Biosystems A15 User manual

A15

SERVICE MANUAL

ENGLISH

TESE00005-11-ING

July - 2009

SERVICE MANUAL

English

TABLE OF CONTENTS

1. INTRODUCTION................................................................................ 8

1.1. GENERAL DESCRIPTION OF THE ANALYZER..............................................................8

1.1.1. Operating arm........................................................................................................................................ 9

1.1.2. Dispensing system................................................................................................................................ 9

1.1.3. Reactions rotor and reading .............................................................................................................. 10

1.1.4. Electronic system................................................................................................................................ 11

1.1.5. Application program ........................................................................................................................... 11

1.2. FUNCTIONING OF THE ANALYSER..............................................................................11

1.3. TRANSPORT AND RESHIPMENT OF THE ANALYZER ...............................................12

2. MECHANICAL ELEMENTS............................................................. 14

2.1. Instrument breakdown...................................................................................................14

2.2. Description of the mechanical elements .....................................................................14

2.2.1. Operating arm...................................................................................................................................... 14

2.2.1.1. X Guide......................................................................................................................................... 15

2.2.1.2. X Carriage .................................................................................................................................... 16

2.2.1.3. Y Carriage .................................................................................................................................... 16

2.2.1.4. Needle unit.................................................................................................................................. 18

2.2.2. Dispensing system.............................................................................................................................. 19

2.2.2.1. Thermostated probe ................................................................................................................... 19

2.2.2.2. Dispensing pump ........................................................................................................................ 19

2.2.2.3. Tubes and containers ................................................................................................................. 21

2.2.2.4. Container level control sensors. ............................................................................................... 22

2.2.2.5. Racks tray with integrated washing station. ............................................................................ 23

2.2.2.6. Washing pumps........................................................................................................................... 23

2.2.3. Reaction rotor with integrated optical system. ................................................................................ 24

2.2.3.1. Thermostated rotor and photometric system .......................................................................... 24

2.2.3.2. Lighting system........................................................................................................................... 26

2.2.4. Electronics cover ............................................................................................................................... 27

2.2.5. Main cover hinges............................................................................................................................... 28

2.2.6. Base...................................................................................................................................................... 29

2.2.7. Casings ............................................................................................................................................... 30

3. Electronic system........................................................................... 31

3.1 CPU Board (CIIM00026) ..................................................................................................31

3.2 Power Supply Board (CIIM00015) ..................................................................................36

3.3 Needle Board (CIIM00017) ..............................................................................................38

3.4 Photometry Board (CIIM00027)......................................................................................40

3.5 XYZ Interconnection Board (CIIM00018).......................................................................41

3.6 Communications Board (CIIM00036)............................................................................42

3.7 Rotor interconnection board (CIIM00029).....................................................................43

3.9 Pump interconnection board (CIIM00028) ....................................................................45

3.10 Component relation .....................................................................................................47

3.11 Auxiliar channel information ........................................................................................47

3.12 Interconnection between boards.................................................................................51

3.13 Schematic liquid circuit................................................................................................57

4. SERVICE PROGRAM ...................................................................... 58

4.1 Initialising the analyser ..................................................................................................58

4.2. ADJUSTMENTS .............................................................................................................60

4.2.1. Adjustment of the needle thermostatation system.......................................................................... 60

4.2.2. Adjustment of the rotor thermostation system ................................................................................ 61

4.2.3. Adjustment of the positioning of the operating arm........................................................................ 62

4.2.3.1 Adjustment of X, Y and Z position for reagent and pediatric racks ............................................. 62

Service manual

4.2.4. Adjustment of the positioning of the rotor ....................................................................................... 65

4.2.4.1. Centering of the rotor with regard to the dispensing point ......................................................... 65

4.2.4.2. Centering of the rotor with regard to the optical system ............................................................. 65

4.2.5 . Adjustment of the positioning of the lter wheel............................................................................ 66

4.2.6. Adjustment of the level control scales.............................................................................................. 67

4.2.7. Adjustment of the level detection sensitivity ................................................................................... 68

4.3. TESTS..............................................................................................................................68

4.3.1. Motor tests........................................................................................................................................... 68

4.3.1.1. Initialization test ............................................................................................................................... 69

4.3.1.2. Movement test .................................................................................................................................. 69

4.3.1.3. Loss step test ................................................................................................................................... 70

4.3.1.4. Stress mode test .............................................................................................................................. 70

4.3.1.5. Z axis security systems test............................................................................................................ 70

4.3.1.6 Maximum Z verication test............................................................................................................. 71

4.3.2. Diaphragm pumps and electrovalves test ........................................................................................ 71

4.3.2.1. Functioning test ............................................................................................................................... 72

4.3.2.2. Stress mode test .............................................................................................................................. 72

4.3.3. Needle self-centering system test ..................................................................................................... 72

4.3.4. Needle level detection system test.................................................................................................... 72

4.3.5. Needle thermostatation system test.................................................................................................. 73

4.3.6. Needle rotor thermostatation system test ........................................................................................ 74

4.3.7. Photometry tests................................................................................................................................. 74

4.3.7.1. Base line and integration times ...................................................................................................... 74

4.3.7.2. Darkness counts .............................................................................................................................. 76

4.3.7.3. Repeatability without moving the lter wheel ............................................................................... 76

4.3.7.4. Stability ............................................................................................................................................. 77

4.3.7.5. Repeatability moving lter wheel ................................................................................................... 77

4.3.7.6. Absorbance measurement .............................................................................................................. 78

4.3.7.7. Reactions rotor check...................................................................................................................... 78

4.3.8. Level control scales test..................................................................................................................... 79

4.3.9. Covers detection test.......................................................................................................................... 79

4.3.10. PC-Analyzer communications channel test.................................................................................... 80

4.3.11. Global stress mode of the analyzer................................................................................................. 80

4.3.12. Photometry tool................................................................................................................................. 81

4.4. UTILITIES .......................................................................................................................82

4.4.1. Disassembly of the dispensing needle ............................................................................................. 82

4.4.2. Fluid system supply............................................................................................................................ 83

4.4.3. Cleaning of the dispensing system................................................................................................... 84

4.4.4. Changing the lamp.............................................................................................................................. 84

4.4.5. Conguration of the lter wheel ........................................................................................................ 85

4.4.6. Demonstration mode .......................................................................................................................... 85

4.4.7 Read/load adjustments and cycles..................................................................................................... 86

4.4.8 Change the rotor type.......................................................................................................................... 87

4.5. REGISTER.......................................................................................................................88

4.5.1. Introducing the analyzer serial number ............................................................................................ 88

4.5.2. Service Reports................................................................................................................................... 89

4.5.3. Language change................................................................................................................................ 89

4.5.4. Users .................................................................................................................................................... 90

4.6. MONITOR .......................................................................................................................90

4.7 User’s program ...............................................................................................................91

4.7.1 Conguration of the level of access to the analyser ....................................................................... 91

4.7.2 Reagent Consumption ........................................................................................................................ 92

5. MAINTENANCE AND CLEANING .................................................. 94

5.1. MAINTENANCE OPERATIONS ......................................................................................94

5.1.1. Housings and covers.......................................................................................................................... 94

5.1.1.1. Removing the needle unit casing .............................................................................................. 94

5.1.1.2. Removing the front housing ...................................................................................................... 94

5.1.1.3. Removing the main cover .......................................................................................................... 95

5.1.1.4. Removing the upper casing ....................................................................................................... 96

5.1.1.5. Removing the spring protector.................................................................................................. 98

5.1.2. Operating arm...................................................................................................................................... 98

5.1.2.1. Fully removing the operating arm ............................................................................................. 98

5.1.2.2. Changing the arm hose ............................................................................................................. 99

5.1.2.3. Changing the X motor............................................................................................................... 100

5.1.2.4. Changing the Y motor............................................................................................................... 102

5.1.2.5. Changing the Z motor............................................................................................................... 102

5.1.2.6. Changing the Y motor belt ....................................................................................................... 103

5.1.2.7. Changing the spring ................................................................................................................. 103

5.1.3. Dispensing system............................................................................................................................ 104

5.1.3.1. Changing the thermostated pipe. ........................................................................................... 104

5.1.3.2. Changing the dispensing pump seal ...................................................................................... 105

5.1.3.3. Changing the dispensing pump motor ................................................................................... 106

5.1.3.4. Changing the dispensing electrovalve ................................................................................... 107

5.1.3.5. Changing the container tube unit............................................................................................ 107

5.1.3.6. Changing the distilled water container lters ........................................................................ 107

5.1.4. Reactions rotor and reading ............................................................................................................ 108

5.1.4.1. Changing the rotor temperature probe ................................................................................... 108

5.1.4.2. Fully removing the rotor........................................................................................................... 109

5.1.4.3. Changing the rotor Peltier cells............................................................................................... 109

5.1.4.4. Changing the rotor cover detector .......................................................................................... 110

5.1.4.5. Changing the rotor start photosensor .................................................................................... 110

5.1.4.6. Changing the rotor motor..........................................................................................................111

5.1.4.8. Changing the lamp.................................................................................................................... 112

5.1.4.9. Changing an optical lter ......................................................................................................... 113

5.1.4.10. Conguration of the lter wheel ............................................................................................ 113

5.1.4.11. Changing the lter wheel start photosensor ........................................................................ 113

5.1.4.12. Changing the lter wheel motor ............................................................................................ 114

5.1.5. Electronic Systems ........................................................................................................................... 114

5.1.5.1. Changing the X, Y and encoder start photosensor................................................................ 114

5.1.5.2. Changing the microprocessor board ...................................................................................... 115

5.1.5.3. Changing the power supply board .......................................................................................... 115

5.1.5.4. Changing the main power supply source............................................................................... 116

5.1.5.5. Changing the photometric system board ............................................................................... 116

5.1.5.6. Changing the front indicator.................................................................................................... 117

5.1.5.7. Changing the rmware program.............................................................................................. 118

5.2. RECOMMENDED PREVENTIVE MAINTENANCE.......................................................118

5.3. CARE AND CLEANING.................................................................................................119

5.3.1. General care of the analyzer ............................................................................................................ 119

5.3.2. Cleaning the optical system............................................................................................................. 119

5.3.3. Cleaning the dispensing system ..................................................................................................... 120

5.3.4. General cleaning of the interior of the apparatus .......................................................................... 120

A I. TECHNICAL SPECIFICATIONS ................................................. 121

A II. ADJUSTMENT MARGINS TABLES .......................................... 125

A III. LIST OF CONSUMABLES, ACCESSORIES AND SPARES ... 126

A IV. LIST OF REQUIRED TOOLS.................................................... 128

A V. SOFTWARE VERSIONS ............................................................ 128

Service manual

1. INTRODUCTION

The A15 analyzer is an automatic random access analyser specially designed for performing biochemical and turbi-

dimetric clinical analyses. The instrument is controlled on-line in real time from an external dedicated PC.

In each of the elements of the A15 analyser, BioSystems has used leading edge technology to obtain optimum ana-

lytical performance, as well as taking into account economy, robustness, easy use and maintenance. A three-axis

Cartesian operating arm prepares the reactions. Dispensing is performed by means of a pump with a ceramic piston

via a detachable thermostated needle. A washing station guarantees that the needle is kept perfectly clean through-

out the process. The reactions take place in a thermostated rotor in which absorbance readings are taken directly by

means of an integrated optical system.

This manual contains the information required for learning about, maintaining and repairing the A15 automatic ana-

lyzer. It should be used by the Technical Service as a learning and consultation document for the maintenance and

repair of the instrument. Chapter 2 describes the different mechanical elements that form the analyzer together with

their functionality, and chapter 3 describes the electronic system. Chapter 4 describes the Service Program. All the

adjustments and checks of the analyzer are carried out through this program, which is independent from the application

program (User Program). The separation of both programs enable it to be maintained separately and the extensions

and improvements of one do not affect the other. The user does not have the service program. The Technical Service

must install it on the user’s computer in order to carry out the service requirements. Once said tasks have been car-

ried out, the Technical Service must uninstall the program. Chapter 5 offers instructions for the different maintenance,

repair and cleaning operations that can be carried out by the Technical Service. The annexes contain a summary of

the technical specications of the analyzer, the adjustment margin tables, the lists of accessories and spares, a list

of software versions and their compatibility and a software troubleshooting guide.

1.1. GENERAL DESCRIPTION OF THE ANALYZER

The A15 analyser is made up of three basic elements: the operating arm, the dispensing system and the reading and

reactions rotor. The electronic system of the instrument controls said elements and communicates with the external

computer containing the application program. Through this program, the user can control all the operations of the

analyzer.

1.1.1. Operating arm

This is a three-axis XYZ Cartesian mechanism. The X and Y axes move the dispensing needle over the analyser

horizontally and the Z axis moves it vertically. It is operated by three step-by-step motors. In each 24-second prepara-

tion cycle, the operating arm performs the following actions: rst of all, it sucks in the reagent from the corresponding

bottle. Next, the needle is washed externally in the washing station and sucks in the sample from the corresponding

tube. It is washed externally again and dispenses the sample and the reagent into the reactions rotor. Finally, it is

exhaustively washed internally and externally before proceeding with the next preparation. The arm has a system

for controlling vertical movement to detect whether or not the needle has collided into anything on descending. If a

collision occurs, as may be the case if, for example, a lid has been left on a bottle of reagent, the arm automatically

restarts, veries the straightness of the needle and continues working issuing the corresponding alert to the user.

A vertical axis retention system prevents the needle from falling in the case of a power cut, avoiding injury from the

needle to the user or the needle being bent by an attempt to move the arm manually. The operating arm only makes

the preparations if the general cover of the analyser is closed. If the cover is raised while it is functioning, the arm

automatically aborts the task in progress and returns to its parked position to avoid injury to the user.

1.1.2. Dispensing system

This system consists of a thermostated needle, supported and displaced by an operating arm and connected to a

dispensing pump. The needle is detachable to enable cleaning and replacement. The analyser has capacity level

detection to control the level of the bottles and tubes and prevent the needle from penetrating too far into the corre-

sponding liquids, thus minimising contamination. An automatic adjustment system informs the user if the needle is not

mounted or if it is too bent. The needle has a sophisticated Peltier thermostatation system, with PID control, capable

of thermostating the preparations at approximately 37º in less than 15 seconds. Dispensing is carried out by means

of a low maintenance ceramic piston pump driven by a step-by-step motor. It is capable of dispensing between 3 and

1250 ml. The exterior of the needle is kept constantly clean by a wash station included in the base. A membrane pump

transports the waste to the corresponding container.

The A15 analyser has a tray with 4 free positions for racks of reagents or samples. Each reagents rack can carry up

to 10 reagents in 20 ml or 50 ml bottles. Each samples rack can contain up to 24 tubes of samples. The samples can

be patients, calibrators or controls. The analyser can be congured to work with 13 mm or 15 mm diameter tubes of

samples with a length of up to 100 mm or with paediatric wells. Any possible conguration of racks can be mounted

from 1 rack of reagents (10 reagents) and 3 racks of samples (72 samples) to 3 racks of reagents (30 reagents) and

1 rack of samples (24 samples).

On the left of the analyser are the waste and distilled water containers. The analyser constantly controls the level of

these containers and issues the appropriate alerts if the distilled water is nearly empty or if the waste container is full.

Service manual

1.1.3. Reactions rotor and reading

The preparations are dispensed in an optical quality methacrylate reactions rotor thermostated at 37ºC. The optical

absorbance readings are taken directly on this rotor. Each reaction can be read for 10 minutes. The readings are

taken as they are programmed in each measurement procedure. The reaction wells have been designed to enable

the mixture of the sample and the reagent during the dispensing. Each rotor has 120 reaction wells. The length of the

light path is 6 mm. The minimum volume required to take the optical reading is 200 uL. The wells have a maximum

useful capacity of 800 uL. When the reactions rotor is completely full, the user must change it for one that is empty,

clean and dry. The reactions rotors can be reused up to 5 times if they are carefully cleaned immediately after use.

The Cleaning the semi-disposable reactions rotor section in the Installation and maintenance manual describes how

to clean the rotors. The user has a test in the computer programme, which he or she may use to check the condition

of the rotor. The rotor is driven by a step-by-step motor with a transmission. A Peltier system with PID control ther-

mostates the rotor at 37ºC.

An optical system integrated in the rotor takes the readings directly on the reaction wells. The light source is a 10 W

halogen lamp. The detector is a silicon photodiode. The wavelength is selected by a drum with 9 positions available

for optic lters. The lters are easily ch an ged by the user from the exterior of the analyser, without the need for disas-

sembling the lter drum. A step-by-step motor positions the drum. The optical system is capable of taking 1.25 readings

per second, with or without a lter change in between. The light beam from the lamp passes through a compensated

interferential lter to select the desired wavelength. It then passes through the rotor well and nally reaches the pho-

todiode, where the light signal is turned into an electric signal. A sophisticated analogical digital integrator-converter

system converts the electric signal into a digital value with which the analyser obtains the absorbance values. The

optical system continues to work when the general cover of the analyser is open, whereby the analyser can continue

to take readings while the user handles, for example, the sample tubes or the reagent bottles. The rotor cover must

be in place for the optical system to work correctly.

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