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Chapter 7: Re-Assembly

ABL77 Service Manual

Valve Board Assembly

Introduction

This procedure describes the process for re-attaching the valve board assembly into
the lower module.

NOTE:

The valve board and analog board are a matched set for the Hct and SC

circuits and must be calibrated when either is replaced. This also applies when
replacing the lower module or electronics module, which contains these boards.
Calibration is not required when these boards are only removed and put back into
the same analyzer. Refer to Chapter 7, Service Programs, for instructions on
performing this procedure.

NOTE:

NOTE:

Wear suitable protection gear during this procedure.

Lower module
diagram

Figure 7-10 may be used for the following procedures.

Figure 7-10

Continued on next page

7-20

Rev.

F

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Summary of Contents for ABL 77 Series

Page 1: ...lyzer Description 3 Troubleshooting 4 Test and Calibration 5 Dismantling 6 Replacements 7 Re Assembly 8 Maintenance 9 Spare Parts Service Notes Date of Issue ABL 77 Series Blood Gas and Electrolyte Analyzer Service Manual ...

Page 2: ...mpile or disassemble the programs By your use of the instrument you agree to the terms of this Agreement and the Microsoft End User License Agreement If you do not accept or agree to the terms you should promptly contact your Radiometer representative for a return of the instrument and a refund of your money TRADEMARKS ABL and RADIOMETER are trademarks of Radiometer Medical A S Denmark ABL is regi...

Page 3: ... 6 Panel Options 1 7 2 Analyzer Description 2 1 Overview 2 1 Functional Description 2 2 SCi Installation 2 3 Calibration 2 5 Sample Analysis 2 12 Module Descriptions 2 18 Upper Module 2 26 Lower Module 2 30 Electronics Module 2 34 3 Installation 3 1 Overview 3 1 General Information 3 2 Cautions and Warnings 3 3 General Guidelines 3 4 Hardware Screen 3 5 Reference Table of Problems Causes and Corre...

Page 4: ...crit Circuits 4 31 Electronic Zero Offset 4 34 Heater Circuit 4 36 Inlet Flap Sensor 4 39 Paper Jam 4 40 Battery Charger 4 43 Battery Pack 4 45 Touch Screen Panel Calibration 4 48 Reprogramming the CPU BIOS Settings 4 50 Re programming the Barcode Scanner 4 52 Resetting the Analyzer Serial Number 4 56 5 Dismantling 5 1 Overview 5 1 Upper Module 5 4 Upper Module 5 4 Backlight Inverter Board 5 7 Dis...

Page 5: ...stribution Board 5 42 Electronic Boards Assembly 5 44 LCD Adapter Board 5 45 Memory Module 5 46 ChipDisk board 5 47 CPU and Touch Screen Boards 5 48 Battery Control Board 5 49 Fan Assembly 5 51 6 Replacements 6 1 Overview 6 1 Main Housing 6 4 Main Housing Assembly 6 4 Carrying Handle 6 5 Upper Module 6 6 Housing Bracket 6 6 Lower Module 6 9 Manifold Gasket 6 9 Valve Board 6 10 Single Valve 6 18 Va...

Page 6: ...ble Analog Board to Battery Control Board 6 50 COM1 Cable 6 52 Power Switch Cable 6 53 Barcode Reader Keyboard Cable 6 54 Ethernet Cable 6 56 7 Re Assembly 7 1 Overview 7 1 Upper Module 7 4 Touch Screen Panel 7 5 LCD Display 7 8 Disk Drive 7 9 Backlight Inverter Board 7 12 Upper Module 7 13 Lower Module 7 15 Valve Boards General Information 7 15 Valve Board Assembly 7 20 Waste Pump And Waste Pump ...

Page 7: ...er Board 7 50 Electronics Boards Module Assembly 7 51 Power Distribution Board 7 54 Interface Board 7 56 Analog Board 7 58 Electronics Module 7 62 8 Maintenance 8 1 Overview 8 1 Valve Maintenance 8 2 Cleaning 8 6 Long Term Storage 8 9 Recommended Service Procedures 8 13 1 Year Service 8 13 2 Year Service 8 14 3 Year Service 8 15 9 Spare Parts 9 1 Overview 9 1 Modules And Externals 9 2 Upper Module...

Page 8: ...Table of Contents ABL77 Service Manual 6 Rev F Table of Contents Continued Service Notes Date of Issue ...

Page 9: ...s an introduction to the servicing of the ABL 77 analyzer and important information for understanding the procedures and requirements Contents This chapter contains the following topics Overview 1 1 Service Policy 1 2 Test Equipment and Tools 1 5 ABL77 Identification 1 6 Panel Options 1 7 Rev F 1 1 ...

Page 10: ...ty claims for parts which suffer from physical damage unauthorized attempted repair or exposure to conditions other than those specified by Radiometer Medical A S e g temperature line voltage outside specified limits will not be accepted Non original parts Spare parts and accessories In order to ensure the reliability durability and operation in accordance with technical specifications use only or...

Page 11: ...ry Some PCBs may be returned to the factory for replacement under the trade in agreement for modules These PCBs are marked with next to the description in the spare parts list Since repair is not allowed in the field detailed circuit diagrams are not included in the service manual Lower Module Most of the electromechanical and pure mechanical parts of the lower module may be repaired to the compon...

Page 12: ...tive body clothing and follow legal requirements and local rules for safe work practices CAUTION The gloves must be free of pinholes and preferably be puncture resistant Please consult the glove manufacturer for further information CAUTION If contaminated materials come into contact with any lesion on the body seek medical advice Calibration and measurement While performing calibrations and measur...

Page 13: ...alibrating the Hct and SC circuit 991 260 Loctite 401 Adhesive Securing the handle to the housing 991 264 Silicone adhesive RTV medical grade Securing cables to prevent disconnect 991 265 Loctite 222 Threadlocker Securing assorted screws and nuts 905 674 Sample path obstruction tool kit Various applications 943 906 Cleaning solution Cleaning the waste drain N A Deionized water or sterile water Var...

Page 14: ...Use of identification The analyzer serial number is the primary identification number e g For tracking purposes both for the analyzer and it s modules For logging service actions As a reference on service work orders When ordering service components and modules Electronic serial number The analyzer serial number is stored electronically in the ChipDisk When the ChipDisk or the electronics module i...

Page 15: ...purchase The analyzer can be upgraded or downgraded after purchase The same configurations are also available in sensor cassette types The different types are controlled through the sensor cassette barcode A full panel sensor cassette may be used on any analyzer configuration The analyzer will report NI Not Installed for non configured parameters A BG Hct or Lytes sensor cassette will only report ...

Page 16: ...ms and the fluidics system This chapter includes various drawings for use during servicing The drawings indicate the location of connection points and general identification Contents This chapter contains the following topics Overview 2 1 Functional Description 2 2 SCi Installation 2 3 Calibration 2 5 Sample Analysis 2 12 Module Descriptions 2 18 Upper Module 2 26 Lower Module 2 30 Electronics Mod...

Page 17: ...ole blood The ABL77 system is intended for use by trained technologists nurses physicians and therapists It is intended for use in a laboratory environment near patient or point of care setting Measuring principles There are three different measuring principles employed Potentiometry A potential is recorded using a voltmeter which relates to the concentration of the sample A reference electrode is...

Page 18: ... the software logic that determine whether the initialization process continues or terminates and what messages are displayed The three conditions are 1 A single mild sensor failure One sensor sensitivity value falls between 50 100 of the minimum acceptable value This is considered a condition that may resolve itself with additional calibration attempts 2 A single severe sensor failure One sensor ...

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Page 20: ...tervals are 1 2 3 or 4 hours The Calibration option on the Main Menu is used to initiate a manual two point calibration as desired Hydration If the calibration is more than 30 minutes past the scheduled time a preliminary flush of Cal1 solution is performed prior to the two point calibration A message hydrating will be displayed Continued on next page Rev F 2 5 ...

Page 21: ...tion process the roller wheel is activated along with valves 1 and 3 This flushes Cal2 solution through the sensor cassette measuring chamber see Figure 2 1 A measurement is then made on this solution The waste pump is also activated to transport residual flush solution to the waste pouch Figure 2 1 Continued on next page 2 6 Rev F ...

Page 22: ...lution Calibration solution Level 1 2 Cal2 solution Calibration solution Level 2 3 Waste bag 4 Cal Pack 5 Main waste line 6 Manifold 7 Manifold luers 8 Side waste line 9 Valves L1 L2 and L3 10 Cassette measuring chamber 11 Roller wheel 12 Inlet probe 13 Waste drain 14 Waste pump 15 Cassette luer Continued on next page Rev F 2 7 ...

Page 23: ...calibration the roller wheel is activated along with valves 2 and 3 This flushes Cal1 solution through the sensor cassette measuring chamber see Figure 2 2 A measurement is made on this solution The waste pump is also activated to transport residual flush solution to the waste pouch Figure 2 2 Continued on next page 2 8 Rev F ...

Page 24: ...lution Calibration solution Level 1 2 Cal2 solution Calibration solution Level 2 3 Waste bag 4 Cal Pack 5 Main waste line 6 Manifold 7 Manifold luers 8 Side waste line 9 Valves L1 L2 and L3 10 Cassette measuring chamber 11 Roller wheel 12 Inlet probe 13 Waste drain 14 Waste pump 15 Cassette luer Continued on next page Rev F 2 9 ...

Page 25: ...y values outside the acceptable range the software will suggest the appropriate next step Suggestions include investigating the fluidic pathways of the analyzer inactivating the sensor or replacing the sensor cassette Parameter Acceptable Sensitivity Range pH 40 0 61 5 CO2 30 0 61 5 O2 0 002 0 052 Na 40 0 61 5 K 40 0 61 5 Ca2 20 0 31 0 Cl 30 0 61 5 Hct 10 0 25 0 Failed calibration status If the ca...

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Page 27: ...tes a brief flush of Cal1 solution to ensure the tip of the inlet probe is filled with fluid Analysis initial flush Analysis phase 1 aspiration To begin the sample analysis the inlet probe flap is lifted to the syringe or capillary position The Aspirate button is then pressed The primary sample pump then draws in 70 microLiters of sample see Figure 2 3 Figure 2 3 Continued on next page 2 12 Rev F ...

Page 28: ...l1 solution Calibration solution Level 1 2 Cal2 solution Calibration solution Level 2 3 Waste bag 4 Cal Pack 5 Main waste line 6 Manifold 7 Manifold luers 8 Side waste line 9 Valves L1 L2 and L3 10 Cassette measuring chamber 11 Roller wheel 12 Inlet probe 13 Waste drain 14 Waste pump 15 Cassette luer Continued on next page Rev F 2 13 ...

Page 29: ... Continued Analysis phase 2 aspiration The analyzer prompts the user to remove the sample and lower the inlet probe The analyzer then advances the sample a second time to complete the positioning of the sample see Figure 2 4 Figure 2 4 Continued on next page 2 14 Rev F ...

Page 30: ...l1 solution Calibration solution Level 1 2 Cal2 solution Calibration solution Level 2 3 Waste bag 4 Cal Pack 5 Main waste line 6 Manifold 7 Manifold luers 8 Side waste line 9 Valves L1 L2 and L3 10 Cassette measuring chamber 11 Roller wheel 12 Inlet probe 13 Waste drain 14 Waste pump 15 Cassette luer Continued on next page Rev F 2 15 ...

Page 31: ... activated along with valves 2 and 3 to flush cal 1 solution through the sensor cassette see Figure 2 5 A measurement is performed using this cal solution prior to final results being displayed ensuring that no drift has occurred The waste pump is activated to transport the flush solution to the waste pouch Figure 2 5 Continued on next page 2 16 Rev F ...

Page 32: ... Manifold 7 Manifold luers 8 Side waste line 9 Valves L1 L2 and L3 10 Cassette measuring chamber 11 Roller wheel 12 Inlet probe 13 Waste drain 14 Waste pump 15 Cassette luer Quality control Routine quality control measurements are suggested to evaluate the performance of the analyzer This ensures the reliability accuracy and precision of patient sample results QC sample measurement follows similar...

Page 33: ...ed diagrams of the modules and connections are included with each module ABL77 analyzer This sub section describes the analyzer external components and disposables Front view of analyzer Figure 2 6 shows the front view and sensor cassette of the ABL77 analyzer Figure 2 6 Part Function 1 Upper module 2 Sensor cassette 3 Lower module Continued on next page 2 18 Rev F ...

Page 34: ...escription Module Descriptions Continued Rear view of analyzer Figure 2 7 shows the rear view and cal pack of the ABL77 analyzer Figure 2 7 Part Function 1 Main housing assembly 2 Cal pack 3 Electronics module Continued on next page Rev F 2 19 ...

Page 35: ...e ABL77 analyzer only It provides the source of AC power to the system when plugged into an active electrical socket see Figure 2 8 Figure 2 8 Battery pack The battery pack is for use with the ABL77 It provides battery power to the analyzer when AC power is not available or not desired see Figure 2 9 Figure 2 9 Continued on next page 2 20 Rev F ...

Page 36: ...e scanner The barcode scanner shown below is for use with the ABL77 analyzer only see Figure 2 10 Figure 2 10 Barcode scanner holder The barcode scanner holder may be installed on the analyzer in any location that is convenient see Figure 2 11 Figure 2 11 Continued on next page Rev F 2 21 ...

Page 37: ...ghout a specified in use life After use these components are considered a biohazard and should be disposed of in a safe and proper manner Sensor cassette The sensor cassette contains the sensor array within a sample flowcell It transmits sensor data to the analyzer for interpretation see Figure 2 12 Figure 2 12 Part Function 1 Sensor window 2 Peristaltic pump tube 3 Inlet flap 4 Inlet probe 5 Rele...

Page 38: ...s the solutions used to calibrate and flush the sensor cassette see Figure 2 13 The cal pack also contains a waste bag to collect all samples solutions and other fluids that are processed through the analyzer 1 3 2 Figure 2 13 Part Function 1 Cal2 pouch 2 Cal1 pouch 3 Waste bag Continued on next page Rev F 2 23 ...

Page 39: ...nalyzer Description ABL77 Service Manual Module Descriptions Continued ABL77 block diagram Figure 2 14 displays the inter connection of primary and secondary components of the ABL77 analyzer Figure 2 14 2 24 Rev F ...

Page 40: ...ABL77 Service Manual Chapter 2 Analyzer Description This page intentionally left blank Rev F 2 25 ...

Page 41: ... gentle pressure from a finger or wand to supply the ABL77 with user input LCD Display This is a 640 x 480 resolution backlit VGA color display used as the primary method to provide display information to the user Backlight Inverter Board This board converts then supplies the power to the LCD display and the backlight bulb Diskette Drive This drive is a standard 3 5 inch floppy drive for 1 44 M by...

Page 42: ...ed Diagrams Figure 2 15 Part Function 1 Upper housing 2 Disk drive 3 Disk drive cable 4 Touch screen cable 5 LCD display cable 6 Backlight inverter cable 7 Backlight inverter 8 Insulating tape 9 Housing bracket 10 Touch screen panel 11 LCD display Continued on next page Rev F 2 27 ...

Page 43: ...Chapter 2 Analyzer Description ABL77 Service Manual Module Descriptions Continued Diagrams continued Figure 2 16 Continued on next page 2 28 Rev F ...

Page 44: ... continued Part Function 1 Backlight inverter board screws 2 Insulating tape 3 Backlight inverter board 4 Housing screws 5 Housing bracket 6 Copper tape 7 Disk drive screws 8 Disk drive washers 9 Copper cloth tape 10 Disk drive 11 LCD display 12 Touch screen panel 13 Upper housing Rev F 2 29 ...

Page 45: ...ion solutions and other fluids into and out of the sensor cassette in carefully controlled step increments for accurate placement of fluids The Waste Pump transports waste fluids from the waste drain to the waste pouch in the cal pack The Sensor Cassette Nest provides a cavity to accommodate the sensor cassette This nest contains the electrical and fluid connections for the sensor cassette allowin...

Page 46: ...BOSS SENSOR LUER J6 J4 J8 J7 J3 12 1 13 24 J2 2587 J6 J5 J4 J9 J8 J7 L2 L1 L3 J10 Figure 2 17 The Valve Board Assembly REF 902 811 includes the valves and tubing Figure 2 18 41449 B 41477 SERVICE BOARD ABL70 77 ASSY REV K1 J5 R2 R18 REVISION J10 PN 902 811 J1 J9 SENSOR BOSS SENSOR LUER J6 J4 J8 J7 J3 12 1 13 24 J2 2587 J6 J5 J4 J9 J8 J7 L2 L1 L3 J10 L3 COM N C N O L1 COM N C N O L2 COM N C N O Fig...

Page 47: ...Description ABL77 Service Manual Module Descriptions Continued Lower module Front Figure 2 19 Part Function 1 Waste drain 2 Waste pump 3 Sensor cassette nest 4 Roller pump wheel 5 Printer Continued on next page 2 32 Rev F ...

Page 48: ...ription Module Descriptions Continued Lower module Rear Figure 2 20 Part Function 1 Printer 2 Sensor luer connector 3 Roller pump motor 4 I O cable connector 5 Valve board 6 Sensor cable connector 7 Opto sensor 8 Manifold 9 Waste pump Rev F 2 33 ...

Page 49: ...alyzer Components Electronics Boards Analog board Power distribution board Interface board ChipDisk LCD adapter board Memory module CPU board Touch screen controller board Battery control board Rear Panel with External Connections Barcode scanner keyboard connector COM1 port Ethernet port Power switch Charger port Battery Pack Continued on next page 2 34 Rev F ...

Page 50: ...arious operations such as thermistor control roller pump motor control and sensor signal A to D conversions This remote intelligence enables the main computer to focus primarily on the operator interface Commands are received from the main computer to turn on valves motors begin sensor heating cycle etc The analog board returns a character string once a second to the main computer that contains th...

Page 51: ... contains the internal speaker and the coin cell battery that supplies the CPU with power to maintain the computer settings See Figure 2 23 This board also receives signals from the barcode scanner and routes data to the printer to produce reports SPK ASSY 41407 Revision BAT 1 SN J3 Figure 2 23 ChipDisk The ChipDisk REF 365 436 is the mass storage media for all records settings and software see Fi...

Page 52: ... the CPU for use by the LCD display see Figure 2 25 The LCD adapter board is a component of the CPU board Figure 2 25 Memory module The memory module REF 365 438 is the active memory RAM that the CPU uses for calculations and command processing see Figure 2 26 The memory module is a component of the CPU board Figure 2 26 Continued on next page Rev F 2 37 ...

Page 53: ...e board connects the microcomputer to its battery support and speaker as well as interfacing with the printer and the COM 1 port Valves motors and sensor states are controlled by commands sent via the serial connection to the custom analog board Figure 2 27 Touch screen controller The touch screen controller REF 365 437 processes all signals from the touch screen and sends these signals to the CPU...

Page 54: ... battery charge status is sent to the analog board and then retransmitted to the main computer so that it can be displayed on the screen for the operator C12 ASSY 41174 J7 J1 J5 R1 J8 J6 R27 R9 R8 R28 R19 R2 R21 R22 R3 R4 R12 R23 R24 R20 R6 R25 R7 R17 R11 R5 R10 R15 R14 R18 R13 D1 D8 D5 D2 D7 D6 D4 D3 Q2 Q3 Q4 U7 J4 J2 J3 Q1 Q6 Q5 Q8 Q7 C8 C9 C1 C2 C13 C14 C15 C7 C10 C11 C6 U3 C19 C3 C5 C4 U2 U5 U...

Page 55: ...Chapter 2 Analyzer Description ABL77 Service Manual Module Descriptions Continued Electronics module assembly Figure 2 30 Continued on next page 2 40 Rev F ...

Page 56: ...on Module Descriptions Continued Rear Panel with External Connections Diagrams Figure 2 31 Part Function 1 Barcode keyboard port cable 2 Power switch cable 3 Ethernet port cable 4 COM1 port cable 5 Fan assembly cable Continued on next page Rev F 2 41 ...

Page 57: ...ABL77 Service Manual Module Descriptions Continued Diagrams continued Figure 2 32 Part Function 1 COM1 port 2 Barcode keyboard port 3 Fan 4 Charger port 5 Ethernet port 6 Power switch 7 Battery door Continued on next page 2 42 Rev F ...

Page 58: ...scription 1 DCD Data Carrier Detect 2 RX Receive Data 3 TX Transmit Data 4 DTR Data Terminal Ready 5 GND Signal Ground 6 DSR Data Set Ready 7 RTS Request To Send 8 CTS Clear To Send 9 RI Ring Indicator Connector Ethernet port The Ethernet port is a connection to the CPU It allows bi directional communication with external computer systems Power switch The power switch is a 2 position switch that p...

Page 59: ...emperature of the pack increases This increased temperature increases the internal pressure of the cells causing a higher voltage across the pack This results in varying charge rates based on the charge state of the battery pack To ensure maximum charging of the pack the charge controller on the Battery Control Board provides a six hour charge cycle For safety purposes the maximum allowed charge c...

Page 60: ... long periods of inactivity and incomplete charging will diminish the expected lifetime and operation of the battery pack NiMH batteries operate at their optimal capacity when regularly exercised and allowed to discharge to a level other than full capacity It is recommended that the analyzer be operated on battery power routinely or at regular intervals to maintain optimal performance of the batte...

Page 61: ... errors or messages that may occur during the operation of the ABL77 analyzer Contents This chapter contains the following topics Overview 3 1 General Information 3 2 Cautions and Warnings 3 3 General Guidelines 3 4 Hardware Screen 3 5 Reference Table of Problems Causes and Corrective Actions 3 8 Reference Table 3 9 System Messages 3 16 3 1 ...

Page 62: ...g ABL77 Service Manual General Information Introduction This section provides information regarding cautions and warnings as well as information on normal operation that can be fundamental to understanding error conditions 3 2 ...

Page 63: ...ear path obstructions whether filled with air or liquid very gently push the syringe plunger to avoid detaching internal tube connections CAUTION Do not inject solution or air into the cal pack ports Injecting solution or air into the cal pack will alter the calibrant values and may cause erroneous measurements and or failure messages CAUTION The cal pack contains two calibration fluid pouches and...

Page 64: ...h Printout of the failed Event Record Only the Event Record contains a complete set of information important for failure investigation An Event Record is printed from the Recall Event screen Highlight the failed calibration initialization or QC analysis Press the icon to print an Event Record of this failed event Analyzer component returns Any analyzer component returned for credit or for failure ...

Page 65: ...assist in troubleshooting The Hardware screen allows manual control of basic analyzer functions The three soft keys across the bottom of the screen allow the user to initiate a single flush of Cal1 solution Cal2 solution or a single aspiration through the inlet probe see Figure 3 2 Description of Hardware screen Figure 3 2 Continued on next page 3 5 ...

Page 66: ...equires an applied current to function can be energized by selecting the check box labeled O2 nA The Hematocrit sensors also require an applied current which is activated by selecting the Hct AD choice on the drop down menu which initially displays OFF AD The other selection in this drop down window refers to the air in sample circuit SC AD is the solution conductivity SC value The units of measur...

Page 67: ... Screen Continued Description of Hardware screen continued A relative charge reading for the battery pack is displayed Bat as well as the function of the battery charger Pak see Figure 3 4 An inlet flap sensor indicator is also displayed Door Figure 3 4 3 7 ...

Page 68: ...e Manual Reference Table of Problems Causes and Corrective Actions Introduction This section summarizes in table form the various types of problems and error conditions which may be encountered during the operation of the ABL77 analyzer 3 8 ...

Page 69: ...stigate the fluidics system using the Hardware screen and the Calibration Lines procedure Follow the instructions on the analyzer screen to help identify the underlying cause Sensor failure Inactivate the failed parameter or replace the SCi Calibration Initialization or QC failures with multiple sensor cassettes over time Valve board worn or corroded pin receptacle Replace the valve board Proceed ...

Page 70: ...Replace Chip Disk See Chapter 5 Dismantling Computer clock malfunction CPU Board Malfunction software versions 1 30 or lower Replace CPU board See Chapter 5 Dismantling Analog board real time clock malfunction or clock battery on analog board depleted software versions 1 32 or higher Replace analog board See Chapter 5 Dismantling Disk Drive Disk drive failure Replace the disk drive See Chapter 5 D...

Page 71: ...4 Battery Pack is not fully charged See Battery Pack in Chapter 4 Battery Charger malfunction See Battery Charger in Chapter 4 Replace as necessary Power intermittent power loss Battery Control Board malfunction Replace battery control board See Chapter 5 Dismantling Printer non functional Corrosion on printer module Replace printer module See Chapter 5 Dismantling Investigate source of fluid cont...

Page 72: ...es BIOS setting incorrect Reset the BIOS setting in the main CPU See Chapter 4 Test and Calibration Procedures No printout The printer must be enabled in the software This option is under Manager Setup Report Setup Print Setup The auto print feature must be selected for patient calibration and QC Paper Jam See Chapter 4 Test and Calibration Procedures Instruct user on proper steps when replacing t...

Page 73: ...lty sensor function Perform a manual calibration and repeat the QC measurement If QC fails repeatedly activate QC lockout inactivate parameter or replace sensor cassette Screen blank dark display Description the screen remains dark and blank despite signs of power beeps fan running etc LCD Display Cable Check the cable connection If securely connected replace the cable See Chapter 6 Replacements B...

Page 74: ...ents Barcode scanner connection or cable Remove barcode scanner Shut down unit Power up unit and verify the touch screen is operating correctly If so reconnect barcode scanner and verify the touch screen is still operating correctly If not replace the barcode scanner Screen Touch Screen display malfunction LCD Display Panel Replace the panel See Chapter 5 Dismantling Description variety of incorre...

Page 75: ...ard See Chapter 5 Dismantling Analog Board component failure Replace the analog board See Chapter 5 Dismantling Waste Drain waste fluids overflowing out the waste drain during flush cycles Blockage in the waste drain tubing Flush the waste drain See Waste Drain in Chapter 4 further in this chapter Waste Pump Motor failure Replace the waste pump a waste pump kit includes the motor and pump head See...

Page 76: ...002 Unable to allocate memory Insufficient memory Cycle the analyzer power off then back on to re boot the computer 1003 Calculation error Unable to calculate sensitivity values due to impossible mathematical values Repeat the measurement If this error persists investigate possible sources of air contamination 1004 The file can not be opened Memory is unavailable Shutdown the analyzer power throug...

Page 77: ...ple detection system has identified air in the measuring chamber during sample analysis The air may affect sample results Carefully evaluate sample analysis results for integrity and acceptable clinical correlation Repeat analysis suggested 1202 Air in calibration fluid Air in sample detection system has identified air in the measuring chamber during the Cal1 phase of sample analysis The air may a...

Page 78: ...ion process was not performed was not allowed to be completed or because the initialization was not successful Complete the initialization If a failure occurs investigate the origin of the failure The important first step is to identify whether the failure is due to a sensor failure or failure of the analyzer s fluidic system to properly transport the calibration fluid to the sensor cassette measu...

Page 79: ...terval has been reached Analysis will not be allowed until BG Lytes QC Level 4 analysis is performed Perform the required BG Lytes QC measurement or inactivate the required QC interval QC Hct Level 1 is required before analysis can be performed Mandatory QC interval has been reached Analysis will not be allowed until Hct QC Level 1 analysis is performed Perform the required Hct QC measurement or i...

Page 80: ...the acceptable range for the most recent BG Lytes Level 2 QC measurement Perform a manual calibration and repeat the BG Lytes Level 2 measurement If results remain out of range inactivate this parameter or replace the sensor cassette QC Level 3 out of range At least one parameter fell outside the acceptable range for the most recent BG Lytes Level 3 QC measurement Perform a manual calibration and ...

Page 81: ...ce the sensor cassette 1400 Calibration Errors 1407 Initialization failed At least one sensitivity value is outside the acceptable range during a cassette initialization Follow the instructions on the screen Investigate the origin of the failure The important first step is to identify whether the failure is due to a sensor failure or failure of the analyzer s fluidic system to properly transport t...

Page 82: ...ent cal pack has consumed all available Cal 2 solution Replace the cal pack 1505 This cal pack has already been installed Please install a new cal pack The cal pack being installed has previously been installed Install a new cal pack 1506 Cal pack creation date is a future date The date the cal pack was manufactured is a date in the future Check the accuracy of the date in the analyzer 1507 Insuff...

Page 83: ...nd Calibration Procedures to investigate the heater circuit 1605 Cal 1 Temperature Not Stable Temperature stabilization criteria not met during Cal 1 measurement See Chapter 4 Test and Calibration Procedures to investigate the heater circuit 1606 Cal 2 Temperature Not Stable Temperature stabilization criteria not met during Cal 2 measurement See Chapter 4 Test and Calibration Procedures to investi...

Page 84: ...HCP check the connections and re boot Using DHCP and the system was not connected when turned on so an IP address was not automatically assigned If using a Computer Name check the integrity of the connection it is not necessary to re boot Using a Computer Name and the system was not connected so this name could not be interpreted as an IP address Evaluate the status of the remote host system 1707 ...

Page 85: ...be unlocked either on the analyzer Options Data Communications Analyzer Lock or if connected to Radiance the system can be unlocked within Radiance see Analyzer Control 3000 Input Errors 3001 Input error The value s input are beyond the acceptable input range Re enter values within the acceptable input range 3002 Invalid password Password entered was not found in the User List Re enter password If...

Page 86: ... the correct order date If necessary verify the correct current date on the analyzer 3008 Invalid bar code The bar code has been entered in an unacceptable format Re enter the bar code correctly 3011 Incorrect barcode scanned The barcode scanned is not for the ABL77 Ensure you are scanning the ABL77 not ABL70 barcode on the cal pack 3012 Bar code scan unsuccessful The scanning process did not resu...

Page 87: ...not met for one or more parameters during sample measurement or calibration No endpoints suggest air in the measuring chamber Investigate possible sources of air Then perform a manual calibration and repeat the measurement N I Not installed A BG Hct only or Lytes only sensor cassette has been installed on a full panel analyzer If all parameters are desired install a full panel sensor cassette N R ...

Page 88: ...ent The sample analysis result has fallen into the user defined critical range No action required The sample analysis result has fallen outside the reportable range Repeat the analysis if appropriate Air was detected in the sample or the associated sample flush solution If air was detected in the sample repeat the analysis If air is detected in the flush solution perform a manual calibration then ...

Page 89: ...ctices with chemicals CAUTION Working with blood gas analyzers may result in contact with blood remnants and with harsh disinfectants During the various procedures wear suitable protection gear gloves face protection and protective body clothing following legal requirements and local rules for safe work practices CAUTION The gloves must be free of pinholes and preferably be puncture resistant Plea...

Page 90: ... Screen Panel Calibration 4 48 Reprogramming the CPU BIOS Settings 4 50 Re programming the Barcode Scanner 4 52 Resetting the Analyzer Serial Number 4 56 Electrostatic discharge protection To ensure the reliability and durability of the analyzer ESD protection precautions must always be taken when handling or exposing ESD sensitive parts Parts such as printed circuit boards may be damaged if handl...

Page 91: ...led on the analyzer 2 Select Options from the Main Menu Enter a Password that will allow access to the Hardware screen Access to this screen requires a password If a user password is not available the generic MK592 may be used NOTE This password is for Radiometer use only Do not share this password with customers Select Hardware from the Options menu RESULT The following screen will appear 3 Press...

Page 92: ...r Carefully observe the measuring chamber The chamber should be completely filled with fluid There should be no air bubbles of any size If air is observed flush Cal2 solution a second time While the pump wheel is turning snap repeatedly on the pump tubing to dislodge any air bubbles in the system 7 If both Cal1 and Cal2 solution fill the measuring chamber without air the fluid transport is functio...

Page 93: ...the sensor cassette measuring chamber If the calibration lines cannot be flushed one or more valves may be functioning improperly Calibration lines procedure Follow the steps below to perform the Calibration Lines procedure Step Action 1 Select Options from the Main Menu 2 Enter a Password as necessary Press OK 3 Press Fluidics RESULT The following screen will appear 4 From the pop up window press...

Page 94: ...yzer will sense when the cassette has been removed and will automatically proceed to the next screen not attached The analyzer will automatically proceed to the next step RESULT The following screen will appear 6 Ensure there is a cal pack on the analyzer to collect the fluids exiting the waste line 7 Introduce 1 cc of Cleaning Solution REF 943 906 into the waste drain black opening located direct...

Page 95: ... the fluid carrying it through the waste line and into the cal pack Press Continue 9 RESULT The following screen will appear 10 Remove the cal pack and press Continue CAUTION The cal pack must be removed before proceeding Performing the following steps with a cal pack in place will result in contamination of the calibration solution 11 RESULT The following screen will appear Continued on next page...

Page 96: ...Fill a syringe with luer adapter from a Sample Path Obstruction Tools kit REF 905 674 with deionized water or sterile water Attach the syringe to the cassette luer of the analyzer see Figure 4 1 Figure 4 1 13 Be prepared to collect fluids exiting the cal pack manifold at the rear of the analyzer see Figure 4 2 Figure 4 2 Continued on next page 4 8 Rev F ...

Page 97: ...uer The Cal1 lines will remain open for 10 seconds The water should exit the Cal1 manifold luer NOTE If any resistance is felt while trying to introduce water into this line DO NOT force the syringe plunger This will cause internal tubing connections to weaken and possibly disconnect 16 The operator may need to repeat this flush attempt to soak free any dried calibrant blockage NOTE If unable to o...

Page 98: ...eionized or sterile water and flush the Cal2 line in a similar manner pressing Cal2 to open a pathway between the cassette luer and the Cal2 manifold luer Repeat as necessary Press OK when flushing is complete 19 Re attach the cal pack and sensor cassette if one is currently installed Press OK RESULT The system will return to the Options menu 20 Perform a manual calibration to ensure proper functi...

Page 99: ...or slot The door indicator in the Hardware screen will change from 1 to 0 This will simulate the presence of a sensor cassette and allow the Pump Cal1 and Pump Cal2 buttons to function 4 Place a soft cloth or gauze over the manifold ports to collect the water from the following steps NOTE Be prepared to collect all fluids that exit the manifold NOTE Observe the valve board and connections for leak...

Page 100: ...e the index card or equivalent from the door slot and the soft cloth or gauze from the manifold ports 10 The calibration resistors may have been inadvertently affected during this procedure To verify proper calibration settings Refer to the procedure Calibrating the SC and Hct Circuits 11 Shut down and re assemble the analyzer 4 12 Rev F ...

Page 101: ...functioning on a valve board with replaceable valves Evaluation Use the following diagrams to determine which type of fluidics system is installed in the analyzer Remove the lower module and compare the tubing arrangements to the analyzer being serviced then proceed to the valve test procedure for the appropriate fluidics system Continued on next page Rev F 4 13 ...

Page 102: ...B J10 K1 J1 REVISION J9 SERVICE BOARD ABL70 77 ASSY REV SENSOR BOSS SENSOR LUER J5 J6 J4 J8 J7 J3 12 1 13 24 J2 2587 R18 R2 J6 J5 J4 J9 J8 J7 L2 L1 L3 Cal2 Waste Cal1 S H LTP3345B C576 A B C PULL PUSH MADE IN MALAYSIA STEPPER MOTOR 5 VDC OHMS COIL 6 25 STEP ANGLE 7 5 L82701 P1 L3 COM N C N O L2 COM N C N O L1 COM N C N O Figure 4 4 Continued on next page 4 14 Rev F ...

Page 103: ...on each time Vacuum is maintained when the plunger returns to its original position after each of the 5 trials A loss of vacuum is identified by the plunger resting increasingly further and further from the original resting position with each pull of the plunger Valve operation Each valve has three ports One is a common port COM and is always open A second port is a normally opened N O port and is...

Page 104: ...ence when testing the check valve fluidics system Figure 4 5 shows the fluidics connections Figure 4 5 Part Function 1 To sensor cassette fitting luer 2 To CAL1 luer 3 To Cal2 luer 4 To printer chassis 5 Plug 6 To waste drain Figure 4 6 identifies the different pieces of tubing used in the check valve fluidics system Figure 4 6 Figure 4 6Continued on next page 4 16 Rev F ...

Page 105: ... L2 then return to the beginning of step 1 and continue testing b If syringe loses vacuum Valve L2 is working Remove hemostat Connect tubing A to COM luer of Valve L1 and proceed to step 4 4 Disconnect tubing B from COM luer of L3 Using a syringe apply a vacuum to the Sensor Luer a If syringe maintains a vacuum replace Valve L1 Return to the beginning of step 4 and continue testing b If syringe lo...

Page 106: ...ning of step 7 and continue testing b If syringe maintains a vacuum proceed to step 8 8 Press Aspirate a If syringe maintains a vacuum replace Valve L3 Return to the beginning of step 7 and continue testing b If syringe loses vacuum proceed to step 9 9 If problems persist consider other causes of air in calibration fluid such as an empty cal pack poorly seated cal pack blockage in the sensor casse...

Page 107: ... screen C Modify the index card to fit in the door slot The door indication in the Hardware screen changes from 1 to 0 This allows for proper operation of Pump Cal1 and Pump Cal 2 D Test the syringe Cap off the syringe and check that it does not exhibit a loss of vacuum NOTE The gradual loss of vacuum is the most difficult to detect The following technique is to be used during the procedure when t...

Page 108: ...This path is between the common Com and normally open N O ports Energized position This describes the normal open fluid path when the valve has a voltage applied to its coil This path is between the common Com and normally closed N C ports NOTE Press Pump Cal1 Valve L2 is energized NOTE Press Pump Cal2 Valves L1 and L3 are energized Valve ports Com N C N O Figure 4 7 Continued on next page 4 20 Re...

Page 109: ...cedures Continued Testing the waste tee path Follow these steps to test the sensor luer to the waste tee path see Figure 4 8 NOTE Ensure no luer caps and or forceps are in place Figure 4 8 Part Function 1 Sensor luer on far side 2 Tee connector Continued on next page Rev F 4 21 ...

Page 110: ...g the Cal1 luer path A loss of vacuum indicates a leaking L1 and or L2 valve 4 Maintaining the pinched off tubing Cap off Cal1 luer at the manifold If vacuum is held L2 valve is malfunctioning Remove cap and forceps and continue to next section Testing the Cal1 luer path Cap off Cal2 luer at the manifold If vacuum is held L1 valve is malfunctioning Remove cap and forceps and continue to next secti...

Page 111: ...present L2 valve is malfunctioning continue to next section Testing the Cal2 luer path 3 While maintaining a vacuum on the Cal1 luer press Pump Cal1 on the Hardware screen A loss of vacuum should occur If there is a loss of vacuum continue to next section Testing the Cal2 luer path If there is no loss of vacuum then L2 and or L3 valves are malfunctioning 4 Disconnect the tubing from the normally o...

Page 112: ...o next section Testing valve L3 3 While maintaining a vacuum on the Cal2 luer press Pump Cal2 on the Hardware screen A loss of vacuum should occur If there is a loss of vacuum go to next section Testing valve L3 If there is no loss of vacuum then L1 and or L2 valves are malfunctioning 4 Disconnect the tubing from the common port on L1 valve 5 While maintaining a vacuum on the Cal2 luer press Pump ...

Page 113: ...l2 on the Hardware screen 5 Apply a vacuum to the Cal1 luer the path must hold a vacuum generally only two to three pulls can be performed If a vacuum is not present then L3 valve is malfunctioning Continue to next section Repairing malfunctioning valves If a vacuum is present then L3 is not malfunctioning 6 Reconnect the tubing Repairing malfunctioning valves Obtain single valve kits REF 902 791 ...

Page 114: ...following screen will appear 2 Press Waste Line from the pop up window Press Yes to continue RESULT If a sensor cassette is attached The analyzer will remove any fluid then prompt the operator to remove the sensor cassette The analyzer will sense when the cassette has been removed and will automatically proceed to the next screen not attached The analyzer will automatically proceed to the next ste...

Page 115: ...roceed to step 7 7 When a blockage persists Repeat steps 4 through 6 allowing additional time to soak and breakup the blockage Use the nylon line provided in the Sample Path Obstruction Tools kit to physically breakup the blockage WARNING DO NOT force any object other than the nylon line through the analyzer waste line 8 If the blockage is Successfully cleared Not successfully cleared Proceed to s...

Page 116: ...Step Action 9 Press OK 10 If the analyzer has a sensor cassette currently installed not currently installed The analyzer will prompt to replace the sensor cassette Then press OK The analyzer will perform a mandatory 2 pt cal then return to the Main Menu The analyzer will immediately exit to the Main Menu 4 28 Rev F ...

Page 117: ...power source Remove any sensor cassette 2 Slide out the printer module DO NOT disconnect the cables 3 Connect the leads of the digital voltmeter to the back side leads of the 2 pin power cable where it attaches to the printer module 4 Plug the battery charger into the rear panel and plug the power cord into AC power 5 Turn the electronics module power switch on Wait for the Main Menu to appear on ...

Page 118: ...nt 4 Re connect the lower module and the electronics module separate from the Main Housing with the I O cable sensor cable printer power cables and printer data cable 5 Connect the leads of the digital voltmeter to the back side leads of the 2 pin power cable where it attaches to the printer module 6 Re connect the AC power source and turn the electronics module power switch on Verify that the Mai...

Page 119: ...ssword If a user password is not available the generic MK592 may be used NOTE This password is for Radiometer use only Do not share this password with customers 2 Select Hardware from the Options menu RESULT The following screen will appear 3 Press Pump Cal 1 to pump fluid through the sensor cassette Verify there is no air in the cassette measuring chamber Ensure the heater is off NOTE Five minute...

Page 120: ...combo box and select SC AD The value displayed should be greater than 1000 6 Press the combo box and select Hct AD The value displayed should be greater than 1000 7 If these values are not observed the sensor cassette may be defective Replace the sensor cassette and repeat steps 2 through 5 8 If the expected values cannot be obtained with a new sensor cassette proceed with the next section Calibra...

Page 121: ...E The Hct potentiometer has a typical adjustment range in excess of 1390 50 6 If unable to reach the target value perform the Calibrate 5 volts procedure in a proceeding section of this chapter 7 If after calibrating the 5 volt supply the Hct value CANNOT be adjusted within the target range replace the valve board If after replacing the valve board the Hct value still CANNOT be adjusted within the...

Page 122: ... the steps below to set the electronic zero offset Step Action 1 Remove the sensor cassette and install the electronic zeroing cassette REF 902 578 onto the cassette nest 2 Select Options from the Main Menu Enter MK592 as the Password Only this password will provide the necessary Set 0 button to adjust the zero offset NOTE This password is for Radiometer use only Do not share this password with cu...

Page 123: ...nts The Th channel should read 36 5 to 37 5 8 Remove the zeroing cassette The pH CO2 and ISE channel values will begin to float This is normal and expected The Hct channel should remain at zero 20 The Th channel should read 100 The O2 channel should remain at zero 0 010 9 If the Hct channel does not remain at zero replace the analog board If the Th channel does not read 100 replace the analog boar...

Page 124: ...formance of the heater circuit Step Action 1 Select Options from the Main Menu Enter a Password that will allow access to the Hardware screen Access to this screen requires a password If a user password is not available the generic MK592 may be used NOTE This password is for Radiometer use only Do not share this password with customers Select Hardware from the Options menu RESULT The following scr...

Page 125: ...to this Hardware screen The Th indicator on the display will display 100 if a sensor cassette is not attached The Th indicator will display ambient temperature if a sensor cassette is attached see Figure 4 11 For example if the temperature is 25 C then the Th window will display a value of 25 0 Figure 4 11 3 Attach a sensor cassette 4 Press the Heater ON check box to activate the heater circuit se...

Page 126: ...f the Th reading is within the target range the heater circuit is functioning properly If the Th reading is outside the target range the sensor cassette may be defective Replace the sensor cassette and repeat step 4 and 5 6 If after replacing the sensor cassette the Th reading is outside the target range replace the analog board 4 38 Rev F ...

Page 127: ... not available the generic MK592 may be used NOTE This password is for Radiometer use only Do not share this password with customers Select Hardware from the Options menu RESULT The following screen will appear 2 Place a sensor cassette on the analyzer 3 Open the inlet flap on the sensor cassette and verify that the Door indicator on the Hardware screen reads 1 4 Close the inlet flap and verify th...

Page 128: ...exit out the door This encourages the paper to roll back onto itself Paper jams can also be caused by tearing the paper off in a horizontal manner rather than straight up or down Clear a paper jam Follow the steps below to clear paper that may be jammed into the printer Step Action 1 Shut down the analyzer from the Main Menu Unplug it from the A C source 2 Open the printer door and remove all acce...

Page 129: ...ter by pulling up and out as shown in Figure 4 17 Figure 4 17 NOTE You will not be able to fully remove the printer because of connecting cables Take care to avoid pulling or otherwise damaging these cables 5 Pull up on the printer roller cover to remove Lift the print head lever and remove all remaining paper from around the printer roller see Figure 4 18 Figure 4 18 6 Replace the print head leve...

Page 130: ...ce with the connecting screws 8 Connect the analyzer to an A C source Turn the analyzer on 9 Re feed the paper roll into the analyzer Figure 4 19 NOTE Ensure the leading edge of the paper feeds out the printer door see Figure 4 19 NOTE Advancing the paper roll 18 to 24 inches 0 5 meter when installing a new roll of paper will prevent the paper from shifting to the left 4 42 Rev F ...

Page 131: ...o an AC source 2 Connect the multimeter to the 6 pin DIN connector on the battery charger as shown in Figure 4 20 Attach the negative lead of a multimeter to either one of the negative pins Attach the positive lead of the multimeter to either one of the positive pins Figure 4 20 3 If the meter reading is 18 18 5 volts the battery charger is performing as expected Continue to the next section Batte...

Page 132: ...ill allow access to the Hardware screen Access to this screen requires a password If a user password is not available the generic MK592 may be used NOTE This password is for Radiometer use only Do not share this password with customers Select Hardware from the Options menu RESULT The following screen will appear 2 Verify that the Pak reading is above 3000 when the charger is plugged in to the anal...

Page 133: ...le will provide a maximum charge to the battery pack Over time the capacity of battery cells diminishes Cycling the battery pack occasionally during normal use will ensure optimal battery performance The useful lifetime of the pack is dependent on the frequency of cycling the pack and the efficiency of recharging Battery pack reading A fully charged battery will read 25 on the battery indicator on...

Page 134: ...ter If the battery charger passes all tests continue to the next step 4 Remove the battery pack access panel at the rear of the analyzer 5 Carefully slide out the battery pack and disconnect from the analyzer Disconnecting the battery pack will reset the battery counter to zero 6 Wait 30 seconds 7 Reconnect the battery pack and replace the access panel 8 Reconnect the battery charger and connect i...

Page 135: ...arge cycle turn on the analyzer 14 At the Main Menu disconnect the battery charger from the analyzer 15 Verify that the Main Menu battery level displays 25 16 Proceed to the Hardware screen and note the Bat reading 17 Return to the Main Menu Select Recall Select 2 Point Cal Select a record Print this record 10 times 18 Return to the Hardware screen Verify the Bat reading has decremented slightly I...

Page 136: ...keyboard 6 The window Stylus Properties will appear Press the Recalibrate button at the bottom of the window 7 A white screen with a cross in the middle of the screen will appear Above the cross will also be the following message Carefully press and briefly hold stylus on center of target Repeat as the target moves around the screen Press the ESC key to cancel 8 NOTE For best results use the tip o...

Page 137: ...and you must start over 12 Once the settings have been accepted the Stylus Properties window will be displayed Press ESC on the keyboard 13 The Stylus Properties window will disappear and the Control Menu will be displayed Press the screen in the top left corner where the word FILE is displayed 14 A drop down menu will appear Tap the screen where the word CLOSE is displayed in the drop down menu 1...

Page 138: ... Using the PageUp PageDown keys change the setting to A C CDROM 6 Press ESC to exit this menu 7 Using the arrow keys highlight Peripheral Setup on the Main BIOS menu and press Enter 8 Using the arrow keys highlight the setting Onboard Parallel Port 9 Using the PageUp PageDown keys change the setting to 278 10 Using the arrow keys highlight the setting Parallel Port Mode 11 Using the PageUp PageDow...

Page 139: ...ontinued Re programming the CPU BIOS continued Step Action 21 If these entries have changed the coin cell battery may need to be replaced Follow the instructions in Chapter 5 for replacing the coin cell battery 22 If the entries have NOT changed remove the keyboard and restart the analyzer Rev F 4 51 ...

Page 140: ...gs NOTE You will hear a tone after each successful scan If you make an error during a multi step sequence scanning CANCEL removes you from that sequence so that you can start again Step Action Tone 1 Hi Low Hi Low Warble 2 Hi Low Hi Low Warble 3 Hi Low Hi Low Warble 4 Short High Tone 5 Short High Tone 6 Hi Low Hi Low Warble Canceling an error If you make an error scan this barcode to start over CA...

Page 141: ...fter Decode Enable Beeper Tone Middle Beeper Volume High Level Decode Attempt Time 1 second Transmit No Decode message No Message Decode Redundancy Disable Code Types All UPC EAN Enable Disable UPC EAN Enable Transmit UPC A Check Digit Enable Transmit UPC E Check Digit Enable Decode UPC Only Disable Transmit EAN 13 EAN 8 Check Digit Enable Transmit Bookland EAN Check Digit Enable Convert UPC E to ...

Page 142: ...Enable Enable Disable Trioptic Code 39 Disable Code32 Enable Disable Code32 Disable Code32 Prefix A Disable Code 93 Enable Disable Code 93 Enable I 2 of 5 Enable Disable Code I 2 of 5 Enable I 2 of 5 Length 55 Modulo 10 Check Digit Disable Transmit I 2 of 5 Check Digit Enabled ITF14 EAN13 Conversion Disable D 2 of 5 Enable Disable Code D 2 of 5 Enable Modulo 10 Check Digit Disable D 2 of 5 Lengths...

Page 143: ...ssey Any Length MSI Plessey Check Digits One Transmit MSI Plessey Check Digits Disable MSI Plessey Check Digit Algorithm MOD 10 MOD 10 Data Options Transmit Code ID Character Disable Prefix None Suffix CR LF Data Transmission Format PREFIX DATA SUFFIX1 SUFFIX2 Caps Lock Scan Data Caps Lock Off Ignore Unknown Character Send Bar codes with unknown characters Intercharacter Delay 0 msec Interpacket D...

Page 144: ... analyzer to the Radiance network Required equipment An AT style keyboard Resetting the serial number Follow these steps to reset the analyzer serial number NOTE This procedure will erase the file containing the stored serial number from the ChipDisk Step Action 1 Disconnect the barcode scanner and attach an AT style keyboard into this port 2 Turn on the analyzer While the analyzer is displaying t...

Page 145: ...eferably be puncture resistant Please consult the glove manufacturer for further information CAUTION If contaminated material comes into contact with any lesion on the body seek medical advice De contamination The analyzer s internal waste line is exposed to blood during normal use This includes the complete pathway from the black waste drain at the front of the analyzer to the middle waste luer o...

Page 146: ...16 Opto Sensor 5 19 Roller Wheel and Roller Pump 5 20 Waste Pump Head and Waste Pump 5 22 Original Valve Board Manifold Assembly 5 25 Valve Board with Replaceable Valves 5 27 Valve Board Styles 5 31 Electronics Module 5 35 Electronics Module 5 35 Analog Board 5 38 Interface Board 5 40 Power Distribution Board 5 42 Electronic Boards Assembly 5 44 LCD Adapter Board 5 45 Memory Module 5 46 ChipDisk B...

Page 147: ...l point Allen wrench REF 920 721 7 64 Ball point Allen wrench REF 920 723 Flat head screwdriver Small flathead screwdriver for adjusting the calibration settings Phillips head screwdriver Needle nose pliers Scissors or equivalent trimming tool Index card or equivalent to block the opto sensor Deionized water or sterile water Soft cloth gauze or other absorbent material 3cc disposable syringe with ...

Page 148: ...de the upper housing This printed circuit board is carrying live current and constitutes a shock hazard WARNING CAUTION Removing the upper module Follow these steps to remove the upper module from the ABL77 analyzer Step Action 1 Remove the screw from the upper middle of the calibration solution pack cavity using a 5 64 Allen wrench as shown in Figure 5 1 Figure 5 1 2 Gently pull the upper module ...

Page 149: ...the brown lock connector down to the left 2 Disconnect the 2 wire backlight inverter cable from the center of the backlight inverter board 3 Disconnect the LCD display cable by using a small tool such as an Allen wrench to loosen the connector holding the ribbon cable Lift the connector away from the LCD display and slide the cable out from beneath the housing bracket 4 Disconnect the 4 wire touch...

Page 150: ...ting the cables continued Figure 5 2 Part Function 1 Upper housing 2 Disk drive 3 Disk drive cable 4 Touch screen cable 5 LCD display cable 6 Backlight inverter cable 7 Insulating tape 8 Backlight inverter board 9 Housing bracket 10 Touch screen panel 11 LCD display 5 6 Rev F ...

Page 151: ...ps to remove the backlight inverter board as shown in Figure 5 3 Step Action 1 Remove the upper module from the analyzer 2 Disconnect the 2 wire backlight inverter cable from the center of the backlight inverter board 3 Remove the two screws from the backlight inverter board and gently lift the board out of the module 4 Disconnect the LCD display cables from the backlight inverter board Figure 5 3...

Page 152: ...hown in Figure 5 4 Step Action 1 Remove the upper module from the analyzer 2 Remove the backlight inverter board 3 Remove the two screws holding the disk drive located on the inside of the housing bracket 4 Remove the four screws holding the housing bracket 5 Remove the housing bracket allowing the cables to pass through and remain with the LCD display 6 Remove the disk drive by sliding it out fro...

Page 153: ...apter 5 Dismantling Disk Drive Continued Disk drive removal continued Figure 5 4 Part Function 1 Backlight inverter board 2 Housing bracket screws 3 Disk drive screws 4 Disk drive 5 LCD display 6 LCD display cables Rev F 5 9 ...

Page 154: ...n Figure 5 5 Step Action 1 Remove the upper module from the analyzer 2 Remove the backlight inverter board from the housing bracket 3 Remove the two screws holding the disk drive located on the inside of the housing bracket 4 Remove the four screws holding the housing bracket 5 Remove the housing bracket allowing the cables to pass through and remain with the LCD display 6 Remove the disk drive 7 ...

Page 155: ...ntling LCD Display Continued LCD display removal continued Figure 5 5 Part Function 1 Backlight inverter board 2 Housing bracket screws 3 Disk drive screws 4 LCD display 5 LCD display cables 6 Touch screen panel 7 Upper housing Rev F 5 11 ...

Page 156: ...s shown in Figure 5 5 Step Action 1 Remove the upper module from the analyzer 2 Remove the backlight inverter board from the housing bracket 3 Remove the two screws holding the disk drive located on the inside of the housing bracket 4 Remove the four screws holding the housing bracket 5 Remove the housing bracket allowing the cables to pass through and remain with the LCD display 6 Remove the disk...

Page 157: ...cessary Using needle nose pliers disconnect the extension spring from the anchor in the printer door 2 Using a flathead screwdriver slide the retaining ring e clip off the notch protruding from the door hinge on the left side of the printer chassis 3 Slide a flathead screwdriver underneath the door hinge and gently lift the hinge off the three notches of the printer chassis 4 Pull the door away fr...

Page 158: ...e printer module as shown in the following figures Step Action 1 Open the printer door Remove the paper roll if necessary 2 Loosen the two panel screws on either side of the printer module 3 Slide the printer module out and disconnect the three cables attached to the back Figure 5 7 Figure 5 8 Part Function 1 Printer panel screws 2 Printer data cable connector 3 Printer power connectors Continued ...

Page 159: ...top of the printer module locate the hex nut on the end of the screw and grip the nut tightly 4 Using a 1 16 Allen wrench remove the screw 5 Replace the metal screw with a nylon screw REF 023 013 6 Hold the hex nut between your forefinger and thumb and tighten the screw with a flathead screwdriver 7 Firmly tighten the nut until it turns in your grip and can no longer be held without the nut turnin...

Page 160: ...ule Introduction This procedure describes the process for removing the lower module from the analyzer Lower module diagram The following diagram Figure 5 10 identifies the major components of the lower module Figure 5 10 Continued on next page 5 16 Rev F ...

Page 161: ...ued Lower module diagram continued Part Function 1 Printer module 2 Sensor cassette luer fitting 3 Roller pump motor 4 I O cable connector 5 Surface mount valve board 6 Sensor cable connector 7 Opto sensor 8 Manifold 9 Waste pump Continued on next page Rev F 5 17 ...

Page 162: ...hassis using a 7 64 Allen wrench 4 Gently pull the lower module away from the main housing The manifold will remain attached to the main housing 5 If the analyzer has a valve board manifold assembly attached go to step 6 If the analyzer has separate valve board and manifold components disconnect the tubing then go to step 8 6 Using a 5 16 nut driver remove the two hex nuts from the manifold while ...

Page 163: ...lower module Step Action 1 Remove the lower module 2 From the back of the lower module locate the opto sensor see Figure 5 12 3 Disconnect the opto sensor cable from the valve board 4 Remove two screws on the opto sensor using a Phillips head screwdriver Figure 5 12 Part Function 1 Opto sensor cable connection 2 Opto sensor 3 Opto sensor screws Rev F 5 19 ...

Page 164: ...move the roller wheel from the front of the lower module as shown in Figure 5 13 This part may be removed without dismantling any other portion of the analyzer Step Action 1 Using a 1 16 Allen wrench loosen the two set screws on the sides of the roller wheel at the front of the lower module 2 Pull the roller wheel from the roller pump shaft Figure 5 13 Part Function 1 Set screws 2 Lower module 3 R...

Page 165: ...emove the roller wheel from the lower module 2 Remove the lower module 3 Locate the roller pump motor at the back of the lower module 4 Disconnect the roller pump cable from J5 on the valve board 5 Using a 5 64 Allen wrench remove the two screws securing the roller pump Lift the roller pump motor away from the lower module Figure 5 14 Part Function 1 Roller pump cable connection 2 Roller pump scre...

Page 166: ...G CAUTION Removing the waste pump head Follow these steps to remove the waste pump head from the front of the lower module as shown in figure 5 15 This part may be removed without dismantling any other portion of the analyzer Step Action 1 Open the printer door 2 Disconnect the two ends of the waste pump tubing from the printer chassis 3 Press in the two clips on the sides of the pump head and pul...

Page 167: ...e backside of the lower module stand the two flanges straight where the waste pump cable is connected to the motor This will allow the motor to slide out the front of the module 3 Disconnect the cable connector 4 From the front of the lower module remove the waste pump head 5 Using a Phillips head screwdriver remove the two mounting screws from the pump motor in the front of the lower module 6 Pul...

Page 168: ...hapter 5 Dismantling ABL77 Service Manual Waste Pump Head and Waste Pump Continued Removing the waste pump continued Figure 5 16 Part Function 1 Waste pump flanges 2 Waste pump cable connector 5 24 Rev F ...

Page 169: ...tection gear during this procedure WARNING CAUTION Removing the valve board Follow these steps to remove the valve board manifold assembly Use the following diagram Figure 5 17 for reference Step Action 1 Remove the lower module 2 Disconnect the roller pump cable from J5 on the valve board 3 Disconnect the opto sensor cable from J6 on the valve board 4 Disconnect the waste pump cable from J4 on th...

Page 170: ...Chapter 5 Dismantling ABL77 Service Manual Original Valve Board Manifold Assembly Continued Diagram Figure 5 17 5 26 Rev F ...

Page 171: ...d put back into the same analyzer Refer to Chapter 4 Test and Calibration Procedures for instructions on performing this procedure NOTE WARNING CAUTION CAUTION Wear suitable protection gear during this procedure Removing the valve board Follow these steps to remove the valve board with replaceable valves assembly as shown in the following figures Step Action 1 Remove the lower module 2 Disconnect ...

Page 172: ...g ABL77 Service Manual Valve Board with Replaceable Valves Continued Removing the valve board continued Figure 5 18 Part Function 1 Sensor cassette luer 2 Waste drain 3 Bulk head connector Continued on next page 5 28 Rev F ...

Page 173: ...m J4 on the valve board 9 Using the 5 16 nut driver remove the hex nut from the sensor cassette fitting luer while holding the cassette fitting luer by hand in the front of the lower module 10 Remove the two screws from the upper left and right corners of the valve board using a 1 16 Allen wrench or a flat head screwdriver as appropriate 11 Remove the support screw from the center of the valve boa...

Page 174: ...ued Removing the valve board continued Figure 5 19 Part Function 1 J5 roller pump connector 2 Surface mount valve board 3 Valve board support screw 4 Valve board screws 5 J6 opto sensor connector 6 Sensor cassette fitting luer 7 J4 waste pump connector Continued on next page 5 30 Rev F ...

Page 175: ...e following diagrams for the different valve board styles Valve board with replaceable valves and J10 Figure 5 20 is an example of the valve board with replaceable valves together with the check valve fluidics and a J10 connector for valve L3 Figure 5 20 Continued on next page Rev F 5 31 ...

Page 176: ...d with replaceable valves and Y cable Figure 5 21 is an example of the valve board with replaceable valves together with the Y cable for L3 attached This cable allows the check valve fluidics to be used on a board without a J10 connector Figure 5 21 Continued on next page 5 32 Rev F ...

Page 177: ...alve Board Styles Continued Valve board with replaceable valves and original fluidics Figure 5 22 is an example of the original valve board with replaceable valves together with the original fluidics Figure 5 22 Continued on next page Rev F 5 33 ...

Page 178: ...Chapter 5 Dismantling ABL77 Service Manual Valve Board Styles Continued Original valve board Figure 5 23 is an example of the original valve board with the original fluidics Figure 5 23 5 34 Rev F ...

Page 179: ...OTE NOTE When replacing the electronics module all data files will be lost As appropriate follow instructions in the Operator s Manual for downloading data files prior to replacing the electronics module NOTE The valve board and analog board are a matched set for the Hct and SC circuits and must be calibrated when either is replaced This also applies when replacing the lower module or electronics ...

Page 180: ...ectronics module Step Action 1 Remove the upper module 2 Remove the lower module 3 Remove five screws from the rear panel using a 5 64 Allen wrench see Figure 5 24 4 Slide the electronics module from the main housing pulling all cables through the vertical slots in the main housing Figure 5 24 Continued on next page 5 36 Rev F ...

Page 181: ...ABL77 Service Manual Chapter 5 Dismantling Electronics Module Continued Electronics module diagram This diagram shows the electronics module removed from the analyzer Rev F 5 37 ...

Page 182: ...when these boards are only removed and put back into the same analyzer Refer to Chapter 4 Test and Calibration Procedures for instructions on performing this procedure NOTE Analog board Follow these steps to replace the analog board Refer to Figure 5 25 Step Action 1 Remove the electronics module 2 Remove the white insulator card and the two cables on the top 3 Remove the analog board by disengagi...

Page 183: ...er 5 Dismantling Analog Board Continued Analog board continued Figure 5 25 Part Function 1 Battery control board to analog board cable 2 CPU board to analog board cable 3 Power distribution board to analog board cable Rev F 5 39 ...

Page 184: ...ctions for re programming the CPU CMOS settings in Chapter 4 Test and Calibration Procedures NOTE Interface board Follow these steps to remove the interface board as shown in Figure 5 26 Step Action 1 Remove the electronics module 2 Disconnect the barcode reader keyboard cable from the left side of the board 3 While pulling straight out on both sides gently remove the interface board 4 Disconnect ...

Page 185: ...ice Manual Chapter 5 Dismantling Interface Board Continued Interface board continued Figure 5 26 Part Function 1 Interface board 2 Coin cell battery 3 Barcode reader keyboard cable 4 Printer data cable Rev F 5 41 ...

Page 186: ...electronics module 2 Remove the analog board 3 Remove the interface board 4 Remove the two screws holding the power distribution board in place Collect the two black standoffs 5 Lift up to separate the power distribution board from the CPU board 6 Disconnect the power board cable and the analog power cable from the bottom of the power distribution board Figure 5 27 Continued on next page 5 42 Rev ...

Page 187: ...wer distribution board screws 2 Power distribution board 3 Black standoffs 14mm 4 CPU board 5 White standoffs 15mm 6 Touch screen board 7 Touch screen cable 8 Power board cable 9 Backlight inverter cable 10 Disk drive cable 11 LCD display cable 12 CPU board to analog board cable 13 CPU board screws 14 Analog power cable Rev F 5 43 ...

Page 188: ... cell battery on the interface board the CPU CMOS will lose its settings and must be re programmed See the instructions for re programming the CPU CMOS settings in Chapter 4 Test and Calibration Procedures NOTE Electronics boards assembly diagram This diagram will be used throughout this section to identify the appropriate boards Figure 5 28 Part Function 1 ChipDisk 2 CPU board 3 Touch screen boar...

Page 189: ... 28 Step Action 1 Remove the electronics module 2 Remove the analog board 3 Remove the interface board 4 Disconnect the COM cable from the front of the CPU board by pulling straight out 5 Push the retaining clips out to the top and bottom of the LCD adapter board This will cause the board to pop up 6 Slide the board out and up to the right Rev F 5 45 ...

Page 190: ...nect the COM cable from the front of the CPU board by pulling straight out 5 Push the retaining clips out to the top and bottom of the LCD adapter board This will cause the board to pop up 6 Slide the LCD adapter board out and up to the right 7 Push the second set of retaining clips out at the top and bottom of the memory module This will cause the board to pop up 8 Slide the memory module out and...

Page 191: ...cing the electronics module or Chip Disk NOTE NOTE When replacing the Chip Disk the analyzer serial number will be lost To reprogram the serial number refer to Chapter 4 Resetting the Serial Number Step Action 1 Remove the electronics module 2 Remove the analog board 3 Remove the interface board 4 Disconnect the COM cable from the front of the CPU board by pulling straight out 5 Gently lift the Ch...

Page 192: ...screwdriver loosen the four screws from the corners of the CPU board 5 Disconnect the two wire power cable from the front of the touch screen controller board 6 Gently lift the CPU board and touch screen controller board assembly up and out NOTE Be careful of the cables in the back and the disk drive cable on the right which must slide out of the board guide 7 Remove the A D cable from the rear of...

Page 193: ...8 Lift out the electronics shelf with board guides 9 Disconnect the battery board cable from the left rear of the battery board 10 Disconnect the battery pack cable from behind the battery door at the rear of the electronics module 11 Using a 5 64 Allen wrench remove three screws securing the battery board to the electronics chassis 12 Using a 5 16 nut driver remove the plate supporting the power ...

Page 194: ...rd Continued Battery control board continued Figure 5 29 Part Function 1 Barcode scanner keyboard cable 2 Power switch cable 3 Ethernet cable 4 COM1 cable 5 A D Cable 6 Power board cable 7 Battery control board 8 Fan assembly cable 9 Printer power cable 5 50 Rev F ...

Page 195: ...eps to remove the cooling fan assembly as shown in Figure 5 30 Step Action 1 Follow the instruction for removing the battery control board 2 Disconnect the fan cable from the battery control board 3 Using a 1 4 nut driver remove the four KEP nuts holding the fan Figure 5 30 Rev F 5 51 ...

Page 196: ...ocal rules for safe work practices CAUTION The gloves must be free of pinholes and preferably be puncture resistant Please consult the glove manufacturer for further information CAUTION If contaminated material comes into contact with any lesion on the body seek medical advice Decon tamination The analyzer s internal waste line is exposed to blood during normal use This includes the complete pathw...

Page 197: ... 6 26 Electronics Module 6 29 Coin Cell Battery 6 29 Rear Panel 6 30 Battery 6 31 Cabling 6 33 Disk Drive Cable 6 36 LCD Display Cable 6 38 Backlight Inverter Cable 6 40 Touch Screen Cable 6 42 Main Analog Cable 6 43 Analog Power Cable 6 44 Power Board Cable 6 45 A D Cable Analog Board to CPU Board 6 47 Printer Data Cable 6 48 Printer Power Cable 6 49 A D Cable Analog Board to Battery Control Boar...

Page 198: ... 7 64 Ball point Allen wrench REF 920 723 Loctite 401 Adhesive REF 991 260 Loctite 222 Threadlocker REF 991 265 Flathead screwdriver Small flathead screwdriver for adjusting the calibration settings Phillips screwdriver Needle nose pliers Scissors or equivalent trimming tool Index card or equivalent to block the opto sensor Deionized water or sterile water Soft cloth gauze or other absorbent mater...

Page 199: ... housing assembly Follow these steps to replace the main housing assembly REF 902 692 Step Action 1 Remove the upper module 2 Remove the lower module 3 Remove the electronics module 4 Remove the manifold 5 Replace the main housing assembly with the new assembly 6 Remove the manifold 7 Re attach the electronics module 8 Re attach the lower module 9 Re attach the upper module 6 4 Rev F ...

Page 200: ...he handle pins 3 Remove the handle from the handle pins 4 If the handle pins require replacement Remove the handle pins Apply two drops of Loctite 401 onto the large diameter of the inner handle pin Insert the inner handle pin into the main housing from the inside of the disk drive slot Insert the outer handle pin from the left outer side of the panel to the inside area of the housing 5 Place the ...

Page 201: ...t Introduction This section describes the procedure for replacing the housing bracket in the upper module Upper module diagram Figure 6 1 is a general representation of the parts of the upper module that relate to this procedure Figure 6 1 Continued on next page 6 6 Rev F ...

Page 202: ...ule items in figure 6 1 Item Function 1 Backlight inverter board screws 2 each 2 Insulating tape 3 Backlight inverter board 4 Assembly screws 4 each 5 Housing bracket 6 Copper tape 2 pieces 7 Washers 8 Cable clamps 9 Copper cloth tape 2 pieces 10 Disk drive 11 LCD display 12 Touch screen 13 Upper housing Continued on next page Rev F 6 7 ...

Page 203: ...pening 11 Remove the backing paper from the two pieces of copper cloth tape that are affixed to the bottom sides of the housing bracket Fold these pieces back so the adhesive side is facing down NOTE These pieces of tape will complete the grounding process when they make contact with the LCD display 12 Insert the bracket into the upper housing Make sure the touch screen cable passes through the op...

Page 204: ...bor intensive effort required to clean the housing before adding a new gasket Orders for a replacement main housing or manifold will include a white manifold gasket The white manifold gasket is not glued in It is held in place with a pressure fit and may be replaced easily Installation Follow these instructions to install the white manifold gasket Step Action 1 Hold the manifold with the luer side...

Page 205: ...analog board are a matched set When either is replaced the Hct and SC circuits and must be re calibrated This also applies when replacing the lower module or electronics module which contains these boards Calibration is not required when these boards are only removed and put back into the same analyzer Refer to Chapter 4 Test and Calibration Procedures for instructions on performing this procedure...

Page 206: ...rs carefully trim 3 8 to 1 2 9 5 to 12 7 mm off and dispose of the disconnected ends of the manifold tubing Make sure the ends are neat and square NOTE The manifold tubing may be trimmed until the length makes re assembly of the analyzer difficult If the tubing has been trimmed to a length that makes re assembly difficult replace the manifold REF 924 297 4 To prevent crystallization and to avoid d...

Page 207: ...system installed in the analyzer Figure 6 2 Valve board with replaceable valves and original fluidics Figure 6 3 Valve board with replaceable valves and check valve fluidics using the Y cable for L3 Figure 6 4 Valve board with replaceable valves and check valve fluidics using the J10 connector Figure 6 5 Surface mount design valve board with check valve fluidics Continued on next page 6 12 Rev F ...

Page 208: ...module NOTE Hold the sensor luer fitting by hand DO NOT use pliers or similar tool to hold the fitting as this may damage the surface and cause leakage A sensor cassette may be used to hold the fitting in place 11 Using a 1 16 Allen wrench or a Phillips head screwdriver as appropriate remove the two screws from the upper left and right corners of the valve board 12 Using a 5 64 Allen wrench or a P...

Page 209: ... Action 1 Place the new valves in the proper positions see figures 6 5 and 6 6 for placement and orientation on the new valve board and attach with the two lock washers and two screws each 2 Tighten the screws down until they are close fitting then turn each screw an additional 1 2 turn to secure Do not tighten more than 3 4 of a turn as this may damage the valve 3 Connect the valve cables as appr...

Page 210: ...adding the 6 flat washer to the board side 10 Apply a drop of Loctite 222 to the threads of the sensor cassette luer fitting 11 Add a hex nut to the sensor cassette fitting luer and tighten with a 5 64 nut driver NOTE Hold the sensor cassette fitting luer by hand DO NOT use pliers or similar tool to hold the luer as this may damage the surface and cause leakage A sensor cassette may be used to hol...

Page 211: ...UER J6 J4 J8 J7 J3 12 1 13 24 J2 2587 J6 J5 J4 J9 J8 J7 L2 L1 L3 J10 L3 COM N C N O L1 COM N C N O L2 COM N C N O J5 J4 J6 J7 J8 J9 J10 Figure 6 8 Items and descriptions The following table describes the cable connections in figure 6 8 Item Function J4 Waste pump cable connection J5 Roller pump cable connection J6 Opto sensor cable connection J7 Former valve L3 connection J8 Valve L1 connection J9...

Page 212: ...oard 41449 B 41477 SERVICE BOARD ABL70 77 ASSY REV K1 J5 R2 R18 REVISION J10 PN 902 811 J1 J9 SENSOR BOSS SENSOR LUER J6 J4 J8 J7 J3 12 1 13 24 J2 2587 J6 J5 J4 J9 J8 J7 L2 L1 L3 J10 Cal2 Waste Cal1 S H LTP3345B C576 A B C PULL PUSH MADE IN MALAYSIA STEPPER MOTOR 5 VDC OHMS COIL 6 25 STEP ANGLE 7 5 L82701 P1 L3 COM N C N O L1 COM N C N O L2 COM N C N O Figure 6 9 Rev F 6 17 ...

Page 213: ...ng and prevent fluid from contacting the electronics during tubing removal Failure to remove all fluid may result in damage to the electronics 2 Disconnect the lower module according to the instructions in this chapter Disconnect the cables from the lower module Disconnect the manifold tubing from the lower module 3 Using scissors carefully trim 3 8 to 1 2 9 5 to 12 7 mm off the disconnected ends ...

Page 214: ...ows the wiring connections of the current design valve board 41449 B 41477 SERVICE BOARD ABL70 77 ASSY REV K1 J5 R2 R18 REVISION J10 PN 902 811 J1 J9 SENSOR BOSS SENSOR LUER J6 J4 J8 J7 J3 12 1 13 24 J2 2587 J6 J5 J4 J9 J8 J7 L2 L1 L3 J10 L3 COM N C N O L1 COM N C N O L2 COM N C N O J5 J4 J6 J7 J8 J9 J10 Figure 6 10 Items and descriptions The following table describes the cable connections in figu...

Page 215: ...ction 1 Remove the protective red boot from the new valve Place the new valve in the proper position see figures 6 10 and 6 11 for placement and orientation on the valve board and attach with two lock washers and two screws 2 Tighten the screws down until they are close fitting then turn each screw an additional 1 2 turn to secure Do not tighten more than 3 4 of a turn as this may damage the valve...

Page 216: ...cribes the cable connections in figure 6 13 Item Function 1 Y cable for valve L3 J4 Waste pump cable connection This connection is used to connect the Y cable which allows both the waste pump cable and valve L3 to connect to this same location J5 Roller pump cable connection J6 Opto sensor cable connection J7 Former valve L3 connection J8 Valve L1 connection J9 Valve L2 connection J10 New valve L3...

Page 217: ...ubing Follow these steps to replace the valve board tubing Make certain all tubing is completely installed Step Action 1 Select Shutdown from the Main Menu Select Long Term Storage and perform this procedure NOTE This procedure will remove all liquid from the internal tubing and prevent fluid from contacting the electronics during tubing removal Failure to remove all fluid may result in damage to ...

Page 218: ...n path 5 Discard tubing appropriately 6 Identify the tubing pieces shown as actual size in figure 6 14 B A F D D E C Figure 6 14 Valve L2 Valve L1 Valve L3 COM N C N O F D E D A C B 2 5 3 4 6 1 Figure 6 15 Item Description of Function 1 To sensor luer 2 To Cal1 3 To Cal2 4 To bulk head connector on the printer chassis 5 Plug no connection 6 To waste drain Continued on next page Rev F 6 23 ...

Page 219: ...ort of valve L3 b Connect the other end to the N O port of valve L1 10 Using one D tubing with a tubing adapter attached connect the open tubing end to the N C port of valve L1 The adapter end of this tube will be connected later to the Cal2 port tubing from the manifold during analyzer re assembly 11 a Connect one end of the E tubing to the COM port of valve L1 b Connect the other end to the N O ...

Page 220: ...om the manifold to the adapter on the tubing connected to the N C port of valve L1 The Cal1 and Cal2 port tubes will cross one over the other 16 Connect the waste port tubing from the manifold to the bulkhead connector item 1 in figure 6 15 on the printer chassis 17 Connect the valve board to the electronics module with the sensor and I O cables 18 Test the tubing connections following the procedu...

Page 221: ... must be replaced with the new separate valve board assembly and manifold CAUTION Wear suitable protection gear during this procedure WARNING CAUTION Removing the old manifold Follow these instructions when removing a manifold Step Action 1 Remove the lower module 2 Disconnect the manifold Cal1 and Cal2 port tubing from the adapters on the valves of the valve board 3 Disconnect the manifold waste ...

Page 222: ...ke certain the tubing is completely installed 3 Connect the new manifold waste tubing to the bulkhead connector item 1 in figure 6 17 on the printer chassis 4 Make certain that all of the cables and tubing are not pinched 41449 B 41477 SERVICE BOARD ABL70 77 ASSY REV K1 J5 R2 R18 REVISION J10 PN 902 811 J1 J9 SENSOR BOSS SENSOR LUER J6 J4 J8 J7 J3 12 1 13 24 J2 2587 J6 J5 J4 J9 J8 J7 L2 L1 L3 J10 ...

Page 223: ...le and two black and red wire power cables to the printer module Layer and insert these cables into the cable clamp located on the main housing 8 Align the lower module with the main housing and push the lower module until it becomes flush with the main housing Make sure that the cables are not pinched between the two housings or obstructing the manifold 9 From the back insert a 6 32 x 5 8 button ...

Page 224: ...ing the CPU CMOS settings in Chapter 4 Test and Calibration Procedures Coin cell battery Follow these steps to replace the coin cell battery Step Action 1 Remove the electronics module 2 Slide the battery out of the coin cell holder item 1 in figure 6 18 3 Slide a new battery into the battery holder 4 Replace the electronics module 5 Restart the analyzer 6 Check the date and time under Options Adj...

Page 225: ...e KEP nuts holding the battery pack housing in place 4 Using a 5 16 nut driver or open end wrench remove the four KEP nuts holding the electronics chassis to the rear panel and remove the rear panel 5 Remove the following cables and connectors from the rear panel as identified in the figure 6 19 1 Bar code reader Keyboard cable 2 Power switch cable 3 Ethernet cable 4 COM1 cable 5 Fan assembly NOTE...

Page 226: ...ew battery in the battery cavity of the analyzer and plug it into the battery control board connector on the left side of the battery compartment Use only a Radiometer ABL77 battery 4 Replace the rear panel battery access door taking care not to damage the battery wires 5 Plug the analyzer into an AC source and charge the battery for at least 5 minutes 6 Turn the analyzer on and ensure it will run...

Page 227: ...Chapter 6 Replacements ABL77 Service Manual This page intentionally left blank 6 32 Rev F ...

Page 228: ...CD display cable 636 439 Backlight inverter cable 636 441 Touch screen cable The following main analog cables 636 440 connect the lower module to the electronics module I O cable Sensor cable There are no cables that directly connect the upper module to the lower module The following cables are connected within the electronics module 636 487 Analog power cable 636 488 Power board cable 636 442 A D...

Page 229: ...Chapter 6 Replacements ABL77 Service Manual Cabling Continued Electronics module diagram Figure 6 20 identifies the cables within the electronics module Figure 6 20 Continued on next page 6 34 Rev F ...

Page 230: ...able 2 Main analog cable I O cable 3 LCD display cable 4 Power switch cable 5 Ethernet cable 6 COM1 cable 7 A D cable analog board to CPU board 8 Disk drive cable 9 A D cable analog board to battery control board 10 Analog power cable 11 Cable clamp 12 Barcode reader keyboard cable 13 Power board cable 14 Touch screen cable 15 Printer data cable 16 Printer power cable 17 Backlight inverter cable R...

Page 231: ... to replace the disk drive cable Refer to Figure 6 21 Step Action 1 Remove the electronics module One end of the disk drive cable will be disconnected when the upper module is removed 2 Remove the analog board 3 Disconnect the cable clamp from the right hand board guide 4 Remove the LCD adapter board 5 On the far right edge of the CPU board is a tan or dark brown colored cable connector Flip the l...

Page 232: ...strip facing up 8 Route the cable through the slot in the right hand board guide attached to the electronics shelf and then under the cable clamp that attaches to the board guide Figure 6 21 Item Description of Function 1 CPU board 2 LCD display cable 3 Right hand board guide 4 Disk drive cable 5 Electronics shelf 9 Place the end of the cable in the cable connector as far as it will go 10 Push dow...

Page 233: ...ble The new design LCD display cable includes the upper module connector as a part of the cable Refer to Figure 6 22 Step Action 1 Remove the electronics module One end of the LCD display cable will be disconnected when the upper module is removed 2 Remove the analog board 3 Disconnect the cable clamp from the right hand board guide 4 On the far right edge of the LCD adapter board is a tan or dark...

Page 234: ...onics shelf and then under the cable clamp that attaches to the board guide Figure 6 22 Item Description 1 CPU board 2 LCD display cable 3 Right hand board guide 4 Disk drive cable 5 Electronics shelf 8 Place the end of the cable in the cable connector as far as it will go 9 Push down on the locking mechanism to secure the cable in place 10 Gently fold the disk drive and LCD adapter cables up and ...

Page 235: ...le One end of the backlight inverter cable will be disconnected when the upper module is removed 2 Remove the analog board 3 Disconnect the old backlight inverter cable from the LCD adapter board 4 Connect the new backlight inverter cable item 1 in figure 6 23 to the LCD adapter board with the two wires away from the front of the electronics module Figure 6 23 Continued on next page 6 40 Rev F ...

Page 236: ...klight inverter cable continued Step Action 5 Route the new backlight inverter cable along the inside of the right hand board guide and out the front of the electronics module item 1 in figure 6 24 6 Re assemble the analyzer starting with the electronics module Figure 6 24 Rev F 6 41 ...

Page 237: ...he front of the touch screen controller board 4 Clean the old RTV adhesive from the header on the touch screen controller board 5 Connect the new touch screen cable item 1 in figure 6 25 to the 16 pin header on the front of the touch screen controller board Position the connector in the bottom row on the far right side so that pin 1 different color strip is to the right Figure 6 25 6 Place RTV adh...

Page 238: ...hese steps to replace either or both main analog cables Step Action 1 Remove the electronics module One end of the main analog cable will be disconnected when the lower module is removed 2 Disconnect the old main analog cable s from the analog board 3 Connect the new main analog cable s to the analog board item 1 and or 2 in figure 6 26 NOTE This cable is keyed for proper orientation Both ends of ...

Page 239: ...power distribution board 4 Connect the new analog power cable item 1 in figure 6 27 to J2 of the power distribution board NOTE The cable is keyed for proper orientation Both ends of the cable have identical wiring connections so either end can be installed 5 Route the analog power cable under the power distribution board and the COM1 connector on the rear panel 6 Re attach the analog board This wi...

Page 240: ...harge cycle will occur 7 Loosen do not remove all three screws on the battery control board approximately 6 turns 8 Loosen the Kep nut at the back of the battery control board that secures the power connector bracket by approximately 3 turns 9 Raise the battery control board to remove the old power board cable 636 488 from J4 10 Install the new power board cable to J4 of the battery control board ...

Page 241: ... 18 Re install the COM1 cable 636 445 into the connector on the front right of the CPU with the red strip on the right Pull excess cable out between the interface board and the cable connector so the cable lays flat on the CPU 19 Ensure all cables lie flat on top of the CPU 20 Re install the analog board into the electronics module 21 Verify that the cable routing does not interfere with the compo...

Page 242: ...le 2 Remove the analog board One end of the A D cable will be disconnected when the analog board is removed 3 Disconnect the old A D cable from the connector at the right rear of the CPU board 4 Connect the new A D cable item 1 in figure 6 29 with the red strip to the right into the 10 pin header on the right rear of the CPU board 5 Re assembly the analyzer starting with the electronics module Fig...

Page 243: ...ata cable from the connector on the interface board 4 Connect the new printer data cable item 1 in figure 6 30 to the interface board NOTE The cable ends are unique for each connection Only the correct end will connect to the interface board Also the cable is keyed so that the connectors can only be installed in the correct orientation 5 Re connect the interface board 6 Re assembly the analyzer st...

Page 244: ... printer power cable from the front of the battery control board 3 Connect the new printer power cable item 1 in figure 6 31 to the battery control board NOTE The cable will only connect to the mated connector Also the connector is keyed so that the connectors can only be installed in the correct orientation 4 Re assembly the analyzer starting with the electronics module Figure 6 31 Rev F 6 49 ...

Page 245: ...lowing cables from the CPU and touch screen controller boards Power board cable Touch screen controller power cable Ethernet cable COM1 cable Barcode reader Keyboard cable 4 Using a 5 64 Allen wrench remove four screws from the outside of the electronics chassis 5 Lift out the electronics shelf with board guides 6 Disconnect the old A D cable from the left rear of the battery control board NOTE Do...

Page 246: ... the Ethernet cable 636 438 into the white connector in the upper right corner of the CPU 10 Re install the COM1 cable 636 445 into the connector on the front right of the CPU with the red strip on the right Pull excess cable out between the interface board and the cable connector so the cable lays flat on the CPU 11 Assure all cables lie flat on top of the CPU 12 Re install the analog board into ...

Page 247: ...3 from the back of the rear panel Insert two gold jack screws with star washers from the front Secure the screws with the split washers and nuts attached on the back If the connector has threaded inserts fasten with the screws and star washers All hardware is provided with the cable IMPORTANT Ensure that the washers are not touching the metal housing of the COM1 cable as this may cause an electric...

Page 248: ... Press the spring latches on the power switch to release the switch from the rear panel and slide the old power switch cable out of the rear panel 5 Verify that the switch rocker on the new power switch cable is in the standby off position down 6 Verify that the unused contacts on the switch are oriented to the right from the back of the rear panel 7 Install the power switch cable into the far lef...

Page 249: ...tate the removal of the bar code gun keyboard cable 4 Disconnect the barcode reader keyboard cable from the left side of the interface board 5 Disconnect the barcode reader keyboard cable from the two cable clamps on the rear panel 6 Remove the screws that secure the connector to the rear panel NOTE If the connector is held with nuts and washers do not drop these parts into the module during remov...

Page 250: ...button head screws NOTE If the connector does not have threaded inserts fasten the screws with two 4 40 hex nuts and two 4 internal star washers 9 Apply a small drop of Loctite 222 to the threads 10 Route the barcode reader keyboard cable through the center and left cable clamps on the rear panel then through the left two cable clamps on the electronics shelf 11 Connect the barcode reader keyboard...

Page 251: ...panel and slide the old Ethernet cable out of the rear panel 5 Hold the new Ethernet cable connector with the tab facing up and the tab lock facing away from you 6 From the inside of the rear panel item 1 in figure 6 36 push the connector through the opening next to the power switch until the tab locks on the outside of the rear panel 7 Route the Ethernet cable up and through all three cable clamp...

Page 252: ...othing following legal requirements and local rules for safe work practices CAUTION The gloves must be free of pin holes and preferably be puncture resistant Please consult the glove manufacturer for further information CAUTION If contaminated material comes into contact with any lesion on the body seek medical advice IMPORTANT Always establish an ESD protected area before removing a module from t...

Page 253: ...Pump and Roller Wheel 7 27 Opto Sensor 7 31 Lower Module 7 32 Printer Module 7 35 Printer Door 7 36 Electronics Module 7 37 Rear Panel Assembly 7 37 Fan Assembly 7 38 Electronics Chassis and Battery Cage 7 39 Battery Control Board 7 40 Electronics Shelf 7 42 Electronic Boards 7 44 Touch Screen and CPU Boards Assembly 7 46 ChipDisk Board 7 47 Memory Module 7 48 Disk Drive Cable 7 49 LCD Adapter Boa...

Page 254: ... 5 16 nut driver part number 920 727 5 16 open end wrench part number 920 726 1 16 Ball point Allen wrench part number 920 722 5 64 Ball point Allen wrench part number 920 721 7 64 Ball point Allen wrench part number 920 723 Loctite 222 Threadlocker REF 991 265 Phillips head screwdriver Needle nose pliers Silicone adhesive RTV medical grade part number 991 264 Rev F 7 3 ...

Page 255: ...nding tape between the housing bracket and the LCD display NOTE When using the cloth copper tape ensure that there are no frayed ends or loose fibers as these may cause shorting if contact is made with an inappropriate surface Step Action 1 Cut two pieces of copper cloth tape p n 993 081 6 25 inches long 2 Take one piece of cut tape and place lengthwise along the long edge of the bottom of the hou...

Page 256: ...ligning the two screws protruding from the sides of the drive with the slots in the opening 7 Replace the two pieces of copper cloth tape that are affixed to the bottom sides of the housing bracket if necessary See Replacing copper cloth tape instructions above NOTE These pieces of tape will complete the grounding process when they make contact with the LCD display 8 Insert the bracket into the up...

Page 257: ...Chapter 7 Re Assembly ABL77 Service Manual Touch Screen Panel Continued Touch screen panel diagram Figure 7 1 Continued on next page 7 6 Rev F ...

Page 258: ...gram continued Part Function 1 Backlight inverter board screws 2 Insulating tape 3 Backlight inverter board 4 Housing screws 5 Housing bracket 6 Copper tape 7 Disk drive screws 8 Disk drive washers 9 Copper cloth tape 10 Disk drive 11 LCD display 12 Touch screen panel 13 Upper housing Rev F 7 7 ...

Page 259: ... the two screws protruding from the sides of the drive with the slots in the opening NOTE These two screws are affixed into the disk drive and should not be removed or tightened during repair procedures 7 Replace the two pieces of copper cloth tape that are affixed to the bottom sides of the housing bracket if necessary See Replacing copper cloth tape instructions above NOTE These pieces of tape w...

Page 260: ...ws are affixed into the disk drive and should not be removed or tightened during repair procedures 5 Replace the two pieces of copper cloth tape that are affixed to the bottom sides of the housing bracket if necessary See Replacing copper cloth tape instructions above NOTE These pieces of tape will complete the grounding process when they make contact with the LCD display 6 Insert the bracket into...

Page 261: ...e sure the bottom edge of the tape covers the copper shielding on the outside edge of the upper module NOTE Ensure that the tape does not contact the small silver plate on the outside of the disk drive 13 Cut a piece of copper tape 1 5 in length 14 Place the tape between the disk drive and the inside of the disk drive slot Make sure the tape does not cover the drive mechanism this bar on the disk ...

Page 262: ...Chapter 7 Re Assembly Disk Drive Continued Disk drive diagram Figure 7 2 Part Function 1 Backlight inverter board 2 Housing screws 3 Disk drive screws and washers 4 Disk drive 5 Upper housing 6 LCD display cables Rev F 7 11 ...

Page 263: ... connector facing the left 2 Re connect the LCD display cables to the board at the matching ends with the black wires facing away from you 3 Attach the board to the upper module with two screws 4 Apply insulating tape across the length of the backlight inverter board to prevent electrical shock Figure 7 3 Part Function 1 Backlight inverter cable 2 Backlight inverter board screws 3 Insulation tape ...

Page 264: ...onnector Secure the cable under the upper cable clamp in the upper module 3 Slide the LCD display cable into the slot in the housing bracket and then connect the LCD display cable to the connector on the LCD display 4 Connect the 2 wire backlight inverter cable to the backlight inverter board with the red wire facing away from the disk drive Secure the cable under the upper cable clamp in the uppe...

Page 265: ... Upper module diagram Figure 7 4 Part Function 1 Upper housing 2 Disk drive 3 Disk drive cable 4 Touch screen cable 5 LCD display cable 6 Backlight inverter cable 7 Backlight inverter 8 Insulating tape 9 Housing bracket 10 Touch screen panel 11 LCD display 7 14 Rev F ...

Page 266: ...ring service Y cable for L3 adapter During the transition process to the Check Valve Fluidics system some existing valve boards were adapted to the Check Valve Fluidics by adding a Y cable for L3 kit REF 905 782 Figure 7 5 Figure 7 5 Part Function 1 Green wire 2 Blue wire 3 Red wires 4 Waste pump connector 5 Valve L3 connector 6 Valve board J4 connector Continued on next page Rev F 7 15 ...

Page 267: ...t the end of the waste pump cable from J4 of the valve board located in the lower left corner of the board 2 Connect the female end of the Y cable to J4 of the valve board in place of the waste pump cable Ensure the green wire is on top and the blue wire is closest to the bottom edge of the board 3 Secure the Y cable midway down the housing standoff with the Ty wrap included in the kit to prevent ...

Page 268: ...lue and green wires of the Y cable with the same color wires of the waste pump cable 6 Disconnect the cable connector of valve L3 from J7 of the valve board in the lower right hand corner 7 Route the L3 valve cable under the L1 valve cable and across the board as shown 8 Connect the L3 valve cable connector to the Y cable connector with the red wires No polarity match is required with this cable C...

Page 269: ...formation Continued Valve board with J10 connector Valve boards built after the release of the check valve fluidics system have an extra connector J10 to make a direct connection for valve L3 902 790 as shown in Figure 7 8 Figure 7 8 Continued on next page 7 18 Rev F ...

Page 270: ...ral Information Continued Surface mount valve board The current valve board uses a surface mount design to take advantage of more advanced technology 902 812 This valve board also has a J10 connector in a more convenient location Figure 7 9 Figure 7 9 Rev F 7 19 ...

Page 271: ...when either is replaced This also applies when replacing the lower module or electronics module which contains these boards Calibration is not required when these boards are only removed and put back into the same analyzer Refer to Chapter 7 Service Programs for instructions on performing this procedure NOTE NOTE Wear suitable protection gear during this procedure Lower module diagram Figure 7 10 ...

Page 272: ...or cassette fitting luer into the other round opening in the front of the module Use an old sensor cassette to hold the boss and luer in place and turn the module over 5 Apply a drop of threadlocker 222 to a 6 32 x screw and insert the screw through the center of the board into the alignment boss and tighten 6 Add a 6 flat washer to the sensor cassette fitting luer Apply a drop of threadlocker 222...

Page 273: ...ble to J6 of the valve board with the green wire in the top position as shown below 2 Connect the roller pump cable to J5 of the valve board with the red wire in the top or right position depending on the board configuration as shown below 3 Connect the waste pump cable to J4 of the valve board with the green wire in the top position as shown below Pre Surface Mount Valve Board 902 790 Surface Mou...

Page 274: ...ch one end of the free waste tubing attached from the N C port of valve L3 to the waste drain 6 Attach the other end of the free waste tubing attached from the N C port of valve L3 to the printer chassis port 7 Connect the Cal1 port tubing from the manifold to the adapter on the tubing connected to the N C port of valve L2 8 Connect the Cal2 port tubing from the manifold to the adapter on the tubi...

Page 275: ...g the waste pump Follow these steps to re attach the waste pump and waste pump cable Step Action 1 From the front of the lower module feed the waste pump cable through the mounting hole in the printer chassis 2 Slide the pump motor into the mounting hole of the chassis 3 Align the mounting holes in the waste pump with the holes in the printer chassis Insert two screws into the mounting holes and t...

Page 276: ...ct the waste pump cable to J4 on the valve board with the green wire in the top position as shown in Figure 7 14 6 Orient the cable connector so that the green wire is on top toward the sensor cassette fitting luer Position the cable to prevent pinching and kinking 7 Bend the waste pump flanges flat with the rear of the motor to prevent shorting against the main housing Figure 7 14 Part Function 1...

Page 277: ...e 7 15 Step Action 1 Open the printer door 2 Slide the waste pump head onto the waste pump shaft with the tubing facing up until the waste pump head snaps into place on both sides 3 Remove the black caps from the latex tubes Trim tubing length as necessary to avoid kinks in the tubing 4 Attach the latex tubes to the tube connectors on the printer chassis Figure 7 15 7 26 Rev F ...

Page 278: ...in Figures 7 16 and 7 17 Step Action 1 From the back of the lower module slide the roller pump shaft into the opening on the left side of the module Ensure that the cabling faces the valve board 2 Insert two flat washers and two screws into the mounting holes and tighten using a 5 64 Allen wrench 3 Connect the roller pump cable to J5 of the valve board with the red wire in the top Figure 7 16 or r...

Page 279: ...Manual Roller Pump and Roller Wheel Continued Attaching the roller pump continued Figure 7 16 Part Function 1 Roller pump cable connection J5 red wire on top 2 Roller pump screws and washers 3 Roller pump Continued on next page 7 28 Rev F ...

Page 280: ...embly Roller Pump and Roller Wheel Continued Attaching the roller pump continued Figure 7 17 Part Function 4 Roller pump cable connection J5 red wire on right 5 Roller pump screws and washers 6 Roller pump Continued on next page Rev F 7 29 ...

Page 281: ...s shown in Figure 7 18 Step Action 1 From the front of the module slide the roller wheel onto the roller pump shaft 2 Using a 1 16 Allen wrench tighten the two set screws on the roller wheel IMPORTANT Do not over tighten the set screws to avoid cracking the screw holes of the roller wheel Important Figure 7 18 Part Function 1 Set screws 2 Cassette nest 3 Roller wheel 7 30 Rev F ...

Page 282: ... sensor into the rectangular opening in the upper right of the housing 2 Fasten the sensor in place with four nylon washer and two Phillips head screws 3 Connect the cable to J6 of the valve board with the green wire in the top position as shown below Figure 7 19 Part Function 1 Opto sensor cable connection J6 green wire on top 2 Opto sensor with cable 3 Opto sensor nylon washers and screws Rev F ...

Page 283: ...g the lower module to the ABL77 analyzer NOTE Lower module service kits do not include a printer door This is because the analyzer serial number resides on the label inside the printer door The printer door must be removed from the old lower module and attached to the new lower module Continued on next page 7 32 Rev F ...

Page 284: ...ies the connection for the main housing Figure 7 20 Part Function 1 Backlight inverter cable 2 LCD display cable 3 Touch screen cable 4 Input Output I O cable J3 5 Sensor cable J2 6 Cable clamps 7 Disk drive cable 8 Printer cables clamp 9 Printer power cable 10 Printer data cable Continued on next page Rev F 7 33 ...

Page 285: ...oard 5 Align the lower module with the main housing and push the lower module until it becomes flush with the main housing Make sure that the cables are not pinched between the two housings or obstructing the manifold 6 From the back insert a 6 32 x 5 8 button head screw into the upper right manifold hole and tighten with a 5 64 Allen wrench Insert a 6 32 x 5 8 socket head screw and a 6 flat washe...

Page 286: ...7 21 Step Action 1 Open the printer door 2 Attach the printer cables to the rear of the printer module 3 Slide the printer module into the printer chassis and hand tighten the two panel screws on either side of the printer module Figure 7 21 Part Function 1 Printer panel screws 2 Printer data cable connection 3 Printer power cable connections Rev F 7 35 ...

Page 287: ...inter door as shown in Figure 7 22 Step Action 1 Slide the printer door onto the right hinge pin of the printer chassis 2 Slide the door hinge into the left side of the door 3 Slip the door hinge over the support post on the printer chassis and slide a retaining ring e clip onto the support post 4 Using needle nose pliers connect the extension spring to the anchor in the printer door 5 Inspect and...

Page 288: ...l Assembly Introduction This section describes the process for re assembling the electronics module Rear panel assembly Follow these steps to re assemble the rear panel assembly Place the rear panel so the elongated section is upward and to the right Figure 7 23 Rev F 7 37 ...

Page 289: ...ng fan as shown in Figure 7 24 Step Action 1 Install fan assembly verifying that one arrow on fan points down to the rear panel and the other points to the left 2 Using a 1 4 nut driver secure the four Kep nuts Do Not over tighten 3 Apply a small drop of threadlocker 222 to the threads Figure 7 24 7 38 Rev F ...

Page 290: ...ear panel see Figure 7 25 Step Action 1 Align the electronics chassis with the mounting screws of the rear panel Using a 5 16 nut driver or open end wrench attach four Kep nuts 2 Apply a small drop of threadlocker 222 to the threads 3 Using a 5 16 open end wrench secure the battery cage to the rear panel and electronics chassis with three Kep nuts Figure 7 25 Rev F 7 39 ...

Page 291: ...nector bracket to the rear panel directly below the UL ground label 4 Connect the power switch cable to J2 on the battery control board 5 Connect the end of the A D cable that has the strain relief to J5 on the battery control board 6 Connect the fan assembly cable to J8 on the battery control board 7 Connect the printer power cable to J6 on the battery control board 8 From the rear place the batt...

Page 292: ...rd diagram Figure 7 26 Part Function 1 Barcode reader keyboard cable 2 Power switch cable 3 Ethernet cable 4 Battery pack cable 5 COM1 cable 6 A D Cable 7 Power board cable 8 Battery control board screws and washers 9 Fan assembly cable 10 Printer power cable 11 Battery control board Rev F 7 41 ...

Page 293: ...r panel 4 Route the 3 pin touch screen controller cable along the side of the battery control board out the front of the rear panel 5 Connect the fan cable to J8 on the battery control board 6 Hold the shelf so the board guides are facing up and the standoffs are on the right NOTE Make sure cables are not sitting on top of the battery cage and that the bar code cable analog board cable and CPU pow...

Page 294: ...elf installation diagram Figure 7 27 Part Function 1 Barcode reader keyboard cable 2 Power switch cable 3 Ethernet cable 4 COM1 cable 5 A D cable 6 Electronics shelf 7 Power board cable 8 Battery control board 9 Fan assembly cable 10 Printer power cable Continued on next page Rev F 7 43 ...

Page 295: ...low these procedures to assemble the electronic boards assembly using the following figures Electronic boards assembled diagram Figure 7 28 Part Function 1 ChipDisk board 2 CPU board 3 Touch screen controller board 4 LCD adapter board 5 Memory module Continued on next page 7 44 Rev F ...

Page 296: ... board screws 2 2 Power distribution board 3 Power board standoffs 2 4 CPU board 5 CPU board standoffs 4 6 Touch screen controller board 7 Touch screen controller cable 8 Memory module 9 Backlight inverter cable 10 Disk drive cable 11 LCD adapter cable 12 LCD adapter board 13 CPU board screws 4 14 ChipDisk 15 Analog power cable Rev F 7 45 ...

Page 297: ...gs are NOTE 1 3 4 5 and 7 are down 2 6 and 8 are up NOTE When the CPU is disconnected from the coin cell battery on the interface board the system BIOS looses it settings and the settings must be re programmed when the analyzer is re assembled See Chapter 4 Reprogramming the CPU BIOS settings Step Action 1 Insert the long leads on the underside of the CPU into the PC104 bus on the touch screen con...

Page 298: ...pDisk is pre programmed at the factory with the latest versions of software Step Action 1 Align the 44 pin socket ChipDisk board with the 44 pin header at the top of the CPU The screw hole on the ChipDisk board will face the right and align with the screw hole on the CPU 2 Press down firmly so the socket is flush with the pins Rev F 7 47 ...

Page 299: ...right side of the CPU is a tan colored bracket with two rows of gold pins Place the gold pins on the memory module in the bottom row of gold pins in the tan bracket Memory module is inserted diagonally 3 Press the memory module firmly towards the bracket so that the gold pins sit securely in the bottom row The pins should line up in a straight line 4 Press down firmly on the memory module until th...

Page 300: ...ree of the connector Step Action 1 On the far right edge of the CPU board is a tan or dark brown colored 26 pin floppy drive connector Flip the locking mechanism on the connector up 2 Hold the disk drive flex cable with the colored strip facing towards the left and place the end of the cable closest to the notch in the floppy connector as far as it will go NOTE The disk drive cable includes a notc...

Page 301: ... notch in the LCD adapter connector as far as it will go NOTE The disk drive cable includes a notch in the shielding at one end of the cable 4 Push the locking mechanism in to the left to secure the cable 5 Insert the backlight cable into the 7 pin connector on the LCD adapter board with the red wire towards the top of the board 6 Hold the LCD adapter board so that the LCD and backlight cables are...

Page 302: ...ard 2 Route the disk drive flex cable under the right board guide Pull the cable so that the colored strip in the connector is almost flat cable is pulled completely through the guide 3 NOTE Route the cabling behind the electronic boards assembly during this step Position the electronic boards assembly on top of the metal standoffs of the electronics shelf so that the PC104 bus will be on the left...

Page 303: ...Chapter 7 Re Assembly ABL77 Service Manual Electronic Boards Module Assembly Continued Electronic boards Module assembly diagram Figure 7 30Continued on next page 7 52 Rev F ...

Page 304: ...rt Function 1 Power board screws 2 2 Power distribution board 3 Power board standoffs 2 4 CPU board 5 CPU board standoffs 4 6 Touch screen controller board 7 Touch screen controller cable 8 Power board cable 9 Backlight inverter cable 10 Disk drive cable 11 LCD adapter cable 12 A D cable 13 CPU board screws 4 14 Analog power cable Rev F 7 53 ...

Page 305: ...he analog power cable under the power distribution board and the COM1 connector on the rear panel 3 Insert a 4 40 x 1 5 screw in each hole of the power distribution board from the non connector side of the board then through one black nylon spacer for each screw 4 Install the power distribution board onto the CPU board by inserting the header leads onto the CPU receptacle push down firmly until th...

Page 306: ...e Assembly Power Distribution Board Continued Power distribution board diagram Figure 7 31 Part Function 1 Power board screws 2 2 Power distribution board 3 Analog power cable 4 Power board cable 5 Power boards standoffs 2 Rev F 7 55 ...

Page 307: ...U board as indicated below 3 Align the 10 pin and 26 pin sockets on the interface board with the 10 pin and 26 pin right angle headers on the front left side of the CPU Press firmly on the interface board until the socket is flush 4 Insert the coin cell battery into the battery holder with the positive side facing out 5 Connect the barcode reader keyboard cable to the red 4 pin connector on the in...

Page 308: ... Manual Chapter 7 Re Assembly Interface Board Continued Interface board install diagram Figure 7 32 Part Function 1 Interface board 2 Coin cell battery 3 Barcode reader keyboard cable 4 Printer data cable Rev F 7 57 ...

Page 309: ...d and analog board are a matched set for the Hct and SC circuits and must be calibrated when either is replaced This also applies when replacing the lower module or electronics module which contains these boards Calibration is not required when these boards are only removed and put back into the same analyzer Refer to Chapter 4 for instructions on performing this procedure Continued on next page 7...

Page 310: ...y the SenDx assembly part number of 41386 on the label that appears on the back of the board this is the side with the I O and sensor cable connectors If the jumper is set to the wrong position the Hct value will give a reading of 0 zero Step Action 1 When installing the new analog board the support rod if present must be removed to make room for the daughter board attached to the analog board 2 W...

Page 311: ... D cable from the CPU board are reversed the analyzer will not power up 4 Plug the gray A D cable from the CPU board into J4 on the analog board 5 Press the analog board into the left and right board guides with the component side down 6 Place the insulator card on top of the analog board to prevent the cables from shorting against the analog board 7 Attach the I O cable to J5 of the Analog Board ...

Page 312: ...ued Analog board install diagram Figure 7 35 Part Function 1 I O cable 2 Sensor cable 3 Analog board 4 Insulator card 5 A D cable from the battery board 6 A D cable from the CPU board 7 Analog power cable 8 Touch screen cable 9 Backlight inverter cable Rev F 7 61 ...

Page 313: ... the main housing LCD display cable Backlight inverter cable Touch screen cable Disk drive cable 5 Insert electronics module into the main housing while gently pulling the cables from the front Ensure the cables are not pinched between main housing and electronics chassis and that the ferrite s on the touch screen and backlight inverter cables lie above the analog board 6 Route the LCD display cab...

Page 314: ...d Main housing cable assemblies diagram Figure 7 36 Part Function 1 Backlight inverter cable 2 LCD display cable 3 Touch screen cable 4 I O cable 5 Sensor cable 6 Cable clamp 7 Disk drive cable 8 Printer cables clamp 9 Printer power cables 10 Printer data cable Rev F 7 63 ...

Page 315: ... safe work practices CAUTION The gloves must be free of pinholes and preferably be puncture resistant Please consult the local glove manufacturer for further information CAUTION If contaminated material comes into contact with any lesion of the body or mucous membranes seek medical advice Contents This chapter contains the following topics Overview 8 1 Valve Maintenance 8 2 Cleaning 8 6 Long Term ...

Page 316: ...TE The Long term Storage procedure further in this chapter is also meant to prevent salt crystal build up within the valves and should be performed any time an analyzer will be turned off for prolonged periods Long term Storage must always be performed prior to shipping an analyzer Valve maintenance Follow these steps to maintain valve performance Step Action 1 Select Options from the Main Menu 2 ...

Page 317: ...er as shown in Figure 8 2 Figure 8 2 11 Be prepared to collect fluids exiting the cal pack manifold at the rear of the analyzer 12 Press Cal1 This will activate internal valves and open a pathway between the cassette luer and the Cal1 manifold luer 13 While the screen displays Cal1 open GENTLY introduce deionized water into the luer The Cal1 line will remain open for ten seconds Fluids will exit t...

Page 318: ...een the cassette luer and the Cal2 manifold luer 20 Refill the syringe with deionized water and press Cal2 to repeat this process one more time 21 Remove the syringe from the analyzer 22 Remove any excess water from the syringe Pull back on the syringe plunger to fill the syringe with air 23 Attach the syringe to the cassette luer and press Cal2 to repeat this process using air 24 Press OK when fl...

Page 319: ...s with Cal1 solution Press Pump Cal2 to prime the internal fluid lines with Cal2 solution NOTE While Cal1 and Cal2 solution are flushing snap the sensor cassette pump tubing to help dislodge all air bubbles as shown in Figure 8 4 Figure 8 4 28 Exit the Hardware screen and return to the Main Menu 29 Perform a manual calibration to ensure proper function prior to sample analysis Rev F 8 5 ...

Page 320: ...e degrading the image quality NOTE Do not use bleach products Analyzer surfaces Use a soft cloth with a disinfectant such as Cidex or Control III etc Bleach solution a 1 9 dilution of bleach sodium hypochlorite to water may also be used The analyzer case should be kept clean of liquids and contaminants Immediately clean all surfaces as they become wet with liquids and contaminants Clean around the...

Page 321: ...e for the analyzer Blood proteins will generally not accrue in the valve bank portion of the analyzer because samples do not traverse beyond the sensor cassette tubing during normal use Follow these steps to clean the waste drain CAUTION Be prepared to collect waste fluids flowing from open luers Step Action 1 From the Main Menu press Options Enter a Password as necessary 2 At the Options menu sel...

Page 322: ...nalyzer will automatically proceed to the next screen 4 Ensure there is a cal pack in place to collect waste fluids Introduce 1 cc of Cleaning Solution REF 943 906 into the waste drain the black opening located directly below the inlet probe when a cassette is in place 5 Activate the waste pump by pressing Pump to carry this fluid through the waste line and into the cal pack Repeat as desired Pres...

Page 323: ... form periodically in the analyzer fluid path if the analyzer is turned off for extended periods of time This tendency is accelerated if a cal pack and sensor cassette are not left on the analyzer These crystals will form obstructions in the fluid path Long term storage The following steps should be performed prior to long term storage of the ABL77 Step Action 1 From the Main Menu press Options En...

Page 324: ...These components are the sensor cassette the waste line and the waste pouch within the cal pack The sensor cassette and cal pack can be discarded as biohazardous waste 5 To decontaminate the waste line ensure there is a cal pack in place to collect waste fluids Introduce 1 cc of Cleaning Solution REF 943 906 into the waste drain the black opening located directly below the inlet probe when a casse...

Page 325: ...tly introduce the deionized water into the luer It will exit the waste port of the manifold Press Continue 11 Remove the syringe and pull back on the plunger to fill the syringe with air Replace the syringe on the cassette luer 12 Press Pump While the waste pump is running gently introduce air into the luer This will remove residual fluids from the side waste line Press Continue 13 Fill the syring...

Page 326: ...with deionized water Replace the syringe on the cassette luer 18 Press Cal 2 While Cal2 Open is displayed on the screen gently introduce the deionized water into the luer It will exit the Cal 2 manifold port Press Continue 19 Remove the syringe and pull back on the plunger to fill the syringe with air Replace the syringe on the cassette luer 20 Press Cal 2 While Cal2 Open is displayed on the scree...

Page 327: ...cal pack fluids It should be free of tears and debris that would inhibit proper positioning of the manifold Replace the manifold gasket as necessary Waste pump with waste pump head REF 580 077 Ensure that the waste pump is free moving without excessive noise Disassemble the waste pump head and inspect the tubing inside The tubing should not be brittle or exhibit tears or shavings Replace the waste...

Page 328: ...y Waste pump with waste pump head REF 580 077 Ensure that the waste pump is free moving without excessive noise Disassemble the waste pump head and inspect the tubing inside The tubing should not be brittle or exhibit tears or shavings Replace the waste pump and waste pump head as necessary Tubing kit for check valve fluidics REF 905 781 Ensure that this waste connector does not exhibit excessive ...

Page 329: ...et as necessary Waste pump with waste pump head REF 580 077 Ensure that the waste pump is free moving without excessive noise Disassemble the waste pump head and inspect the tubing inside The tubing should not be brittle or exhibit tears or shavings Replace the waste pump and waste pump head as necessary Tubing kit for check valve fluidics REF 905 781 Ensure that this waste connector does not exhi...

Page 330: ...he fan is free of dust and debris Verify that the fan runs continuously while the analyzer is on Verify that the fan does not make excessive noise Replace the fan assembly as necessary All cables connections and fittings see Chapter 9 Spare Parts list for applicable part numbers Ensure all cable connections are securely attached and free of kinks ...

Page 331: ... may be serviced as only the parts listed may be replaced When ordering spare parts always include the REF number and the description of the part Trade in parts The parts marked with an asterisk may be returned to RADIOMETER SenDx under trade in agreement Contents This chapter contains the following topics Overview 9 1 Modules and Externals 9 2 Upper Module Components 9 4 Lower Module Components 9...

Page 332: ... pages Trade in agreement Item REF Quantity Description 1 902 695 1 Upper module 2 902 694 1 Lower module 3 902 693 1 Electronics module 4 886 484 1 Carry handle 5 902 692 1 Main housing 6 886 494 1 Battery door 7 924 295 1 Battery insulator card 8 431 016 1 Battery pack 9 924 286 1 Bar code gun holder 10 902 660 1 Bar code gun 11 981 751 1 Label luer capping 5 each 12 924 301 4 Luer caps 20 each ...

Page 333: ...ABL77 Service Manual Chapter 9 Spare Parts Modules and Externals Continued Module diagrams continued Rev F 9 3 ...

Page 334: ...iption 1 008 932 4 Screw pan head Phillips m2 5 x 6 2 992 190 A R Teflon insulating tape 3 902 689 1 Backlight inverter board 4 008 926 4 Screw pan head Phillips m2 5 x 20 5 902 688 1 Upper housing bracket 6 993 080 A R Copper foil tape 7 046 117 2 Washer Flat 4 8 924 242 924 322 2 Cable clamp Main top 25 each Cable clamp Main top 5 each 9 993 081 A R Copper cloth tape 10 910 257 1 Disk drive 11 3...

Page 335: ...ABL77 Service Manual Chapter 9 Spare Parts Upper Module Components Continued Upper module component diagram Rev F 9 5 ...

Page 336: ... 1 Alignment boss 2 924 241 1 Waste drain mount 3 008 921 4 Screw machine tap pan head Phillips 4 046 107 6 Washer 6 flat 5 902 624 1 Waste pump head 6 008 920 2 Screw Phillips 6 x 1 7 008 919 2 Screw socket head cap 6 32 x 7 8 8 856 644 856 645 1 Hinge printer chassis 10 each Hinge printer chassis 2 each 9 875 911 1 Spring extension 10 924 170 924 319 1 Retaining ring E clip 100 each Retaining ri...

Page 337: ...ABL77 Service Manual Chapter 9 Spare Parts Lower Module Components Continued Lower module external diagram Continued on next page Rev F 9 7 ...

Page 338: ...4 902 811 1 Valve board assembly 5 886 496 1 Printer cover top 6 886 495 1 Printer chassis 7 902 690 1 Lower housing 8 902 684 1 Cable opto sensor 9 008 925 2 Screw 4 x 3 8 10 046 112 4 Washer nylon 11 924 297 1 Manifold 12 924 240 924 317 1 Tee tubing connector 40 each Tee tubing connector 2 each 13 842 335 842 339 2 Silicone tubing 3 inch 25 each Silicone tubing 3 inch 4 each 14 805 167 1 Bulk h...

Page 339: ...ABL77 Service Manual Chapter 9 Spare Parts Lower Module Components Continued lower module internal diagram Continued on next page Rev F 9 9 ...

Page 340: ...x 2 902 812 1 Valve board ABL77 3 008 938 1 Screw Phillips head 6 32 x 4 902 814 3 Single valve kit ABL77 5 032 908 1 Nut hex 10 32 6 046 107 1 Washer 6 flat 7 905 776 6 Valve hardware kit screws washers 8 842 338 1 Valve tubing plugs 9 924 298 924 324 3 Valve tubing adapters 25 each Valve tubing adapters 6 each A E 905 781 1 Tubing kit pre cut tubing pieces Valve board diagram Continued on next p...

Page 341: ...ve a J10 connector must use the Check Valve Conversion kit with the Y cable for L3 to use the current check valve fluidics system Valve board diagram continued Item REF Quantity Description 905 782 1 Check valve conversion kit Figure 9 1 Part Function 1 Main housing standoff 2 Y cable for L3 3 Waste pump cable Rev F 9 11 ...

Page 342: ...cable clamp 25 each Upper module cable clamp 5 each 2 008 917 3 Screw button head cap 6 32 x 5 8 3 834 656 1 Manifold gasket 4 046 108 2 Washer external star 5 032 906 2 Nut hex 6 32 6 924 243 924 320 1 Main housing center cable clamp 25 Main housing center cable clamp 5 7 008 918 1 Screw socket head cap 6 32 x 5 8 8 046 107 1 Washer 6 flat Main housing front view diagram Continued on next page 9 ...

Page 343: ...rences in this table Main housing rear view Item REF Qty Description 1 008 917 4 Screw socket button cap 6 32 x 5 8 2 834 656 1 Manifold gasket 3 008 918 1 Screw socket hex cap 6 32 x 5 8 4 046 107 1 Washer 6 flat 5 855 155 855 157 4 Rubber feet 50 each Rubber feet 4 each Main housing rear view diagram Rev F 9 13 ...

Page 344: ...Chapter 9 Spare Parts ABL77 Service Manual This page intentionally left blank 9 14 Rev F ...

Page 345: ...s module top Item REF Qty Description 1 636 440 2 Cable main analog I O and Sensor 2 924 244 1 Electronics insulator card 3 902 682 1 Analog board 4 636 487 1 Cable analog power 5 902 838 1 Power distribution board 6 008 940 2 Screw pan head Phillips 4 40 x 1 7 046 118 2 Spacer black nylon 4 4mm 8 902 681 1 Interface board 9 902 679 1 CPU board 10 365 436 1 ChipDisk 11 902 678 1 LCD adapter board ...

Page 346: ...rd 21 636 439 1 Cable backlight inverter 22 924 237 924 321 3 Main housing top cable clamp 25 each Main housing top cable clamp 5 each 23 636 494 1 Cable LCD display 24 924 245 1 PC Board guides contains Ref No 26 25 924 280 1 Cable clamp ABL77 contains Ref No 27 26 008 930 2 Screw button head cap 4 40 x 27 008 925 4 Screw pan head Phillips 4 x 3 8 28 837 160 1 Bumper strip 5 5 29 886 492 1 Electr...

Page 347: ...ABL77 Service Manual Chapter 9 Spare Parts Electronics Module Components Continued Electronics module top diagram Continued on next page Rev F 9 17 ...

Page 348: ...internal star 6 7 902 680 1 Battery control board 8 636 435 1 Cable printer power 9 008 916 4 Screw socket button cap 6 32 x 10 886 490 1 Electronics chassis 11 636 437 1 Cable power switch 12 636 438 1 Cable Ethernet 13 636 445 1 Cable COM port with hardware 14 636 436 1 Cable barcode gun keyboard 15 924 258 924 323 2 Rear panel cable clamp 25 each Rear panel cable clamp 5 each 16 008 930 2 Screw...

Page 349: ...ABL77 Service Manual Chapter 9 Spare Parts Electronics Module Components Continued Electronics module bottom diagram Continued on next page Rev F 9 19 ...

Page 350: ...onents Continued See the Electronics module external diagram for references in this table Electronics module external Item REF Qty Description 1 008 916 6 Screw socket button cap 6 32 x 2 046 104 6 Washer internal star 6 Electronics module external diagram 9 20 Rev F ...

Page 351: ... Loctite 401 instant adhesive 991 265 1 bottle Loctite 222 threadlocker 924 237 25 each Main housing top cable clamp 25 2 33 924 321 5 each Main housing top cable clamp 5 2 33 924 242 25 each Cable clamp main top 25 1 53 924 322 5 each Cable clamp main top 5 1 53 924 243 25 each Main housing center cable clamp 25 1 25 924 320 5 each Main housing center cable clamp 5 1 25 924 258 25 each Rear panel...

Page 352: ...100 Nut Kep 4 40 032 910 100 Nut Kep 6 32 835 475 100 O ring 924 170 100 Retaining ring E clip 855 155 50 Rubber feet 008 925 100 Screw 4 x 3 8 008 936 100 Screw 4 20 x 001 908 100 Screw button cap 4 40 x 008 923 100 Screw button head cap 6 32 x 5 16 008 922 100 Screw button head cap 6 32 x 7 8 008 928 100 Screw button hex 4 40 x 008 921 100 Screw machine tap pan head Phillips 008 935 100 Screw ma...

Page 353: ...x cap 4 40 x 5 8 008 918 100 Screw socket hex cap 6 32 x 5 8 008 919 100 Screw socket hex cap 6 32 x 7 8 008 933 100 Screw thread cutting 4 40 x 046 109 25 Spacer nylon 4 5mm 875 911 50 Spring extension 924 211 2 Standoff manifold 832 223 20 Ty wrap 14 5 046 111 100 Washer 4 flat 046 107 100 Washer 6 flat 046 108 100 Washer external lock 6 046 115 100 Washer flat 2 046 117 100 Washer flat 4 046 10...

Page 354: ...ons to the service manual The table below lists the revisions performed The SN column lists the part numbers of the service notes issued the Issue column lists the issue of the service note equal to the new issue of the service manual and the Revisions column lists the most important revisions SN Issue Revisions 77000912 B Regulatory and design improvements 77000929 C Revise upper temperature rang...

Page 355: ...ABL77 Service Manual Date of Issue Date of Issue Manufacturer Publication July 2003 Edition F Ordering number 989 578 Radiometer Medical A S Copenhagen Denmark 2003 All rights reserved 1 ...

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