Maintenance Guide FA-200,300,400.doc

Maintenance Guide FA-200/300/400 Fully Automatic Biochemistry Analyzer Analyzer

CLINDIAG !"#$ B%&%B%A%

CLINDIAG !"#$ B%&%B%A%

Contents

1 Basic Principle................................................................................................1 2 Operational Environment................................................................................1 3 Warnings and Precautions..............................................................................1 4 Qualifications and Tools.............................................................................. Tools.............................................................................. ....1 4.1 M !"TE""#E $T%% Q&'!%!#T!O"$........................................................1 4.2 ("OW'E)*E +EQ&!+E).............................................................................2 4.3 TOO'$.......................................................................................................2 , Maintenance...................................................................................................2 !'- M !"TE""#E..................................................................................2 ,.1 ) !'5.1.1 Maintenance with Power ON .............................................................2 .............................................................2 5.1.2 Maintenance with Power OFF ...........................................................3 ...........................................................3 ,.2 WEE('- M !"TE""#E..............................................................................3 ,.3 MO"T'- M !"TE""#E............................................................................3 ,.4 -E+'- M !"TE""#E...............................................................................3 / Basic $tructure and Main #omponents..........................................................4 /.1 M !" #O"T+O' P "E'...............................................................................4 6.1.1 Functions...........................................................................................4 Functions...........................................................................................4 6.1.2 Basic Structure..................................................................................4 Structure..................................................................................4 /.2 MOTO+ )+!0E MO)&'E..............................................................................4 6.2.1 Functions...........................................................................................4 Functions...........................................................................................4 6.2.2 Basic Structure.................................................................................., Structure.................................................................................., /.3 POWE+ $-$TEM......................................................................................... /.4 "'-T!# $-$TEM...................................................................................... 6.4.1 Optical System.................................................................................. System.................................................................................. 6.4.2 Heatin System................................................................................. System................................................................................. 6.4.! "est System....................................................................................... System....................................................................................... 6.4.4 #eplacements.................................................................................... #eplacements.................................................................................... /., $ MP'!"* $-$TEM..................................................................................13 6.5.1 Functions.........................................................................................13 Functions.........................................................................................13 6.5.2 $nstallation o% #eaent Plate an& Sample Plate..............................13 Plate..............................13 /./ T&B!"* $-$TEM.......................................................................................1/ 6.6.1 Functions.........................................................................................1/ Functions.........................................................................................1/ 6.6.2 Structure o% "u'in System.............................................................1/ System.............................................................1/  +eplacement of Easil )amaged Parts........................................................1 .1 +EP'#EME"T O% ' MP...........................................................................1 .2 )!'&TE+ P!$TO" +EP'#EME"T ...............................................................1 .3 P+OBE +EP'#EME"T .............................................................................1 .4 #&0ETTE +EP'#EME"T ..........................................................................25 ., %&$E +EP'#EME"T................................................................................25 ./ )6&$TME"T O% P+OB!"* $E"$!T!0!T-....................................................21 . )6&$TME"T O% *!" ") O%%$ET......................................................21 (.(.1 )&*ustment o% OFFS+" ,alue.........................................................21 ,alue.........................................................21

(.(.2 )&*ustment o% -)$N ,alue...............................................................23  Trou7les8ooting............................................................................................23  ppendi9: Wiring )iagram of % $eries................................... ....................2

1 Basic Principle Bioc8emistr anal;er 7ases its testing principle on 'am7ert 'eer 'a<. B mi9ing up reagents and patient serum samples in a fi9ed proportion and t8en incu7ating t8e mi9ture in a cuvette at a certain temperature= t8e instrument continuousl measures lig8t a7sorption of a certain
2 Operational Environment "ormal operational environment re>uires: ?? m7ient Temperature: 15℃?35℃@ ?? +elative umidit: 35％?5％@ ?? ir Pressure: /.58Pa?15/.58Pa@ ?? Po
3 Warnings and Precautions "ote t8e Warnings  Precautions <8en performing installing and servicing: ?? l
4 Qualifications and Tools

4.1 aintenance !taff Qualifications $ervice and maintenance s8all 7e done 7 #lindiag after?sale engineers or aut8ori;ed professionals.

4.2 "no#ledge $e%uired ?? Basic Cno
?? Basic Cno
4.3 Tools *eneral Tools: 1 medium?si;ed P8ilips scre
& aintenance

&.1 'ail( aintenance )ail maintenance incorporates maintenances
&.1.1 aintenance #it) Po#er O* ?? Turn on po
&.1.2 aintenance #it) Po#er O++ ?? #licC G#8ecC cuvette 7lanCH icon. ?? %ill
MG 02 17/08/2009 FA-200/300/400 Fully Automatic Biochemistry Analyzer a!e 2 o" 32

&.2 Wee,l( aintenance ?? Perform maintenance once a
&.3 ont)l( aintenance ?? #8ecC and soaC clean cuvettes
&.4 -earl( aintenance -earl maintenance s8all 7e done 7 #lindiag professional engineers or trained engineers. ?? +emove dust from components inside t8e instrument= suc8 as fans and sensors. ?? #8ecC 7elt operation for eac8 component. dust 7elt tig8tness if necessar. ?? #8ecC tu7ing sstem. !f t8ere are an aged pipes= replace t8em. ?? +eplace sringe piston. ?? dust ) voltage value and O%%$ET value on main control panel. ?? BacCup data7ase files and empt ta7les starting 7 G$H in data7ase.

 Basic !tructure and ain Components

.1 ain Control Panel .1.1 +unctions Main control panel= core component in t8e instrument= is to e9ecutive orders <8en connected to computers. B controlling operation of eac8 component= it collects and amplifies signals for ) conversion= <8ic8 t8en

.1.2 Basic !tructure Main control panel is mainl composed of digital signal processor= comple9 programma7le logic device= memor c8ip= ) conversion c8ip= ) amplification c8ip= +$232 interface= parallel interface of reaction plate and +$4, parallel 7us. T8e 7asic structure of main control panel is s8o
+igure /1 Basic structure of main control panel

.2 otor 'rive odule .2.1 +unctions Motor drive module receives orders from main control panel to collect sensor signals= drive motor and control solenoids.

.2.2 Basic !tructure Motor drive module consists of a motor 7racCet= 7us plate= motor 7oard= 8ig8 pouid level detecting 7oard. T8e 7asic structure of motor drive module is s8o

+igure /2 Basic structure of motor drive module

Motor 7racCet is a mec8anical component used for 8olding motor 7oards. !t is designed
+igure /3 Bus plate

Motor 7oard drives motors of sampling arm and sample rotor and controls solenoid onKoff. !ts address code can 7e set as re>uired I1?1/J Ias s8ouence of 1= 2= 4= and  from outside to inside and can 7e connected
MG 02 17/08/2009 FA-200/300/400 Fully Automatic Biochemistry Analyzer a!e # o" 32

+igure /& 0ddress code

ig8 po
+igure /& ig) po#er motor oard

+eaction plate motor 7oard is to control operation of reaction plate. !t is under direct control of main control panel 7 means of parallel serial ports Ias s8o
+igure / $eaction plate motor oard

,0 po
s8ouid level detecting 7oard controls level signals to adust li>uid level detecting sensitivit.

'i>uid 'evel )etecting Board

,0 Po
+igure / i%uid level detecting oard and po#er oard

.3 Po#er !(stem Pouired voltages to instrument and to control instrument onKoff. #ircuit diagram of po
+igure /5 Circuit diagram of po#er s(stem


.4 0nal(tic !(stem naltic sstem is essential to t8e instrument.

.4.1 Optical !(stem Optical sstem is mainl composed of a 8alogen lamp= an optical fi7er and a filter. $tructure c8art of optical sstem is s8o
+igure /6 Optical s(stem

.4.2 eating !(stem eating sstem consists of a 8eating ring= a temperature meter= a po
+igure /17 eating s(stem

.4.3 Test !(stem Test sstem contains a test 7oard= signal ca7les and a main control panel. #ircuit diagram of test 7oard is s8o

+igure /11 Circuit diagram of test oard

.4.4 $eplacements

.4.4.1 Code W)eel 0d8ustment Tig8ten acCscre
+igure /12 Code #)eel

Tig8ten scre
+etaining $cre<


#leaning ead Tra Optical %i7er eating +ing

+igure /13 eating ring

.4.4.2 Optical +ier ?? dust optical fi7er copper pillar until facula diameter is close to 2.,mm. ?? Optical fi7ers are se>uentiall addressed 7 natural num7ers. "o. 1 is for use of 345 nm test c8annel= "o. 2 for 45, nm test c8annel and ot8ers for t8e rest of test c8annels. ?? Tig8ten optical fi7er 8ead
%i7er

$8eat8

$trip +igure /14

'ig8t 7eams are gat8ered at t8e center of cuvette after installing optical fi7er. &se a <8ite card7oard uires more reagents <8ile lo

+igure /1&

.4.4.3 Optical Coupler $eplacement +eaction plate is designed
+igure /1

$8ort Optical #oupler 'ong #oupler

Optical

+igure /1

.4.4.3 +ilter $eplacement #8ecC filter. !f filter is severel damaged after long time operation or filter is mould due to moist operational environment= replace filter. MG 02 17/08/2009 FA-200/300/400 Fully Automatic Biochemistry Analyzer a!e 11 o" 32

?? %irst remove t8e fault filter. ?? !nstall filter cover
eating +ing 6acCscre<

%ilter %ilter #over

+igure /15 9nstallation of filter

.& !ampling !(stem .&.1 +unctions $ampling sstem is to automaticall add re>uired reagents and samples during testing process. $ampling sstem consists of a reagent plate= a sample plate= a sampling arm= a sampling needle= a diluter= a mi9er= pipes= etc.

.&.2 9nstallation of $eagent Plate and !ample Plate

.&.2.1 otor $eplacement ?? 'oosen four cre

Motor +etaining $cre<

BracCet +etaining $cre<

Motor

$nc8ronous Pulle

Belt

+igure /16 $eplacement of motor

.&.2.2 Belt 0d8ustment and $eplacement Belt

#ode

Optical #oupler

Belt +igure /27 $eplacement of elt

.&.2.4 Peltier Cooler $eplacement ?? +emove fault Peltier cooler. ?? Evenl appl t8ermall conductive silicone onto contact surface of reagent plate= surfaces of Peltier cooler and radiator. ?? Before installing radiator= place Peltier cooler surface against metal surface of reagent plate and cooling pad against 8eating surface Ias s8o
Metal surface

Peltier #ooler

+adiator

#ooling Pad

+igure /21

. Tuing !(stem ..1 +unctions Tu7ing sstem automaticall cleans sampling needle during sampling process and cleans cuvetes after anal;ing samples.


..2 !tructure of Tuing !(stem Tu7ing sstem is composed of an inlet pump= draining pump= a 3?
+igure /22 Pipe connection

 $eplacement of Easil( 'amaged Parts +egularl maintain= adust or replace components to ensure instrument normal operation. *ote Maintenance= adustment or replacement of components s8all 7e done 7 professional engineers or users trained
MG 02 17/08/2009 FA-200/300/400 Fully Automatic Biochemistry Analyzer a!e 1# o" 32

.1 $eplacement of amp MaCe sure t8at t8e lamp doesnt
'amps8ade

#eramic socCet $8ell 'amp +igure /23 amp replacement

*ote ?? #8ecC and confirm t8e instrument is s
.2 'iluter Piston $eplacement &se t8e follo
?? #lose diluter
+igure /24

#orrect

+igure /2& Wrong

*ote ?? )o not scratc8 piston <8en installing. %ailure to do so ma decrease accurac of test results caused 7 pipe leaCage. ?? Be sure to install piston at t8e center of glass tu7e. %ailure to do so ma reduce service life of piston or cause damage to glass tu7e. ?? ppl seal grease to piston ever t8ree mont8.

.3 Proe $eplacement &se t8e same steps to replace sampling needle and reagent needle. ?? %irst open t8e cap on t8e needle. T8en use pliers to snip t8e string t8at fi9es needle. ?? &nscre< t8e scre

+igure /2

+igure /2

*ote ?? MaCe sure t8e pro7e is vertical. ?? +etaining scre
.4 Cuvette $eplacement !f 7lanC a7sor7enc is 8ig8er t8an 5.52= <8ic8 is caused 7

?? )o not touc8 front and 7acC sides of cuvette. ?? (eep upper surfaces of cuvettes at t8e same 8ori;ontal level. %ailure to do so ma cause
.& +use $eplacement &se t8e follo
. 0d8ustment of Proing !ensitivit( &se t8e follo
+igure /25


$ensitivit: 4 1248 +igure /26

. 0d8ustment of :09* and O++!ET ..1 0d8ustment of O++!ET ;alue #8ecC O%%$ET value <8en unusual reaction curve= a7normal a7sor7enc value or e9tremel 8ig8 a7sor7ance of 2.2= or poor repeata7ilit occurs. ?? fter resetting t8e device= access G#8ecC cuvette 7lanCH interface and clicC G+eal time c8ecCH. s s8ouired value of 25?,5.

+igure /37


+igure /31

..2 0d8ustment of :09* ;alue fter resetting instrument= access G#8ecC cuvette 7lanCH interface and clicC G+eal time c8ecCH. s s8o
5 Troules)ooting T8e trou7les8ooting is listed as Ta7le ?1. %a&le 8-1 %rou&leshootin! Prolem

Cause

!olution

T8e instrument

Wrong connection of

#8ecC and confirm po
doesnt
po
cord is correctl connected.

starting up. IPo
Main program not started

Turn off t8e instrument for ,

indicator doesnt come on.J

min. t8en restart it. Blo
#8ecC t8e fuse. !f fuse is 7lo
'i>uid leaCage

"o po
#8ecC if t8ere is po
outlet

# po
)amaged pipes

Turn off po
)etac8ed oints

)iluter leaCage

#8ecC for an signs of loose

BlocCed 3?
oints= damaged pipes= leaC

Pump leaCing

pump or 7u77le case.

'eaCage in 7u77le unit


On?line failure or t8e

!ncorrect #OM port

+eset #OM1 port for t8e

instrument doesnt

M!"#OM5（#OM1 ）

instrument.

+$232 data ca7le isnt

#8ecC data ca7le

indicator comes

properl connected or

connections.

on.J

poor contact in internal
+ec8ecC settings of test

correctl.

c8annel under GBioc8emistr ssa setupN)evice.

#OM port of t8e computer

+eplace #OM port of t8e

fails to
computer.

)etac8ed signal
#8ecC and confirm motor

motor control

control
Main program not started

$
or main control 7oard

, min. t8en restart it.

fault Missing 8ard
BacCup 8ard
parameters

parameters or restore data
T
#lose a
at t8e same time. !ncorrect selection of 12

$elect a rig8t c8annel.

c8annel under Gard
BlocCed sampling needle

samples

&se an acupuncture pin to clear 7locCage and perform maintenance to sampling needle.

)iluter doesnt
#8ecC diluter= motor= address code of diluter as
'eaC diluter

+eplace diluters piston.

$ampling needle comes

dust 8eig8t of sampling

into contact
needle.

7ottom. $ampling needle cant

'ouid level sensitivit

sense li>uid level properl.

of sampling needle and c8ecC its connecting

#racCed pipes or

#8ecC pipes for an

detac8ed oints

detac8ed oints or cracCed pipes.

BroCen solenoids or

&se 120 voltage to test

solenoids arent under

solenoids.

control. $ampling needle

)isconnected
#8ecC and confirm
comes into contact

poor contact in li>uid level

li>uid level sensor are

sensor

properl connected.

ig8er or lo
dust sensitivit of li>uid

of li>uid level detecting

level detecting 7oard I?13J.

or sampling needle cant 7e lo
7oard !ncorrect descending

dust descending 8eig8t of

8eig8t of needle

reagent needle to 3mm a7ove cuvette 7ottom= and sampling needle to 3mm a7ove 7ottoms of cuvette and serum cup.

BroCen motor control

&se t8e program to test

7oard

motor 7oard.

)istorted sample cup

+eplace
'i>uid drop remains

ir leaCage caused 7

on tip of needle after cracCed or detac8ed pipes

#8ecC pipes for an leaCage.

cleaning BlocCed reagent needle

+inse needle or use an acupuncture pin to clear 7locCage.

BroCen solenoids

&se t8e program to test motor 7oard.

'eaC diluter

+eplace diluters piston or tu7e glass. ppl lu7ricants on piston.

$ample needle cant touc8

dust 8eig8t of sample

cuvette 7ottom.

needle or li>uid level detecting sensi7ilit I?13J.

Bu77les in pipes

+inse

)ripping cleaning

$8ort needle
+emove pipes for cleaning.

needle

dripping after cleaning=

T8en appl reverse

and one?
pressure to close one?
doesnt sta closed.

valve.

$8ort needle
dust descending dept8 to

dripping after cleaning=

allo< cleaning 7locC of long

and needle is lo
needle to contact cup

do
7ottom.

'ong and s8ort needles of

dust long needles to

cleaning 8ead
t8e same 8ori;ontal line.

dripping= uneven long

(eep #leaning 7locC

needles

1mm longer t8an t8e  long needles.

3?
Open solenoid to clean

tig8tl closed if s8ort

valve.

needle
old cleaning 7locC
!mproperl positioned

dust cleaning 7locC to a

cleaning 7locC

vertical position. dust position of cleaning 8ead or 8older to put cleaning 7locC at t8e center of cuvette.

!ncorrect results

)irt cuvette

+eplace
%acula isnt at t8e center

dust reaction plate to

of cuvette

center facula and Ceep facula 1., ? 2mm a7ove cuvette 7ottom.

#uvette voltage isnt

+eadust *!" and

O%%$ET values.

#racCed or detac8ed

#8ecC pipes for an

pipes

a7normit.

'eaC diluter

+eplace glass tu7e or piston. )o not forget to appl seal grease on piston.


sampling needle

dust position and 8eig8t of

position or 8eig8t

sampling needle.

incorrect !nvalid reagents or

+eplace reagents or control

control materials

materials.

BroCen solenoids

&se t8e program to test solenoids.

'i>uid level sensing


function failure

level detecting 7oard.

!ncorrect test parameters

#8ecC and reset parameters <8en it is necessar.

&nsta7le test voltage

#8ecC ground and voltage

and a7sor7enc

sta7ili;ation. #8ecC if t8e follo
BlocCed suction needle

+inse needle or use an acupuncture pin to rule out 7locCage.

!ncorrect temperature

+ec8ecC or readust

in reaction plate

temperature control of reaction plate.

'ose +$232 data ca7le

Properl connect data ca7le.

%luid remains in cuvette

dust cuvette position and

caused 7 improperl

8eig8t of cleaning 8ead to

positioned cuvette or

maCe it 8ori;ontal.

incorrect 8eig8t of cleaning 8ead #ode <8eel ru7s
+eadust code <8eel to a

optical coupler

center position. #lean optical coupler
MG 02 17/08/2009 FA-200/300/400 Fully Automatic Biochemistry Analyzer a!e 2# o" 32

Poor contact in test

+econnect test lines.

lines &nused detecting

#onnect Pin 2 and Pin 3 on

c8annels not umpered

main control 7oard
'oose computing

Tig8ten computing optical

optical coupler

coupler

!nsufficient cleaning
!ncrease
in cuvette

ensure t8e cuvette is 8alf full for complete cleaning.

0oltage is or less

'amp failure

+eplace lamp if necessar.

'oose connecting
#8ecC lamp connecting

lamp

7normal voltage to lamp

#8ecC or replace po
t8an 5 during 7lanC c8ecC

suppl if necessar. Wrong signal connecting

#8ecC signal connecting

Main control panel failure

+eplace main control panel if necessar.

+eagents and
%ilter affected
+eplace t8e filter.

!ncorrectl connected

#8ecC connecting
+$232
replace t8em if necessar.

BlocCed suction needle

+inse needle or use an

cant 7e sucCed in or

acupuncture pin to clear

delivered

7locCage. 'eaC diluter

+eplace glass tu7e or piston.

'i>uid level sensing


function failure

level detecting 7oard.

#orresponding solenoids

&se t8e program to test

failure

solenoids.

)etac8ed pipes

#8ecC pipes for an a7normit.

Mec8anical parameters cant 7e

ard
+emove t8e read?onl attri7 ute.

saved

MG 02 17/08/2009 FA-200/300/400 Fully Automatic Biochemistry Analyzer a!e 2$ o" 32

Blue or red color

+ed indicates t8at

+eplace cuvettes <8en

during 7lanC c8ecC

detecting voltage is

detecting voltage is less

7eond normal range of

t8an 35=555. dust

35=555/2=555.

detecting voltage <8en it is more t8an /2=555.

Blue indicates t8at

#lean or replace

7lanC a7sor7enc is

cuvettes
7eond normal range

gap if necessar.

and cuvettes gap is too large. !ncorrect

!ncorrect
$elect a rig8t
)isordered c8aracters in

Open t8e file and empt its

#up7lanC

contents. )o 7lanC c8ecC

a7sor7enc

again and save t8e values.

6 0ppendi<= Wiring 'iagram of +0 !eries ?? Wiring diagram of %?455 Motor )rive $stem is s8o


W8ere， ?? M1: Motor Board of +eaction Plate ?? M1,: Was8ing rm ?? M1/: )iluter ! ?? M1: )iluter !! ?? M1: )iluter !!! ?? M/: +eagent rm ! ?? M: +eagent rm ! ?? M: +eagent rm !! ?? M15: +eagent rm !! ?? M12: $ampling rm ?? M13: $ampling rm ?? M,: $ample Plate ?? M3: +eagent Plate !! ?? M4: +eagent Plate ! ?? M33: Mi9ing rm ! ?? M34: Mi9ing rm ! ?? M3,: Mi9ing rm !! ?? M3/: Mi9ing rm !! ?? M3: Electrolte ?? M3: Electrolte ?? M41:)iluter


?? Wiring diagram of %?355 Motor )rive $stem is s8o
W8ere= ?? M12: Mi9ing rm ?? M13: Mi9ing rm ?? M1/: +eagent  )iluter ?? M1: +eagent B )iluter ?? M1: +eaction Plate ?? M4: +eagent Plate ?? M,: $ample Plate ?? M1,: #leaning +od ?? M/: +eagent "eedle ! ?? M: +eagent "eedle ! ?? M: +eagent "eedle !! ?? M15: +eagent "eedle !! ?? $1: +eagent "eedle 'i>uid 'evel ?? $2: $ample "eedle 'i>uid 'evel


-- Wiring diagram of %?255 Motor )rive $stem is s8o
W8ere= ?? M1: +eaction Plate ?? M4: +eagent Plate ?? M,: $ample Plate ?? M1,: #leaning rod ?? M/: +eagent "eedle ?? M: +eagent "eedle ?? M1/: )iluter ?? M: Mi9ing rm ?? M15: Mi9ing rm

E*'

C9*'90: !-!TE! B.;.B.0.


Maintenance Guide FA-200,300,400.doc

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