SOP05-5002F Service Manual Prolyte
SOP05-5002F Service Manual Prolyte
SOP05-5002F Service Manual Prolyte
Service Manual
P R O L Y T E
A N A L Y Z E R
Chapter
Product Description
1.a System Overview
The proLYTE analyzer is designed to make service and repair quick and easy. Modular construction is used throughout the design. The basic operating system consists of a motor which drives the peristaltic pump. The peristaltic pump draws the desired fluid through the system. A second motor drives the sample probe through the solutions valve to aspirate the appropriate fluid for pumping: sample; standards; or air. The sample detector in the fluid path communicates the position of the fluid in the line. Please note that mechanical and electrical assemblies can be replaced. Follow the instructions in the TROUBLESHOOTING SECTION to determine if assembly replacement is necessary. Refer to the Replacement List in this section which lists replaceable assemblies, components, and appropriate part numbers.
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RUN CALIBRTN
YES NO
ANALYZE BLOOD?
Whole Blood, Serum, or Plasma Analysis YES NO
DAILY CLEANER?
End/Beginning of Day Cleaning YES NO
STANDBY MODE?
Fluid Conservation, Maintenance YES NO
*SECOND MENU?*
YES NO
*PACK USAGE?* Check % Pack Used, Install New Pack, Reset % Countdown YES *QUAL CONTROL?* Run Controls, See Last Control, See/Print Statistics, Delete Results YES NO NO
*OPER FUNCTS?* On Demand Calibration, Wash, Solution Prime, Probe Wiping, I.D.#, Syringe Sample, Diluted Values
YES
NO
*DIAGNOSTICS?* Check: Calibration Values; Fluid Flow; Electrode Values; Sample Detector; Pump Calibration YES NO
YES
NO
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Table of Symbols
NOTES Helpful information or references to other related sections of the manual. Could take the proLYTE analyzer out of operation.
KEY INFORMATION
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1.b
This section describes the main assemblies of the proLYTE front and rear assemblies. Refer to Figures P1, P2, and P3 for the location of each component. Front Housing front case of the analyzer Power Supply powers the analyzer Entry Module connection for the power cable Fuse Bay holds 2 fuses Power Supply Cable connects the power supply to the CPU assembly Voltage Selector to select 110V or 220V power source CPU Board contains the CPU board with digital components and analog sensor inputs: Auto-Sampler Port port for Auto-Sampler device Serial Port port for RS-232 for serial device Display Assembly shows proLYTE prompts/results on LCD screen Display Screen 2 line display Display/Sample Detector Cable connects the display to the CPU assembly and sample detector to the display board Peristaltic Pump Assembly peristaltic pump to move fluids through the analyzer Peristaltic Pump Motor powers pump Peristaltic Pump Head Assembly contains pump rotor and rollers Peristaltic Pump Connection connects the pump to the CPU assembly Probe Motor Assembly moves the probe arm Linear Actuator powers lead screw Probe Motor Support holds probe motor assembly in place Sample Probe Position Locator indicates the home position for the sample probe arm Optical Switch senses the location of the probe arm using the position locator and connects to the CPU board Probe Arm holds and moves the probe to aspirate samples and calibrants Printer prints a hard copy of analysis, diagnostics or maintenance results Printer Cable connects the printer to the CPU assembly Electrode Jack(s) connects electrodes to the CPU assembly Rear Housing rear case
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Front Housing
Display Screen
Electrode Jacks
Peristaltic Pump
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Display Cable
CPU Board
Serial Port
Linear Actuator
Voltage Selector
Entry Module
Power Supply
Fuse Bay
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A N A L Y Z E R
Electrode Jacks
CPU Mounts
Optical Switch
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1.c
This section describes the components of the proLYTE electrode assembly. Refer to Figure P4 for the location of each component. Electrodes sodium, potassium, chloride, and reference Sample Detector detects presence of air/liquid, sets sample position inside electrodes Internal Filling Solution 2 molar KCL solution, acts as a salt bridge for the reference electrode Fill Plug prevents the internal filling solution from evaporating Membrane Assembly creates the connection between the reference electrode and the other electrodes
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Membrane Assembly
Fill Plug
Electrode Housing
Fill Solution
Locating Pins
Reference Electrode
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1.d
Replacement List
Description Electrode Housing Na/K/Cl Power Supply CPU Board Display, 2 Line Pump Probe Motor Assembly Sample Probe Position Sensor Stepper Motor Daughter Board Printer Electrode Jack Part No. ME-0885D ME-1676D ME-1937D ME-1901D ME-1271D ME-1392D ME-1306D ME-1148D ME-1296D ME-0173D
The CPU Board is supplied with the software installed to operate the proLYTE.
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Chapter
Troubleshooting
2.a Troubleshooting Overview
This section describes troubleshooting of the mechanical and electrical functions of the proLYTE analyzer. This section is based on the principle of replacing suspected faulty assemblies with new assemblies. Diamond Diagnostics recommends keeping an inventory of functioning test assemblies for troubleshooting the proLYTE. Refer to the Troubleshooting Guide in this section to determine the cause and corrective action that must be taken to properly service the proLYTE analyzer.
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2.b
Troubleshooting Guide
Refer to the chart below to help determine the problem and corrective action needed. Problem Description Blank Display Problem Source Power Malfunction or Defective Display Power Malfunction or Defective Display Connection Faulty EEPROM Installation or Power Malfunction Probe Motor Malfunction Pump Motor Malfunction Printer Malfunction Sample Detector/Circuit Malfunction Electrodes or Signal Input Malfunction Serial Cable or Transmission Protocol Corrective Action Steps AC Power Verification DC Power Verification Display Verification Display Assembly Verification DC Power Verification Inspect EPROM Installation DC Power Verification Probe Motor Verification Perform PUMP CAL test In DIAGNOSTICS? Menu Pump Motor Verification Printer Verification Sample Detector Verification
PRB Errors PMP Errors or No Pump Movement Printer Does Not Print Sample Detector Test Failure Result 255 Or 000 Bad Electrode Voltages Serial Transmission Failure
Check Electrode Installation And Performance Signal Input Verification Serial Communication Verification
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2.c
DC Power Verification
1. Remove the rear housing. See Rear Housing Removal in the REPAIR SECTION for details. 2. Connect the power cord first to an outlet, then to the entry module. 3. Connect the reference side of the voltage meter to TP12 on the CPU board. 4. Verify the voltage at each test point listed below.
Tolerance +/- 0.15 V +/- 2.0 V +/- 0.15 V +/- 0.10 V +/- 0.15 V
5. If any of the voltage values in STEP 4 are not within specification, AND the AC power verification is successful, replace the CPU board.
2.d
Display Verification
1. Disconnect the display cable from the CPU board. See Display Assembly Removal in the REPAIR SECTION for details. 2. Connect a known good display assembly to the CPU board and connect the main power cord. Verify that the test display is operative. Based on the test results, take the appropriate corrective action. -Display Blank and/or YES/NO buttons DO NOT operate: Remove the test display cable. Perform AC and DC power verification. If the AC and DC power tests are successful, replace the CPU board with a new CPU board, and return to normal operation. See CPU Board Removal in the REPAIR SECTION for details. -Display On and YES/NO buttons function: Remove the original display assembly and replace with a new display assembly. See Display Assembly in the REPAIR SECTION for details.
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2.e
C. Repeat STEP 1. If no errors occur, resume normal operation. 4. If the probe arm moves and stops anywhere except the top position, or if the probe arm vibrates against the top of the proLYTE housing, replace the probe position sensor. To replace the sensor, first remove the CPU Board and the probe position locator. Refer to Probe Motor Assembly Removal in the REPAIR SECTION for details. 5. If the probe does not move at all, check for a short circuit on the CPU Board between TP12 and TP2. If there is a short circuit, replace the Stepper driver daughter board at positions U35 and U36. See Front and Rear Assembly Components in the Product Description Section. 6. If no short circuit is found, replace the probe motor assembly. Refer to the Probe Motor Assembly in the REPAIR SECTION for details.
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2.f
1. 2. 3.
Printer Verification
Press the printer paper advance button. If the printer head moves proceed to STEP 2. If the printer head does not move, proceed to STEP 3. Verify that the printer is on. Turn the printer on by pressing NO to the PRINTER OFF? question in the USER OPTIONS section. If the printer is still not working, remove the power cord from the analyzer and wait for ten seconds, then install the power cord back into the entry module. The printer head should move across the paper and the paper should advance forward printing proLYTE. If the printer is still not working, remove the printer cover and check for any paper obstruction in the printer head area. Remove any obstructions if possible, without damaging the printer assembly or printer window. If an obstruction is present and cannot be removed, replace the Printer Assembly. Refer to Printer Removal and Installation in the REPAIR SECTION for details. If there are no obstructions, but the printer does not work, perform the following steps. a. b. c. d. 6. Remove the rear housing as detailed in the REPAIR SECTION. Remove the printer cable at the bottom right of the CPU board. Compress the strain-relief cap to firmly seat the printer cable. Reinstall the printer cable into the CPU Board.
4.
5.
If the printer still does not print, connect a test printer assembly to the CPU Board. If the test printer works, install a new printer assembly. If the test printer does not work, replace the CPU board. Refer to CPU Board Installation in the REPAIR SECTION for details.
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2.g
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2.h
1.
2.
Serial Interface Specifications Serial Cable Settings Connector Pin Type Pin Assignments Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 7 RS-232 Protocols Transmission Rate Bit Configuration Bit Parity Control Codes All lines end with Carriage return line feed (CRLF) All transmission is ASCII string Chassis, Not Connected TxD RxD RTS CTS Signal Ground 1200 baud 8 data bits, 1 stop None None 25-pin, D-Sub Male RS-232
3.
When correctly linked the proLYTE will transmit to the external device all of the data that is printed by the proLYTE printer, in the same format.
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Chapter
Repair
3.a Repair Overview
Always consult the TROUBLESHOOTING SECTION first to determine the problem before attempting to repair the analyzer. Always remove the solutions pack and the electrode housing from the analyzer before beginning any repair work. Refer to the proLYTE Operators Manual for detailed instructions. Follow the assembly and removal instructions in the order outlined in this section unless otherwise noted. Always unplug the power cord from the analyzer before beginning any repair work. Note that only complete mechanical and electronic assemblies can be replaced. Refer to the Replacement List in the PRODUCT DESCRIPTION SECTION which lists replaceable assemblies as well as consumable items. Consult the list to determine the appropriate replacement item and part number.
3.b
Recommended Tools
The following is a list of the tools required to perform repairs on the proLYTE analyzer. Please refer to this list to determine the appropriate tool and size needed. 0.050 Hex Driver 5/16 Hex Driver 3/16 Hex Driver Phillips Screw Driver, One Small Phillips Screw Driver, One Large Allen Wrench, 1/16 inch Scissors Hex Nut Driver, 11/32 inch, electrode jack installation and removal tool Volt Meter
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3.c
3.d
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3.e
3.f
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3.g
Printer Removal
1. Remove the printer lid from the printer. 2. Remove the paper roll from the printer bay. 3. Remove the rear housing. 4. Detach the printer cable from the retaining clamps located along the right side of the CPU board.
5. Detach the two screws using a Phillips head screw driver. Remove the printer body, as shown in
Figure P7. 6. Pull the printer cable up from behind the CPU board, while holding the printer body as shown in Figure P8.
3.h
Printer Installation
1. Slide the printer cable behind the CPU board. 2. Install the printer body into place. See Figure P8. 3. Attach the two screws using a Phillips head screw driver. See Figure P7. 4. Connect the printer cable to the CPU board. 5. Using scissors, cut the beginning of the paper roll into a V shape. Insert the paper into the feeder slot inside the printer bay, and press the paper feed button. 6. Place the printer roll into the printer bay. 7. Place the printer lid onto the printer. 8. Attach the printer cable to the retaining clamps located along the right side of the CPU board.
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Printer Bay
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Printer Connection
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3.i
1.
2. Disconnect the electrode jacks from behind the CPU board. See figure below for the location of the electrode jacks. To disconnect, gently pull electrode jack straight away from the connector pin of the CPU board. The connector pins are extremely delicate. Avoid pin breakage when removing the electrode jacks, gently pull the electrode jacks straight away from the pins. If a pin breaks the entire CPU board will require replacement. 3. Disengage the CPU board from the four plastic mounting posts as shown. 4. Slide the CPU board off the mounting posts. See Figure P9.
3.j
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3.k
Display Removal
1. Detach the two screws from the sample detector board using a Phillips head screw driver. 2. Move and hold the display cable to expose the three display assembly screws. Detach the three screws from the display assembly using a Phillips head screw driver. See Figure P10. 3. Carefully remove the display cable from the LCD screen, holding both items together. See Figure P11. Notice the orientation of the LCD screen which is extremely important when installing the display assembly. The display has soldered leads located on the bottom of the LCD screen. There is an orientation notch on the display adapter. The display mounts on the two posts below the window. When installing the display adapter, the orientation notch is located on the top inside edge of the adapter.
3.l
Display Installation
1. Place the foam pad on the display board between the screen and mounting plate. 2. Place the LCD screen on top of the foam pad. The orientation of the LCD screen is extremely important, see Figure P11. The display has soldered leads located on the bottom of the LCD screen. 3. Position the front housing so that the front of the analyzer is facing down. Align the display assembly and insert into place, as shown in Figure P11. Use mounting holds as a guide. 4. Hold the display in place and attach the three screws using a Phillips head Screw driver. See Figure P10. 5. Align the sample detector board so the sample detector cable is positioned on the right side. Attach the two screws lightly, using a Phillips head screw driver, see Figure P10. 6. Install the sample detector in the front of the analyzer to verify the sample detector board alignment. When properly aligned fully tighten the sample detector screws.
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3.m
1. Remove the pump tubing from the front of the analyzer. 2. Detach the four screws from the front of the analyzer, using a Phillips head screw driver or 1.5 Hex as applicable. See Figure P12. 3. Remove the pump motor assembly, as shown in Figure P13.
3.n
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3.o
3.p
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B. Manually move the probe arm until the sample probe hole is aligned with the top chamber on the solutions valve. When the sample probe is aligned, DO NOT move the probe arm until the probe motor installation is complete. 7 Place the locator into position. The locator should be seated inside the probe position sensor and inside the mounting bracket slot.
8. Attach and slightly tighten the washer and screw at the top of the position locator. Do not fully tighten the screw. 9. Align the probe position locator slot within the center of the optical switch. Gently move the locator to the left and visually confirm the alignment. Refer to Figure P2 for correct alignment. Confirm that the sample probe hole is aligned with the top chamber on the solutions valve before continuing. 10. When alignment is complete, fully tighten the probe position screw into place using a Phillips head screw driver.
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3.q
3.r
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3.s
3. Pull the electrode jacks from the front housing of the analyzer, as shown in Figure P16.
3.t
1. 2. 3.
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