Bayer HealthCare Clinitek Atlas, 5023, 5258 Service Manual

Download

Clinitek® Atlas® Rack Sample Handler

Service Manual

Cover

?998 Bayer Corporation

Second Edition

June 1998

Company Confidential

Information contained herein is proprietary to Bayer Corporation and is classified company confidential. It is furnished to Bayer Field Service Engineers for maintenance and overhaul of the subject equipment only. It shall not be disclosed, duplicated, or used in whole or in part for any other purpose without the prior written permission of Bayer Corporation.

Information contained in this service manual is designed for servicing of the CLINITEK?ATLAS?Rack Sample Handler by qualified and properly trained service personnel using appropriate tools and test equipment. If you do not possess the proper service tools and equipment and proper technical training, do not attempt to service this instrument.

This service manual is kept current by service bulletins issued from the United States by Bayer Corporation, Diagnostics Division. These bulletins are distributed world-wide to Bayer service personnel and others who have received technical training from Bayer Diagnostics. Other possessors of this manual will not receive these bulletins.

TABLE OF CONTENTS

CHAPTER Page 1

GENERAL DESCRIPTION

1-1

Using the Manual............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1-1

1-2

Instrument Description................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1-2

1-3

Specifications....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1-3

METHODS OVERVIEW

2-1

Introduction............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2-1

2-2

Methods Overview.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2-1

INSTALLATION

3-1

3-2

Installation..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3-1

OPERATIONS / PROCEDURES SUMMARY

4-1

4-2

Operation.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4-2

Figure 4-1 Main Menu Operation Block Diagram

PREVENTATIVE MAINTENANCE

5-1

5-2

Routine Maintenance................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5-1

5-3

Preventative Maintenance........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5-1

FUNCTIONAL BLOCK DIAGRAMS and THEORY

6-1

6-2

Set朥p and Use..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-2

6-3

Instrument Modules...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-2

6-3-2

The Rack Feed Assembly......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-2

Figure 6-1 Rack Feed Assembly (In Feed and Out Feed)

6-3-3

The Cross Feed Assembly...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-4

Figure 6-2 Cross Feed Assembly

......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-3

6-3-4

The Return Feed Assembly................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6-4

Figure 6-3 Return Feed Assembly

6-3-5

Power Module, Atlas Interconnect PC Bd. & Power Supply............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6-6

Figure 6-4 The Power Module

Figure 6-5 The Atlas Interconnect PC Board and R1 Relay

6-3-6

The Display Assembly................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6-6

6-3-7

The Card Cage Assembly......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-8

Figure 6-6 The CPU - I/O PC Board Assembly

Figure 6-7 The Mother PC Board

Figure 6-8 The CPU PC Board

Figure 6-9 The I/O PC Board

TABLE OF CONTENTS (Cont.)

CHAPTER Page 6

FUNCTIONAL BLOCK DIAGRAMS and THEORY (Contd.)

6-3-8

The Driver Assembly................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-10

Figure 6-10 The Driver Assembly

Table 6-2 Rack Sample Handler Motors

6-3-9

The Stat Tube Holder.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-12

Figure 6-11 The Stat Tube Holder

6-3-10

The Barcode Reader.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6-13

6-3-11

Instrument Sensors..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6-13

Figure 6-12 Locating Instrument Sensors

Table 6-1 Sensor Status

Figure 6-13 Infeed Operation

Figure 6-14 Crossfeed Operation

Figure 6-15 Outfeed and Returnfeed

EXERCISE / DIAGNOSTICS / TROUBLESHOOTING

7-1

7-2

Service Test Mode............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-2

Figure 7-1 Service Mode Block Diagram

7-2-4

Without Tube Run...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-4

7-2-5

With Tube Run................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-4

Figure 7-2 Without Tube Run and With Tube Run Routine

7-2-6

Barcode Test........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-6

Figure 7-3 Barcode Test

7-2-7

Sensor Monitor............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7-8

Figure 7-4 Sensor Monitor Routine

Table 7-1 Sensor Status

7-2-8

Output Test..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-10

Figure 7-5 Output Test

7-2-9

Display Test..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7-10

Figure 7-6 Display Test

7-3

Troubleshooting Chart........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7-12

ALIGNMENTS / ADJUSTMENTS

8-1

8-2

Index....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8-1

8-3

Adjusting the Rack Guides.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8-3

Figure 8-1 Adjusting Cross Guide and Return Parts Guide

8-4

Adjusting the Power Supply...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8-3

Figure 8-2 The Power Supply

8-5

Adjusting the Sensors................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8-5

Figure 8-3 Location of Instrument Sensors

Figure 8-4 Adjusting a Sensor Using a Tube Rack

iii

TABLE OF CONTENTS (Cont.)

CHAPTER 8 Page

8-6

PH4 Sensor Adjustment............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8-7

Figure 8-5 Adjusting Tube Sensor PH4

Table 8-1 PH4 LED Status

8-7

Barcode Reader Checkout Procedure............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8-8

8-8

Setting the Motor Reference Voltages................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 8-10

Figure 8-6 Adjusting the VR1-4 Pots on the Driver Board

8-9

Adjusting the Solenoid Bracket.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8-11

REPAIR / REPLACEMENT

9-1

9-2

9-3

Removing instrument Covers................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9-3

Figure 9-1 Removing the Covers, Part One

Figure 9-2 Removing the Covers, Part Two

9-4

Removing, Inspecting and Installing the Return Feed Assembly.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9-5

Figure 9-3 The Return Feed Assembly

9-5

Removing, Inspecting and Installing the Rack Feed Assembly...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9-7

Figure 9-4 The Rack Feed (Infeed / Outfeed) Assembly

9-6

Removing, Inspecting and Installing the Main Chassis Assembly...................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9-13

Figure 9-5 The Main Chassis Assembly

Figure 9-6 The CPU - I/O Board Assembly

9-7

Accessing and Repairing the Cross Feed Assembly.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9-15

Figure 9-7 The Cross Feed Assembly

9-8

Removing and Replacing Wire Cables.................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9-17

Figure 9-8 Proper Installation of Wire Cables on Wiring Drums

Figure 9-9 Wire Cable Deflection

9-9

Removing and Replacing the Top Plate....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9-19

Figure 9-10 Removing and Replacing the Top Plate

PARTS BREAKDOWN / ILLUSTRATED ASSEMBLIES................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 10-1

SUPPLEMENTARY DATA (SERVICE BULLETINS)................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 11-1

SCHEMATICS................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 12-1

APPENDIX A

ERROR REPORTING TO THE CLINITEK ATLAS SYSTEM......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... A-1

CHAPTER ONE

GENERAL DESCRIPTION

1? Using the Manual

1-1-1 This service manual provides service information for the CLINITEK?ATLAS?Rack Sample Handler,

model 5023 and the CLINITEK?ATLAS?Rack Sample Handler Bar Code Reader, model 5258.

1-1-2 Throughout this book, this symbol may be found:

 Use this 揵ook?to locate more information on the same subject.  To locate specific servicing information, refer to the Table of Contents on page iii.

1-1-3 The CLINITEK ATLAS Rack Sample Handler (also known as the Rack Sample Handler) is mounted

to, and used with, a CLINITEK?ATLAS?Automated Urine Chemistry Analyzer, models 5001C, 5001L or 5011. Using retrofits, It may also be added to models 5001B and 5001X.

 See Service Bulletins ATLAS-101 and ATLAS-102 for more information regarding retrofitting

model 5001B and 5001X units to accommodate the Clinitek Atlas Rack Sample Handler.

 To service the Clinitek Atlas Analyzer, refer to the Clinitek Atlas Service Manual, part number

99A50018.

 For information on Clinitek Atlas operation, refer to the Clinitek Atlas Operating Manual with

Rack Sample Handler, part number 99950239.

1-1-4 This manual is current as of the copyright date (June 1998). Any future revisions or additional

servicing information will be covered by Service Bulletins.

1-1

1? Instrument Description

1-2-1 Together, the Rack Sample Handler and Clinitek Atlas Analyzer become an automated system for

the analysis of CLINITEK?ATLAS?Reagent Pak, product code 5017. Each pak contains 490 +10/-0 reagent strips. Each strip contains ten pads used to provide nine different reagents and one characteristic (colour). Two additional tests (Specific Gravity and Clarity) are done by this sys-tem.

1-2-2 The Rack Sample Handler plugs into the Clinitek Atlas analyzer through connector J1401 on the

Clinitek Atlas unit. In doing this, it replaces the CLINITEK?ATLAS?Sample Handler, part number

5003A.

1-2-3 The CLINITEK?ATLAS?Rack Sample Handler Fixed Bar Code Reader, model 5258 is an optional

addition to the Rack Sample Handler. This bar code reader reads sample tube bar code labels for positive sample identification, collated with the urine results obtained on the Clinitek Atlas analyzer.

1-2-4 Urine specimen tubes are loaded into Clinitek?Atlas?Specimen Tube Racks, product code 5262 (ten

to a pack-age). Each rack holds ten tubes. Racks are placed into the Rack Sample Handler load area. Each rack is transported in, across, and out of the Rack Sample Handler to analyze the urine specimens. Test results are displayed and may be sent to an external printer and computer. The rack is then moved into the unloading area, where it can be removed and new specimens added. Up to 20 racks of ten tubes each can be loaded at one time (200 tubes); a full run of 200 tubes can be tested in about one hour.

1-2-5 A Clinitek?Atlas?Stat Rack, product code 5263, may also be used to run STAT samples. 1-2-6 A Stop Marker (part number 50361095) may be inserted into a rack to stop operation once the

marker is identified by the system.

1-2

1-3 Specifications

NOTE:

Unless otherwise specified, all of the following specifications refer only to the Clinitek Atlas Rack

Sample Handler. Refer to the Clinitek Atlas Service Manual (part number 99A50018) for Atlas specifications.

Power Requirements (Model 5023 only):

Line Voltage:

NOTE:

The CLINITEK ATLAS Rack Sample Handler was manufactured as a 100 to 120 VAC

instrument. Before being used at a voltage higher than 120 VAC, the instrument power cord and/or rating labels must be changed in order to comply with the specific requirements of each country.

Current Draw at 100 VAC (average):

......................................................................................................................................... 1 amp

Power Consumption:

Heat Output:

Leakage Current with power cord ground connected:

Leakage Current in single faults condition, with power cord ground opened for testing

(testing protocol and allowable limits as specified by the safety standards for laboratory equipment outlined in UL 1282 and CSA 22.2, Number 151):

(3500 microamps)

Power Requirements (Model 5023 with the Clinitek Atlas unit):

Line Voltage:

Current Draw at 100 VAC (average):

......................................................................................................................................... 7 amps

Power Consumption:

Heat Output:

Leakage Current:

Physical Specifications (Model 5023 only):

Height:

Width:

Depth:

Weight:

1-3

Physical Specifications (Model 5023 connected to the Clinitek Atlas instrument):

Height:

Width:

Depth:

Weight:

Operating Temperature (Model 5023 only):

............................................10?to 40?C (50?to 104?F)

Operating Temperature (Model 5023 connected to the Clinitek Atlas instrument):

Operating Humidity (Model 5023 with or without the Clinitek Atlas instrument):

Storage Temperature (Model 5023 with or without the Clinitek Atlas unit):

Storage Altitude (Model 5023 with or without the Clinitek Atlas unit):

Storage Humidity (Model 5023 only):

Shock ?Packaged (Model 5023 only):

Shock ?Unpackaged (Model 5023 only):

................................................................................................................... 10 cm free fall drop with one-side support / 4杝ide

Vibration ?Packaged (Model 5023 only):

................................................................................................................ 5?50 Hz/ 1g/ Vertical/ 30 minute

Vibration ?Unpackaged (Model 5023 only):

.........................................10?5 Hz/ 0.18 mm amplitude/ Vertical/ 30 minutes

Safety Certification (Model 5023 only):

......................................................................................................................................................... 1. CSA-C22.2 Number 1010.1

Note:

As of March 1997, this instrument has not received certification of the above standards. The

system was designed to meet these standards and certifications have been applied for and are pending.

Electromagnetic Emissions (Model 5023 only):

1-4

Electromagnetic Immunity (Model 5023 only):..................................................................................................................................................................... 1. IEC 801-2 Level 4 (ESD)

NOTE:

Model 5023 conforms to EMC Directive 89/336, Amendments 92/31/EEC.

Model 5023 Input/Output Connector Interface to the Clinitek Atlas instrument:

Interface:

Input Connector:

Baud rate:

Data code:

Parity bit:

Stop bit:

Total bit/character:

Software Handshake:

Checksum:

Connector Pin Arrangement:

pin number 42 = RXD (Received Data) pin number 43 = TXD (Transmit Data) pin number 45 = Signal Ground pin number 47 = RTS (Reqst. To Send) pin number 48 = CTS (Clear To Send)

Model 5023 Input/Output Connector Interface to the Barcode Reader (2 Sets):

Interface:

Input Connector:

Baud rate:

Data code:

Parity bit:

Stop bit:

Total bit/character:

Software Handshake:

Checksum:

Connector Pin Arrangement:

pin number 2 = RXD pin number 3 = RTS pin number 4 = CTS pin number 5 = Inzone pin number 6 = Open pin number 7 = Signal Ground pin number 8 = VCC

1-5

Sample Tube Throughput:................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 225 sample tubes per hour, or one sample tube each

16 seconds

Rack Capacity:

Sample Tube Capacity:

Rack:

Rack Tube Capacity:

Sample Tube Circulation:

Approved-For-Use Specimen Tubes:

2. Sera-Pitz Tubes

3. Low-Volume Bayer Italia Tube

Specimen Tube Requirements:

Width: 16 mm Height: 100 to 104 mm

Rack Dimensions:

Height:

Length:

Width:

Rack Sample Hole Diameter:

Model 5258 Bar Code Reader Formats:

........................................................................................................................................... 1. Code 39

2. Codabar (NW7)

3. Interleaved 2 of 5

4. Code 128

Bar Code Voltage and Current Usage:

................................................................................... 24 VDC at 100 milliamps

Bar Code Communication Format:

.............................................................................................................................................................................. EIA RS-232C

Bar Code Operating Temperature:

Bar Code Humidity Range:

Bar Code Minimal Bar Height:

Bar Code Narrow Bar size:

Bar Code Digit Capacity:

Bar Code Print Contrast Ratio:

Bar Code Label Maximum Length:

Bar Code Minimum Scan Length:

Bar Code Minimum Module Size:

Bar Code Scan Frequency:

1-6

CHAPTER TWO

METHODS OVERVIEW

2-1 Introduction

2-1-1 This chapter describes how to locate operating system software routines used by the CLINITEK?

ATLAS?Rack Sample Handler.

2-2 Methods Overview



Since this system operates under the control and direction of the Clinitek?Atlas?Analyzer, refer

to that service manual, part number 99A50018, in Method Overview Chapter Two for an explanation of Clinitek Atlas software operation.

 Also see Appendix A in this manual for an explanation of error handling between the two

instruments.

2-1

CHAPTER THREE

INSTALLATION

3-1 Introduction

3-1-1 This chapter explains how to locate information regarding installation of the CLINITEK?ATLAS?Rack

Sample Handler.

3-2 Installation



Refer to the Clinitek Atlas Automated Urine Chemistry Analyzer with Rack Sample Handler

Operating Manual, part number 99950239, Section 2, for instructions on installing this system.

3-2-1 In addition to the instructions in the operating manual, the following should be checked during the

installation:

the waste tubing from the Clinitek Atlas system Rinse Well to the waste bottle must be fixed to

the rear wall without any sag. If there is a sag or stagnation of waste water in the waste tubing, waste water may over-flow from the Rinse Well and electrical problems may then occur with the Rack Sample Handler unit.

The waste tubing must have a little slope towards the left side wall of the Atlas unit. The tube

end of the waste tubing must be cut so as to not touch the surface of the waste container, even if this waste container becomes full.

the system must be placed on a flat, stable and level surface for optimum performance.

NOTE:

If problems are seen during an initial installation, the Mother PC Board connectors

may have come loose. See paragraph 9-6 on page 9.13 to access these connectors. Then reseat all the connectors, using the paper guide printed on top of the card cage and Figure 6-7 on page 6.9

3-1

CHAPTER FOUR

OPERATIONS / PROCEDURES SUMMARY

Figure 4-1 Main Menu

Operation Block Diagram

4-1

4-1 Introduction

4-1-1 This chapter describes basic instrument operation for the CLINITEK?ATLAS?Rack Sample Handler.

4-2 Operation

4-2-1 The Rack Sample Handler system has three main menus to select from:

Main Menu

User Setup Menu

Service Menu

4-2-2 Main Menu functions are shown in Figure 4-1 on page 4.0 and are described below.



For more information regarding operation and all menus, see the Clinitek?Atlas?Automated

Urine Chemistry Analyzer with Rack Sample Handler Operating Manual, part number

99950239. NOTE:

If the left (green) and right (red) keys are pressed when the power is first turned

ON, a Service Menu and System Set-Up Menu are displayed.

 See Chapter Seven for more information regarding the Service Menu.

4-2-3 Main Menu (see Figure 4-1) begins by turning on the instrument. At Power On a display appears

showing the model and (software version (2.01). An Initializing screen then appears.

4-2-4 A Standby message screen (screen 1 on Figure 4-1) then appears, from which the Menu softkey can

be pressed. Pressing the Menu key takes the display to screens 4 through 5 to select from the various menu modes.

4-2-5 The following display screens (see item numbers on Figure 4-1) may then be seen:

•

Screen 2 appears only if a Barcode error was detected.

•

Screen 3, Rack SEQ No., displays the rack sequence number and appears only if KEY option

was selected in the Rack No. Reset menu.

•

Screen 4, Start Sample, shows the first sample number in a ten-tube rack (xx) that will be run

when a routine analysis is run.

•

Screen 5, User Setup, permits entering the Setup Menu if ENT is pressed.

•

Screen 6 shows the Last sample number (xxx-yy) run and the oldest error date (xxx-yy). In all

cases, pressing ESC will return the display to screen 1 (Standby-Message)..

4-2

CHAPTER FIVE

PREVENTATIVE MAINTENANCE

5-1 Introduction

5-1-1 This chapter describes routine maintenance done by a customer and preventative maintenance to be

performed by a field engineer while on a service call.

5-2 Routine Maintenance

5-2-1 The Transfer Plate (top steel plate racks travel on) should be cleaned daily with a damp cloth and

mild detergent. Afterwards, dry the plate off with a clean, soft cloth. A dirty Transfer Plate may

搒

queak?loudly during rack transfer and may cause rack jams to occur.

5-2-2 Tube racks should also be cleaned daily by scrubbing them with a soft cloth and mild detergent,

followed by rinsing under water and drying carefully.

 Refer to the Operating Manual for all routine general maintenance to perform as a part of

normal operation.

NOTE:

The CLINITEK?ATLAS?Rack Sample Handler MUST be balanced with a levelling

device to operate properly. Otherwise, rack jams may occur.

5-3 Preventative Maintenance

5-3-1 A field engineer on a service call on this system should do the following as part of the call:

Verify Transfer Plate (see item 9 on page 10.36) and racks are clean.

Verify the Reflection Plate (see item 2 on page 10.4) is clean and not scratched or loose.

Verify PH1-7 and PH9 sensor windows are clean (see Figure 8-3 on page 8.4)

Verify Barcode Reader window is clean (if instrument is using a barcode reader).

Verify waste tubing is draining properly into the waste receptacle.

Clean all covers with a soft, clean, damp cloth and mild detergent. Follow-up with a soft, clean,

damp cloth and dry carefully with a soft, clean cloth.

Lastly, perform a With Tube Run in Service Mode for at least 30 minutes to verify system is

working properly.

 Refer to the Preventative Maintenance Checklist on page 5.2.  See page 7.4 for more information about the Service Mode With Tube Run test.  For special preventative maintenance to be performed by a field engineer on the Clinitek

Atlas Analyzer, refer to the Clinitek Atlas Service Manual, part number 99A50018, Chapter Five.

5-1

5-3-2 Use the following Preventative Maintenance (PM) Checklist to do a 損m?on the Rack Sample

Handler unit:

 Verify Transfer Plate (see item 9 on page 10.36) and racks are clean.  Verify the Reflection Plate (see item 2 on page 10.4) is clean and not scratched or loose.  Verify PH1-7 and PH9 sensor windows are clean (see Figure 8-3 on page 8.4)  Verify Barcode Reader window is clean (if instrument is using a barcode reader).  Verify waste tubing is draining properly into the waste receptacle.  Clean all covers with a soft, clean, damp cloth and mild detergent. Follow-up with a soft, clean,

damp cloth and dry carefully with a soft, clean cloth.

 Lastly, perform a With Tube Run in Service Mode for at least 30 minutes to verify system is

working properly.

5-2

CHAPTER SIX

FUNCTIONAL BLOCK DIAGRAMS AND THEORY

Figure 6-1 Rack Feed Assembly (In Feed and Out Feed Assembly)

6-1

6-1 Introduction

6-1-1 This chapter describes basic theory of operation for the CLINITEK?ATLAS?Rack Sample Handler.

6-2 Set-Up and Use

6-2-1 Prior to instrument operation, the Rack Sample Handler must be connected to the Clinitek?Atlas?

Analyzer.

6-2-2 The Rack Sample Handler and Clinitek Atlas unit must be installed on a level, flat, stable surface.

 See the Clinitek Atlas Automated Urine Chemistry Analyzer with Rack Sample Handler

Operating Manual (part number 99950239), Section 4, for setup instructions.

6-3 Instrument Modules

6-3-1 The Rack Sample Handler consists of the following major modules:

Rack Feed Assembly (paragraph 6-3-2)

Cross Feed Assembly (paragraph 6-3-3)

Return Feed Assembly (paragraph 6-3-4)

Power Module, Atlas Joint PC Board and Power Supply (paragraph 6-3-5)

Display Assembly (paragraph 6-3-6)

Card Cage Assembly (paragraph 6-3-7)

Driver Assembly (paragraph 6-3-8)

Stat Tube Holder (paragraph 6-3-9)

Barcode Reader (paragraph 6-3-10)

10.

The Instrument Sensors (paragraph 6-3-11)

6-3-2 The Rack Feed Assembly

6-3-2-1

Each Rack Sample Handler instrument contains two nearly identical Rack Feed Assemblies (see

Figure 6-1):

an Infeed Assembly to move a tube rack towards the pipette for sample testing

an Outfeed Assembly to move the tube rack away after specimen sampling is completed.

The sole difference between the two units are the ID tags for motors and sensors, which are different on each unit.

6-3-2-2

Using steel cables (items 36 and 37 on Figure 6-1) and plastic pulleys (16 and 50), the In Feed /

Out Feed Units move the trays with two levers (5 and 44) that contact the racks. These levers are pressed down by the tube racks when their motions are reversed.

6-3-2-3

On the In Feed Assembly, a 24 VDC PF55-48K1 1/5 PM1 Stepper Motor (item 29), rotates a

Winding Drum (31) which moves the steel cables. This motor is homed using ORG1 (搊rigin sensor 1?, a 5VDC EE-SX153 photodiode / phototransistor sensor (item 26).

6-3-2-4

The same 24 VDC Stepper Motor is used by the Out Feed Assembly: it is called the PM3 Out Feed

Motor (item 29). On the Out Feed Assembly, this motor is homed using ORG3, a photodiode / photo-transistor sensor (26)

6-2

Figure 6-2 Cross Feed Assembly

6-3

6-3-3 The Cross Feed Assembly

6-3-3-1

The Cross Feed Assembly (see Figure 6-2) cross feeds or moves the tube racks across the rear

wall of the instrument. A 24 VDC PF42T-48071G 1/15 Stepper Motor PM2 (item 3) drives a Timing Pulley (15) which in turn moves a Timing Belt (16). Attached to the belt is a Cross Feed Arm (32), used to move the tube rack from right to left.

6-3-4 The Return Feed Assembly

6-3-4-1

The Return Feed Assembly (Figure 6-3) moves the tube racks across the front instrument wall, so

racks may be rotated in an 揺ndless loop.?A 24VDC PF42T-48071G 1/10 stepper motor, called PM4 (item 17 on Figure 6-3), rotates a Winding Drum pulley (item 14), whose steel cable Wire (22) and plastic Pulleys (13 and 21) move a Lever (34) to push the tube racks from left to right. The tube rack presses down the lever when its motion is reversed. Motor PM4 is homed using ORG4, a 5VDC EE-SX153 photodiode/phototransistor sensor (item 24)

Figure 6-3 Return Feed Assembly

6-4

Figure 6-4 Power Module Figure 6-5 The Interconnect PC Board and R1 Relay

6-5

6-3-5 The Power Module, Atlas Interconnect PC Board and Power Supply

 Refer to Figures 1, 2, 6 and 7 in Chapter 12 (Schematics) while reading the following.

6-3-5-1

The Power Module (see Figure 6- 4) receives AC line power via an FN9260B-4- 06 Fuse Holder

and Line Filter (item 8). In Japan and North America, two 3 Amp 250V small-size fuses are used in the fuse holder.

6-3-5-2

From this module AC line power goes through a 12 VDC Relay R1 (item 3). R1 is controlled by 12

VDC supplied on the Clinitek Atlas instrument Power Driver PC Board at its connector P1305 pins 31 and 34. This 12 VDC is sent to Clinitek Atlas instrument floating connector J1401, which connects the Clinitek Atlas unit to the Rack Sample Handler. The 12 VDC then goes to connector CN116 on the Rack Sample Handler Atlas Interconnect PC Board (see Figure 6-5) and from there to the R1 relay to control AC line power to the Rack Sample Handler. This places the relay in an 揙R?relationship with the On/Off Power Switch, permitting the Rack Sample Handler to be operated either by turning on its On/Off switch or by turning this switch OFF but with the handler connected to a powered Clinitek Atlas instrument.

6-3-5-3

The On/Off switch (Figure 6-4 item 7) on the Power Module breaks the AC power (when relay R1 is

disabled). This AC is then supplied to the Power Supply. The DC Power Supply (see schematic page 12.5 and item 10 on page 10.26) is a TDK model FGW24-4R2 device with one 24 VDC output. A green LED on the supply turns on when AC power is supplied to it.

6-3-5-4

A 3.15 amp 250V Fuse (F1) on this power supply is connected to the AC input. Two additional

potentiometers are used for DC voltage adjustment (R102, mounted to a small piggyback pc board near the terminal strip) and current limit (R28). To locate these pots, see page 8.2. The outputted 24 VDC goes through a 6 amp 250V Fuse, mounted to the Main Chassis Assembly (see item 5 on page 10.26). Terminal strip TB1 (item 4 on page 10.26) distributes the 24 VDC to the Fan and the Driver Assembly (pins 1 and 2) and to the Mother Board (pins 3 and 4); see schematic on page

12.5. To locate the power supply, see item 10 on page 10.26.

6-3-6 The Display Assembly



See Figure 4 on page 12.9 for the keyboard and display schematic.

6-3-6-1

The Display Assembly (see page 10.14) is made of three lighted key switches (items 1, 2 and 3 on

page 10.14), a DM2423-7BL3 24 x 2 Display Module (item 14 on page 10.14) and connecting cables, hardware and the cover. It plugs into centronics- style connector CN100. C100 carries display and keyboard signals to and from the Mother PC Board in the CPU - I/O Board Assembly (see paragraph 6-3-7)

6-6

Figure 6-6 The Card Cage Assembly

6-7

6-3-7 Card Cage Assembly

 Review schematic Figure 1 in Chapter Twelve while reading the following.

6-3-7-1

The Card Cage Assembly (see Figure 6-6) is made of a Mother PC Board (item 3), a program card

(item 6) and a CPU - I/O PC Board Unit (item 5). The CPU - I/O PC Board Assembly is two pc boards 搒andwiched?together:

the I/O (or Sub) PC Board (on top) and

the CPU (or Main) PC Board (on bottom)

6-3-7-2

The Mother PC Board (see Figure 6-7) contains fifteen connectors (CN1-13 in the back, J1-2 in the

front). CN1 to CN13 connect all the electronics, including all sensors, to the Main Board Assembly. The CPU and I/O PC boards connect onto the Mother board on two additional header connectors: J1 and J2.Review schematic Figure 1 in Chapter Twelve while reading the following.

6-3-7-1

The Card Cage Assembly (see Figure 6-6) is made of a Mother PC Board (item 3), a program card

(item 6) and a CPU - I/O PC Board Unit (item 5). The CPU - I/O PC Board Assembly is two pc boards 搒andwiched?together:

the I/O (or Sub) PC Board (on top) and

the CPU (or Main) PC Board (on bottom)

6-3-7-2

The Mother PC Board (see Figure 6-7) contains fifteen connectors (CN1-13 in the back, J1-2 in the

6-3-7-3

The I/O PC board (see Figure 6-8) is a surface mounted pcb device that contains a DC-DC

converter to convert the power supply 24 VDC into 5 VDC. It also uses latches and buffers to store the out-puts of the ORG1-4 origin sensors and PH1-9 rack and tube sensors.

6-3-7-4

The CPU PC Board (see Figure 6- 9) directs Rack Sample Handler activities. A 2 meg (256K byte)

UV EPROM Program Card plugs into the front of this board (Figure 6-6 item 6). The microprocessor on this board is an H8/3003 HD6413003F16 device (U4). Potentiometer VR1 adjusts display brightness.

6-3-7-5

Together the CPU and I/O PC Boards control all Rack Sample Handler activity under the

supervision of the Clinitek Atlas operating system software.

Figure 6-7 The Mother PC Board

6-8

Figure 6-8 The CPU PC Board Figure 6-9 The I/O PC Board

6-9

6-3-8 The Driver Assembly



See schematic Figures 1 and 11 on pages 12.3 and 12.23 while reading the following paragraphs.

6-3-8-1

The Driver Assembly (also called the 4-Axis Driver, see Figure 6-10) contains the driver

components needed to control the four DC stepper motors (PM1 to 4) used in this instrument. See Table 6-2 for a list and description of these four motors. U1 to U4 are TA8415P motor control chips which generate control and drive signals for the power stage of the four phase DC step-per motors.

6-3-8-2

The two CK (clock) inputs receive CW (clockwise) and CCW (counter-clock-wise) control signals

that come from the Main PC Board and determine the direction of motor movement; the four phase out-puts each control one phase of the motor. U5 to U8 are NP-7024M Dual Full Bridge Driver chips. Each OUT line on U5 to U8 enables one phase of the motor. POWER DOWN signals from the Main PC Board at connector FCN1 pull down the current for each motor. Potentiometers VR1 to VR4 are used to set the reference voltages or motor current.

Figure 6-10 The Driver Assembly

6-10

TABLE 6-1 SENSOR STATUS

SENSOR TYPE ACTIVE STATUS when ACTIVE

ORG1 (In Feed Home Sensor)

EE-SX153 on (5 VDC) PM1 (In Feed) Motor is at home

ORG2 (Timing Belt or Cross Feed Home Sensor)

EE-SX671A on (5 VDC) PM2 (Crossfeed) Motor home

ORG3 (Out Feed Home Sensor)

EE-SX153 on (5 VDC) PM3 (Out Feed) Motor at home

ORG4 (Return Feed Home Sensor)

EE-SX153 on (5 VDC) PM4 (Return Feed) at home

PH1 (Return/In Feed Sensor)

EE-SPY412 on (24 VDC) Tube Rack is at far right against the front

wall.

PH2 (In Feed/Cross Feed Sensor)

EE-SPY412 on (24 VDC) Tube Rack is at far Infeed position against

back wall.

PH3 (Sampling Position Sensor)

PM2-LL10 on (24 VDC) Tube Rack is aligned with Pipette for

Sampling

PH4 (Tube Sensor)

E3S-R61 on (24 VDC) Tube is in front of tube sensor.

PH5 (Cross Feed/Out Feed Sensor)

EE-SPY412 on (24 VDC) Tube Rack is at far left of the Crossfeed

section at back wall.

PH6 (Outfeed/Return Sensor)

EE-SPY411 on (24 VDC) Tube Rack is at far left position

(Returnfeed) against front wall.

PH7 (End of Tray Marker Sensor)

GXL-15F on (24 VDC) Tube Rack at Crossfeed section contains

end of tray marker.

PH9 (Stat Tube Sensor)

PM2-LL10 on (24 VDC) Tube was detected in the STAT Tube

Holder.

6-11

TABLE 6-2 Rack Sample Handler Motors

MOTOR #

POSITION NAME STYLE PM1 In Feed Motor PF55-48K1 1/5 PM2 Cross Feed Motor PF42T-48071G 1/15 PM3 Out Feed Motor PF55-48K1 1/5 PM4 Return Feed Motor PF42T-48071G 1/10

6-3-9 The Stat Tube Holder

6-3-9-1

The Stat Tube Holder (see Figure 6-11) is used to run stat tubes, or patient samples requiring

immediate results. A tube holder (item 19) is pulled out by hand using a handle (18), the stat tube inserted into it and then the holder is pushed back into the system. The holder travels on steel shafts (15) and a steel shutter (17) which 搑olls?and 搖nrolls?with holder movement. When 24VDC solenoid SOL1 (11) is activated, its plunger goes into a hole at the base of the tube holder, pre-venting the holder and STAT tube from being retracted during a STAT run or SG Cleaning. PH9 (1) is a Photomicron PM2- LL10 24VDC photodetector that detects the presence of the STAT tube holder when the holder is pushed all the way into the unit.

Figure 6-11 The State Tube Holder

6-12

6-3-10 The Barcode Reader

6-3-10-1

The Barcode Reader is a BCR5242-STA BL-185 5 VDC LED device. It is used to read barcode

printed labels mounted on sample tubes in the racks. Two-way RS-232D serial communication with the Main PC Board is done using connector CN4 on the Mother Board to connect the two assemblies. One, two or no bar code readers may be used on this system. If one reader is selected, it is mounted next to the PH4 Tube Sensor into connector CN103.

6-3-10-2

TxD (transmitted serial data from bar code reader), RxD (received data into bar code reader), RTS

(request to send data from the bar code reader), CTS (clear to send data to the Main Board), Vcc (5 VDC supplied to reader) SG (signal ground) and Inzone (data carrier detect, or 揵arcode reader is present? signals are all supported.

6-3-11 Instrument Sensors

6-3-11-1

The twelve sensors detect:

a tube in a sample position (Omron E3S R61 Photoelectric Switch, PH4),

the location of a tube rack in operation ((Photomicron sensor EE-SPY 412 (PH1, 2 and 5),

EE-SPY 411 (PH6) and PM2-LL10 (PH3)),

the home position of a motor (Photomicron sensor EE-SX153, ORG1, ORG3 and ORG4)

the home position on the Timing Belt (Photomicron sensor EE-SX671A ORG2)

a metal Stop Marker in a rack (Proximity sensor GXL-15F, PH7)

and a STAT tube (Photomicron sensor PM2-LL10, PH9)

 Table 6-1 on page 6.12 describes each sensor. See Figure 6-12 to locate sensors.  To test and adjust all of the sensors, see pages 7.8, 8.5 and 8.7

Figure 6-12 Locating Instrument Sensors

6-13

+ 155 hidden pages

Bayer HealthCare Clinitek Atlas, 5023, 5258 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual