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Diatron ABACUS 4, Service Manual

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 Abacus 

4

 

Service Manual 

 

 

 

4

 

2.  FUNCTIONAL DESCRIPTION 

2.1.  Main electronic parts of the analyzers 

ABACUS 4 

contains the following electronic parts: 

1. 

Counting chamber with electrodes and measuring aperture 

2. 

HGB Measuring Head 

3. 

Cell Counter Amplifier Board (behind the chamber) 

4. 

CPU Board with Dimm-PC and measurement processing unit (COMB Board) 

5. 

Safe configuration E

2

PROM board connecting CPU board and PPB 

6. 

Pneumatic  and  Power  Board  with  6  motor  controllers,  valve  &  pneumatic  controller, 
pump driver and power supply for internal printer (+8V) and digital circuitry (+5V) 

7. 

Motors with common opto-board of needle moving motors (H/V) and sample rotor 

8. 

Main dilutor block with opto-board for diluent, lyse, and lyse EOS  

9. 

Micro-dilutor block with opto-board for sampling 

10.  Valve boards (set of 5 and 6) 
11.  Peristaltic Pump 
12.  Pressure Sensor 
13.  Digital Reagent Sensor Board 
14.  Graphic LCD Display and Keyboard Controller with integrated High Voltage Module  
15.  Internal Printer 

 

ABACUS 4 

Electronic Functional Block Diagram 

Summary of Contents for ABACUS 4

Page 1: ...Abacus 4 Service Manual 0 ABACUS 4 Hematology Analyzer Service Manual 1 0 release DIATRON MI PLC H 1038 Budapest Papírgyár utca 58 59 Tel 361 4369800 www diatron com support diatron com ...

Page 2: ...ernal Power Supply 14 2 2 MAIN MECHANIC AND FLUIDIC PARTS OF THE ANALYZER 15 2 2 1 Sample rotor 16 2 2 2 Sampling needle 16 2 2 3 Wash head 16 2 2 4 H V moving unit 17 2 2 5 Main Dilutor 18 2 2 6 Micro Dilutor 19 2 2 7 Puffer reservoir 19 2 2 8 Pump 19 2 3 ASSEMBLED ANALYZER 20 2 3 1 Abacus 4 20 3 OPERATION OF THE FLUIDIC SYSTEM 24 3 1 FLOW DIAGRAM OF MEASUREMENT 25 3 2 INITIALIZATION OF THE FLUID...

Page 3: ...PTION 47 6 5 ERROR MESSAGES 48 6 5 1 Error code list 49 6 5 2 Abacus 4 message code list 52 6 6 POSSIBLE CAUSES OF NOISE 53 6 6 1 Contaminated reagent 53 6 6 2 Bad earth grounding 53 6 6 3 External electrical noise 54 6 6 4 Internal noise sources 54 7 MAINTENANCE 56 7 1 WEEKLY MAINTENANCE BY USER 56 7 1 1 Cleaning the washing head 56 7 2 PERIODIC MAINTENANCE BY SERVICE 56 7 2 1 Check Self test and...

Page 4: ...CUS 4 can process 20 samples per hour in 4 part mode 28 tests per hour in 3 part mode and is intended to determine the following 20 hematology parameters from a 50µl 25µl in 3 part mode whole blood sample WBC LYM MON NEU EOS LYM MON NEU EOS five part WBC differential HGB RBC HCT MCV RDW MCH MCHC PLT MPV PCT PDW 1 3 Integrated software The integrated software controls the instrument operations disp...

Page 5: ...B 6 Pneumatic and Power Board with 6 motor controllers valve pneumatic controller pump driver and power supply for internal printer 8V and digital circuitry 5V 7 Motors with common opto board of needle moving motors H V and sample rotor 8 Main dilutor block with opto board for diluent lyse and lyse EOS 9 Micro dilutor block with opto board for sampling 10 Valve boards set of 5 and 6 11 Peristaltic...

Page 6: ...ctrode assembly and U shaped metal fixing as it is shown in the figure below The aperture is made of ruby and it is molded into the measuring tube 2 1 2 HGB Head Hemoglobin head is placed around the measuring chamber It contains light source LED at 540 nm wavelength and Photo Detector TSL235 The Photo Detector converts the light to frequency The HGB concentration is a logarithmic function of this ...

Page 7: ... switches U1 U3 to connect high voltage to the probe with HSW signal and isolate the input of the amplifier respectively Test circuit allows generating test pulses with TEST and PLS signals through FETs for checking the proper operation of the amplifier channel Amplifier board includes a 3 stage main amplifier channel which gains input signal to the 0 5 V range this is the input range of the A D c...

Page 8: ...e is easily replaceable as it has an open socket it has also a screw for safe fixing COMB card contains single ICs and some drivers protection circuits for the interfaces such as LPT COM1 PS2 USB IDE Floppy and Speaker Measurement processing is based on FPGA circuit After power on FPGA holds the Dimm PC in wait state with IOCHRDY signal until a PIC microcontroller configures the FPGA circuit from ...

Page 9: ...ed on the Dimm PC DimmPC is the Trade Mark of Kontron Embedded Modules GmbH 2 1 5 Configuration and ID E2 PROM board IDEPROM This board is the interconnection between COMB and PPB cards Pneumatic I2 C bus power lines and internal printer signals are connected through this card The board also contains a 24FC256 serial E2 PROM which stores the FPGA s configuration data and identity information of th...

Page 10: ...ation 2 1 7 Optical boards for stepper motors There are six stepper motors in the system Horizontal and Vertical motors which make the movements of the sampling needle the main Dilutor motors 2 which move the syringes diluent lyse lyse EOS the micro Dilutor motor which operates during sampling phase and the motor moving the sample rotor The stepper motor opto boards provide connections between the...

Page 11: ...inds of valve boards Valve board 1 5 and Valve board 6 12 The instrument has 6 valves in Valve board 6 12 module The valve boards are connected to controller and driver chips located on the PPB Opto switches LEDs for Horizontal motor Opto switches LEDs for Vertical motor LEDs for Sample rotor Connections for Horizontal Vertical motors Valves Valve Board Connection to PPB ...

Page 12: ...This board contains three liquid detector opto detectors optos and a reference opto for automatic temperature and stray light compensation The reference opto is located in the middle and it has the same temperature and backlight conditions as the sensing ones The Reagent Sensor Board is connected to the PPB card and the valve driver micro controller makes the sensing and compensating operations Th...

Page 13: ... measuring voltage 50V The high voltage board is connected to the system through the amplifier board and the COMB card The CFSW digital signal from the COMB card controls HVB logical LOW turns inverter on The MVON digital signal from the COMB card switches the measuring voltage 50 V on off by O1 opto switch Start key and status LED board Keypad connector HVB module LCD display connector HVB to amp...

Page 14: ...e LED has three pins and the actual color depends on the controlled pins Start key and status LED are controlled by COMB 2 1 12 Keypad The analyzer has a 29 button foil keypad including numerical keypad 0 9 cursor moving OK and Del buttons and 6 6 function buttons above and under the LCD display as it is shown in the picture below Function buttons Function buttons Cursor buttons Status LED START B...

Page 15: ... usage with 230V or 115V mains outlet and it has the CE and UL safety certification The input socket of the power supply is a standard 3 terminal plug with power cable connection the output is a special lockable socket as it is shown in the picture Use only the provided power supply with the instrument Protek Electronics Corp Model ID PUP80 12 N8 or ELPAC POWER SYSTEMS model No FW8012 115V or 230V...

Page 16: ...f the Analyzer ABACUS 4 Hematology Analyzer consists of the following mechanic and fluidic parts 1 Sample rotor 2 Sampling needle 3 Washing head 4 H V moving unit 5 Micro Dilutor 6 Dilutor 7 Chamber 8 Cell counter probe 9 Puffer reservoir 10 Pump 11 Valves 12 Tubing ...

Page 17: ...ree 2 2 2 Sampling needle Sampling needle is assembled in the H V moving unit and it makes the sample aspirations Correct setting of sampling needle is necessary and very important see Chapter Adjustments 2 2 3 Wash head Wash head is located at the bottom of the H V moving unit and it is for cleaning the outer surface of the sampling needle This washing process is made with diluent reagent and the...

Page 18: ...re required for correct initialization and error detection All sensors have status LEDs to show actual conditions The Vertical motor works with a special opto wheel for detecting home end positions See the Adjustment section of this manual to place this wheel to the proper position Greasing of the horizontal vertical guiding rods should be done regularly using Photolube a PTFE based thin lubricant...

Page 19: ...ral silicon grease to the cogged end of the Dilutor and Lyse pistons between the syringe and the tip itself This will ensure optimum sealing and longer lifetime of piston tips DO NOT grease the piston with black bottom plastic part Greasing of the cogged transmission parts cogwheel and cogged bar should be done regularly using machine grease It is recommended to check and repeat greasing of piston...

Page 20: ...s its own driver circuit Darlington If the tube of the peristaltic pump becomes worn it can be broken causing Pressure error It is recommended to check the state of the tube and replace it every 2 years or after 20 000 measurements Always replace the peristaltic pump tube to the same PharMed type with the same length Replacement tube is provided as accessory spare part with each analyzer For servi...

Page 21: ...nalyzer 2 3 1 ABACUS 4 Front Panel Rear panel Back door to access pump and main dilutor Reagent inlets Power switch Keyboard Serial Port Function keys Foil keypad 320 240 dots 64 color LCD display Start button Sample rotor USB A Port USB B Port ...

Page 22: ...nstruction right side Washing head Chamber and aperture Sample rotor Needle moving mechanics Amplifier assembly Reagent inlets Valve block Valve block Pressure sensor Sample rotor Electronic block Dilutor rear side Pump motor Needle moving mechanics ...

Page 23: ...bacus 4 Service Manual 22 Construction back note orange reagent inlet for Lyse EOS main dilutor and valve block with 6 valves Reagent sensors Reagent connectors Valve block Main Dilutor Peristaltic pump ...

Page 24: ...Abacus 4 Service Manual 23 Construction left side Pneumatic and Power Board PPB ID Eprom Board IDEPROM Control and Measurement Board COMB ...

Page 25: ...g process 4 Needle washing process 5 LyseEOS Diluting process 6 MIX RBC Diluting process 7 Lysing process 8 Counting process 9 Chamber draining process 10 Cleaning process 11 Shutdown process In the detailed process description figures the active tube is filled with black color while an arrow shows the direction of the flow Moving mechanic parts have another arrow indicating direction of movement ...

Page 26: ...amber draining Chamber flush with LyseEOS Fill up with 2 ml LyseEOS for dilution Horizontal motor moves out sample rotor turn in needle moves down Sampling process LyseEOS Needle washnig needle positioning into the chamber LyseEOS dilution 1 160 Mixing with bubbles Needle washing Sampling process MIX Horizontal motor moves out sample rotor turn in needle moves down 3P only N Y ...

Page 27: ...urn in needle moves down Sampling process MIX Needle washnig needle positioning into the chamber MIX dilution 1 160 WBC only Needle washing Y RBC sampling N Lysing process Filling of electrode lines generating measuring vacuum HGB measurement Filling of electrode lines generating measuring vacuum EOS measurement Chamber washing Needle washing ...

Page 28: ...g Cleaning cleaner High voltage cleaning pulses backflush Washing diluent Blank HGB measurement Y WBC only Fill up with 1 ml diluent for RBC dilution RBC dilution 1 32000 Filling of electrode lines generating measuring vacuum RBC measurement N Motor synchronizations End ...

Page 29: ...reagents and calibrating reagent sensors Cleaning of tubing measuring chamber Cleaning of aperture with high pressure back flush cleaner reagent high voltage burning 3 3 Sampling process The aspirating needle aspirates 25 µl of blood sample The Micro dilutor syringe makes the aspirating while the M4 Micro dilutor motor moves down There are three sampling process during the 5 part measurement cycle...

Page 30: ... that the total length of it is washed and cleaned This process is called total sampling needle washing and it is mainly used after taking primary sample from sample tube Another process which is washing only a smaller part of the sampling needle is the same but the needle does not move in the total length Some procedures perform this kind of sampling needle washing The Macro syringe pushes the di...

Page 31: ... the M3 Dilutor motor moves upwards meanwhile some Lyse2 reagent pulled into the chamber The amount of the diluents and the Lyse2 lysing reagent is depending on the actual profile possible amount of diluent 0 5 2 0ml Lyse2 0 2 0ml but the whole liquid in the chamber is always 4 0 ml So this process makes a 1 160 dilution rate in the chamber After the dilution a small amount of air bubbles aspirate...

Page 32: ...t diluting step the sample is dispensed into the measuring chamber with 3 ml of diluent which comes from the Macro syringe through V8 On and Micro dilutor while the M3 Dilutor motor moves upwards This process makes the 1 160 first dilution rate in the chamber The RBC sample 25 µl of MIX dilution is stored in the sampling needle during the WBC measurement and the cleaning process The instrument mak...

Page 33: ...easuring chamber through V9 On while the Lyse syringe moves upwards This process makes the WBC HGB dilution with lyse reagent For better mixing the macro syringe pushes some air bubbles aspirated through the washing inlet of the chamber and V3 after the lysing process through V8 Off V7 On V4 Off V3 On ...

Page 34: ...ir aspirates the diluted sample LyseEO WBC or RBC from the chamber through V2 On valve The instrument counts the cells for 8 seconds in all counting phases Lyse2 WBC and RBC For noise prevention there is no mechanical or electronic activity during the counting process and the door should be closed for better shielding ...

Page 35: ...ining process Chamber draining is made under pressure control Pump drains chamber while puffer reservoir and thus the pressure sensor is connected to the draining tube The instrument can detect the empty state of the chamber from drop of vacuum ...

Page 36: ...ning in the tube between V10 and V4 into the chamber The liquid detector Diluent Cleaner detector can detect the presence absence of cleaner solution 3 10 Shutdown process The fluidic shutdown performs the following steps Priming chamber with reagent to avoid drying out of aperture Sampling needle is positioned above counting chamber needle up Lyse and Lyse EOS syringes are positioned up Diluent s...

Page 37: ...the vertical motor movements because this adjustment sets the opto end switches of the H V moving unit The top of this block is called HV head and it is shown in the figure below Set the distance to 1 2 mm between the moving carriage and the stable part of the head Loose A screws to allow free movement of the timing belt Adjust the opto wheel to home position i e home hole must be in home sensor a...

Page 38: ...e is held by motors Needle setting menu Fix the B screws Be careful with the bent upper end of the sampling needle because if badly aligned during movement it can hit other mechanical components causing mechanical jam and therefore damages or error 4 2 Hardware settings 4 2 1 Amplifier offset setting Amplifier offset should be between 5mV Run self test to determine whether offset is within this ra...

Page 39: ...t and offset Amplifier transfer by generating 20000 test pulses incl gain related peak value noise related deviation Amplifier Noise test during a 5 second period Atmospheric pressure stands for outer pressure Vacuum reports pump operation vacuum made by the pump in a 10 second period of time Drift represents pressure loss of vacuum measured in a 10 second period of time Power 12V shows the amplif...

Page 40: ... on amplifier board Electrode voltage LOW or HIGH Fault on High Voltage or Amplifier board Check measuring voltage 50V on High voltage and Amplifier boards Current LOW or HIGH Fault on Amplifier board Check current generator and test generator FET on Amplifier board Offset LOW or HIGH Fault on Amplifier board Check the offset potentiometer on Amplifier board Amplifier test LOW Amplifier Boards is ...

Page 41: ...vice menu 6484 5 2 2 Main Service Menu The Main Service menu provides access to submenus and service utilities 5 2 3 Edit service contact Here you can edit the Information card fields by cursor keys or by an external keyboard Press the OK button if a field is completed This information will appear in the User Service menu 5 2 4 Device Information In the Device Information menu the model name the s...

Page 42: ... parameters of the automatic functions in this dialog menu Autoclean cycle after how many measurements the instrument makes an autocleaning Language this setting will adjust the user language The Service menu always uses English language Database capacity Can be set to 1000 2000 5000 records default is 1000 Any change in the database capacity will lead to loss of previous records the instrument wa...

Page 43: ... the waste container for proper usage of the software waste full alert Set this value two liters less than the total volume of waste container Diluent Lyse EO lyse Cleaner capacity by setting the correct value for the containers the software is able to alert the user when any of these reagents is empty Reagent pack stability the instrument is able to alert the user if the reagent pack is expired 5...

Page 44: ...te 1 is On state Use cursor keys for selecting and setting valve state or press OK to toggle state The fluidic diagram is an addition to the previous Valve Test Menu in order to help the better identification of the valves and their functions 5 2 1 Motor Test By selecting the numbers from 1 6 the instrument will move the corresponding motors between their home and end positions for 10 cycles By pr...

Page 45: ... from this mode press the START button at the end of a normal cycle until the Stress operation is finished 5 2 3 Cleaning 5 cycles This function performs 5 cleaning cycles can be interrupted by the user 5 2 4 Miscellaneous In this menu you can directly perform Software upgrade this will restart the instrument Clear Device Statistics Device statistics number of measurements aperture clogging and ot...

Page 46: ...as on user level On the login screen by pressing F1 the first function key from the left below the display than in the user list the Service user name will appear The code is 729456 entering it gives the right for the service engineer to administrate all the other users ...

Page 47: ...ler PIC display module displays the greeting screen After 6 seconds it starts to scan the keypad and behaves like an MDA adapter to the PC although the displayed screen is still holding the greeting screen If you switch to MDA emulation mode the system boot events can be displayed and the CMOS SETUP program can be started if necessary If the main program will not start in 90 seconds the PIC will a...

Page 48: ...Alt H General help window Esc Exit this menu or Arrow key Select a different menu or Arrow key Move cursor up and down Tap or Shift Tap Cycle cursor up and down Home or End Move cursor to top or bottom of current window PgUp or PgDn Move cursor to next or previous page F5 or Select the previous value for the current field F6 or or Space Select the next value for the current field F9 Load default c...

Page 49: ...ronic parts during measurement The system shows the type of the error on the LCD display if any kind of malfunction is detected The electronic parts have a very little chance to fail only the connections and cables could disconnect which can cause the malfunction of the electronic system The mechanic and fluidic system have a bit more chance to go wrong because it has moving parts In 6 7 1 section...

Page 50: ...empty or the dil clean sensor is too sensitive try recalibrating the sensors or there are lot of bubbles in the diluent tube Replace the diluent reagent container with a filled one If this is still a problem with a filled diluent container run Reagent sensor calibration and check the tubing and fittings of diluent path 1103 Check Lyse container Lyse tank is empty or the lyse sensor is too sensitiv...

Page 51: ...tubing and fittings of rinse path 1111 The sampler rotor was jammed during sampling process Retry sampling Cap was not taken off from the sample tube or tube is not placed correctly or other mechanical jam Check the adapter and the tube Press Retry or Stop 1112 The sampler rotor was jammed Mechanical problems like adapter is moved out from the right place Check the adapter and the tube Press the b...

Page 52: ...ight overstep the margin Modify the paper setup in the Settings Printer settings sub menu 1411 Error d in printer initialization Printer software error Check the connections between the instrument and the printer and check the printer setup in the Settings Printer settings sub menu Try to make a software upgrade 1900 You have to add at least one user to use multi user mode Multi user problem Follo...

Page 53: ...such type of data 5200 New reference ranges will be saved Press OK to confirm 5300 Some or all of the calibration factors are out of range 5400 12V too low 5401 12V too high 5402 Battery voltage too low 5901 Insert software update USB drive The system will restart 5902 Are you sure to delete all device statistics 5903 This function will delete all measured results Are you sure 5904 This function w...

Page 54: ...e the background PLT blank becomes high Wash the reagent tube which is in connection with the reagent with 1 of bleach solution then rinse with clean distilled water or diluent It can avoid the bacteria to grow inside If tank is open and cap is not installed or closed external dust can make reagent dirty 6 6 2 Bad earth grounding In this case external ground referenced noise can get into the syste...

Page 55: ...is metal box allows this coupling to disappear forever 6 6 4 Internal noise sources The most annoying but real cause is some sort of internal noise The reason for this phenomenon is that inside electrode hot point of the measuring circuit must be well insulated from surrounding electronics otherwise inside noise sources can take their effect A Bad chamber insulation bad shielding of the chamber fl...

Page 56: ... socket or replacement of amplifier is required Check for the correct soldering of reference cable and its connector circuit board bad soldering or component failure Check the shielded cable connections as well Sometimes inside out connection hot electrode goes outside as a shield is the problem both ends of amplifier signal cable must be reversed analog signal ribbon cable it picks up noise Check...

Page 57: ...tral silicon grease Apply just a thin layer and move it along the perimeter of the piston so that some of the material goes into the gaps between the sealing rings Repeat this step for lyse and dilutor pistons as well DO NOT USE grease for the lyse Vet5 black bottom part Check the condition of the micro piston sealing and replace if necessary 7 2 4 Cleaning and Lubricating Needle Moving Mechanics ...

Page 58: ... 8 Bleaching of Fluidic System It is recommended to run a bleaching procedure to remove stains from the fluidic system 1 Connect 2 5 hand warm clean bleach solution to all reagent inputs and perform priming on all reagent inputs 2 Leave it in the tubing for not more than 2 3 minutes 3 Remove the bleach prime on air 4 Connect distilled water 100 ml and perform priming all reagents again Connect rea...

Page 59: ...rsonnel Low temperature reagents can cause it as well mainly diluent in this case you will have to wait until they reach room temperature Warning flags in lowercase refer to RBC or PLT problems Flag Meaning Recommended user action p PLT blank is high or no PLT blank Run cleaning and repeat the blank measurement Diluent or system cleanliness problem If it is stable high replace the diluent by openi...

Page 60: ...4 Service Manual 59 1 2 3 Pump 2 PUFFER P 1 1 1 2 2 2 3 3 3 V1 2 2 1 2 3 V8 V7 1 1 2 2 3 3 1 3 V11 1 1 2 3 2 1 2 4 8 L Lyse EO D M V4 V3 V10 V9 V6 V5 D 4 A 4A D L C Lyse EO W V2 1 2 9 2 Abacus4 tubing diagram ...

Page 61: ...l 60 9 3 Recommended kit of tools PC standard keyboard PS 2 Screwdrivers Cross Slot Screwdrivers Philips Slot Screwdrivers Hexagon Screwdrivers 3 5 2 5 2 0 1 5 mm sizes Pocket digital multimeter Diagonal Cutter plier Nipper ...

Page 62: ...Abacus 4 Service Manual 61 Revision history Section By Date All Csaba Magyar Jenő Feldider May 20 2008 All Jenő Feldider Aug 8 2008 ...

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