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Maintenance Guide

SA-10/20 Semi-Automatic
Chemistry Analyzer
CLINDIAG SYSTEMS B.V.B.A.
Contents
1 BASIC PRINCIPLE........................................................................................1
2 OPERATIONAL ENVIRONMENT..................................................................1
3 WARNINGS AND PRECAUTIONS................................................................2
4 SERVICE AND MAINTENANCE...................................................................2
4.1 MAINTENANCE STAFF QUALIFICATIONS........................................................2
4.2 TOOLS........................................................................................................2
4.2.1 General Tools.....................................................................................2
4.2.2 Specific Tools.....................................................................................3
4.3 DAILY MAINTENANCE..................................................................................3
4.4 WEEKLY MAINTENANCE...............................................................................3
4.5 OTHER MAINTENANCE................................................................................3
5 MAIN COMPONENTS....................................................................................4
5.1 OPTICAL SYSTEM.......................................................................................4
5.1.1 Light Source.......................................................................................5
5.1.2 Filter Wheel........................................................................................6
5.1.3 Flow Cell and Preamplifier.................................................................8
5.2 MAIN BOARD............................................................................................10
5.3 PERISTALTIC PUMP...................................................................................11
5.4 POWER CONNECTION...............................................................................12
6 Troubleshooting............................................................................................12
1 Basic Principle
The analyzer is designed on the basis of Lambert-Beer Law.
Also known as Beer's Law, it is a very important yet simple relationship
between how much light is absorbed and the concentration of the absorbing
species in a sample.
Definitions:
Transmittance: T = P / Po
Light initially directed toward a sample is called Radiant Power and
Transmittance is a measure of the fraction of initial radiant power (Po) that
passes through a sample, emerges (P) and reaches a detector.
Absorbance: A = -log T = log (Po/P)
Absorbance is a measure of the amount of Radiant Power absorbed by a
sample. Absorbance is indirectly proportional to Transmittance. That is, if a
sample absorbs 10% of Radiant Power, then the transmittance of Radiant
Power through the sample is 90%. Absorbance is an important characteristic
because it is directly proportional to the concentration (c) of the light
absorbing species in the sample.
The measurement process is explained as Figure 1-1.

Figure 1-1 Basic principle

2 Operational Environment
Normal operational environment requires:
-- Power Supply: AC220V10%, 50Hz2% or AC110V10%, 60Hz2%
-- Fuse: 2A
-- Input Power: 150W
-- Ambient Temperature: 15-30
-- Relative Humidity: 30-70
-- Air Pressure: 86.0KPa-106.0KPa
--Avoid intense electromagnetic interference.
-- Reliable ground connection.
-- Avoid intense light or direct ultraviolet light.

3 Warnings and Precautions


-- Do not place or operate the instrument on an unstable table.
-- There are ventilating openings and pipeline interfaces at back panel. Make

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sure to reserve a 20 cm space at the back of instrument for cooling down.
Also do not operate the instrument in a closed environment.
-- Check and confirm that the power socket is correctly installed and well
grounded.
-- Check and confirm that all plugs on the instrument are properly connected,
well grounded and reliable.
-- Make sure to use matched supply voltage on the instrument.
-- Be sure to cut off power and turn off the instrument before repairing it.
Perform repairs with the instrument running may result in electric shock or
component breakage, and should be done by professional engineers.
-- Always use a specified fuse.
-- Be sure to turn off instrument before connecting wires or sockets. Failure
to do so may cause damage to instrument.
-- Switch off the instrument and pull out power plug if you finish testing or
wont use it for a long time.
-- Do not make physical concact with patients serums to avoid potential risks.

4 Service and Maintenance

4.1 Maintenance Staff Qualifications


Service has to be done by Clindiag after-sale engineers or our authorized
professionals.

4.2 Tools

4.2.1 General Tools


General tools for maintenance:
-- One medium-sized Philips screwdriver
-- One small Philips screwdriver
-- One medium-sized slot-head screwdriver
-- One small slot-head screwdriver
-- One pair needle nose pliers
-- One set inner hexagon spanner
-- One 150W electric iron
-- One pack soldering tin
-- One digital multimeter
-- One pair of tweezers

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4.2.2 Specific Tools
Specific tools for maintenance:
-- Soft cloth
-- Neutral cleaner
-- Lubricants
-- Cotton swap
-- Rubbing alcohol
-- Rubber gloves
-- Lens paper

4.3 Daily Maintenance


Daily maintenance steps are as follows:
-- Clean the instruments operational environment.
-- Rinse flow cell with distilled water. Go to main menu of the instrument and
insert a pipe into distilled water. Press Wash to begin rinsing.

4.4 Weekly Maintenance


Weekly maintenance steps are as follows:
-- Clean the instruments operational environment.
-- Rinse flow cell with distilled water. Go to main menu of the instrument and
insert a pipe into distilled water. Press Wash to begin rinsing.
-- Rinse flow cell with cleaning solution. Go to main menu of the instrument
and insert a pipe into cleaning solution. Press Wash to begin rinsing.

4.5 Other Maintenance


After 6-7 months of using, peristaltic pump needs replacing due to heavy
wearing. Refer to section 5.3 for more details on pump pipe replacement.
After 2,000 hours of using, lamp needs replacing. Refer to section 5.1.1 for
more details on lamp replacement.

5 Main Components

5.1 Optical System


Function: Optical system is the heart of the instrument. Light generation, light
splitting, color comparison, reception and amplification of optical signals are
all done in this system. Moreover, it transmits amplified optical signals to main
board for further processing and controls temperature in flow cell.

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Structure: Optical system is mainly consists of light source, filter wheel, flow
cell, preamplifier and heating unit (heating block and A/D590 temperature
sensor). Structure of optical system is shown as Figure 5-1 and Figure 5-2.

A/D590

Heating
Block

Figure 5-1 Side view of optical system

Filter Wheel Flow Cell

Light Preamplifier
Source

Figure 5-2 Top view of optical system

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5.1.1 Light Source
Optical system uses a 6V10W halogen lamp to generate light. The lamp is
installed on a holder which is held by a large screw cap on optical system.
Normally, service life of the lamp is about 2,000 hours.
Use the following steps to replace halogen lamp:
-- Turn the large screw cap counterclockwise to remove lamp and its holder
from optical system as shown in Figure 5-3 and Figure 5-4.
-- Install new lamp and holder onto optical system. Turn screw cap clockwise
to tighten it.
-- Fine tuning of lamp position to maximum AD.
Fine tuning:
-- When the large screw cap is tightened, hold lamp holder with one hand
and loosen jackscrews at the side of lamp holder with the other hand as
shown in Figure 5-5.
Open testing software and go to AD Signal Test menu. Observe real-time
AD value of a certain wavelength and adjust vertical position of lamp holder
until AD value reaches a maximum. Tighten jackscrews to secure the holder.

Figure 5-3

Screw Cap

Lamp Holder

Lamp

Figure 5-4

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Figure 5-5

5.1.2 Filter Wheel


All filters are installed in a filter wheel, which is also called filter pack.
Filter wheel is shown as Figure 5-6.

Filter Wheel

Optical Coupler

Figure 5-6 Filter wheel


There are 10 holes on filter wheel. Filter installation for an instrument of
standard configuration is shown as Table 5-1.
Table 5-1 Filter actual position
No. 1 2 3 4 5 6 7 8 9 0
Wavelength 340 405 492 510 546 578 620 Unused Unused Blocked
Filter Hole 6 8 9 0 1 2 3 4 7 5

Each filter, except for the 340 nm filter, is placed behind a pre-filter to adjust
optical signal intensity of different wavelengths. A longer wavelength
corresponds to a pre-filter with smaller aperture.
If magnification value of a filter is 7 after automatic zero set of AD,
transmission of the filter is on the low side. Enlarge aperture of its pre-filter or

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replace filter to solve the problem.
Use the following steps to replace filter:
-- Remove snap rings from the filter with tweezers as shown in Figure 5-7.
-- Remove the filter and pre-filter with an offset socket wrench as shown in
Figure 5-8.
-- Enlarge aperture of its pre-filter or replace the filter. Actual pictures of pre-
filter, filter and snap ring are shown as Figure 5-9.

Figure 5-7

Figure 5-8

Pre-filter Filter Snap Ring


Figure 5-9

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5.1.3 Flow Cell and Preamplifier
Flow cell is used for color comparison of reaction fluid. The thin pipe is
connected to pipe for fluid inlet and the thick pipe is connected to peristaltic
pump for fluid outlet.
Preamplifier is installed at back end of the flow cell for receiving and
amplifying optical signals. The two adjustable potentiometers on it are used
for adjusting AD value and background value.

Inlet
Outlet

AD Value Background
Value

Figure 5-9
Explanations on AD value, background value and magnification value:
-- AD value is the initial intensity of optical signal for a certain wavelength.
Normal range of AD value is between 26,000-38,000. Due to the differences
in light intensity of various wavelengths, pre-filters of different apertures are
placed before filters to adjust light intensity of different wavelengths.
-- Background value is also the voltage value when preamplifier doesnt
receive any optical signals. Make sure that background value is kept within
the range of 1-300.
-- Magnification value magnifies AD value and background value to keep AD
value within normal range as shown in Table 5-2.

Table 5-2
Magnification Value AD Value Details

0 8,000 Value of amplification increases by 1


when AD value is below normal range.
1 16,000 AD value is magnified to 16,000, which
is still below normal range. Value of
magnification increases by 1.
2 24,000 AD value is magnified to 24,000, which
is still below normal range. Value of
magnification increases by 1.

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3 32,000 AD value is magnified to 32,000, which
is within normal range. Instrument
completes automatic zero set.

As is shown in above table, when the instrument performs AD automatic


zero set, value of magnification will be adjusted accordingly. If AD value is
below normal range, value of magnification increases by 1. If AD value is
beyond normal range, value of magnification decreases by 1. The normal
range for value of magnification is 0-7. If AD value is still below normal range
when value of magnification is 7, light transmittance of filter is on the low side.
Enlarge aperture of the pre-filter or replace filter to solve the problem.

5.2 Main Board


Function: Main board controls operation of the instrument, including motor
control, temperature control and data processing.
Structure: structure and wiring schematic diagram is shown as Figure 5-10.
Sensor
Sensor Preamplifier Display Screen

Power Supply
Printer Data
Cable

Printer Power
Voltage Output Membrane Key

Voltage Output
Sampling Button
Optical Coupler

Filter WheelPeristaltic PumpRS232


Motor Motor

Figure 5-10 Structure of main board

Temperature control
There are 6 potentiometers VR201 - VR206 and 2 chips
IC205IC206 on main board for adjusting and controlling temperatures in
flow cell and incubator. Actual temperatures can be adjusted by changing
voltages on potentiometers as indicated by the red square in Figure 5-10.
Corresponding relation between potentiometer voltage and temperature is
shown in Tables 5-3 and Table 5-4.

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Table 5-3 Temperature control in flow cell
Controller Chip Pin Potentiometer Voltage Temperature
IC205 15 VR203 3.10V 37.0
14 VR202 3.03V 30.0
13 VR201 2.98V 25.0

Table 5-4 Temperature control in incubator


Controller Chip Pin Potentiometer Voltage Temperature
IC206 15 VR206 3.10V 37.0
14 VR205 3.03V 30.0
13 VR204 2.98V 25.0

Connect one end of voltmeter to GND terminal and the other end to pin of
controller chip when measuring voltage of a corresponding potentiometer.
Turn the potentiometer clockwise to increase or counterclockwise to decrease
voltages. Actual temperature will increase/decrease by 0.1 when voltage
increases/decreases by 0.01V.

5.3 Peristaltic Pump


Function: Peristaltic pump sucks fluids into flow cell through pipes.
Structure: Connection mode of peristaltic pump and pump pipes is shown as
Figure 5-11.
Waste Fluid Pump Pipe

Outlet of Flow Cell Pump Impeller


Figure 5-11
Use the following steps to replace pump pipes:
-- Remove pump pipes from pump impeller.
-- Disconnect pump pipes from pump joints.
-- Connect new pump pipes to pipe joints.
-- Install new pump pipes onto impeller of peristaltic pump.

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5.4 Power Connection
Schematic diagram of power connection is shown as Figure 5-12.

Fan Lamp

Figure 5-12 Schematic diagram of power connection

6 Troubleshooting
The troubleshooting is listed as table 6-1.
Table 6-1 Troubleshooting
Problem Cause Solution
The instrument Loose plug Check if power plug or
fails to start outlet is plugged into
place.
Blown fuse Replace the blown fuse.

No output from power Replace power supply.


supply
Self-check failure Printer power cord is loose. Properly connect power
cord of printer.

Printer data cable is loose. Properly connect data


cable of printer.

Filter wheel cant be reset. Replace optical coupler


of filter wheel.

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Flow cell cant be No heating voltage Replace main board.
warmed up
Heating block failure Replace heating block.

Temperature sensor failure Replace temperature


sensor.

Incubator cant be No heating voltage Replace main board.


warmed up Heating block failure Replace heating block.
Temperature sensor failure
Replace temperature
sensor.
When AD is Lamp failure Replace faulty lamp.
automatically set
to zero, the value
is equal to
background value.
When AD is Aged filter Enlarge aperture of its
automatically set pre-filter or replace filter.
to zero,
magnification
value of a certain
wavelength
reaches 7.
When AD is Aged lamp Replace faulty lamp.
automatically set
to zero, Bubbles in cell Rinse cell.
amplification
values of all Preamplifier failure Replace preamplifier.
wavelengths reach
7 and AD value is
on the low side.
Cant suck in fluid Motor of peristaltic pump Replace motor of
doesnt work peristaltic pump.

Sampling parameter Recalibrate sampling


Incorrect parameter

Aged peristaltic pump pipes Replace peristaltic pump


pipes.

Leaky or blocked pipes Replace faulty pipes.

Built-in printer Printer power cord is loose. Properly connect printer


doesnt work power line.

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Printing paper incorrectly Correctly load with
loaded printing paper.

No display on Loose connecting wires of Check if wires of display


screen or missing display screen screen are properly
lines Display screen failure connected.
Replace display screen.
Membrane key no Loose connecting wires of Check and confirm wires
response membrane key of display screen are
properly connected.

Short circuit in sampling Replace or adjust


pushbutton sampling pushbutton.

Membrane key failure Replace membrane key.

END

CLINDIAG SYSTEMS B.V.B.A.

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