Mindray BC User manual

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BC-3000 Plus Auto Hematology Analyzer

Service Manual

SHENZHEN MINDRAY

Statement

SHENZHEN MINDRAY Mindray) owns all rights to this unpublished work and intends to maintain this work as confidential. Mindray may also seek to maintain this work as an unpublished copyright. This publication is to be used solely for the purposes of reference, operation, maintenance, or repair of Mindray equipment. No part of this can be disseminated for other purposes.

BIO-MEDICAL ELECTRONICS CO., LTD. 2003

BIO-MEDICAL ELECTRONICS CO., LTD. (hereinafter called

In the event of inadvertent or deliberate publication, Mindray intends to enforce its rights to this work under copyright laws as a published work. Those having access to this work may not copy, use, or disclose the information in this work unless expressly authorized by Mindray to do so.

All information contained in this publication is believed to be correct. Mindray shall not be liable for errors contained herein nor for incidental or consequential damages in connection with the furnishing, performance, or use of this material. This publication may refer to information and protected by copyrights or patents and does not convey any license under the patent rights of Mindray, nor the rights of others. Mindray does not assume any liability arising out of any infringements of patents or other rights of third parties.

Content of this manual is subject to changes without prior notice.

PROPERTY OF

SHENZHEN MINDRAY

BIO-MEDICAL ELECTRONICS CO., LTD.

Responsibility on the manufacturer party

Mindray is responsible for safety, reliability and performance of this equipment only in the condition that:

Auto Hematology Analyzer Service Manual (V1.1) i

•

all installation, expansion, change, modification and repair of this equipment are conducted by Mindray qualified personnel;

•

applied electrical appliance is in compliance with relevant National Standards;

•

the instrument is operated under strict observance of this manual.

Note

This equipment is not intended for family usage. This equipment must be operated by skilled/trained clinical personnel.

Warning

It is important for the hospital or organization that employs this equipment to carry out a reasonable maintenance schedule. Neglect of this may result in machine breakdown or injury of human health.

Upon request, Mindray may provide, with compensation, necessary circuit diagrams, calibration illustration list and other information to help qualified technician to maintain and repair some parts, which Mindray may define as user serviceable.

ii Auto Hematology Analyzer Service Manual (V1.1)

Warranty

Workmanship & Materials

Mindray guarantees new equipment other than accessories to be free from defects in workmanship and materials for a period of one year from date of shipment under normal use and service. Mindray's obligation under this warranty is limited to repairing, at Mindray’s option, any part which upon Mindray's examination proves defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANT ABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Exemptions

Mindray's obligation or liability under this warranty does not include any transportation or other charges or liability for direct, indirect or consequential damages or delay resulting from the improper use or application of the product or the substitution upon it of parts or accessories not approved by Mindray or repaired by anyone other than a Mindray authorized representative.

This warranty shall not extend to any instrument which has been subjected to misuse, negligence or accident; any instrument from which Mindray's original serial number tag or product identification markings have been altered or removed, or any product of any other manufacturer.

Safety, Reliability and Performance

Mindray is not responsible for the effects on safety, reliability and performance of the BC-3000plus Hematology Analyzer if:

■ assembly operations, extensions, re-adjusts, modifications or repairs are carried out by persons other than those authorized by Mindray.

■ Personnel unauthorized by Mindray repairs or modifies the instrument.

Auto Hematology Analyzer Service Manual (V1.1) iii

Return Policy

Return Procedure

In the event that it becomes necessary to return a unit to Mindray, the following procedure should be followed:

1. Obtain return authorization. Contact the Mindray Service Department and obtain a Customer Service Authorization (Mindray) number . The Mindray number must appear on the outside of the shipping container. Return shipments will not be accepted if the Mindray number is not clearly visible. Please provide the model number, serial number, and a brief description of the reason for return.

2. Freight policy. The customer is responsible for freight charges when equipment is shipped to Mindray for service (this includes customs charges).

Company Contact

Address: Mindray Building, Keji 12th Road South, Hi-tech

Industrial Park, Nanshan, Shenzhen, P. R. China

Phone: +86 755 26582888 Fax: +86 755 26582680

Authorized Representative

Name: Shanghai International Holding Corp. GmbH (Europe)

Address: Eiffestrasse 80 D-20537 Hamburg Germany

Phone: +49 40 2513175 Fax: +49 40 255726

iv Auto Hematology Analyzer Service Manual (V1.1)

Conventions Used in This Manual and Instrument

Warnings, Cautions and Notes

Warnings, cautions and notes are used in this manual to alert or signal the reader to specific information.

WARNING

Warning alerts the user to the possible injury or death associated with the use or misuse of the instrument.

CAUTION

Caution alerts the user to possible injury or problems with the instrument associated with its use or problem such as instrument malfunction, instrument failure, damage to the instrument.

NOTE

Note provides specific information, in the form of recommendations, pre-requirements, alternative goods or supplemental information.

WARNING

Potential biohazard

Avoid contacting with the sample probe.

WARNING

Auto Hematology Analyzer Service Manual (V1.1) i

Content

Chapter 1 General………………………………………………...……………………………1-1

1.1 Introduction ..............................................................................................................1-1

1.2 Service Policy...........................................................................................................1-2

1.3 Specification.............................................................................................................1-3

1.4 Panel Description.....................................................................................................1-7

1.4.1 Front Panel and Keys............................................................................................1-7

1.4.2 Rear Panel............................................................................................................1-9

1.4.3 Front review without front panel.......................................................................... 1-11

1.4.4 Right-side view without the door .........................................................................1-12

1.4.5 Left-side view without the door............................................................................ 1-13

1.5 Menu Structure Chart.............................................................................................1-14

Chapter 2 Troubleshooting…………………………………………………………………….2-1

2.1 Check Procedure .....................................................................................................2-1

2.2 Check Items before Instrument Check.....................................................................2-2

2.3 How to Check Sample Data.....................................................................................2-4

2.4 Troubleshooting Erroneous Data............................................................................2-16

2.5 Troubleshooting......................................................................................................2-21

2.6 Alarm......................................................................................................................2-27

Chapter 3 Hardware……………………………………………………………………………3-1

3.1 CPU Board...............................................................................................................3-2

3.2 Analog Signal Board.................................................................................................3-6

3.3 Power Drive Board.................................................................................................3-10

3.4 Keypad...................................................................................................................3-13

3.5 Recorder Board...................................................................................................... 3-14

3.6 Volumetric Metering Board.....................................................................................3-16

3.7 Power Supply Board ..............................................................................................3-18

Chapter 4 Hydraulic System…………………………………………………………………..4-1

4.1 Hydraulic System Block Diagram.............................................................................4-1

4.2 Units of Hydraulic System........................................................................................4-2

4.3 Whole Blood Count Cycle........................................................................................ 4-3

4.4 Flow Charts of Main Procedures..............................................................................4-4

4.4.1 Power on...............................................................................................................4-4

4.4.2 Whole Blood Count ...............................................................................................4-5

4.4.3 Prediluted Count ................................................................................................... 4-6

4.4.4 Startup...................................................................................................................4-7

4.4.5 Flush Apertures.....................................................................................................4-8

4.4.6 Dispense Diluent...................................................................................................4-9

4.4.7 Shut Down ..........................................................................................................4-10

Auto Hematology Analyzer Service Manual (V1.1) 1

Content

4.5 Hydraulic System Flow Diagram............................................................................ 4-11

4.5.1 Inspire Sample and Diluent (Whole Blood Mode)................................................ 4-11

4.5.2 Inspire Sample and Diluent (Prediluted Mode) .................................................... 4-12

4.5.3 WBC Injection & Lyse Preparation......................................................................4-13

4.5.4 RBC & Lyse Injection..........................................................................................4-14

4.5.5 Mixture ................................................................................................................4-15

4.5.6 Count Cycle.........................................................................................................4-16

4.5.7 Cleaning..............................................................................................................4-17

4.5.8 Flush...................................................................................................................4-18

4.5.9 Empty Tube.........................................................................................................4-19

Chapter 5 System Structure…………………………………………………………………..5-1

5.1 Disassemble/Replace Parts and Components.........................................................5-1

5.1.1 Disassemble Syringe and Replace Piston ............................................................5-1

5.1.2 Replace Sample Probe .........................................................................................5-7

5.1.3 Replace Sample Probe Wipe Block ....................................................................5-12

5.1.4 Replace Vacuum Chamber.................................................................................5-18

5.1.5 Replace Pump.....................................................................................................5-19

5.1.6 Replace Count Bath............................................................................................5-22

5.1.7 Clean or Replace V11 or V12 Valve....................................................................5-26

5.1.8 Replace V11 or V12 ............................................................................................5-27

5.1.9 Clean V11 or V12................................................................................................5-31

5.1.10 Replace TFT Screen.........................................................................................5-33

5.1.11 Replace Recorder Paper...................................................................................5-35

5.1.12 Replace Recorder Module ................................................................................ 5-37

5.2 Disassemble/assemble Circuit Boards...................................................................5-38

5.3 Connect Power Supply...........................................................................................5-39

5.4 Connect Circuit Boards..........................................................................................5-41

5.4.1 CPU board connectors defined...........................................................................5-43

5.4.2 Power Driver Board Connectors Defined ............................................................ 5-48

5.4.3 Analog Board’s connectors defined.....................................................................5-52

5.4.4 Keyboard Connectors defined.............................................................................5-54

5.4.5 Indicator Board Connector Defined.....................................................................5-55

5.4.6 MTB Connector Defined......................................................................................5-55

Chapter 6 Adjustment………………………………………………………………………….6-1

6.1 General....................................................................................................................6-1

6.2 Adjusted procedures ................................................................................................6-1

6.3 Gain of WBC (whole blood and prediluted) Channel................................................6-4

6.4 Gain of RBC Channel............................................................................................... 6-6

6.5 Gain of PLT Channel.............................................................................................. 6-10

6.6 Gain of HGB Channel ............................................................................................ 6-11

6.7 Adjust Display Brightness.......................................................................................6-12

6.8 Adjust Vacuum and Pressure.................................................................................6-13

2 Auto Hematology Analyzer Service Manual (V1.1)

Content

6.9 Adjust Count time...................................................................................................6-14

6.10 Adjust Auto Clean Time........................................................................................6-16

6.1 1 Adjust Volumetric Metering Board ........................................................................6-17

6.12 Re-calibrating Instrument.....................................................................................6-19

Chapter 7 Maintenance………………………………………………………………………..7-1

7.1 Daily maintenance....................................................................................................7-1

7.2 Monthly maintenance...............................................................................................7-1

7.3Half-year maintenance..............................................................................................7-2

Chapter 8 Spare Part List…………..………………………………………………………….8-1

Chapter 9 Performance Test…………………………………………………………………..9-1

Chapter 10 Histograms and Pulse Graphs…………………………………………………10-1

10.1 Histograms...........................................................................................................10-1

10.2 Pulse Graphs .......................................................................................................10-4

10.2.1 Normal Pulse Graphs........................................................................................ 10-4

10.2.2 Abnormal Pulse Graphs .................................................................................... 10-6

Chapter 11 Password and Upgrade software………………………………………………11-1

11.1 Password.............................................................................................................. 11-1

11.2 Upgrade System Software.................................................................................... 11-2

Appendix………………………………………………………………………………………..A-1

Hardware Diagram of BC-3000PLUS.............................................................................A-1

Hydraulic Diagram of BC-3000PLUS .............................................................................A-2

Auto Hematology Analyzer Service Manual (V1.1) 3

General

Chapter 1 General

1.1 Introduction

CAUTION

To maintain the instrument in normal condition, the user must perform the periodic maintenance. Refer to the user manual.

This service manual provides useful information to help service personnel to understand, troubleshoot, service, maintain and repair the Hematology Analyzer.

All replaceable parts or units of this instrument and its optional units are clearly list with exploded illustration to help you locate the parts quickly.

The maintenance must be periodically performed because the instrument has fluid paths and precision parts. Accordingly, the user is responsible for performing the periodic maintenance. The “maintenance” chapter in this service manual describes the maintenance that should be performed by the qualified service personnel. The “maintenance” chapter in the user manual describes the maintenance that can be performed by the user.

NOTE

If the instrument has a problem and there has been no periodic maintenance, the instrument will usually be normal again by cleaning the fluid paths or replacing a consumable with a new one.

The information in the user manual is primarily for the user. However, it is important for service personnel to thoroughly read the user manual and service manual before starting to troubleshoot, service, maintain or repair this instrument. This is because service personnel needs to understand the operation of the instrument in order to effectively use the instrument in order to effectively use the information in the service manual.

Auto Hematology Analyzer Service Manual (V1.1) 1-1

General

1.2 Service Policy

CAUTION

Be careful not to directly touch any place where blood is or may spread to. Wear rubber gloves to protect yourself from infection before doing maintenance.

Our company’s basic policy for technical service is to replace faulty units, printed circuit boards or parts. We do not support component-level repair of boards and units outside the factory.

NOTE

When ordering parts or accessories from your nearest distributor, please quote the part number and part name which is listed in the service manual, and the name or model of the unit in which the required part is located. This will help us to promptly attend to your needs. Always use parts and accessories recommended or supplied by our company to assure maximum performance from your instrument.

1-2 Auto Hematology Analyzer Service Manual (V1.1)

1.3 Specification

Hemoglobin Analysis

Wavelength 525nm

Sampling Features

Volumes Required for Each Analysis： Whole Blood Mode (vein blood) 13uL

Prediluted Mode (capillary blood) 20uL

Aspirated volumes： 500uL of lyse first dilution per cycle for WBC measurement 300uL of second dilution per cycle for RBC and PLT measurement

Dilution Ratios Whole Blood Prediluted

General

WBC/HGB 1: 308 1:407

RBC/PLT 1:44833 1: 44274

Cell Counting Aperture Size： WBC 100um RBC 70um

Throughput more than 60 samples/hour

Check Diluent, Rinse and Lyse

The applied volume of each reagent is:

Diluent Rinse Lyse E-Z

Normal Startup 42ml 10ml

Prepare a sample

25.4ml 6ml 0.5ml

(whole blood)

Prepare a sample

25.1ml 6ml 0.26ml

(prediluted)

Normal Shutdown 32ml 10ml 1.6ml

Performance Specifications

Imprecision Imprecision is based on replicate determinations of the same sample. The first

Auto Hematology Analyzer Service Manual (V1.1) 1-3

General

result is not used in the calculation.

Imprecision Specifications

Parameter Level Units CV%

WBC 7.0-15.0 109/L

RBC 3.5-6.0 1012/L HGB 110 – 180 g/L

MCV 80.0 – 110.0 fL

PLT 200 – 500 109/L

Operating Range

Parameter Range Units

WBC 0.0-999.9 109/L

RBC 0.00-9.99 1012/L

HGB 0-300 g/L

MCV 0-250 fL

PLT 0-3000 109/L

≤ 2.5

≤ 2 ≤ 1.5 ≤ 0.5

≤ 5

Linearity

Parameter Linearity Range Units

WBC 0.3-99.9 109/L ±0.3 or ±5%

RBC 0.20-9.99 1012/L ±0.05 or ±5% HGB 0-300 g/L ±2 or ±3%

PLT 10-999 109/L ±10 or ±10%

Display Liquid Crystal Display（LCD），resolution: 640×480

Input/Output Two RS232/C serial ports One printer port One keyboard interface

Difference

(whichever is greater)

Built-in Thermal Recorder

1-4 Auto Hematology Analyzer Service Manual (V1.1)

Printer (optional) EPSON LX-300, EPSON LX-300+

Scanner(optional)

TYSSO CCD-82

Reagents Required

DILUENT M-30D DILUENT RINSE M-30R RINSE LYSE M-30L LYSE E-Z CLEANSER（Enzyme cleanser） M-30E CLEANSER PROBE CLEANSER M-30P CLEANSER

Power Input: AC 220V±10% AC 110V±10%

General

50/60±1 Hz 50/60±1 Hz Consumption: 180 VA 180 VA Fuse: 2A 4A

Ambient Temperature and Humidity Temperature:

15℃～35℃ (59℉～95℉)

Humidity:

10%～85% without condensation

Dimensions

Height Width Depth

46cm 39cm 40cm

Weight

25KG

Recommended Anticoagulant

A salt of K

EDTA with the proper proportion of blood to anticoagulant, as specified by

the tube manufacturer.

Sample Identification An 8-digit identification number is mandatory sample identification.

Auto Hematology Analyzer Service Manual (V1.1) 1-5

General

Results Output

The system can transmit sample and control data to an external computer. Sample results screen shows sample identification number, sample mode, sample results and any sample result flags. The system provides a printout of all data.

1-6 Auto Hematology Analyzer Service Manual (V1.1)

1.4 Panel Description

1.4.1 Front Panel and Keys

Figure 1-1

No. Name Description

General

1 Display Screen Display various messages, measured data and histograms 2 Keypad Touch key (all of the description refer to under lists), 23 buttons 3 Recorder Print out measured result 4 Power Light Show hematology analyzer work status 5 [Start] key Press to aspirate the sample and start counting 6 Sample Probe Aspirate the sample

Dispenses the diluent when in capillary blood mode.

Keypad

[START]

In Count screen, QC Count screen and Auto Calibration screen, press it to count. In the status of Adding Diluent, press it to add Diluent.

[MENU]

Press this key to switch between window operation and menu operation

3 4

[PRINT] [FEED]

Press this key to print using either recorder or printer Press this key to feed paper of the recorder. Release it to stop the operation.

5 6

[MUTE] [DEL]

Mute the alarm and clear some of the error messages. Delete the selected data in Review screen. Delete error message in Error Message screen. Delete reference data and running control data in QC Edit screen. Call default value in Normal Range screen.

[0]...[9]

Auto Hematology Analyzer Service Manual (V1.1) 1-7

Enter numbers

General

8 9 10

11 12 13

[↑][↓][←][→] [ID] [DILUENT]

[PgUp][PgDn] [ENTER] [STARTUP]

[FLUSH]

Move the cursor in the window area or menu area. Enter the ID number of the sample In the Count screen of Prediluted mode, press this key to enter the Adding Diluent status. Scroll the screen up or down page by page. Confirm Clean the tubing, baths and sample probe then check the background. Press the key to execute the Flush operation to remove the clogs

1-8 Auto Hematology Analyzer Service Manual (V1.1)

1.4.2 Rear Panel

General

Figure 1-2

No. Name Description

1 Keyboard Interface Connect the standard keyboard 2 RS-232C Serial Port 1 Connect computer and transfer data to computer

CAUTION

In order to avoid any safety hazard, only coonect personal computer which are approved to IEC950

The instrument should only be connected to an external instrument which complies with the CISPR 11 Second Edition 1990-09, Group 1 and Class B standard

3 RS-232C Serial Port 2 Connect a bar code scanner 4 Printer Interface Connect the external print er LX-300+ (LX-300) 5 DILUENT Tubing Connector Inlet for diluent. Connect one end of the tube (standard

accessory) to the diluent inlet and attach the other end of the tube to the diluent

6 BNC socket for DILUENT

sensor

7 BNC socket for RINSE

sensor

Auto Hematology Analyzer Service Manual (V1.1) 1-9

connector for diluent. Connect one end of the connector of the cable. connector for rinse. Connect one end of the connector of the cable.

General

8 WASTE Tubing Connector Inlet for waste. Connect one end of the tube (standard

accessory) to the waste inlet and attach the other end of the tube to the waste

9 RINSE Tubing Connector Inlet for rinse. Connect one end of the tube (standard

accessory) to the rinse inlet and attach the other end of the tube to the rinse

10 Equipotential ground

terminal

11 Power switch

AC source Fuse holder

Connects the ground lead to the Equipotential ground terminal on the wall for earth grounding Turns power on or off Connects the AC power cord to supply the AC power to the instrument Contains the time lag fuse (T 2A for 220V or T 4A for 110v)

Fuses cut the power off when an abnormality occurs in the hematology analyzer. Remove the malfunction before replacing the fuse. Before replacing a fuse, turn the power off anf disconnect the AC power cord from the instrument. Fuse replacement should be done by a qualified person.

CAUTION

1-10 Auto Hematology Analyzer Service Manual (V1.1)

1.4.3 Front review without front panel

General

Figure 1-3 1--- Fluctuating Motor 2--- Sample Probe 3--- Sample Probe Wipe Block 4--- WBC unit shield 5--- RBC/PLT unit shield 6--- [Start] key 7---Valve 11

8--- Valve 12 9---Floppy Disk Driver

Auto Hematology Analyzer Service Manual (V1.1) 1-11

General

1.4.4 Right-side view without the door

Figure 1-4

1--- valve 8 2---volumetric unit 3---vacuum chamber 4---valve 15 5---valve 16 6---valve 14 7---valve 13 8---valve 10 9---valve 2 10--- valve 9 11---2.5ml and 50ul motor 12---10ml motor 13---2.5ml syringe 14---50ul syringe 15---10ml syringe 16---valve 4 17---valve 3 18---valve 1 19---valve 6 20---valve 5 21---valve 17 22---valve 7 23---valve 18

1-12 Auto Hematology Analyzer Service Manual (V1.1)

1.4.5 Left-side view without the door

General

Figure 1-5

1---hard disk (Module on disk) 2---vacuum pump 3---pressure pump 4---pressure chamber

Auto Hematology Analyzer Service Manual (V1.1) 1-13

General

1.5 Menu Structure Chart

Count

Whole Blood

Sample Mode

Review

Prediluted

Sample Review

Search Review

Sample Table R eview

Sample Histogram Review

Search Table Review

Search Histogram Review

Qu a lity Control

Setup

Com merical

Control

X-B Analysis

Count Time

Password

Patie n t L imits

Transm ission

Date & Time

Gain

Auto Clean Time

Re ag e n t E x p. Date

Prin t C a ptio n

Parameter U n its

QC Edit

QC Count QC Graph QC Table

Limit

Sample /B atc h

Start/Stop

X-B Graph

X-B Table

General

Man

Woman

Ch ild

Neonate

File 1

File 1 File 2

File 3 File 4

File 5 File 6

File 7 File 8

File 2 File 3 File 4

File 5 File 6

File 7 File 8

File 9

WBC Count Time

RBC Count Time

Mid Max Width

File 1 File 2

File 3 File 4

File 5 File 6

File 7 File 8

File 9

Prin t

Select

Prin t

Format

Auto Print

Version

Language

Type

File 1 File 2

File 3 File 4

File 5 File 6

File 7 File 8

File 9

Service

M ain te na n ce

System Status

Valve Test

Prepare to Ship

Error Messa ge

Ca libr atio n

Help

M an u a l C a lib ra ton

Au to C a lib rat ion

Shutdown

:item s ca n be v ie w e d O n ly af ter in pu t th e co rr es po n d in g pa s sword

:included items, not sub-menu

1-14 Auto Hematology Analyzer Service Manual (V1.1)

Pale tte

Recorder

Type

Chapter 2 Troubleshooting

2.1 Check Procedure

Check the instrument according to the check procedure below.

Measurement operation check Was the quantity of each reagent sufficient fo measurement? Were the correct or recommended reagents used? Was the operating temperature proper? Was the supplied main power voltage correct?

fter turning on the instrument. Did the instrument fail to generate an alarm? NO DILUENT HARDWARE FAIL

Background noise measurement. Did the instrument fail to generate an alarm? Was the result within the specification?

Control measurement Did the instrument fail to generate an alarm? Was the result reproducibility good for: HGB? RBC? WBC? PLT? HCT? (Was the obtained data within the range?)

END

before Instrument Check”

Troubleshooting

Refer to “Check Items

Refer to

“Troubleshooting

and Alarm”

Auto Hematology Analyzer Service Manual (V1.1) 2-1

Troubleshooting

2.2 Check Items before Instrument Check

Use the instrument and diluent under the following

Check items before Instrument check

operating conditions:

Around instrument Diluent

- temperature: 15 to 35℃ temperature: 15 to 30℃

- humidity: 10 to 85%

- atmospheric pressure: 860 to 1060hPa （Working）

If the temperature is less than 15℃, it slows the reaction rate from hemoglobin to cyanmethemoglobin. This may result in increase of the hemoglobin data. It may also result in increase of the WBC count because the RBCs are not sufficiently hemolysed due to the lower temperature. Insufficiently hemolyzed RBCs will be included in the WBC count as RBC ghosts.

Sampled Whole Blood Handling Check

Storage for Blood Sample

Measure all required parameters soon after sampling the whole blood from a patient. As time elapses after blood sampling, the blood cells’ volume and density change. The ratios of the volume and density variations depend on the environmental conditions and patient. If the blood sample isleft in an air conditioned room for a long time, the volume of the red blood cell increases and the MCV, RDW and MPV will be affected, and moreover, the PLT will be easily aggregated.

WBC part differential

To get high reliability on the acquired data, measure the blood samples within 6 hours after sampling the whole blood. If the blood sample is left in an air conditioned room for a long time, geerally, the WBC membrane’s resistance against hemolysing reagent is decreased. Therefore the WBC histogram of the correct shape cannot be obtained.

Blood Sample from a Patient with Specified Conditions To measure a blood from a patient who has hepatopathy, certain special treatments, or is a neonate, it may be necessary to use a method other than the hematology. Analyzer. This is because the RBC membrane’s resistance against hemolysing

2-2 Auto Hematology Analyzer Service Manual (V1.1)

Capillary Blood Handing Check

Troubleshooting

reagent is increased (insufficient hemolysing) and it will cause an increase of the WBC count when the blood is measured with the hematology analyzer.

Furthermore, the bilirubin and WBC in the blood may affect the hemoglobin concentration in the measurement.

CAUTION

In the capillary blood mode, the instrument aspirates the diluted sample of 20uL. In this mode, if the venous blood is incorrectly aspirated instead of capillary blood, there is a high possibility that the fluid path is clogged or the background noise is not easily decreased.

Most causes of data error using capillary blood are due to incorrect technique for the capillary blood sampling and diluting. Therefore, take care the following notes and make a capillary blood sample.

NOTE

Dilute the sampled capillary blood correctly the first time, because it is difficult to sample the blood twice from the capillary.

Auto Hematology Analyzer Service Manual (V1.1) 2-3

Troubleshooting

2.3 How to Check Sample Data

Background Noise Check

This check is used to make sure that the counted and

calculated data of a diluent sample is not affected by background noise. If the background checking value exceeds the tolerable dilute data shown in the table below, the diluent data counted and calculated before background noise is reduced erroneous. In the table below, each diluent data is defined as follows:

Recommended diluent data

This data is best for acquiring accurate data of the sample.

Acceptable dilunt data

This data is the minimum value for acquiring accurate data of the sample.

Recommended diluent Data Acceptable diluent Data

WBC 0.0 WBC RBC 0.00 RBC HGB 0 HGB 1g/L or 0.1g/dL HCT 0.0 HCT 0.5% PLT 3 PLT

Refer to “Troubleshooting Erroneous Data” of this chapter for the possible causes of background noise and how to reduce it.

Check Procedure

1. Press the start key to count and calculate the

2. Make sure the counted and calculated data is less

Parameter Data Check with Diluent

Check that the background values are less than or equal to the data in the previous table. Discard the other parameter values because they are not affected by noise. Especially check the data for the PLT parameters. When the diluent includes the particles of dust smaller

9/L

0.3x

12/L

0.03x

9/L

10x

diluent. There is no need to aspirate the diluent from the sampling probe.

than or equal to the acceptable diluent data as shown upper. If they are out of range, decrease the background noise.

2-4 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

than WBC and RBC parameters, the data of them is not affected by the dust but the data for the PLT parameter increases because the volume for the PLT parameter is smaller than the WBC and RBC parameters. I f the data for the PLT parameter exceeds 10X10

/L, do the action described below to reduce the

background noise.

Reducing Background Noise

To reduce the background noise when the background check value exceeds the acceptable diluent data shown in the previous table, perform the following.

1. Make sure connecting grounding well.

2. Execute the “clean Bath” program which in the service menu. If this does not reduce the background noise, perform the following steps.

3. Execute the “E-Z cleanser cleaning” and “Diuent Prime” program.

4. Perform the background check to make sure that the background noise is reduced.

If the data of the background check is still outside the acceptable diluent data values shown in the previous table, replace the diluent with diluent from a new, sealed container.

NOTE

When the instrument is used every day and the background noise rarely exceeds the lower limit for the diluent data, the instrument is not severely contaminated. However, this contamination builds up in the instrument and cannot be easily removed if the instrument is not cleaned periodically.

Auto Hematology Analyzer Service Manual (V1.1) 2-5

Troubleshooting

Reproducibility Check This check is used to check reproducibility of the

instrument, using pintout data value of a diluted sample from the same hematology control. When the values are out the specification range, the reproducibility of the instrument is poor. If the reproducibility is found to be poor, this printed result is used to troubleshoot the instrument as described in “Troubleshooting Erroneous Data” of this chapter.

Check Procedure

1. Reduce the background noise. Refer to “Background Noise Check” of this chapter.

2. Access “Quality Control” → normal level Controls→ QC Edit→ File “X” to set a new control file and input each parameter’s specification.

3. Access “Quality Control” → Commercial Controls→ QC Count→ Count a diluted sample from the same sufficiently mixed hematology control 10 times.

4. Access “Quality Control” → Commercial Controls→ QC Graph→ File “X” to review the result and CV value.

5. If you want to print out the displayed values with an built-in thermo-printer unit, press the print key which on the keypad directly in the graph screen or table screen.

Data Check with Hematology Control The CV (Coefficient of Variation) indicates the data reproducibility on each parameter. A lower CV value for a parameter indicates better reproducibility for the parameter (i.e. each sample data for the parameter deviates less).

Check the CV value for each parameter by comparing it with the CV specifications (as shown in the next page) described in the brochure. You get the CV value by counting a normal concentration hematology control 10 times consecutively.

If the acquired CV values are out of the CV specifications, the reproducibility of the instrument is poor. To troubleshoot the instrument, refer to “Troubleshooting Erroneous Data” of this chapter.

2-6 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

N X CV% CV Specification WBC 10 10.0 1.05 2.5% or less RBC 10 4.23 1.22 2% or less HGB 10 130 0.77 1.5% or less PLT 10 201 3.25 5% or less Lymph# 10 4.0 1.47 Lymph% 10 41.0 1.28 Gran# 10 4.9 1.77 Gran% 10 48.2 1.15 HCT 10 36.1 1.28 MCV 10 86.9 0.24 0.5% or less MCH 10 31.6 1.02 MCHC 10 353 1.08

N: Number of samples for each parameter X: Mean of sample data for each parameter CV: Standard deviation divided by mean X

Note Normally, the hematology analyzer counts approx

4.0X10

blood cells for 16 seconds per one RBC counting. The reproducibility for the hematology analyzer is statistically determined by the number of blood cells aspirated through the aperture. The reproducibility is better as the number of counted blood cells increases; the reproducibility is worse as the number of counted blood cells decreases. That is, the acquired data has more deviation when a blood sample of lower concentration is counted.

The following explanation and diagram show what the CV values mean for data of each parameter.

For example, when noting the RBC data on the printout (see the previous table), the mean of the RBC data is 4.43 and CV is 0.8%. 0.8% of 4.43 is 0.035. Therefore the range is 4.395 to 4.465 (4.43±0.035). This means that six of the ten acquired RBC data are within the range.

Auto Hematology Analyzer Service Manual (V1.1) 2-7

Troubleshooting

Accuracy Check

4.37 4.39 4.40 4.43 4.44 4.45 4.45 4.45 4.46 4.47 4.48

(2 data) (6 data) (2 data)

4.395 4.465

This check is used to check the accuracy of the measurement by comparing the actually measured data of the hematology control with expected value on the assay sheet of the hematology control. If there is a large difference between them, calibrate the instrument by resetting the calibration coefficient for each parameter.

Check Procedure

1. Gently take the hematology control out of the

refrigerator and place it in a normal temperature environment for a while to raise it to room temperature. The hematology control must be within the expiration data.

2. Confirm that the hematology control is not

hemolysed. Normally the hematology control is separated into blood plasma and blood serum of the hematology control may be mixed. Also, if the hematology control is frozen, it is hemolysed.

3. Measure each parameter with the hematology

control.

4. Check that the obtained sample data for each

parameter is within the range between the lower and upper expected values on the assay sheet. Run the control again, replace a new control to try again if the results are out of range. After that, if the result are still unacceptable, recalibrate the instrument with the following procedures.

When the condition temperaare range is out of (20 to 26℃), control results maybe out of limits.

2-8 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

Parameter Data Check with Hematology Control

Check that the obtained sample data for each parameter is within the range of the assay values on the assay sheet.

NOTES

If the data for any parameter is out of range, calibrate the instrument according to “Calibration” of the operator’s manual. To calibrate the instrument for more accuracy, refer to the following “Procedure for Instrument Fine Calibration” of this chapter.

Procedure for Instrument Fine Calibration

The instrument allows the user to input the factors manually with the range between 75% and 125%.

The procedures of manual are:

1 . Confirm the sample mode. 2 . Run the calibrator in Count screen for at least five times. The reproducibility of WBC, RBC, HGB, MCV and PLT must satisfy following limits.

Parameter CV

WBC RBC HGB MCV PLT

≤2.5 ≤2.0 ≤1.5 ≤0.5

≤5

3. Calculate the new calibration factors.

4. Enter the new calibration factors.

Calculate the New Calibration Factors

Use the below formula to calculate the new calibration factors

factornew

valuereferencefactorold

valuetestofaverage

Auto Hematology Analyzer Service Manual (V1.1) 2-9

Troubleshooting

Example: Reference value of WBC = 8.4 In whole blood mode, three running values of WBC are

8.1, 8.0, 8.1, 8.1 and 8.3. The mean value of WBC is

8.12. Old calibration factor in the whole blood mode is

98.9%.

∑

Mean

12.8

CV < 2%

4.8%9.98

factornew

valuereferencefactorold

valuetestofaverage

Enter the Calibration Factors

In the menu operation, move the cursor to the “Calibration/Manual Calibration” and press [ENTER] to access the manual calibration screen as shown in below figure.

Press [ENTER] to access the Edit Parameter state.

12.8

%3.102

Figure 2-1

Press [↑][↓] to select the item and [←][→] to move the cursor within the item. Press [0] – [9] to enter numbers. The “fixed decimal” format is adopted so that the user need not enter the decimal point.

2-10 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

The factor should be within the range of 75% -- 125%.

Confirm the New Calibration Factors

After entering the new factors, press [MENU] key to return to menu operation, then the dialog box pops up as shown in below figure.

Figure 2-2 Select “Yes”, store the new factors. Select “Cancel”, reserve the old factors.

Verification After entering the new factors, run the calibrator in Count screen. Verify that the results are within the specified range.

•The Automatic Calibration procedures are:

1. Set up the sample mode to Whole Blood or Prediluted.

2. Enter the reference value of the calibrator.

3. Run the calibrator.

4. Confirm the calibration factors.

Auto Hematology Analyzer Service Manual (V1.1) 2-11

Troubleshooting

Figure 2-3 In menu operation, move the cursor to “Calibration/Auto Calibration”, press [ENTER] key to access Auto Calibration screen.

Figure 2-4 Edit the reference:

Press [1] to access “Edit Reference” status. Enter

the reference values of the calibrator.

Press [↑][↓] to select the item and [←][→] to move the cursor within the item. Press [0] – [9] to enter numbers. The “fixed decimal format” is adopted so that the user need not enter the decimal point.

Press [ENTER] to exit edit status and access the Count status.

2-12 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

Figure 2-5

Run Calibrator Procedure

WARNING

void contacting with the sample probe.

1. Place the well-mixed calibrator to the probe so that the tip is well into the tube, and press the [START] to run. The process of run is the same as that of count. After running, the screen displays as shown in below figure.

Figure 2-6

Select “Yes” to validate the results.

Auto Hematology Analyzer Service Manual (V1.1) 2-13

Troubleshooting

Select “Cancel” to invalidate the results.

The below figure shows an example of the results after five times of running.

Figure 2-7 The average value of calibration and the new calibration factors automatically calculated by the system are displayed in the right side of the screen.

“***” refers to invalid results, which means that the average value of the parameter and the calibration factor are invalid.

Maximum 5 samples can be counted for auto calibration. The auto calibration result will be displayed only after 3 samples are counted. If the calibration factor of a parameter is out the range of 75% ~ 125%, it will not be displayed, find the reason. If necessary, contact the Mindray Customer Service Department or the distributor.

Confirm the New Calibration Factors

Press [MENU] to return to the menu operation. The dialog box pops up as shown in below figure.

2-14 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

Figure 2-8 Select “Yes”, save the new calibration factors. Select “Cancel”, keep the original calibration factors.

Verification When the new calibration factors are adopted, count the calibrator in the Count screen and verify that the result is within the specified range.

Auto Hematology Analyzer Service Manual (V1.1) 2-15

Troubleshooting

2.4 Troubleshooting Erroneous Data

Background Noise

When the count data of a container filled with diluent just exceeds the tolerable value of the parameter shown in the table in ”Background Noise Check” of this chapter, the seven possible causes of error are:

(1) Dirty diluent (2) Dirty diluent container (3) Dirty baths (4) Dirty valves

NOTE

Before storing the instrument for a long time, clean and empty all fluid tubings in the instrument with distilled water. Otherwise, the diluent salt adheres to the baths and cannot be removed easily.

(5) Electronic noise affecting the counting/calculation

circuit: AC line, backlight converter, peripheral equipment such as microwave treatment machine, motors in the instrument

(6) Mechanical noise affecting the counting/calculation

circuit: Vibration from motor in or around the instrument, such as a centrifuge

(7) Tubing noise affecting the counting/calculation

circuit: Liquid flow with some remained electric charges

As a countermeasure to the above 7 causes, take the following actions.

Cause (1) or (2)

− Replace the diluent with diluent from a sealed container.

Cause (3) or (4)

− Clean the baths with E-Z cleanser

− Clean the baths with probe cleanser

2-16 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

− Clean valves with distilled water

− Exchange the other same model valves to try

Cause (5)

−Securely ground the instrument, including any optional units such as external printer. Cause (6)

− Keep the instrument away from the vibration source.

Cause (7)

− Securely ground the tubing.

Auto Hematology Analyzer Service Manual (V1.1) 2-17

Troubleshooting

For Reproducibility

This subsection describes the cases when the reproducibility for the following measuring parameter or calculated parameter is poor.

− PLT

− HGB

− WBC

− RBC

− Data other than red cell indexes (MCV, MCH and

MCHC)

− RBC and PLT coefficient related parameters

− HCT and MCV

2-18 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

Poor Reproducibility for PLT

Possible Cause Countermeasure The background data on PLT is

Refer to “Background Noise Check“ of this chapter high Dirty RBC aperture Clean the aperture. Dirty RBC bath Clean the bath. Refer to the “Maintenance” of the

operator’s manual. Dirty measuring tube Clean the tube below the RBC bath Dirty wipe block Clean the wipe block

Replace a new wipe block The sample probe position is not

Adjust the probe position using localizer correct The 3-way valve (SV11) is dirty Clean the valves

Replace this valve The 3-way valve (SV11) cannot

Replace the 3-way valve (SV11). drain liquid empty. The diuent syringe exists

Remove the bubbles from the syringe bubbles Faulty circuit Replace the ANALOG board

Poor Reproducibility for HGB

Possible Cause Countermeasure Dirty WBC measurement bath Clean the WBC bath with E-Z cleanser or probe

cleanser The voltage output from the HGB sensor is not optimal

Adjust the HGB voltage. Refer to “Adjust Gain” of

this manual.

Adjust the adjustable resistance VR3 & VR4 to

adjust the output voltage of HGB to 4.4v-4.6v The 3-way valve (SV12) cannot

Replace the 3-way valve (SV12). drain liquid empty. The 3-way valve (SV12) is dirty Clean or replace the valves The specified diluent and

Use the correct reagent hemolysing reagent were not used Cyanide in the hemolysing reagent has been dissolved by

Replace the hemolysing reagent with a new

reagent and tighten the cap of the reagent bottle. sunlight or heat The HGB 2.5 mL syringe exists

Remove the bubbles from the syringe bubbles The light axis of the HGB LED is deviated

Adjust the light position

Replace the light

Auto Hematology Analyzer Service Manual (V1.1) 2-19

Troubleshooting

The light of HGB is aging Replace the HGB unit The diuent syringe exists

Remove the bubbles from the syringe bubbles Faulty the Analog board Replace the analog board

Poor Reproducibility for WBC

Possible Cause Countermeasure The background data on WBC is

Refer to “Background Noise Check“ of this chapter high Dirty WBC measurement bath Clean the WBC bath with E-Z cleanser or probe

cleanser Dirty measuring tube Clean the tube below the WBC bath Dirty wipe block Clean the wipe block

Replace a new wipe block The sample probe position is not

Adjust the probe position using localizer correct The 3-way valve (SV12) cannot

Replace the 3-way valve (SV12). drain liquid empty. The 3-way valve (SV12) is dirty Clean the valves

Replace this valve The lyse reagent has been dissolved by sunlight or heat The constant current is not

Replace the lyse reagent with a new reagent and

tighten the cap of the reagent bottle.

Change the transformer or analog board stable The diuent syringe exists

Remove the bubbles from the syringe bubbles Faulty the Analog board Replace the analog board

Poor Reproducibility for RBC

Possible Cause Countermeasure The background data on RBC is

Refer to “Background Noise Check“ of this chapter high Dirty RBC measurement bath Clean the RBC bath with E-Z cleanser or probe

cleanser Dirty measuring tube Clean the tube below the RBC bath Dirty wipe block Clean the wipe block

Replace a new wipe block The sample probe position is not

Adjust the probe position using localizer correct The 3-way valve (SV11) cannot

Replace the 3-way valve (SV11). drain liquid empty.

2-20 Auto Hematology Analyzer Service Manual (V1.1)

The 3-way valve (SV11) is dirty Clean the valves

Replace this valve The constant current is not

Change the transformer or analog board stable The diuent syringe exists

Remove the bubbles from the syringe bubbles Faulty the Analog board Replace the analog board

Troubleshooting

Auto Hematology Analyzer Service Manual (V1.1) 2-21

Troubleshooting

2.5 Troubleshooting

Burn fuse when power on unit AC input power is not stable

Power supply board is short circuit

Bubbles Bubbles in the sample

Regents are not enough Setting count time is long The aperture is broken Counting channel is leakage

Background testing is abnormal

Counting time is sometimes too short and sometimes normal Clog Big cells or debris in the

Diluent injection time becomes longer, and make WBC bath full Display is not clear Backlight is too bright or too

Fluctuating and rotatory motor error

Regents are dirty Electronic noise Dirty bath Dirty valves

The CPU board has some problem

sample Setting count time is short The aperture is blocked Diluent is not enough

Volumetric board is broken

SV3 valve doesn’t close properly

dark

LCD screen is old

The environment temperature is low Tubing which on the sample

Using a manostat (voltage regulator) Replace the power supply board Remove the bubbles Re-prime the regents Re-set the count time Change a new aperture Replace the leakage parts Change new regents Connect ground well Clean the bath Clean the valves

Replace the CPU board

Remove the debris from the sample Re-set the count time Clean the aperture Check the diluent syringe and diluent Replace the volumetric board

Replace the SV3 valve

Adjust the unique resistor on the CPU board Replace the LCD screen

Increase environment TEMP and add UPS Loose the tubing

2-22 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

probe assembly is too tight The detectors are broken

Replace the two detectors

Hang during initiation (Initiation stop)

Software has some problem

Power supply board is broken

Re-install the software or replace a new Moduleondisk Replace power supply

board HGB always alarm WBC bath is dirty Clean WBC bath HGB error and WBC clog The 10ml syringe’s piston

Re-fix the piston

falls off Hematology analyzer leakage and vacuum is abnormal HGB background voltage is abnormal, no chance to make

The tubing of waste

assembly is kink

WBC bath is dirty or HBG

gain is not correct

Release the tubing and empty the liquid Dip in the WBC bath

and adjust HGB gain it down HGB error HGB background voltage is

abnormal (0-3.2v or

4.9-5.0v), it’s out of acceptable range

Adjust the HGB gain

or the resistor (VR3

&VR4 which on the

analog board) to

4.2V-4.6V

HGB adjust error HGB background voltage is

abnormal (3.2-3.4v or

4.8-4.9v), it’s out of acceptable range

Adjust the HGB gain

or the resistor (VR3

&VR4 which on the

analog board) to

4.2V-4.6V

Initiation time is too long disk on module is broken Replace hard disk

(disk on module)

Keyboard, some buttons no response

CPU board or keyboard is broken

Replace the CPU

board or keyboard

LCD screen, there is a line on the screen

CPU board is broken if the line is a dot line and the position is fixed LCD screen is faulty if the line is a continuous black or light line

Replace the CPU

board

Replace the LCD

screen

Auto Hematology Analyzer Service Manual (V1.1) 2-23

Troubleshooting

LCD screen is dark The color palette setting is

not correct The backlight is too dark

Re-set the color

palette to 8-color

Adjust the unique

resistor on the CPU

board Leakage Vacuum chamber is broken,

waste liquid tubing is kink,

tubing leakage

Analog board is broken

The air filters are dirty

Change the vacuum

chamber

Loose the waste liquid

tubing

Check the default

point

Replace a new analog

board

Replace this two fiters

mid-size cell’s percent is sometime too high and sometime normal

Put the sample to long time Add too much anti-coagulant

Count the sample in

30mins

Reduce the value of

anti-coagulant

No diluent injected Diluent is empty

The piston falls off

No sample inspired and no

SV4 valve doesn’t work Replace the SV4 valve

Change a new bottle

of diluent

Re-fix the piston

diluent injected No initialization, but exist backlight and a moment it

The CPU board is broken Replace the CPU

board becomes black, the indicators flash like saver No rinse (diluent, lyse) alarm The rinse (diluent, lyse)

sensor is broken or plastic washer falls off

Replace the rinse

(diluent, lyse) sensor

or re-fix the washer No backlight The inverter is broken Replace the inverter

PLT/RBC’s result shows “**.*” Test the RBC aperture

Replace the RBC bath

voltage is not stability, the range is 4.5-11.0V

PLT result is always over 1000 The RBC bath is dirty Clean or replace the

RBC bath Power-on is normal, but the screen is black suddenly after

Power supply board and CPU board are broken

Replace the power

supply board and CPU

2-24 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

initiation board Power-on is normal, but no display, no initiation, no

The CPU board is broken Replace the CPU

board response PLT background is abnormal Connecting ground is not

proper, or with high voltage

Pressure error Pressure pump leakage or

tubing broken Pressure filters are blocked

Reconnect ground

wire

Replace pump or

tubing

Replace new filters

Rotatory motor error The tubing connecting

sample probe is loose, and

Replace the proble

mosule

liquid enters the motor to

make the resistance higher RBC bath full and liquid overflows RBC/PLT’s result shows “**.*” Test the RBC aperture

The V11 valve doesn’t work

or dirty or doesn’t work well

Clean or replace the V11 valve

Replace the RBC bath voltage is not stability, the range is 4.5-11.0V

RBC always clog 1. RBC bath is dirty

2. The count time is a little

longer than the setting time

3. One of the sensor which on the MTB board is broken

1. Clean the bath using E-Z cleanser or probe cleanser

2. Re-set the count time

3. Replace the MTB board

RBC bath is leakage RBC bath is broken with

Replace the RBC bath

cranny RBC background and value is too high

RBC bath is broken with

cranny

Replace the RBC bath

RBC no result Analog board is broken Replace the analog

board

Stability is bad, and PLT over 1000 sometime

There are some bubbles in

Diluent syringe and make

Replace the SV3 valve

the injected diluent not

enough Sample probe leakage SV4 valve is leakage Replace the SV4 valve Show “8002 error code” The disk on module is

broken

Replace the disk on module

Show ”48V is low” The transformer or analog Replace transformer

Auto Hematology Analyzer Service Manual (V1.1) 2-25

Troubleshooting

board is broken or analog board

TEMP is low The environment

temperature is low

Increase the environment TEMP

Vacuum is low Air filters are so dirty

Waste liquid tube is kink

Tube is leakage

Vacuum pump is leakage

Vacuum chamber is leakage

Replace the filters Loose the tube Replace one new tube Replace a new pump Replace a new chamber

WBC always clog 1. WBC bath is dirty

2. The count time is a little longer than the setting time

3. One of the sensor which

on the MTB board is broken

1. Clean the bath using E-Z cleanser or probe cleanser

2. Re-set the count time

3. Replace the MTB board

WBC bath leakage WBC bath is broken with

Replace the WBC bath

cranny WBC background and value is too high WBC bath full and liquid overflows WBC result is not stable WBC bath is broken with

WBC bath is broken with

cranny

The V12 valve doesn’t work

or dirty or doesn’t work well

Replace the WBC bath

Clean or replace the V12 valve Replace the WBC bath

cranny Wipe-block is leakage Wipe-block is old Replace wipe-block WBC value is too high and RBC is zero or “***”

Mis-use the Rinse and

diluent

Exchange the two reagents

WBC clog, no count time WBC aperture clog Clean the aperture

using probe cleanser WBC differential part is abnormal, and it’s end point at

WBC channel gain is not correct

Adjust WBC channel

gain 200fl WBC bubbles during counting SV8 valve is leakage Replace the SV8 valve WBC no result Analog board is broken Replace the analog

board

2-26 Auto Hematology Analyzer Service Manual (V1.1)

2.6 Alarm

Error Message Possible Cause

Com Error

2.5ml & 50ul Motor Error

10ml Motor Error

Rotatory Motor Error

Fluctuating Motor Error

DC/DC Error

12V Power Error

48V Power Error WBC A/D Error 1. The CPU board is abnormal.

RBC A/D Error 1. The CPU board is abnormal. PL T A/D Error 1. The CPU board is abnormal. WBC Interrupt Error 1. The CPU board is abnormal.

1. The transmission settings between BC-3000PLUS and the external computer are different.

1. The position optical coupler is abnormal.

2. The driving motor is abnormal.

3. The communication wire of the motor is bad connected.

4. The 2.5ml syringe or/and 50ul syringe is damaged or the resistance of it has increased.

5. The 2.5ml syringe or/and 50ul syringe is not mounted to the right position.

1. The position optical coupler is abnormal.

2. The driving motor is abnormal.

3. The communication wire of the motor is bad connected.

4. The 10ml syringe is damaged or the resistance of it has increased.

5. The 10ml syringe is not mounted to the right position.

1. The position optical coupler is abnormal.

2. The driving motor is abnormal.

3. The communication wire of the motor is bad connected.

4. The motor compone nts loosen or mounted to the wrong position.

5. The pin clip loosens, if the tubing connecting the sample probe moves randomly or touches the wall when the motor operates.

6. The tubing connecting the wipe block is over tightly

fastened.

1. The position of the optical coupler is abnormal.

2. The driving motor is abnormal.

3. The communication wire of the motor is bad connected.

4. The motor compone nts loosen or mounted to the wrong position.

5. The screw lever is not enough smooth.

1. The DC/DC component is abnormal.

2. The analog signal board is abnormal.

1. The power supply board is abnormal.

2. The analog signal board is abnormal.

1. The power supply part is abnormal.

2. The analog signal board is abnormal.

Troubleshooting

Auto Hematology Analyzer Service Manual (V1.1) 2-27

Troubleshooting

RBC Interrupt Error 1. The CPU board is abnormal. PLT Interrupt Error 1. The CPU board is abnormal.

1. The HGB LED loosens.

2. The HGB unit is bedabbled.

HGB Error

3. The HGB LED is damaged.

4. WBC bath is dirty.

5. Diluent is polluted or exceeds its Exp. date.

1. The HGB LED loosens.

2. The HGB unit is bedabbled.

HGB Adjust

3. Light intensity of the HGB LED is set incorrectly.

4. WBC bath is dirty.

5. Diluent is polluted or exceeds its Exp. date.

Vacuum Filter Error 1. The filter is clogged by dirt.

1. Vacuum pump is damaged.

2. Tubing or vacuum chamber has leaks.

3. Tubing connecting vacuum chamber to sensor loosens

Vacuum Low

or falls off.

4. The valve connecting the vacuum chamber is damaged.

5. The waste container is placed over normal position, or

the waste tubing is too thin or too long, or the waste tubing cannot drain the liquid smoothly.

1. The environment temperature is over the range

Envir. Temp. Abnormal

15℃～35℃

2. The temperature sensor is abnormal.

1. The count baths or apertures are dirty.

2. There are bubbles in the tubing system.

Background Abnormal

3. The reagents are polluted or exceed their Exp. date.

4. There is clog or bubbles error when test the background.

1. The WBC aperture is clog or dirty.

2. Foreign object has clogged the WBC bath.

3. WBC reference count time is set up improperly.

4. Optical couplers on the volumetric metering board are

damaged or the values of potentiometers are set improperly.

5. The liquid cannot flow in the tubing smoothly (pressed,

WBC Clog

bends or clogged by foreign object).

6. Inadequate reagent.

7. Can not form stable surface in WBC metering glass

tube.

8. The tubing has leaks or the vacuum system has

problem.

9. The sample has problem, such as the type and

proportion of anticoagulant is selected improperly or

2-28 Auto Hematology Analyzer Service Manual (V1.1)

WBC Bubbles

RBC Clog

RBC Bubbles

Diluent Empty

Rinse Empty

Lyse Empty

Pressure1 Low

Troubleshooting

there is blood clots.

1. WBC reference count time is set up improperly.

2. Optical couplers on the volumetric metering board are

damaged or the values of potentiometers are set improperly.

3. Inadequate reagent.

4. not form stable surface in WBC metering glass tube.

5. tubing has leaks or the vacuum system has problem.

1. The RBC aperture is clog or dirty.

2. Foreign object has clogged the RBC bath.

3. RBC reference count time is set up improperly.

4. Optical couplers on the volumetric metering boa rd are

damaged or the values of potentiometers are improperly set.

5. The liquid cannot flow in the tubing smoothly (pressed,

bends or clogged by foreign object).

6. Inadequate reagent.

7. Can not form stable surface in RBC metering glass

tube.

8. The tubing has leaks or the vacuum system has

problem.

9. The sample has problem, such as the type and

proportion of anticoagulant is selected improperly or there is blood clots.

1. RBC reference count time is set up improperly.

2. Optical couplers on the volumetric metering board are

damaged or the values of potentiometers are improperly set.

3. Inadequate reagent.

4. Can not form stable surface in RBC metering glass

tube.

5. The tubing has leaks or the vacuum system has

problem.

1. There are no diluent in the diluent container.

2. The liquid sensor is not connected correctly.

3. The liquid sensor is damaged.

1. There is no rinse in the rinse container.

2. The liquid sensor is not connected correctly.

3. The liquid sensor is damaged.

6. There are no lyse in the lyse container.

7. The liquid sensor is not connected correctly.

8. The liquid sensor is damaged.

9. Pressure pump has fault.

10. Tubing, vacuum chamber has leaks.

Auto Hematology Analyzer Service Manual (V1.1) 2-29

Troubleshooting

Pressure2 Low

Recorder Out of Paper

Recorder Too Hot

File Error

Bar Code Invalid

Bar Code Com Error

Printer Error

Diluent Expiry

Rinse Expiry

Lyse Expiry

11. Tubing connecting vacuum chamber to sensor loosens or falls off.

12. The valve connecting the vacuum chamber is damaged.

13. Pressure pump has fault.

14. Tubing, pressure chamber has leaks.

15. Tubing connecting pressure chamber to sensor loosens or falls off.

16. The valve connecting the pressure chamber is damaged.

1. There are no papers in the recorder box.

2. The sensor is abnormal.

1. The thermal head is too hot.

2. The sensor is abnormal.

1. The system software is destroyed.

2. The DiskOnModule disk has bad pars.

1. The format of bar code inputted is invalid for

BC-3000PLUS.

1. There are some errors when the bar code scanner

communicates with BC-3000PLUS host.

1. The printer is not connected correctly.

2. There are no papers in the printer.

3. Wrong type printer which BC-3000PLUS does not

support.

1. Diluent exceeds its Exp. date.

2. The diluent Exp.data inputted is incorrect.

1. Rinse exceeds its Exp. date.

2. The rinse Exp.data inputted is incorrect.

1. Lyse exceeds its Exp. date.

2. The Lyse Exp.data inputted is incorrect.

Trouble Possible Cause

1. Operation is not normalized, sample is not completely mixed up.

2. Sample is heavily polluted.

Poor repeatability

3. Sample is improperly selected (such as the sample has blood clots).

4. Wipe block is inaccurately positioned.

5. Instrument has interference.

6. Reagents are polluted or exceed their Exp. date.

1. Shielding box of sample bath is not well mounted.

Severe interference

2. Shielding wire of analog signal board is not connected correctly.

2-30 Auto Hematology Analyzer Service Manual (V1.1)

Troubleshooting

3. Valve V11 or V12 connecting count bath is not well closed or has dirt.

4. The gain is set incorrectly.

5. The input power is unstable.

Power-off during running 1. Unstable input power, it exceeds the protective range.

Auto Hematology Analyzer Service Manual (V1.1) 2-31

Chapter 3 Hardware

The instrument has the following hardware:

CPU Board Power Drive Board Analog Signal Board Keypad Recorder Board Volumetric Metering Board Power Supply Board Display Screen Linear Transformer

Hardware

Auto Hematology Analyzer Service Manual (V1.1) 3-1

Hardware

3.1 CPU Board

Function and Modules

The board consists of three modules:

● Computer System Module With CPU as the core, the computer system module also includes some peripheral circuits like RTC, WDT, SDRAM, Flash, and Super I/O. The super I/O circuit uses Super I/O chip as the core and includes other sub-circuits like keyboard, serial port, parallel port, floppy disk drive interface and IDE interface.

CPU, SDRAM and Flash construct the basic computer system and the basic environment for the operation of software.

RTC provides calendar and clock.

WDT is designed to protect the system in case the software fails to function. It will generate reset signal once the software fails to function.

Super I/O provides external interfaces, including one parallel port, two serial ports, one keyboard interface and one floppy disk drive interface.

● A/D&I/O Module A/D&I/O module use FPGA and CPLD as the core and include other peripheral circuits like FIFO, ADC and I/O.

The A/D circuit can convert the analog signal pre-processed by the analog signal board and then send it to CPU via FIFO.

CPU uses I/O interfaces to manage interrupts, control valves and pumps, control the gain of analog signal board, and zap function and HGB light.

● Display Module The display module uses FPGA as the core and includes other peripheral circuits like SRAM, display interface I/O.

Display module is designed to display the information on the LCD screen.

Block Diagram of CPU Board

3-2 Auto Hematology Analyzer Service Manual (V1.1)

Figure 3-1 shows the block diagram of CPU board.

Computer system of

CPU Board

RTC WDT SDRAM Flash SuperI/O

CPU

Hardware

Display module

FPGA

A/D collection

FPGA

I/O port

CPLD

A/D & I/O

Figure3-1

● Computer System Computer system includes CPU (U33), SDRAM (U1, U2), Flash (U3), RTC (U7), WDT (U6) and Super I/O (U30).

CPU, SDRAM and Flash make up of the basic computer system. Flash serves to store BIOS and FPGA configuration data. During initialization, CPU can read the FPGA configuration data from the Flash in order to set up FPGA. By executing the startup program in BIOS, CPU can transfer the main program on the DiskOnModule disk into SDRAM and accordingly run the program.

RTC and WDT together use I RTC. RTC has backup battery, therefore it can run normally even in the shutdown state. WDT is adopted to provide protective function. It can forcibly reset CPU when software fails to function.

Super I/O provides external interfaces. The parallel port is for connecting printer. Serial port 1 may connect bar code scanner. Serial port 2 may realize the

Auto Hematology Analyzer Service Manual (V1.1) 3-3

C bus. CPU may get the current time by accessing

Hardware

communication with external computer. The keyboard interface is designed to connect standard keyboard.

● A/D & I/O Circuit of this part includes A/D collection and I/O.

A/D sample: this board has three pieces of A/D chips. U37 is a 12-bit A/D to sample voltages of WBC, HGB and WBC apertures as well as RBC aperture, vacuum, pressure, 5V supply, +12V, -12V and +48V supplies of analog signal board, and 12V supply of power board. CPU select channel by using the analog switch on the analog signal board and saves the data sampled by U37 into U40 and U41. U35 and U36 are 8-bit A/D, used respectively to detect PLT and RBC. The sampled data are separately saved into U39 and U38. U38~U41 are 8-bit and 2K FIFO. When FIFO is half-full, it sends interrupt to CPU. CPU can read the data from FIFO via FPGA (U42). Besides, U42 is used to control the analog signal board, including gain control, zap control, HGB light and constant-current source control.

● Display Module The display circuit is made up of FPGA (U43) and VRAM (U47~U49). CPU writes the display data into VRAM via FPGA. FPGA can generate LCD driving timing. CPU reads data from VRAM in terms of the driving timing and displays them on LCD.

■ PCB Layout of CPU Board

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Hardware

Recorder Power Supply

Recorder

Keypad Start

Volumetric

Metering

Valve and

Liquid SensorLCD Interface

Analog Signal

Pump Drive

3-Wire

Serial

Port

IDE Interface

A/D Control Signal

Figure 3-2

FDD

Keyboard

PS/2

RS-232C

Serial Port

RS-232C

Serial Port

Parallel Port

Auto Hematology Analyzer Service Manual (V1.1) 3-5

Hardware

3.2 Analog Signal Board

Functions and Modules

The main functions of the analog signal board are

1. Process the original signal into the situation matching the requirement of A/D

conversion;

2. Amplify the weak signal of WBC and RBC/PLT channels to the value between

0.2V-5V;

3. Amplify HGB signal;

4. Monitor the environmental temperature;

5. Monitor the pressure and vacuum in chambers;

6. Monitor the accessorial power supplies.

The analog signal board includes the following modules:

1. RBC/PLT and WBC amplification circuit: blood cells count channel, including WBC

unit and RBC/PLT unit. This circuit can amplify the WBC and RBC/PLT signals by using multistage AMP and band-pass filters. Every channel in this circuit uses digital potentiometer to adjust the AMP multiple. There is voltage-limited protective output at the end stage of output circuit;

2. HGB measuring circuit: amplify HGB signal via using current-voltage conversion

and voltage AMP circuit. At the same time, it acts as the constant-current driver circuit for the LED when measuring HGB. The output current of this circuit is adjustable between 5-25mA. ON/OFF of the constant-current source is controlled by optical coupler. This circuit uses digital potentiometer to adjust the AMP multiple;

3. Pressure measuring circuit: This circuit can transfer the changes of vacuum and

pressure into voltage signal by pressure sensor, then amplify this signal and send it to A/D converter on CPU board to acquire digital signal. The AMP circuit uses AD620. The adjustable resistors are placed at the output and the feedback loop of the AMP circuit to adjust the zero point and full-scale output range of pressure measurement;

4. Temperature measuring circuit: use thermistor to monitor the environmental

temperature. The changes of the thermal-sensitive resistor is amplified by AD620 and then output to CPU board;

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Hardware

5. Power supply circuit: provide +48V DC, 120V AC and ±12V supplies. The ±12V

supply is realized by using the DC-DC module with +5V input. The +48V circuit provides constant-current source necessary for RBC/PLT measurement. The 120V AC circuit provides the necessary voltage to zap the apertures;

6. Multiplexer circuit: supply the function that multiple-way signals can be transmit

through the same A/D channel. Use multiplexer to control the sequence of multiple-way output signals to CPU board. The signal controlling the analog switch comes from CPU board.

7. Supply monitoring circuit: monitor +48V and ±12V voltages. Obtain the desired

amplitude of the output signal by using resistor to divide voltages.

Block Diagram of Analog Signal Board

The block diagram of analog signal board is shown in figure 3-3.

Pressure Module

Vacuum Signal Pressure Signal

Hematocyte Signal Module

Power Supply Module

＋12V －12V ＋48V

120VAC

WBC Signal RBC Signal PLT Signal WBC-HOLE Signal RBC-HOLE Signal

Monitor Module

＋48V Monitor ＋12V Monitor －12V Monitor

HGB Signal Module

CPU Board

Temperature Monitor Module

Figure 3-3

Auto Hematology Analyzer Service Manual (V1.1) 3-7

Hardware

● WBC and RBC/PLT AMP Module The circuits of three AMP channels WBC, RBC and PLT are basically the same except difference on small points. RBC and PLT channel uses the first two stages of AMP circuit and is separated from each other since the third stage. The following description uses WBC channel as the example. The input signal is AC signal from uV to mV grade. Therefore using capacitors to filter direct current signal and connect the AMP channel at the preliminary stage. The preliminary stage AMP uses U14 to amplify the signal. At the end of this stage, passive RC circuit is applied to realize high-pass filter. The second stage AMP uses U15. Its feedback loop is the same as the first stage. It uses parallel-connected capacitors to realize low-pass filter. The third stage AMP uses U10. Its feedback loop adopts electronic potentiometer U19, which is controlled by CPU board so that circuit of this stage can provide different AMP multiples and realize the adjustable program-controlled gain. Besides, a voltage regulating tube is connected to the circuit of this stage to protect U19 from being damaged due to too high voltage. A passive RC circuit is connected at the end of this stage to finish high-pass filter. After amplifying the signal to the value within the required range, use U11 to realize active RC filter circuit in order to realize low-pass filter as well as limit the band width of the signal within the required range. At last the circuit outputs the signal that has passing circuit of removing negative pulse and buffer circuit.

● HGB Measuring Module The input signal of HGB circuit is current signal. Before amplifying the signal, the current signal shall be first converted into voltage signal. OP AMP U27 is adopted to construct this circuit. The circuit uses classical current-voltage converting circuit. Resistor is connected into the feedback loop in order to convert current signal into voltage signal. A capacitor is parallel connected into the feedback loop to realize low-pass filter. After converting the current signal into voltage signal, input the voltage signal into the voltage AMP stage. U28 is used to realize the AMP circuit. Adjustable resistor is connected into the feedback loop in order to adjust the AMP multiple. Besides, a zero adjusting circuit is connected to the input end via an add circuit in order to ensure that when the input is zero the input signal of the circuit has positive voltage. An adjustable resistor is used to control the output of zero point.

● Pressure Monitor Module and Temperature Monitor Module Both pressure measuring and temperature measuring circuits use instrumentation amplifier to amplify the signal. The circuits for measuring pressure and temperature

3-8 Auto Hematology Analyzer Service Manual (V1.1)

Hardware

are basically the same. The following description uses pressure measuring circuit as the example.

The circuit uses U25 to construct the constant current source to power the pressure sensor. The pressure sensor has bridge circuit. Its output signal is transmitted into U20 by means of difference. U20 can adjust the AMP multiple via the adjustable resistor at its R

pin so as to amplify and output the signal. Additionally, an adjustable

resistor is connected to the output of the pressure measuring circuit to adjust the zero output of the pressure sensor.

● Power Supply Monitor The ±12V voltage powering the analog circuit is converted from +5V voltage. This part is realized by using DC-DC module U30. Add a LC filter circuit at the end output of the power supply to reduce its ripple.

On this board, relay is used to control ON/OFF of the 120V AC so as to zap the apertures.

+48V voltage is converted from the 53V AC voltage. This part first uses DB104 to implement DC conversion, then use U29 to obtain the +48V DC voltage. Optical coupler is used to control ON/OFF of the supply.

The monitor circuit adopts the form of voltage-division with resistor. Its output is transmitted to the CPU board by a follower. The power supplies to be monitored are +48V and ±12V.

Auto Hematology Analyzer Service Manual (V1.1) 3-9

Hardware

3.3 Power Drive Board

Functions and Modules

The power drive board is designed to control the rotatory motor, fluctuating motor and syringe motors. Besides, it also receives the switch signal from the host to control the pump and valve. The power board has three modules: ON/OFF control module, motor control module and power supply module.

The ON/OFF control module consists of optical coupler isolation circuit, valve driving circuit and pump driving circuit.

Optical coupler isolation circuit: isolate the parallel ON/OFF signal coming from the host; eliminate the interference of large current signal to the front-end control circuit.

V alve driver circuit: realize power driving function for 18-way valves; the driving current is

1.5A and the driving voltage is 12V.

Pump driver circuit: realize power driving function for 4-way pumps, the driving current of

three ways is 1.5A and the driving current of the other way is 3A. The driving voltage is 12V.

Motor control circuit: it consists of serial port communication circuit, program control circuit, current-limiting circuit, motor driving circuit and protective circuit.

Serial port communication circuit: realize serial port communication with the host, the

signal level is compliable with RS232 serial port. According to the requirement for isolation, the communication between the host and the module is isolated by using optical coupler. Besides communication management circuit is used to realize multi-machine communication management.

Program control circuit: control the rotatory motor, fluctuating motor, and 10ml syringe

motor and 2.5ml&50µl syringe motor according to the command from the host. Three 53-series CPUs are used to realize the control. At the same time, receives information of received command and returns the executed results to the host.

Current-limiting circuit: use constant current to control the syringe motor and the

3-10 Auto Hematology Analyzer Service Manual (V1.1)

Hardware

fluctuating motor in order to obtain good results.

Motor driver circuit: drive the step motor. The driving current of each phase should be 1A. Protective circuit: Because the motor is inductive load, protective circuit should supply continuous current for it.

Power supply module: provide +7.2V and +5V supplies to respectively power of the recorder and the power board.

Block Diagram of Power Drive Board

Figure 3-4

● Switch Control Module The control signals of 18 ways valves and 4 ways pumps are transmit to the power board through parallel port. 7 optical couplers are used to isolate the digital supply from the driving supply in order to avoid the interference of big current on the

Auto Hematology Analyzer Service Manual (V1.1) 3-11

Hardware

front-end circuit. The circuit driving the valve uses ULN2068B as the driver chip. Its driving voltage is 12V. The maximum driving current of each valve is 1.5A.

Similar to the circuit driving the valve, the circuit driving the pump also uses ULN2068B as the driver chip. Their difference lies in that a pump with big power consumption uses transistor Q1 to amply the current in order to obtain 3A driver current. The control logic level is TTL, which is valid at low level. It means when the input signal is “0”, the corresponding pump or valve is connected through.

● Motor Control Module Receive the command from the host via serial port under the control of serial port communication and management circuit. For serial port communication circuit, the optical coupler isolation OP7 and OP8 as well as level transition U10 are adopted to realize isolation and level transition. Besides, U28 is applied to manage the communication circuit so as to realize multi-machine communication.

The 4-step motors are controlled by three modules which U21 controls the rotatory and fluctuating motor in order to control the sample probe assembly. The rotatory motor uses constant-voltage full step driver way while the fluctuating motor adopts constant-current half-step driver way. In addition, U26 and U27 are used to control the motors of 10ml syringe and 2.5ml&50µl syringe by means of constant-current half-step drive.

The driving circuit of rotatory motor uses optical coupler isolation and is driven by U9. U15 acts to drive the fluctuating motor and syringe motors. Its output can be 2A per phase.

Current-limiting circuit and voltage protective circuit are realized respectively by L6506D and UC3610. The setup limit current is 1A. The driving voltage of motor shouldn’t exceed 50V.

● Power Supply Provide +5V for power board. U29 is used to realize the constant-voltage output and Q2 for amplifying the current. The maximum current that can be pr ovided is 4.5A. The internal control supply of the power board is realized by LM7805.

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Hardware

3.4 Keypad

Functions and Modules

The keypad circuit may not only support the input via man-machine interface but also control the buzzer and LCD backlight. The main circuit modules are:

1. Key matrix: the key matrix circuit I0～I6, O0～O3 make up of 7×4 key matrix. There are totally 23 keys on the keypad. When single key is pressed, only a unique pair between I0~I6 and O0~O3 are connected through to identify the key function.

2. Circuit for controlling LCD backlight: this circuit first uses a piece of 7805 to obtain the constant 5V supply. Then it can acquire the voltage used to control the backlight brightness through using 2 resistors with fixed resistance and an adjustable resistor. The voltage-division range is between 1V ~ 3V. LCDBCTL signal is used to control the existence of backlight.

3. Buzzer: use control signal I7 and a dynatron to control the buzzer.

Block Diagram of Keypad

I0厖 I6

Key Matrix

Circuit for controlling

Buzzer circuit

LCD backlight

O0厖 O3

Figure 3-5

Auto Hematology Analyzer Service Manual (V1.1) 3-13

Hardware

3.5 Recorder Board

Functions and Modules

The main function of the recorder board is to receive the data from the CPU board via serial port, process them and send them to the thermal head. At the same time, it drives the motor of the thermal head to feed paper so that the received data can be printed out in the form of characters or graphs.

Block Diagram of Recorder Board

Thermal Head

Motor

Driver

CPLD

9536

Status

Detection

DC/DC

12V>8V

CPU

Signal & 5V

Figure 3-6

● Thermal head

The thermal head, the core component in the recorder, is the PTMBL1306A thermal head, manufactured by the ALPS company.

● CPU system

The CPU system is the core of the drive board. Its task is to receive the data from the host and generate lattice messages after calculation using a specified algorithm. These messages are then sent to the thermal head to be printed out. The CPU system can simultaneously collect data from both thermal head and drive board and display data sent to the host.

3-14 Auto Hematology Analyzer Service Manual (V1.1)

Hardware

● Power conversion

The recorder requires the system to provide two voltages: 12 V and 5 V. The 5 V is directly driven by the logic and analog circuit of the drive board and the thermal head. Its current is less than 150 mA. The 12 V is converted into 8 V (by the DC/DC on the board) to drive the thermal head and he motor. The current required is determined by the printing content and ranges from 0.5 A to 2 A.

● Motor drive

A small motor is used to control the p aper movement at the thermal head. The processor on the drive board uses two motor drives IC LB1843 V to control and drive the motor. These two IC’s use constant current to control and drive the motor.

● Status detection

To correctly and safely control and drive the thermal head and the motor, the drive board must use the sensor inside the thermal head to detect the following signals: the position of the chart paper, if the paper is installed and if the temperature of the thermal head has exceeded the limit.

● Key Test Points

NO. NAME LOCATION FUNCTION

1 12 V JP3.1 Power input, range: 10~18 V 2 GND JP3.2 Power and signal ground

Power supply for heating thermal head

3 VPP U7.8

and drive motor: 7.8 V~8.4 V

4 VCC U1.14 +5 V supply: 4.75~5.25 V

CPU reset signal. At high level(>2.4 V)

5 RESET U3.10

after power-on

Auto Hematology Analyzer Service Manual (V1.1) 3-15

Hardware

3.6 Volumetric Metering Board

Functions and Modules

The volumetric metering board can calculate liquid volume with the help of volumetric tube and optical coupler. It is used to ensure the accuracy of WBC and RBC/PLT count. The volumetric metering board has two channels: WBC channel and RBC/PLT channel. Each channel consists of one volumetric tube and two optical couplers. When the system starts counting, the liquid starts flowing in the volumetric tube. When the liquid is passing through the first optical coupler, the comparator outputs signal of starting count. After the liquid is passing through the second optical coupler, the comparator outputs the signal of stopping count. In this way we can know the time when the system starts and stops counting process.

The circuit has four parts:

1. Circuit for driving optical coupler: provide driving current for the four optical couplers. Besides, its activity is controlled by CPU board in order to decide whether the optical coupler works.

2. Circuit for detecting signal of optical couplers: this circuit collects the signal of voltage variation when the liquid is flowing through the optical coupler and then transmit the signal to the subsequent circuit.

3. Circuit for generating comparative level: generate the comparative threshold level of the comparator.

4. Circuit for outputting comparative signal: compare the voltage output from the circuit for detecting signal of optical coupler with the comparative threshold and accordingly output start count or stop count signal.

Block Diagram of Volumetric Metering Board

Circuit

for

Detect circuit for WBC start

count optical coupler

Detect circuit for WBC end

count optical coupler

Circuit for generating

comparative voltage

Circuit for generating

comparative voltage

Circuit for outputting

comparative signal

Circuit for outputting

comparative signal

driving

optical

couplers

Detect circuit for RBC/PLT

start count optical coupler

Circuit for generating

comparative voltage

Circuit for outputting

comparative signal

Detect circuit for RBC/PLT

end count optical coupler

Circuit for generating

comparative voltage

Circuit for outputting

comparative signal

Figure 3-7

3-16 Auto Hematology Analyzer Service Manual (V1.1)

Hardware

● Circuit for Driving Optical Couplers

To obtain the same light intensity of the four optical couplers, we need to use uniform constant-current sources. The source is made up of U3 and resistor with the output range of 5～25mA. CPU board generates signal to control the optical couplers. This signal is isolated from Q1 by an optical coupler.

● Circuit for Detecting Signal of Optical Couplers

The detecting signal is output from the receive terminal of the optical coupler. Use potentiometer to adjust the output voltage so that the output voltage of the detecting signal of the optical coupler can be 2.5V.

● Circuit for Outputting Comparative Signal

Connect U11 with the comparator to form hysteresis comparator with the hysteresis difference set to 0.25V. Moreover, a LED is added into this part to serve as the indicator. LED lighting on means the optical coupler has detected liquid.

Auto Hematology Analyzer Service Manual (V1.1) 3-17

Hardware

3.7 Power Supply Board

General

This power supply is designed for use only on BC-3000PLUS hematology analyzer. There are two types of power supply board, one input power is AC220V±20% and another input power is AC110V±20%.The outputs of rating load are +5V& 3Amax, +12V&3Amax and +32V&1A. The outputs of maximum load are +5V& 7Amax, +12V&6.5Amax and +32V&3A peak. The outputs of the three ways are isolated from each other in order to reduce the noise interference.

Working Principle

The two types power supply boards have the same working principle. The power supply board filters and rectifies the input AC supply in order to obtain a smooth DC volt age with the amplitude about 1.2 times of the input AC voltage. At the same time, the input AC supply provides a startup voltage for U2 control chip to control the supply converter. U2 controls the on/off of the main switch through monitoring the voltage and current of the +12.5V and +5V feedback circuits in order to stabilize the output of +12.8V and +5V. In addition, the turn ratio of the transformer is used to stabilize the +30V output.

At the same time, this power supply has over-voltage and under-voltage protecting functions for +12.8V, +5V and +30V. On the primary side, after the power supply becomes stable, the transformer will provide the VCC necessary for U2.

Block Diagram of Power Supply Board

AC inpu t , filte r an d

rectification

Startup circuit and

auxiliary power

supply

Shutdown

circuit

DC-DC isolation and conversion circuit

UCC3810 PWM

control circuit

+12.8V filter

and output

+30Vfilter and

output

+5V fil te r a n d

output

+12.8V feedback

and over/under-

voltage detection

+5Vfeedback and

over/under-voltage

detectio n

+12V output

+30Vfeedback

and over/under-

voltage

detection

Figure 3-8

3-18 Auto Hematology Analyzer Service Manual (V1.1)

Hardware

Difference Between Two Types Power Supply Board

The difference between the two types power board is the rectification circuit. The figure 3-9 is the 220V input rectification circuit and the figure 3-10 is the 110V input rectification circuit. The difference on PCB layout is if there is a connection wire between BD1 and the joint of C5 and C6 as shown in figure 3-10.

Figure 3-9

Figure 3-10

Do not confuse the type of the power supply board otherwise lead

to the instrument damage or body hazard.

Auto Hematology Analyzer Service Manual (V1.1) 3-19

Chapter 4 Hydraulic System

4.1 Hydraulic System Block Diagram

Hydraulic System

1718

Figure 4-1 Hydraulic System Block Diagram

Auto Hematology Analyzer Service Manual (V1.1) 4-1

Hydraulic System

4.2 Units of Hydraulic System

■ Sensor Unit

This part is made up of front bath, aperture, rear bath, electrodes and seal washer. This part is the most important for the whole instrument. Simply speaking this part is a sensor. Most measuring results are generated by this part.

■ HGB Unit

This part is used to measure the hemoglobin concentration.

■ Dilute Unit

This part consists of 4 step motors (rotatory motor, fluctuating motor and two syringe driving motors), 2 syringes (10ml and 50ul), wipe block and sample probe. It is used to aspirate and dilute the sample and clean the system.

■ Volumetric Unit

This part implements the function of measuring the volume; we can calculate the concentration of blood cells with the number of pulses and the value of volume. This part is mainly made up of glass tubes and optical couplers.

■ Vacuum Unit

V acuum is the impetus to drive the counting process of hematology analyzer. It is made up of vacuum chamber, valves and vacuum pump.

■ Pressure Unit

The pressure of this part is provided by pressure pump. It has the function of mix-up dilution.

■ Auxiliary Unit

This part mainly refers to the connecting tube, connectors and valves which are mainly used for connection

4-2 Auto Hematology Analyzer Service Manual (V1.1)

Hydraulic System

4.3 Whole Blood Count Cycle

In whole blood mode, press the “Start” key, the system transmits “Start Count” request to CPU, which will feedback the response signal.

1. The 50ul syringe aspirates 13ul of EDT A-K2 anticoagulant whole blood into the probe.

The instrument reads HGB blank. The WBC bath rinses and drains. The 10ml syringe dispenses diluent into the WBC bath to prefill it.

2. The probe moves to the WBC bath and the 10ml and 50ul syringes dispense the

sample (13ul) and diluent into the WBC bath, making a 1:269 dilution.

3. The 50ul syringe aspirates 15.6ul of the 1:269 dilution into the probe for the RBC/PLT

dilution. The RBC bath rinses and drains. The 10ml syringe dispenses diluent into the RBC bath to prefill it.

4. The 2.5ml syringe sends 0.5ml lyse reagent to the WBC bath for a final 1:308 dilution,

while the 10ml and 50ul syringes dispense 15.6ul of the 1:269 dilution and additional diluent into the RBC bath for a final RBC/PLT dilution of 1:44833.

5. Mixing bubbles enter the baths to mix the bath contents. The vacuum chamber

drains.

6. Both dilutions (WBC and RBC/PLT) are drawn through the apertures via regulated

vacuum.

7. The instrument counts 500ul dilution for WBCs and counts 300ul dilution for RBCs

and PLTs. After counting finishes, the flow ends.

8. The system takes an HGB sample reading.

9. The system analyzes the data while the WBC and RBC baths drains and rinses.

10. The system zaps the apertures and the probe moves to the aspirating position. The

system displays results on the screen.

11. The system is ready for the next sample.

Auto Hematology Analyzer Service Manual (V1.1) 4-3

Hydraulic System

4.4 Flow Charts of Main Procedures

4.4.1 Power on

Power on

Information about last

shutdown

Abnormal

Startup sequence of

abnormal shutdown

Ready to count

Normal

Startup sequence of

normal shutdown

Background Check

Pass

Abnormal background error

Ready to count

Empty tubing

Startup sequence after

empty tubing

Count time < 2

Clog: Clog moving sequence

Bubbles: Cleaning sequence

End

Figure 4-2 Power On

4-4 Auto Hematology Analyzer Service Manual (V1.1)

4.4.2 Whole Blood Count

Hydraulic System

Whole Blood Count

Read HGB blank

50ul syringe aspirate 13ul blood sample

Add 0.5ml lyse reagent to the WBC bath

1:308 dilution

in WBC bath

WBC Count

Read HGB sample

Rinse and drain WBC bath Dispense d iluent prefill the WBC bath

1:269 dilution in WBC bath

50ul syringe aspirate 15.6ul blood dilution

1:44833 dilution in RBC bath

RBC/PLT Count

Rinse and drain RBC bath Dispense d iluent prefill the RBC bath

Rinse WBC bath

Zap the apertures

End

Rinse RBC bath

Figure 4-3 Whole Blood Count

Auto Hematology Analyzer Service Manual (V1.1) 4-5

Hydraulic System

4.4.3 Prediluted Count

Well-mixed 1:80 prediluted

sample

10ml syringe aspirate 0.7ml 1:80

prediluted sample

Prediluted Mode Count

Rinse and drain WBC bath Dispense d iluent prefill th e WBC bath

1:366 dilution in WBC bath

Read HGB blank

Add 0.36ml lyse reagent to the WBC bath

1:407 dilution

in WBC bath

WBC Count

Read HGB sample

Rinse WBC bath

50ul syringe aspirate 24.8ul blood dilution

1:44274 dilution in RBC bath

Zap the apertures

End

Rinse and drain RBC bath Dispense diluent prefill the RBC bath

RBC/PLT Count

Rinse RBC bath

Figure 4-4 Prediluted Count

4-6 Auto Hematology Analyzer Service Manual (V1.1)

4.4.4 Startup

Clean WBC bath

Clean RBC bath

Hydraulic System

Startup

Create positive pressure in

vacuum chamber

Flush WBC and RBC

apertures

Clean WBC bath

Clean RBC bath

Clean WBC bath

Clean RBC bath

Check background

End

Restore the pressure to normal

state in vacuum chamber

Figure 4-5 Startup

Auto Hematology Analyzer Service Manual (V1.1) 4-7

Hydraulic System

4.4.5 Flush Apertures

Empty WBC bath

Empty RBC bath

Flush Apertures

Create positive pressure in

vacuum chamber

Flush WBC and RBC

apertures

Clean WBC bath

Adjust pressure in

vacuum chamber

Clean RBC bath

End

Figure 4-6 Flush Aperture

4-8 Auto Hematology Analyzer Service Manual (V1.1)

4.4.6 Dispense Diluent

10ml syringe aspirates 1.6ml

10ml syringe primes 1.6ml

Dispense Diluent

diluent

diluent to the cup

Exit dispense diluent

Hydraulic System

Clean the sample probe

End

Figure 4-7 Dispense Diluent

Auto Hematology Analyzer Service Manual (V1.1) 4-9

Hydraulic System

4.4.7 Shut Down

Shutdown

10ml syringe aspirates 1.6ml E-Z

cleanser by sample probe from

vial

Empty WBC and RBC baths

Add diluent and 0 .8ml E-Z

cleanser from sample probe to

WBC bath

Add diluent and 0 .8ml E-Z

cleanser from sample probe to

RBC bath

Prime the volumetric glass tubes with E-Z cleanser from the WBC and RBC baths

Add diluent to WBC bath

Add diluent to RBC bath

10ml syringe moves to the end

position

End

Figure 4-8 Shut Down

4-10 Auto Hematology Analyzer Service Manual (V1.1)

4.5 Hydraulic System Flow Diagram

4.5.1 Inspire Sample and Diluent (Whole Blood Mode)

Hydraulic System

1718

Figure 4-9 Inspire Sample and Diluent (Whole Blood Mode)

Auto Hematology Analyzer Service Manual (V1.1) 4-11

Hydraulic System

4.5.2 Inspire Sample and Diluent (Prediluted Mode)

18 17

Figure 4-10 Inspire Sample and Diluent (Prediluted Mode)

4-12 Auto Hematology Analyzer Service Manual (V1.1)

4.5.3 WBC Injection & Lyse Preparation

Hydraulic System

1718

Figure 4-11 WBC Injection & Lyse Preparation

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Hydraulic System

4.5.4 RBC & Lyse Injection

18 17

Figure 4-12 RBC & Lyse Injection

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4.5.5 Mixture

Hydraulic System

1718

Figure 4-13 Mixture

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Hydraulic System

4.5.6 Count Cycle

Figure 4-14 Count Cycle

4-16 Auto Hematology Analyzer Service Manual (V1.1)

4.5.7 Cleaning

Hydraulic System

Figure 4-15 Cleaning

Auto Hematology Analyzer Service Manual (V1.1) 4-17

Hydraulic System

4.5.8 Flush

Figure 4-16 Flush

4-18 Auto Hematology Analyzer Service Manual (V1.1)

4.5.9 Empty Tube

Hydraulic System

Figure 4-17 Empty Tube

Auto Hematology Analyzer Service Manual (V1.1) 4-19

System Structure

Chapter 5 System Structure

5.1 Disassemble/Replace Parts and Components

5.1.1 Disassemble Syringe and Replace Piston

WARNING

Potential biohazard

It is unnecessary to remove the syringe assembly from the instrument.

Push the switch as shown in figure 5-1 and open the right side door of the machine.

Figure 5-1

Figures 5-2 through 5-8 show how to remove the 10ml syringe and replace the piston.

1. Take out the screw on the baffle.

Figure 5-2

2. Remove the baffle.

Auto Hematology Analyzer Service Manual (V1.1) 5-1

System Structure

Figure 5-3

3. Take out the fixing screw between the 10ml motor lever and white metal connector.

Figure 5-4

4. Rotate the step motor lever out from the metal connector.

Figure 5-5

5. Remove the syringe and metal connector.

5-2 Auto Hematology Analyzer Service Manual (V1.1)

Mindray BC User manual

Specifications and Main Features

Frequently Asked Questions

User Manual