DXC 600 800 Basic Service Workbook Ver B

Introductions
DxC Basic Phase 1
UNICEL DxC 600/800 Pro Basic Service, Introductions Page 1 of 12

Version A 08282006 Brea Training Center
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Acronyms and Definitions
Unicel DxC
ASCII American Standard Code for Information Interchange
ASTM American Society for Testing and Materials
CAU Chemistry Analytical Unit
CC Cartridge Chemistries (also referred to as Random Access (RA))
CD Compact Disk
DMD Dual Motor Driver

GSM Generic Smart Module (Refers to software common to all smart
HC16 The DMD Micro-controller
ICC Instrument Control Computer
ICD In-Circuit Debugger (Cable)
ICS Instrument Control System
MC Modular Chemistries (also referred to as Parallel Process (PP))
MPC Multi Product Console
MSMC Multiple Smart Module Controller
OS Operating System
PARISE Parallel processing cup and ISE chemistry software

PP Parallel Process (see MC)
RA Random Access (see CC)
SM Smart Module (see DMD)
SRS Software Requirements Specification
TS-CTS Thick Stopper - Closed Tube Sampling
TCP/IP Transmission Control Protocol / Internet Protocol

Tools Parts List
KIT, TOOLS DxC 600/800 SYSTEM P/N: A18779 AC

PART NUMBER DESCRIPTION QTY
A18396 TOOL, ALIGN PROBE CAR, DXC 2
A18397 TOOL, ALIGN, TWO CAR, DXC 1
A20658 SCRIBER, POCKET STYLE, STEEL 1
389476 TOOL, STIRRER REMOVAL 1
389524 WRENCH, RETAINER NUT 1
450893 SCD, PENLIGHT CX3 SYSTEMS 1
467731 PLIERS, RETAINING RING RWRK 1
471803 ALIGNMENT TOOL, REACTION WHEEL 1
473100 CUVETTE ALIGNMENT TOOL 1
473181 KIT, FLUSH FLOWCELL 1
476211 TOOL, PROBE ALIGNMENT LX20 1
756613 TUBING ASSY,PROBE CLEANER 1
756934 STANDARD, BARCODE PKG/5 1
756956 PLUG, WHEEL ALIGNMENT 4
759473 GAGE, FEELER CUVETTE WASH SENSOR 1
891349 SCREWDRIVER, 5 LG 3/16 BLADE 1
949109 WRENCH, SPANNER 1
970334 WRIST STRAP, ESD ADJUST 1
970531 SCREWDRIVER, PHILIPPS NO.1 3 LG 1
970534 WRENCH, 5/16 IGNITION 15 & 80 DEG 1
975561 WRENCH SET, ALLEN 0.05-5/16 1
977929 PLUG 1
979071 MIRROR, INSPECTION 1
Miscellaneous Tools
475865 TOOL, ALIGNMENT, SAMPLE TUBE (Cap Piercer )
474433 Carbon Bridge Striking Tool
977655 Cable Kit; Diagnostic Tools

DXC 600 / 800 BASIC SERVICE TRAINING
COURSE AGENDA PHASE 1
Week 1
Day 1 Monday
Time Event Location
Introduction Student survey
Load DXC IFU, REF, VER, HOST, CIM Manuals
Load DXC In-Lab Training Manual
08:00 09:30 Classroom
Replicate DXC Databases, Application Repository.
Check Diagnostic Tools, DxC 600 & 800 Simulator
System Overview
System Overview
Software Overview
09:30 11:30 Laboratory
System Parameters / Setup
Enable Metering Exercise
11:30 12:30 Lunch
MC Reagent Preparation and Loading Exercise
Reagent Calibration Exercise
Read DxC Instructions For Use Chapter 13:
"Troubleshooting Calibration and Result Errors"
Day 2 Tuesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 09:00 QC / Customer Maintenance Classroom
09:00 11:30 QC & Sample Programming / Processing Exercises Laboratory
11:30 12:30 Lunch
Event Logs, QNX, and Boot Sequence
12:30 1:30
Instrument Control Subsystem
Event Logs, QNX, Boot Sequence and Instrument
1:30 5:00 Control Computer Exercises Laboratory
Troubleshooting Exercises
Day 3 Wednesday
Time Event Location
08:30 10:00 Power Subsystem, Smart Modules & Classroom
Communications Subsystems
10:00 11:30 Power & Fans Exercises Laboratory
11:30 12:30 Lunch
1:00 5:00 Smart Modules & Communications Exercises Laboratory

Week 1 Continued
Day 4 Thursday
Time Event Location
08:30 10:00 Utilities Hydro-pneumatics Subsystem Theory Classroom
10:00 11:30 Hydro Exercises Laboratory
11:30 1:00 Lunch
1:00 5:00 Hydro Exercises Laboratory
Day 5 Friday
Time Event Location
08:30 10:00 Sample Rack Handling Subsystem Theory Classroom
Reserved Racks
TS-CTS Cap Piercer
10:00 11:30 Sample Rack Handling Exercises Laboratory
11:30 12:30 Lunch
12:30 5:00 Sample Rack Handling Exercises Laboratory

Week 2
Day 6 Monday
Time Event Location
08:30 10:00 MC Sample Handling, Level Sense, Obstruction
Detection, MC Cups Theory
10:00 11:30 Dual Syringe, Sample Probe Exercise Laboratory
MC Cups Exercises
11:30 12:30 Lunch
12:30 5:00 MC Cups Exercises Laboratory
Day 7 Tuesday
Time Event Location
08:30 10:00 ISE Theory Classroom
10:00 11:30 Preventive Maintenance Minor (ISE/MC) Laboratory
11:30 12:30 Lunch
12:30 5:00 PM continued Laboratory
Day 8 Wednesday
Time Event Location
08:30 11:30 PM completion Laboratory
Decontamination Procedure Overview Exercise
11:30 12:30 Lunch
12:30 5:00 Troubleshooting Exercises, Cont... Laboratory
Day 9 Thursday
Time Event Location
08:30 11:30 Troubleshooting Exercises Laboratory
11:30 1:00 Lunch
1:00 2:00 Lab Cleanup Laboratory
2:00 5:00 Student Survey Classroom
Mentoring Period Requirements


Personal Progress Report
Name: ____________________
Instructions The Personal Progress Report is your way of monitoring your skill
development. At the end of each exercise, monitor your progress by
comparing your answers or reports to the Reference Key. Initial your
Personal Progress Report and ask your Instructor to do the same.
ITEMS PERTINENT TO INSTALLATION ARE IN BOLDFACE
Day 1 Monday
Student Instructor
Exercise Objectives
Initials Initials
System Overview Identify major system components
and locations _______ _______
Software Overview Software operation, menus, icons
and options _______ _______
System Set Up Set up / review all System
Parameters _______ _______
Metering Activate Service Mode using
Password Generator program
Initialize Metering
Disable Service Mode
Accessing Metering Information
Utilize Meter-Use Manual _______ _______
MC Reagent Identify preparation requirement
Preparation & AUTO load MC reagents
Loading MANUAL load of MC reagents
Edit volumes _______ _______
MC Reagent Assign calibrator IDs
Calibration Calibrate MC and CC Reagents
With barcodes
Without barcodes
Reprint (recall) previous calibration
reports _______ _______
DxC IFU Read Chapter 13: Troubleshooting
Calibration and Result Errors _______ _______

Day 2 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
QC and Program & process QC
Sample Program & process samples:
Programming /
With bar code labels
Processing
Without bar code labels
Requesting Load Lists
Clear rack assignments
Recall results
Sample replicates and chem replicates
Statistical summary report
Absorbance versus Time Plots/Tables _______ _______
Customer Review customer maintenance procedures
Maintenance in the IFU _______ _______
Software Initiate Hyper Terminal session
Boot Sequence Observe boot process in the Hyper
Terminal window
Identify information provided in the Hyper
Terminal window _______ _______
Instrument Remove & reinstall ICS components
Control Perform Console Only Boot
Subsystem Enter hardware ethernet address and
serial number _______ _______
QNX Locate and review QNX procedures
Procedures Understand when they may be applicable _______ _______
Event Logs View and identify the information displayed
in the Event Logs _______ _______
Day 3 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
Power Locate Power Subsystem components
Subsystem Remove and reinstall power supply
Observe normal power up sequences
Identify LED display codes
Adjust power supplies
Power supply measurements Min Max _______ _______
Smart Modules Locate the Smart Modules on the DxC
Fiber Optics Troubleshooting Fiber Optics _______ _______

Day 4 Thursday
Student Instructor
Exercise Objectives
Initials Initials
Identify Hydro components
Observe instrument & instrument status
during routine operations _______ _______
Hydro- Observe proper valve operation
pneumatics Remove and reinstall valves
Perform Diagnostic tests
Vacuum and Air Pump test
Float Switch Tests
Hydro valves tests
Pump Box access
Review PMC Procedures
Review decontamination procedure
Day 5 Friday
Student Instructor
Exercise Objectives
Initials Initials
Cap Piercer Remove and reinstall bar code reader
TS-CTS Remove and reinstall TS-CTS
Blade and wick removal and replacement _______ _______
Auto gloss pump repair and replacement
One blade TS-CTS functional alignment
Sample Rack Shuttle latch solenoid removal and
Handling replacement
Remove and reinstall onload tray _______ _______
assembly
Remove and reinstall offload tray
assembly
Remove and reinstall shuttle assembly
Perform sample rack handling alignment
procedures
Verify alignments
Review TS-CTS event log entries

Day 6 Monday
Student Instructor
Exercise Objectives
Initials Initials
Dual Sample Remove and reinstall the Dual Sample
Syringe Assy. Syringe Drive Assembly _______ _______
MC Sample Remove and reinstall MC crane
Crane Remove covers from the Triple Crane
Assembly and observe its function
Remove and reinstall MC probe
Perform MC Crane Alignments _______ _______
Identify LED status/colors
MC Cups Remove and reinstall MC cup module
Remove and reinstall pump and valves
Remove and reinstall stirrer motor
Adjust cup temperature via diagnostics
Remove and reinstall lamp via diagnostics _______ _______
Perform lamp calibration
Day 7 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
MC ISE Replace Carbon Bridge
Strike the Carbon Bridge _______ _______
Preventive Perform PMC Minor (ISE/MC)
Maintenance
Procedure _______ _______
Day 8 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
Decontamination Locate, review and understand the
Procedure system decontamination procedures. _______ _______

Operations
Exercises 1
UNICEL DxC 600/800 Pro Basic Service, Operations Page 1 of 20

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Lab Exercise: System Overview
Objectives This exercise will guide you through the following:

Identifying system components and locations
Software overview
Why Identify system components and locations in preparation for more

detailed training.
Overview the software to become familiar with the icons and menus
for more detailed operation.
Reference DxC In-Lab Training Manual

Materials DxC Reference Manual
Please feel free to consult with an instructor if you have

any questions about the information in this exercise.

System Overview:
Reference:
DxC In-Lab Training Manual
Chapter 1 System Components
System Read the above chapter reference and identify all components and
Components locations on your instrument.
When you have completed the above move on to the next section.
References:
DxC In-Lab Training Manual:
Chapter 2 Software Overview
Software Read the above chapter reference and identify the sections of the
Overview main screen on your instrument.
Locate an instructor for sign off on this exercise.

Be prepared to answer any questions and demonstrate what you
have learned.

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

system parameters based on your customer's needs. This exercise
will also provide you with the opportunity to explore the software.
Reference DxC Instructions For Use Manual

Materials DxC Reference Manual


System Parameters Setup:
References:
DxC Reference Manual:
Chapter 3 Detailed System Setup
DxC Information For Use Manual
Chapter 4 System Setup Operations
Do not enable auto serum index on your training instrument.

Auto Serum
1 Index / Note:
ORDAC Auto serum index checks for hemolysis, lipemia, and
icterus on ALL samples!
DIL1 reagent must be loaded on the instrument when
testing for serum index. Auto serum index is intended for
sample integrity assessment only, not for patient
diagnosis!
Numeric values (indices) are printed on the patient
report. The corresponding relative concentration of each
interfering substance may be found in the DxC Chemistry
Information Manual Serum Index Tab.
It is also possible to enable/disable serum index via the
Samples Icon (see F3 Option).
2 Chem
Config/ Using the information found in the table below, define the
Sample Type Chemistry Print Names for the following chemistries.
Chemistry Print Name

Na Sodium
K Potassium
Cl Chloride
Ca Calcium
Date/Time
Set up the date and time information on your instrument
3 using PST.
Demographics
4
Setup
Review menu with the references.
5
Immediate Set up Module Chemistries for ALL to Printer only and
Report Immediate Report of Reruns
Review this menu and take note of Default Panel feature.
The Default Panel of tests is automatically run if the host
6 Panels fails to respond within the designed time period to a host
query.

System Parameters Setup, cont.
7 Replicates Review menu with the references.
8 Report Setup Review menu with the references.
9 Reportable Ranges Review menu with the references.
10 Reference/ Critical Ranges Review menu with the references.
11 Sample Comments Review menu with the references.
Enable the following Special Calculations:
12 Special Calculations ANION GAP (1)
BUN/CREA RATIO
13 Setup Summary
Review Should be the same information
as on the HELP Icon.
14 Units / Precision Review menu with the references.
15 User-Defined Chemistries Review menu with the references.
16 Bar Code Review menu with the references.
17
Reserved Racks / Enable the Obstruction Detection feature on
Obstruction Detection your training instrument.
18 Disable Service Monitor Review menu with the references.
19 External Water Monitor Review menu with the references.
20 Host Communication Review menu with the references.
21 Language / Keyboard Review menu with the references.
22 Printer Setup
Review menu with the references.
23 Service Setup This will be performed in the next exercise.
24 System Configuration Review menu with the references.
25 Version Upgrade Review menu with the references.
26 Status Alarm / Annunciator Test the alarm selections choose Alarm 1.
27 Chem Update Review menu with the references.
28 Password Setup Review menu with the references.
29 Auto Generation of Control Review menu with the references.

Be prepared to answer any questions and to demonstrate what you
have learned.


Lab Exercise: Metering
Objective Activate Service Mode using the Password Generator

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

Needed
Reference DxC Service Manual

Materials DxC Metered Use Manual


Metering, cont
Reference:
DxC Metered Use Manual:
Operational Overview
Enable Read the Operational Overview.

Metering To enable metering on your training instrument.
Main Menu
Select Setup on the Icon Menu Bar
Select [23] Service Setup
Obtain password using Service Password Generator
Enter password on Password Screen and select [OK}
If you have generated and entered the correct password, you will
be in the Service Setup Screen, if not repeat the process.
On the Service Setup Menu select [5] Service Mode Active
Acknowledge the Service Mode Active pop-up
Select Utilities on the Icon Menu Bar
On the Utilities Menu select [9] Metering
Enter the following information:
Facility Name: DxC Service Training Lab
Facility Address: Beckman Coulter, Inc.
250 S. Kraemer Blvd.
Brea, CA 92822
Meter day-of-the Month: 25
Reference:
Metering Data Transfer Procedure
- Operating in Service Mode
Disable Read the above reference
Service Disable Service Mode:
Mode System Setup Menu - [18] Disable Service Monitor
Questions What color distinguishes Service Mode from Normal Operations?

__________________________
Why disable the Service Mode?

Metering, cont
Reference:
Metering Data Transfer Procedure
Adjustments to Standard Replenishments
Assume the DxC has alerted you with the message:
METER DATA IS DUE.

PROCEED TO UTILITIES SCREEN AND SELECT METERING.
Perform the following adjustments on your training instrument.
Part Replenishment/Adjustment
472481 - CO2 Acid [HOLD]
445865 - WASH CONCENTRATE Decrease by 1 box
Print a copy of a meter report and the Replenishment /Adjustment

screen. Review the information found in the print out.
Question If your customer transmits their Metering Report via modem to BCI,
how will they be informed that the transmission was successful?
___________________________________________
___________________________________________

have learned.


Lab Exercise: MC Reagent Preparation and Loading
Objective This exercise will guide you through the following:

Identify preparation requirements
Loading of MC reagents
Auto load of MC reagents
Manual load of MC reagents
Edit volumes
Why: When installing the DxC one of the first things you will need to do is
place the MC reagents on the DxC. Some require preparation.
Load Once placed on the DxC you will need to load them on the system.
The term loading reagents on an DxC means that we are loading
the following information into the system parameters memory:
The test or reagent name
The lot number
The expiration date
The serial number
Typically, reagent parameter information is automatically loaded using

the hand-held barcode reader.
If the barcode reader fails, however, reagents can still be loaded

using manual load typing the information in.
The only way that you can be sure that the information has been
loaded is to watch the Reagent Load Screen to see that the data
changes.
Edit When the bulk reagents are scanned the system assumes 100%
Volume volume.
This can cause serious problems with ISE results if it is not accurate.
Reference DxC Reagent Preparation Quick Reference Card

Materials DxC Instructions For Use Manual
DxC Reference Manual
DxC Chemistry Information Manual


MC Reagent Preparation:
References:
Reagent Preparation Quick Reference Card:
Supplied with all DxC instruments. (P/N A18595)
DxC Instructions For Use
MC Reagent The MC reagents for your training instrument have already been
Preparation prepared and placed on the CAU (Chemistry Analytical Unit).
Take special note of the numbers and letters that are on the tubing
that is attached to the MC reagent straws.
MC Reagent Load:
References:
DxC Instructions For Use:
Chapter 5 Reagent Load / Calibration
Chapter 3 Procedures and Processes
AUTO Using the bar code reader, load all of the MC reagents in the bulk
(Reagent) reagent compartment and the Wash Concentrate II. Load the No
Load Foam and, if your DxC has a cap piercer installed, the CTS Auto-
Gloss. They are located in the middle section of the instrument in
the Hydropneumatics compartment.
Note: If any of the reagents have unreadable barcodes, load them in

the next step.
Manual
(Reagent) Manually load CO2 Alkaline Buffer reagent located on the ISE
Load Module and any bulk reagents that have bad barcodes.

MC Reagent Edit Volumes:
References:
DxC Instructions For Use Manual:
Chapter 1- General Information
- Precautions
- Insufficient ISE Reagents
Chapter 5 Reagent Load/Calibration
Edit Volume If the volume displayed does not match the actual reagent volume,
enter the correct % estimate for each reagent in the Vol field on the
Reagent Status side of the Rgts/Cal screen.
Warning:
This is an extremely important step for the ISE reagents! There
is no other mechanism for the system to warn of insufficient
ISE reagents the system will report erroneous results. In
some cases, results will be obtained without reagents.
Questions 1. Which of the bulk reagents require preparation before placing

the reagent on the instrument?
_________________________________________________
2. The MC reagent tubes attached to the reagent straws have

numbers and letters attached. What do the letters represent?
_________________________________________________
3. Can the Vol field be adjusted while in the Reagent Status

Screen?
_________________________________________________
4. What chemistries are permanently configured on the DxC?

_________________________________________________

Be prepared to answer any questions and to demonstrate where
the answers can be found.


Lab Exercise: MC Reagent Calibration:
Objective This exercise will guide you through the following:

Assigning calibrator IDs
Calibration of MC chemistries with and without bar code
labels
Reprint (recall) previous calibration reports
Why: This exercise guides you through the steps that you will need on an
installation to calibrate the instrument in preparation for precision and
carry over tests.
As with the other exercises some steps are slightly out of order so
that you can see the pop up messages that indicate what you need to
do first.

Materials DxC Chemistry Information Manual


MC Reagent Calibration:
References:
Chemistry Information Sheets
-Specific Chemistry Tab
-Calibration
-Calibrator Required
Cal Status Check the calibration status of all the reagents currently loaded.
Requesting Press the appropriate button in the Chemistry or Position column
Calibration on the Reagent Status side of the Rgts/Cal Screen to select the
following chemistries for calibration:
DxC 800 Na, K, Cl, CO2, Calc, BUNm, CREm, GLUCm, PHOSm,
TPm, ALBm and Mg
DxC 600 Na, K, Cl, CO2, Calc, GLUCm and Mg
Note: Magnesium (Mg), a Cartridge Chemistry, has already been

loaded on your instruments for the purpose of these exercises.
Press the Cal [F4] function button.
Question What do the pop-up messages say?
1. ______________________________________________
2. ______________________________________________
Look up the calibrator(s) you will need in the Chemistry Information

Manual or the Tech Marketing Support Info database on Lotus
Notes for those chemistries that still show Cal Required.
List of You can find out which calibrator parameters have been loaded on
Calibrators the instrument by checking the List of Calibrators menu.
Press the Assign [F7] button.
On the Assign Barcode/Rack Menu press or click on the pull down
arrow next to the Calibrator Name. If the calibrator(s) you need are
not on this list, you will need to load the calibrator diskette.

MC Reagent Calibration, cont
Loading Press Options [F6].

Calibrator
Diskette Press option button [1] Load calibrator diskette on the Cal
Options Menu
Load the calibrator diskettes you need. Verify that the lot numbers
of the calibrator you are using match the lot number on the
diskette.
Note: Protein Cal is not used on the DxC 600.
Assign Now that the calibrator parameters have been loaded on the
Calibrator ID system, the instrument needs to know where the calibrator samples
will be located when they are run. We can do that in three ways:
1. Assign a calibrator ID barcode.
2. Assign a rack number and position number to the calibrator.
3. Assign a barcode ID and a rack and position number.
Assign the calibrator ID for AQUA CAL (and PROTEIN CAL if your
instrument is a DxC 800). You will find the IDs on the sample
container barcodes located in the labeled gray racks on your
workstation.
Assign
Calibrator Multi Calibrator does not have a barcode for this exercise, so
Rack assign it a rack and position number
.
Reserved Since barcodes labels are too long for the sample cups, we have to
Racks place them in a container long enough to accommodate them.
These cups are referred to as Nested Cups. The details will be
discussed later in the course, but for now, we need to reserve any
racks that have nested cups.
Go to the setup menu.

Arrow down and select button [17] Reserved Racks / Obstruction
Detect
Type in the rack numbers for the nested calibrators in the Reserved
Racks text box.
Define the rack sizes as appropriate.
Cal Status Recheck the calibration status of all the reagents currently loaded,
and select for calibration all those that require it.

MC Reagent Calibration, cont
List Press [F5] List to identify the calibrators required for the selected
chemistries.
Calibration Pour the calibrators into either a 0.5 ml sample cup or a 2.0 ml
using bar sample cup and nest these cups into their respective bar code
code labels labeled containers.
Calibration Pour the calibrator for Mg into a 0.5 ml sample cup and place it in
without bar position on the rack assigned for Multi Calibrator.
code labels
Initiate calibration!
Printing While your instrument is calibrating, press [F6] Options on the
Calibration Rgts / Cal screen and select option number 10 to familiarize
Reports yourself with printing of current and previous cal reports.
If your instrument is a DxC 600, obtain a calibration report for all of

the chemistries from one of the DxC 800s.

have learned.
Review the DxC 800 calibration report obtained above while

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

Operations
Exercises 2
SYNCHRON, DxC 600 / 800 Pro Basic Service, Customer Maintenance Page 1 of 12
Lab Exercise: QC and Sample
Programming/Processing
Objective This laboratory exercise will guide you and your partner through:
Define quality control files
Assign control ids
Programming and processing of qc
Programming and processing patient samples with and
without bar code labels
Requesting load lists
Clear rack assignments
Recall results
Sample replicates and test replicates
Statistical summary report
Absorbance versus time plots and tables.
Why You need to know how to program and process QC samples to be

able to troubleshoot perceived QC problems in the field. In addition,
knowing how the customer runs patient samples will assist you in
deciding customer induced problems.
Knowing how to request load lists and clearing rack assignments will
help in determining whether there is a test still pending or the rack is
unavailable for programming in some problem situations.
Recalling results and statistical summary reports are easy ways to

check precision results.
Absorbance versus Time Plots can be very useful in troubleshooting

particular chemistry problems, especially since the DxC Tech
Marketing Support Info Database on Lotus Notes has examples of
good plots for all chemistries in Section 17.

Materials DxC In-Lab Training Manual

QC and Sample Programming/Processing
Reference:
Chapter 6 Quality Control
-Defining a Control
Chapter 3 Procedures and Processes
-Program / Process QC
Define Using the information found in the table below, define the following
Quality quality control files:
Control
Files
Control Name: Unicel Level 1

Control Lot #: XX605330
Sample Type: Serum
Standard
QC File Target Value
Chemistry Deviation
Number (Assigned Mean)
(Assigned SD)
Calcium 101 6.9 0.3
Carbon
102 10.0 1.5
Dioxide
Chloride 103 79 2.0
Potassium 106 2.5 0.15
Sodium 107 115 2.5
Control Name: Unicel Level 2

Control Lot #: XX605330
Sample Type: Serum
Standard
QC File Target Value
Chemistry Deviation
Number (Assigned Mean)
(Assigned SD)
Calcium 201 10.2 0.45
Carbon
202 20.0 1.5
Dioxide
Chloride 203 101 2.5
Potassium 206 5.0 0.2
Sodium 207 144 3.0
QC and Sample Programming/Processing, cont
Reference:
Control ID Assignments
Assign Using the information found in the table below, assign bar code IDs
Control ID for the 2 QC files you had just defined.
Control Name Control ID

Unicel Level 1 SYN1
Unicel Level 2 SYN2
Reference:
- Running Control Samples
-- Running Control Samples With Bar Code
Labels and Auto Generation of Control
Enabled
Program and
Process Program and process Unicel Controls, Levels 1 and 2.
Quality
Control
WITH bar
code labels
Reference:
Chapter 3 Preparing Samples for Analysis
- How to Use Reserved Racks
-- Processing Bar Coded Samples
Patient Using the information that is provided in the table below, process
Samples simulated patient samples.
WITH Bar NOTE: These samples have readable barcodes.
Code labels Using the Sampling Template, verify adequate sample volume!
Request a Load List and print it.
Sample ID Sample Type Patient Name Chemistries

101264 Serum Arthur Edwards NA, K, Cl, CO2, CALC
101375 Serum Mark West NA, K, Cl, CO2, CALC
Reference:
Chapter 3 Preparing Samples for Analysis
- How to Use Reserved Racks
-- Processing Unreadable Bar Coded
Samples
Chapter 7 Sample Programming
-Identifying Samples
--Manually Assigning Rack and Position
Patient Using the information that is provided in the table below, program
Samples and process simulated patient samples.
WITHOUT NOTE: These samples do not have readable bar code labels!
bar code Request a Load List and print it.
labels
Sample ID Sample Type Patient Name Chemistries
101526 Serum George Jetson NA, K, Cl, CO2, CALC
101638 Serum June Cleaver NA, K, Cl, CO2, CALC
Reference:
DxC Instructions For Use Manual
Chapter 7 Sample Programming
- Prior to Programming
-- Rack Status
Clear Racks When all the results have printed, CLEAR racks of any manually
assigned samples!
Reference:
Chapter 9 Results Recall
Results Recall and reprint the results for the following samples:
Recall
Arthur Edwards Sample ID: 101264
George Jetson Sample ID: 101526
Reference:
Select Sample Menu Icon

On the Program Sample Menu select [F3] Options
System
Replicates Program the following samples in the same rack choosing the
and Test options listed:
Replicates
Sample ID SYNC L1
Chemistries K, CL
Sample Replicates 5
Reps leave blank
Sample ID SYNC L2
Chemistries K, CL
Sample Replicates 1
Reps K 5
CL 5
Using Unicel Controls Levels 1 & 2 as samples, run them.
Questions How many pages were printed out?

SYNC L1 __________
SYNC L2 __________
Answer to When running precision tests with 20 replicates as on an installation or

your for troubleshooting:
question Selecting Sample Replicates will print out each sample on a
separate page, 20 pages in all.
Selecting Reps (Test Replicates) will print out all 20 on one
page.
Reference:
- Results Recall
-- Statistical Summary Report
Recall Print a Statistical Summary report for the precision tests SYNC L1
Results and and SYNC L2.
Print This feature provides all of the statistical results needed for the
Statistical precision tests on an installation.
Summary
Report
Reference:
- Results Recall
- Absorbance Versus Time
Absorbance Recall the Absorbance Plot and Table for one of the above results
vs. Time and print the Plot.
Compare it to the plot for that chemistry on the next page.

have learned.
Generated by ABS vs Time Macro V1.0 JAD - June 1998
Patient ID: Last Name: First Name:

Sample ID: SYN 2 Rack: 30 Position: 2
Chem: K Lot#: Serial#:
Resp: -1732.611328 Rslt: 4.774033
blank window reaction window
0
0 5 10 15 20 25 30 35 40 45
-1000
-2000
-3000
ISE-ADC
-4000
-5000
-6000
-7000
-8000
t / sec
Generated by ABS vs Time Macro V1.0 JAD - June 1998
Patient ID: Last Name: First Name:

Sample ID: SYN 2 Rack: 30 Position: 2
Chem: CL Lot#: Serial#:
Resp: 1508.083252 Rslt: 100.511436
blank window reaction window
4000
3500
3000
2500
ISE-ADC
2000
1500
1000
500
0
0 5 10 15 20 25 30 35 40 45
t / sec
Lab Exercise: Customer Maintenance
Objective This laboratory exercise guides you through the following maintenance
procedures:
Review Customer Maintenance Procedures
Why It is important to know which procedures the customer is expected to

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

Materials
UNICEL DxC 600/800 Pro Basic Service, Operations Continued Page 11 of 12

Version AA Created on 08272006 Brea Training Center
Customer Maintenance Exercise
Reference:
Chapter 10 Maintenance
- Maintenance Overview
Maintenance Review the above document

Action Log
Locate an instructor for sign off of this exercise.

answers can be found.
UNICEL DxC 600/800 Pro Basic Service, Operations Continued Page 12 of 12

Version AA Created on 08272006 Brea Training Center
Software & ICS
Exercises
UNICEL DxC 600/800 Pro Basic Service, Software and ICS Page 1 of 16
Lab Exercise: Software Boot Sequence
Objectives This exercise will guide you and your partner through the following
procedures:
Proper power down and power up
Initiate a Hyper Terminal session
Observe boot process in Hyper Terminal window
Identify the information in Hyper Terminal window
Why The purpose of this exercise is to provide you with a better

understanding of the boot sequence.
Materials RS232 AT Serial Modem Cable, DB 9-Pin Female to a DB 25-Pin

Needed Male, Belkin (P/N F2L088-06) or equivalent.
Belkin USB Serial Bridge (P/N F5U109) or equivalent.
Reference DxC In-Lab Training Manual

Unicel DxC Service Manual on Lotus Notes

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

procedure.
Reference:
- Chapter 20: Service Tools
-ICC Hyperterminal
- Items 1, 2 & 3
Hyper Install hardware connection for HyperTerminal.

Terminal Setup and configure a HyperTerminal Session.
Power on DxC CAU only.
Observing Observe the ICC boot progress in the Hyper Terminal window on
the ICC Boot your laptop.
Question What event on the Hyper Terminal window indicates that the ICC is
ready to communicate with the DxC?
__________________________________________________
Observing
the CAU Power on the DxC console.
Boot Notice that new lines begin to appear in the HyperTerminal screen.
Question What happens when the <REBOOT> line appears?

__________________________________________________
Software Boot Sequence, Cont...
Observing Power down the DxC through proper shutdown procedure.

Shutdown Observe the HyperTerminal Screen for new information.
Disconnect your laptop from the DxC
Verify the system boots to Standby.
Reference:
- Chapter 20: Service Tools
- CAU Boot Errors
Questions Refer to Item 3, Action #1.

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

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

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

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

Materials
ICS Removal and Replacement
Reference:
Unicel DxC Service Manual on Lotus Notes on Lotus Notes
- Chapter 10 ICS/Dual Motor Drivers/Smart Modules
- Removal and Replacement
- Items 1 through 3
- Diagrams and Schematics
- The ICS Expanded View
Power down the instrument.
You must follow proper electrostatic discharge safety procedures.
The ESD Kit is provided in your tool box.
The strap portion should be placed around the wrist.

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

THE INSTRUMENT CONTROL COMPUTER
Instrument Locate the ICS and remove it from the instrument.

Control
Subsystem
Remove and reinstall the following ICS components:
ICC
MSMC #1
Fiber Optic Board
Power Controller Board
Reinstall the ICS.
Locate the UPS Battery
Power up the DxC.
Verify the system boots to standby.
ICS Removal and Replacement, Cont...
Reference:
- Chapter 18: Software Troubleshooting
- Item 6 Booting Into Console Only Mode
"Console Boot to "Console Only".

Only" Boot
Note:
In addition to the tones, there are also visual cues:

As soon as Starting QNX windows server on node 1
disappears the whole screen will be black.
An instant later, it will turn gray.
It is at this point that shift-alt-c must be pressed.
If you are too early in the black screen, the normal boot will
continue and you have missed your opportunity.
If you are too late after the gray screen appears, you will
have missed it.
Ethernet On the DxC monitor, select SETUP.

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

have learned.
Lab Exercise: QNX Procedures
Objectives This exercise will direct you and your partner to the QNX procedures
that can be useful in resolving corrupted database problems.
Why Improper shutdown by an operator who did not follow proper

procedures often results in corrupted databases. Upon boot, software
tries to correct any problem detected in the databases. This process
can be lengthy and, often times, results in a big clock on the screen.
The larger the database, the longer the boot process will take.
Abnormal shutdowns can also result in host communication problems.

A host can transmit information to the DxC, but the DxC cannot
transmit information to the host. If host communication problems are
experienced after an abnormal termination, the hostcomm database
should be initialized. If the DxC is in standby, it can be initialized by
accessing QNX via Service Setup
There are 3 ways to access QNX - the method used will depend on
the status of the DxC console.
The procedures are self explanatory and do not require practice

as a laboratory exercise, but it is important to review the
document for future use in the unlikely event that you will need
them.
Reference Unicel DxC 600/800 Service Manual on Lotus Notes

Materials
QNX Procedures, cont
Reference:
- Chapter 18: Software
- Software Troubleshooting
- Operating System & Network Communication
SCENARIO 1 A power outage should not normally cause a corrupted database on

the DxC console due to the presence of the Uninterruptible Power
Supply.
In the rare event that the UPS did not function correctly and the DxC
was not shut down properly, the databases can become corrupted.
If the Event Log Database is extremely full, it is possible that the
system will not be able to repair the corruption before QNX Windows
appears.
In that case, a large clock indicating that the databases are being
corrected will appear telling the operator to please wait and stating that
the process can take up to two hours.
SCENARIO 2 A more likely cause of corrupted databases is when someone in the

lab has turned off the DxC improperly.
This can happen when a pop-up error occurs in the middle of the night
shift and a trained operator isn't there. The alarm constantly going off
might cause untrained personnel to shut the console off in any way
and at any cost.
Next morning they have the clock.
Resolution It would be best to let the instrument finish its process if at all possible,
since it might be finished in five minutes and often is before you even
arrive at the account.
QNX If that is not an option, the databases can be re-initialized through

access to QNX.
The procedures in the above reference are self explanatory and do
not require practice.
Review the document above to familiarize yourself with its
contents.
Please feel free to consult with an instructor for clarification.
Lab Exercise: Event Logs
procedures:
Viewing information displayed in the Event Log.
Identifying information found in the Event Log
Why Because the Event Log records both error and normal conditions that
occur within the instrument, it is a valuable source of information while
troubleshooting.
Event Log Error Codes are referred to throughout the service manual
for troubleshooting specific problems.
Event Log troubleshooting will be used throughout this course and is

an integral part of DxC Basic Training.


Event Logs
Reference:
Chapter 18: Software
Software Troubleshooting - Event Log
Chapter 21: System Troubleshooting
Event Log Error Codes
Chapter 12 Utilities- Event Codes
Event Logs Read the above references while reviewing each event log on your
instrument.
Load an empty sample rack with the bar code label facing the
wrong direction. Observe the information presented on the DxC
monitor.
Questions What message appeared on the DxC monitor?

________________________________________________
What were the Event ID and Class Number (for the pop-up message
on the DxC monitor)?
________________________________________________
Event Logs
Locate the error message in the Event Log. Print the screen that
displays the event log information regarding this event.
Program the following request on DxC. Since a barcode label will

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

sample! Initiate the run and observe the DxC monitor.
Questions What message appeared on the DxC monitor?

________________________________________________
What were the Event ID and Class Number?

________________________________________________
Event Logs, Cont
Event Logs Locate the error message in the Event Log. Print the screen that
displays the event log information regarding this event.
Questions In the table below, match the severity code with its correct
Cont... description.
Severity Code Description
System Error All significant events that are not errors are assigned
this severity code.
Important Recovery from this error can only be done by re-

Message booting the instrument.
Message An event with this severity code indicates a situation of

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

wherein the operator needs to be informed, but no
immediate action or acknowledgment is required.
Which severity codes will cause a pop-up on the monitor?

________________________________________________

have learned.
Power
Smart Modules
Fiber Optics
Exercises
UNICEL DxC 600/800 Pro Basic Service; Power, Smart Modules, Fiber Optics Page 1 of 10
Version B 04162007 Brea Training Center
Lab Exercise: Power Subsystem
Objectives This lab exercise will guide you and your partner through the following:
Location of Power Subsystem components
Remove and replace power supply
Observe normal power up sequence
Identify LED display codes
Power supply adjustments
Power supply measurements
Why Troubleshooting the power subsystem starts with a good

understanding of the power up sequence, the components within the
system, and how these components are integrated.
Materials Fluke DMM provided.

Materials Fluke 187 & 189 Users Manual on the training CD

Power Subsystem
Reference:
Chapter 4: Installation
Item 4 Computer Setup
Chapter 14: Power Subsystem
Removal and Replacement
Power down the instrument.

Unplug the CAU input power from the UPS
Components Locate the following Power Subsystem Components:
Isolatran
220vac input J101
220vac outputs J100A, J100B & J100C
+24.5vdc Power Supply
Power Distribution Board
Power Remove and reinstall the +24.5vdc power supply.
Supplies Check one more time to insure correct cabling.
Plug the input power back into the UPS.
Do not power up.
Reference:
- Troubleshooting
- Item #3 The diagnostic four digit display
- Item #6 The Power Distribution
Initialization / Startup
LED Display Review the above references.

Compare Item #3 to what is occurring on the instrument as you
power up the DxC.
Verify that the instrument goes into standby.
Power Subsystem, Cont...
Reference:
Fluke 187 & 189 Users Manual
Power Measure the inputs to the Isolatran and power supplies and the
Measurements outputs of each power supply and fill in the information below.
Inputs
Ground (G/Y) to Ground (G/Y) to Neutral (BLU) to
Supply
Neutral (BLU) Load (BRN) Load (BRN)
Isolatran
+24.5vdc
+36.0vdc
Outputs
+24.5vdc
+36.0vdc
Reference:
- Adjustment
Fluke 187 & 189 Users Manual
Power Perform power supply adjustments.

Adjustments
DC Power Check the power supply outputs under load conditions.

Measurements 1. Connect the DMM using alligator clips to the output of the
Under Various +24vdc power supply.
Load 2. Enter the MIN MAX mode.
Conditions
3. Press the stop button on the DxC.
4. Exit the MIN MAX mode.
5. Enter the MIN MAX mode.
6. Home the DxC.
7. When the instrument reaches standby, record the minimum
and maximum readings in the table below.
8. Repeat steps 1 through 8 for the +36vdc power supply.

During Stop MIN ____________ MAX ____________
During Home MIN ____________ MAX ____________

During Stop MIN ____________ MAX ____________
During Home MIN ____________ MAX ____________
Reference:
- Electronics
Power Distribution Board
Review the Electronics document in the above reference and

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

have learned.
Lab Exercise: Smart Modules & Fiber Optics
Objective This lab exercise guides you and your partner through the following
procedures:
Location of the various smart modules in the DXC
Troubleshooting Fiber Optics
Why By performing the procedures in this lab exercise, you will familiarize
yourself with the system's electronics components and how they
communicate with one another.

Materials
Smart Modules & Fiber Optics:
Reference:
Unicel DxC Service Manual on Lotus Notes:
Chapter 10: ICS/Dual Motor Drivers/Smart Modules
- Diagrams and Schematics
- Smart Module Locations
DxC Basic Service Training CD
- Fiber Optics Diagrams
- Troubleshooting Fiber Optics
Smart Remove the covers and locate all the smart modules on your
Module training instrument.
Identification Identify the address switch locations on the smart modules.
Compare your instrument with the Fiber Optics Diagram.
Fiber Optic Perform MSMC Loop-back Test located on Service Setup Menu.
Checks Main Menu
Select Setup on the Icon Menu Bar
Select [23] Service Setup
Obtain password using Service Password Generator
Enter password on Password Screen and select [OK}
If you have generated and entered the correct password, you will
be in the Service Setup Screen, if not repeat the process.
On the Service Setup Menu select [8] MSMC Loopback Test
Follow the on-screen instructions.

Review the fiber optics troubleshooting procedure on the DxC
Basic Service Training CD
Feel free to consult an instructor for clarification or demonstration.

have learned.
Hydropneumatics
Exercises
UNICEL DxC 600/800 Pro Basic Service, Hydropneumatics Page 1 of 10


Lab Exercise: Hydropneumatics
procedures:
Component identification
Observe instrument status during routine hydro operation
Valves:
Removal & replacement of valves
Perform the following diagnostics tests:
Vacuum and air pump test
Float switch tests
Hydro valves tests
Pump Box access
Review PMC procedures
Review decontamination procedure
Why The hydropneumatics system is essentially the heart & lungs of the
instrument.
Diagnostics allows the operator the ability to test the functionality of a
component (pump, float switch, etc.) without having to shut down the
system. In addition, diagnostics provides the operator with real-time
feedback while they are adjusting pressures.

Materials

Hydropneumatics
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 9: Hydropneumatics
Component Shutdown the DxC.

Identification Locate the following hydropneumatic components on your training
instrument.
Components Remove the center section and the left section air ducts from the
Location back of the DXC.
Rear of Unplug the center fan and both left fans.
Instrument Remove the fans to access the frame compartment s.
Inspect the following hydropneumatic components on your training
instrument.
Gravity drain assembly
Restrictor Reservoir A19456
Waste connections
DI water connections
Pump Box Locate the Pump Box Stop Bracket with pump on/off switch from
front of the DxC.
Pull out the Pump Box per procedure.
Remove the cover and identify the components using the Pump
Box Diagram provided.
Reinstall the Pump Box and associated assemblies,
Reinstall the fans.
Reinstall the air ducts.
Power up the DxC
Components Observe the operation of the hydro drawer while the instrument is
Location homing, when the pumps come on, valve operation, etc.
Hydro On the DxC, locate all of the components depicted on the Master
Drawer and Hydropneumatic Schematic in the above reference.
System Do the same with the major assemblies on DxC 600/800 Hydro-
Pneumatic Diagram P/N A18111.

Hydropneumatics, Cont
Routine View instrument's Hydro Status on your instrument's monitor.

Hydro Home the instrument.
Operation While the instrument is homing, observe the information displayed
on the Status screen.
Pump Initiate 20 primes on the instrument:

Volume and While the instrument is priming:
Recovery Observe how low each of the pressure and vacuum gauges
dip during this process it is an important indicator of the
ability of the pumps to provide a constant volume when under
stress.
Record the values in the table below.
Volume Stress Test

Vacuum - inHg MIN ____________ MAX ____________
10psi MIN ____________ MAX ____________
17psi MIN ____________ MAX ____________
25psi MIN ____________ MAX ____________
Questions When the DI Water Reservoir float switch reaches the 'EMPTY'
position, which valve and LED turns on to fill the canister?
Valve(s) #: ___________________LED(s) #:
___________________
What is the responsibility of each valve?

___________________________________________
___________________________________________
___________________________________________

Valves If your instrument is still priming, STOP the prime.

Operation
Locate DI Water Inlet Valve, V0, and the gray valve override button.
Manually fill the DI Water Reservoir using this valve.
FYI
While manually filling the DI Water Reservoir, it is important NOT to
turn the gray button while pushing in. Doing so will cause it to
remain open.
Select Hydro Maintenance from the Utilities-Maintenance menu.

Remove the Wash Solution canister from the instrument. Empty out
its contents. Note: Do NOT lose the O-ring! This is required to
ensure a tight seal.
Replace the canister back on the instrument.
Exit out of Hydro Maintenance.
Observe the canister as it is being filled and answer the questions
below.
Questions Which valve(s) and LED(s) are responsible for filling this canister?
Valve(s) #: __________________LED(s) #: __________________
What is the responsibility of each valve?

_________________________________________
_________________________________________
_________________________________________
Valves Remove Valves V31 & V32.

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

Reference:
- Troubleshooting
Note:
Information displayed under STATUS is updated every

Diagnostics 9 seconds. To view "real-time" information, perform adjustments
in Diagnostics mode.
Vacuum and Access the Vacuum and Air Pump Tests

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

Questions Why is it important to turn OFF DI water at V0 when exercising float

switches even though the canisters are not under pressure?
_______________________________________________
_______________________________________________
List the 3 possible readings/conditions that you may see for float
switches:
_________________________________
_________________________________
_________________________________
Hydro Access the Hydro Valves Diagnostic

Valves Each button has an indicator that turns blue when the valve is
Diagnostic ready to be turned on.
The [Set] button will actually activate the selection.
Once on it will not turn off until the button is selected again and the
[Set] button is pressed.
Select valve(s) by clicking on the check box to the left of the
valve(s). One or more valves or all valves at the same time.
Once the valve(s) is selected, click on <Set>. Watch the selected
valve light(s) come on and each valve clicks open and closed.
Deselect the valve check box(s) and select <Close>.
If a valve light fails to come on, check the connection and
harnesses.
If the light continues to fail, replace the valve.
Exit Diagnostics
Turn the DI water inlet valve back on.
Home the instrument.
Instrument Verify that the instrument is in Standby mode and that all the
Verification instrument status is within specifications.
Calibrate all Modular Chemistries


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


Sample Rack
Handling Subsystem
Exercises
UNICEL DXC 600/800 Pro Basic Service, Sample Rack Handling, TS-CTS Page 1 of 8
Version AA 08292006 Brea Training Center
Lab Exercise: Cap Piercer TS-CTS
procedures:
Bar-code reader removal and replacement
TS-CTS removal and replacement
Blade & wick removal and replacement
Autogloss pump repair and replacement
One blade TS-CTS functional alignment
Why We have discussed some of the problems you might see in the field
regarding the cap piercer. Use this opportunity to become familiar with
the operation, repair and alignment of the TS-CTS.

Materials
Cap Piercer TS-CTS:
Reference:
Chapter 17: Sample Handling
- The Barcode Reader
Barcode Remove the barcode reader as described in the above reference.

Reader Do not replace it at this time.
Removal
Reference:
Chapter 6: Cap Piercer
- The Blade, Wick removal and
replacement Procedure
-The Linear Pump Replacement and
Alignment
Blade & Perform the procedure as described in the above reference.

Wick
Removal
Linear Pump Perform the procedure as described in the above reference.

Removal and
Replacement
Reference:
Chapter 6: Cap Piercer
- Cap Piercer Removal and Replacement
Procedure

have learned.
Lab Exercise: Sample Rack Handling
procedures:
Shuttle latch solenoid removal and replacement
Onload tray assembly removal and replacement
Offload tray assembly removal and replacement
Shuttle assembly removal and replacement
Sample rack handling alignment procedures
Why The Sample Rack Handling subsystem is one of the subsystems within
the DXC. Its primary function is to introduce sample racks containing
sample containers. The shuttle mechanism guides the sample rack to
the bar code reader, the cap piercing stations (if present), and onto the
sample wheel. Once the rack is on the sample wheel, the MC and CC
sample probes can access the samples in order to process any
requested test(s). At the completion of a run, the rack is off loaded
from the sample wheel to the offload tray.

Materials
Sample Rack Handling:
Reference:
Unicel DxC 600/800 Service Manual on Lotus Notes
- Arm/Latch Solenoid
- Onload Tray
- Offload Tray
- Shuttle Assembly
Arm/ Latch Remove and reinstall the shuttle latch solenoid.

Solenoid
Onload Tray Remove the Onload Tray and inspect the replaceable components.
Removal Compare the DxC 600 Onload Tray with the DxC 800 Onload Tray.
Offload Tray Remove the Offload Tray and inspect the replaceable components.
Removal
Shuttle Remove the Shuttle Assembly and inspect the replaceable

Assembly components.
Removal
Reinstall all Reinstall all Sample Rack Handling Components on your training
SRH instrument:
Components Shuttle Assembly
Offload Tray
Onload Tray
TS-CTS Cap Piercer
Barcode Reader.
Sample Rack Perform the following Functional Area alignment procedures
Handling Sample Carousel
Alignments Sample Rack Handling
Cap Piercer
Sample Rack Handling, Cont...
Alignments To test the alignments you have just made:

Verification Place an un-programmed 75mm or 100mm rack with four
capped tubes in the onload tray.
Press the Run Button.
Observe that the caps are pierced on all four tubes.
Event Logs Clear all sample IDs from your instrument.
Previously Clear the event logs on your instrument
Un-pierced In a non-reserved rack place:
Tube - A capped bar-coded tube in position #1
- An uncapped tube with no barcode in position #2
- A cup in position #3
- Nothing in position #4
Place the rack on the instrument and press the run button.
Observe the cap piercer as each rack position is presented to it.
Do not clear the event logs.
Event Logs Do not clear the sample IDs from your instrument.
Previously Re-run the same sample rack from the above steps.
Pierced Tube Observe the cap piercer as each rack position is presented to it.
Do not clear the event logs.
Event Logs Clear the sample IDs from your instrument.
Reserved Reserve the rack that you have just used in the above steps.
Rack Place the rack on the instrument and press the run button.
When the instrument offloads the rack, bring up Event Log #10 and
print it.
Event Log Find each instance where the run button was pressed, highlight it
#10 and review the subsequent events, such as pierce status, when it
Information is loaded on the sample wheel, etc. .
Compare the <container type> on the printout with the table on the
next page.
Sample Rack Handling, Cont...
Description Codes
Event Message Event or Log Description
Description
10 E ID: <sample ID> < container type>:

0=unknown
r: <rack ID> 1=empty
2=tube
p: <cup position> 3=cup
4=reserved
dba: <DB addr> <sample type>:
0=patient sample
c: <container type> <priority>:
0=normal
ptype: <sample type> 1=rerun
2=reflex
pri: <priority> 3=critical rerun
4=STAT
Chems: <chems list> <chemistry list>:
Format xxxx-yy
where xxxx is
chemistry ID and yy
is number of
replications.
Max of 15
chemistries listed.

have learned.
MC Sample
MC Cups
Exercises
Unicel DxC 600/800 Pro Basic Service, MC Sample & Cups Exercises Page 1 of 12
Lab Exercise: MC Sample Syringe Drive Assembly
Objectives This exercise will guide you and your partner through the removal and
reinstallation of MC Sample Syringe Drive Assembly.
Why The Syringe Drive Assembly can become noisy. Replacement of the
Syringe Drive Shaft Assembly may be necessary.

Materials
MC Sample Syringe Drive Assembly
Reference:
No reference in the Service Manual.
Consult an instructor when necessary.
MC Sample Shutdown your DxC properly.

Syringe Run the syringe rods down manually by rotating the lead screw flex
Assembly coupling.
Remove the syringes from the Dual Syringe Assembly.
Remove the 3 way shear valve from both the MC and CC Sample
Syringe Assemblies.
Notice the spring on the shaft. Together with the offset pin on the
motor shaft, it forms a key which prevents the valve from being
placed on the motor shaft incorrectly.
Remove the Dual Sample Syringe Pump Assembly and become

familiar with its replaceable components.
Reinstall the Dual Sample Syringe Pump Assembly.
Reinstall the shear valves.
Replace the syringes.
MC Sample Syringe Drive Assembly, Cont...
Syringe The following will bring the syringes to a position where an operator
Replacement can replace them without shutting the instrument down or pressing the
Maintenance stop button to move them manually.
Procedure Utilities
[2] Maintenance
[7] Syringe Rod Replacement
[Continue]
Verify Power up the DxC.

Verify that the instrument comes to standby.
Prime Prime the sample system
Utilities Icon
[1] Prime
[CC F2]
[Sample Delivery Subsystem]
5 primes
Observe the instrument as it primes.
Proceed to the sample crane exercises.
Lab Exercise: DxC Sample Cranes
Objectives This exercise will guide you and your partner through the following:
Removal and replacement of (MC) Crane
Inspect the Triple Crane Assembly
Removal and replacement of (MC) probe
Perform MC Crane Alignments
Why Occasionally the MC Sample Crane shaft assembly rails (3) require
cleaning with isopropyl alcohol.
Damaged and/or misaligned MC sample probes can affect chemistry

performance problems resulting in level sense errors, suppressed
results, flyers, and imprecision.

Materials
DxC 800 MC Sample Crane
Reference:
DxC 800 MC Sample Crane (Diagram)
No reference in the Service Manual.
Consult an instructor when necessary.
DxC 800 Dirt and dust, which may accumulate along the guide rails of a crane
MC Sample assembly, can affect the timing and motion of the probe travel
Crane (triggering motion errors and/or level sense errors). It is therefore
important to clean these guide rails periodically with alcohol pads.
Shutdown the DxC.

Remove the MC Crane from your training instrument. Inspect the
guide shafts & clean if necessary. Verify that the shaft coupling has
not come loose.
Reinstall the MC Sample Crane.
DxC 600 Triple Crane
Reference:
DxC 600 Triple Crane Overview
DxC 600 Remove the covers from the MC Sample Crane and observe the
Triple Crane replaceable components.
DxC MC Sample Probes
MC Sample Remove and reinstall the MC sample probe.

Probe Loosen the collar wash clamp and pull the collar wash out
leaving the tubing connected.
Remove the probe taking care not to lose the 'o' ring.
Reinstall the probe and the collar wash.
MC Sample Crane, Cont.
Reference:
Unicel DXC Service Manual:
- Alignment and Adjustment
- CC and MC Sample Probe Alignments
Alignment Since you had performed removal/replacement procedures of the

MC crane & probe, it is necessary to perform the following
alignment procedures:
[1] MC Sample Probe Liquid Level Sense
[2] MC Sample Probe Rotary Home
[3] MC Sample Probe Rotary to Sample Carousel
[4] MC Sample Probe Rotary to Cups
[5] MC Sample Probe Rotary to EIC
[6] MC Sample Probe Vertical Home and Wash
[7] MC Probe Sample Height
[8] MC Probe Cup Height
[9] MC Probe EIC Height
[10] MC Sample Probe Obstruction Detection
Don't forget to backup your new alignment information to a disk.

have learned.
Lab Exercise: Modular Chemistry - Cups
Identification of LED status/colors
Removal and reinstallation of an MC cup module
Removal and reinstallation of reagent pump and valves
Removal and reinstallation of stir motor
Adjustment of temperature via diagnostic
Removal and reinstallation of an MC lamp via diagnostics
Lamp calibration
Why Each cup must go through the fill, stir and drain process during normal
operation. Inadequate cup filling, stirring or draining can lead to
erroneous patient results. Should these events occur, it might become
necessary to replace components within the cup module assembly.
All cup modules have preheaters. Their primary function is to preheat

both the reagent and the rinse DI water to the appropriate reaction
temperature. For most of the cups, the appropriate reaction
temperature 37C, with the exception of CREm which is 41C.
Temperature adjustment becomes necessary when temperature is not
within specifications.
Another cup component that may require replacement is the lamp. On

the DXC lamp replacement can be performed only when:
The instrument is powered down.
Or
The lamp is turned off in the ADC/Analog Board Test that is
located in the Diagnostics section of the Utilities Menu.
Replacing a lamp when the instrument is powered up and not in

Diagnostics can damage the loop control section of the power
supply on the cup controller board.
Test Calibrated Temperature Probe.

Equipment

Materials
Modular Chemistry Cups
Reference:
Chapter 8: Cup Modules
- Items #1 through # 9
Shutdown Shutdown the DxC.

Cup Module Remove GLUm cup module.
Controller Remove and reinstall the GLUm controller board.
Board
Stirrer Motor Remove and reinstall the stirrer motor.

Reagent Remove and reinstall the reagent pump.
Pump
Reagent Remove and reinstall the reagent valves.

Valves
Reinstall Reinstall the GLUm cup module back on the instrument.

Cup Module
MC Manifold Locate MC Manifold on both a DxC 600 and 800 and note the
differences.
DxC 800 Locate the waste restrictor.

Power Up Power up the DxC and verify that it reaches standby.
Reference:
- Alignment and Adjustments
Temperature Adjust GLUm cup temperature.

Adjust
Modular Chemistry Cups, Cont
Reference:
- MC Modules Lamp Replacement
DxC 800 Remove and replace a cup module lamp per the procedure above.
Lamp Calibrate all lamps and the GLUm sensor.
Removal and
Replacement
Utilities Icon
[2] Maintenance
[8] CUPs Lamp/Sensor Calibration
Select all available entries.
DxC 600 Follow the above steps to calibrate the Glucose Sensor.

have learned.
MC/ISE
Preventive
Maintenance
Exercises
UNICEL DxC 600/800 Pro Basic Service, MC ISE & Preventive Maintenance Page 1 of 6
Lab Exercise: MC/ISE & Preventive Maintenance
Remove the Flow Cell and replace the Carbon Bridge.
Strike carbon bridge
Preventive Maintenance ISE & MC
Why This is your opportunity to take a closer look at the ISE and review the
PMC checklist / procedures.

Materials
Carbon Bridge Replacement Exercise:
Reference:
- The Carbon Bridge
- Replacing of the Carbon Bridge
- Carbon Bridge Striking
Carbon On the instrument select the Utilities Icon, Maintenance, ISE

Bridge Service and Continue.
Replacement Do not exit this menu until procedure is completed.
Exiting this menu before completion of procedure will
damage the electrodes.
Replace the carbon bridge.
Removal side Insertion side

Carbon Bridge Replacement Tool
P/N 450627
Striking the Striking the carbon bridge on the DXC is part of the installation
Carbon procedure. Please take the time and review the procedure as
Bridge described in the reference above. A striking tool is available for
you to inspect and/or use while here in training.
Carbon Bridge Striking Tool P/N 474433
Calibrate Calibrate the Flowcell.

the Please feel free to consult an instructor.
Electrolytes When all electrolytes have calibrated, move on to the next
exercise.
Preventive Maintenance
Reference:
Chapter 5: Preventive Maintenance
- UniCel DxC 600/800 Preventative Maintenance
Checklists.
- UniCel DxC 600/800 PMC Schedule and Kit Part
Numbers
- UniCel DxC 600/800, PM A Kit, (Major CC), P/N
A22681
- UniCel DxC 600/800 PM B Kit, (Major MC/CC),
P/N A22683
- UniCel DxC 800, PM Minor Kit, (ISE/MC), P/N
A37245
- UniCel DxC 600, PM Minor Kit, (ISE/MC), P/N
A37244
PMC Using the above references, perform a PM Minor on your

instrument.
Do not perform Items # 2.12, 2.13 & 2.14
Please feel free to consult with an instructor if you find any

discrepancies or have any questions about the information
in this exercise.

have learned.
DxC 600/800
System
Decontamination
Exercise
UNICEL DxC 600/800 Pro Basic Service, Decontamination Page 1 of 10


Lab Exercise: Decontamination
Decontamination Procedures
Why There are occasions when the same symptoms seem to be recurring
in a periodic manner.
This might be the result of repairing the symptom rather than the root
cause.
One of the possible causes might be bacterial contamination of the

instrument, for example:
1. Chronic LOW NA and HIGH CO2 fliers.
2. Chronic LOW K or Sample Reference Drift error flag
3. CO2 fails to calibrate but calibrates when the ISE Reference
Solution is replaced.
To resolve this situation, the DxC Decontamination Procedure must be

performed.

Materials

DxC System Decontamination:
Reference:
- DxC 600/800 System Decontamination
Procedure (MC/ISE/HYDRO)
For your convenience, the above document has been

reproduced on the following pages.
Please feel free to consult with an instructor if you find any

discrepancies or have any questions about the information
in this exercise.
DxC 600/800 You have already demonstrated the skills required to perform this
System procedure, so practice is unnecessary.
Thoroughly read the following document and using your
instrument as a reference, familiarize yourself with the
procedures involved.

ISE
DECONTAMINATION
GUIDE
FOR
FIELD SERVICE

Possible signs of contamination:
Chronic LOW NA and HIGH CO2 fliers

Chronic LOW K or Sample Reference Drift error flag
Before performing the decontamination procedure:
1. -Check alignment of sample probe to EIC

-EIC valves
-Illegal grounds spills, leaks, ISE drain
-Carbon bridge
-Check / replace electrodes of chemistry exhibiting fliers
-Sample probe collar washer for alignment and buildup
-(Refer back to DxC Service Manual for appropriate information)
2. With the help of the hospitals microbiology dept, culture taking

swabs from the following areas listed below. In the case of the DI
Water going from the tanks into the System if the bacteria count is
greater than 50 cfu/mL, then the water is contaminated.
-All measuring electrodes bacteria count should be less than 400

cfu/mL
-Incoming and outgoing reagent lines bacteria count should be

less than 400 cfu/mL
-ISE reagents bacteria count should be less than 400 cfu/mL
-Sample injection port bacteria count should be less than

400 cfu/mL
-DI water reservoir/canisters on system bacteria count should be

less than 100 cfu/mL
Note inserted by Professional Development:

In Microbiology, colony-forming unit (CFU) is a measure of viable bacterial
numbers. Unlike in direct microscopic counts where all cells, dead and living,
are counted, the cfu measures viable cells. A sample is spread or poured on a
surface of an agar plate, left to incubate and the numbers of colonies formed
are counted. Cfu number is not an exact measure of numbers of viable cells,
as a colony-forming unit may contain more cells.

Decontamination Procedure
NOTE 1: When performing the decontamination procedure, you MUST COMPLETE

both the Acetic Acid/Hydrogen Peroxide and Chlorine Dioxide decontamination
procedures as listed below:
NOTE 2: To reduce decontamination time, Tech Support suggests engineer prepares

Chlorine Dioxide solution first, because the solution needs to sit for 1 hour prior to
use. (Chlorine Dioxide solution will turn to a pale green color after 1 hour). Mix 2 liters
of DI water to one packet of Chlorine Dioxide. (Two packets required for 4L.) Let it
sit for one hour. This is a 100-ppm solution.
NOTE 3: Both procedures, (1. Acetic Acid/Hydrogen Peroxide 2. Chlorine Dioxide)

are used to remove biological contaminants that contribute to erroneous ISE results.
Please read carefully and perform both procedures.
Note 4: Have the customer soak a Potassium tip and Calcium tip in LX ISE
Reference Solution for 24 hrs before starting procedure.
Materials needed for Acetic Acid/Hydrogen Peroxide procedure:
-DxC PM Minor Kit (A22682)

-10% Glacial Acetic Acid (A24880) Qty: 2
-3% Hydrogen Peroxide (A24881) Qty: 2
-Cap and Straw Kit x 2 (476293)
-2 Large Mouth Beakers or containers (1L or greater)
-DI Water
-Gloves
-Safety Glasses
Materials needed for Chlorine Dioxide procedure:
-Dummy ISE electrodes (P/N 668077), or old used electrodes for the ISE, Glucose
and BUN
-One kit of Chlorine Dioxide (P/N A22197 Kit contains 2 packets)
-Fresh bottles of Electrolyte Buffer, Electrolyte Reference and CO2 Acid
-One clamp (hemostat)
-One four-liter container
-One 1L beaker
-Degasser (471650)
-0.2 Micron Filter (949898)
-Potassium Tip (669117)
-Calcium Tip (467769)
-NA Electrode (668295)

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

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

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

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

DIOXIDE (Kit P/N A22197)
1. Remove the wash solution canister and dump out the contents, clean with DI
water, fill the canister with DI water and install it back on the hydro.
2. Clamp off Wash Concentrate line #145. This line is coming out of the top of
the wash concentrate canister.
3. Prime hydro 10 times to remove all wash concentrate out of the system.
Waste reservoir should not have suds at the end of the priming cycles.
4. Put the straws from the electrolyte buffer, reference and CO2 acid bottles into
a 1L beaker with prepared chlorine dioxide solution. Make sure there is
enough solution (approx. 200ml) for 20-30 primes. ISE will turn a greenish
color.
5. With rest of the four-liter container, shut off customer outlet valve and remove
the DI water line from that point and put line into four liter container. Note: The
0.2 micron filter will remain with DI water line, but will be replaced at a later
step in the procedure.
a. You will need to follow the document "Filling the DI Water Reservoir
using V3 Vacuum," in Chapter 9: Hydropneumatics of the DxC 600/800
Service Manual.
6. Prime all 15 times. You should see the greenish Chlorine Dioxide solution in
the DI water and the wash solution canisters.
7. After prime, let the solution sit for one hour in the system. (Very Important).

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

Be prepared to answer any questions and to demonstrate what
you have learned.

DxC 600/800
Mentoring Program
Documentation
UNICEL DxC 600/800 Pro Basic Service, Mentoring Documentation Page 1 of 10


Post Classroom Mentoring Program
It is the trainees responsibility to complete this program.
The most important aspect of the mentoring process is the training that the mentors
provide by example. Mentors are selected because they have shown a commitment
to quality and a track record for doing the right thing. Demonstrating by example is
the best training that can be provided to ensure the success of engineers new to the
instrument or product line.
When enrolling the trainee for class, the manager assigns a mentor.
The manager sets the goal for mentoring completion based on workgroup needs.
Mentoring requirements are based on demonstration of the knowledge and skills needed to service
the instrument in the field. The requirements should be determined by the mentor in consultation with
the manager and will depend upon the individual trainee's ability and the type of instrumentation.
Minimum requirements are suggested in the Mentoring Packet for the individual instrument. The
packet can be downloaded from the Chemistry/Immunoassay link in the Training Resources Database
on BirchNotes/BII.
The trainee and the mentor arrange time to complete mentoring requirements. This is best done in
person, with the mentor and the trainee performing service calls together. If it is not possible for the
mentor and trainee to meet in person in a timely manner, the mentor, with the manager's approval,
may designate another engineer who has been certified on the instrument. Whenever possible a
variety of call types should be selected PMs, installations, trouble calls, etc. to broaden the learning
experience.
If the trainee has been certified on the instrument by Professional Development, the
mentor can elect to assign calls to the trainee when he determines that the situation
warrants it. The mentor should review all call assignments for the product by
telephone with the trainee before the trainee goes on site. An action plan for the
call should be devised and the trainee should know how to reach the mentor quickly
if the plan is not appropriate. The trainee must update the mentor at the close of the
call.
By completing and e-mailing the Mentor Validation Form on page 2, the Mentor
confirms that:
1) The trainee has mastered the skills required to:
o Operate the instrumentation as a system
o Perform Preventive Maintenance Procedures on the instrument
o Troubleshoot and repair basic hardware problems on the instrument
2) Plans have been formulated to provide assistance and support in those areas where the
trainee may need additional practice.
3) The trainee has demonstrated the ability to assess, review and resolve instrument problems
and customer concerns independently.
4) The trainee has the required tools and test equipment needed to service the instrumentation
and has demonstrated a working knowledge of their use and function.
5) The mentor and the trainee have reviewed documentation related to servicing the product,
including:
o Location and use of the service manual
o Location of Service Memos/Modifications, Technical Updates and other relevant
information on Lotus Notes, Odyssey and electronic media in use by the field.
o Location and use of the North America Commercial Operations (NACO) Database on
Lotus Notes and the documents contained in the Service Section. (Call Closeout,
Installation, DOA reporting, Escalation, ESD, etc.)
6) The mentor confirms that the trainee has a basic car stock for the instrument.

Mentor Validation Form
Trainee
Trainee Employee Number
Trainee's Mailing Address:
Address
City
State
Zip
Trainee's Shirt Size
Instructor
Class
Class End Date
Mentoring Completion Date
RM
Mentor
The above mentioned trainee has completed the Mentoring Program.

He/she is familiar with all procedures and processes relating to servicing this product
and is prepared to make calls without further direct supervision for the following
instrumentation:
Mentor (sign)
Date
Save this file as '(Trainee's Name) Mentoring Form.doc'
E-mail the completed form to:
Sharon Howard/BII (Lotus Notes Address) or

showard@Beckman.com (Internet Address)
Please copy the student.

DxC 600/800 New Hire Overview
COURSE The DxC New Hire Service Training class is a 17 day class divided
DESCRIPTION into two sessions.
Session one nine days, Monday of the first week thru

Thursday of the second week.
Separated by a minimum three week mentoring period.
Session two eight days, Tuesday of the first week thru
Thursday of the second week.
25% of the students' time will be spent on theory and
troubleshooting problems in the classroom.
75% of the students' time will be devoted developing skills
on instrument operation, troubleshooting and repair.
SESSION 1 TRAINING Basic Operation

DVM/Motors/Sensors/Compressors/Vacuum Pumps
Power
Instrument Control Subsystem, Microsoft Hyperterminal
Smart Modules
Communications / Fiber Optics
Hydro-pneumatics
Sample Rack Handling, TS-CTS & Reserved Racks
MC Alignments
MC Sample Aspiration, Delivery & Level Sense
MC Cups
ISE
Preventive Maintenance Minor (ISE/MC)
MID-SESSIONS During the time between Sessions 1 and 2, the student

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

instrument. They must be accompanied by an engineer who
has been certified on the DxC on all DxC service calls. It is
imperative that the new engineers be effectively mentored to
ensure their success.

Mid-Sessions Mentoring
MENTORING Re-enforcing what was learned in Session 1 and familiarization
SUGGESTIONS with actual field operations are the two major goals of mid-session
mentoring.
It is up to the mentor, with guidance from his manager, to

determine the best course to provide the new engineer with
maximum exposure to the field requirements for the chemistry
product line.
The trainee and the mentor arrange time to perform service calls
together. It is important that the trainee accompany a mentor on a
daily basis on all service calls scheduled for that day, including
if necessary instruments other than DxC 600/800.
The most important aspect of the mentoring process is the

training that the mentors provide by example. Mentors are
selected because they have shown a commitment to quality
and a track record for doing the right thing.
Providing that example is the best training that can be

provided and will ensure the new engineer's success.
RECOMMENDED
MINIMUM If it is not possible for the mentor and trainee to meet in person in
REQUIREMENTS a timely manner, the mentor, with the manager's approval, may
designate another engineer who has been certified on the DxC
600/800.
It is recommended that the trainee perform a minimum of 3

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

LX20 Minor Preventive Maintenance Procedure (ISE/MC) with a
certified engineer will provide the needed exposure to the common
aspects of both systems.
It is recommended that the trainee assist in a minimum of 9

DxC 600/800 ISE/MC service calls during this period with the
mentor or a designated certified engineer.
In the absence of DxC calls, LX20 calls with a qualified engineer

will provide the needed exposure to the common aspects of both
systems.

Post Sessions Mentoring
SESSION 2 TRAINING Discussion of Log Sheets from mid-sessions mentoring
Group Summary and QC Interpretation with Stan Johnson
MC, ISE, Hydro and Power Review and Troubleshooting
CC Sample Aspiration, Delivery & Level Sense
CC Reagent Aspiration, Delivery & Level Sense
Refrigeration
CC Reaction Subsystem
o Photometer Subsystem
o Reaction Wheel Subsystem
PVT, ChemAssist, LISA
Installation overview and cleaving
Preventive Maintenance A (Major CC)
POST SESSIONS The major goal for Post Sessions Mentoring is for the trainee to be
MENTORING able to perform independently when servicing the DxC 600/800.
At the completion of Session 2 Training, the student was certified

on the DxC 600/800 System.
The length of the post sessions mentoring period will be the

determined by the manager.
RECOMMENDED The requirements for Post Sessions Mentoring are determined by

MINIMUM the mentor, in consultation with the manager, and depend upon
REQUIREMENTS the individual trainee's ability.
DIRECT The certified trainee should be accompanied by the mentor or a

SUPERVISION designated certified engineer for a minimum of:
3 DxC CC Service Calls

1 UniCel DxC 600/800 PM B, Major MC/CC
1 UniCel DxC 600/800 PM A, Major CC
1 DxC 600/800 Installation
Since the trainee has been certified on the instrument, the mentor
INDIRECT can elect to assign calls to the trainee when he determines that
SUPERVISION the situation warrants it.
The mentor should review all call assignments for the product by
telephone with the trainee before the trainee goes on site. An
action plan for the call should be devised and the trainee should
know how to reach the mentor quickly if the plan is not
appropriate. The trainee must update the mentor at the close of
the call.

Mentoring Recommendations
Mid-Sessions Mentoring Trainee accompanies the mentor or a designated certified
engineer on-site for the following:
Direct Supervision
9 DxC MC/ISE Service Calls
3 Unicel DxC 600/800, PM Minor, ISE/MC.
1 DxC 600/800 Installation (Can be done in Post Sessions
Mentoring Phase)
Post Sessions Mentoring Trainee should complete the following with the mentor or a
designated certified engineer on-site:
Direct Supervision
3 DxC CC Service Calls
1 UniCel DxC 600/800 PM B, Major MC/CC.
1 UniCel DxC 600/800 PM A, Major CC.
Post Sessions Mentoring Trainee should successfully complete the following without on-
site supervision:
Indirect Supervision
6 DxC MC/ISE or CC Service Calls
1 UniCel DxC 600/800 PM B, Major MC/CC
1 UniCel DxC 600/800 PM A, Major CC
1 Unicel DxC 600/800, PM Minor, ISE/MC
Completion of the The 'Post Classroom Mentoring Program' document is

Mentoring Validation available on the Chemistry/Immunoassay link of the Training
Form Resources Database in Lotus Notes.
The 'Mentor Validation Form' attached to the above document

effectively releases the certified trainee to service the DxC
600/800 independently.
The trainees must demonstrate to the satisfaction of the

mentor that they have the knowledge and skills required to
perform service calls on the DxC 600/800 without direct
supervision.
The mentor may require more than or less than what the above
guidelines recommend when evaluating an individual trainee.
The mentor should adjust the requirements for the trainee

accordingly, in consultation with the manager.
Any reservations that the mentor or trainee has about

signing the form should be jointly discussed with the
manager and an appropriate action plan devised.

Record only DxC 600/800 Service Calls *
Servic
Event
e Trouble-
Reason for Problem Log Successful?
Order shooting
call Observed Error If not, explain.
# Process
Code
& Date
*Save this document as 'Your Name DxC Log Week # (as appropriate)
E-mail the completed form weekly to your instructor.

Introductions
DxC Basic Phase 2
UNICEL DxC 600/800 Pro Basic Service, Phase 2 Introductions Page 1 of 6


Week 1
Day 10 Tuesday
Time Event Location
Review Mentoring Logs
QC & Calibration Review
Diagnostic Tools: ChemAssistant, LISA & Group
Summary
09:30 11:30 Calibrate / ISE & MC Cups Laboratory
11:30 12:30 Lunch
ChemAssistant / Precision, LISA
Day 11 Wednesday
Time Event Location
Group Summary and QC Interpretation
08:00 11:30 Presented by Stan Johnson Classroom
Questions & Answers
11:30 12:30 Lunch
Program QC using Group Summary
12:30 5:00 ISE Preamp Test Box Laboratory
Day 12 Thursday
Time Event Location
08:30 09:30 Refrigeration Subsystem Classroom
09:30 11:30 Refrigeration Exercises Laboratory
11:30 1:00 Lunch
Day 13 Friday
Time Event Location
CC Sample Aspiration & Delivery
CC Reagent Aspiration & Delivery
09:30 11:30 CC Sample & Reagent Exercises Laboratory
11:30 12:30 Lunch

Week 2
Day14 Monday
Time Event Location
Reaction Subsystem
Reaction Wheel & Photometer
10:00 11:30 Removal and Replacement Laboratory
11:30 12:30 Lunch
12:30 5:00 Removal and Replacement Laboratory
Day 15 Tuesday
Time Event Location
08:30 11:30 Reaction Subsystem / PVT2, PVT3 & PVT5 Laboratory
11:30 12:30 Lunch
Day 16 Wednesday
Time Event Location
10:00 11:30 Preventive Maintenance Major Laboratory
11:30 12:30 Lunch
12:30 5:00 PM continued Laboratory
Day 17 Thursday
Time Event Location
11:30 1:00 Lunch
1:00 2:00 Lab Cleanup Laboratory
2:00 5:00 Student Survey Graduation Classroom

Personal Progress Report
Name: ____________________
Instructions The Personal Progress Report is your way of monitoring your skill
development. Initial your Personal Progress Report and ask your
Instructor to do the same.
ITEMS PERTINENT TO INSTALLATION ARE IN BOLDFACE
Day 10 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
Calibrate and Troubleshoot MC/ISE.
Tools Perform precision tests using ChemAssistant.
Test instrument communications using LISA ______ _______
Day 11 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
QC
Program & process QC using Group
Summary. ______ _______
ISE
Troubleshoot ISE using ISE Preamp Test ______ _______
Box.
Day 12 Thursday
Student Instructor
Exercise Objectives
Initials Initials
Locate all refrigeration components
Remove and reinstall Cooler Assembly
Refrigeration Remove and reinstall Thermistors
Remove and reinstall cooler fan
Remove and reinstall Peltier Drivers ______ _______
Day 13 Friday
Student Instructor
Exercise Objectives
Initials Initials
Identify reagent handling components
CC Sample Remove and reinstall reagent carousels home
& sensors and motors
Reagent Remove and reinstall bar code readers
Handling Perform belt adjustment
_______ _______
Perform alignment procedures

Personal Progress Report, cont...
Day 14 Monday
Student Instructor
Exercise Objectives
Initials Initials
Remove and reinstall reaction drive
assembly & its associated components
Remove and reinstall of photometer _______ _______
Reaction module & its associated components
Wheel & Remove and reinstall of cuvette wash
Photometer manifold and valves
Identify components and part numbers
Perform Diagnostic tests
Day 15 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
Performance Perform PVT2 Wash Station Test
Verification Cuvette Dryness
Tests Perform PVT3 Carryover Tests
Wash Station
Reagent Probes
CC Sample Probe
CC Mixer Paddles
Perform PVT5 Precision Tests
Normal Precision
On-Line Dilution
Review PVT5 Sample Probe Precision
Day 16 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
Preventive Perform Major PM
Maintenance

ISE Troubleshooting
Pre-Amp Test Box
UNICEL DXC 600/800 Pro Basic Service, ISE Troubleshooting Exercises Page 1 of 4
Lab Exercise: ISE Preamp Test Box
procedures:
Use of the ISE Preamp Test Box
Why To familiarize the engineers with the procedures for using the ISE
Preamp Test Box to eliminate the preamp board as a possible cause
for ISE problems.

Materials
ISE Preamp Test Box:
Reference:
Chapter 20: Service Tools
- ISE Electrode Simulator Box
1. Using the ISE Electrode Simulator to
help troubleshoot the ISE
2. Troubleshooting
3. Important Notes
4. Specifications
5. ADC Count Verification Using ISE
Simulator Module
6. Box Description/Part Number
7. Box Drawing
8. Board Description
ISE Read and understand the above documentation.

Electrode Remove the battery from the test box and measure its voltage.
Simulator
Box Note: It is important that the battery is an alkaline 9vdc battery and
measures at least 9vdc. The specifications provided for the test
results are based on a new battery in the test box.
Perform item # 5 above.

have learned.
Refrigeration
Exercises
UNICEL DXC 600/800 Pro Basic Service, Refrigeration Exercises Page 1 of 4


Lab Exercise: Refrigeration
procedures:
Removal of the Cooler Assembly
Removal of Peltier Driver Assembly
Why To familiarize the engineers with the procedures for replacement of the
cooler assembly and its associated components

Materials
TOP of Cable
Bracket DxC
1 8
P J159
Peltier Banks Thermal
Switch
COLD 1 2 3
PLATE
4 5 6
IN AIR J156B J156A
J155 TECFAN2 TECFAN4
Thermistors

Cooler Assembly and Peltier Drivers:
Reference:
Chapter 16: Reagent Handling
- Item 7 Peltier Assembly Removal and
Replacement Procedure
Cooler Read the above procedure carefully.

Assembly Remove the cooler assembly
Removal and Remove and reinstall the thermistors
Replacement Remove and reinstall the thermal switch
Remove and reinstall the TEC fans
Reinstall the cooler assembly
Reference:
- Item 7 Peltier Driver A Assembly
- Item 8 Peltier Driver B Assembly
Peltier Driver Read the above procedure carefully.

Removal and Remove and reinstall Peltier Driver A.
Replacement

have learned.

CC Subsystem
Exercises
Sample & Reagent

Handling
UNICEL DxC 600/800 Pro Basic Service, CC Subsystem Sample & Reagent Page 1 of 8
Lab Exercise: CC Sample Handling
Objectives
This exercise will guide you and your partner through the following
procedures:
Locate & identify sample handling components
CC Sample Syringe Assembly
Sample & Mixer Module
Remove and reinstall rotational motor
Why To become familiar with the components and assemblies that may
require repair or replacement.

Materials
CC Sample Handling:
Reference:
Sample Remove the covers from the CC Sample Crane Arm and the CC
Handling Mixer Crane Arm
System
Locate the vertical and rotational motors, sensors and belts or
gears for each.
CC Sample Remove and reinstall the sample mixer rotational motor.

Mixer
Alignment Perform the alignment procedures :

Procedures
CC Sample Crane or Probe:
1. CC Sample Probe Rotary Home
2. CC Sample Probe Rotary to Cuvette
3. CC Sample Probe Rotary to Sample Carousel
4. CC Sample Probe Vertical Home and Wash
5. CC Sample Probe Cuvette Height
6. CC Sample Probe Sample Height
CC Sample Mixer Crane or Body:

1. CC Sample Mixer Rotation Speed
2. CC Sample Mixer Rotary
3. CC Sample Mixer Height
Lab Exercise: CC Reagent Handling
procedures:
Locate & identify reagent handling components
Remove & reinstall the following components:
A/B Valve Assembly
Bubble Generator Assembly
Reagent Carousel Home Sensors Assembly
Reagent carousel motors
Bar code readers
Perform belt adjustments
Why To become familiar with the components and assemblies that may
require repair or replacement.

Materials
Tools required for Reagent Probe A & B Rotary to Cartridge
DxC Two Carousel Alignment Tool DxC Probe-Carousel Alignment Tool

P/N A18397 P/N A18396
CC Reagent Handling:
Reference:
1. Reagent Probe A and B Installation Procedure
2. Collar Wash Removal and Replacement Procedure
3. Reagent Crane Vertical Motor Removal and
4. Reagent Carousel Removal and Replacement
Procedure
5. Reagent Carousel Dual Drive Assembly Removal and
6. Reagent Carousel Home Sensor Assembly Removal
and Replacement Procedure
Reagent Remove and reinstall the A/B valve

Handling
System Remove and reinstall the Bubble Generator
Remove and reinstall the Reagent Syringe Assembly
Reagent Remove and reinstall Reagent Probe A or B
Probes
Collar Remove and reinstall one of the reagent probes collar wash assy.
Wash
Reagent Remove and reinstall Reagent Crane A Vertical Motor
Crane
Reagent Remove and reinstall the Reagent Carousels
Carousel
Dual Drive Remove and reinstall the Lower Carousel Drive Motor
Mechanism
Home Remove and reinstall the Home Sensor Assembly
Sensor
Bar Code Remove and reinstall the bar code readers.
Reader
CC Reagent Handling, cont...
Alignment Perform the alignment procedures:

Procedures
Reagent A Crane or Probe:
2. Reagent Probe A Rotary Home
3. Reagent Probe A Rotary to Cuvette (post requisite to 2.)
4. Reagent Probe A Vertical Home and Wash
5. Reagent Probe A Height in Cuvette (post requisite to 4.)
6. Reagent Probe A & B Rotary to Cartridge (post requisite to 2.)
7. Reagent Probe A Height in Cartridge (post requisite to 4.)
Reagent B Crane or Probe:

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

1. Reagent Mixer Rotational Speed
2. Reagent Mixer Rotary
3. Reagent Mixer Height
Instrument Verify that the instrument is in Standby mode and that all the instrument
Verification status is within specifications.
Calibrate Mg.

have learned.
Reaction Wheel
&
Photometer
Exercises
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 1 of 12
Lab Exercise: Reaction Wheel and Photometer
procedures:
Removal and replacement of cuvette wash manifold
assembly
Removal and replacement of cuvette wash drive assembly
Testing the wash station valves
Removal and replacement of reaction drive assembly & its
associated components
Removal and replacement of photometer module & its
associated components
Perform Diagnostics tests
Why In the event components within the reaction wheel assembly,

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

Materials
Reaction Wheel Subsystem
Reference:
Training CD:
Quick Reference Diagrams:
DxC Cuvette Wash Valve Manifold A11106
Cartridge Chemistries
Reaction Wheel Subsystems
A11106-AC DxC Cuvette Wash Valve
Manifold Assy.+
Cuvette Perform the following steps to remove the Cuvette Wash Manifold
Wash
Power down the system.
Manifold
Assembly Remove Sample Carousel evaporation cover.
Disconnect Sample Mixer Wash Cup fluid line and drape to center
section.
Remove the retaining screw from manifold bracket.
Loosen Wash Head captive retaining screws and lift Wash Head
from Cuvette Wash Drive.
Lift Cuvette Wash Manifold and Wash Head to gain access to
Manifold fluid connectors.
Disconnect fluid lines 134, 135, 151 and 175.
NOTE: Some fluid will leak from the Manifold. Capture with paper
towels.
Disconnect solenoid connectors 71P1, 71P2, 71P3, 71P4 and
71P5.
Disconnect heater power cables 71P6 and 71P7.
Lift assemblies away from instrument.
Using the above references, become familiar with the components
in the Cuvette Wash Manifold Assembly, valves, heaters, fluid
lines, probes, etc.
Remove and reinstall valve V2.
Reaction Wheel Subsystem, cont...
Cuvette Perform the following steps to remove the Cuvette Wash Drive.
Wash Drive
Assembly
Remove Smart Modules Center Cover.
Disconnect Cuvette Wash Drive motor connector 71PM1 from
Smart Module 71.
Remove (2) Phillips retaining screws from Drive base.
Lift Drive from instrument while carefully guiding motor cable
through harnesses and tubing maze.
Reinstall both the cuvette wash manifold and cuvette wash drive
assembly.
To prevent damage to the instrument (during power up &

homing process):
Position the wash head off to the side with the probes
placed into a large plastic beaker.
Cuvette Power on the instrument.

Wash Tests
When the instrument comes to standby, perform the following test.
Utilities, (4) Diagnostics, Functional Area Reaction System, Sub-
Functional Area Cuvette Wash, Test No. (1) Cuvette Wash,
Rinse and Vacuum Test.
Wash Fluid Remove cuvette probe assembly from wash tower.
Check
Place probes in a large container.
Select start cycle in the diagnostics routine.
Probes 1, 2 and 3 will each deliver fluid.
Insure that each probe is injecting three separate and uniform
streams into the container all starting and stopping at the same
time.
Listen to the valves operating during the wash all cuvettes. Refer
to Hardware Chronicles Wash Station Evaluation.
If the streams are off on a probe it could be probe, valve, tubing,
etc.
Wash Valve Remove cuvette probe assembly from wash tower.
Check
Place probes 1, 2 & 3 in separate test tubes/cuvettes.
Select start cycle in the diagnostics routine.
Probes 1, 2 and 3 will each deliver fluid.
At some point, the fluid level in each tube rises to the probe tip
where it will be evacuated.
If the fluid valves are delivering a consistent volume and the waste
valves are evacuating a consistent volume, the level in all three
tubes will stay the same.
If probes 2 & 3 are working properly, check the wiper probe (4) to
insure that it is aspirating fluid.
Reference:
Chapter 15: Reaction Subsystem
- Reaction Subsystem Removal and Replacement
Reaction Following the instructions in the above reference, remove the

Drive reaction drive assembly from your instrument.
Note for Step 7:

You may find it more convenient to remove the two wash
stations from the trough and place them in their gravity
drain holes.
This will prevent forgetting to reconnect the tubing later on
which will cause wash to be sprayed all over the
instrument.
If you choose to remove the lines and gamble on breaking the
fittings, drop them into their respective drains until the trough is
re-installed later in this exercise.
Reaction While the reaction drive assembly is off the instrument, remove,
Drive inspect and reinstall the following components from the reaction
Assembly drive assembly:
Slip ring assembly
Drive motor
Home sensor
Flash encoder
Drive shaft
(Plastic) gear
Reinstall the reaction drive assembly. Do not replace the reaction
wheel trough at this time.
Alignments Because the reaction wheel platter has been removed, the probes
and the cuvette wash station need to be realigned to the reaction
carousel.
Perform the following Alignments:
Functional Area Reaction Carousel
1. Reaction Carousel Home
2. Cuvette Wash Station
3. CC Sample Probe Rotary to Cuvettes
4. CC Sample Probe Cuvette Height
5. CC Sample Mixer Rotary
6. CC Sample Mixer Height
7. Reagent Probe A Rotary to Cuvettes
8. Reagent Probe A Height in Cuvette
9. Reagent Probe B Rotary to Cuvettes
10. Reagent Probe B Height in Cuvette
11. Reagent Mixer Rotary
12. Reagent Mixer Height
.030" Feeler Gage
471803 Rx Wheel Align Tool 476211 Cuvette Wash Probe Align Tool
Photometer Subsystem
Reference:
- Photometer Removal and Replacement
Photometer Note:
Removal and Do not loosen or remove the reaction wheel platter. Doing
Replacement so will require the Reaction Carousel alignments to be
repeated!
Remove the 3 fiber optics connecting the Photometer Preamp and

the LPIA Photometer.
Following the above reference, remove the photometer.
Lamp While the photometer module is off the instrument, remove and
Removal and reinstall the Photometer Lamp.
Replacement Remove the four Allen screws holding the trigger pack to the
monochromator assembly.
Remove the 2 screws and 2 clamps holding the lamp into place
inside the trigger pack assembly. Be careful not to loose the 2
clamps that hold the lamp in place.
Photometer Loosen the three long screws on the back of the preamp housing
Preamp which extend through the internal spacers one turn.
Removal
Note:
The diagram on the next page show where these screws are.
The reason they are loosened is to allow the 4 captive thumb
screws that hold the preamp to the base plate to be loosened
by hand.
Disconnect the three fiber optic cables between the Photometer
Controller and the Lamp Power Supply. Leave the fiber optics
connected to the Lamp Power Supply.
Loosen all 4 captive screws which secure the Preamp Assembly to
the monochromator housing.
Gently lift the Preamp Assembly from the monochromator. Set
aside.
Photometer Subsystem, cont...
Photometer Loosen the three long screws on the replacement Preamp
Preamp Assembly which extend through the internal spacers one turn.
Removal and
Note:
Replacement
The reason they are loosened on a new preamp is that the
thumb screws must be tightened by hand to avoid placing
torque on the box which will misalign the wavelength diodes
causing failure of the diagnostic tests.
Gently install the replacement Preamp onto the monochromator
base plate, being careful to guide the reference detector into the
cavity in the fiber receptacle. Take note that the edges of the
Preamp housing are inside the channels in the base plate.
By hand, tighten the 4 captive screws which secure the Preamp
Assembly onto the monochromator base plate.
Tighten the three long screws which extend through the internal
spacers.
Reconnect the fiber optic cables from the Lamp Power Supply to the
Photometer Controller.
Re-install the Photometer Assembly on the instrument.
Loosen these 3
screws 1 turn
and 1 turn only!
Reference:
- Alignment and Adjustment
1. The Photometer Lamp Calibration
2. The Photometer Flash Encoder Test
3. The Photometer Lamp Alignment and Power
4. The Photometer Flash Lamp Power Supply
5. The Photometer Smart Module & Preamp Test
6. The Reaction Wheel Temperature Test
7. The Reaction Wheel Heater Controller
8. The Reaction Wheel Home Alignment Test
To prevent damage to the instrument (during power up &
homing process):
Position the wash head off to the side with the probes
placed into a large plastic beaker.
Power up the instrument.

Photometer Read the above documentation thoroughly.
Diagnostics Perform Lamp Alignment and Power
& Alignment
Tests Note for Step 11:
Do not replace the reaction wheel trough at this time.
Perform Cuvette Center Alignment.
Note:
Do not perform Wash All Cuvettes at this time. Visually inspect
the cuvettes for cleanliness and dryness instead.
Perform Lamp Calibration
When your instrument's photometer has met performance
specifications, move on to the LPIA photometer exercise.
Reference:
Chapter 12: LPIA
Alignment and Adjustment
1. The Cuvette Centering Alignment Procedure
2. The LED DAC Setting
LPIA Read the above documentation thoroughly.

Photometer Perform Cuvette Center Alignment for the LPIA
Diagnostics Perform LED DAC Setting
& Alignment Perform Photometric Performance Diagnostics
Tests
When your instrument has passed the performance specifications:
1. Exit Diagnostics
2. Select the Utilities Icon
3. (2) Maintenance
4. (6) Wash All Cuvettes
5. Continue
When your instrument reaches Standby, calibrate Mg.

have learned.
Cleaving
Exercise
SYNCHRON, DxC 600 / 800 Pro Basic Service, Cleaving Exercise Page 1 of 4
Lab Exercise: Cleaving
This exercise will guide you through separating an assembled DxC

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

Materials
DxC Cleaving:
Reference:
Chapter 4: Installation
- DxC 600 Cleaving
- DxC 800 Cleaving
Cleaving Following the appropriate procedure above, separate the instrument

into its three basic sections.
Reassemble the sections by reversing the appropriate procedure.
Perform all alignments required.
Instrument
Verification
Verify that the instrument is in Standby mode and that all the
instrument status is within specifications.
Calibrate the MC chemistries and Mg.
Locate an instructor for sign off of this exercise.

answers can be found.

DXC 600 800 Basic Service Workbook Ver B

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Introductions

DxC Basic Phase 1

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 1 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 2 of 12

ASCII American Standard Code for Information Interchange

ASTM American Society for Testing and Materials

CAU Chemistry Analytical Unit

CC Cartridge Chemistries (also referred to as Random Access (RA))

DMD Dual Motor Driver

HC16 The DMD Micro-controller

ICC Instrument Control Computer

ICD In-Circuit Debugger (Cable)

ICS Instrument Control System

MC Modular Chemistries (also referred to as Parallel Process (PP))

MPC Multi Product Console

MSMC Multiple Smart Module Controller

PARISE Parallel processing cup and ISE chemistry software

RA Random Access (see CC)

SM Smart Module (see DMD)

SRS Software Requirements Specification

TS-CTS Thick Stopper - Closed Tube Sampling

TCP/IP Transmission Control Protocol / Internet Protocol

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 3 of 12

KIT, TOOLS DxC 600/800 SYSTEM P/N: A18779 AC

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 4 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 5 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 6 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 7 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 8 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 9 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 10 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 11 of 12

UNICEL DxC 600/800 Pro Basic Service, Introductions Page 12 of 12

UNICEL DxC 600/800 Pro Basic Service, Operations Page 1 of 20

UNICEL DxC 600/800 Pro Basic Service, Operations Page 2 of 20

Objectives This exercise will guide you through the following:

Why Identify system components and locations in preparation for more

Reference DxC In-Lab Training Manual

Please feel free to consult with an instructor if you have

UNICEL DxC 600/800 Pro Basic Service, Operations Page 3 of 20

Locate an instructor for sign off on this exercise.

UNICEL DxC 600/800 Pro Basic Service, Operations Page 4 of 20

Why During an installation, you may be asked to define the instrument's

Reference DxC Instructions For Use Manual

Please feel free to consult with an instructor if you have

UNICEL DxC 600/800 Pro Basic Service, Operations Page 5 of 20

Do not enable auto serum index on your training instrument.

Chemistry Print Name

UNICEL DxC 600/800 Pro Basic Service, Operations Page 6 of 20

Locate an instructor for sign off on this exercise.

UNICEL DxC 600/800 Pro Basic Service, Operations Page 7 of 20

UNICEL DxC 600/800 Pro Basic Service, Operations Page 8 of 20

Objective Activate Service Mode using the Password Generator

Materials Service Password Generator Program on your laptop.

Reference DxC Service Manual

Please feel free to consult with an instructor if you have

UNICEL DxC 600/800 Pro Basic Service, Operations Page 9 of 20

Enable Read the Operational Overview.

Questions What color distinguishes Service Mode from Normal Operations?

Why disable the Service Mode?

UNICEL DxC 600/800 Pro Basic Service, Operations Page 10 of 20

Assume the DxC has alerted you with the message:

METER DATA IS DUE.