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Chemray 240

Auto Chemistry Analyzer


Service Manual

Rayto Life and Analytical Sciences Co., Ltd.


Telephone: +86 755 88832350
Fax: +86 755 86168796
E-mail:support@rayto.com
Website: www.rayto.com
Version: 1.0e

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Contents
1. INSTRUMENT INTRODUCTION ................................................................ 4
1.1 PRINCIPLES AND INTENDED USE .....................................................................................4
1.2 MAIN STRUCTURE OF INSTRUMENT .................................................................................4
1.2.1 Sample/reagent disc....................................................................................................................5
1.2.2 Sampling system .........................................................................................................................6
1.2.3 Sampling washing system ...........................................................................................................8
1.2.4 Stirring system.............................................................................................................................8
1.2.5 Reaction disc temperature control ...............................................................................................9
1.2.6 Reaction disc ...............................................................................................................................9
1.2.7 Reaction Cup.............................................................................................................................10
1.2.8 Optical System ..........................................................................................................................10
1.2.9 Heat emission and dust-proof of the whole machine .................................................................11
1.2.10 Display.....................................................................................................................................11

1.3 TECHNICAL PARAMETERS............................................................................................. 11

2. INSTRUMENT INSTALLATION AND CALIBRATION ............................... 13


2.1 INSTRUMENT UNSEALING .............................................................................................13
2.2 INSTALLATION ENVIRONMENT .......................................................................................13
2.3 INSTRUMENT CONNECTIONS.........................................................................................14

3. FUNCTIONAL DESCRIPTION.................................................................. 16
3.1 CHEMRAY240 FUNCTION BOX ......................................................................................16
3.2 FUNCTION DESCRIPTION OF EACH BOARDS ....................................................................18
3.2.1 Main board (MCON) ..................................................................................................................18
3.2.2 Temperature Control Board (TCON)..........................................................................................24
3.2.3 Photoelectric conversion board (IVAB) ......................................................................................26
3.2.4 Photoelectric amplification board (ADCB) .................................................................................26
3.2.5 Optic-coupler fixing board (OCBD) ............................................................................................27
3.2.6 Feeding and dispensing liquid alarm board (WSIF)...................................................................28
3.2.7 Liquid level detection board (LDCB) ..........................................................................................29
3.2.8 Serial Port Transfer Board (RSIF)..............................................................................................29
3.2.9 Temperature Sensor Transfer Board (TMDT) ............................................................................30

4. PARTS REPLACEMENT .......................................................................... 31


4.1 INSTRUMENT ASSEMBLY...............................................................................................31
4.2 LIGHT SOURCE LAMP REPLACEMENT .............................................................................31
4.3 REACTION CUP REPLACEMENT .....................................................................................34
4.4 PUMP\VALVE REPLACEMENT ........................................................................................35
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4.5 CABLES REPLACEMENT ...............................................................................................36

5. MAINTENANCE TO THE INSTRUMENT ................................................. 38


5.1 BASIC MAINTENANCE ..................................................................................................38
5.1.1 Daily Maintenance ...................................................................................................................38
5.1.2 Weekly Maintenance .................................................................................................................38
5.1.3 Monthly maintenance ................................................................................................................38
5.1.4 Biannual maintenance ...............................................................................................................39

5.2 THE TREATMENT TO BLOCKED SAMPLING NEEDLE ...........................................................39


5.3 CLEAN THE WASHING STATION ......................................................................................40

6. TROUBLE SHOOTING ............................................................................. 42


6.1 COMMON TROUBLE SHOOTINGS ..................................................................................42

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1. Instrument Introduction
1.1 Principles and Intended use
The instrument Is using the principle of colorimetry, suitable for clinical routine biochemical tests. This
device has no external energy output, no risk of over-temperature, excess radiation output. The
matters needing attention mainly include mechanical motion risk and electric shock risk: when
repairing or dissemble the cover for other reasons, you must cut off the power and shutdown the
mainframe.
Chemray 240 is easy to operate, has friendly interface to user, It is a good choice for clinical chemistry
laboratories.
Chemray 240 system has the following features:
1. Powerful software, five worksheets, each one with 39 samples.
2. 38 reagent positions, position of single and double reagent can be set randomly.
3. Display and print results in different styles, including the storage of test results and info of
patients.
4. End point, two point and kinetic method, test with double-wavelength is supported.
5. Calculation by calibration, factor and other method.
6. 8 standard filters: 340nm, 405nm, 450nm, 510nm, 546nm, 578nm, 630nm, 670nm, Other
wavelengths are optional according to users requirement.
7. The system will continuously detect and control during the operation, to avoid errors, Error
message will be displayed when detected errors, provide instruction to the user to choose
correct buttons and operations

1.2 Main structure of instrument


The outside view of the Chemray 240 automatic biochemical analyzer is shown below:

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The instrument mainframe is mainly composed of sample/reagent processing system, mixing system,
reaction system, and photoelectric detection system. The structure of each function module is as
following:

1.2.1 Sample/reagent disc


The sample and reagent disc are located in a same big plate body, and there are 40 sample positions
and 40 reagent positions.
The sample bracket supports the standard test tube, the original blood sampling tube, and the micro
sample cup, the specifications are as follows:

Standard test tube: 1268.5, 1299, 12.775, 12.7100, 1375, 13100;

Original blood sampling tube: 1268.5, 1299, 12.775, 12.7 100, 1375, 13100;

Micro sample cup: 10 37, 12 37

The reagent disc can hold two sizes of reagent bottles (one big, another small), the volumes are 40ml
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and 18ml, and the reagent bottles of different sizes can be used together.

The system will automatically detect the positions of the working reagents. Before each operation, you
can check the position of each reagent should be placed, as well as the total volume of reagent
required for this test. Indications will also be displayed.
The core functional components of the reagent/sample disc cooling system is composed of fan,
radiator, Peltier and other component parts. The cool side of peltier is close to the bottom of the
refrigeration cabin but the hot side should be close to the radiator.
1.2.2 Sampling system
The driver component of the sampling system has two optical couplers, one located at the vertical
direction, another at the horizontal direction, to determine the original mechanical position of the
vertical and horizontal directions precisely. The system also has two stepping motors on the vertical
and horizontal directions to control the accurate movement of the sampling needle at the vertical and
horizontal directions, which is driven by belt and pulley.
The sampling needle with liquid sensor function will contact with the liquid, to aspirate the required
volume. When the reagent or sample is not enough, the instrument will give prompt message
automatically. During the operation of Chemray 240, the aspiration cycle of the sampling needle is as
follows:
1. The sampling needle enters the bottle of the reagent 1, aspirate reagent with required volume, and
eliminate the return error;

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2. The sampling needle moves to the reaction cup and dispense reagent 1;
3. The sampling needle moves to the washing station, and perform washing;
4. The sampling needle moves to the sample cup to aspirate sample with preset volume, and eliminate
the return error;
5. The sampling needle moves to the washing station for cleaning;
6. Transfer the sample and reagent into the Reaction disc wells;
7. The mechanic arm moves back to the washing station, to wash the sampling needle and mixer;
8. A bit of air and 100L distilled water is aspirated into the flowcell, rinse the flowcell to clean the
remaining samples of last test.
9. The sampling needle aspirate 80L reaction liquid and a bit of air into the flowcell, rinse the flowcell
to prevent the cross-contamination between samples;
10. Aspirate the remaining reaction liquid into the flowcell for measurement;
11. The mechanic arm moves back to its original position (the washing station); clean the sampling
needle and the sample-aspiration circle starts again.
Generally, when testing with end-point method items and double-reagents items, you can set the
stirring time as 1 ~ 2 seconds.

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When pre-heating the reagent, if the required volume of the reagent is more than 250 micro liters, the
frozen reagent should be treated with the pre-heating module, and the temperature is 30 ~ 35 after
pre-heating.
Reagent pre-heating needs an over-temperature protection, and an intelligent temperature control.
Before adding into the reaction cup, the reagent mainly obtains heat from the tube of the middle
heating section, perform the pre-heating by the mixing of high temperature reagent and low
temperature reagent.
In order to ensure the accuracy and repeatability of test results, the suggested sample volume should
be more than 4L.

1.2.3 Sampling washing system


The sampling washing system and the stirring washing system use the same materials, called
"Washing station"; use water-spring-type washing method to wash the surface of needle and the
stirring rod.
When the operator has performed an illegal operation or errors of procedure occurred, make the
instrument perform wrong actions, the waste liquid in the waste bottle may overflow, it will be drained
from the mandatory drainage holes at the bottom of instrument.

1.2.4 Stirring system


The stirring rod using the structure of cam, it has two limit positions in the washing station and the
reaction cup, this structure is simple and practical, and the risk of movement has also been reduced in
a certain degree. Oar-shaped mixing head can achieve rapid mixing effect through the micro DC
motor.

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1.2.5 Reaction disc temperature control

Using air bath, three fans inside, to make internal hot air rotate and circulate up and down;

Using high quality insulation materials externally will effectively resist the interference to the
internal temperature-controlled room from the external environment.

using over-temperature protection, the system will cut off the power if the heating air exceeds
a certain temperature to avoid overheating resulting in fires and other accidents;

Intelligent temperature control system;

1.2.6 Reaction disc


The Reaction disc pot body is the same with the reagent/specimen disc body with external insulation,
but the external insulation is mainly to ensure that the Reaction disc internal temperature control easy
to be implemented, because if the effect of insulation is not good, the reaction disc outside will be
featured with fast heat exchange and it is not good to the implementation of constant temperature.

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Reaction cup replacement


entrance

External insulation

Light source part of the


optical assembly
1.2.7 Reaction Cup
There are 81 reaction positions. Use high-quality plastic semi-permanent reaction cup, with jointly
linked structure, each row has 9 cups; the optical path is 5 0.02mm;

1.2.8 Optical System


Standard configuration: 340, 405, 450, 510, 546, 578, 630, 670 nm filters, total of 8 wavelengths.
Interference filter, front spectrum, has a separate dark current detection channel. Using 2,000 hours
long-life tungsten halogen lamp, 12 V, 20W.

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Photodiode component

Optical block

Light source component

Filter wheel component

1.2.9 Heat emission and dust-proof of the whole machine


The light source uses a direct thermal fan, without any separate air path, use the negative
pressure to aspirate air naturally;
The reagent refrigeration air path is separate;
The whole machine heat emission adopts downdraught system, the whole machine can aspirate
air from front and side air.
1.2.10 Display
Chemray 240 uses color LCD screen to display WINDOWS software, with friendly user interface.
Operator can operate the software step by step according to the related instructions.

1.3 Technical parameters


System

Random optional, multi-channel, multi-parameters

Test Type

Colorimetric method, immuneoturbidimetric method, etc.

Weight

140kg (desktop)

Power

AC220V ,50-60Hz

Fuse

250 V/10 A

Analysis methods

End-point, two-point, kinetics method, support double reagents


and double-wavelengths

Filter

8 optical filters (340,405,450,510,546,578,630,670 nm)

Temperature Control

Ambient temperature 25, 30, 37


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Reagent positions

40

Reagent volume

Less than 500uL

Specimen positions

40

Specimen volume

3 ~ 45uL

Light source

Halogen lamp 12V, 20W

Linear range

0-3.5 Abs1%

Sensitivity

0.0001Abs

Work environment

15-30 , relative humidity 18-85%

Test Method

Factor method, single-point standard, multi-point standard

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2. Instrument Installation and calibration


2.1 Instrument unsealing
Unpack the package of the instrument and remove the materials for transport. Save the packing box
and the packaging materials well, for your convenience in the future of re-packaging the instrument.
1) Take out the instrument from the box.
2) Take away the packaging materials, and take out the instrument from the plastic packaging bag.
3) Check the items in the box and confirm that the following items are within the box:
Chemray 240 mainframe
Users Manual
Packing List
Warranty certificate
Accessories: power cord, printer, print cable, LCD monitor, mouse, keyboard, RS-232 serial
cable, spare fuses, etc. (see packing list).
Note: If the items are inconsistent with the packing list or have any defects, please contact with
the supplier.

2.2 Installation Environment


Chemray 240 auto chemistry analyzer must be installed by authorized professionals. The instrument
must be installed in a clean dust-free operation room, to avoid shock, humidity, strong magnetic fields
and direct light. The working environment is of 15~30, the relative humidity is 35~85%
(non-condensing).
The power supply must be 220V/50 Hz, and should be well grounded. If the laboratory voltage change
is greater than +10%, it is recommended to install an external regulator above 1500-watt. As this
machine is a full computer-controlled precision instrument, it is proposed to install an UPS above
2000W (uninterruptible back-up power supply).
The back-face of the instrument should be 0.5 m to the wall at least, in order to ensure the heat
dissipation requirements.
If it is a desktop machine, the water bucket should be placed at the right lower adjacent to the analyzer,
pay attention to ensure that the waste liquid pipe should always be downward, to avoid the situation
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such as upward wrap (it can be resolved by adjusting the tube length).
In order to ensure the normal operation of the instrument, it is prohibit to placing the instrument in the
following places:
A place of large temperature difference
A place of extreme environments in temperature, altitude, and air pressure
A place of heavy dusts
A place of vibrated table, and large tilt angle
A place close to the magnetic field of electromagnetic devices
Note:
The AC power supply must be well grounded (zero ground voltage <5V).
The AC power must be stable and it is prohibited to share power supply with the appliances of
high power. Recommend to fit with a large 2000W UPS Power Supply.
When unplugging the power cord, please seize the plug itself, rather than the power cord.
If the instrument is found to have smoke, smell or abnormal sounds, immediately turn off the
power, and contact with the Rayto service center immediately.

2.3 Instrument connections


1. Interface of the whole machine
RS-232: Standard RS-232 Interface
Ground Interface

2. Electrical interface and switch


AC Power Input
Fuse T10AL 250V
Reagent refrigerated position

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CPU

3. The external bucket connection interfaces


If the color mark is still remained, you can connect according to the color mark, if the color
identification is missed, then connect in line with the following figure to ensure proper connection.

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3. Functional Description
3.1 Chemray240 function box

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3.2 Function description of each boards


3.2.1 Main board (MCON)
The main board is machine's central control unit, including the mid-position machine, and five
hypostasis machine modules;
The mid-position machine is responsible for the channel scheduling of the five control modules;
Module 1 is for the movement control of the reagent disc motor and the filter wheel motor;
Module 2 is for the movement control of the reaction disc motor and the auto-rinsing motor;
Module 3 is for the control of the sampling needle up and down movement motor, the sampling needle
rotating motor, and the syringe motor;
Module 4 is for the control of the stirring rod up and down movement motor and the stirring rod rotation
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DC motor;
Module 5 is an independent board, it is a temperature control module, which can independently
complete the temperature control for the reaction disc constant temperature heating, sampling needle
pre-heating, auto-rinsing pre-heating, and the reagent disc cooling;
The interfaces are defined as follows:
(1) Testing components:
OC1: Reagent/specimen disc initial position sensor
OC2: Reagent/code disc of specimen disc sensor
OC3: Filter wheel initial position sensor
OC4: Reaction disc initial sensor
OC5: Code disc of reaction disc sensor
OC6: Auto-rinsing upper and lower sensor
OC7: Sampling needle up and down position sensor
OC8: Sampling needle rotation initial position sensor
OC9: Syringe initial position sensor
OC10: Stirring rod initial position sensor

(2) Control components (motor part):


JM1: Reagent/specimen disc motor
JM2: Filter Wheel Motor
JM3: Reaction disc motor
JM4Auto-rinsing motor
JM5: Sampling needle up and down movement motor
JM6: Sampling needle rotation motor
JM7: Syringe motor
JM8: Stirring rod up and down movement motor
DM: Stirring rod rotation DC motor
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(3) Control components (pump valve part):


V1: Inner wall cleaning valve
V2: Auto-rinsing liquid feeding valve A, 1-2-step
V3: Auto-rinsing liquid feeding valve B, 3-6-step
V4: Auto-rinsing liquid feeding valve C, 7-8-step
P1: Sampling needle inner wall scavenging pump
P2: Sampling needle outer wall scavenging pump
P3: Auto-rinsing liquid feeding valve A, 1-2-step
P4: Auto-rinsing liquid feeding pump B, 3-6-step
P5: Auto-rinsing liquid feeding pump C, 7-8-step
P6: Auto-rinsing liquid dispensing pump A, 1-2-step
P7: Auto-rinsing liquid dispensing pump B, 3-7-step
P8: Auto-rinsing liquid dispensing pump C, 8-step

(4) Control components (buzzer):


BUZZER1: Wash liquid and waste liquid alarm;
BUZZER2: Sampling needle movement fault alarm.

(5) Some interfaces:


J1: The interface to serial port transfer board, communicate with computer;
U15: The interface to the temperature control board, and communicate with it;
JP4: The interface to the liquid feeding and dispensing alarming board;
J2: The interface to the optic-electronic amplification board;
HP: Power Interface.

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Picture of main board (PCB No.001)


U15

J1

HP

J2

OC1~OC10

P1~P8

JP4
BUZZER1

V1~V4

BUZZER2

JM1~JM8

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3.2.2 Temperature Control Board (TCON)


Temperature Control Board performs the whole machine temperature control, it can complete the
temperature control for the reaction disc constant temperature heating, sampling needle pre-heating,
auto-rinsing pre-heating, and the reagent disc cooling independently;
The control parameters will be loaded through the serial port by the main board, and the temperature
data will be inquired by the main board.
The interfaces are defined as follows:
(1) Testing components:
T1: Reaction disc temperature sensor;
H_HEAT1: Sampling needle pre-heating temperature sensor;
H_HEAT3: Auto-rinsing pre-heating temperature sensor;
H_COLD: Reagent disc cooling temperature sensor;

(2) Control components (motor part):


J1: Reaction disc heating membrane;
J3: Sampling needle heating rod;
J5: Auto-rinsing heating rod;
PX1: Cooling Peltier 1;
PX2: Cooling Peltier 2;
PX3: Cooling Peltier 3;
(3) Some interfaces:
PWCN: heating control power interface;
PW3: refrigeration control power interface;
PW1: AC power input interface;
HP: Power Interface.

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Picture of temperature control board (PCB No.002)

RS0

PX1~PX3

PW3

T1

H_COLD

H_HEAT1

H_HEAT3
PWCN

J1

PW1

J3

J5

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3.2.3 Photoelectric conversion board (IVAB)


Photoelectric conversion board is to convert the photodiode current signal into voltage signal, and
perform the first-class amplification, A1 = 1.5
The interface is defined as follows:
J1: the signal output interface.
The specific circuit diagram is as follows:

J1

3.2.4 Photoelectric amplification board (ADCB)


The photoelectric amplification board is for the second stage amplification of the photoelectric signal,
the magnification is adjusted by the digital potentiometer, the specific regulation should follow the
corresponding settings in the engineering debugging software, the magnification A2 = 1 + (R
Number/1k);
Input the former two stage amplified signal into the AD conversion chip for analog-digital conversion,
the control signal is from the main board, and the output signal will return back to the main board;
Total photoelectric signal amplification, A = A1 * A2.
Interfaces are defined as follows:
J1: The signal interface to the main board.
J2: The interface to the photoelectric conversion board.

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Picture of photoelectric amplification board (PCB No.004)

J2

J1

3.2.5 Optic-coupler fixing board (OCBD)


The machine has 10 correlation-type infrared photoelectric sensors, commonly known as
optic-coupler;
The 10 correlation-type infrared photoelectric sensors will be fixed on board, connected to the main
board by 3pin cable, supporting the main board for collecting the position signals of various fixed
optic-couplers.
The interfaces are defined as follows:
J1: The interface to the main board optic-coupler input end.
Picture of optic-coupler fixing board (PCB No.005)

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J1
3.2.6 Feeding and dispensing liquid alarm board (WSIF)
This board will connect to the alarm sensors of the wash bottles and the waste bottle, the connector is
designed as audio interface, connect to the main board through the 10pin flat cable, for the alarm
circuit signal processing;
It is designed with two-way cleaning liquid bottle alarm inputs, two-way waste liquid bottle alarm inputs,
which should be installed according to the actual situation.
The interfaces are defined as follows:
JP1: Feeding and dispensing liquid alarm line interface;
WASH1: wash liquid 1 alarm line input;
WASH2: wash liquid 2 alarm line input;
WASTE1: Waste liquid 1 alarm line input;
WASTE2: Waste liquid 2 alarm line input;

Picture of feeding and dispensing liquid alarm board (PCB No.006):

JP1

WASH

WASH2

WASTE1

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WASTE2

3.2.7 Liquid level detection board (LDCB)


The liquid level detection board is to perform the liquid level detection when the sampling needle is
aspirating the reagent or specimen, and the test principle is capacitance. When moving the sampling
needle up and down, from up and down movement to contact with the liquid surface, the capacitance
of the sampling needle will change, the adjusted voltage signal will change, refers to the liquid surface
information;
The crash-proof signal detection of the sampling needle up and down movement will be completed by
the combination of an optic-coupler and a retaining piece;
The liquid level detection signal and the up and down crash-proof signal will be connected to the main
board through 5pin flexible cable, for signal judgment.
The interfaces are defined as follows:
J1: The interface connected to the sampling needle.
JP1: The interface to the main board.

Picture of liquid level detection board (PCB No.007):


TP1

J1

TP2

VR1

VR2

JP1

VR3

3.2.8 Serial Port Transfer Board (RSIF)


It is the Serial Port transfer board of the whole instrument, one end will be connected to the main board
serial converter with 3 pin cable, and the other end will be connected to the computer serial port
through an external serial cable.
The interfaces are defined as follows:
J1: The interface to the main board.

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RS232: The interface to the computer.


Picture of serial port transfer board (PCB No.008):
RS232

J1

3.2.9 Temperature Sensor Transfer Board (TMDT)


The interfaces are defined as follows:
J1: Temperature control board interface.
Picture of temperature Sensor transfer board (PCB No.009):
J1

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4. Parts Replacement
4.1 Instrument assembly
Chemray 240 is a high- precision instrument, if the instrument has trouble and can not be resolved with
the method in this manual, it should be repaired by professionals; If it is confirmed that the internal
parts of the instrument have some troubles which should be replaced for repairing, please follow the
below steps to dismantle the instrument:
1. Turn off the instrument power switch (unplug the power cord to prevent from turning on the
power switch accidently).
2. Remove the eight screws which fix the rear-board of the machine with a screwdriver and
remove the rear board, pay attention to protect the board, avoid falling damage.
3. After removing the rear-board, you can see the instrument's internal hardware boards, pump
valves, the board sockets of the cable at a glance, so it is convenient for electrical maintenance.

4.2 Light source lamp replacement


The lamp light source will gradually age to make energy attenuation when used for a long time, if the
system has given out alarm message, or the total working time is estimated to be over 1000 hours,
need to replace the light source lamp.
1. Turn off the power to make the lamp and lamp box cool for 30 minutes.

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Note:
Must wait more than 30 minutes after shutdown, even after 30 minutes, you must be careful to touch
the shell body of the light source lamp, because the hot lamp and lamp box will cause skin burns.
2. Unscrew the light source cover at the worktable.

3. Unscrew the three cross screws on the top of the light source body shell.
4. Wait until the light source shell will not burn your skin because of high temperature, pinch the light
source cable connectors with hand and hold up the shell;
5. Remove the light source components, replace new light source lamp, connect the light source line
well, and then put back the supporting base and lock the three cross screws unscrewed before.
Note:
When assembling or disassembling the light source, even if the lamp has no heat, please do
not touch the translucent lamp surface with your hands, because this may change the
characteristics of the light source due to grease, dirt and other reasons, if inadvertently make
the translucent surface stained with grease, dirt, you can wipe it with a clean cotton swab
dipped with absolute ethanol.

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Light source shell fixing


screw
Light source
connection cable

Light source component fixing screw

6. The light source lamp has been positioned by screws, no need for fine-tuning, but because of the
differences of various lamps, you need to adjust the received light energy, it is recommended to
replace all the reaction cups here, in order to avoid the large differences between the old and new
cups. Method 1: turn on the instrument, enter into the "Chemray 240 auto chemistry analyzer
management software" "Status" "Reaction disc", click on Change Cuvette" button, and then you
can replace it based on prompt, (method 2: or from the " Chemray 240 auto chemistry analyzer
management software," "Maintenance" "Blank" and then click on "Change Cuvette" button, but
note that this method requires a user authorization; Method 3: "Engineering debugging software"
"Blank" "Change Cuvette".
7. Users usually operate only with method 1 and 2, after correct replacement of the reaction cup, from
the " Chemray 240 auto chemistry analyzer management software" "Maintenance" "Blank" and
then click on Check Blank button, record the proximate light intensity AD value of each wavelength,
and then enter into "Maintenance" Configure, adjust the magnitude ratio of each wavelength, make
the light intensity AD value of each wavelength to be about 55000, but for the wavelengths over 510nm,
its AD value could be about 57000 (if it can not successfully auto-configure the magnitude ratio, you
must configure it manually, the AD value is proportional to the configured value), after completing the
configuration, please perform the blank check once more, please observe whether it is appropriate or
not, you may need to repeat several times before it meets the requirements.

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8. After confirming that there is no problem, you can tighten the light source cover of the worktable.
Note: When adjusting the location of the light source lamp, do not let the light directly shine your eyes,
because the strong light may hurt your eyes.

4.3 Reaction cup replacement


1) Open the reaction cup replacement entrance on the worktable.
2) The method to replace the reaction cup is the same with the steps mentioned in section 4.2. Method
1: turn on the instrument, enter into the "Chemray 240 auto chemistry analyzer management software"
"Status" "Reaction disc", click on Change Cuvette" button, and then you can replace it based on
prompt, (method 2: or from the " Chemray 240 auto chemistry analyzer management software,"
"Maintenance" "Blank" and then click on "Change Cuvette" button, but note that this method
requires a user authorization; Method 3: "Engineering debugging software" "Blank" "Change
Cuvette".
3) If the instrument is with auto-rinsing system, when replacing the reaction cup, carefully unscrew the
reaction cup fixing screw; do not let it slide inside. If it has been slid inside, the proposed operation is to

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shutdown firstly, and rotates the reaction disc in place by hand or takes the falling screw out with
tweezers or magnetic screwdriver.
4) If the instrument is not with auto-rinsing system, when replacing the reaction cup, pay attention to
take it out vertically to prevent the reaction cup orientation column breaking accidently; when
placing the new reaction cup, please put it vertically, after it has been positioned well, press the cup
joint slightly, to check whether it is flat or not;
5) Because that the reaction cups may have differences in different batches, it is proposed that you
should observe the Cuvette blank after replacing the reaction cup; from " Chemray 240 auto
chemistry analyzer management software," "Maintenance" "Blank" and then click on Check
Blank button, observe the proximate light intensity AD value of each wavelength, to determine
whether need to adjust the magnitude ratio;
6) Close the reaction cup replacement entrance cover-plate on the worktable.

The reaction cup replacement

entrance cover-plate

4.4 Pump\valve Replacement


Firstly, disassemble all the pump\valve components requiring for replacement, and then replace the
specific pump\valves.

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Sampling needle inner and


outer wall washing pump valve
Auto-rinsing pump valve
fixing component
fixing component

Note: Pay attention to the bonding wire on the pump valve, so as not to break; be careful of liquid
spilling when you unplugging the pipes.

4.5 Cables replacement

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When replacing the cables, please pay attention to the labels on them, do not replace them with the
cable of incorrect labels, if you really have no correct label on the cables, you can write the correct
label on a piece of paper and cover it onto the original label, then twist it with transparent tape.
When plug and unplug the cables, please do not shake around.

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5. Maintenance to the instrument


Chemray 240 is a precise clinical analyzer, in order to maintaining the instrument in a good condition;
you must do the routine maintenance work well. The maintenance of Chemray 240 is very simple, but
it must be performed carefully.

5.1 Basic Maintenance


5.1.1 Daily Maintenance
Keep the instrument working environment clean.
The cleaning of the instrument surface must be performed with some neutral detergents and damp
cloth.
LCD display must be cleaned with a soft cloth.
Check the sampling needle to make sure that it is in good condition, no impairment, and no dirt;
wipe it with some neutral detergents and cloth.
Check the stirring rod to make sure that it is in good condition, no impairment, and no dirt; wipe it
with some neutral detergents and cloth.
Check the deionized-water bucket/waste-liquid bucket/cleaning-liquid bucket to determine whether
the connection of the pipeline is normal, and whether need to add water or drain.
Check whether the syringe is leaky.
Check whether the paper inside the printer is adequate.

5.1.2 Weekly Maintenance

Rinse the sampling needle


Rinse the stirring rod
Clean the instrument panel
Clean the reagent/specimen disc cavity
Rinse the deionized-water bottle
Rinse the waste bottle

5.1.3 Monthly maintenance

Rinse the inner and outer wall of the sampling needle

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Rinse the washing station of the cleaning needle and the stirring rod
Rinse the syringe
Clean the dust screen of the outside shell fan
Prime the pipeline with cleanser

5.1.4 Biannual maintenance

Clean the ball spline shaft and the ball bearing of the sampling needle component (with grease
lubrication)
Clean the guide rail of the stirring rod component (with grease lubrication)
Rinse the washing station: Add several milliliter of diluted bleach (5:1000), clean the inner surface
of the visible part of the washing station by a swab;
Recommend to replace the lamp

5.2 The treatment to blocked sampling needle


1. Turn off the instrument power, and open the rear end plate of the instrument.
2. Pull out the connector piece between the valve and the transferring jointer, as shown in the following
picture.
3. Prepare a syringe of 10ml and aspirate the distilled water, install a cuvette head on the syringe and
insert it into the pipeline just pulled out, push the syringe to inject the water into the washing station
(the needle must be on the top of the washing station at this time), repeat the above step for more
times until the water flow from sampling needle of cuvette head smoothly.

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Pull out the pipe here


Inner wall pump

Outer wall pump, connect to


washing tank

5.3 Clean the washing station


In order to avoid the breeding of bacteria, we recommend users to clean the washing station (the
washing stations of the sampling needle and the stirring rod) regularly. Infuse the diluted bleach liquid
of 5:1000 into the washing station and keep it for 15 to 20 minutes, then wipe it with a medical swab,
after wiping, rinse with plenty of distilled water to ensure that there is no cotton residue in the washing
station.

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Stirring rod washing


station

Sampling

needle

washing station

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6. Trouble Shooting
6.1 Common Trouble Shootings
Trouble

Solutions

Analyzer can not start up

- Check whether the power plug is loose


- Check the fuse
- Check the voltage

The lamp has no light

- Check whether the power is normal before replacing the


lamp
- If the computer and instrument can start normally, just no
light, replace the lamp please.

Operating software can not be

- Shutdown and wait for about 10 seconds, then restart the

initialized

machine

Printer can not start up

- Check whether the printer plug or the computer printer


connection is loose
- Check the ON / OFF button of the printer
- Check the fuse

Printer can not print

No liquid gushes from the


washing station

- Check whether the printer plug or the computer printer


connection is properly connected

- Check whether the pump of the washing station is working


- Check whether the related pipeline of the washing station is
properly connected
- Check whether there is water in the deionized water bottle

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Bubble and spattering liquid gush

- If the liquid-path is not used for a long-term, this happens

from the

during the early prime period.

washing station

- Check whether the related pipeline of the washing station is


properly connected or broken
- Check whether there is water in the deionized water bottle
- The pipette may have been aging, should be replaced

Absorbency/blank AD value is
displayed incorrectly

- Check whether the light source is emitting light normally


- Try to execute the reading under another wavelength to
provide the estimation
- Check whether the parts of the light-path is loose or installed
error

Blank value is too high

- Rinsing the reaction cup


- Check the cleanser
- Check the lamp
- Check whether the sampling needle is blocked
- Check the blood sample to determine whether the hemolysis
occurs or the height of the serum liquid is less than 3mm.

Poor reproducibility of the results

-Some reaction cup may be contaminated, replace it


- Check the aspiration status of the sampling needle
- Check the parameter settings of the reagent
- Replace the lamp and adjust the magnitude ratio
- The connection air-tightness of the syringe T-way pipeline is
not good
- The sample or the reagent is contaminated or deteriorated
- Check whether the volume of the tested sample is adequate

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- Check whether the margin of the reagent is adequate

The aspiration volume of the


sampling needle is not a constant

- Check whether the sampling needle is blocked


- Check the connection air-tightness of the syringe T-way
pipeline

Quality control is not within the

- Check the period of validity of the quality control liquid, and

target value

verify that the quality control liquid is not contaminated


- Check the item parameter settings, and determine whether
the parameter needs to be modified
- Re-test with another method
- Check the incubation temperature of the Reaction disc, retest
with a new reagent or the quality control material

There are a lot of air bubbles in

- Check the connection air-tightness of the syringe T-way

the reaction cup

pipeline
- Check whether the sample volume of 450 micro-liter is ok
(determine the stroke)
- Check whether the work of the syringe motor is normal (judge
the speed)

There are bulbs in syringe

- Confirm that the piston is tight and no-leak.


- Clean the syringe with Tween 20 solution (2 drops / liter
distilled water)
- Replace the inner O-ring of the syringe
- Check the pipeline connected with the syringe

Sample is contaminated

- Check the connection air-tightness of the syringe T-way

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pipeline
- Carry out the appropriate cleaning or replace the sampling
needle
- Clean the washing station
- Confirm that there is no residual liquid in the sampling needle
- Confirm whether the deionized is stored for a long time or
contaminated
- The sample cup is dirty, need to replace a new cup or a
one-off cup

Incubation chamber is not warm

- Check the temperature settings, appropriately adjust the


parameter to ensure it keep at 37 0.2

Liquid leaks from the analyzer

- Check whether the draining pipeline of the waste liquid is

below

inserted into the waste liquid bucket


- The waste liquid bottle is filled out
- The pipeline of the washing station is blocked

If there is any instrument failure, please contact with the dealer in time to obtain technical support!

Chemray 240: Calculation item settings


As for the calculation item, recommend to use the following codes to fill in its item name and item
code.
1. GLB (Globin) = TP (Total protein)-ALB (Albumin)
ALB / GLB

the ratio of albumin and globin

2. TBIL (Total bilirubin)-DBIL (Direct bilirubin) = IBIL (Indirect bilirubin)


3. AST / ALT

the ratio of aspartate transaminase and alanine transaminase

4. LDH / AST

the ratio of lactate dehydrogenase/aspartate transaminase

5. GGT / AST

the ratio of GGT / aspartate transaminase

6. ApoA / ApoB

the ratio of apolipoprotein A/apolipoprotein B

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7. LDL (Low Density Lipoprotein) = CHO (Total Cholesterol)-HDL (High Density Lipoprotein)-TRIG
(Triglyceride)/2.2
Note:
This manual may contain other proprietary notices and copyright information, and the related
provisions must be observed. The information in this manual may contain some technical
inaccuracies or typographical errors.

This manual may be changed or updated without notice. Rayto can also improve and/or change
the described products and/or processes without notice at any time.

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