PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: B

ADVIA 120 Hydraulic Troubleshooting Guide

Date of Issue: Subject: Products: 3/24/99 Hydraulic Troubleshooting Guide ADVIA 120

ADVIA 120 HYDRAULIC TROUBLESHOOTING GUIDE

The following is a troubleshooting chart that attempts to guide Field Service through some common hydraulic problems on the ADVIA 120. This is a REVISED version which contains extensive changes to page 14 concerning troubleshooting probe clogs and conductivity problems. Important Tips: When using this chart, the obvious has been eliminated. It assumes that on board Hydraulic Functions like System Wash and Flowcell Washes have been performed. Remember to return devices and tubing to their original positions before proceeding to the next procedure. If using the exerciser and opening Valves, do a Valve Check to close all valves.

PPI #024-0005-14 Hydraulic Troubleshooting Guide March 1999 Rev B

PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
Table of Contents

TROUBLESHOOTING: RBC PATHWAYS ....................................................................................................................................................................................................................... TROUBLESHOOTING: PEROX PATHWAYS.................................................................................................................................................................................................................... TROUBLESHOOTING: LEAKS at ASPIRATION MODES............................................................................................................................................................................................... TROUBLESHOOTING: CLOGS at ASPIRATION MODES................................................................................................................................................................................................ TROUBLESHOOTING: CONDUCTIVITY PROBLEMS (PROBE CLOGS) ........................................................................................................................................................................ TROUBLESHOOTING: IMPRECISION - SINGLE METHOD........................................................................................................................................................................................... TROUBLESHOOTING - DOME VALVES, REAGENT DIAPHRAGM................................................................................................................................................................................. CONTINUOUS IMPROVEMENT IDEAS ..........................................................................................................................................................................................................................

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: RBC PATHWAYS COMPLAINT PATHWAY TESTED STEPS TYPICAL TIME RESULT CORRECTIVE ACTION [If Pathway Tested Fails]

Rate flags in RBC/Baso/Reti c Channels No Results

1.UFC Vacuum Test

1. 2. 3. 4.

Go to Exerciser. Access the Pneumatics Screen and verify UFC and Main Vacuum readings. Open V5, V7, V10, and V13, Return to Pneumatics Screen and monitor UFC and Main Vacuum.

Monitor for at least 1 min.

UFC Vacuum should not differ from Main vacuum by more than 5 in Hg. Note: Capacity of Vacuum Pump should be 24"-25" Hg. If pump is compromised, this could cause vacuum problems.

1. 2. 3. 4. 5. 6. 7.

8. 2.RBC Shuttle and Flowcell 1. 2. Go to Exerciser. Dispense RBC reagent into reaction chamber by putting Shear Valve in Dispense Position and actuating V80. Open V21, V9. Open V20 and measure time to empty the chamber. Go to Exerciser. Dispense RBC reagent into reaction chamber by putting Shear Valve in Dispense position and actuate V80. Disconnect RBC flowcell sample line at top of sample syringe Disconnect RBC flowcell shuttle line at the bottom of flowcell and reconnect to nipple at the top of the sample syringe. Open V21 and V9. Open V20 and measure time to empty the <11 sec. Measures pathways of V9, RBC syringe ,CFM, V20, V21 and UFC Vacuum.
1. 2. 3. 4.

Replace large vacushield on the waste jug. Check fittings on waste jug including spigot and waste exit port. Close all valves and allow vacuum to recover. Restart test. If test fails again, and system has an Auto-waste configuration, bypass the in-line check valve in the waste line to the waste jug. Close all valves and allow vacuum to recover. Restart test. If test fails again, check for clogs in the waste lines from the UFC and in the lines to and from the waste manifold (behind power supply drawer). Clean out the waste manifold. Repeat test. If UFC Vacuum Test Passes, perform RBC Shuttle pathway test to isolate. If RBC shuttle pathway passes, do an F/C Wash. Repeat this test. If it still fails, go to RBC Shuttle Pathway Test. If RBC Shuttle Pathway Passes, clean or replace the CFM. Fill a 10 ml syringe with 50% bleach and attach to the side of the sample syringe. Open V20, V21 and allow vacuum to pull bleach through pathway. Close Valves. Go to Shuttle Chamber drain if unable to complete. Fill a 10 ml syringe with 50% bleach and attach to RBC/Baso sample line going into the UFC. Open V9, V10 and allow vacuum to pull bleach through pathway. Close Valves. Repeat this test.

3. 4.

3.RBC Shuttle Pathway

1. 2.

< 8 sec.

Measures pathways of V9, syringe, V20, V21, and UFC Vacuum.

1. 2.

3. 4. 5. 6.

3.

4.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
chamber. 4.RBC Shuttle Chamber Drain (V21) 1. 2. 3. 4. 5. Go to Exerciser. Connect 8" length of 0.081tubing to RBC Vacuum Shuttle chamber Vent. Submerge tubing in 10 ml of RBC Sheath/Rinse. Open V21. Open V22 and measure the time to aspirate 10ml. <10 sec. Measures pathways of V22, V21 and UFC Vacuum. 1. 2. 3. 4. 5. Attach syringe with 50% bleach to flowcell shuttle line going to the UFC. Verify tubing is connected to shuttle vent and placed in overflow container. Open V20 and V22. Open V21 and gently push bleach into RBC shuttle Chamber. If necessary, let bleach soak with valves open and compressor on for up to 1 hour. (Opening and closing V21 'pulsating' intermittently may also help.)

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: RBC PATHWAYS continued COMPLAINT PATHWAY TESTED STEPS TYPICA L TIME RESULT CORRECTIVE ACTION [If Pathway Tested Fails]

5.RBC Sheath Dispense

1. 2. 3. 4. 5.

Go to Exerciser. Disconnect sheath input to RBC sheath syringe. (This is the tubing from V23 to sheath syringe.) Actuate V34 to pressurize the RBC sheath diaphragm pump. Open V23. Open V19 and measure dispense time.

<35 sec.

Measures pathways between Universal Sheath/Rinse, DP5 (V34), Sheath filter, V19, Flowcell, and V23

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

7.

Verify there is no leakage of sheath filter and it is < 1 month old. Change filter if suspect. Do flowcell wash Verify connections at DP5. Verify DP5 and check valves are working properly. Verify 5psi and 20 hg at DP5. Remove Sheath/Rinse straw and remove the filter. Reinstall straw. Repeat this test. If the test passes, the filter is the problem. If test does not pass, disconnect the tubing to the Sheath/Rinse straw and insert tubing directly into Sheath/Rinse container. [Note: you will have to place straw into container to overcome the level sensor. Prime Sheath/Rinse 5 times. Repeat this test. If the test passes, the check valve inside the straw is the problem. Verify V23 and V37 are opening. Verify tubing going to waste manifold behind the power supply drawer is not constricted. Verify tubing from waste manifold to waste jug is not constricted. Verify Waste Manifold does not have clog in it.

6.RBC/Baso Sheath Syringe to Waste

1. 2. 3.

4. 5.

Go to Exerciser. Remove the fitting going into V23. Attach a syringe filled with 10 ml of Rinse/Sheath to the place you just removed the fitting at V23. Open V23. Open V27 and measure the time to aspirate 10 ml.

< 14 sec.

Measures pathways of V23, V27, Waste Manifold, and Waste jug.

1. 2. 3. 4.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: PEROX PATHWAYS COMPLAINT PATHWAY TESTED 1.UFC Vacuum Test STEPS TYPICA L TIME Monitor for at least 1 min. RESULT CORRECTIVE ACTION [If Pathway Tested Fails] 1. Replace large vacushield on the waste jug. Check fittings on waste jug including spigot and waste exit port. Close all valves and allow vacuum to recover. Restart test. If test fails again, and system has an Auto-waste configuration, bypass the in-line check valve in the waste line to the waste jug. Close all valves and allow vacuum to recover. Restart test. If test fails again, check for clogs in the waste lines from the UFC and in the lines to and from the waste manifold (behind power supply drawer). Clean out the waste manifold. Repeat test. If UFC Vacuum Test Passes: Perform Perox Chamber Drain Test to isolate. If Perox Chamber Drain Test Passes, do a Perox Shuttle Pathway Test. If Perox Shuttle Pathway Test Passes, do a Perox Shuttle Chamber Test. If Perox Shuttle Chamber Test passes, do a flowcell wash. If necessary, clean, replace CFM. Fill Perox chamber with CN-Free Hgb Rgt. Open V5 and V7. Repeat twice. If necessary, remove chamber and clean drain port according to Cleaning Perox Chamber Ports (ADVH23). Go into Exerciser. Fill Perox chamber with CN-Free Hgb Rgt. Unscrew fitting from side of Perox sample syringe

Rate flags in Perox Channel Perox Carryover

1. 2. 3. 4.

Go to Exerciser. Access the Pneumatics Screen and verify UFC and Main Vacuum readings. Open V5, V7, V10, and V13, Return to Pneumatics Screen and monitor UFC and Main Vacuum.

UFC Vacuum should not differ from Main vacuum by more than 5 in Hg.

Note: Capacity of Vacuum Pump should be 24"-25" Hg. If pump is compromised, this could cause vacuum problems.

2. 3. 4. 5. 6. 7.

8. 2.Perox Shuttle and Flowcell 1. 2. 3. 4. Go to Exerciser. Manually fill Perox Chamber to very top with Sheath/Rinse or DI Water. Open Valves 17, 5, 6. Open V16 and measure time to empty the chamber. <10 sec. Measures pathways between Perox Reaction chamber, V5, V6, CFM and V16 (shuttle chamber). Also UFC vacuum. 1. 2. 3. 4. 5. 3.Perox Chamber Drain
1. 2. 3. 4.

Go to Exerciser. Manually fill Perox Chamber to very top with Sheath/Rinse or DI Water. Open Valves 5. Open Valve 7 and measure time to empty chamber. Go to Exerciser. Manually fill Perox Chamber to very top with Sheath/Rinse or DI Water.

< 3 sec.

Measures pathway between Perox Reaction chamber and V7.

1. 2. 3. 4.

4.Perox Shuttle Pathway

1. 2.

<1min.

Measures pathways between Perox Sheath, DP1(V26), Sheath Filter, V15, flowcell

1. 2. 3.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
3. 4.

5. 6.

Disconnect Perox flowcell sample line at top of sample syringe. Disconnect Perox shuttle line at the bottom of flowcell and reconnect to nipple at the top of the sample syringe. Open Valves 17, 5, 6. Open V16 and measure time to empty chamber.

and V24.
4. 5.

6.

and attach to flowcell cleaning syringe. Open Valves 5,and 6, Push and pull syringe to flush CN-Free back and forth. Open V7 to drain. Repeat flushing 2 times, allowing reagent to sit 10 minutes. Flush final time and repeat with water. Repeat test.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: PEROX PATHWAYS continued COMPLAINT PATHWAY TESTED 5.Perox Shuttle Chamber Drain STEPS TYPICAL TIME <1 min. RESULT CORRECTIVE ACTION [If Pathway Tested Fails]
1. 2.

1. 2. 3. 4. 5.

Go to Exerciser. Connect 8 in. length of 0.081 tubing to Perox Vacuum Shuttle Chamber VENT. Submerge tubing into 10 ml RBC Sheath/Rinse or DI Water. Open V17 Open V18 and measure time to aspirate 10 ml.

Measures pathway from Perox shuttle to V17. Also UFC vacuum.

3. 4.

5.

Go into Exerciser. Unscrew Perox sample tubing from side of block and attach to flowcell cleaning syringe filled with CNFree Hgb Rgt. Open V16 and V18. Flush CN-Free back and forth. Open V17 to drain. Repeat flushing 2 times, allowing reagent to sit for 10 minutes. Flush final time and repeat with water. Verify there is no leakage of sheath filter and it is < 1 month old. Do flowcell wash. Verify connections at DP1. Verify DP1 and check valves are working properly. Verify 5psi and 20 hg at DP1. Verify that reagent filter to Perox Reagent bottle is not clogged. Verify V24 and V25 are opening. Verify tubing going to waste manifold behind the power supply drawer is not constricted. Verify tubing from waste manifold to waste jug is not constricted. Verify Waste Manifold does not have clog in it.

6.Perox Sheath Dispense

1. 2. 3.
4. 5.

Go to Exerciser. Disconnect sheath input to Perox sheath syringe. Place into small container. Actuate V26 to pressurize the Perox sheath diaphragm pump. Open V24. Open V15 and measure dispense time.

<1 min.

Measures pathways between Universal Sheath/Rinse, DP1 (V26), Sheath fllter, V15 Flowcell and V24.

1.
2. 3. 4.

7.Perox Sheath Syringe to Waste

1. 2. 3.

4. 5.

Go to Exerciser. Remove the fitting going into V24. Attach a syringe filled with 10 ml of Rinse/Sheath to the place you just removed the fitting at V24. Open V24. Open V25 and measure the time to aspirate 10 ml.

<17 sec

Measures pathways of V24, V25, Waste Manifold, and Waste jug.

1. 2. 3. 4.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: LEAKS at ASPIRATION MODES COMPLAINT PATHWAY TESTED STEPS TYPICAL TIME RESULT CORRECTIVE ACTION [If Pathway Tested Fails]

Leaks from Autosampler Needle/ Centering Collar

1. Centering Collar 2a. Autosampler Rinse Vacuum Lines - V44

1.

Remove centering collar and check for clogs at centering collar nipples. Go to Exerciser Disconnect tubing leading to V44 at the Autosampler Centering Collar. Submerge open end of tubing in 10 ml of RBC Sheath/Rinse. Open V44 and measure apiration time. <26 sec.

Checks for clogs in centering collar. Measures UFC Vacuum, tubing to AS centering collar, pathway at UFC for V44.

1.

Clean out ports and proceed to procedures below for checking waste lines. If both tests fail, verify UFC Vacuum with UFC Vacuum Test. [Note: both V44 and V45 lines could be clogged or pinched.] If one fails: verify tubing to specific valve is not clogged or pinched.. Try to aspirate 50% bleach into tubing and alternate with slugs of air. Remove coupling and verify that tubing connection at coupling is secure and that connector has no clog. Also, verify there is no clog at inlet of UFC. With coupling removed, open specific valve and try to dispense 50% bleach into valve area with alternate slugs of air. If not successful, replace coupling and tubing and aspirate 50% bleach through specific valve. While bleach is being aspirated, close valve and allow bleach is sit to try to deteriorate clog. Repeat test. Verify UFC Vacuum with UFC Vacuum Test. Verify tubing to V4 is not clogged or pinched. Verify nipple at wash block is not clogged. Aspirate 50% bleach into tubing and alternate with slugs of air. Remove coupling and verify that tubing connection at coupling is secure and that connector has no clog. Also, verify there is no clog at inlet of UFC. With coupling removed, V4 and try to dispense 50% bleach into valve area with alternate slugs of air using transfer pipette.. If not successful, replace coupling and tubing and aspirate 50% bleach through specific valve. While bleach is being aspirated, close valve and allow bleach is sit to try to deteriorate clog. Repeat test. Verify UFC Vacuum with UFC Vacuum Test. Verify tubing to V46 is not clogged or pinched.

1. 2. 3. 4.

1. 2. 3. 4.

2b. Autosampler Rinse Vacuum Lines - V45

1. 2. 3. 4.

Go to Exerciser Disconnect tubing leading to V45 at the Autosampler Centering Collar. Submerge open end of tubing in 10 ml of RBC Sheath/Rinse. Open V45 and measure aspiration time.

<23 sec.

Measures UFC Vacuum, tubing to AS centering collar, pathway at UFC for V45.

5. 6.

7. Leaks from Manual Open Tube Probe Manual Open Tube Sampler Vacuum Line at Wash Block 1. 2. 3. 4. 5. 6. Go to Exerciser. Remove sample probe. Remove Wash Block. Disconnect tubing leading to V4 from Wash Block. Submerge open end of tubing in 10 ml of RBC Sheath/Rinse. Open V4 and measure aspiration time. <36 sec. Measures UFC Vacuum, tubing from Wash Block to V4, pathway at UFC for V4. 1. 2. 3. 4. 5.

6. 7. 8.

Leaks from Manual Closed

Manual Closed Tube Sampler

1. 2.

Go to Exerciser. Remove MCTS Needle Chamber.

<17 sec.

Measures UFC Vacuum, tubing from

1. 2.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
Tube Needle Vacuum Line at Needle Chamber 3. 4. 5. Disconnect line leading to V46 on side port of Needle Chamber. Submerge open end of line in 10 ml of RBC Sheath/Rinse. Open V46 and measure aspiration time. the Needle Chamber to V46, pathway at UFC for V46. 3. 4. 5. 6. 7. 8. Check side nipple on MCTS chamber is not clogged or tubing pinched. Aspirate 50% bleach into tubing and alternate with slugs of air. Remove coupling and verify that tubing connection at coupling is secure and that connector has no clog. With coupling removed, open V46 and try to dispense 50% bleach into valve area with alternate slugs of air. If not successful, replace coupling and tubing and aspirate 50% bleach through specific valve. While bleach is being aspirated, close valve and allow bleach is sit to try to deteriorate clog. Repeat test.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: CLOGS at ASPIRATION MODES COMPLAINT PATHWAY TESTED STEPS TYPICA L TIME RESULT CORRECTIVE ACTION [If Pathway Tested Fails]

Poor Aspiration from Any or All Modes Poor Aspiration in certain Selectivity Probe Clogs Failed Aspiration

Aspiration Modes: Open MCTS

1. 2. 3.

Go to Exerciser. Verify that V1 and V47 are closed. If testing open mode aspiration, use sample probe and place selector valve in open mode. If testing MCTS aspiration, use tubing attached to the bottom of the needle and place selector valve in MCTS. If testing AS aspiration, use tubing attached to the bottom of the needle and place selector valve in AS.

<1min 50 sec.

Measures UFC Vacuum, pathway from specific aspiration mode through shear face, clot filter, selector valve, and all associated tubing in pathway.

1. 2. 3.

4. 5. 6.

Autosampler

Verify UFC Vacuum with UFC Vacuum Test. Check the clot filter. By pass the selector valve by using syringe coupling to connect the sample line from the UFC directly into the fitting containing the clot filter on the selector valve. [If significantly faster, troubleshoot selector valve for clogs or alignments.] If bypassing the selector valve does not correct, clean shear face off line and clean ports on rear shear face. Repeat procedure for test using 50% bleach and alternating with slugs of air. Follow this with DI water. Repeat test.

Selectivity: CBC CBC/Diff CBC/Diff/Reti c

1.

Submerge open tube probe in 10 ml of RBC Sheath/Rinse. 2. Open V47 3. Open V72 for CBC, Open V72, V73 for CBC/Diff Open V72, V73, and V74 for CBC/Diff/Retic 4. Open V1 and measure time to aspirate 10 ml. 1. 2. 3. 4. 5. Go to Exerciser Adjust 40 psi down to 30 psi. Pressurize both rinse diaphragm pumps (V28 and V29) Observe suspect rinse valves (V2, V8, V37, V11, V66). Verify that rinse is not seeping past valve into the chamber. Go to Exerciser. Access the Pneumatics Screen and verify UFC and Main Vacuum readings. Monitor for at least 1 min. Checks for sealing of the dome valves 1. 2. 3. 4. Check pilot pressure (40 psi) path from the pneumatic drawer to the UFC. Check small vacushield filter for integrity. Look for constrictions or leaks. If there is one valve in particular that is leaking (i.e. rinse entering chamber during test) and it is not a dome valve failure, as a last resort, replace the pilot valve.

Probe Clogs Failed Aspiration

Rinse Dome Valve Sealing Test

Poor Aspiration or Dripping Probe

UFC Vacuum Test

1. 2.

Monitor for at least 1 min.

UFC Vacuum should not differ from Main vacuum by more than 5 in Hg.

1.

Replace large vacushield on the waste jug. Check fittings on waste jug including spigot and waste exit port.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
Compressor Timeout Vacuum Out of Range 3. 4. Open V5, V7, V10, and V13, Return to Pneumatics Screen and monitor UFC and Main Vacuum. Note: Capacity of Vacuum Pump should be 24"-25" Hg. If pump is compromised, this could cause vacuum problems. 2. 3. 4. Close all valves and allow vacuum to recover. Restart test. If test fails again, and system has an Auto-waste configuration, bypass the in-line check valve in the waste line to the waste jug. Close all valves and allow vacuum to recover. Restart test. If test fails again, check for clogs in the waste lines from the UFC and in the lines to and from the waste manifold (behind power supply drawer). Clean out the waste manifold. Repeat test.

5. 6. 7.

8.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: CONDUCTIVITY PROBLEMS (PROBE CLOGS) COMPLAINT PATHWAY TESTED
Aspiration Mode

STEPS

TYPICA L TIME
< 20 sec.

RESULT

CORRECTIVE ACTION [If Pathway Tested Fails]

1. Go to CLOGS at ASPIRATION MODE

Probe Clogs

1. 2. 3.

Check for probe clogs in all aspirate modes. Check for Aspiration time <20 sec.

1.

Clog only in one mode.

<20 sec. Determine which detector is not functioning properly by aspirating sample and watching green light and blood.

2. 3.

> 20 SEC. If light continues flashing, or needle does not retract, Cond. #1 not detecting change in state. If blood is aspirated straight to waste, Cond. #2 not detecting change. Mode 1A

2. 3.

Go to CLOGS at ASPIRATION MODE Go to Step 4.

4.

During the next aspiration, read voltage of effected detector on Parallel Node brd.at the test points listed below before the sample reaches detectors(dry) and when the sample contacts the sensors(wet). There are two failure modes.

N/A

4.

4.

Mode 1A

A voltage of-0.5V to -5.0V is measured at the analog test point when the path should be dry.

Mode 1 - A sensor is conducting when the aspiration path should be dry. Mode 2 - A sensor is not conducting when the aspiration path has sample in it. An alternate method to test conductance is to use the exerciser. Go into the valves section and open valves 1,47,72. Go into syringes pumps section and put the selector valve in the open position. In the pneumatics section move the shear valve to the aspirate mode. You can now aspirate continuously from the open tube mode. Thus you can aspirate while looking at the indicators screen in the exerciser. The conductors should be detecting when the sample is present and not conducting when the line is dry. Analog test points Cond#1 = TP 9-4 &TP11-1gnd or

Determine if voltage is because Offset >0.6. Remove cable from UFC to Scrambler brd. If voltage is >0.3, is v due to cable cross talk or grounding. If voltage <0.3 but goes back up when reconnected rinse may be left in pathway(usually this voltage will decrease as rinse dries). Do UFC Vacuum test. If passes, do Rinse Dome Valve Sealing test. Check for leaks in the waste system. Clean out sample pathway with bleach solution. Consult TTN before changing UFC. Mode 1B Make sure threshold of 0.6v is set at threshold TPs. Check for signal transition at TP9-3 or TP11-3. This is the digital signal(TTL) out for conductance. It should toggle when the analog signal at TP9-4 or TP11-4 passes through 0.6v. If not the parallel node board is suspect.

Mode 1B A voltage of less than -0.5v is measured at the analog test point when the path is dry but the system still reports conductance.

Mode 2A A voltage of less than 1v is measured at the analog test point when the path has sample in it. Use a high control for worst case.

Mode 2A Check cable continuity. Make sure pins in cable connectors are making good contact. Check version of parallel node bd. Re-tighten screws going to the conductivity sensor on the back of the UFC. Note serial # and mfg of UFC. Clean out sample pathway across

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Control Number: 024-0005-14 Revision: A
U9 pin 8 & TP11-1 gnd Cond#2 = TP11-4 & TP11-1 gnd or U12 pin1 & TP11-1 gnd Threshold test points Cond#1 TP9-2 and gnd Cond#2 TP11-2 and gnd Mode 2B A voltage greater than 1v is detected at the analog test point but the system does not detect conductance. detector with bleach solution. Consult TTN before changing UFC. Mode 2B Repeat as in mode 1B.

UFC Vacuum Test

1. 2. 3. 4.

Go to Exerciser. Access the Pneumatics Screen and verify UFC and Main Vacuum readings. Open V5, V7, V10, and V13, Return to Pneumatics Screen and monitor UFC and Main Vacuum.

Monitor for at least 1 min.

UFC Vacuum should not differ from Main vacuum by more than 5 in Hg as both vacuums drop. Note: Capacity of Vacuum Pump should be 24"-25" Hg. If pump is compromised, this could cause vacuum problems.

1. 2. 3. 4.

5. 6. 7.

8. Probe Clogs Failed Aspiration Rinse Dome Valve Sealing Test 1. 2. 3. 4. 5. Adjust 40 psi down to 30 psi Go to Exercisor. Pressurize both rinse diaphragm pumps (V28 and V29) Observe suspect rinse valves (V2, V8, V37, V11, V66). Verify that rinse is not seeping past the valve into the chamber. Monitor for at least 1 min. Checks for sealing of the dome valves 1. 2. 3. 4.

Replace large vacushield on the waste jug. Check fittings on waste jug including spigot and waste exit port. Close all valves and allow vacuum to recover. Restart test. If test fails again, and system has an Auto-waste configuration, bypass the in-line check valve in the waste line to the waste jug. Close all valves and allow vacuum to recover. Restart test. If test fails again, check for clogs in the waste lines from the UFC and in the lines to and from the waste manifold (behind power supply drawer). Clean out the waste manifold. Repeat test. Check pilot pressure (40 psi) path from the pneumatic drawer to the UFC. Check small vacushield filter for integrity. Look for constrictions or leaks. If there is one valve in particular that is leaking (i.e. rinse entering chamber during test) and it is not a dome valve failure, as a last resort, replace the pilot valve.

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Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: IMPRECISION - SINGLE METHOD COMPLAINT PATHWAY TESTED STEPS TYPICA L TIME RESULT CORRECTIVE ACTION [If Pathway Tested Fails]

Imprecision for a Single Method

1.Reaction Chamber / Vent for Specific Method

1. 2. 3.

Go to Exerciser. For Perox problem use E-Z Kleen. For RBC/Baso/Retic problem us 50% bleach. Open the appropriate waste valve for the specific method: Perox -V5, V6, V7. RBC - V-10, Baso - V13, Retic - V65. Aspirate the appropriate fluid through the vent for the method and drain line. Check vent lines for pinches. Check Perox cap for clog. Locate a magnifying glass or loupe. Locate the sample delivery and reagent delivery line for the method in question. Trace the reagent delivery back to the reagent bottle Prime the reagent line using the hydraulic prime cycles. With the magnifying glass, examine the reagent delivery to the chamber.

Cleans chamber pathway including vent and waste for effected method.

1. 2.

Repeat Precision after this test. If not corrected go to next procedure.

2.Reagent Delivery for Specific Imprecise Method

1. 2. 3. 4. 5.

No air or bubbles should be seen in the reagent lines during prime cycles. Note: If imprecision is selectivity specific, check for air leak or clogging in specific mode.

1.

2. 3.

4.

5. 3.Noise Caused by Improper Grounding 1. 2. Run Saline samples in the Autosampler mode. Look for significant noise in the cytogram of the method in question. Go to Exerciser. Exercise the reagent pump associated with the method while monitoring vacuum and Minimum noise should be seen in any channel. 1. 2.

If the bubbles are seen rising up from the shear face, trace the line back to the line from the reagent pump to the shear face. If no bubbles are seen in #1 then clean the shear face. If bubbles are seen in # 1, then examine the reagent pump as it fills from the prime cycles. If bubbles are injected, check the reagent line for leaks. Swap ends of the reagent line to the reagent pump and reagent bottle. Prime several times to allow bubbles to clear. If this does not correct, remove reagent fitting from straw filter. Place fitting directly into reagent to see if filter on straw is the problem. Repeat test. If noise is present, block the light path. If noise is still present with the light path blocked, check that the system ground strapping is proper.

4.Leak from 11-Position Manifold

1. 2.

Should not see a significant drop in pressure or vacuum (>2-3 psi or >1-2"Hg). If a small drop is

1. 2.

Access the 11 position manifold and pinch off the pressure vacuum line that goes to the reagent pump. Repeat test.

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Control Number: 024-0005-14 Revision: A
pressure readings from the pneumatic screen. seen, it should recover while pump is still exercised. Large drop in pressure or vacuum and/or failure to recover indicates a leak associated with the 11 position manifold, pneumatic valve, or at tubing to specific pump or manifold. 3. 4. If results are good, the leak is in the line to the pump. If the results are not good, then swap the pneumatic valve with another position to isolate the problem to the valve itself. Cross check by testing the valve in its new position.

5.

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Control Number: 024-0005-14 Revision: A
TROUBLESHOOTING: IMPRECISION - SINGLE METHOD continued COMPLAINT PATHWAY TESTED STEPS TYPICAL TIME RESULT CORRECTIVE ACTION [If Pathway Tested Fails]

Imprecision for a Single Method cont.

5.Rinse Dome Valve Sealing Test

1. 2. 3. 4. 5.

Go to Exerciser Adjust 40 psi down to 40 psi. Pressurize both rinse diaphragm pumps (V28 and V29) Observe suspect rinse valves for the method in question: (V2, V8, V37, V11, V66). Verify that rinse is not seeping past valve into the chamber. Turn the 20 psi down to 14 psi. Run 10 to 20 sample precision. Examine only the HGB precision. Disregard all other parameters. If precision is improved and "Flatness" is good, then violent mixing in the Hgb chamber is suspect.

Monitor for at least 1 min.

Checks for sealing of the dome valves

1. 2. 3.

Check pilot pressure (40 psi) path from the pneumatic drawer to the UFC. Look for constrictions or leaks. If there is one valve in particular that is leaking (i.e. rinse entering chamber during test) and it is not a dome valve failure, as a last resort, replace the pilot valve.

Hgb Imprecision

1. 2. 3. 4.

Perform this test if no significant bubbles are observed in the reagent line and the transmission has a curve at the beginning of the sample portion of the Hgb histogram.

1. 2. 3. 4.

If failure seen at 20 psi but improved at 14 psi then problem could be incorrect entry angle of sample. # 1 could be due to Obstruction in Sample Line Troubleshoot this pathway # 1 could be due to Air Leak in Reagent Line Troubleshoot this pathway. Raise pressure to 19.5. If sample portion of the Hgb histogram is still good when running samples, re-run precision.

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TROUBLESHOOTING - DOME VALVES, REAGENT DIAPHRAGM

COMPLAINT

PATHWAY TESTED

STEPS

TYPICA L TIME

RESULT

CORRECTIVE ACTION [If Pathway Tested Fails]

Loss of Vacuum at UFC Caused by Pilot Valve

UFC Dome Valve and Pilot Valve integrity

1. 2. 3.

4. 5. 6.

If dome valve failure is suspected, verify that the pilot valve associated with this dome valve is functioning. Go to Exerciser. In the Valves Screen, open the valve for the suspected failure. If the Valve on screen remains green while exercised, then the system is registering the correct electrical response. If the Valve shows red, then the indication is there is an electrical failure. Troubleshoot by swapping the Valve Driver Boards to see if the problem moves. If the Valve Driver swap does not correct, then replace the suspect pilot valve according to the procedure in the Service Guide. Check to see if Pilot valves vacuum supply (middle rear) has fluid in it. Check to see if there is fluid at the back of the UFC coupling (pull out Pnematics drawer to view) in the tubing from port 15 to the waste manifold. Verify integrity of each diaphragm pump. If a pump is found faulty and fluid has invaded the vacuum system, then the small vacushields will be wet.

Test to see if Pilot Valve is the problem for Dome Valve Failure.

1.

If this test does not fail, then go to loss of Vacuum caused by Dome Valve.

Caused by Dome Valve

1. 2.

No fluid should be seen in the Pilot valve vacuum line from the UFC to the UFC coupling

1.

If fluid is seen in the Pilot Valve vacuum line from the rear of the UFC, then the integrity of one of the dome valves is compromised and the UFC should be changed.

Loss of Vacuum at UFC Caused by Diaphragm Pump Failure/Leak

Diaphragm Pump Integrity

1. 2.

Note: these vacushield filters are designed to hold back moisture. If a large amount of fluid is experienced, then it will penetrate these filters

No fluid should be seen in the vacuum/pressure lines from the diaphragm pump to the 11position manifold. Note: If a leak is experienced in a diaphragm pump, then any of the vacuum lines to the 11- position manifold can have fluid in them since the vacuum supply is

1. 2. 3.

If a diaphragm pump is found to be faulty, then replace it with a new one. The vacuum lines involved will have to be dried out and vacushields replaced. Note: Additional parts may have to be replaced if fluid did invade, including the 11-position manifold, vacuum regulator, vacuum head and pressure node board.

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Control Number: 024-0005-14 Revision: A
universal.

Loss of Vacuum at UFC Caused by Reagent Pump Failure/Leak

Reagent Pump Integrity

Verify integrity of each reagent diaphragm pump. 2. If a pump is found faulty and fluid has invaded the vacuum system, then the small vacushields will be wet. Note: these vacushield filters are designed to hold back moisture. If a large amount of fluid is experienced, then it will penetrated these filters.

1.

No fluid should be seen in the vacuum/pressure lines from the diaphragm pump to the 11position manifold. Note: If a leak is experienced in a diaphragm pump, then any of the vacuum lines to the 11- position manifold can have fluid in them since the vacuum supply is universal.

1. 2. 3.

If a reagent pump is found to be faulty, then replace it. The vacuum lines involved will have to be dried out and vacushields replaced. Note: Additional parts may have to be replaced if fluid did invade, including the 11-position manifold, vacuum regulator, vacuum head and pressure node board.

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PRELIMINARY PRODUCT INFORMATION

Control Number: 024-0005-14 Revision: A
CONTINUOUS IMPROVEMENT IDEAS Use this page to keep track of ideas for change as you think of them. Forward your suggestions to Pat Frank: By e-mail: Patricia Frank/TRYTN/DIAG/US/BAYER, Or Fax 1-91524-2249 Thank you for contributing!

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