Mindray BC-5800 Service manual

BC-5800

Auto Hematology Analyzer

Service Manual

Copyright

© 2008 Shenzhen Mindray Bio-medical Electronics Co., Ltd. All rights Reserved.

Intellectual Property Statement

SHENZHEN MINDRAY BIO-MEDICAL ELECTRONICS CO., LTD. (hereinafter called Mindray) owns the intellectual property rights to this Mindray product and this manual. This manual may refer to information 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.

Mindray intends to maintain the contents of this manual as confidential information. Disclosure of the information in this manual in any manner whatsoever without the written permission of Mindray is strictly forbidden.

Release, amendment, reproduction, distribution, rent, adaption and translation of this manual in any manner whatsoever without the written permission of Mindray is strictly forbidden.

,are the registered trademarks or trademarks owned by Mindray in China and other countries. All other trademarks that appear in this manual are used only for editorial purposes without the intention of improperly using them. They are the property of their respective owners.

Responsibility on the Manufacturer Party

Contents of this manual are subject to changes without prior notice.

All information contained in this manual 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 manual.

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

all installation operations, expansions, changes, modifications and repairs of this product are conducted by Mindray authorized personnel;

the electrical installation of the relevant room complies with the applicable national and local requirements;

the product is used in accordance with the instructions for use.

I

zThis equipment must be operated by skilled/trained medical professionals.

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

zBe sure to operate the analyzer under the situation specified in this manual; otherwise, the analyzer will not work normally and the analysis results will be unreliable, which would damage the analyzer components and cause personal injury.

II

Warranty

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY 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 use of parts or accessories not approved by Mindray or repairs by people other than Mindray authorized personnel.

This warranty shall not extend to:

any Mindray product which has been subjected to misuse, negligence or accident;

any Mindray product from which Mindray's original serial number tag or product identification markings have been altered or removed;

any product of any other manufacturer.

Return Policy

Return Procedure

In the event that it becomes necessary to return this product or part of this product 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. Returned 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 this product is shipped to Mindray for service (this includes customs charges);

3.Return address: Please send the part(s) or equipment to the address offered by Customer Service department.

III

Company Contact

	Manufacturer:	Shenzhen Mindray Bio-Medical Electronics Co., Ltd.
	Address:	Mindray Building, Keji 12th Road South, Hi-tech Industrial Park,
		Nanshan,ShenZhen 518057, P.R.China,
	Phone:	[phone] 26582888
	Fax:	[phone] 26582500

IV

		Table of Contents
Copyright			I
	Warranty.............................................................................................................................		III
	Return Policy......................................................................................................................		III
Table of Contents			1
1	Using This Manual		1-1
	1.1	Introduction..........................................................................................................	1-1
	1.2	Who Should Read This Manual...........................................................................	1-2
	1.3	How to Find Information ......................................................................................	1-3
	1.4	Conventions Used in This Manual.......................................................................	1-4
	1.5	Special Terms Used in This Manual ....................................................................	1-5
	1.6	Symbols...............................................................................................................	1-6
2	System Structure		2-1
	2.1	System Overview.................................................................................................	2-1
	2.2	Fluidic System .....................................................................................................	2-2
	2.3	Hardware System ................................................................................................	2-3
	2.4	Main Structure......................................................................................................	2-4
	2.5	Software Structure .............................................................................................	2-12
3	Fluidic System		3-1
	3.1	Introduction of Fluidic Parts.................................................................................	3-1
	3.2	Introduction of Pneumatic Parts ..........................................................................	3-7
	3.3	Fluidic System .....................................................................................................	3-9
	3.4	Basic Cycle Design Description.........................................................................	3-16
	3.5	Sample Predilution Flowchart............................................................................	3-25
4	Hardware System		4-1
	4.1	Main Board ..........................................................................................................	4-3
	4.2	Signal Processing Board ...................................................................................	4-21
	4.3	Driver Board.......................................................................................................	4-36
	4.4	Power Board ......................................................................................................	4-75
	4.5	Interface Board ..................................................................................................	4-84
	4.6	Indicator Board ..................................................................................................	4-90
	4.7	Touchscreen Control Board ...............................................................................	4-93
	4.8	Pneumatic Control Board ..................................................................................	4-97
	4.9	Pre-amplification Board, Laser Control Board and Volumetric Board .............	4-103
	4.10	Sample Transport Board..................................................................................	4-122
	4.11	Sample Detecting Board..................................................................................	4-137
	4.12	Pressure Detecting Board ...............................................................................	4-148
		1

Using This Manual

	4.13	SATA and IDE Signal Conversion Board .........................................................	4-154
5	Servicing		5-1
	5.1	General ................................................................................................................	5-1
	5.2	Disassembling the Panels ...................................................................................	5-2
	5.3	Replacing the Power Supply Assembly.............................................................	5-12
	5.4	Replacing the Touchscreen Assembly...............................................................	5-16
	5.5	Replacing the Fluidic Components....................................................................	5-22
	5.6	Replacing the RBC Assembly............................................................................	5-56
	5.7	Replacing the HGB Bath Assembly...................................................................	5-66
	5.8	Replacing the WBC Bath Assembly ..................................................................	5-70
	5.9	Replacing the Reagent Preheating Assembly ...................................................	5-76
	5.10	Replacing the Open Vial Sampling/SRV Assembly...........................................	5-78
	5.11	Replacing the Sample Transmitting Assembly ..................................................	5-96
	5.12	Replacing the Autosampler and Mixer Assemblies .........................................	5-115
	5.13	Replacing the Pneumatic Unit .........................................................................	5-130
	5.14	Replacing the Ambient Temperature Sensor...................................................	5-138
	5.15	Replacing the Blood Sensor ............................................................................	5-140
	5.16	Replacing the Filtering Cartridge .....................................................................	5-142
6	Optical System		6-1
	6.1	Optical System Adjustment and Servicing ..........................................................	6-1
	6.2	Removing and Installing Optical System Assemblies..........................................	6-2
	6.3	Adjustment.........................................................................................................	6-11
	6.4	Common Failures of the Optical System...........................................................	6-27
7	Troubleshooting		7-1
	7.1	Error code and information..................................................................................	7-1
	7.2	Causes of Common Errors ..................................................................................	7-6
	7.3	Function Sequence Codes and Information ......................................................	7-14
	7.4	Error analysis and processing ...........................................................................	7-16
8	Maintaining Your Analyzer		8-1
	8.1	List of Parts That Need to Be Replaced Periodically ..........................................	8-1
	8.2	Basic Maintenance from Service Engineer .........................................................	8-1
9	Appendices		A-1

2

1 Using This Manual

1.1 Introduction

The chapter explains how to use the BC-5800 service manual. This manual provides the reference information and procedures needed in servicing the BC-5800. Before servicing the BC-5800, read and understand the manual carefully to ensure the proper servicing of the equipment and personnel safety.

This manual is to be used together with the operation manual of BC-5800. It does not contain information and procedures already covered in the operation manual of BC-5800.

zBe sure to operate and service the analyzer strictly as instructed in this manual and the operation manual.

1-1

Using This Manual

1.2 Who Should Read This Manual

To use this manual effectively, you need to have the following capacities:

Comprehensive knowledge of electric circuit and fluidic system;

Comprehensive knowledge of reagents;

Comprehensive knowledge of quality control;

Thorough understanding of troubleshooting;

The ability to operate the analyzer skillfully;

The ability to use basic mechanical tools and understand related terminology;

The ability to use a digital voltmeter and an oscilloscope masterly;

And the ability to read pneumatic/hydraulic schematics and understand related terminology.

1-2

Using This Manual

1.3 How to Find Information

This operation manual comprises 8 chapters and 5 appendices. Refer to the table below to find the information you need.

If you want to …	See …
learn about the system structure and the basic	Chapter 2 System Structure
principle of BC-5800
learn about the fluidic system	Chapter 3 Fluidic System
learn about the hardware system	Chapter 4 Hardware System
learn about how to service the BC-5800	Chapter 5 Servicing
learn about the optical system of BC-5800 and its	Chapter 6 Optical System
maintenance methods
learn about how to troubleshoot the common errors	Chapter 7 Troubleshooting
of the BC-5800
learn about how to maintain the BC-5800	Chapter 8 Maintenance
learn about the main spare parts of the BC-5800	Appendix A List of Spare parts
learn about the main wearing parts of the BC-5800	Appendix B List of Wearing Parts
learn about the schematic diagram of the fluidic	Appendix C Fluidic Diagram
system of the BC-5800
learn about the function of each valve and pump of	Appendix D Pump and Valve
the BC-5800	Function Table
learn about the tubing connection of the BC-5800	Appendix E Tubing

1-3

Using This Manual

1.4 Conventions Used in This Manual

This manual uses certain typographical conventions to clarify meaning in the text:

Format

Meaning

[XX]all capital letters enclosed in [ ] indicate a key name (either on the pop-up keyboard or the external keyboard)

“XX”	letters included in " " indicate text you can find on the screen
	of BC-5800
XX	italic letters indicate titles of the chapters that are referred to
XX	all-capitalized, bold and italic letters indicate a major operation
	defined in Section 1.4

All illustrations in this manual are provided as examples only. They may not necessarily reflect your analyzer setup or data displayed.

1-4

Using This Manual

1.5 Special Terms Used in This Manual

	When you read …			It means …
	CLICK	to press the desired item lightly with your finger; or to left-CLICK
		it with the mouse.
		to CLICK the desired edit box and use the external keyboard or
	ENTER	the pop-up keyboard to enter the desired characters or digits; or
		to scan the number by using the bar-code scanner.
		to move the cursor to the character or digit that you want to delete
		by clicking	the left	button	of	the	mouse	or	using
	DELETE	[←][→][Home][End],
		and then delete the character after the cursor by pressing [Del], or
		delete the character before the cursor by pressing [BackSpace]
		([←] on the upper right part of the soft keyboard).
		to CLICK the arrow buttons at the ends of the scroll bar; or to
		CLICK and hold the mouse button down while dragging the scroll
	DRAG SCROLL BAR	bar until the desired information is displayed; or to touch the scroll
		bar and rest your finger there until the desired information is
		displayed.
		to CLICK the down arrow button of the desired box to display the
	SELECT from	pull-down list, (and DRAG SCROLL BAR) to browse and then
		CLICK the	desired	item;	or	to	press	the	keys
	“ ** “ pull-down list
		([↑][↓][PageUp][PageDown]) to browse the current list and press
		[ENTER] to select the desired item.

1-5

Using This Manual

1.6 Symbols

You will find the following symbols in this manual.

When you see…	Then…
	read the statement below the symbol. The statement is
	alerting you to an operating hazard that can cause
	personnel injury.
	read the statement below the symbol. The statement is
	alerting you to a possibility of analyzer damage or
	unreliable analysis results.
	read the statement below the symbol. The statement is
	alerting you to information that requires your attention.
	read the statement below the symbol. The statement is
	alerting you to a potentially biohazardous condition.

You may find the following symbols on the analyzer, reagents, controls or calibrators.

When you see…

It means…

CAUTION, CONSULT ACCOMPANYING

DOCUMENTS.

BIOLOGICAL RISK

HIGH VOLTAGE

WARNING, LASER BEAM

WARNING, HOT SURFACE

PROTECTIVE EARTH (GROUND)

1-6

Using This Manual

EARTH (GROUND)

ALTERNATING CURRENT

FOR IN VITRO DIAGNOSTIC USE

TYPE B DEVICE

BATCH CODE

USE BY (YYYY-MM-DD)

SERIAL NUMBER

MEASUREMENT AUTHORIZATION

SYMBOL

DATE OF MANUFACTURE

MANUFACTURER

TEMPERATURE LIMITATION

CONSULT INSTRUCTIONS FOR USE

Be sure to observe the following precautions for the safety of patients, operators and yours when you are servicing the analyzer.

1-7

Using This Manual

zIt is important for the hospital or organization that employs this equipment to carry out a reasonable service/maintenance plan. Neglect of this may result in machine breakdown or harm to human health.

zNever use combustible gas (e.g. anesthetic) or combustible liquid (e.g. ethanol) around the analyzer. Otherwise, the risk of explosion may exist.

zWhen servicing the analyzer, be sure to turn off the power. Servicing the analyzer when it is on may bring risk of electric shock or damage to electronic components.

zConnect the analyzer to a socket having sole fuse and protective switch. Do not use the same fuse and protective switch with other equipment (e.g. life supporting equipment). Otherwise, the equipment failure, over current or impulse current that occurs at the startup moment may lead to tripping.

zTo prevent personal injury during maintenance, keep your clothes, hairs and hands from the moving parts, such as sample probe, clipper and piercer.

zPossible mechanical movement of the warned position may lead to personal injury during the normal operation, removal and maintenance.

zBe sure to dispose of reagents, waste, samples, consumables, etc. according to government regulations.

zThe reagents are irritating to eyes, skin and mucosa. Wear proper personal protective equipment (e.g. gloves, lab coat, etc.) and follow safe laboratory procedures when handling them in the laboratory.

zIf the reagents accidentally spill on your skin, wash them off with plenty of water and if necessary, go see a doctor; if the reagents accidentally spill into your eyes, wash them off with plenty of water and immediately go see a doctor.

1-8

Using This Manual

zImproper maintenance may damage the analyzer. Maintain the analyzer strictly as instructed by the service manual and inspect the analyzer carefully after the maintenance.

zFor problems not mentioned in the service manual, contact Mindray customer service department for maintenance advice.

zTo prevent personal injury or damage to equipment components, remove metal jewelry before maintaining or servicing electronic components of the equipment.

zElectrostatic discharge may damage electronic components. If there is a possibility of ESD damage with a procedure, then do that procedure at an ESD workstation, or wear an antistatic wrist strap.

zThis equipment must be operated by skilled/trained medical professionals.

zSamples, controls, calibrators and waste are potentially infectious. Wear proper personal protective equipment (e.g. gloves, lab coat, etc.) and follow safe laboratory procedures when handling them in the laboratory.

zAll the analyzer components and surfaces are potentially infectious. Take proper protective measures for operation or maintenance.

zThe sample probe tip is sharp and may contain biohazardous materials. Exercise caution to avoid contact with the probe when working around it.

1-9

2 System Structure

2.1System Overview

Hardware

Hardware is designed for signal gathering, the controlling and driving of motion components and the processing and display of data. It is mainly composed of main board, power drive board, signal processing board, power board, blood sensor board and pressure sensor board.

Interfaces

BC-5800 offers many interfaces to facilitate data processing and selection of various accessories. It provides 4 USB interfaces, 1 network interface, 1 pneumatic unit control interface and 1 reserved interface. USB interfaces can be used to connect mouse, keyboard, printer, scanner and USB, and to perform software upgrade. The network interface adopts built-in network card, can perform networking function.

Software running environment

System software can be divided into boot software, operation software and application software. The boot software and operation software are stored in the FLASH chip of the main board, and the application software is stored in the hard disk. The boot software has two main functions, one is to configure address space, and the other is to initialize system memory. The operation system completes the resource initialization of CPU board and provides operation system environment to the application software. The application software offers an interactive operation interface.

Fluidic system

Fluidic system is the tubing structure of the analyzer where reagent, sample and air flow through. All hydraulic parts are connected correspondingly, and they are controlled by software and drive hardware according to the specified order to realize control over the allocation and direction of media.

2-1

System Structure

2.2 Fluidic System

Please refer to Chapter 3 Fluidic System of this manual.

2-2

System Structure

2.3 Hardware System

Please refer to Chapter 5 Hardware System of this manual.

2-3

System Structure

2.4 Main Structure

BC-5800 5-differential auto hematology analyzer consists of the main unit (analyzer), pneumatic unit and accessories.

Figure 2-1 Front of the Analyzer

1	----Touch screen	----4	Sample probe
2----	Power button	5----	Aspirate key
3----	Power indicator

2-4

System Structure

Figure 2-2 Front of the Analyzer (Autoloader Configured)

1	----Touch screen	5	----Aspirate key
2----	Power button	6----	Sample tube
3----	Power indicator	7----	Tube rack
4----	Sample probe	8----	Autoloader

2-5

System Structure

		1
		2
	21	3
	20
	19
	18	4
	17	5
	16
	15
	14

	13	12	11	10	9	8	7	6
				Figure 2-3 Back of the Analyzer
1----	USB interface					12----	M-58D diluent inlet
2----	Reserved interface					13----	M-58D diluent sensor BNC connector
3----	Pneumatic unit control interface					14----	M-58LBA lyse inlet
4----	USB interface					15----	M-58LBA lyse sensor BNC connector
5----	Power input					16----	M-58LEO( ) lyse inlet
6----	Vacuum interface					17----	M-58LEO( ) lyse sensor BNC connector
7----	Pressure interface					18----	M-58LEO( ) lyse sensor BNC connector
8----	M-58 diluent sensor BNC connector					19----	M-58LEO( ) lyse inlet
9----	Waste sensor BNC connector					20----	M-58LH lyse inlet
10----	M-58 cleanser inlet					21----	M-58LH lyse sensor BNC connector
11----	Waste outlet

2-6

System Structure

Figure 2-4 Front of the Analyzer (Front Cover Removed)

1	----RBC & HGB bath unit	5	----Cover photocoupler protecting unit
2	----Cover support unit	6----	Manual sampling and SRV(Sample
		Rotator Valve) unit
3----	WBC bath unit	7----	START on/off unit
4----	RBC premix bath unit	8----	Syringes

2-7

System Structure

Figure 2-5 Front of the Analyzer (Front Cover Removed, Pierce & Mix Unit Configured)

----1	RBC & HGB bath unit	6	----Manual sampling and SRV(Sample
		Rotator Valve) unit
2----	Cover support unit	7----	START on/off unit
3----	WBC bath unit	8----	Syringes
4----	RBC premix bath unit	9----	Pierce & mix unit
5----	Cover photocoupler protecting
unit

2-8

System Structure

1 2

3

4

8

7

6

5

Figure 2-6 Inside Right of the Analyzer (Right Door Removed)

----1	Optical system	----5	Burkert valve unit
2----	Valve & pump unit	6----	Pinch valve unit
3----	Cistern and waste chamber	7----	Waste chamber
unit
4----	Waste five-way valve unit	8----	Reagent preheating unit

2-9

System Structure

9

10

11

12

8

7

6

5

4

3

2

1

Figure 2-7 Inside Left of the Analyzer (Left Door Removed)

1	----Power input	----7	Pressure sensor board
2----	Interface board	8----	Fan
3----	Filter	9----	Hard disk unit
4----	Air valve unit	----10 Main board and signal board unit
5----	Pressure regulator unit	----11 PCB support bar unit
6----	Power drive board unit	12----	Volumetric unit

2-10

System Structure

Figure 2-8 Front of Pneumatic Unit

----1 Relief valve

----2 Power indicator

2-11

System Structure

2.5 Software Structure

Software system can be divided into boot software, operation software and application software. Boot software is autoloaded by hardware; its code runs in FLASH to configure address space and to initialize system memory. Operation system completes the resource initialization of CPU board, loading application software and transferring the CPU control authority to application software. The code of application software runs in SDRAM, it obtains the resource data needed from external hard disk to provide functions like counting, parameter setting, quality control, device maintenance, data management, assistance, help, etc. The application software sends control command to corresponding fluidic units at the specified time according to the fluidic unit control sequence in basic sequence.

2.5.1 Menu Structure

1. Main screen

There are 8 function icons in the main screen menu. Operators can click on the function icons in the main screen to enter into corresponding screens to perform all functions of the analyzer. See Figure 2-9 for the submenu structure of the main screen.

Figure 2-9 Menu Structure of the Main Screen

2. Counting screen

Counting screen comprises four parts: status region, measurement result and data region of the current sample, data display region of the next sample and function button region. Operators can click each function button in the counting screen to perform the functions of the analyzer.

See Figure 2-10 for the menu structure of the counting screen:

2-12