onload tray.  Press the Run Button.  Observe that the caps are pierced on all four tubes.

Event Log s Previously Un-pierced Tube

 Clear all sample IDs from your instrument.  Clear the event logs on your instrument  In a non-reserved rack place:

Event Log s Previously Pierced Tube

   

Do not clear the sample IDs from your in strum ent. Re-run the same sample rack from the above steps. Observe the cap piercer as each rack position is presented to it. Do not clear the event logs.

Event Log s Reserved Rack

   

Clear the sample IDs from yo ur ins trument. Reserve the rack that you have just used in the above steps. Place the rack on the instrument and press the run button. When the instrument offloads the rack, bring up Event Log #10 and print it.

Event Lo g #10 Information

 Find each instance where the run button was pressed, highlight it

A capped bar-coded tube in position #1 An uncapped tube with no barcode in position #2 A cup in position #3 Nothing in position #4  Place the rack on the instrument and press the run button.  Observe the cap piercer as each rack position is presented to it.  Do not clear the event logs.

-

and review the subsequent events, such as pierce status, when it is loaded on the sample wheel, etc. .  Compare the on the printout with the table on the next page.



Sample Rack Handling, Cont...

Description Codes Event

Message

10

E

Event or Log Description ID: r: p: dba: c: ptype: pri: Chems:

Description

< container type>: 0=unknown 1=empty 2=tube 3=cup 4=reserved : 0=patient sample : 0=normal 1=rerun 2=reflex 3=critical rerun 4=STAT : Format xxxx-yy where xxxx is chemistry ID and yy is number of replications. Max of 15 chemistries listed.


have learned.



MC Sample MC Cups Exercises

Unicel DxC 600/800 Pro Basic Service, MC Sample & Cups Exercises Version A 08292006





Lab Exercise: MC Sample Syringe Drive Assembly Objectives

This exercise will guide you and your partner through the removal and reinstallation of MC Sample Syringe Drive Assembly.

Why

The Syringe Drive Assembly can become noisy. Replacement of the Syringe Drive Shaft Assembly may be necessary.

Reference Materials





MC Sampl e Syri nge Drive Assembly Reference: Unicel DXC Service Manual on Lotus Notes No reference in the Service Manual. Consult an instructor when necessary.

MC Sample Syringe Assembl y

 Shutdown your DxC properly.  Run the syringe rods down manually by rotating the lead screw flex

coupling.  Remove the syringes from the Dual Syringe Assembly.  Remove the 3 way shear valve from both the MC and CC Sample Syringe Assemblies.

 Notice the spring on the shaft. Together with the offset pin on the

motor shaft, it forms a key which prevents the valve from being placed on the motor shaft incorrectly.

 Remove the Dual Sample Syringe Pump Assembly and become

familiar with its replaceable components.  Reinstall the Dual Sample Syringe Pump Assembly.  Reinstall the shear valves.  Replace the syringes.



MC Sample Syrin ge Drive As sembly, Cont... Syringe Replacement Maintenance Procedure

The following will bring the syringes to a position where an operator can replace them without shutting the instrument down or pressing the stop button to move them manually.  Utilities  [2] Maintenance  [7] Syringe Rod Replacement  [Continue]

Verify

 Power up the DxC.  Verify that the instrument comes to standby.

Prime

 Prime the sample system  Utilities Icon  [1] Prime  [CC F2]  [Sample Delivery Subsystem]  5 primes  Observe the instrument as it primes.

 Proceed to the sample crane exercises.



Lab Exercise: DxC Sample Cranes Objectives

This exercise will guide you and your partner through the following: Removal and replacement of (MC) Crane Inspect the Triple Crane Assembly Removal and replacement of (MC) probe Perform MC Crane Alignments • • • •

Why

Occasionally the MC Sample Crane shaft assembly rails (3) require cleaning with isopropyl alcohol. Damaged and/or misaligned MC sample probes can affect chemistry performance problems resulting in level sense errors, suppressed results, flyers, and imprecision.

Reference Materials





DxC 800 MC Sample Crane Reference: Unicel DxC Service Manual on Lotus Notes Chapter 17: Sample Handling DxC 800 MC Sample Crane (Diagram) No reference in th e Service Manual. Consult an instr uctor w hen necessary. DxC 800 MC Sample Crane

Dirt and dust, which may accumulate along the guide rails of a crane assembly, can affect the timing and motion of the probe travel (triggering motion errors and/or level sense errors). It is therefore important to clean these guide rails periodically with alcohol pads.  Shutdown the DxC.  Remove the MC Crane from your training instrument. Inspect the

guide shafts & clean if necessary. Verify that the shaft coupling has not come loose.  Reinstall the MC Sample Crane.

DxC 600 Triple Crane Reference: Unicel DxC Service Manual on Lotus Notes Chapter 17: Sample Handling DxC 600 Triple Crane Overview DxC 600 Tripl e Crane

 Remove the covers from the MC Sample Crane and observe the

replaceable components.

DxC MC Sample Probes MC Sample Probe

 Remove and reinstall the MC sample probe.  Loosen the collar wash clamp and pull the collar wash out

leaving the tubing connected.  Remove the probe taking care not to lose the 'o' ring.  Reinstall the probe and the collar wash.



MC Sample Crane, Cont…. Reference: Unicel DXC Service Manual: Chapter 17: Sample Handling - Alignment and Adjustment - CC and MC Sample Probe Alignments Al ignm ent

 Since you had performed removal/replacement procedures of the

MC crane & probe, it is necessary to perform the following alignment procedures: [1] MC Sample Probe Liquid Level Sense [2] MC Sample Probe Rotary Home [3] MC Sample Probe Rotary to Sample Carousel [4] MC Sample Probe Rotary to Cups [5] MC Sample Probe Rotary to EIC [6] MC Sample Probe Vertical Home and Wash [7] MC Probe Sample Height [8] MC Probe Cup Height [9] MC Probe EIC Height [10] MC Sample Probe Obstruction Detection • • • • • • • • • •

 Don't forget to backup your new alignment information to a disk.  Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and to demonstrate what you

have learned.



Lab Exercise: Modular Chemistry - Cups Objectives

This exercise will guide you and your partner through the following: Identification of LED status/colors Removal and reinstallation of an MC cup module Removal and reinstallation of reagent pump and valves Removal and reinstallation of stir motor Adjustment of temperature via diagnostic Removal and reinstallation of an MC lamp via diagnostics Lamp calibration • • • • • • •

Why

Each cup must go through the fill, stir and drain process during normal operation. Inadequate cup filling, stirring or draining can lead to erroneous patient results. Should these events occur, it might become necessary to replace components within the cup module assembly. All cup modules have preheaters. Their primary function is to preheat both the reagent and the rinse DI water to the appropriate reaction temperature. For most of the cups, the appropriate reaction temperature 37 ºC, with the exception of CREm which is 41 ºC. Temperature adjustment becomes necessary when temperature is not within specifications. Another cup component that may require replacement is the lamp. On the DXC lamp replacement can be performed only when: The instrument is powered down. Or The lamp is turned off in the ADC/Analog Board Test that is located in the Diagnostics section of the Utilities Menu. •

•

Replacing a lamp when the instrument is p owered up and not in Diagnost ics can damage the loop con trol s ection of t he power supply on the cup controller board.

Test Equipment

Calibrated Temperature Probe.

Reference Materials





Modular Chemistry – Cups Reference: Unicel DXC Service Manual on Lotus Notes Chapter 8: Cup Modules - Items #1 through # 9 Shutdown

 Shutdown the DxC.

Cup Module

 Remove GLUm cup module.

Controller Board

 Remove and reinstall the GLUm controller board.

Stirrer Motor

 Remove and reinstall the stirrer motor.

Reagent Pump

 Remove and reinstall the reagent pump.

Reagent Valves

 Remove and reinstall the reagent valves.

Reinstall Cup Module

 Reinstall the GLUm cup module back on the instrument.

MC Manifold

 Locate MC Manifold on both a DxC 600 and 800 and note the

differences. DxC 800

 Locate the waste restrictor.

Power Up

 Power up the DxC and verify that it reaches standby.

Reference: Unicel DXC Service Manual on Lotus Notes Chapter 8: Cup Modules - Alignment and Adjustments Temperature Ad ju st

 Adjust GLUm cup temperature.



Modular Chemistry – Cups, Cont… Reference: Unicel DXC Service Manual on Lotus Notes Chapter 8: Cup Modules - Removal and Replacement - MC Modules Lamp Replacement DxC 800 Lamp Removal and Replacement

DxC 600

 Remove and replace a cup module lamp per the procedure above.  Calibrate all lamps and the GLUm sensor.  Utilities Icon  [2] Maintenance  [8] CUPs Lamp/Sensor Calibration  Select all available entries.  Follow the above steps to calibrate the Glucose Sensor.


have learned.






MC/ISE Preventive Maintenance Exercises

UNICEL DxC 600/800 Pro Basic Service, MC ISE & Preventive Maintenance Version B 02062007





Lab Exercise: MC/ISE & Preventive Maintenance Objectives

This exercise will guide you and your partner through the following: Remove the Flow Cell and replace the Carbon Bridge. Strike carbon bridge Preventive Maintenance ISE & MC • • •

Why

This is your opportunity to take a closer look at the ISE and review the PMC checklist / procedures.

Reference Materials





Carbo n Bridge Replacement Exercise: Reference: Unicel DXC Service Manual on Lotus Notes Chapter 11: ISE Module - The Carbon Bridge - Replacing of the Carbon Bridge - Carbon Bridge Striking Carbon Bridge Replacement

 On the instrument select the Utilities Icon, Maintenance, ISE

Service and Continue.  Do not exit this menu until procedure is completed.

Exiting t his menu before completion of procedure will damage the electro des.  Replace the carbon bridge.

Removal side Insertion side Carbon Bridge Replacement Tool P/N 450627

Striking the Carbon Bridge

 Striking the carbon bridge on the DXC is part of the installation

procedure. Please take the time and review the procedure as described in the reference above. A striking tool is available for you to inspect and/or use while here in training.

Carbon Bridge Striking Tool P/N 474433

Calibrate the Electrolytes

 Calibrate the Flowcell.  Please feel free to consult an instructor.  When all electrolytes have calibrated, move on to the next

exercise.



Preventive Maintenance Reference: Unicel DxC Service Manual on Lotus Notes Chapter 5: Preventive Maintenance - UniCel DxC 600/800 Preventative Maintenance Checklists. - UniCel DxC 600/800 PMC Schedule and Kit Part Numbers - UniCel DxC 600/800, PM A Kit, (Major CC), P/N A22681 - UniCel DxC 600/800 PM B Kit, (Major MC/CC), P/N A22683 - UniCel DxC 800, PM Minor Kit, (ISE/MC), P/N A37245 - UniCel DxC 600, PM Minor Kit, (ISE/MC), P/N A37244 PMC

 Using the above references, perform a PM Minor on your

instrument.  Do not perform Items # 2.12, 2.13 & 2.14

Please feel free to co nsult with an instruc tor i f you find any disc repancies or h ave any qu estio ns about the info rmation in this exercis e.


have learned.






DxC 600/800 System Decontamination Exercise

UNICEL DxC 600/800 Pro Basic Service, Decontamination Version B 02222007





Lab Exercise: Decontamination Objectives

This exercise will guide you and your partner through the following: Decontamination Procedures •

Why

There are occasions when the same symptoms seem to be recurring in a periodic manner. This might be the result of repairing the symptom rather than the root cause. One of the possible causes might be bacterial contamination of the instrument, for example: 1. Chronic LOW NA and HIGH CO2 fliers. 2. Chronic LOW K or Sample Reference Drift error flag 3. CO2 fails to calibrate but calibrates when the ISE Reference Solution is replaced. To resolve this situation, the DxC Decontamination Procedure must be performed.

Reference Materials





DxC System Decontamination: Reference: Unicel DXC Service Manual on Lotus Notes Chapter 11: ISE Module - DxC 600/800 System Decontamination Procedure (MC/ISE/HYDRO)

For your convenience, the above document has been reproduced on the foll owin g pages. Please feel free to consul t wit h an instr uctor if y ou fin d any disc repancies or h ave any questio ns about the info rmation in t his exercise.

DxC 600/800 System

 You have already demonstrated the skills required to perform this

procedure, so practice is unnecessary.  Thoroughly read the following document and using your instrument as a reference, familiarize yourself with the procedures involved.



ISE DECONTAMINATION GUIDE FOR FIELD SERVICE



Possible signs of contamination: Chronic LOW NA and HIGH CO2 fliers Chronic LOW K or Sample Reference Drift error flag

Before performin g th e decontamination p rocedure: 1. -Check alignment of sample probe to EIC -EIC valves -Illegal grounds – spills, leaks, ISE drain -Carbon bridge -Check / replace electrodes of chemistry exhibiting fliers -Sample probe collar washer for alignment and buildup -(Refer back to DxC Service Manual for appropriate information)

2. With the help of the hospital’s microbiology dept, culture taking swabs from the following areas listed below. In the case of the DI Water going from the tanks into the System if the bacteria count is greater than 50 cfu/mL, then the water is contaminated. -All measuring electrodes – bacteria count should be less than 400 cfu/mL -Incoming and outgoing reagent lines – bacteria count should be less than 400 cfu/mL -ISE reagents – bacteria count should be less than 400 cfu/mL -Sample injection port – bacteria count should be less than 400 cfu/mL -DI water reservoir/canisters on system – bacteria count should be less than 100 cfu/mL Note inserted by Professional Development: In Microbiology, colony-forming unit (CFU) is a measure of viable bacterial numbers. Unlike in direct microscopic counts where all cells, dead and living, are counted, the cfu measures viable cells. A sample is spread or poured on a surface of an agar plate, left to incubate and the numbers of colonies formed are counted. Cfu number is not an exact measure of numbers of viable cells, as a colony-forming unit may contain more cells.



Decontamination Procedure NOTE 1: When performing the decontamination procedure, you MUST COMPLETE both the Acetic Acid/Hydrogen Peroxide and Chlorine Dioxide decontamination procedures as listed below: NOTE 2: To reduce decontamination time, Tech Support suggests engineer prepares Chlorine Dioxide solution first, because the solution needs to sit for 1 hour prior to use. (Chlorine Dioxide solution will turn to a pale green color after 1 hour). Mix 2 liters of DI water to one packet of Chlorine Dioxide. (Two packets required for 4L.) Let it sit for one hour. This is a 100-ppm solution. NOTE 3: Both procedures, ( 1. Acetic Acid/Hydrogen Peroxide 2. Chlorine Dioxide) are used to remove biological contaminants that contribute to erroneous ISE results. Please read carefully and perform both procedures. Note 4: Have the customer soak a Potassium tip and Calcium tip in LX ISE Reference Solution for 24 hrs before starting procedure. Materials needed fo r Ac etic Aci d/Hydrogen Peroxide pro cedure: -DxC PM Minor Kit (A22682) -10% Glacial Acetic Acid (A24880) Qty: 2 -3% Hydrogen Peroxide (A24881) Qty: 2 -Cap and Straw Kit x 2 (476293) -2 Large Mouth Beakers or containers (1L or greater) -DI Water -Gloves -Safety Glasses Materials needed f or Chlori ne Dioxide procedure: -Dummy ISE electrodes (P/N 668077), or “old” used electrodes for the ISE, Glucose and BUN -One kit of Chlorine Dioxide (P/N A22197 – Kit contains 2 packets) -Fresh bottles of Electrolyte Buffer, Electrolyte Reference and CO 2 Acid -One clamp (hemostat) -One four-liter container -One 1L beaker -Degasser (471650) -0.2 Micron Filter (949898) -Potassium Tip (669117) -Calcium Tip (467769) -NA Electrode (668295)



PERFORM DECONTAMINATION PROCEDURE USING ACETIC ACID (Acetic Acid , 10% 500ml/bo ttle) AND HYDROGEN PEROXIDE (Hydrogen Peroxide 3% 500ml/bottle) 1. Remove straws from reagent bottles except line 33 from Alkaline Buffer bottle. 2. Dry prime by using “All ISE” command 20 times to remove reagent fluid from ISE module. Remove reagent bottles when complete. 3. Remove reagent tray. Note: Removing reagent tray is used to install lines 11,12,13,14, and 15 for better access., , 4. Remove/disassemble ISE tubing, flowcell/electrodes, ratio pump chambers, Alkaline Buffer damper, and EIC assy. Note: When disassembling ratio pump and EIC remove the solenoid valves, leaving the electrical connections alone. Make sure the o-rings on the solenoids are still in place. 5.

Prepare 1Lbeaker by pouring 2 bottles (500ml each) of 10% dilution of Acetic Acid or container that has sufficient room to soak and bathe the ratio pump and flow cell parts. A one-liter beaker works well for this purpose. Flow cell parts can be bathed in the beaker after the ratio pump parts. Safety Note: Wearing gloves and safety glasses are a must due to the acid, which will irritate unprotected skin and eyes.

6. Prepare another 1L beaker by pouring 2 bottles (500ml each) of Hydrogen Peroxide. Soak disassembled parts from ratio pump, flow cell, EIC assembly and damper for 10 minutes in the Acetic Acid solution, rinse thoroughly with DI water. Then soak disassembled parts in the Hydrogen Peroxide solution for 10 minutes. Rinse thoroughly with DI water. 7. Wipe the face of the solenoids (ratio pump and EIC) with Acetic Acid then Hydrogen Peroxide solution, and finish with DI water. 8. Reassemble and install ratio pump with new seals, damper, flowcell, EIC Cup with new spacer and o-ring. Note: When replacing electrodes use NEW QUAD RINGS. Install for now, “old/dummy” electrodes in flowcell, Glucose, and BUN modules. 9. Install NEW ISE tubing. 10. Replace the Buffer and Reference caps and straws with new.



11. Put these straws in the beaker of Acetic Acid/DI water solution that was used earlier and prime 15 times “All ISE”. Every 3 minutes do 1 prime. Complete this procedure 5 times. Upon completion, the Acetic Acid solution will remain in the Buffer/Reference lines for a total of 15 minutes.. (This is used to clean various other areas i.e.…ratio pump piston, valve manifold) 12. Remove straws from the Acetic Acid solution; wipe straws dry and prime once for an air slug. Put straws in the Hydrogen Peroxide beaker that was used earlier and repeat the priming procedure as same as Acetic Acid. 13. Remove straws out of the Hydrogen Peroxide and wipe clean. Put straws in a beaker of DI water and prime 25 times “All ISE”. Prime 5 times with the straws out of the DI water to drain tubing of fluids. 14. This completes first procedure.

DECONTAMINATION PROCEDURE OF HYDRO USING CHLORINE DIOXIDE (Kit P/N A22197) 1. Remove the wash solution canister and dump out the contents, clean with DI water, fill the canister with DI water and install it back on the hydro. 2. Clamp off Wash Concentrate line #145. This line is coming out of the top of the wash concentrate canister. 3. Prime hydro 10 times to remove all wash concentrate out of the system. Waste reservoir should not have suds at the end of the priming cycles. 4. Put the straws from the electrolyte buffer, reference and CO 2 acid bottles into a 1L beaker with prepared chlorine dioxide solution. Make sure there is enough solution (approx. 200ml) for 20-30 primes. ISE will turn a greenish color. 5. With rest of the four-liter container, shut off customer outlet valve and remove the DI water line from that point and put line into four liter container. Note: The 0.2 micron filter will remain with DI water line, but will be replaced at a later step in the procedure. a. You will need to follow the document "Filling the DI Water Reservoir using V3 Vacuum," in Chapter 9: Hydropneumatics of the DxC 600/800 Service Manual. 6. Prime all 15 times. You should see the greenish Chlorine Dioxide solution in the DI water and the wash solution canisters. 7. After prime, let the solution sit for one hour in the system. (Very Important). UNICEL DxC 600/800 Pro Basic Service, Decontamination Version B 02222007


8. Remove the four-liter container and beaker from the instrument and prime one time. 9. Reattach the DI water line to customer outlet valve along with the new 0.2 Micron filter (949898) and put the ISE buffer, ISE reference reagent and CO 2 acid reagent straws into a beaker of DI water. 10. Prime the ISE 20 times with the straws in the DI water, then remove the straws and prime with air 5 times. 11. Install new “K” and “Calc” tips. Clean the CO 2 and NA Reference Electrode glass ends with alcohol pads several times. Note: When replacing electrodes, use NEW QUAD RINGS. Replace NA and Chloride Electrodes, and remembrane the CO 2 Electrode. Install original BUN and Glucose electrodes. Strike the flowcell carbon bridge. 12. Next, put on new bottles of ISE electrolyte buffer, ISE electrolyte reference and CO2 acid. Replace the Degassers (471650). Reset reagent volumes to current values. 13. Prime all 20 times. 14. Remove wash solution canister, empty contents, clean and reinstall. 15. Remove clamp from line #145. 16. Prime hydro 5 times to fill wash solution canister. 17. Prime all 5 times, calibrate MC side tests and then program a run of 20 Potassium samples to coat the flow cell. 18. Calibrate the electrolytes again and run controls.

This complete comp letes s the decon decontamination tamination p rocedure. roc edure.

 Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and to demonstrate what

you have learned.



DxC Dx C 600/80 600/800 0 Mentor nt orin ing g Pro Prog g ram ram Documentation

UNICEL DxC 600/800 Pro Basic Service, Mentoring Documentation Version A 12202006





Post Classroom Mentoring Program It is the trainee’s responsibili ty to complete this prog ram.

The most important aspect of the mentoring process is the training that the mentors provide by example. Mentors are selected because they have shown a commitment to quality and a track record for doing the right thing. Demonstrating by example is the best training that can be provided to ensure the success of engineers new to the instrument or product line. When enrolling the trainee for class, the manager assigns a mentor. The manager sets the goal for mentoring completion based on workgroup needs. Mentoring requirements are based on demonstration of the knowledge and skills needed to service the instrument in the field. The requirements should be determined by the mentor in consultation with the manager and will depend upon the individual trainee's ability and the type of instrumentation. Minimum requirements are suggested in the Mentoring Packet for the individual instrument. The packet can be downloaded from the Chemistry/Immunoassay link in the Training Resources Database on BirchNotes/BII. The trainee and the mentor arrange time to complete mentoring requirements. This is best done in person, with the mentor and the trainee performing service calls together. If it is not possible for the mentor and trainee to meet in person in a timely manner, the mentor, with the manager's approval, may designate another engineer who has been certified on the instrument. Whenever possible a variety of call types should be selected – PMs, installations, trouble calls, etc. to broaden the learning experience.

If the trainee has been certified on the instrument by Professional Development, the mentor can elect to assign calls to the trainee when he determines that the situation warrants it. The mentor should review all call assignments for the product by telephone with the trainee before the trainee goes on site. An “action plan” for the call should be devised and the trainee should know how to reach the mentor quickly if the plan is not appropriate. The trainee must update the mentor at the close of the call. By completing and e-mailing the Mentor Validation Form on page 2, the Mentor confirms that: 1) The trainee has mastered the skills required to: o o o

Operate the instrumentation as a system Perform Preventive Maintenance Procedures on the instrument Troubleshoot and repair basic hardware problems on the instrument

2) Plans have been formulated to provide assistance and support in those areas where the trainee may need additional practice.

3) The trainee has demonstrated the ability to assess, review and resolve instrument problems and customer concerns independently.

4) The trainee has the required tools and test equipment needed to service the instrumentation and has demonstrated a working knowledge of their use and function.

5) The mentor and the trainee have reviewed documentation related to servicing the product, including: Location and use of the service manual o UNICEL DxC 600/800 Pro Basic Service, Mentoring Documentation Version A 12202006


o

o

Location of Service Memos/Modifications, Technical Updates and other relevant information on Lotus Notes, Odyssey and electronic media in use by the field. Location and use of the North America Commercial Operations (NACO) Database on Lotus Notes and the documents contained in the Service Section. (Call Closeout, Installation, DOA reporting, Escalation, ESD, etc.)

6) The mentor confirms that the trainee has a basic car stock for the instrument.



Mentor Validation Form Trainee Trainee Employee Number Trainee's Mailing Address: Address City State Zip Trainee's Shirt Size Instructor Class Class End Date Mentoring Completion Date RM Mentor The above mentioned trainee has completed the Mentoring Program. He/she is familiar with all procedures and processes relating to servicing this product and is prepared to make calls without further direct supervision for the following instrumentation: Mentor (sign) Date Save this file as '(Trainee's Name) Mentoring Form.doc' E-mail the completed form to: Sharon Howard/BII (Lotus Notes Address) or [email protected] (Internet Address) Please copy the student. UNICEL DxC 600/800 Pro Basic Service, Mentoring Documentation Version A 12202006


DxC 600/800 New Hire Overview COURSE DESCRIPTION

The DxC New Hire Service Training class is a 17 day class divided into two sessions. •

• •

•

•

SESSION 1 TRAINING

Session one – nine days, Monday of the first week thru Thursday of the second week. Separated by a minimum three week mentoring period. Session two – eight days, Tuesday of the first week thru Thursday of the second week. 25% of the students' time will be spent on theory and troubleshooting problems in the classroom. 75% of the students' time will be devoted developing skills on instrument operation, troubleshooting and repair.

Basic Operation DVM/Motors/Sensors/Compressors/Vacuum Pumps Power Instrument Control Subsystem, Microsoft® Hyperterminal Smart Modules Communications / Fiber Optics Hydro-pneumatics Sample Rack Handling, TS-CTS & Reserved Racks MC Alignments MC Sample Aspiration, Delivery & Level Sense MC Cups ISE • • Preventive Maintenance Minor (ISE/MC) • • • • • • • • • • •

MID-SESSIONS MENTORING PERIOD OVERVIEW

•

•

•

•

•

During the time between Sessions 1 and 2, the student should ride as much as possible with the designated mentor who has been certified on the DxC 600/800. During this period, the student is required to complete the 'DxC New Hire Service Call Log', an electronic log sheet for each DxC service call they participate in. The log file is located on the Chemistry/Immunoassay link of the Training Resources Database in Lotus Notes. The student will e-mail the log to the Service Trainer weekly to update his/her progress to the training staff. If it is noted that the student is not assisting on service calls, the appropriate managers will be notified.

Note: The students have not been certified to work on this instrument. They must be accompanied by an engineer who has been certified on the DxC on all DxC service calls. It is imperative that the new engineers be effectively mentored to ensure their success.



Mid-Sessions Mentoring MENTORING SUGGESTIONS

Re-enforcing what was learned in Session 1 and familiarization with actual field operations are the two major goals of mid-session mentoring. It is up to the mentor, with guidance from his manager, to determine the best course to provide the new engineer with maximum exposure to the field requirements for the chemistry product line. The trainee and the mentor arrange time to perform service calls together. It is important that the trainee accompany a mentor on a daily basis on all service calls scheduled for th at day, including if necessary instruments other than DxC 600/800. The most im portant aspect of t he mentoring pr ocess is the training that the mentors provide by example. Mentors are selected because they have shown a com mitment to quality and a track record for doing the right thing. Providing that example is the best tr aining that can be provided and w ill ensure the new engineer's succ ess.

RECOMMENDED MINIMUM REQUIREMENTS

If it is not possible for the mentor and trainee to meet in person in a timely manner, the mentor, with the manager's approval, may designate another engineer who has been certified on the DxC 600/800. 

It is recommended that the trainee perform a minimum of 3 Unicel DxC 600/800 Minor Preventive Maintenance Procedures (ISE/MC) during the mid-sessions mentoring period with the mentor or a designated certified engineer. (The trainee has successfully completed this procedure during Session 1 training.)

In the absence of DxC Preventive Maintenance scheduling, 3 LX20 Minor Preventive Maintenance Procedure (ISE/MC) with a certified engineer will provide the needed exposure to the common aspects of both systems. 

It is recommended that the trainee assist in a minimum of 9 DxC 600/800 ISE/MC service calls during this period with the mentor or a designated certified engineer.

In the absence of DxC calls, LX20 calls with a qualified engineer will provide the needed exposure to the common aspects of both systems.



Post Se Sessions ssi ons Mento Mentorin ring g Discussion of Log Sheets from mid-sessions mentoring Group Summary and QC Interpretation with Stan Johnson MC, ISE, Hydro and Power Review and Troubleshooting CC Sample Aspiration, Delivery & Level Sense CC Reagent Aspiration, Delivery & Level Sense Refrigeration CC Reaction Subsystem o Photometer Subsystem Reaction Wheel Subsystem o PVT, ChemAssist, LISA Installation overview and cleaving Preventive Maintenance A (Major CC)

•

SESSION 2 TRAINING

• • • • • •

• • •

POST SESSIONS MENTORING

The major goal for Post Sessions Mentoring is for the trainee to be able to perform independently when servicing the DxC 600/800. At the completion of Session 2 Training, Training, the student was certified certified on the DxC 600/800 System. The length of the post sessions mentoring period will be the determined by the manager.

RECOMMENDED MINIMUM REQUIREMENTS

The requirements for Post Sessions Mentoring are determined by the mentor, in consultation with the manager, and depend upon the individual trainee's ability.

DIRECT SUPERVISION

The certified trainee should be accompanied by the mentor or a designated certified engineer for a minimum o f:    

INDIRECT SUPERVISION

3 DxC CC Service Calls 1 UniCel DxC 600/800 PM B, Major MC/CC 1 UniCel DxC 600/800 PM A, Major CC 1 DxC 600/800 Installation

Since the trainee has been certified on the instrument, the mentor can elect to assign calls to the trainee when he determines that the situation warrants it. The mentor should review all call assignments for the product by telephone with the trainee trainee before the trainee goes on site. An “action plan” for the call should be devised and the trainee should know how to reach the mentor quickly if the plan is not appropriate. The trainee must update the mentor at the close of the call.



Mentoring Recommendations Mid-Sessions Mentoring

Trainee accompanies the mentor or a designated certified engineer on-site for the following:

Direct Direct Supervision Supervision   

Post Sessions Mentoring

9 DxC MC/ISE Service Calls 3 Unicel DxC 600/800, PM Minor, ISE/MC. 1 DxC 600/800 Installation (Can be done in Post Sessions Mentoring Phase)

Trainee should complete the following with the mentor or a designated certified engineer on-site:

Direct Direct Supervision Supervision   

Post Sessions Mentoring

3 DxC CC Service Calls 1 UniCel DxC 600/800 PM B, Major MC/CC. 1 UniCel DxC 600/800 PM A, Major CC.

Trainee should successfully complete the following without onsite supervision:

Indirect Indirect Supervision Supervision    

Completion of the Mentoring Validation Form

6 DxC MC/ISE or CC Service Calls 1 UniCel DxC 600/800 PM B, Major MC/CC 1 UniCel DxC 600/800 PM A, Major CC 1 Unicel DxC 600/800, PM Minor, ISE/MC

The 'Post Classroom Mentoring Program' document is available on the Chemistry/Immunoassay link of the Training Resources Database in Lotus Notes. The 'Mentor Validation Form' attached to the above document effectively releases the certified trainee to service the DxC 600/800 independently. The trainees must demonstrate to the satisfaction of the mentor that they have the knowledge and skills required to perform service calls on the DxC 600/800 without direct supervision. The mentor may require more than or less than what the above guidelines recommend when evaluating an individual trainee. The mentor should adjust the requirements for the trainee accordingly, in consultation with the manager. An y res erv ati on s th at th e ment m ent or or tr ain ee has abo ut signing the form should be jointly discus sed with the manager and and an appropri ate acti acti on plan devis ed.



Reco Record rd only on ly DxC 600 600/8 /800 00 Serv Servic ice e Calls Calls * Servic e Order # & Date

Reason for call

Problem Observed

Event Log Error Code

Troubleshooting Process

Successful? If not, explain.

*Save this document as 'Your Name DxC Log Week # (as appropriate) E-mail the completed form weekly to your instructor.



Introductions DxC Basic Phase 2

UNICEL DxC 600/800 Pro Basic Service, Phase 2 Introductions Version A 10222006


This page intentionally left blank



DXC 600 / 800 BASIC SERVICE TRAINING COURSE AGENDA PHASE 2 Week 1 Day 10 Tuesday Time 08:00 – 09:30 09:30 – 11:30 11:30 – 12:30 12:30 – 5:00

Event Review Mentoring Logs QC & Calibration Review Diagnostic Tools: ChemAssistant, LISA & Group Summary Calibrate / ISE & MC Cups Lunch ChemAssistant / Precision, LISA Troubleshooting Exercises

Day 11 Wednesday Time Event Group Summary and QC Interpretation 08:00 – 11:30 Presented by Stan Johnson Questions & Answers 11:30 – 12:30 Lunch Program QC using Group Summary 12:30 – 5:00 ISE Preamp Test Box Troubleshooting Exercises Day 12 Thur sday Time 08:00 – 08:30 08:30 – 09:30 09:30 – 11:30 11:30 – 1:00 1:00 – 5:00 Day 13 Friday Time 08:00 – 08:30 08:30 – 09:30 09:30 – 11:30 11:30 –12:30 12:30 – 5:00

Location Classroom Laboratory

Laboratory

Location Classroom

Laboratory

Event Review: Questions & Answers Refrigeration Subsystem Refrigeration Exercises Lunch Troubleshooting Exercises


Event Review: Questions & Answers CC Sample Aspiration & Delivery CC Reagent Aspiration & Delivery CC Sample & Reagent Exercises Lunch Troubleshooting Exercises

Location Classroom


Laboratory

Classroom Laboratory Laboratory


DXC 600 / 800 BASIC SERVICE TRAINING COURSE AGENDA PHASE 2 Week 2 Day14 Monday Time 08:00 – 08:30 08:30 – 10:00 10:00 – 11:30 11:30 – 12:30 12:30 – 5:00 Day 15 Tuesday Time 08:00 – 08:30 08:30 – 11:30 11:30 – 12:30 12:30 – 5:00

Event Review: Questions & Answers Reaction Subsystem Reaction Wheel & Photometer Removal and Replacement Lunch Removal and Replacement

Event Review: Questions & Answers Reaction Subsystem / PVT2, PVT3 & PVT5 Lunch Troubleshooting Exercises

Day 16 Wednesday Time Event 08:00 – 08:30 Review: Questions & Answers 10:00 – 11:30 Preventive Maintenance Major 11:30 – 12:30 Lunch 12:30 – 5:00 PM continued Day 17 Thur sday Time 08:00 – 08:30 08:30 – 11:30 11:30 – 1:00 1:00 – 2:00 2:00 – 5:00

Event Review: Questions & Answers Troubleshooting Exercises Lunch Lab Cleanup Student Survey – Graduation


Location Classroom Classroom Laboratory Laboratory

Location Classroom Laboratory Laboratory

Location Classroom Laboratory Laboratory

Location Classroom Laboratory Laboratory Classroom


Personal Progress Report Name: ____________________ Instructions

The Personal Progress Report is your way of monitoring your skill development. Initial your Personal Progress Report and ask your Instructor to do the same. ITEMS PERTINENT TO INSTALLATION ARE IN BOLDFACE

Day 10 Tuesd ay Exercise Tools

Objectives  Calibrate and Troubleshoot MC/ISE.  Perform precision tests using ChemAssistant.  Test instrument communications using LISA

Student Initials

______

Instructor Initials

_______

Day 11 Wednesd ay Exercise QC ISE

Objectives

Student Initials

Instructor Initials

 Program & process QC using Group

Summary.  Troubleshoot ISE using ISE Preamp Test Box.

______

_______

______

_______

Day 12 Thursday Exercise

Refrigeration

Objectives     

Locate all refrigeration components Remove and reinstall Cooler Assembly Remove and reinstall Thermistors Remove and reinstall cooler fan Remove and reinstall Peltier Drivers

Student Initials

______

Instructor Initials

_______

Day 13 Frid ay Exercise CC Sample & Reagent Handling

Objectives

Student Initials

Instructor Initials

 Identify reagent handling components  Remove and reinstall reagent carousels home

sensors and motors  Remove and reinstall bar code readers  Perform belt adjustment  Perform alignment procedures


_______

_______


Perso nal Progr ess Repor t, cont...

Day 14 Monday Exercise

Objectives

Student Initials

Instructor Initials

_______

_______

 Remove and reinstall reaction drive

Reaction Wheel & Photometer

    

assembly & its associated components Remove and reinstall of photometer module & its associated components Remove and reinstall of cuvette wash manifold and valves Identify components and part numbers Perform Diagnostic tests Perform alignment procedures

Day 15 Tuesday Exercise Performance Verification Tests

Objectives

Student Initials

Instructor Initials

Student Initials

Instructor Initials

 Perform PVT2 Wash Station Test  Cuvette Dryness  Perform PVT3 Carryover Tests  Wash Station  Reagent Probes  CC Sample Probe  CC Mixer Paddles  Perform PVT5 Precision Tests  Normal Precision  On-Line Dilution  Review PVT5 Sample Probe Precision

Day 16 Wednesday Exercise Preventive Maintenance

Objectives  Perform Major PM



ISE Troubleshooting Pre-Amp Test Box

UNICEL DXC 600/800 Pro Basic Service, ISE Troubleshooting Exercises Version A 08282006





Lab Exercise: ISE Preamp Test Box Objectives

This exercise will guide you and your partner through the following procedures: Use of the ISE Preamp Test Box •

Why

To familiarize the engineers with the procedures for using the ISE Preamp Test Box to eliminate the preamp board as a possible cause for ISE problems.

Reference Materials





ISE Preamp Test Bo x: Reference: Unicel DXC Service Manual on Lotus Notes Chapter 20: Service Tools - ISE Electrode Simulator Box 1. Using the ISE Electrode Simulator to help troubleshoot the ISE 2. Troubleshooting 3. Important Notes 4. Specifications 5. ADC Count Verification Using ISE Simulator Module 6. Box Description/Part Number 7. Box Drawing 8. Board Description ISE Electrode Simulator Box

 Read and understand the above documentation.  Remove the battery from the test box and measure its voltage.

Note: It is important that the battery is an alkaline 9vdc battery and measures at least 9vdc. The specifications provided for the test results are based on a new battery in the test box.  Perform item # 5 above.


have learned.



Refrigeration Exercises

UNICEL DXC 600/800 Pro Basic Service, Refrigeration Exercises Version A 08282006





Lab Exercise: Refrigeration Objectives

This exercise will guide you and your partner through the following procedures: Removal of the Cooler Assembly Removal of Peltier Driver Assembly • •

Why

To familiarize the engineers with the procedures for replacement of the cooler assembly and its associated components

Reference Materials



TOP of Cable Bracket

DxC

1

8

J159 Thermal Switch

P Peltier Banks

COLD

1 2 3

PLATE

4 5 6 IN AIR

J155 Thermistors

J156B TECFAN2


J156A TECFAN4


Cooler A ssembly and Peltier Drivers: Reference: Unicel DXC Service Manual on Lotus Notes Chapter 16: Reagent Handling - Removal and Replacement - Item 7 Peltier Assembly Removal and Replacement Procedure

Cooler Assembl y Removal and Replacement

     

Read the above procedure carefully. Remove the cooler assembly Remove and reinstall the thermistors Remove and reinstall the thermal switch Remove and reinstall the TEC fans Reinstall the cooler assembly

Reference: Unicel DXC Service Manual on Lotus Notes Chapter 16: Reagent Handling - Removal and Replacement - Item 7 Peltier Driver A Assembly - Item 8 Peltier Driver B Assembly

Peltier Driver Removal and Replacement

 Read the above procedure carefully.  Remove and reinstall Peltier Driver A.


have learned.



CC Subsystem Exercises – Sample & Reagent Handling

UNICEL DxC 600/800 Pro Basic Service, CC Subsystem – Sample & Reagent Version A 08282006





Lab Exercise: CC Sample Handling Objectives This exercise will guide you and your partner through the following procedures: Locate & identify sample handling components CC Sample Syringe Assembly Sample & Mixer Module Remove and reinstall rotational motor Perform alignment procedures •

• •

Why

To become familiar with the components and assemblies that may require repair or replacement.

Reference Materials





CC Sample Handl ing : Reference: Unicel DXC Service Manual on Lotus Notes

Sample Handling System

 Remove the covers from the CC Sample Crane Arm and the CC

Mixer Crane Arm  Locate the vertical and rotational motors, sensors and belts or

gears for each.

CC Sample Mixer Al ignm ent Procedures

 Remove and reinstall the sample mixer rotational motor.

 Perform the alignment procedures : •

1. 2. 3. 4. 5. 6.

CC Sample Crane or Probe: CC Sample Probe Rotary Home CC Sample Probe Rotary to Cuvette CC Sample Probe Rotary to Sample Carousel CC Sample Probe Vertical Home and Wash CC Sample Probe Cuvette Height CC Sample Probe Sample Height

CC Sampl e Mixer Crane or B ody: 1. CC Sample Mixer Rotation Speed 2. CC Sample Mixer Rotary 3. CC Sample Mixer Height •



Lab Exercise: CC Reagent Handling Objectives

This exercise will guide you and your partner through the following procedures: Locate & identify reagent handling components Remove & reinstall the following components: A/B Valve Assembly Bubble Generator Assembly Reagent Carousel Home Sensors Assembly Reagent carousel motors Bar code readers Perform belt adjustments Perform alignment procedures • •

• •

Why

To become familiar with the components and assemblies that may require repair or replacement.

Reference Materials



Tools requir ed f or Reagent Probe A & B Rotary to Cartridge

DxC Two Carousel Alignment Tool P/N A18397

DxC Probe-Carousel Alignment Tool P/N A18396



CC Reagent Handling: Reference: Unicel DXC Service Manual on Lotus Notes Chapter 16: Reagent Handling 1. Reagent Probe A and B Installation Procedure 2. Collar Wash Removal and Replacement Procedure 3. Reagent Crane Vertical Motor Removal and Replacement Procedure 4. Reagent Carousel Removal and Replacement Procedure 5. Reagent Carousel Dual Drive Assembly Removal and Replacement Procedure 6. Reagent Carousel Home Sensor Assembly Removal and Replacement Procedure Reagent Handling System

 Remove and reinstall the A/B valve  Remove and reinstall the Bubble Generator  Remove and reinstall the Reagent Syringe Assembly

Reagent Probes

 Remove and reinstall Reagent Probe A or B

Collar Wash

 Remove and reinstall one of the reagent probes collar wash assy.

Reagent Crane

 Remove and reinstall Reagent Crane A Vertical Motor

Reagent Carousel

 Remove and reinstall the Reagent Carousels

Dual Drive Mechanism

 Remove and reinstall the Lower Carousel Drive Motor

Home Sensor

 Remove and reinstall the Home Sensor Assembly

Bar Code Reader

 Remove and reinstall the bar code readers.



CC Reagent Handli ng, cont ... Al ignm ent Procedures

 Perform the alignment procedures: •

•

•

•

Instrument Verification

Reagent A Crane or Pro be: 2. Reagent Probe A Rotary Home 3. Reagent Probe A Rotary to Cuvette (post requisite to 2.) 4. Reagent Probe A Vertical Home and Wash 5. Reagent Probe A Height in Cuvette (post requisite to 4.) 6. Reagent Probe A & B Rotary to Cartridge (post requisite to 2.) 7. Reagent Probe A Height in Cartridge (post requisite to 4.) Reagent B Crane or Pro be: 2. Reagent Probe B Rotary Home 3. Reagent Probe B Rotary to Cuvette (post requisite to 2.) 4. Reagent Probe A & B Rotary to Cartridge (post requisite to 2.) 5. Reagent Probe B Vertical Home and Wash 6. Reagent Probe B Height in Cuvette (post requisite to 5.) 7. Reagent Probe B Height in Cartridge (post requisite to 5.) Reagent Carousel: 1. Reagent Carouse Load 2. Reagent Probe A& B Rotary to Cartridge (post requisite to 1.) 3. Reagent Probe A Height in Cartridge 4. Reagent Probe B Height in Cartridge Reagent Mixer Crane or Body: 1. Reagent Mixer Rotational Speed 2. Reagent Mixer Rotary 3. Reagent Mixer Height

 Verify that the instrument is in Standby mode and that all the instrument

status is within specifications.  Calibrate Mg.  Locate an instructor for sign off on this exercise.  Be prepared to answer any questions and to demonstrate what you

have learned.






Reaction Wheel & Photometer Exercises

UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Version B 08282006





Lab Exercise: Reaction Wheel and Photo meter Objectives

This exercise will guide you and your partner through the following procedures: Removal and replacement of cuvette wash manifold assembly Removal and replacement of cuvette wash drive assembly Testing the wash station valves Removal and replacement of reaction drive assembly & its associated components Removal and replacement of photometer module & its associated components Perform Diagnostics tests Perform alignment procedures •

• • •

•

• •

Why

In the event components within the reaction wheel assembly, photometer assembly and cuvette wash station require removal and replacement, it would be to your advantage to have had the opportunity to perform these procedures on a training instrument prior to actual hands-on work at your customers' lab.

Reference Materials





Reaction Wheel Subsystem Reference: Training CD: Quick Reference Diagrams: DxC Cuvette Wash Valve Manifold A11106 Cartridge Chemistries Reaction Wheel Subsystems A11106-AC DxC Cuvette Wash Valve Manifold Assy.+ Cuvette Wash Manifold Assembl y

 Perform the following steps to remove the Cuvette Wash Manifold  Power down the system.  Remove Sample Carousel evaporation cover.  Disconnect Sample Mixer Wash Cup fluid line and drape to center

section.  Remove the retaining screw from manifold bracket.  Loosen Wash Head captive retaining screws and lift Wash Head

from Cuvette Wash Drive.  Lift Cuvette Wash Manifold and Wash Head to gain access to

Manifold fluid connectors.  Disconnect fluid lines 134, 135, 151 and 175.

NOTE: Some fluid will leak from the Manifold. Capture with paper towels.  Disconnect solenoid connectors 71P1, 71P2, 71P3, 71P4 and

71P5.  Disconnect heater power cables 71P6 and 71P7.  Lift assemblies away from instrument.  Using the above references, become familiar with the components

in the Cuvette Wash Manifold Assembly, valves, heaters, fluid lines, probes, etc.  Remove and reinstall valve V2.



Reaction Wheel Subsystem, cont... Cuvette Wash Drive Assembl y

 Perform the following steps to remove the Cuvette Wash Drive.  Remove Smart Modules Center Cover.  Disconnect Cuvette Wash Drive motor connector 71PM1 from

Smart Module 71.  Remove (2) Phillips retaining screws from Drive base.  Lift Drive from instrument while carefully guiding motor cable

through harnesses and tubing maze.  Reinstall both the cuvette wash manifold and cuvette wash drive

assembly. To prevent damage to the instr ument (during po wer up & homing process): Position t he wash head off to the side with th e probes placed into a large plastic beaker. •

Cuvette Wash Tests

 Power on the instrument.  When the instrument comes to standby, perform the following test.  Utilities, (4) Diagnostics, Functional Area – Reaction System, Sub-

Functional Area – Cuvette Wash, Test No. (1) Cuvette Wash, Rinse and Vacuum Test. Wash Fluid Check

 Remove cuvette probe assembly from wash tower.  Place probes in a large container.  Select start cycle in the diagnostics routine.  Probes 1, 2 and 3 will each deliver fluid.  Insure that each probe is injecting three separate and uniform

streams into the container all starting and stopping at the same time.  Listen to the valves operating during the wash all cuvettes. Refer

to Hardware Chronicles Wash Station Evaluation.  If the streams are off on a probe it could be probe, valve, tubing,

etc.



Reaction Wheel Subsystem, cont... Wash Valve Check

 Remove cuvette probe assembly from wash tower.  Place probes 1, 2 & 3 in separate test tubes/cuvettes.  Select start cycle in the diagnostics routine.  Probes 1, 2 and 3 will each deliver fluid.  At some point, the fluid level in each tube rises to the probe tip

where it will be evacuated.  If the fluid valves are delivering a consistent volume and the waste

valves are evacuating a consistent volume, the level in all three tubes will stay the same.  If probes 2 & 3 are working properly, check the wiper probe (4) to

insure that it is aspirating fluid. Reference: Unicel DXC Service Manual on Lotus Notes Chapter 15: Reaction Subsystem - Reaction Subsystem Removal and Replacement

Reaction Drive

 Following the instructions in the above reference, remove the

reaction drive assembly from your instrument. Note for Step 7: You may find it more convenient to remove the two wash stations from the trough and place them in their gravity drain holes. This will prevent forgetting to reconnect the tubing later on which will cause wash to be sprayed all over the instrument. If you choose to remove the lines and gamble on breaking the fittings, drop them into their respective drains until the trough is re-installed later in this exercise.



Reaction Wheel Subsystem, cont... Reaction Drive Assembl y

 While the reaction drive assembly is off the instrument, remove,

inspect and reinstall the following components from the reaction drive assembly: Slip ring assembly Drive motor Home sensor Flash encoder Drive shaft (Plastic) gear • • • • • •

 Reinstall the reaction drive assembly. Do not replace the reaction

wheel trough at this time. Al ignm ents

 Because the reaction wheel platter has been removed, the probes

and the cuvette wash station need to be realigned to the reaction carousel.  Perform the following Alignments: Functional Area – Reaction Carousel • 1. Reaction Carousel Home 2. Cuvette Wash Station 3. CC Sample Probe Rotary to Cuvettes 4. CC Sample Probe Cuvette Height 5. CC Sample Mixer Rotary 6. CC Sample Mixer Height 7. Reagent Probe A Rotary to Cuvettes 8. Reagent Probe A Height in Cuvette 9. Reagent Probe B Rotary to Cuvettes 10. Reagent Probe B Height in Cuvette 11. Reagent Mixer Rotary 12. Reagent Mixer Height

.030" Feeler Gage

471803 Rx Wheel Align Tool

476211 Cuvette Wash Probe Align Tool



Photometer Subsystem Reference: Unicel DXC Service Manual on Lotus Notes Chapter 15: Reaction Subsystem - Photometer Removal and Replacement Photometer Removal and Replacement

Note: Do not loosen or remove the reaction w heel platter. Doing so wi ll requir e the Reaction Carousel alignm ents to be repeated!  Remove the 3 fiber optics connecting the Photometer Preamp and

the LPIA Photometer.  Following the above reference, remove the photometer. Lamp Removal and Replacement

 While the photometer module is off the instrument, remove and

Photometer Preamp Removal

 Loosen the three long screws on the back of the preamp housing

reinstall the Photometer Lamp.  Remove the four Allen screws holding the trigger pack to the monochromator assembly.  Remove the 2 screws and 2 clamps holding the lamp into place inside the trigger pack assembly. Be careful not to loose the 2 clamps that hold the lamp in place.

which extend through the internal spacers one turn. Note: The diagram on the next page show where these screws are. The reason they are loosened is to allow the 4 captive thumb screws that hold the preamp to the base plate to be loosened by hand.  Disconnect the three fiber optic cables between the Photometer Controller and the Lamp Power Supply. Leave the fiber optics connected to the Lamp Power Supply.  Loosen all 4 captive screws which secure the Preamp Assembly to the monochromator housing.  Gently lift the Preamp Assembly from the monochromator. Set aside.



Photometer Subsystem, cont... Photometer Preamp Removal and Replacement

 Loosen the three long screws on the replacement Preamp

Assembly which extend through the internal spacers one turn. Note: The reason they are loosened on a new preamp is that the thumb screws must be tightened by hand to avoid placing torque on the box which will misalign the wavelength diodes causing failure of the diagnostic tests.  Gently install the replacement Preamp onto the monochromator

base plate, being careful to guide the reference detector into the cavity in the fiber receptacle. Take note that the edges of the Preamp housing are inside the channels in the base plate.  By hand, tighten the 4 captive screws which secure the Preamp Assembly onto the monochromator base plate.  Tighten the three long screws which extend through the internal spacers.  Reconnect the fiber optic cables from the Lamp Power Supply to the Photometer Controller.  Re-install the Photometer Assembly on the instrument.

Loosen these 3 screws 1 turn and 1 turn only!



Photometer Subsystem, cont... Reference: Unicel DXC Service Manual on Lotus Notes Chapter 15: Reaction Subsystem - Alignment and Adjustment 1. The Photometer Lamp Calibration 2. The Photometer Flash Encoder Test 3. The Photometer Lamp Alignment and Power 4. The Photometer Flash Lamp Power Supply 5. The Photometer Smart Module & Preamp Test 6. The Reaction Wheel Temperature Test 7. The Reaction Wheel Heater Controller 8. The Reaction Wheel Home Alignment Test To prevent damage to the instr ument (during pow er up & homing process): Position t he wash head off to the side with th e probes placed into a large plastic b eaker. •

 Power up the instrument.

Photometer Diagnostics & Alignment Tests

 Read the above documentation thoroughly.  Perform Lamp Alignment and Power

Note for Step 11: Do not replace the reaction wheel trough at this time.  Perform Cuvette Center Alignment.

Note: Do not perform Wash All Cuvettes at this time. Visually inspect the cuvettes for cleanliness and dryness instead.  Perform Lamp Calibration  When your instrument's photometer has met performance

specifications, move on to the LPIA photometer exercise.



Photometer Subsystem, cont... Reference: Unicel DXC Service Manual on Lotus Notes Chapter 12: LPIA Alignment and Adjustment 1. The Cuvette Centering Alignment Procedure 2. The LED DAC Setting

LPIA Photometer Diagnostics & Alignment Tests

    

Read the above documentation thoroughly. Perform Cuvette Center Alignment for the LPIA Perform LED DAC Setting Perform Photometric Performance Diagnostics When your instrument has passed the performance specifications: 1. Exit Diagnostics 2. Select the Utilities Icon 3. (2) Maintenance 4. (6) Wash All Cuvettes 5. Continue

 When your instrument reaches Standby, calibrate Mg.


have learned.






Cleaving Exercise

SYNCHRON, DxC 600 / 800 Pro Basic Service, Cleaving Exercise Version A 05042007





Lab Exercise: Cleaving Objective

This exercise will guide you through separating an assembled DxC 600/800 into its three basic assemblies.

Why

Sometimes there are installations that require the DxC 600/800 to be reduced in size in order to fit through doorways or elevators that are too small to accommodate the complete instrument.

Reference Materials





DxC 600 800 Basic Service Workbook Ver B

Recommend Documents