BioSystems A-15 Service manual

Name: BioSystems A-15
Brand: BioSystems
SKU: 7454264
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A15

SERVICE MANUAL

ENGLISH

SERVICE MANUAL

English

TESE00005-11-ING

July - 2009

TABLE OF CONTENTS
1. INTRODUCTION.................................................................................	8
1.1. GENERAL DESCRIPTION OF THE ANALYZER..............................................................	8
1.1.1. Operating arm........................................................................................................................................	9
1.1.2. Dispensing system................................................................................................................................	9
1.1.3. Reactions rotor and reading...............................................................................................................	10
1.1.4. Electronic system................................................................................................................................	11
1.1.5. Application program............................................................................................................................	11
1.2. FUNCTIONING OF THE ANALYSER..............................................................................	11
1.3. TRANSPORT AND RESHIPMENT OF THE ANALYZER................................................	12
2. MECHANICAL ELEMENTS.............................................................	14
2.1. Instrument breakdown...................................................................................................	14
2.2. Description of the mechanical elements......................................................................	14
2.2.1. Operating arm......................................................................................................................................	14
2.2.1.1. X Guide.........................................................................................................................................	15
2.2.1.2. X Carriage.....................................................................................................................................	16
2.2.1.3. Y Carriage.....................................................................................................................................	16
2.2.1.4. Needle unit..................................................................................................................................	18
2.2.2. Dispensing system..............................................................................................................................	19
2.2.2.1. Thermostated probe....................................................................................................................	19
2.2.2.2. Dispensing pump.........................................................................................................................	19
2.2.2.3. Tubes and containers..................................................................................................................	21
2.2.2.4. Container level control sensors.................................................................................................	22
2.2.2.5. Racks tray with integrated washing station..............................................................................	23
2.2.2.6. Washing pumps...........................................................................................................................	23
2.2.3. Reaction rotor with integrated optical system..................................................................................	24
2.2.3.1. Thermostated rotor and photometric system...........................................................................	24
2.2.3.2. Lighting system...........................................................................................................................	26
2.2.4. Electronics cover................................................................................................................................	27
2.2.5. Main cover hinges................................................................................................................................	28
2.2.6. Base......................................................................................................................................................	29
2.2.7. Casings ................................................................................................................................................	30
3. Electronic system...........................................................................	31
3.1 CPU Board (CIIM00026)...................................................................................................	31
3.2 Power Supply Board (CIIM00015)...................................................................................	36
3.3 Needle Board (CIIM00017)...............................................................................................	38
3.4 Photometry Board (CIIM00027).......................................................................................	40
3.5 XYZ Interconnection Board (CIIM00018)........................................................................	41
3.6 Communications Board (CIIM00036)............................................................................	42
3.7 Rotor interconnection board (CIIM00029).....................................................................	43
3.9 Pump interconnection board (CIIM00028).....................................................................	45
3.10 Component relation ......................................................................................................	47
3.11 Auxiliar channel information.........................................................................................	47
3.12 Interconnection between boards..................................................................................	51
3.13 Schematic liquid circuit.................................................................................................	57
4. SERVICE PROGRAM.......................................................................	58
4.1 Initialising the analyser...................................................................................................	58
4.2. ADJUSTMENTS ..............................................................................................................	60
4.2.1. Adjustment of the needle thermostatation system..........................................................................	60
4.2.2. Adjustment of the rotor thermostation system.................................................................................	61
4.2.3. Adjustment of the positioning of the operating arm........................................................................	62
4.2.3.1 Adjustment of X, Y and Z position for reagent and pediatric racks..............................................	62

Service manual
4.2.4. Adjustment of the positioning of the rotor........................................................................................	65
4.2.4.1. Centering of the rotor with regard to the dispensing point..........................................................	65
4.2.4.2. Centering of the rotor with regard to the optical system..............................................................	65
4.2.5 . Adjustment of the positioning of the filter wheel.............................................................................	66
4.2.6. Adjustment of the level control scales..............................................................................................	67
4.2.7. Adjustment of the level detection sensitivity....................................................................................	68
4.3. TESTS..............................................................................................................................	68
4.3.1. Motor tests............................................................................................................................................	68
4.3.1.1. Initialization test................................................................................................................................	69
4.3.1.2. Movement test...................................................................................................................................	69
4.3.1.3. Loss step test....................................................................................................................................	70
4.3.1.4. Stress mode test...............................................................................................................................	70
4.3.1.5. Z axis security systems test............................................................................................................	70
4.3.1.6 Maximum Z verification test..............................................................................................................	71
4.3.2. Diaphragm pumps and electrovalves test.........................................................................................	71
4.3.2.1. Functioning test................................................................................................................................	72
4.3.2.2. Stress mode test...............................................................................................................................	72
4.3.3. Needle self-centering system test......................................................................................................	72
4.3.4. Needle level detection system test....................................................................................................	72
4.3.5. Needle thermostatation system test..................................................................................................	73
4.3.6. Needle rotor thermostatation system test.........................................................................................	74
4.3.7. Photometry tests..................................................................................................................................	74
4.3.7.1. Base line and integration times.......................................................................................................	74
4.3.7.2. Darkness counts...............................................................................................................................	76
4.3.7.3. Repeatability without moving the filter wheel................................................................................	76
4.3.7.4. Stability..............................................................................................................................................	77
4.3.7.5. Repeatability moving filter wheel....................................................................................................	77
4.3.7.6. Absorbance measurement...............................................................................................................	78
4.3.7.7. Reactions rotor check......................................................................................................................	78
4.3.8. Level control scales test.....................................................................................................................	79
4.3.9. Covers detection test..........................................................................................................................	79
4.3.10. PC-Analyzer communications channel test....................................................................................	80
4.3.11. Global stress mode of the analyzer..................................................................................................	80
4.3.12. Photometry tool.................................................................................................................................	81
4.4. UTILITIES ........................................................................................................................	82
4.4.1. Disassembly of the dispensing needle..............................................................................................	82
4.4.2. Fluid system supply............................................................................................................................	83
4.4.3. Cleaning of the dispensing system....................................................................................................	84
4.4.4. Changing the lamp...............................................................................................................................	84
4.4.5. Configuration of the filter wheel.........................................................................................................	85
4.4.6. Demonstration mode...........................................................................................................................	85
4.4.7 Read/load adjustments and cycles.....................................................................................................	86
4.4.8 Change the rotor type...........................................................................................................................	87
4.5. REGISTER........................................................................................................................	88
4.5.1. Introducing the analyzer serial number.............................................................................................	88
4.5.2. Service Reports....................................................................................................................................	89
4.5.3. Language change................................................................................................................................	89
4.5.4. Users.....................................................................................................................................................	90
4.6. MONITOR ........................................................................................................................	90
4.7 User’s program ...............................................................................................................	91
4.7.1 Configuration of the level of access to the analyser ........................................................................	91
4.7.2 Reagent Consumption .........................................................................................................................	92
5. MAINTENANCE AND CLEANING...................................................	94
5.1. MAINTENANCE OPERATIONS.......................................................................................	94
5.1.1. Housings and covers...........................................................................................................................	94
5.1.1.1. Removing the needle unit casing...............................................................................................	94
5.1.1.2. Removing the front housing.......................................................................................................	94
5.1.1.3. Removing the main cover...........................................................................................................	95

5.1.1.4. Removing the upper casing........................................................................................................	96
5.1.1.5. Removing the spring protector..................................................................................................	98
5.1.2. Operating arm......................................................................................................................................	98
5.1.2.1. Fully removing the operating arm..............................................................................................	98
5.1.2.2. Changing the arm hose ..............................................................................................................	99
5.1.2.3. Changing the X motor...............................................................................................................	100
5.1.2.4. Changing the Y motor...............................................................................................................	102
5.1.2.5. Changing the Z motor...............................................................................................................	102
5.1.2.6. Changing the Y motor belt........................................................................................................	103
5.1.2.7. Changing the spring..................................................................................................................	103
5.1.3. Dispensing system............................................................................................................................	104
5.1.3.1. Changing the thermostated pipe. ............................................................................................	104
5.1.3.2. Changing the dispensing pump seal.......................................................................................	105
5.1.3.3. Changing the dispensing pump motor....................................................................................	106
5.1.3.4. Changing the dispensing electrovalve....................................................................................	107
5.1.3.5. Changing the container tube unit............................................................................................	107
5.1.3.6. Changing the distilled water container filters.........................................................................	107
5.1.4. Reactions rotor and reading.............................................................................................................	108
5.1.4.1. Changing the rotor temperature probe....................................................................................	108
5.1.4.2. Fully removing the rotor...........................................................................................................	109
5.1.4.3. Changing the rotor Peltier cells...............................................................................................	109
5.1.4.4. Changing the rotor cover detector...........................................................................................	110
5.1.4.5. Changing the rotor start photosensor.....................................................................................	110
5.1.4.6. Changing the rotor motor..........................................................................................................	111
5.1.4.8. Changing the lamp....................................................................................................................	112
5.1.4.9. Changing an optical filter..........................................................................................................	113
5.1.4.10. Configuration of the filter wheel.............................................................................................	113
5.1.4.11. Changing the filter wheel start photosensor.........................................................................	113
5.1.4.12. Changing the filter wheel motor.............................................................................................	114
5.1.5. Electronic Systems............................................................................................................................	114
5.1.5.1. Changing the X, Y and encoder start photosensor................................................................	114
5.1.5.2. Changing the microprocessor board.......................................................................................	115
5.1.5.3. Changing the power supply board...........................................................................................	115
5.1.5.4. Changing the main power supply source...............................................................................	116
5.1.5.5. Changing the photometric system board................................................................................	116
5.1.5.6. Changing the front indicator....................................................................................................	117
5.1.5.7. Changing the firmware program..............................................................................................	118
5.2. RECOMMENDED PREVENTIVE MAINTENANCE........................................................	118
5.3. CARE AND CLEANING.................................................................................................	119
5.3.1. General care of the analyzer.............................................................................................................	119
5.3.2. Cleaning the optical system.............................................................................................................	119
5.3.3. Cleaning the dispensing system......................................................................................................	120
5.3.4. General cleaning of the interior of the apparatus...........................................................................	120
A I. TECHNICAL SPECIFICATIONS..................................................	121
A II. ADJUSTMENT MARGINS TABLES...........................................	125
A III. LIST OF CONSUMABLES, ACCESSORIES AND SPARES ...	126
A IV. LIST OF REQUIRED TOOLS....................................................	128
A V. SOFTWARE VERSIONS.............................................................	128

Service manual

1. INTRODUCTION

The A15 analyzer is an automatic random access analyser specially designed for performing biochemical and turbidimetric clinical analyses. The instrument is controlled on-line in real time from an external dedicated PC.

In each of the elements of the A15 analyser, BioSystems has used leading edge technology to obtain optimum analytical performance, as well as taking into account economy, robustness, easy use and maintenance. A three-axis Cartesian operating arm prepares the reactions. Dispensing is performed by means of a pump with a ceramic piston via a detachable thermostated needle. A washing station guarantees that the needle is kept perfectly clean throughout the process. The reactions take place in a thermostated rotor in which absorbance readings are taken directly by means of an integrated optical system.

This manual contains the information required for learning about, maintaining and repairing the A15 automatic analyzer. It should be used by the Technical Service as a learning and consultation document for the maintenance and repair of the instrument. Chapter 2 describes the different mechanical elements that form the analyzer together with their functionality, and chapter 3 describes the electronic system. Chapter 4 describes the Service Program. All the adjustments and checks of the analyzer are carried out through this program, which is independent from the application program (User Program). The separation of both programs enable it to be maintained separately and the extensions and improvements of one do not affect the other. The user does not have the service program. The Technical Service must install it on the user’s computer in order to carry out the service requirements. Once said tasks have been carried out, the Technical Service must uninstall the program. Chapter 5 offers instructions for the different maintenance, repair and cleaning operations that can be carried out by the Technical Service. The annexes contain a summary of the technical specifications of the analyzer, the adjustment margin tables, the lists of accessories and spares, a list of software versions and their compatibility and a software troubleshooting guide.

1.1. GENERAL DESCRIPTION OF THE ANALYZER

The A15 analyser is made up of three basic elements: the operating arm, the dispensing system and the reading and reactions rotor. The electronic system of the instrument controls said elements and communicates with the external computer containing the application program. Through this program, the user can control all the operations of the analyzer.

1.1.1. Operating arm

This is a three-axis XYZ Cartesian mechanism. The X and Y axes move the dispensing needle over the analyser horizontally and the Z axis moves it vertically. It is operated by three step-by-step motors. In each 24-second preparation cycle, the operating arm performs the following actions: first of all, it sucks in the reagent from the corresponding bottle. Next, the needle is washed externally in the washing station and sucks in the sample from the corresponding tube. It is washed externally again and dispenses the sample and the reagent into the reactions rotor. Finally, it is exhaustively washed internally and externally before proceeding with the next preparation. The arm has a system for controlling vertical movement to detect whether or not the needle has collided into anything on descending. If a collision occurs, as may be the case if, for example, a lid has been left on a bottle of reagent, the arm automatically restarts, verifies the straightness of the needle and continues working issuing the corresponding alert to the user.

A vertical axis retention system prevents the needle from falling in the case of a power cut, avoiding injury from the needle to the user or the needle being bent by an attempt to move the arm manually. The operating arm only makes the preparations if the general cover of the analyser is closed. If the cover is raised while it is functioning, the arm automatically aborts the task in progress and returns to its parked position to avoid injury to the user.

1.1.2. Dispensing system

This system consists of a thermostated needle, supported and displaced by an operating arm and connected to a dispensing pump. The needle is detachable to enable cleaning and replacement. The analyser has capacity level detection to control the level of the bottles and tubes and prevent the needle from penetrating too far into the corresponding liquids, thus minimising contamination. An automatic adjustment system informs the user if the needle is not mounted or if it is too bent. The needle has a sophisticated Peltier thermostatation system, with PID control, capable of thermostating the preparations at approximately 37º in less than 15 seconds. Dispensing is carried out by means of a low maintenance ceramic piston pump driven by a step-by-step motor. It is capable of dispensing between 3 and 1250 ml. The exterior of the needle is kept constantly clean by a wash station included in the base. A membrane pump transports the waste to the corresponding container.

The A15 analyser has a tray with 4 free positions for racks of reagents or samples. Each reagents rack can carry up to 10 reagents in 20 ml or 50 ml bottles. Each samples rack can contain up to 24 tubes of samples. The samples can be patients, calibrators or controls. The analyser can be configured to work with 13 mm or 15 mm diameter tubes of samples with a length of up to 100 mm or with paediatric wells. Any possible configuration of racks can be mounted from 1 rack of reagents (10 reagents) and 3 racks of samples (72 samples) to 3 racks of reagents (30 reagents) and 1 rack of samples (24 samples).

On the left of the analyser are the waste and distilled water containers. The analyser constantly controls the level of these containers and issues the appropriate alerts if the distilled water is nearly empty or if the waste container is full.

Service manual

1.1.3. Reactions rotor and reading

The preparations are dispensed in an optical quality methacrylate reactions rotor thermostated at 37ºC. The optical absorbance readings are taken directly on this rotor. Each reaction can be read for 10 minutes. The readings are taken as they are programmed in each measurement procedure. The reaction wells have been designed to enable the mixture of the sample and the reagent during the dispensing. Each rotor has 120 reaction wells. The length of the light path is 6 mm. The minimum volume required to take the optical reading is 200 uL. The wells have a maximum useful capacity of 800 uL. When the reactions rotor is completely full, the user must change it for one that is empty, clean and dry. The reactions rotors can be reused up to 5 times if they are carefully cleaned immediately after use. The Cleaning the semi-disposable reactions rotor section in the Installation and maintenance manual describes how to clean the rotors. The user has a test in the computer programme, which he or she may use to check the condition of the rotor. The rotor is driven by a step-by-step motor with a transmission. A Peltier system with PID control thermostates the rotor at 37ºC.

An optical system integrated in the rotor takes the readings directly on the reaction wells. The light source is a 10 W halogen lamp. The detector is a silicon photodiode. The wavelength is selected by a drum with 9 positions available for optic filters. The filters are easily changed by the user from the exterior of the analyser, without the need for disassembling the filter drum.Astep-by-step motor positions the drum. The optical system is capable of taking 1.25 readings per second, with or without a filter change in between. The light beam from the lamp passes through a compensated interferential filter to select the desired wavelength. It then passes through the rotor well and finally reaches the photodiode, where the light signal is turned into an electric signal. A sophisticated analogical digital integrator-converter system converts the electric signal into a digital value with which the analyser obtains the absorbance values. The optical system continues to work when the general cover of the analyser is open, whereby the analyser can continue to take readings while the user handles, for example, the sample tubes or the reagent bottles. The rotor cover must be in placefor the optical system to work correctly.

A detector tells the analyser of the presence of the cover. The analyser aborts the readings if the user removes the rotor cover while the optical system is taking photometric measurements. If the rotor is not covered, the analyser informs the user so that he or she places the rotor cover when it sends samples to be analyzed.

1.1.4. Electronic system

The described elements are controlled by an electronic system based on a microprocessor. The microprocessor has two external communication channels to connect the instrument to the computer containing the application program. The electronic system is made up of the following independent boards:

-Microprocessor board

-Photometric system board

-Needle conditioning board

-Fluid system interconnection board

-Arm interconnection board

-Rotor interconnection board

-Power supply board

1.1.5. Application program

The application program makes it possible to control all the operations of the analyzer. From this program, the user can monitor the state of the analyzer and the work session, program parameters, e.g. technique parameters, prepare the work session, prepare results reports, configure different analyzer options, activate various test utilities, prepare and maintain the instrument and carry out internal quality control processes. The purpose of this manual is not to explain the functioning of the user program. For detailed information to this regard, please consult the User Manual included with the analyzer.

1.2. FUNCTIONING OF THE ANALYSER

The A15 analyser is an automatic random access analyser specially designed for performing biochemical and turbidimetric clinical analyses. The analyser performs patient-by-patient analyses and enables the continual introduction of samples. The analyser is controlled from a dedicated PC that is permanently communicated to the instrument. The programme, installed on the computer, keeps the user constantly informed of the status of the analyser and the progress of the analyses. As results are obtained, the computer shows them to the user immediately.

When a Work Session is begun, the analyser proposes performing the blanks, calibrators and controls programmed

Service manual

for the measurement procedures it is to carry out. The user may choose between performing the blanks and the calibrators or not. If they are not performed, the analyser uses the last available memorised data. The controls can also be activated or not. During a session, while the analyser is working, the user can introduce new normal or urgent samples to be analyzed. Each time a new sample is added, the analyser automatically proposes the possible new blanks, calibrators or controls to be performed. A work session can remain open for one or more days. When a session is closed and another new session is opened (Reset Session), the analyser again proposes performing the blanks, calibrators and controls. It is recommended that the session is reset each working day.

The analyser determines the concentrations of the analytes based on optical absorbance measurements. To measure the concentration of a certain analyte in a sample, the analyser uses a pipette to take a specific volume of the sample and the corresponding reagent, quickly thermostates them in the needle itself and dispenses them into the reactions rotor. The very dispensing speed together with the geometry of the reaction well causes the mixture to be shaken and the chemical reaction begins. In the bireagent modes, the reaction begins when the analyser later dispenses a second reagent in the same reaction well. The reactions can be biochemical or turbidimetric. In both cases, the reaction or the chain of reactions produced generate substances that attenuate certain wavelengths, either by absorption or by dispersion. Comparing the light intensity of a certain wavelength that crosses a well when there is a reaction and when there is not a reaction can determine the concentration of the corresponding analyte. This comparison is quantified with the physical magnitude called absorbance. In some cases, the concentration is a direct function of the absorbance, and in other cases, it is a function of the variation of the absorbance over time, depending on the analysis mode.

1.3. TRANSPORT AND RESHIPMENT OF THE ANALYZER

If the analyser is to be reshipped or moved using a transport vehicle, it is important to block the operating arm and use the original packaging to ensure that the apparatus is not damaged. To package the instrument, we recommend you follow the following instructions: (on the unpackaging instructions sheet)

Service manual

2. MECHANICAL ELEMENTS

2.1. Instrument breakdown

The physical structure of the analyzer can be broken down as follows:

-Operating arm -X guide -Y guide

-X carriage -Y carriage -Needle unit -Dispensing system

-Thermostated probe -Dispensing pump -Tubes and containers

-Container level control sensors

-Racks tray with integrated washing station -Waste pump

-Reactions rotor with integrated optical system

-Thermostated rotor and photometric system. This contains the electronic photometric system board -Lighting system

-Electronics box.This houses the electronic boards of the microprocessor, the power supply and the front indicator -Main cover hinges

-Base -Housings

-Upper casing -Front housing -Arm casing -Main cover

The following is a brief description of each of the mechanical elements that make up the analyzer.

2.2. Description of the mechanical elements

2.2.1. Operating arm

This mechanism positions the dispensing needle appropriately during the preparation of the analyses. An encoder checks the vertical movement of the needle and a spring automatically stops it from falling in the case of a power cut. The dispensing pipe and the electrical hoses of the arm pass through the front casing

(1)X GUIDE

(2)X CARRIAGE

(3)Y CARRIAGE

(4)Y GUIDE

(5)NEEDLE UNIT

(6)CONTROL AND DISPENSING PIPE HOSE

The needle unit (5) supports the thermostated needle and can move on the Y carriage (3), which can move on the Y axes (4). The Y axes are supported by the X carriage, which moves on the X axes (1). In this way, the needle can be moved in the three Cartesian directions of X, Y and Z. The hose (6) houses the Teflon dispensing tube and all the electrical hoses of the arm.

1	2	6
		6
		5

2.2.1.1. X Guide.

(1)UPPER X TOOTHED AXIS

(2)LOWER X AXIS

(3)X START PHOTOSENSOR

(4)BEARING X AXIS

(5)X MOTOR

(6)X START PHOTOSENSOR TAB

(7)AXIS SUPPORTS

This consists of two supports (7) that hold the steel axes (1 and 2) on which the X carriage moves. The photosensor

(3) indicates the start position of the X carriage movement. The motor X (5) is moved by a rack (2). The X carriage is supported by the second axis (2) by means of a bearing (4).

Service manual

2.2.1.2. X Carriage

(1)X CARRIAGE BODY

(2)UPPER X AXIS - RACK

(3)LOWER X AXIS

(4)X MOTOR

(5)Z MOTOR

(6)ENCODER

(7)XYZ INTERCONNECTION PCB

(8)BEARINGS

The X carriage body (1) moves along the two axes (2, 3). The upper axis (2) acts as a rack. The X motor (4) is fitted with a pinion that moves the carriage. The X carriage also supports the interconnection PCB (7) and the Z motor (5). To enable the movement, it uses linear bearings (8).

2.2.1.3. Y Carriage

(1)Y CARRIAGE BODY

(2)Y GUIDE AXES

(3)Y MOTOR

(4)BELT

(5)BELT RETURN PULLEY

(6)START PHOTOSENSOR

(7)START TAB

(8)NEEDLE UNIT

(9)BEARINGS

4	1	2

The body of the Y carriage (1) moves along the two axes (2) on linear bearings (9). The said axes are supported by the X carriage. The movement is made by the Y motor (3) by the belt (4) and the return pulley (5). The start of the movement is controlled by the tab (7) and the start photosensor (6) located on the X carriage (10). The body of the Y carriage (1) also supports the needle unit.

3 2 1

Service manual

2.2.1.4. Needle unit

(1)Z GUIDE

(2)RACK

(3)Z MOTOR

(4)ENCODER

(5)TRANSMISSION AXIS

(6)RETURN SPRING

(7)THERMOSTATATION PIPE

(8)CONTROL PCB

(9)Y CARRIAGE

The Z guide (1) supports the thermostatation pipe (7) and the control PCB (8) where the heating elements are located, together with the thermistor signal amplifier and level detection and the Z axis start photosensor. The rack (2) supports the Z guide (1) which crosses the Y carriage (9) on two bearings. The Z motor (3) is fastened to the X carriage (10) and is moved by a transmission axis (5) fitted with a pinion that acts on the rack. The return spring (6) acts on the transmission axis and prevents the needle from falling in the event of a power cut: The encoder (4), which detects any obstruction to the movement of the thermostated needle (9) is located on the same axis and on the part of the motor.

2.2.2. Dispensing system

The dispensing pump dispenses the preparations through the thermostated needle. The needle is washed internally and externally at the washing station. The racks tray makes it possible to position the samples to be analyzed and the required reagents. The level of the distilled water and waste containers is controlled by the analyzer by capacity.

2.2.2.1. Thermostated probe

(1)THERMOSTATATION PIPE

(2)PCB

(3)TEFLON DISPENSING TUBE

(4)ELECTRICAL CONTROL HOSE

(5)FASTENING NUT

(6)REMOVABLE NEEDLE

The thermostatation pipe (1) preheats the reagent during dispensing. It is fitted with two connectors at each end. The removable needle (6) is connected to one and the Teflon dispensing pipe (3) is connected to the other, fixed by the fastening connector (5). The PCB (2) contains the thermostatation elements, the thermistor and associated circuits. The various thermistor and element action signals (3) pass through the hose (4).

1	3
2	4
	5

2.2.2.2. Dispensing pump

(1)BODY

(2)FLUIDIC CHAMBER

(3)SEAL

(4)SEAL SUPPORT

(5)CERAMIC PISTON

(6)PISTON SUPPORT

(7)START DETECTION BARRIER

(8)AXIAL BEARING

(9)ENDLESS SCREW

(10)MOTOR

(11)START PHOTOSENSOR

(12)PUMP NUT

(13)PUMP-ELECTROVALVE TEFLON TUBE

Service manual

(14)3-CHANNEL ELECTROVALVE

(15)ELECTROVALVE NUT

The plastic body (1) joins the different elements that make up the pump. The transparent methacrylate fluidic chamber

(2) makes it possible to observe the flow of liquid through the pump. The support (4) fastens the seal (3). The ceramic piston (5) dispenses by displacing a certain volume of liquid in the chamber. The piston is adhered to the support (6), which moves alternatively by the rotation of the endless screw (9) fixed to the motor axle (10). The barrier (7), joined to the piston support, obstructs the photosensor (11) when the piston reaches its start position. The axial bearing

(8) prevents any longitudinal displacement of the motor axle for greater precision in the dispensing operation. The 3-channel electrovalve (14) makes it possible to connect the pump chamber to the distilled water container or to the thermostated needle. The Teflon tube (13) connects the chamber to the electrovalve. It is connected to each of these elements by the nuts (13) and (15).

2.2.2.3. Tubes and containers

(1)WATER CONTAINER

(2)WATER CONTAINER LID

(3)WATER CONTAINER TUBES FASTENING

(4)WATER CONTAINER TEFLON TUBE

(5)TEFLON TUBE FILTER

(6)ELECTROVALVE NUT

(7)SYSTEM LIQUID LEVEL SENSOR CABLE

(8)LEVEL SENSOR

(9)WASTE CONTAINER

(10)WASTE CONTAINER LID

(11)FAST COUPLING NUT

(12)WASTE CONTAINER PVC TUBE

(13)GROMMET

(14)WASTE LEVEL SENSOR CABLE

The Teflon tube (4) connects the distilled water container (1) to the electrovalve of the dispensing pump. This tube is installed at the end of the filter container (5). It is connected to the electrovalve of the dispensing pump through the nut

(6) The Teflon pipe passes through the rubber piece (3) in the lid (2) of the container, which fastens them in position.

The PVC tube (12) connects the waste extraction membrane pump to the waste container (9). The waste container lid (19) has a fast coupling nut (11) with automatic drip-proof closing when disconnected. All the tubes pass into the interior of the analyzer through the rubber grommet (13).

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2.2.2.4. Container level control sensors.

(1)LEVEL DETECTION SHEETING

(2)SIGNAL CONNECTOR

The analyzer has a capacitance system to control the level of the distilled water and waste containers. For this, there is an emission plane (1) under the bottles where a signal is injected through the connector (2). The base supporting the bottles is above this. They have 2 rods that collect the signal and indicate the presence or absence of liquid.

2.2.2.5. Racks tray with integrated washing station.

(1)TRAY

(2)WASHING STATION

(3)LEVEL DETECTION SHEETING

(4)WASTE PVC PIPE

The plastic injection tray (1) is part of the base of the instrument. The washing station (2) is installed on the right. The plate (3) detects the level of the dispensing needle. The PVC tube (4) connects the washing station drain to the waste extraction pump.

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2.2.2.6. Washing pumps

(1)MEMBRANE WASTE PUMP

(2)WASHING STATION-PUMP PVC TUBE

(3)WASTE BOTTLE-PUMP PVC TUBE

(4)SAFETY FLANGES

The needle washing system has a waste extraction pump (1). This is connected to the washing station by the PVC (2).

The pump expels the waste through the pipe (4) into the waste bottle. The pipes are fastened by two safety flanges.

Service manual

2.2.3. Reaction rotor with integrated optical system.

The reactions rotor is thermostated at 37ºC. The optical system, made up of a lighting system and a photometric system takes the readings directly on the rotor reaction wells. The lighting system has a halogen lamp, a filter drum for the selection of the wavelength form the appropriate beam of light. The photometric system contains a silicon photodiode and the corresponding electronics to obtain a digital value that is proportionate to the light intensity received.

2.2.3.1. Thermostated rotor and photometric system

(1)METHACRYLATE ROTOR

(2)HEATING CANAL

(3)THERMAL INSULATION OF THE HEATING CANAL

(4)PELTIER CELLS

(5)HEATSINKS

(6)FANS

(7)TEMPERATURE PROBE

(8)ROTOR CENTRING UNIT

(9)ROTOR FASTENING SCREW

(10)HOME ROTOR PHOTODETECTOR

(11)BEARINGS

(12)PINION

(13)ROTOR MOTOR

(14)ROTOR CROWN

(15)MOTOR SEPARATOR

(16)PHOTOMETRIC SYSTEM BOARD

(17)ELECTRONIC BOARD SUPPORT COVER

(18)OPTICS COVER

(19)PHOTODIODE GAP CENTRING UNIT

(20)ROTOR GAP

(21)COVER DETECTOR

(22)ROTOR AXLE

The dispensing system dispenses the reagents and the samples in the methacrylate rotor (1). The optical system measures the absorbance directly on the rotor wells. The aluminium heating canal (2) surrounds the rotor and keeps it at 37ºC. The canal is thermally insulated from the exterior by means of the moulded expanded polystyrene insulation (3). The Peltier cells (4), with their respective radiators (5) and fans, act on the canal to control the temperature. The sensor used to control the temperature is the probe (7). The methacrylate rotor is fastened to its centring unit

(8) by means of the screw (9). The centring unit is fixed to the heating canal through the axis (22), which is fitted on bearings (11). The barrier obstructing the photosensor (10) when the rotor reaches its start position forms part of the centring unit (8). The centring unit also acts as gearing. The pinion (12), fixed to the motor (13), acts through the crown (14), which also acts as a centring unit. The separator (15) does not allow the motor temperature to reach the heating canal. The electronic board of the photometric system (16) is housed in a cavity in the heating canal. The upper cover of this cavity (17) supports the electronic board. The seal (18) keeps the cavity hermetically closed in the case of possible liquid spillage. The housing of the filter drum is closed at the bottom by the cover (18). The part (19) centres the photodiode with regard to the lighting system and also acts as a grill to prevent the incidence of unwanted light. The grill (20) limits the light hitting the reactions rotor. The detector (21) tells the analyzer if the rotor cover is in position or not.

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2.2.3.2. Lighting system

(1)BODY

(2)LAMP HOLDER

(3)HALOGEN LAMP

(4)LAMP HOLDER FASTENING

(5)FILTER WHEEL

(6)FILTER HOLDER

(7)FILTER HOLDER NUT

(8)MATCHED INTERFERENTIAL FILTERS

(9)WHEEL AXLE

(10)HOME PHOTODETECTOR

(11)FILTER MOTOR

(12)DIAPHRAGM

(13)FILTER WHEEL WINDOW COVER

(14)FILTER WHEEL

(15)GAP

The aluminium body (1) is the structure that supports all the elements of the lighting system. The lamp holder (2), fastened to the body by means of the fastening system (4), keeps the halogen lamp (3) in position without the need for adjustments. The filter drum (5) has 10 positions for optical filters. Position 0 must always be taken up by a covered filter. The other positions can be taken up by an interferential filter (8) or by other covered filters. No position in the drum must be left unoccupied. Each filter is fitted on a filter holder (6) and fastened to it by the nut (7). The filter holders can be dismounted from the drum by simply pulling on them. The cover (13) allows easy access to the filter drum. The filter drum is fastened to the axle (9). This axle can be turned by the direct action of the motor (11). Its end is guided by the bearing (14). The photosensor (10) indicates the start position of the drum. The light from the lamp, limited by the diaphragm (12). The light passes through the filter drum, which selects the desired wavelength, and through the aperture(15), which adapt the form of the light beam to the geometry of the rotor wells.

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2.2.4. Electronics cover

(1)BACK COVER OF THE ELECTRONICS

(2)MAINS SWITCH

(3)FUSE HOLDER

(4)ID LABEL

(5)NETWORK CONNECTOR

(6)COM1 CONNECTOR

(7)COM2 CONNECTOR

(8)HINGES

The metal cover (1) supports the mains switch (2) and the fuse holders (3), as well as the identification label (4). The

COM1 and COM2 connectors (6, 7) and the mains connector (5) are fastened to the electronics box. The cover(1) opens on 2 hinges (7).

Service manual

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2.2.5. Main cover hinges

(1)HYDRO-PNEUMATIC SPRING

(2)ARTICULATED STEEL STRUCTURE

(3)COVER OPEN PHOTOSENSOR (on right-hand hinge only)

The two hinges enabling the raising of the main cover of the analyzer consist of an articulated steel structure (2) operated by a hydro-pneumatic spring (1). The right-hand hinge includes a photosensor (3) to detect whether or not the cover of the analyzer is open or closed.

2.2.6. Base

(1)LOWER PLASTIC CASING

(2)BASE

(3)WASHING STATION AND RACK TRAY

(4)ARM UNIT

(5)ELECTRONICS BOX

(6)DISPENSING PUMP

(7)REACTION ROTOR AND INTEGRATED OPTICAL SYSTEM

(8)BOTTLE LEVEL DETECTION PLATE

(9)LEVEL DETECTION PLATE

(10)PUMP AND MICROPROCESSOR INTERCONNECTION BOARD

(11)MAIN COVER HINGES

(12)FRONT INDICATOR

(13)ADJUSTABLE LEG

The base (2) on which all the elements of the analyser are fixed is fastened directly to the lower plastic casing. The rack tray and washing station form part of the base. The instrument stands on 4 rubber legs . The front right leg (13) is adjustable in height to adapt the instrument to the work surface.

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2.2.7. Casings

(1)FRONT CASING

(2)UPPER CASING

(3)MAIN COVER

(4)LOWER CASING

(5)ARM HOUSING

(6)ROTOR COVER

(7)RETURN SPRING COVER

The front casing (1) is fastened to the upper casing (2) and the upper casing is fastened to the lower casing (4). The top cover (3) is transparent and lets users see the analyser in operation with the cover closed.

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