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HumaStar 600

| Service Manual

Cat No. 16660/002

REVISION LIST OF THE MANUAL


Rev. /DATE.

REVISION DESCRIPTION

01/2008-06

First edition

02/2012-09

Second Edition implement Hardware development, New Software


Features

03/2015-02

Third Edition Implement new ISE Modlue

SYSTEM VERSION

COPYRIGHT
Copyright 2010, Human Gesellschaft fr Biochemica und Diagnostica mbH, Wiesbaden,
Germany. All rights reserved.
No part of this documentation may be reproduced in any form, nor processed, copied or
distributed by means of electronic systems, without prior permission of HUMAN in writing. Since all precautionary measures were taken into account in producing these operating
instructions, the manufacturer accepts no responsibility for any errors or omissions. This
includes any liability for damage that could arise from possible incorrect operation based on this
information. Subject to changes without notice as result of technical development.

SERVICE UND SUPPORT

CONTENTS

TABLE OF CONTENTS
1 SAFETY INSTRUCTIONS

1.1INTRODUCTION

1.2 USER WARRANTY

1.3 INTENDED USE OF THE INSTRUMENT

1.4 GENERAL SAFETY WARNINGS

1.5 DISPOSAL MANAGEMENT CONCEPT

1.6 BIOHAZARD WARNING

1.7 INSTRUMENT DISINFECTION

2 SYSTEM DESCRIPTION

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2.1 INSTRUMENT ARCHITECTURE

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2.2 DETAIL OF COMPONENTS

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2.2.1 Device parameters handling


2.2.2 Motor controller boards
2.2.3 CLot Detector System
2.2.4 Electronic scale for DI water and waste bottle

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2.3 USER OPERATION OF SYSTEM MODULES

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2.4 OPERATION OF MANUAL MOVEMENTS

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2.5 UNDERSTANDING ERRORS.LOG

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3 SECTION II
3.1 GENERAL TROUBLESHOOTING

3.1.1 Visible faults


3.1.2 Automatic cuvette washer malfunctioning.
3.1.3 Measurement inconsistencies
3.1.4 ISE troubleshooting
3.2 VERIFICATION AND DIAGNOSTIC PROCEDURES

3.2.1 VD-01: Standard troubleshooting procedure


3.2.2 VD-02: Reload instrument parameters being offline
3.2.3 VD-03: General Voltage checking
3.2.4 VD-04: Lamp voltage stability checking
3.2.5 VD-05: Photometer calibration check
3.2.6 VD-06: Photometer and lamp alignment check
3.2.7 VD-07: Instrument general status check
3.2.8 VD-08: Concentrators check
3.2.9 VD-09: Probe dispensing pump check
3.2.10 VD-10: Washer hydraulics check
3.2.11 VD-11: Dispensing hydraulics check

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3.2.12 VD-12: Probe robotics check


3.2.13 VD-13: Probe level sensing check
3.2.14 VD-14: Tray movement check
3.2.15 VD-15: Washer mechanical check
3.2.16 VD-16: Movement test
3.2.17 VD-17: Diluter belt check
3.2.18 VD-19: Measure tension belt and value settings

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4 TROUBLE SHOOTING

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4.1 SYSTEM TESTS

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4.1.1Temperature
4.1.2 Stray light
4.1.3Noise
4.1.4Stability
4.1.5 Tip Pump
4.1.6 Level detection
4.1.7 Washer hydraulics
4.1.8Washer
4.1.9Dilution
4.1.10 Photometer linearity
4.1.11 Diluter linearity
4.1.12 Chemistry analysis
4.1.13 Clot detector

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5 SECTION IV

133

6 APPENDIX

141

CONTENTS

Safety Instructions

1 SAFETY INSTRUCTIONS

1.1 Introduction
This manual is considered part of the instrument and must be available to the
operator and the maintenance personnel. For accurate installation, use and
maintenance, please read the following instructions carefully.
In order to avoid damage to the instrument or personal injury, carefully read
the GENERAL SAFETY WARNINGS, describing the appropriate operating procedures. Please contact your HUMAN authorised local Technical Service in the
event of instrument failure or other difficulties with the instrument.

1.2 User Warranty


HUMAN warrants that instruments sold by one of its authorised
representatives shall be free of any defect in material or workmanship, provided
that this warranty shall apply only to defects which become apparent within
one year from the date of delivery of the new instrument to the purchaser.
The HUMAN representative shall replace or repair any defective item within this
warranty period at no charge, except for transportation expenses to the point
of repair.
This warranty excludes the HUMAN representative from liability to replace
any item considered as expendable in the course of normal usage, e.g.: lamps,
valves, syringes, glassware, fuses, tubing etc.
The HUMAN representative shall be relieved of any liability under this warranty
if the product is not used in accordance with the manufacturers instructions,
altered in any way not specified by HUMAN, not regularly maintained, used with
equipment not approved by HUMAN or used for purposes for which it was not
designed.

1.3 Intended Use of the Instrument


The instrument must be used for its intended purpose (see paragraph 2). It must
be operated in perfect technical conditions, by qualified personnel, in such
working conditions and maintained as described in this manual, in the GENERAL
SAFETY WARNINGS. This manual contains instructions for qualified professional
operators.

[IVD]

1.4 General Safety Warnings


Use only chemical reagents and accessories specified and supplied by HUMAN
and/or mentioned in this manual. Place the product so that it has proper ventilation.
The instrument should be installed on a flat, stationary working surface, that is
free of vibrations.
Do not operate in area with excessive dust.
Operate at temperature and at a humidity level in accordance with the
specifications listed in this manual (chapter 6 Appendix, page 141).
Do not operate this instrument with covers and panels removed.
Use only the power cord specified for this product, with the grounding conductor of the power cord connected to earth ground.
Use only the fuse type and rating specified by the manufacturer for this instrument.
The use of fuses with improper ratings may pose electrical and fire hazards.
To avoid fire or shock hazard, observe all ratings and markings on the instrument.
Do not power the instrument in environments that are potentially explosive or
at risk of fire.
Prior to cleaning and/or performing maintenance on the instrument, switch off
the instrument and remove the power cord.
Only cleaning materials described in this manual may be used, as other materials may damage parts. It is recommended to always wear protective clothing
and eye protection while using this instrument.
All warning symbols that appear in this manual must be carefully observed.

1.5 Disposal Management Concept


The applicable local regulations governing disposal must be observed. It is the
users responsibility to arrange for proper disposal of the individual components.
All parts which may contain potentially infectious materials must be disinfected by suitable, validated procedures (autoclaving, chemical treatment) prior to
disposal. Applicable local regulations for disposal must be carefully observed.
The instruments and electronic accessories (without batteries, power packs etc.)
must be disposed of according to the applicable local regulations for the disposal of electronic components.
Batteries, power packs and similar power sources must be removed from electric/electronic parts and disposed of in accordance with applicable local regulations.

HumaStar 600 | Service manual

Safety Instructions

1.6 Biohazard Warning


Analytical instruments for in vitro diagnostic application involve the handling of
human samples and controls which should be considered at least potentially infectious. Therefore every part and accessory of the respective instrument which
may have come into contact with such samples must equally be considered as
potentially infectious.
The BIOHAZARD warning label must be affixed to the instrument prior to first
use with biological material!
Figure 1
Biological Hazard Symbol

1.7 Instrument Disinfection


Before performing any servicing on the instrument it is very important to thoroughly disinfect all possibly contaminated parts. Before the instrument is removed from the laboratory for disposal or servicing, it must be decontaminated.
Decontamination must be performed by authorised well-trained personnel, and
in observance of all necessary safety precautions.

HumaStar 600 | Service manual

Safety Instructions

Notes:

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HumaStar 600 | Service manual

System description

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2 SYSTEM DESCRIPTION

2.1 Instrument Architecture


Metrolab 4000 is composed by a set robotics and dispensing devices divided
in two channels, Front and Back. This arrangement provides both speed and
redundance to ensure backup mode operation.
Each channel includes the following devices:
---------

Diluter
Probe assembly
Reaction tray
Dual beam photometer reading channel
Peristaltic pump for cuvette washer
Probe tip cleaning pump
Reaction aspiration pump
Drying pump

Additional devices complete system functions include:


-- Bar code reader
-- Sample / Reagent tray
-- Reagent cooler
Figure 2

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2.2 Detail of components


Sample and reagent trays
Sample and reagent trays are driven by stepper motors capable of rotation
in both clockwise and counter-clockwise directions.
Home of tray reference is given by an optical switch, for positioning verification
purposes; an additional optical sensor with slotted-wheel set, provides detection on loose of steps. Detection and recognition of samples is provided by a
barcode mounted on the outer border of sample tray.
Probe assemblies front and back
Probe assembly consists of two stepper motors for vertical and horizontal movements, two optical switches for sensing home position and verification for
each movement working similar to sample tray.
Complete assembly also includes a capacitive level detect circuitry, a probe preheater (for thermostating reagent 0.5 oC above selected reaction chamber
temperature), a collision detector for prevent accidental probe damage and
mixer system.
Reaction trays
Reaction trays Front and Back consist of a stepper motor, optical switches
home and verification sensors.
Each reaction tray is loaded with 80 reaction disposable cuvettes (in strips of
five units with
0.6 cm path lenght). Max. volume is 700uL.
Diluters
Two diluters equipped with 500uL syringe each and aspirates reagent and
sample consecutively. Air gaps separate liquids to prevent early mixing and
contamination.
Photometer
The double beam photometer is provided with 12 interference filters mounted
in a rotating filter wheel, with reference channel.
Light from a tungsten halogen source passes through the selected filter and a
beam spitter set divides beam in three paths.
One beam traverses the reaction cuvette of front reaction tray, the other one
through the cuvette for back reaction tray; the third one is directed towards a
reference detector.

HumaStar 600 | Service manual

System description

The reading is obtained as the ratio of each signal to the reference signal, and
the system is therefore immune to source fluctuations, filter variations or dirt
accumulation on optical surfaces.
This double beam design allows the detection of reaction cuvettes in the reaction tray setting an alarm when cuvettes are missing or defective.
Automatic cuvette washers
There are two washing stations, one for each reaction tray. First pipe aspirates
test liquids and delivers washing solution; next three pipes deliver washing
solution and empty cuvettes; and the last one contains a drying block.
Operation of instrument is commanded by two intelligent microcomputers known as concentrators (C1 and C2) to handle communication packets
between computer and instrument devices providing the following services:
Information exchange to specific devices
Parameters storage
Packets tracking / detection of lost packets. Provision of a standard communication framework
Type

C1

C2

Attached intelligent devices


-- Diluters
-- Temperature controllers
-- Preamplifier & photometer motor controller.
-- Bar code reader
-- ISE controller
-- Clot detector
-- Sample, reagent and reaction trays
-- Washers and probes.
-- Peristaltic pumps.
-- Spare slot functional unit

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2.2.1 DEVICE PARAMETERS HANDLING


Each device has internal parameters to be loaded for ensure proper operation (e.g. allowed maximum speed, required acceleration profile, configuration
of sensors, internal data, internal delays, timeouts, etc).
Parameter information is contained on the eeprom memory of the concentrator
and it is sent to the device during the instrument power-on.
When the computer is performing the connect procedure to recognize the instrument, a backup of both concentrators eeprom contents is stored on hardisk.
On the event of concentrator parameter or memory corrupted the computer
will automatically restore the latest available backup.

2.2.2 MOTOR CONTROLLER BOARDS


Except for the filter wheel motor controller, any other motor controller boards is
generic and completely exchangeable, although they have different programs
and parameters according the task to perform, they automatically recognize
their function identifying the slot currently installed during power up.
Checking any motor controller board involves just exchanging with another one.

2.2.3 CLOT DETECTOR SYSTEM


DESCRIPTION
The clot detector is a module to detect and warn about potential clogs or blood
clots during a run.
Module is composed by a pressure transducer connected between the hydraulic
line of the diluter to the probe and the electronic circuit to measure, and transmit the information using the same diluter communication bus.
During the instrument run, when a sample is aspirated, the vacuum in the line
between diluter and probe is measured to identify abnormal pressure patterns
related with clot conditions.
Before a running the instrument check the clot detector system and calibrate
it. The calibration of clot detector is automatic and doesnt need any solution.

HumaStar 600 | Service manual

System description

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Figure 3

CLOT DETECTOR BOARD


1. FRONT SENSOR & TUBING CONNECTORS
2. BACK SENSOR & TUBING CONNECTORS

NOTE: During the first system


startup of the day, it could be

Software configuration: From Maintenance > Parameters > Software > General
tab:

necessary to perform several system flushes in order to prime the


clot detector. Maintenance > Ope-

-- Enabled check box on: behaviour on detection is possible in order to select


the way instrument will handle the event of clot. Available options include,
to flag the sample or invalidate it.
-- Enable check box off: Disable the clot detector feature

rations > Hydraulic tab > System


Flush.

Installation parameter: clot detector is installed or uninstalled in Maintenance >


Service > Parameters > Instrumentals > Others
Debug options: From Maintenance > Service > debug, you can mark these
options: log curve when clot is detected or log curve allways. If you have
problems these options can help to make a better diagnostic from factory.
All information is stored in the servicebackupfile.

Note: Important: If you mark


these options you will reduce
the speed of the instrument.

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2.2.4 ELECTRONIC SCALE FOR DI WATER AND WASTE BOTTLE


DESCRIPTION
It uses a load cell to weight each bottle (see picture). The weight is compared
against the two thresholds to provide hysteresis.
Instrument is factory calibrated with a thresholds of 1/3 and 2/3 for both wash
and waste bottles.
When waste bottle level is more than 2/3, the waste full signal will be generated, but it will not turn off until the waste bottle volume drops below 1/3. For the
water bottle level operation is similar, when available volume is less than 1/3,
system will generate empty water bottle signal that will be cleared once the
level is higher than 2/3. This prevents rapid switching of the signal around the
set point and alows an easy interface to an external water station to the instrument. To control an external water station the instrument has in its rear pannel
a DB9 connector with isolated relay contact.
Figure 4

HumaStar 600 | Service manual

System description

1.
2.
3.
4.

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DB9 connector for external automatic water station


Load cell for DI water bottle.
Position of PL400310W load cell controller board.
Load cell for waste bottle.
Figure 5

Lload cell controller board


Setting scale thresholds
The M400-P310 board has four microswitches (S1,S2,S4,S5) to program the
values of low and high level thresholds for both waste and water bottle.Those
thresholds are factory pre-programmed.
For both water and waste bottles, defining of the setpoints is similar. For
example to set high level threshold for waste bottle hold on waste high level
(S2) button for five seconds to set the high level for waste bottle.

Note: The load cell controller


board has 4 lights that indicated waste bottle full or empty and
water bottle full or empty.

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External connector specifications:


Figure 6

Note: This feature is not supported by HUMAN

PIN OUT DB9 CONNECTOR


PIN OUT DESCRIPTION
PIN 5 - NC
PIN 1,6 WASTE CONTACT 1
PIN 2,7 WASTE CONTACT 2
PIN 3,8 DI WATER CONTACT 1
PIN 4,9 DI WATER CONTACT 2

SPECIFICATION
Voltage, Switching 24VDC MAX
Current, Switching 100 mA
Current, Carry 200 mA

Figure 7

Communication between concentrators and devices

HumaStar 600 | Service manual

System description

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2.3 User operation of system modules


Enter to Maintenance > Operations to perform habitual maintenance tasks (e.g.
purge hydraulics after wash bottle refill, reset counters after consumable parts
replacement) or perform tasks requiring operation of serveral devices (e.g. complete dispensing cycle).
Figure 8

Hydraulic tab:
Select range and reaction tray to wash cuvettes.
Choose dry only when cuvettes are already clean to enhance drying.
Turn off washing pumps. To quiet pumps after a washing operation.
System flush. to purge both tubings and syringe.
Tip cleaning. To perform wash/soak of probe tip.
Intensive cuvette cleaning. Operator can select volume, time of action and
washing solution. This action is very useful for cuvettes used with latex type of
reagents or other contaminant fluids. Perform it at the end of the working day.

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Intensive washer cleaning. This procedure consist of using a suitable cleaning


solution defined in the screen of cleaning solutions with a volume up to 500
microliters and repeated up to 10 times (default value is 4), either back or front
or both. At the end, a normal wash and drying cycle is performed.
Figure 9

Photometer tab:
Press buttons to give full power or Stand by of the lamp Cuvettes.
To perform a report of absorbance cuvette
Figure 10

Motors tab:
Press turn off to de- enegize all motors.

HumaStar 600 | Service manual

System description

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Movements tab: Perform general operations involving


-- sample/reagent/reaction dispensing
-- tip pumping
-- photometer readings
-- diluter operation
-- cuvette washer
-- move the back probe to ISE dispensing into the cup
Versions tab:
Displays firmware version and serial numbers for each device.
Figure 11

ISE tab:
Startup button performs all the operations required by the module (date, wet,
etc.), before starting to operate it.
Cleaning operation requires to have the ISE cleaning solution in the ray.
Use Empty/Fill chamber button to load/unload the ISE liquid column with the
ISE cup contents.

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Purge button starts a process to remove the air and bubbles from the tubings.
Calibration button performs the internal two-point calibration.
Wet starts a sequence to maintain the membrane humidity within the appropiate levels. Dispense Std A/B activates the pinch valve to fill the the ISE cup.
Remember to press the fill chamber button to load the ISE liquid column.
Pinch valve time button sets the dispensed volume in the ISE cup. To note, when
dispensing three times Std A/B, volume must be 500uL in the ISE cup.
Electrode conditioning. Perform a conditioning with serum from prime position.
Figure 12

Note: For lubrication issue,


perform AR27 when the instrument reach 250.000 cicles or
6 months.

HumaStar 600 | Service manual

Wear tab:
Displays amount of use cycles, limits of use and last replacement date.

System description

2.4 Operation of manual movements


This mode allows a quick testing of each single device to obtain additional information when user is unable to describe the specific issue. Click on Data > Log as
Supervisor > type password 31415 then Maintenance > service > manual to see
a window having tabs to access all available modules: Vertical, Horizontal, Trays,
Pumps, Washing stations, Temperature, Diluters, BCR, Photometer, Filter wheel,
Steppers, Cool tray, Options, and Stress.
On the right, another two windows display the high level (command level) communications and low level (packet level) communications. Use right mouse
button to open packet interpreter window and see communication details. (See
section I, protocol overview).

Remember when using this mode:


-- Set Maintenance > service > debug > Manual movement safety restrictions
to activate the automatic protection of mechanics.
-- Initialization of any device is always required prior to its use.
-- Washer initialization is required before reaction tray initialization.
-- Vertical initialization is required before sample, reagent, reaction tray or horizontal initialization.
-- Arrow buttons on each module alow single step movement.
-- To prevent probe crashes do not use TURN AROUND command as it does not
detect errors.
-- For movement and device continuous test use options on stress tab and
check errors.log file for results.

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Figure 13

Vertical tab:
Use selector to choose for front or back arms.
Initialize, moves the vertical to home position.
Move to position, locates the vertical on desired number of steps down home.
Find level, moves the probe down looking for liquid level, slow value, is the position to start looking for level while moving slower, bottom value represents the
maximum alowable steps to go down, and down level value is the amount of
steps to submerse the probe into the liquid.
Move up slowly button moves the boom up slowly and increases the speed after
the number of steps defined by the Slow steps parameter.
Turn on/off vibrator buttons. Mixer system control.
Turn off motor: Unblock motor.

HumaStar 600 | Service manual

System description

25

Horizontal tab:
Choose front or back arm and then initialize to move the horizontal to home
position, Move to position, to move the desired number of steps from home,
Move to sample position, to locate an specific sample number into the specific
sector. (Sector must be already located on the
tray).
Move to reagent, reaction, washing and ISE position, work similar to previous
buttons.:
Turn off motor: Unblock motor.

Figure 14

Trays tab:
Choose desired tray and use initialize to move tray to home, Move to tray position, to advance a
number of steps, and Move to sample position: for an specific sample number,
sector and arm.
Turn off motor: Unblock motor.

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Figure 15

Pumps tab:
Select front or back, for peristaltic pump and then, initialize, advance or go back.
Front/back Tip pump when set to 1, will be on an amount of time given by the
timeout parameter. Note: set diluter to bypass position before activation of tip
pump.
Turn off motor: Unblock motor.
Figure 16

HumaStar 600 | Service manual

System description

27

Washing stations:
Choose for front or back wash head, then initialize, move to position, or move
to position using a second speed for avoid spillage during drying block cleaning.
Drying pump, when set to 1 turns on the drying block.
Water suction pump, when set to 1 turns on stations 2,3,4 and 5.
Reagent suction pump, when set to 1 turns on stations 1.
Turn off motor: Unblock motor.
Figure 17

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Temperature tab:
Choose temperature controller then Initialize, to tranfer internal PID parameters, read temp, set temp and disable temp to operate temperature module.
Figure 18

Diluter tab:
Choose front or back, Initialize
And then Move to (steps, speed)
Set baud rate button. Refer to AR23 Diluter replacement procedure
Valve positions:
-- bypass is pump to tip
-- input is pump to syringe
-- output is syringe to probe

HumaStar 600 | Service manual

System description

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Figure 19

BCR tab:
Press Initialize to start operation.
Read, shows result of barcode in front of BCR device.
Program, sets internal BCR
device parameters.
Advanced reading options:
Read sector code (tray position) Read sample code (sect, pos) Read reagent code
(position)
Figure 20

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ISE tab:
Press Identify to check the ISE requests (date, calibration, etc.) Liquids button
informs the remaining volume of standards in the kit.
Use Empty/Fill chamber button to load/unload the ISE liquid column with
the ISE cup contents.
Purge button starts a process to remove the air and bubbles from the tubings.
Send date loads the current system date into the ISE module.
Urine/serum sample button sets the measurement mode.
Measure triggers the measurement process.
Wet button starts a sequence to maintain the membrane humidity within the
appropiate levels
Rinse button is used to perform a longer washing process than wet button.
Custom button sends ISE specific commands to the module.
Parameter section allows to inspect/modify parameters for the different
operating modes
Figure 21

HumaStar 600 | Service manual

System description

31

Photometer tab: development only screen


For single reading, choose desired photometer and filter.
-- Start convertion and Read to show current reading.
-- Continuous reading triggers Meas. readings waiting interval mseg after
each filterwheel turn.
Figure 22

Cool tray tab:


Press Read temp. to display current temperature (it shows zero when cool tray
is off).
Set temperature will set both high and low trips.
PRESS INSTRUMENT GREEN PUSHBUTTON TO TURN ON THE COOL TRAY.

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Figure 23

Concentrator tab:
Press AYA button to check the communication from PC to CPU.
Press Reset button to perform a reset of complete instrument.
Figure 24

HumaStar 600 | Service manual

System description

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Clot detector tab:


Press Get version button to know the firmware version and check the communication to clot detector board..
Press Calibrate button to perform a simulation of clot detector calibration. For
more information go to system test clot detector.
Figure 25

Stress tab:
It moves randomly desired number of cycles and show errors of each movement.
Check errorslog.txt to see errors details.

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Warning: Do not try to stress both horizontal and vertical at


the same time as no further checking is performed.

2.5 Understanding errors.log


When a single error event is produced, information is automatically stored on
errors.log file (no matter if instrument recovered from event and finished processing). Dump of errors.log file is composed by several parts:
[E.0206.S.03] Sample Tray - Home sensor 09/06/2006 01:36:18 p.m.
Software development tracing THabInicializarTodas-THabInicUnidFuncinformation
TAcPlatoInic
High level comm
High level communication
Tx: 0206 00
(single command)
Rx: 0206 00000000 00 00030000
Front dilutor: 0
Back diluter: 0
Front horizontal: 139
Back horizontal: 140
Front washer: 0
Coordinates after the last
Back washer: 0
sucessful command
Sample tray: 0
Reagent tray: 0
Front reaction tray: 0
Back reaction tray: 0
Front vertical: 131
Back vertical: 120
Error code + Error Message

HumaStar 600 | Service manual

System description

621
Tx: 06000208007C006026
13:36:9.812
622
Rx: 05010208007C15BC
13:36:9.828
623
Tx: 06000209007D000C26
13:36:9.828
624
Rx: 05010209007D152C
13:36:9.828
625 Rx:
0E0002080078000000000000000000E7AB
13:36:10.125
626
Low level communication
627
Tx: 050102080078D6BD
(including ACK packets, packets
Rx: 0E000209007900000000000000000
numbers and CRC information).
0E107 13:36:10.125
13:36:10.125
628
Tx: 050102090079D62D
13:36:10.125
629 Rx:
0D0001100025000000000000006076A8
13:36:11.531
630
Tx: 0501011000256CFC
13:36:11.531
631 Rx:
0D000111002600000000000000607AB8
13:36:11.953
On next page, a table indicates how to translate high level communication to
obtain device specific details.

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High level protocol

Table 1

HumaStar 600 | Service manual

System description

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HumaStar 600 | Service manual

SECTION II

3 SECTION II

3.1 General troubleshooting

3.1.1 VISIBLE FAULTS


General faults
Symptom
Drops on probe tip after dispensing

Corrective Action
Verify hydraulic system in accordance to users manual.
Clean probe tip by submerging in Solution 1 for 5 minutes.
Drops on tip after wash cycle.
Verify hydraulic system for leaks or
obstructions.
Abnormal noises.
Defective fans.
Moving parts blocked or frozen.
Temperature in reaction tray is too
Room temperature too high, (should
high. (Do not be concerned about arm always be at least 4C lower than seprobe temperature)
lected working temperature).
Example: For 37C incubation temperature, Room temperature should not
exceed 33C.
Temperature in reaction tray is too
Room temperature excessively low.
low. (Do not be concerned about
Verify instrument operating range,
arm probe temperature)
and adequate the room temperature.

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3.1.2 AUTOMATIC CUVETTE WASHER MALFUNCTIONING.


Symptom
At the end of wash cycle, tiny water
droplets are in the cuvette walls

High cross-contamination

Corrective Action
Verify that all pumps are working.
Verify that no tubing are clogged
Replace drying block
Calibrate washer unit position.
Identify cross-contaminants and set
methods in the Table of interferences
Increase the wash volume
Increase the number of wash cycles

3.1.3 MEASUREMENT INCONSISTENCIES


Consider storage and handling of reagents, standards and controls:
1. Verify expiration date, storage temperatures on and off analyzer.
Check that reagent was not frozen.
2. Check color changes, sediments, turbidity, no foam.
3. Check not for mixed reagents from different lots nor re-use of reagent
bottles.
All methods
1. Verify cuvettes for dirt or scratching.
2. Remove cuvettes from reaction tray and check volumes for affected cuvettes.
3. Verify there are no bubbles or droplet.
4. Verify there are no obstructions on probe, check for non constant or regular
flow.
5. Recalibrate photometer.
6. Perform energy, noise and photometric stability tests.

HumaStar 600 | Service manual

SECTION II

Colorimetrics with high dispersion


1. Replace sample by a standard and verify dispersion again, check reaction cuvette- beam alignment.
2. Perform hydraulic verification.
3. Check for sample centrifugation, increase time and speed.
4. Perform energy, noise photometric stability and dilution tests.
Colorimetrics with proper dispersion but values too high or low
1. Verify standard, compare calculated factor with stored (historic) factors, and
recalibrate method. If problem persists, replace standard and/or reagent.
2. Clean probe and check for cross contamination by changing the order of dispensing
(Time priority for reagents parameter). Check proper probe washing/clean
probe.
3. Check for exceeded method linear range; compare method definition with
reagent specification.
4. Verify sample volume is not excessive.
5. Perform stray light verification, high range and low range linearity test, and
dilution test.
Kinetics with high dispersion or low linearity
1. Verify if incubation time is too short or heaters are not working properly.
2. Verify for abnormally high initial absorbance for decreasing kinetics (problems with reagent preparation) or too low on increasing kinetics. Replace
reagents and compare results.
3. Check lamp for stability.
4. Use new cuvettes and test again, check cuvettes for dirt or scratching.
5. Perform noise and photometric stability, align lamp, clean filters, and check
reaction tray-beam alignment.
6. For some kinetics: verify if sample volume is too low.
7. For some kinetics: verify centrifugation (increase time and speed).

41

42

Kinetics with normal values too high


1. Perform energy, noise and photometric stability.
2. Perform temperature verification.
3. Some kinetics: incorrect factor for selected temperature and volume.
4. Replace lamp, align lamp, clean filters verify reaction tray positioning.
Kinetics with normal and pathological values too high
1. Verify incubation time and temperature. Perform temperature test.
2. Verify if factor matches selected temperature. Remember selected temperature is usually 37oCKinetics with normal and pathological values too low
1. Check for short incubation time or low temperature.
2. Verify if factor matches selected temperature. Remember selected temperature is usually 37oC.
Kinetics with values too low or too high on the whole range
Verify if factor matches selected temperature. Remember selected temperature
is usually 37oC.
Two point kinetics (high dispersion)
1. Verify if standard absorbance is too low (verify data provided by standard
manufacturer).
2. Verify initial consumption is too high (verify data provided reagent manufacturer).
3. Perform energy tests.
4. Verify reagent handling and storage.
5. Check method parameter for reagent, low sample volume or too short interval times.
6. Check time table for dispersion on first measurement.
Two point kinetics (high dispersion)
Verify factor, standard and method for reagent.

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43

Repetition or dilution (colorimetrics or non linear kinetics)


1. Verify if sample volume is too high, check reagent linear limit.
2. Replace reagent and compare.
Repetition or dilution (two point kinetics)
This is not actually an error; it is because volume / absorbance change relationship is not linear, and so it is necessary to dilute standard and compare.
Reactions (general comparison between reactions)
1. Control quality of water.
2. Verify proper usage of solutions (wash solution, rinse solution, etc).
3. Use uric acid to check water quality.
4. Verify for frosted cuvettes (presence of salts).
5. Verify scratching or old reactions residues (not enough washing).
6. Perform instrument validation tests.
Clot detector troubleshooting
Symptom

Corrective Action

-- Clot detector system calibrati--on error, before a run.


-- False positive clot detection. --- Fail system test -> Calibration
---- Fail system test -> Dilution -----

-- Fail system test -> Noise

-----

Verify hydraulic system for leaks or obstructions. (Tips, tubes, connectors)


Purge hydraulic system. Perform several
system flushes.
Verify air bubbles in the hidraulic system
Clot detector board
Verify hydraulic system for leaks or obstructions. (Tips, tubes, connectors)
Purge hydraulic system. Perform several
system flushes.
Verify air bubbles in the hidraulic system
Verify use DI water for reagent and sample
for this test,
Clot detector board,
Clot detector board.
Power supply of clot detector board.
Power supply cables

44

Electronic scale troubleshooting


Symptom

Corrective Action

-- Dont change filling status of-- Bad calibration of scale thresholds in the
bottles.
controller board setting again.
-- Check base of bottles, it should be move
free and only touch load cell.
-- Connector of load cell is not connected
-- Load cell is connected in a wrong position.
-- Dont repeat threshold levels. -- Bad calibration of scale thresholds in the
controller board setting again.
-- Check base of bottles, it should be move
free and only touch load cell.

3.1.4 ISE TROUBLESHOOTING


ERROR
Kit not installed
Kit expired
Empty kit
Invalid kit

ION
Any
Any
Any
Any

Error in filling

Any

Error in emptying Any

HumaStar 600 | Service manual

DESCRIPTIN
No startup
No startup
No startup
No startup

CORRECTIVE ACTION
Install a valid kit
Replace ISE pack
Replace ISE pack
Utilize ISE pack designed for your instrument and/or country.
Inspect pump tubing, remove from
No data
pump and rub with fingers. When reacquired or
peated, ISE module operation is abortcalibration
ed. Check for valves, inlet tubing and
performed
pressure in
pack bottles,
No access to the Inspect peristaltic pump and tubing.
following sample Check leaks and kinks in tubing
or no calibration and electrodes.

SECTION II

Na unstable
(*)

K unstable
(*)

Cl unstable
(*)

Timeout

45

Sodium

No stable
plateau reached
in samples and
calibration.
Slope out of the
allowed range

Electrode deteriorated. Erroneous


slope after a calibration.
Some samples can display this message. Only check if it persists
for many samples.
Clean electrodes with Sodium conditioning solution.

No stable
Electrode deteriorated. Erroneous
plateau reached threshold in module.
Potassium in samples and
Some samples can display this mescalibration.
sage. Only check if it persists for many
Slope out of the samples.
allowed range
No stable
plateau reached Electrode deteriorated. Erroneous
in samples
threshold in module.
Sodium
and caliSome samples can display this mesbration. Slope
sage. Only check if it persists for many
out of the
samples.
allowed range
Erroneous date orCommunication interrupted. Instru-----module missment off.
connection.

For further details, check AR-24: ISE maintenance procedure.

46

3.2 Verification and diagnostic procedures

3.2.1 VD-01: STANDARD TROUBLESHOOTING PROCEDURE


1. Identify symptom
-- Obtain a detailed description about the issue from a skilled instrument end
user (avoid unspecific descriptions).
-- Ask for any symptom (leaks, noises, beeps, last operations performed before
the event)
-- Review section II, general troubleshooting to identify additional actions to be
performed by user to obtain extra information.
2. Recognize variables affecting the result
-- Group togheter symptom or problems to isolate the main cause, consider
settings of affected methods (e.g. results are lower than expected on high
controls, unstability on methods having low sample volume).
3. Use diagnostic tools to isolate the main cause (do not perform resolution
steps before identifying main causes):
-- Manual movements window
-- Instrument tests
-- Information provided on errors.log file.
4.
----

Fix the cause


Run fresh controls
Remove jams, tighten connections
Repair or replace

5. Check that solution worked


-- Use same tools used before to check resolution of issue.

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47

3.2.2 VD-02: RELOAD INSTRUMENT PARAMETERS BEING OFFLINE


1. Enter to Data > Log as supervisor use as password pinion
2. Enter to Data > load parameters from the bin folder of autoanalyzer choose
the file memorybackup.ini.

3.2.3 VD-03: GENERAL VOLTAGE CHECKING

Warning: Reagent cooler power supply is turned on by the green


pushbutton.

1. Turn on instrument.
2. Check if red power push button is blinking (No blink=all power supplies are
OK).
3. Check the green led located on each power supply.
4. In case led is off, test the power supply without load, follow schematic diagrams to find the short circuit.
5. Disable power on off board (see schematics).

3.2.4 VD-04: LAMP VOLTAGE STABILITY CHECKING


1. Check lamp voltage (12v) is steady (1mV) during instrument operation.
2. Check lamp power supply output voltage (Meanwell S-40-12). Check connections, replace PL400273 in case it introduces the instability.

48

3.2.5 VD-05: PHOTOMETER CALIBRATION CHECK


1. Enter to Data > Log as supervisor > pasword pinion, then Maintenance > Calibration > Filterwheel.
2. Press start and check that peak for each filter and channel is centered (Ignore
saturating channels) see image below.
3. Filter 13 is blocking (no signal) and shows no main peak.
Figure 26

4. Choose Maintenance > Calibration > Photometer select sumarize tab


Figure 27

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SECTION II

49

Proper calibration is defined as:


-- -3000 < Zero < 3000
-- 20000 < Front, back, and ref channels < 480000
-- Highest gain = 16 (for filter #1).

3.2.6 VD-06: PHOTOMETER AND LAMP ALIGNMENT CHECK


1. Remove preamplifier.
2. Turn on instrument.
3. Gently block filterwheel movement and rotate gently to choose a bright
filter.
4. Locate a paper on the preamplifier cavity, check alignment against the reaction tray main rod.
5. In case alignment is not ok, check lamp aligning socket.
6. Once gross alignment is completed perform AR-21: Lamp alignment optimization.
Figure 28

50

3.2.7 VD-07: INSTRUMENT GENERAL STATUS CHECK


Choose maintenance > electronic status, instrument will show its internal status
as shown below:
Board status
FRTW Temperature: 36 C Voltage: 37
BRTW Temperature: 32 C Voltage: 37
SRT Temperature: 43 C Voltage: 36
FBPP Temperature: 32 C Voltage: 37
FVH Temperature: 35 C Voltage: 37
BVH Temperature: 33 C Voltage: 36
System boards status
Id: 0
Ok Id: 1
Ok Id: 2
Ok Id: 3
Ok Id: 4
Ok Id: 5
Ok Id: 6
Ok Id: 7
Ok Id: 8
Ok Id: 9
Ok Id: 10
Ok Id: 11
Ok Id: 12
Ok Id: 13
Ok
Cooler thermostat: Ok

HumaStar 600 | Service manual

SECTION II

3.2.8 VD-08: CONCENTRATORS CHECK


1. Enter to Data > Log as supervisor > pasword 31415. then type Maintenance
> Service > Manual
2. Choose Stress tab, then choose Memory concentrator 1 & 2.
3. Set movements to 100, press white hand button to start
4. Review results on errors.log file

3.2.9 VD-09: PROBE DISPENSING PUMP CHECK


1. Enter to Maintenance > Operations choose movements tab, set Steps to 500
on pump water section.
2. Press A key, check dispensed volume using a buret,
3. Check for clogs or identify the faulty pump in case specified range is not meet.
(See section IV, hydraulics schematics).

3.2.10 VD-10: WASHER HYDRAULICS CHECK


1. See washer hydraulics schematics
2. Log as service (Data > Log as supervisor > pasword 31415), then choose
maintenance > System test > washer hydraulics.
3. Dispensed volume should range from 400uL to 700uL depending on method
settings.
-- When volume is low on all pipes, check/replace peristaltic pump tubing or log
as supervisor and check Maintenance > Service > Parameters > Instrumental
parameters Washing station section > front/back volumes.
-- When volume is low on a given pipe, check for twisted tubing, clogs, or dirtness.
4. Aspiration level should range from 2uL to 5uL, when higher than specified on
every pipe, check aspiration pump, when higher than specified on a specific
pipe, check for clogs, dirtness or twisted tubing.

51

52

3.2.11 VD-11: DISPENSING HYDRAULICS CHECK


Note:
Dilution test should be performed with a sample of Potassium Chromate of 2 g/l
in acidic solution. Use as reagent the tip washing solution. For a final volume of
4/400, CV should be less than 1.5%
When no potassium chromate is available, test settings can be modified to use
cholesterol reagent and cholesterol standard as sample.
1.
2.
3.
4.
---5.
6.
7.
8.

Clean or replace water mesh filter (see hydraulic schematics).


Remove syringe and check syringe glass to plunger contact is tight.
Perform dilution test (Maintenance > system test > dilution).
During the test observe the following:
Check probe tip during operation not for droplets (e.g. dirty probe or damaged Teflon coating).
Check for air bubbles on defective tubing joints.
Check for bubbles on syringe plunger edge during aspiration operation
(damaged plunger).
Check / replace probe.
Check beam alignment on cuvette.
Check for twisted/clogged tubings.
If no faulty tubing is identified, externally connect each tubing and repeat the
test to identify a faulty (puncture) tubing.

Note:
When no faulty tubing is identified, use the tubing kit to externally bypass each
tubing and repeat the test to isolate the faulty one.

3.2.12 VD-12: PROBE ROBOTICS CHECK


1. Reset instrument (press red pushbutton).
2. Gently move the probe from side to side and up to down checking movement is smooth without jams.
3. Ensure that neither flag or disc touch optocoupler sensor body.
4. Compare zero and verification led blinking against the other probe.
5. Swap front/back motor controllers boards. Check connections.
6. In case of step loss: Check for belt damage (e.g. cracked belt surface or missing teeth), loose pulley to rod joint or heavy motor.

HumaStar 600 | Service manual

SECTION II

3.2.13 VD-13: PROBE LEVEL SENSING CHECK


1.
2.
-----

Perform Level detecion test (Maintenance > system tests > Level detection).
In case probe stops on air (falsely detecting liquid level),
Check lab neutral to ground mains below to 1V (both DC and AC modes).
Check or replace probe.
Check or replace level sensing board.
Check or replace wiring from level sensing board to distribution board.

3.2.14 VD-14: TRAY MOVEMENT CHECK


1. Reset instrument (press red pushbutton).
2. Gently move the tray side to side checking movement is smooth without
jams.
3. Move the tray from side to side checking controller leds.
4. Ensure that neither flag or disc touch optocoupler sensor body.
5. Swap front/back motor controllers boards.
6. In case of step loss: Check for belt damage (e.g. cracked belt surface or
missing teeth), loose pulley to rod joint or heavy motor.

3.2.15 VD-15: WASHER MECHANICAL CHECK


1. Reset instrument (press red pushbutton).
2. Gently move the wash head up and down to check that movement is smooth
without jams.
3. Swap controllers.
4. Ensure that neither flag or disc touch optocoupler sensor body.
5. Check connections.
6. In case of step loss: Check for belt damage (e.g. cracked belt surface or
missing teeth), loose pulley to rod joint or heavy motor.

53

54

3.2.16 VD-16: MOVEMENT TEST


Note:
This kind of test will move randomly the selected device with no further
checking.
Do not check two conflictive devices simoultaneously (e.g. do not test both
vertical and horizontal at the same time).
1. Enter to Data > Log as supervisor > pasword 31415 then enter to
Maintenance > Service > Manual select stress tab.
2. Select movement or operation to test.
3. Set movements to 100, press white hand button to start
4. Review results on errors.log file
When complete tray and arm movement test is required, use
Maintenance > system test
> Level detection.

3.2.17 VD-17: DILUTER BELT CHECK


1. Turn off instrument.
2. Identify diluter belt.
3. Gently rotate belt pulley and use a mirror to check for any belt damage (e.g.
cracked belt surface or missing teeth).VD-18: Temperature controller check
1. Initialize instrument. Enter to Data > Log as supervisor > pasword 31415
then enter to Maintenance > Service > Manual select temperature tab.
2. Select the temperature control device. Initialize temperature controller and
set temp value.
3. Press read temperature button.
4. In case no value is shown, review errors.log file for further details.

HumaStar 600 | Service manual

SECTION II

55

3.2.18 VD-19: MEASURE TENSION BELT AND VALUE SETTINGS


To measure the tension belt. We recommend to use the follow instrument:

Figure 29

SONIC TENSION METER MODEL:507C BRAND:GATES


For more information please refer to user manual of sonic tension meter.
Tension values and parameters for tension meter.

56

MOVEMENTS

VERTICAL

HORIZONTAL

REACTION

SAMPLE

REAGENT

WASHER

HumaStar 600 | Service manual

PARAMETERS
Cat. N
Mass
With
Span
Freq. Range
Value
Cat. N
Mass
With
Span
Freq. Range
Value
Cat. N
Mass
With
Span
Freq. Range
Value
Cat. N
Mass
With
Span
Freq. Range
Value
Cat. N
Mass
With
Span
Freq. Range
Value
Cat. N
Mass
With
Span
Freq. Range
Value

SN: XXXX41XX
147 MXL
1,3
6
170
Standard
13 -17
2MR-186-06
1,3
6
50
Standard
25-40
3MR- 630-06
4,5
6
205
Standard
27-60
283XL
2,4
10
70
Standard
18-22
220XL
2,4
10
120
Standard
30-35
640 MXL
1,3
6
60
Standard
18-22

SN: XXXX40XX
136 MXL
1,3
6
150
Standard
13 -17
72MXL
1,3
6
50
Standard
25-40
280XL
2,4
6
180
Standard
27-60
283XL
2,4
10
70
Standard
18-22
220XL
2,4
10
120
Standard
27-60
640 MXL
1,3
6
60
Standard
18-22

Trouble Shooting

4 TROUBLE SHOOTING

4.1 System tests

To access to system tests, select


Maintenance > System test
Results of tests are stored and printed out in PDF files in the Working Directory\
System Tests.

4.1.1 TEMPERATURE
This test measures the time required for reaching preset temperatures and
final stability of reading. It includes cooler tray temperature. The test records
the minimum reached temperature and the last time in which the temperature reached the band between minimum and maximum allowed values. If the
temperature is turned off, the test stops and a warning is issued.

4.1.2 STRAY LIGHT


This test is based on the use of two solutions: one uv sharp blocking and other
visible blocking.
Visible blocking is usually Potassium Chromate in high concentration (more
than 5 g/l) and should block all light passing the cuvette at the specified wavelength. If it fails, light is arriving directly to sensor without traveling through the
cuvette.

57

58

UV blocking, if visible is passed, indicates actual filter stray light. The use of Sodium Nitrite, 50 g/l and reading at 340 nm is recommended.
There are two options: either instrument dispenses solutions or user put them
directly in the selected cuvettes. Use Already dispensed for selection.
Test is passed if read values are less than 0.1%T.
Volume selection can be used to determine minimum volume that can be safely
measured.

4.1.3 NOISE
This test determines the departure of individual readings from the mean
value. Noise is evaluated separately from drift. For stability evaluation, total
time (Number of readings X Time interval) should be at least 10 minutes. Noise
evaluation is performed without moving tray and data are directly related to
photometer behavior.
When Absorbance correction is selected (recommended for solutions and not
for filters), results are expressed as equivalent to 1 cm cuvette measurements.
Noise test is relevant for absorbances over 1.300. Potassium Chromate (1.2 to
1.5 g/l in acidic media) is recommended.
Relevant data are peak-to-peak (maximum) difference. They should not exceed
0.002 for 1 minute total time.

4.1.4 STABILITY
Stability test is very similar to noise test, but the tray is randomly moving between readings. Comparison of data from noise and stability tests can give a
hint on mechanical positioning problems. Use conditions as described in 1.7.3.

4.1.5 TIP PUMP


This test allows determining if washing tip pump is delivering the correct
amount of water. Procedure is performed in a reagent bottle located in position
1, where initial liquid level should be at least to a height of 2 cm. Procedure is
repeated several times and averaged.

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Trouble Shooting

59

4.1.6 LEVEL DETECTION


Reagent is taken from a vial located in a fixed position and tip reaches the
surface of other reagent located in a different position. Next, reagent is delivered in the original one. This procedure is sequentially repeated while volume
is varied every cycle within fixed limits. Results and plot will show if level detection is accurate.
Use this test if detection problems are observed with a given method or Brand.
When using, be sure that no foam is present in reagents or samples. If test is
repeated many times, be sure that no foam is formed in the process.

4.1.7 WASHER HYDRAULICS


Figure 30

Calibration for cuvette bottom should be performed, prior to other operations.


A liquid pumping level check will be performed by dispensing water with D1 to
D4 and measuring the liquid level with sensor probe (positions 2 to 5). The calculated volume will be recorded for each station (1 to 4).
A liquid suction level check will be performed drawing water with S1 to S5 and
measuring the liquid level (if any) with sensor probe. To be able to measure such
small remnant amount, the syringe full loaded with water (500L) will dispense
100 L in each position (1 to 5). The calculated remnant volume will be recorded
for each station (1 to 5).

60

A liquid pumping level stability test will be performed dispensing water with D1
to D4, the number of times determined by the parameter, in different cuvettes
(positions 6 to 9, 10 to 13,) and measuring the liquid level with sensor probe. The
following volumes will be recorded for each station (1 to 4):
individual measurements;
average volume;
standard deviation and variance;
minimum and maximum volumes;
difference between minimum and maximum volumes;
difference between minimum and maximum average volumes of the
4 stations;
relative deviation error of average volumes.
A cuvette wash will be performed in all the used cuvettes.

4.1.8 WASHER
Washer test consists of performing cuvette cleaning cycle on a programmed
number of cuvettes. Absorbances are read on new cuvettes before cleaning action, immediately after cleaning and at some fixed time (Drying time). All three
data are shown in the graph.
If cuvettes are properly dried and not scratched by the system, values should
return to the original ones, with a tolerance of about 0.020 abs.

4.1.9 DILUTION
Dilution test should be performed with a sample of Potassium Chromate of 5 g/l
in acidic solution. Use as reagent the tip washing solution.
For a final volume of 4/400, CV should be less than 1.5%

HumaStar 600 | Service manual

Trouble Shooting

4.1.10 PHOTOMETER LINEARITY


This test is intended for evaluation of photometer linearity. To achieve this goal,
the test will measure absorbance (A0 to A4) of 5 different solutions (points 0
to 4) in front and back channels using a specific filter. Each solution will be prepared by dilution of a stock solution located in a specific on-tray position. For a
default initial sample volume of 8 microliters, system will automatically generate dilutions of 0/300, 8/292, 16/284, etc. maintaining the total solution volume unchanged.
A cuvette diluent blank will be performed prior to dispensing using a certain
volume. Dilution will use the remaining volume of diluent. After dispensing, a
certain time will be observed prior to reading. A certain number of replicates will
be done for each point.
This test differs from 1.7.11 in the range of volumes. For volumes above 8 microliters, it is assumed that diluter linearity is out of question and any linearity
departure is related to electronics or optics.

4.1.11 DILUTER LINEARITY


This test requires a concentrated Potassium Chromate solution (3 g/l in Perchloric 5 mmol/l) and washing solution as reagents. Given an initial volume (3ul as
default) system will generate dilutions using 1, 2, 3, 4 times the initial volume.
Linear correlation and departure from linearity are evaluated. Departures of +/5% are accepted.

4.1.12 CHEMISTRY ANALYSIS


Test allows selecting any method from any already defined Control Set and perform statistical analysis. Several analysis on methods belonging to the same
control can be measured. Precisions are set default in 3% but operator should
decide the required level.

61

62

4.1.13 CLOT DETECTOR


Several determinations can be made over both detectors (front and back):
-- Noise (dispersion): perform an evaluation of the pressure sensor baseline,
this is to identify any issue from electronics origin or power supply related
issue.
-- Calibration: Determines a Factor (CF) is a similar routine to the calibration at
the beginning of a run.
-- Dilution Test can be performed with a sample or with water and a real reagent in tray. If the real used sample has high density or clot the test will fail,
but this apparent failure is the verification of proper detector functioning, if
the calibration is successful.
a. Adjust and replacement procedures
i. AR-01: Full mechanical calibration
Initialize instrument.
1. Photometer
This calibration will determine the optimum reading position in the middle of
each cuvette.
1. Select Front Tray, remove cuvette cover.
2. Press F1 function or Start button
3. Use buttons or letters Q and E in keyboard until cuvette number 3 is close to
photometer position. Use 10 steps or 1 step option as required. Photometer
position is labeled with an arrow.
4. Close cover
5. Press Scan button. Instrument will scan cuvette number 3 and in Position
window will write optimum calibration value.
6. Press F3 function or Confirm button.
7. Select Back Tray and repeat procedure.
Figure 31

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Trouble Shooting

63

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and item 3 can be
skipped. Once Start button is pressed, calibration can be aborted by pressing the
Skip button.
2. Arm and Reaction Tray
This calibration will define that tip falls in the reaction tray in the middle of the
reaction cuvette. Also, it defines the cuvette vertical position, which in turn, will
define the dispensing height. Calibration includes positioning of cuvette washer module.
1. Select Front Tray; remove cuvette cover and cuvette retainer cover.
2. Press F1 function or Start button.
3. Use buttons or letters A and D in keyboard until tip is close to the center of
cuvettes. Use 10-step or 1-step option as required.
4. Use buttons or letters W and S in keyboard until tip is few millimeters above
cuvette.
5. Rotate tray by using buttons or letters Q and E in keyboard until cuvette
number 1 (labeled with a sticker) coincides with tip position.
6. Repeat steps 3 and 5 until tip falls in the middle of cuvette number 1. For
better sensitivity, use 1-step buttons. Do not fine tune vertical position at
this time.
7. Press F3 function or Confirm button
8. Press F3 function or Confirm button.
9. Shift probe horizontally until tip is above cuvette body but outside cuvette
itself.
10. Use buttons or letters W and S in keyboard and 1-step mode until tip just
touches upper flat part of cuvette body.
11. Press F3 function or Confirm button.
12. Select Back Tray and repeat procedure.
Figure 32

64

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and item 3 can be
skipped.
Once Start button is pressed, partial calibrations can be aborted by pressing the
Skip button.

Note: Last button does not

Important: Before to confirm a position, press F5 to test this movement in normal operation to avoid a bad calibration due to backlash.

act on vertical positions. This


is so to prevent tip damage.

3. Washer
Use this window to calibrate the position when the drying block goes down to a
cuvette. From the washer calibration window
1. Choose front or back washers, and then push Start.
2. Loosen washer head screws.

Figure 33

3. Use buttons or letters R and F in keyboard to download the washer into the
cuvette. When moving down the washer, use the index finger to move up
the dryer block, release it, and check if moves down freely. Center washer
pipes in the cuvette. Pre adjust screws.

HumaStar 600 | Service manual

Trouble Shooting

65

Figure 34
Figure 35

4. Continue moving down until the dryer block reaches the cuvette bottom.
The dryer spring should not be activated. Stop before it happens.
Figure 36

66

5. Confirm than the dryer block moves freely, and the pipes are centered in the
cuvette and tighten screws.
Figure 37
Figure 38

6. Continue moving down until station 5 spring compresses about 0.5 mm. The
block dryer block should not move the reaction tray, you have to test it with
test button. Use 10-step or 1-step option as required.
Figure 39

7. Push Skip to cancel or Confirm to accept the calibration.


8. From the Maintenance->Operation window, wash 10 cuvettes 5 times.
9. Check if the washer is not scratching the cuvettes.

HumaStar 600 | Service manual

Trouble Shooting

67

4. Arm and Washing Station


1. Select Front Tray.
2. Press F1 function or Start button.
3. Position match from left movement. Use buttons or letters A and D in keyboard until tip is close to the center of washing station and touch the bottom. Use 10-step or 1-step option as required.
4. Press F3 function or Confirm button.
5. Position match from right movement. Use buttons or letters A and D in keyboard until tip is close to the center of washing station and touch the bottom. Use 10-step or 1-step option as required.
6. Press F3 function or Confirm button.
Important: Before to confirm a position, press F5 to test this movement in
normal operation to avoid a bad calibration due to backlash.

5. Arm and Sample


1. Select Front Probe.
2. Press F1 function or Start button.
3. Use buttons or letters A and D in keyboard until tip is close to the center of
inner sample ring. Use 10-step or 1-step option as required.
4. Rotate Sample tray by using buttons or keys Q and E in keyboard.
5. Repeat 3 and 4 until tip is in the center of sample vial number 1.
6. Press F3 function or Confirm button.
Figure 40

68

7. Use buttons or letters W and S until tip just touches bottom of sample vial.
Pull up frequently the vial while stepping down
8. Press F3 function or Confirm button.
9. Use buttons or letters A and D in keyboard until tip is close to the center of
outer sample ring. Use 10-step or 1-step option as required.
10. Rotate Sample tray by using buttons or keys Q and E in keyboard.
11. Repeat 3 and 4 until tip is in the center of sample vial number 2.
12. Press F3 function or Confirm button.
13. Use buttons or letters W and S until tip just touches bottom of sample vial.
Pull up frequently the vial while stepping down
14. Press F3 function or Confirm button.
15. Select Back Probe and repeat procedure.

Note: Last button does not


act on vertical positions. This
is so to prevent tip damage

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and items 3, 4, 9,
and 10 can be skipped. Once Start button is pressed, partial calibrations can be
aborted by pressing the Skip button.
Important: Before to confirm a position, press F5 to test this movement in
normal operation to avoid a bad calibration due to backlash.
6. Arm and Reagent Tray
1.
2.
3.
4.
5.
6.
7.
8.
9.

HumaStar 600 | Service manual

Fully remove the reagent cover.


Select Front Probe.
Press F1 function or Start button.
Use buttons or letters A and D in keyboard until tip is close to the center of
cap of outer reagent ring. Use 10-step or 1-step option as required.
Rotate Reagent tray by using buttons or keys Q and E in keyboard.
Repeat 3 and 4 until tip is in the center of cap of reagent vial number 1.
Use buttons or letters W and S until tip just touches cap of reagent vial.
Press F3 function or Confirm button.
Use buttons or letters A and D in keyboard until tip is close to the center of
inner reagent ring. Use 10-step or 1-step option as required.

Trouble Shooting

69

10. Rotate Reagent tray by using buttons or keys Q and E in keyboard.


11. Repeat 3 and 4 until tip is in the center of reagent vial number 25 and vial 49
(physically located as the inner split vial on position 25)..
12. Use buttons or letters W and S until tip just touches cap of reagent vial.
13. Press F3 function or Confirm button.
14. Use buttons to achieve bottom of reagent 1.
15. Press F3 function or Confirm button.
16. Select Back Probe and repeat procedure.
Figure 41

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and items 4 and 9 can
be skipped. Once Start button is pressed, partial calibrations can be aborted by
pressing the Skip button.
Important: Before to confirm a position, press F5 to test this movement in
normal operation to avoid a bad calibration due to backlash.

70

7. Sample Tray
This calibration is intended for alignment of sample sectors into the removal
area.
1. Press F1 function or Start button.
2. Rotate Sample tray by using buttons or keys Q and E in keyboard until zone
1 is visible in the load area.
3. Re-adjust until sector can be loaded and unloaded through the loading area.
4. Press F3 function or Confirm button.
Figure 42

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and item 1 can be
skipped.
Once Start button is pressed, calibration can be aborted by pressing the Skip
button.
Important: Before to confirm a position, press F5 to test this movement in
normal operation to avoid a bad calibration due to backlash.

HumaStar 600 | Service manual

Trouble Shooting

71

8. Reagent Tray
This calibration is intended for alignment of reagents into the removal area.
1. Press F1 function or Start button.
2. Rotate Reagent tray by using buttons or keys Q and E in keyboard until Reagents 1 and 25 are visible in the load area.
3. Re-adjust until reagents 1 and 25 can be loaded and unloaded through the
loading area.
4. Press F3 function or Confirm button.
Figure 43

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and item 1 can be
skipped. Once Start button is pressed, calibration can be aborted by pressing the
Skip button.
9. Bar Code Reader
1. Press F1 function or Start button.
2. Install in reagent 1 position a vial with valid bar code.
3. Use buttons or letters A and D in keyboard until vial is in front of BCR window. Use the 1-step option.
4. Press button or key R in keyboard and verify if code is read.
5. Repeat steps 3 and 4 until code is read. Look for the central position if code is
read in a range of positions.

72

6. Press F3 function or Confirm button.


7. Install in sample 1 position a vial with valid bar code.
8. Use buttons or letters Q and E in keyboard until vial is in front of BCR window.
Use the 1-step option.
9. Pres button or key R in keyboard and verify if code is read.
10. Repeat steps 3 and 4 until code is read. Look for the central position if code is
read in a range of positions.
11. Press F3 function or Confirm button.
Figure 44

If instrument was already calibrated, Last button will position tray where last
calibration was determined. Once Start button is pressed, partial calibrations
can be aborted by pressing the Skip button.
10. ISE Module
1. Press F1 function or Start button.
2. Use buttons or letters A and D in keyboard until tip is close to the center of
ISE loading window. Use 10-step or 1-step option as required.
3. Press F3 function or Confirm button.
4. Use buttons or letters S and W in keyboard until tip touch bottom cup. Use
10-step or 1-step option as required.
5. Press F3 function or Confirm button.
6. Use buttons or letters A and D in keyboard until tip is close to the center of
ISE priming position. Use 10-step or 1-step option as required.
7. Press F3 function or Confirm button.
8. Use buttons or letters S and W in keyboard until tip is in the bottom of the ISE
priming position. Use 10-step or 1-step option as required.
9. Press F3 function or Confirm button.

HumaStar 600 | Service manual

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73

If instrument was already calibrated, Last button will position tray where last
calibration was determined. This procedure will save time and item 2 can be
skipped.
Once Start button is pressed, partial calibrations can be aborted by pressing the
Skip button.
Important: Before to confirm a position, press F5 to test this movement in normal operation to avoid a bad calibration due to backlash.

Note: Last button does not


act on vertical positions. This
is so to prevent tip damage.

11. Photometer Calibration


Photometer calibration consist of automatic adjust of gains for front, back and
reference channels. Also, energy ratios front/reference and back/reference are
evaluated.
Ratios are used for absorbance calculations.
Calibrations must be performed only when lamp is changed or filters are
cleaned or replaced.
Channel Ratio must be re-calculated about once every two weeks.
When calibration or ratio evaluation is started, instrument ask for a new cuvette
in position 1.
When calibration is performed, error messages will be issued if gains are too
high or too low. No conditions are established on ratios.
12. Sample sector definition
For sector definition, select Maintenance > Parameters > Sector definition, then
define a new sector with a number and assign the STAT condition, if required.
Be sure that number is not already defined in the column to the right. If so, first
delete definition and then re- enter new definition, including STAT condition.
ii. AR-02: Filter Wheel cleaning
1. Verify that instrument is turned off.
2. Remove left side cover.
3. Identify photometer and filter wheel.
4. Use cotton swabs to remove dirt from filters surface. Rub gently until opalescence is removed.
5. After cleaning is complete, reinstall cover, turn the instrument on and allow
it to warm up for 15 minutes.
6. NOTICE: Filter No. 0 is an opaque dummy, and requires no cleaning.
7. Perform a Calibration.

74

iii. AR-03: Probe replacement


1. Remove probe assembly plastic cover.
2. Disconect both electrical and hydraulic connections.
3. Release setscrew in the disk that fix probe.
4. Install the mixer assembly on the new probe and install the new probe.
5. Perform AR-01: Full mechanical calibration procedure to adjust: Arm and reaction tray, arm and washing station, arm and sample, arm and reagent tray
and ise module.
6. Perform AR-04: Mixer checking procedure.
iv. AR-04: Mixer checking
1. Initialize instrument. Enter to Data > Log as supervisor > pasword 31415
2. Access to Maintenance > Service > Manual and choose vertical tab.
3. Initialize vertical and press turn on vibrator button.
4. Check that probe mixer movement amplitude is about three times the diameter of probe tip.

Figure 45

HumaStar 600 | Service manual

Trouble Shooting

75

v. AR-05: Complete removal of reaction tray


Figure 48
Figure 49

1. Remove reaction tray cover

2. Remove cuvette holder


Figure 46
Figure 47

3. Remove the four screws and the


plastic reaction tray ring

4. Remove the two screws for the


cuvette holder lock
Figure 50

5. Remove center screw and pull


up the reaction tray support

76

vi. AR-06: Removal of preamplifier


1. Perform AR-05: Complete removal of reaction tray procedure.
2. Remove the preamplifier screw.
vii. AR-07: Removal and replacement of reaction tray heater
1. Perform AR-05: Complete removal of reaction tray procedure.
2. Remove the four screws located on heat sink to access to heater
viii. AR-08: Removal and replacement of reaction tray fan
1. Perform AR-05: Complete removal of reaction tray procedure.
2. Remove air director from the fans and remove fans.
ix. AR-09: Removal of complete boom assembly (vertical & horizontal)
1. Disconnect the arm tubing (tubing connector is located in the middle way of
arm and diluter end).
2. Remove the three biggest screws from the boom assembly, gently pull it up
and disconnect J1, J2 and J3 from the distribution board.
Figure 51

x. AR-10: Removal of complete washer


1. Remove the wash head by removing its two screws.
2. Disconnect J1, J3, J4 and J5 from distribution board.
3. Identify and remove the two biggest screws located on washer fixture.

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77

Figure 52
1 Wash head screws
2 Collision sensitivity

1
2

xi. AR-11: Adjust washer collision sensitivity


1. Identify collision sensitivity screw (the bigger one). Rotate clockwise to reduce
washer collision sensitivity.
xii. AR-12: Removal of complete reagent cooler assembly
1. Perform AR-25 Removal for reagent fridge temperature sensor replacement:
Steps from 1 to 21.
xiii. AR-13: Removal of Peltier thermoelectric devices
1. Perform AR-25 Removal for reagent fridge temperature sensor replacement:
Steps from 1 to 25.
Notes for checking Peltier devices:
As a Peltier device varies its conductivity against the temperature and a
current produces an internal temperature gradient, required instrument for a
lab measurement is an AC-O. For field service purposes a DMM is enough to
check it:
-- Use a DMM on the lowest resistance range.
-- Check not for shorts nor open Peltiers.
-- Compare device against others on the cooler assembly
-- Measure device in both directions Check that resistance varies against the
time.

78

xiv. AR-14: Access to reagent verification sensor


1. Remove complete cooler assembly, identify home/verification sensor assembly
Figure 53

xv. AR-15: Reagent tray belt replacement and tension belt adjustment
*Belt replacement
1. Perform AR-25: Removal of complete reagent cooler assembly procedure.
Steps from 1 to 21.
2. Remove reagent verification sensor and motor.
3. Remove belt.
*Tension belt adjustment
1. Release screws. See picture.
2. Move motor to adjust the tension belt.
3. Perform VD-19 to verify tension and values settings.
Figure 54

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79

xvi. AR-16: Vertical arm belt replacement and tension belt adjustment
*Belt replacement
1. Perform AR-09: Removal of complete boom assembly (vertical & horizontal)
2. Release screw from pulley support. See picture
3. Move pulley support and remove the vertical verification sensor and release
the guiding shaft to loose and remove the belt.
*Tension belt adjustment
1. Perform AR-09: Removal of complete boom assembly (vertical & horizontal)
2. Identify the vertical belt.
3. Move pulley support to adjust belt tension.
4. Perform VD-19 to verify tension and values settings.
Figure 55

Model for instruments SN:_ _ _ _ 4 0 _ _


Figure 56

Model for instruments SN:_ _ _ _ 4 1 _ _

80

xvii. AR-17: Horizontal belt replacement and tension belt adjustment


*Belt replacement
To remove the belt attached to the motor
1. Perform AR-09: Removal of complete boom assembly (vertical & horizontal)
2. Release motor screws. See picture
3. Remove the verification sensor board.
4. Remove the belt.
To remove the belt attached to the movement shaft
5. Release the belt attached to the motor (as mentioned on steps 1 to 4).
6. Release the setscrew. See picture. Only for SN_ _ _ _ 40 _ _.
7. Use the hole to rotate the eccentric to release the belt attached to the movement shaft. Only for SN_ _ _ _ 40 _ _.
8. Release The belt attached to the shaft.
*Tension belt adjustment
Model for instruments SN_ _ _ _ 40 _ _
1. Perform AR-09: Removal of complete boom assembly (vertical & horizontal)
2. Release motor screws. See picture
3. Release the setscrew. See picture
4. Use the hole to rotate the eccentric to adjust the belt tension attached to the
movement shaft.
5. Perform VD-19 to verify tension and values settings.
6. Fix setscrew.
7. Move motor to adjust the tension belt attached to the motor.
8. Perform VD-19 to verify tension and values settings.
Model for instruments SN_ _ _ _ 41 _ _
1. Perform AR-09: Removal of complete boom assembly (vertical & horizontal)
2. Release motor screws. See picture
3. Move motor to adjust the tension belt attached to the motor.
4. Perform VD-19 to verify tension and values settings.

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81

Figure 57

Model for instruments SN:_ _ _ _ 4 0 _ _


Figure 58

Model for instruments SN:_ _ _ _ 4 0 _ _

82

Figure 59

Model for instruments SN:_ _ _ _ 4 1 _ _


xviii. AR-18: Sample tray belt replacement and tension belt adjustment
*Belt replacement
1. Release the two ball bearings
2. Remove the verification sensor disk.
*Tension belt adjustment
1. Release the two ball bearings.
2. Move ball bearings to adjust tension belt.
3. Perform VD-19 to verify tension and values settings.
Figure 60

HumaStar 600 | Service manual

Trouble Shooting

83

xix. AR-19: Adjustment of filter delays


WARNING:
This is a factory adjustment and it should not be modified unless a major servicing is required (motor replacement, sensor
position adjust, etc.)
Do not use if a filter is replaced.
This procedure will reset preamplifiers gain, photometer calibration is further required.
1. Enter to Data > Log as supervisor > pasword 31415, then Maintenance >
Calibration > Filterwheel.
2. Remove all cuvettes from light path.
3. Choose reset gains and set reset delays to 20, use normalization by channel
and then press start.
4. Choose main delay to see noise on filter # 13
5. Adjust each filter delay to center the three signal peaks (use stay on filter
option).
6. Press stop button when done.
Figure 61

xx. AR-20: Photometer calibration


Calibration is performed on four steps:

84

-- During the Initialization, instrument checks communication to the other


modules.
-- Zero setting, defines the baseline reading level of darkness, it uses filter #13.
-- Gain setting, adjusts internal signal levels to ensure linear operation of A/D
converter.
-- Ratio calculation, establishes the relationship between both front and back
sample channels against reference channel.
1. Enter to maintenance > calibration > photometer.
Figure 62

2. Check that range for zero is 2000.


Figure 63

3.
----

Choose Sumarize tab and check:


-2000 < Zero < 2000
20000 < Front, back, and ref channels < 480000
Highest gain = 16 (for filter #1).

In case readings of front, back and ref channels are not similar, perform AR-19:
Adjustment of filter delays. In case issue persists, perform VD-06: Photometer
and lamp alignment check.

HumaStar 600 | Service manual

Trouble Shooting

xxi. AR-21: Lamp alignment optimization


1. Enter to Data > Log as supervisor > pasword 31415 then enter to
Maintenance > Calibration > Lamp intensity
2. Choose reading for filter #1 and press start button.
3. Re-adjust of lamp socket to maximize reading while getting both channels
as equal as possible.
4. For testing purposes it is possible to stop filter wheel and then return it to
normal mode.
xxii. AR-22: Special replacement procedure for Head board (M400- P299 or
M400-P317)
1. Remove board plastic cover.
2. Disconnect both hydraulical and electrical connections to the board.
3. Set JP1 jumper according to the position of the board:
JP1 close for front
arm. JP1 open for
back arm.
1. For instruments with M400-P317 board please perform AR-26 Adjust probe
optical collision sensor.
2. Reconnect and reinstall plastic cover.
xxiii. AR-23: Special replacement procedure for Diluter
1. Set the new diluter accordingly: for Front diluter (left located) Rotary switch
set to ID = 5. J4 termination jumpers installed for Back diluter (right located)
Rotary switch set to ID = 6 J4 termination jumpers not installed
2. Turn the instrument off.
3. Install the new diluter (front/back)
4. Disconnect the other diluter (back/front)
5. Turn the instrument on.
6. Enter to Data > Log as supervisor > 31415 then Maintenance > service >
Manual then choose diluter tab and the proper front / back diluter installed.
7. Press Set baud rate to store the proper baud rate into the new diluter EEPROM.
8. Turn off the instrument.
9. Wait for 10 seconds.
10. Reconnect the other diluter.

85

86

xxv. AR-25: Procedure for reagent fridge temperature sensor replacement.


1. Remove instrument deck.
2. Remove instrument right side panel and rear panel.
3. Remove the gas spring
Figure 64

4. Remove instrument cover.


Figure 65

5. Remove tensors screw.


Figure 66

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87

6. Remove detachable lateral bar.


Figure 67

7. Remove the supply connection and the data connection of the fridge controller (see three arrows).
Figure 68

8. Removing the drain condensation tubing from the fridge. See hydraulic
diagram.
Figure 69

88

9. Identify the fridge assembly inside the instrument. On the right side of the
picture, you will see two post to support guiding wheels for the sample tray
metal ring.
Figure 70

10. Identify the first post located on the right of the fridge assembly, perform
a marking using a permanent marker. The mark should be a straight line
joining both the positioning rod and the flat surface as shown in the picture.
This is to be able to locate this part exactly to the same position when re(
assembly.
Figure 71

11. Release the setscrew to be able to rotate the post.


Figure 72

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89

12. Identify the hole and use an allen wrench to rotate the post about 90o, this
will turn an eccentric piece that will release the tray.
Figure 73

13. Release the pulley using an hex wrench and a 10mm wrench from the other
side.
Figure 74

14. Remove the belt by gently sliding out of the big pulley of the sample tray.
Figure 75

90

15. Remove the sample ring by slowly and gently rotating the sample ring counter- clockwise while lifting it.
Figure 76

16. Remove the upper setscrew


Figure 77

17. Use a thin pin and a hammer to hit and remove the locking pin of the white
plastic support.
Figure 78

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91

18. Remove the plastic support


Figure 79

19. Remove the white ring.


Figure 80

20. Identify the four screws you will need to remove to separate the fridge from
its support.

Figure 81

92

21. Identify the four screws you will need to remove to separate the fridge from
its support.
Figure 82

22. Identify the four screws you will need to remove to separate the fridge from
its support.
Figure 83

23. Identify the four screws you will need to remove to separate the fridge from
its support.
Figure 84

HumaStar 600 | Service manual

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93

24. Identify the condensation tubing of the fridge.


Figure 85

25. Gently pull the fridge (the white part that has attached two square pipes
with fans). Before pulling from the fridge, it is necessary to release the condensation tubing (shown in previous step) and also check if it is necessary to
disconnect any other wire from a sensor before pulling the fridge.
Figure 86

26. Use a soft cloth on the table to protect against scratchings the delicate surfaceof the fridge. Put the fridge upside down.
Figure 87

94

27. Disconnect the sensor (see flat wire is disconnected from the board).
Figure 88

28. There are three screws holding each square pipe. Slide the fridge towards
you to be able to access the screws (the screws are located inside of chamber
where is normally located the reagent tray) and remove the three screws.
Then lift the square pipe that has attached the controller board to access
peltier elements as shown.
Notice that peltier elements are mounted in this fashion:
Graphite sheet + Peltier element + Graphite sheet
The graphite sheet improves thermal conductivity between peltiers and
fridge surfaces. Take care of the graphite sheets, because are very delicate
and easy to break.
In case you break a graphite sheet replace it and clean properly with alcohol the
surface of the peltier elements to avoid any residues on them.
Figure 89

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29. During the release of the screws attached to the pipe, take care of the
support of each screw.
Figure 90

30. Identify the temperature old sensor, remove.


Figure 91

31. Identify the new sensor, it should have two screws and two white washers.
Figure 92

96

32. Clean the parts properly using gently an utility knife.


Figure 93

33. Apply a layer of silicone sealant.


Figure 94

34. Layer should cover completely the surface of the slot.


Figure 95

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Trouble Shooting

97

35. Screw the sensor do not force the screws, just screw to ensure sensor is in
proper contact with the metal surface.
Figure 96

36. Final view of the sensor mounted.


Figure 97

37. Cover the sensor with a generous layer of silicone sealant.


Figure 98

98

38. Final view of the sensor mounted with the silicone sealant.
Figure 99

39. Identify the screws supports and position them properly on the fridge
Figure 100

34. Proceed from step 25 to 1 to mount the fridge on the instrument.


-- You will receive spare graphite sheets to replace the damaged ones.
-- Remember to mount the peltier elements with one graphite sheet on each
side.
-- Before mounting graphite sheets, clean both sides of peltiers with alcohol.
-- You can use a drop of thermal grease to temporaly glue the graphite sheet
and ease mounting.

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99

WARNING!!: When reassembling the fridge back to the fridge support, take care
that shaft should be properly centered on its hole before tightening the screws
(See pictures below)
Figure 101
Figure 102

xxvi. AR-26: Adjust and verify probe optical collision sensor. M400-P317 Head
board.
1. Tip collision is detected by the interruption of the light emitted by an optical
sensor generated by the movement in the collision flag. When the flag is
moved, the hole in the flag will not be aligned anymore with the optical light
path of the sensor and the collision will be detected.
Figure 103
Figure 104

Optical collision sensor

Sensor light path

100

Figure 105

2. The collision flag hole must be aligned with the sensor optical path. You
must center vertical and horizontal sides of the collision flag with the optical
sensor. Collision flag must be equally distant from the sensor sides.
Figure 106
Figure 107
Figure 108

3. To achieve alignment, you will need to loosen board screws and move the
board up and down. Small adjustments can be obtained. Once finished, tighten the screws.
Figure 109

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Trouble Shooting

101

4. If you cant perform the alignment procedure, you will need to use flat nose
pliers in order to adjust the collision flag.
Figure 110
Figure 111

5. To verify a correct adjustment go to Maintenance > service > Manual > Vertical Turn on and off vibrator quickly and check that the collision led (DL4) is
always turned off.
xxvii.

AR-27: Lubrication procedure.

Lubrication procedure should be repeated every six months. For units with
continuous work that exceeds the 1500 analysis/day the procedure should be
repeated every four months.
Starting software version 1.8.1, an automatic warning will be issued when the
lubrication becomes necessary.
Use mineral oil SAE 15 or SAE 20. DO NOT USE MORE THAN TWO DROPS IN
EACH OILING POINT, otherwise excess of oil could fall on sensors and belts and
damage the system.
Oil can be added with an hypodermic syringe. For reference, two drops is
equivalent to 50 microliters.

102

Remove cover and top desk as follows:


a) Remove the six setting screws located on top of desk.
b) Remove both arm covers and the small closing arm covers.
c) Rotate arms until they point towards the center of the reagent tray.
d) Remove rings and mountings of both washing stations.
e) Carefully remove desk, front side first
Remove also right side panel.
1. Bushing. Horizontal movement
Remove two screws that hold upper limiter plate. Push firmly the vertical
axis up. This will leave a gap between belt and washer of about two millimeters. With the hypodermic needle introduce oil in the gap, as deep as
possible.

Figure 112

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103

2. Bushing. Vertical movement, parallel rod.


Figure 113

3. Bearing. Vertical movement.


Figure 114

104

4. Free pulley. Lower end, vertical belt.


Be sure that the amount of oil is very small; otherwise it could spill on sensors. Oil drop should fall over the Teflon washer.
Figure 115

5. Bushings. Parallel rods. Washer.


Figure 116

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Trouble Shooting

105

6. Bushing. Reagent tray axis.


Use a pipette with a drop in the tip or a rod with cotton wetted with oil,
wrapped at its end. Introduce the pipette/rod above the motor located between the two cooling fans. Touch the upper end of bushing with rod or
blow the oil standing at the pipette tip. If using rod with cotton, rotate by
hand the tray and repeat procedure.
Figure 117

Figure 118

106

xxviii. AR-28: Washer belt replacement and tension belt adjustment


*Belt replacement
1. Release nut of pulley support. See picture.
2. Remove the belt.
*Tension belt adjustment
1. Release nut of pulley support. See picture.
2. Move pulley to adjust belt tension.
3. Perform VD-19 to verify tension and values settings.
Figure 119

Figure 120

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Trouble Shooting

107

xxix. AR-29: Reaction tray belt replacement and tension belt adjustment
*Belt replacement
1. Release screws. See picture.
2. Move motor and remove the belt.
*Tension belt adjustment
1. Release screws. See picture.
2. Move motor to adjust the tension belt
3. Perform VD-19 to verify tension and values settings.
Figure 121

xxx. AR-30: Procedure to replace PL400242W stepper motor controller board


for PL400313W microstepper motor controller board.
Figure 122

108

Figure 123

1. The instrument has 6 motor controller boards to drive movements


(PL400242W or PL400313W).
2. You can replace a PL400242W for PL400313W. Note: You can not replace a
PL400313W for PL400242W in instruments with SN:xxxx41xx.
3. After replace the board you have to perform the mechanical calibration of
the movement that this board controls.
Important:
-- To use an instrument with PL400313W board you must run a rayo software
version 1.8.0 or higher.
-- Take note that if you replace only one board (PL400313W), for example the
front vertical and horizontal arm movement, both arms will move different.
The front arm will has smoother movement and less mechanical noise.

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xxxi. AR-31: Procedure to replace cooler heating fans.


1. Perform AR-25 from step 1 to 22.
2. Remove fan screws.
3. Fans will be mounting with air flow direction to outside of the instrument.
Figure 124

4. To see fans PN go to spare part list.

Note: The only difference between fans is length wire.

xxxii. AR-32: Diluter valve replacement


1. Remove as much fluid as possible from system flush tip without the water
bottle.
2. Initialize the diluter from maintenance->service->manual->diluter
3. Move the plunger to the bottom of travel from maintenance->service>manual->diluter.
4. Remove the syringe and tubing.
5. Remove the two socket head screws on the front of the valve, then remove
the valve from the pump.
6. Install the new valve by placing it on the front panel so that the screw holes
line up. The valve coupler fitting mates to the valve motor shaft. The shaft
should be in the correct position
7. Replace the valve screws but do not tighten completely.

110

8. Install the syringe and pull the syringe plunger until it is aligned with the
carriage. Align the valve using the plunger as a guide, and tighten from 1/4
to 1/2 turn after the screws contact the valve body.
9. Pull the syringe plunger all the way into the carriage and secure by tightening the plunger lock screw.
Figure 125

xxxiii. AR-33: Syringe diluter replacement

Note: Make sure the plunger


lock screw is securely tightened and the plunger button is free
to move on the plunger lock
screw.

HumaStar 600 | Service manual

1.
2.
3.
4.
5.
6.

Remove the plunger lock screw.


Install the syringe as shown in Figure 2-7, following these steps:
Screw the syringe into the valve.
Pull the syringe plunger down to the plunger holder assembly.
Align the plunger button through hole to the carriage mounting hole.
Slide the plunger lock screw through the plunger button and fasten to the
carriage.

Trouble Shooting

111

Figure 126

112

xxxiv AR-34: Halogen lamp replacement.


1. Unplug the equipment.
Figure 127

2. Remove the lamp access panel.


Figure 128

3. Remove the halogen lamp from the socket pushing the lever.
Figure 129

HumaStar 600 | Service manual

Trouble Shooting

113

4. Place the new halogen lamp into the socket. Take care of the lamp polarity.
The big terminal should goes up.
Figure 130

5. Close the lamp access panel and plug the equipment.


6. Turn on the software. Perform a system flush, and replace the first cuvette
strip from both trays.
7. Perform a full photometer calibration from
Maintenance > Photometer Calibration.
xxxv. AR-35: Drying block replacement.
1. Unscrew the drying block.
2. Screw the new one. Take care of the drying block position.
Figure 131
Figure 132

114

3. Perform the washer calibration procedure.


4. Once replaced, proceed to reset cycle counter in
Maintenance > Operations > Wear.
xxxvi. AR-36: Peristaltic pump tubing replacement.
1. Pull fittings up and out of bracket.
Figure 133
Figure 134

2. Pull tube out of its lodging rotating by hand the pump rotor if necessary.
Figure 135

HumaStar 600 | Service manual

Trouble Shooting

115

3. Clean the mesh filter.


Figure 136

4. Insert new tube on the fittings.


5. Push tube inside of its lodging. Turn slowly rotor by hand until tubing is properly lodged.
Figure 137

6. Once replaced, proceed to reset cycle counter in


Maintenance > Operations > Wear.

116

xxxvii. AR-37: Peristaltic pump rotor replacement.


1. Remove the peristaltic pump tubing following the peristaltic pump tubing
replacement procedure.
Figure 138

2. Locate the rotor set screw.


Figure 139

HumaStar 600 | Service manual

Trouble Shooting

117

3. Using an allen key metric 2, unscrew the rotor set screw.

Figure 140
Figure 141

4. Remove the pump rotor.


5. Place the new pump rotor. The shaft flat position should point up.
Figure 142

6. Tighten the set screw.


7. Insert the pump tubing following the peristaltic pump tubing replacement
procedure.
8. Once replaced, proceed to reset cycle counter in
Maintenance > Operations > Wear.

118

xxxviii. AR-38: Diaphragm for drying and water pump replacement.


1. Unplug the equipment.
Figure 143

2. Remove the equipment back panel.

Figure 144

HumaStar 600 | Service manual

Trouble Shooting

119

3. Identify the pump which the diaphragm will be replaced


Figure 145
Figure 146

4. For the 2 pumps in the left of the photo (FDP and FWP), in order to have
access to the pump head, you will need to remove the pump from the mounting base. Using a screwdriver remove the 3 mounting screws.
Figure 147
Figure 148

120

Figure 149
Figure 150

5. Remove the 4 pump head screws.


Figure 151
Figure 152

6. Carefully remove the pump head.


Figure 153

HumaStar 600 | Service manual

Trouble Shooting

121

7. Turn the diaphragm counterclockwise in order to remove it.

Figure 154
Figure 155

8. Place the new diaphragm and close the pump head.


9. Place the pump in position.
10. Once replaced, proceed to reset cycle counter in
Maintenance > Operations > Wear.
xxxix. AR-39: Washer pumps filter replacement / cleaning.
1. Unplug the equipment.
Figure 156

122

2. Remove the equipment back panel.


Figure 157

3. Identify the pump which the filter will be replaced/cleaned. Due to biological
risk, we recommend to replace the FRP and BRP mesh filters. FWP and BWP
filters can be cleaned.

Figure 158
Figure 159

HumaStar 600 | Service manual

Trouble Shooting

123

4. Replace or clean the desired mesh filter.

Figure 160
Figure 161

xl. AR-40: Tubing Sets 12 month.


1. Unplug the equipment.
Figure 162

124

2. Remove the equipment back, front and side panels in order to have access to
the washers and tip water pumps
Figure 163

3. You will need to replace the tubing from the washer, including the water
suction pump tubing (pipes 16 to 19), water delivery pump tubing (pipes 11
to 14), reaction pump tubing (pipe 15), and drying block pump tubing (pipe
28). Also you will need to replace the DI water intake tubing from the DI water bottle (T022F and T022B).
Figure 164

HumaStar 600 | Service manual

Trouble Shooting

125

Figure 165

4. Check the hydraulic diagram for more information regarding tubing


connection.
xli. AR-41: Fan filters cleaning.
1. Locate all the fan filters from the back and side panels of the equipment.
Figure 166

126

2. Remove, clean, and place it again one at a time. Place the filters under the
tap in order to clean it. Dried properly before placing.
xlii. AR-42: Procedure for install instrument cover
1. Remove right lateral and rear panel.
2. Install the instrument cover in the position and place the hinge axis, do not
adjust the set screw in this step.
Figure 167

3. Install the gas spring.


Figure 168

4. Check the adjustment of the instrument cover over the deck. If there isnt
collisions adjust the set screw.

HumaStar 600 | Service manual

Trouble Shooting

127

5. If you detect side collisions, between the instrument cover and decks borders turn the tensor screw as the schema to move the instrument cover to
the right position.

Figure 169
Figure 170

Figure 171
Figure 172

6. Adjust the rear hinges set screws, put the lock cup to the gas spring, and
place the lateral and rear panel.

128

xliii. AR-43: 6 month maintenance kit.


Code: KitMaint40006
Quantity
2
1
2
1

Code
VOSB1206
M400BH21/3
M400BH19W
KITOIL4000

Description
Syringe Cavro 73804 for HS600
Peristaltic pump tubing
Washer filter
Lubrication Kit

1. Follow procedure AR-33 Syringe diluter replacement


2. Follow procedure AR-36 Peristaltic pump tubing replacement.
3. Follow procedure AR-39 Washer pumps filter replacement/cleaning. You
should replace the front reaction pump (FRP) and back reaction pump (BRP)
mesh filters, and clean FWP and BWP mesh filters.
4. Follow procedure AR-27 Lubrication procedure.
5. Follow procedure AR-41 Fan filters cleaning.
xliv. AR-44: 12 month maintenance kit.
Code: KitMaint400012
Quantity
2
1
2
1
1
2
2
2
2
1

HumaStar 600 | Service manual

Code
VOSB1206
M400BH21/3
M400BH19W
KITOIL4000
LAR12V20W
OTDI700A
OTDI700L
M40J14W
M400BH09W
M4000TUH

Description
Syringe Cavro 73804 for HS600
Peristaltic pump tubing
Washer filter
Lubrication Kit
Halogen Lamp 12V
Diaphragm for Drying pump
Diaphragm for Water pump
Drying block
Peristaltic pump rotor
Tubing Sets 12 month

Trouble Shooting

1. Follow procedure AR-33 Syringe diluter replacement.


2. Follow procedure AR-36 Peristaltic pump tubing replacement. Once you removed the tubing, and before placing the new one, you should replace the
pump rotor following procedure AR-37 Peristaltic pump rotor replacement.
3. Follow procedure AR-39 Washer pumps filter replacement/cleaning. You
should replace the FRP and BRP mesh filters, and clean FWP and BWP mesh
filters.
4. Follow procedure AR-38 Diaphragm for drying and water pump replacement.
You should replace the diaphragm for the FWP, BWP, FDP, and BDP.
5. Follow procedure AR-40 Tubing Sets 12 month.
6. Follow procedure AR-35 Drying block replacement.
7. Follow procedure AR-27 Lubrication procedure.
8. Follow procedure AR-34 Halogen lamp replacement.
9. Follow procedure AR-41 Fan filters cleaning.
b. General parameters
See the table in next page for details.
Notes
* Parameters cannot be modified when instrument is in use.
* Wear parameters refers to a factory recommendation for warning on consumables expected life. Each parameter, when surpassed, triggers a warning message.
The warning message presence does not prevent from instrument usage.
* For the cuvette washer, water is delivered in four cuvettes at the same time,
between 500 and 700 microliters in each one. So, total volume is between 2000
and 2800 microliters. Calibration is in step of peristaltic pumps.

129

130

Table 2

TYPICAL

NAME

BLOCK

Low limit (Abs)

Cuvette Blank

High limit (Abs)

Cuvette Blank

0,2

Tolerance

Cuvette Blank

0,04

Sample vials

950

Primary area (mm2


x 10)
Secondary area
(mm2 x 10)
Filter 1 (Lambda)

Filter 2 (Lambda)

Filter 3 (Lambda)

Filter 4 (Lambda)

Filter 5 (Lambda)

Filter 6 (Lambda)

Filter 7 (Lambda)

Filter 8 (Lambda)

Filter 9 (Lambda)

Sample vials

950

Photometer

340

Photometer

Photometer

Photometer

Photometer

Photometer

Photometer

Photometer

Photometer

Filter 10 (Lambda) Photometer

Filter 11 (Lambda) Photometer

HumaStar 600 | Service manual

VALUE

380

405

450

490

505

550

590

620

650

700

COMMENTS
Minimum absorbance for
a valid cuvette
Maximum absorbance for
a valid cuvette
Tolerance to detect a dirty
cuvette after washing
Area for the default vial
Area for the secondary or
pediaric vial
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter
Wavelenght for the specified filter

ACCESS
LEVEL
User
User
User
User
User

Service

PATH
Maintenance\Parameters\Use
Maintenance\Parameters\Use
Maintenance\Parameters\Use
Maintenance\Parameters\Use
Maintenance\Parameters\Use
Maintenance\Service\Parameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters

Trouble Shooting

Filter 12 (Lambda) Photometer

Filter 13 (Lambda) Photometer

Front Arm

Temperatures

131

750

41

Wavelenght for the specified filter


Wavelenght for the specified filter

Preheater temperature

Maintenance\Service\PaService

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Filters
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Back Arm

Reaction Tray

Cool Tray (H/L)

Low limit (Abs)

High limit (Abs)

Tolerance (Abs)

Pinch valve time

Serum

Temperatures

Temperatures

Temperatures

Cuvette Blank

Cuvette Blank

Cuvette Blank

ISE

ISE Thresholds

41

39

8 (H) / 7 (L)

0,2

0,04

500

1700

Preheater temperature

Incubation chamber temperature


Temperature control range
for the reagent cooler
Minimum absorbance for
a valid cuvette
Maximum absorbance for
a valid cuvette
Tolerance to detect a dirty
cuvette after washing
Time to activate the pinchvalve to fill the ISE

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Threshold to detect serum Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Urine

ISE Thresholds

3000

Threshold to detect urine Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Std A

ISE Thresholds

1500

Threshold to detect urine Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Std B

Time int ext wash


(ms)

ISE Thresholds

Pumps

2500

750

Threshold to detect urine Service

Time to wash the probe


before a new dilution

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others

132

Time sys flush (ms) Pumps

Decompression
(ms)

Pump turns

Syringe cycles

Pumps

Wear

Wear

Dryer block cycles Wear

ISE number of
samples
Front volume
(Steps)
Back volume
(Steps)
Front time down
(ms)
Back time down
(ms)

Volume

Diluter speed

HumaStar 600 | Service manual

Wear

Washing Station

Washing Station

4750

250

50000

100000

20000

10000

1500

1500

Time the pump is on for a


system flush
Time required to decompress the pump
Maximum allowed
number of cycles
Maximum allowed
number of cycles
Maximum allowed
number of cycles
Maximum allowed
number of cycles
Number of steps to fill the
cuvette during washing
Number of steps to fill the
cuvette during washing

Maintenance\Service\PaService

Others
Maintenance\Service\PaService

1300

head down during the

Service

1300

head down during the

Service

Pre & Post Wash

100

4320

Volume for pre and post


washes
Syringe speed during the
pre and post washes

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

drying cycle
Pre & Post Wash

rameters\Instrumental\
Others
Maintenance\Service\Pa-

drying cycle
Time to keep the wash
Washing Station

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Time to keep the wash


Washing Station

rameters\Instrumental\

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others
Maintenance\Service\Pa-

Service

rameters\Instrumental\
Others

SECTION IV

133

5 SECTION IV
Charts and diagrams
a. Location of belts and sensors
Figure 173
Photometer assembly top view

Figure 174
Robot assembly overview
side view

134

Figure 175
Washer assembly side view

Figure 176
Sample and reagent tray
assembly bottom view

HumaStar 600 | Service manual

SECTION IV

135

Figure 177
Reaction tray bottom view

136

b. ISE Hydraulics schematic.


Figure 178

HumaStar 600 | Service manual

SECTION IV

137

c. Complementary information
i. Identification of system leds
Location
On each power supply

Led silkscreen/color
Green led

Description
Power good signal from power
supply
Power on push button
Red lamp
Blinks on a power supply fault
event
Backplane board
+36_1/Red
36v on J21*
PL400245
+36_2/Red
36v on J20*
+36_3/Red
36v on J60*
+36_4/Red
36v on J57*
+12/Green
12v on J72*
Bar code reader interfase
DL1/Green
Read Ok
board PL230224
DL2/Red
Read order / init to BCR
RS232 to RS232
+5vPC/Red
Power from standby power suppIsolated board
+5vCPU/Red
ly (allways on)
PL400282
Power from CPU board (on when
instrument is on)
Microconverter baseplane DL1/Green
+12 input
& Power supply board
DL2/Red
+12A output
PL400248
DL3/Red
-12A output
Power ON/OFF control board+12v cooler led/Red
Power good from power supply
PL400255
+12v lamp led/Red
Power good from power supply
+36v heater led/Red
Power good from power supply
+36v Motor II led/Red
Power good from power supply
+36v Motor I led/Red
Power good from power supply
+12v Logic led/Red
Power good from power supply
+24v Diluters led/Red Cooler
Power good from power supply
activated led Solid state relay/ JP1: cooler pushbutton bypass
Red
JP2: mains pushbutton bypass
Mains activated led Solid state
relay/Red
ISE protocol interfase board
+12
PL400268
DL1/Red
Ise busy
DL2/Red
RS485 Cavro Blink
DL3/Red
(development purposes)
DL4/Red
Trigger 1 (development purposes)
Cooler control board
DL1/Red
Power on J12/J13: Peltiers
PL400269
DL2/Red
Power on J14/J15: Peltiers
DL3/Green
+12

Table 3

138

Lamp Control board


PL400273
Pumps distribution board
PL400283

DL1/Red

Lamp on signal

DL1/Red
DL2/Red
DL3/Red
DL4/Red
DL5/Red
DL6/Red
DL7/Red
DL8/Red

Front tip pump


Back tip pump
Not in use: Front Water pump
Front Drier pump Front Reagent
pump Back Reagent pump Back
Drier pump
+12

Notes:
* Remove all motor controller boards to perform led checkings (any motor controller internally
wires J21 to J20 and J60 to J57 depending its position on backplane).
-- Dual Stepper motor controller PL400242 status leds:
Normal Mode

Green led

Red 1 led

Red 2 led

-- On

-- Home signal

-- Verification signal
-- Collision(wa sher only)

-- Filter wheel motor controller status leds:


Normal Mode
Green led
Busy
-- On
Verification problem
-- Off
No home detection
-- Blinking
-- Blinking

Red 1 led
-- Home signal
-- On
-- Off
-- On

Red 2 led
-- Filter signal
-- On
-- Off
-- Off

To obtain the program folder press the right button on the autoanalyzer icon and choose
properties.

HumaStar 600 | Service manual

SECTION IV

139

ii. Computer program folder contents


.Root
Backup

Historic
Interfase
Lims
NSI data
Priv
Priv thread
Reports
Translator
Use data
iii.

Autoanalyzer Program folder and Main .exe file


Backup of Data, Historic, Translator and Use data folders Bin
Software parameters, wears, memory backups and about.txt
data Configurations, methods, caligrations, etc.
All historical tables
Tables shown on screen
Information for laboratory information management system
Calibration reports and summaries, communication logging, etc.
Used by the database engine
Used by the database engine
Tables containing information to build reports
Information for language support
Samples, patients, tests, tray definition.

Main menu user messages

MESSAGE
On line
Operating
Connecting
Offline
System log

OPERATION
Instrument is ready to process commands.
Instrument is busy.
Computer trying to set the link to the autoanalyzer.
Computer was not able to connect to the instrument.
Instrument was unable to recover from an error A fatal error occurred.
System Alerts
User attention required.
Reaction tray Full
Washer is disabled and no empty cuvettes available.
Reaction pending Acc.
Awaiting confirmation of result by the user.
Calculated pending Acc.
Awaiting confirmation of calculated result by the user.
Reagent blank pending Acc. Awaiting confirmation of measured blank by the user.
PreAutomatic
Instrument performing hydraulic priming and
reaction tray heater warm up.
Instrument processing samples (cuvette checking, reAutomatic
agent level checking, processing of blanks, standards,
controls and samples).
Post-Automatic
Instrument washing used cuvettes and cleaning the
probes with wash and soak solutions

140

HumaStar 600 | Service manual

APPENDIX

6 APPENDIX
a. Glossary
Absorbance. Absorbance, or optical density, is a measure of the amount of
light absorbed by a solution. Absorbance is equal to the logarithm of the ratio of
incident light to transmitted light.
Acceptance. The action of approving or rejecting the result of an assay. Used by
the operator to confirm calibrations or out of range assays results.
Accuracy. The closeness of the result of a measurement to the true value.
Aliquot. A measured portion of a sample taken for analysis.
Analyte. A specific compound or element of interest undergoing chemical
analysis.
Batch. A quantity of material produced or processed in one operation, considered to be a uniform discrete unit.
Batch-sample. One of the samples drawn from a batch.
Batch-size. The number of samples in a batch-lot.
Bichromatic measurement. The substraction of a secondary wavelenght
absorbance reading from a primary wavelenght absorbance reading to obtain a
delta absorbance reading.
BRTW. Back reaction tray and washer.
BVH. Back vertical & horizontal.
Calibrate. To determine, by measurement or comparison with a standard, the
correct value of each scale reading on a meter or other device, or the correct
value for each setting of a control knob.
Calibration curve. The graphical relationship between the known values for a
series of calibration standards and instrument responses.
Calibration drift. the difference between the instrument response and a
reference value after a period of time without recalibration.
Calibration standard. A substance or reference material used to calibrate an
instrument.
Certified Reference Material. A material that has been certified for accuracy,
stability and physical form.
Coefficient of variation (CV). A measure of relative dispersion (see precision). It
is equal to the ratio of the standard deviation divided by the arithmetic mean.

141

142

Concentration. The concentration of an analyte is a measurement of the amount


of mass of the analyte per unit volume or weight. The mass may be expressed in
grams, moles, international units (IU), or other units. The liquid volume may be
expressed in milliliters or other units of volume. Sometimes only the total mass
of the analyte is used.
Control limits. A range within which specified measurement results must fall to
be compliant.
Control Specimen. A control specimen is material from a single pool of unknown specimen(s) from which an aliquot is measured every analyte run to
monitor assay to assay reproducibility and to provide an indirect measurement
of the performance of the assay components.
Correlation coefficient. A number between -1 and 1 that indicates the degree
of linearity between two variables or sets of numbers. The closer to -1 or +1,
the stronger the linear relationship between the two (i.e., the better the correlation.) Values close to zero suggest no correlation between the two variables.
Dilution factor. Indicate the ratio between the original concentration and the
new dilution concentration. Used when analyte concentration is too high and
sample have to be diluted in order to perform the assay. A typical dilution of 1
part of sample in 10 parts of final solution, is commonly represented as 1:10 (1
in 10) or 1+9 (1 plus 9).
Duplicate. A second aliquot of a sample that is treated the same as the original
sample in order to corroborate the obtained result.
Eeprom. Electrically erasable and programable read only memory.
End Point Measurements. End point measurements are measurements of a reaction, which is made at a fixed time, usually after the reaction has been completed.
Error Message. An error message is a warning which is displayed whenever an
error occurs during the operation of the program. A record of the type of error,
its location, and its cause is stored in the Errors.Log text file.
External quality control. The activities which are routinely initiated and performed by persons outside of normal operations to assess the capability and
performance of a measurement process.
FBPP. Front & back peristaltic pumps.
FRTW. Front reaction tray and washer.
FVH. Front vertical & horizontal.
FW. Filter Wheel.

HumaStar 600 | Service manual

APPENDIX

Good laboratory practices (GLP). Either general guidelines or formal regulations


for performing basic laboratory operations or activities that are known or believed to influence the quality and integrity of the results.
Goodness-of-fit. the measure of agreement between the data in a data set and
the expected or hypothesized values.
Interference. a positive or negative effect on a measurement caused by a variable other than the one being investigated.
IR Infrared.
Kinetics Analysis. A kinetics analysis measures the change in concentration of
the starting and end products over time. Usually applied to enzymatic reactions.
Laboratory control standard. A standard, usually certified by an outside agency,
used to measure the bias in a procedure.
Lambert-Beer Law. The Lambert-Beer Law is an equation which describes the
linear relationship between the absorption and the concentration of the
absorbing material (absorber). The law states that absorbance (ABS) is equal
to absorptivity a, multiplied by the pathlength or the distance the light travels
through the sample b, multiplied by the concentration c (ABS= abc).
Linearity. In kinetics determinations, the degree of agreement between the
measured points and a straight line assumption.
Mixer. Robotic component that agitates the probe on the cuvette.
Pool (biological). A combination of biological specimens (i.e., urine or serum)
from many workers that is used to prepare small aliquots to be run with each
batch of analyses. Aliquots of these pools are analyzed with each batch of samples and the data are used to develop quality control charts.
Precision. The repeatability or reproducibility of individual measurements expressed as
Coefficient of variation (CV).
Preventative maintenance. An orderly program of activities designed to ensure
against equipment failure.
Proficiency testing. Any inter-laboratory testing program where stable specimens are sent to participating laboratories for analysis. Results from all participating laboratories are compared, pooled, and tabulated by the testing program operator with the purpose of improving laboratory performance.
Quality assurance program.
Written policies and procedures that outline how the laboratory intends to produce data of known and accepted quality
controls.

143

144

Quality Control (QC). The operational techniques and activities that are used to
fulfil requirements for quality.
Reagent blank Reagent(s), without analyte or sample added, which are analyzed
to determine their contribution to the total absorbance reading.
Reliability. The likelihood that an instrument or device will function under
defined conditions for a specified period of time.
SRT. Sample & Reagent Tray.
Standard solution. A solution containing a known concentration of analytes,
prepared and verified by a prescribed method or procedure and used routinely
in an analytical method.
Standard. Standard samples are aliquots of calibration specimens containing
predetermined quantities of the analyte. The response of each standard, along
with the standards predetermined concentration, is used to construct a standard calibration curve. From this standard curve, sample concentrations can be
computed using the response from the sample.
Stat. Assay requiring immediate ressults.
TC. Temperature controller.
Test result. A product obtained from performing a test or assay determination.
UV. Ultraviolet.

HumaStar 600 | Service manual

APPENDIX

b. Technical specifications
Throughput:
450 tests/hour double reagent, 650 tests/tour
mono reagent, max. 770 tests/hour with optional ISE unit.

Reagents:
Maximum number of simultaneous tests: 36 double to
72 single reagent tests + 3 with optional ISE unit.
1 to 3 reagents, 5 to 500 L/test each (in
increments of 1 L), final total solution volume 180 to
Analysis Modes:
500
L/test
End point with sample or reagent blank. Factor
Reagent
bottles capacities: 25, 40 and 70. Reagent cooor standard.
ling
compartment:
72 cooled positions.
Priority selection by sample (profile) or by reagent (batch).
Reaction:
Calibration curve with up to 10 standards.
Water consumption: 3 L / hour.
Automatic curve fit. Turbidimetry.
Warm air incubator: room, 30C and 37C. Reaction
Fast and two-point kinetics (zero and first
cuvette: re-usable plastic 6 mm path light cuvettes
order).
Reaction time: 0 to 10 min.
Routine, batch, STAT procedures, profiles. En- Reaction temperature: 37C 0.1C. Stirring: After diszymes. Drugs.
pensing each reagent.
Automatic sample dilution on abnormal levels, Optic System: Double beam
excessive substrate consumption
Photometric Range: -0.1 to 3.6 A. Measuring waveand/ or lack of linearity.
length: 340 to 800 nm (selectable among 12 waveFull quality control: Levy-Jennings plots, West- lengths).
gard multirules.
Photometry: Single or Double-wavelength
Import/export data, methods and historic files. simultaneous reading.
Automatic backup procedure.
ISE Unit:
Test selection, automatic calibration, calibration Na+, K+ and Cl- measurements.
curve, multipoint calibration, polygonal.
Samples: serum or urine. Other electrodes on request.
Serum indices: sample blank compensation,
Data Management:
calculated tests, Quality control, auto re-run,
Windows TM based Software. Interface LIS: bi-directioprozone check, record of calibration, data stonal RC 232 C, according to ASTM 1394 requirements.
rage (historic results).
Printout: Customers optimized (Analysis result, work
Automatic pre-dilution and post-dilution
list,
serums list, Quality Control, Calibration curves, etc.)
(ratio 1:5 to 1:100)
Stat: Highest priority in operation. Continuous Power Requirements:
110/220V, 50/60 Hz, 2.0 kVA
sample load
Environmental Requirements
Sampling and reagent Samples:
Sample volume: 2 to 100 L/test (in increments Temperature: max 30 degree Celcius
of 0.2 L.
Humidity: max 80%
Sample Tray: 95 (5 racks x 19 positions) ID
Dimensions:
bar code equipped positions for routine, stat
97(w) x 67(D) x 100 (H) cm.
and control samples and standard solutions.
Primary tube (length up to 100 mm), Pediatric Weight:
115 Kg.
vial

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HumaStar 600 | Service manual

HUMAN
Gesellschaft fr Biochemica und Diagnostica mbH
Max-Planck-Ring 21 65205 Wiesbaden Germany
Tel.: +49 6122/9988 0 Fax: +49 6122/9988 100
eMail: human@human.de www.human.de