Abbott CELL-DYN 3000 User manual

24Sep1997
16:11
CELL-DYN®3000/3500 SAMPLE LOADER
TROUBLESHOOTING GUIDE
CATALOG NO. 8921133701
Abbott Laboratories © 1997 Abbott Laboratories
Abbott Park, IL 60064
Click on item below:
Troubleshooting
Parts Lists
Verification Procedures
Sensors, LEDs, POTs
Error Messages
EXIT
CD-ROM

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 PROPRIETARY INFORMATION i
PROPRIETARY INFORMATION
This CELL-DYN 3000/3500 Sample Loader Troubleshooting Guide was developed solely for use with
Abbott Laboratories equipment as specified in the operating instructions. The Guide is copyrighted by
Abbott. No part of this document may be reproduced, stored, or transmitted in any form or by any
means electronic, mechanical, photocopied, recorded, or otherwise without the prior written
permission of Abbott Laboratories.
This CELL-DYN 3000/3500 Sample Loader Troubleshooting Guide is published by Abbott Diagnostics
Division, Abbott Laboratories, Abbott Park, IL 60064-3500, U.S.A. Please direct all inquiries
concerning information in this guide to the foregoing address.
Vacutainer is a registered trademark of Becton-Dickinson and Company.
This troubleshooting guide was developed to be used, in the field, by trained Abbott Laboratories Field
Service Representatives and by in-house support personnel. The revision status of this guide is the
responsibility of the guide holder.
In no event shall Abbott Laboratories or its subsidiaries be liable for any injury, loss or damages
incurred in connection with or arising from the use of this guide by unauthorized personnel or persons
not fully trained by Abbott Laboratories.
© 1997 by Abbott Laboratories. All rights reserved.
END

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 REVISION LOG ii
REVISION LOG
The Revision Status of this guide is indicated below. Be sure that the guide contains the latest revision
number of all pages. Additional copies of this guide may be ordered using Catalog Number
8921133701.
END
REVISION DATE PAGES REVISED/ADDED TSBs INCORPORATED ISAs INCORPORATED
Original Issue 9/95 Not Applicable 95-001 through 95-053
97-001 through 97-012
95-001 through 95-029
97-001 through 97-006
Rev B 6/97 Add Chapter 3 Parts List 95-030 through 95-042
97-013 through 97-022 97-006 through 97-020

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 HAZARDS iii
HAZARDS
General Biosafety
WARNING: Potential Biohazard. Consider all clinical specimens and reagent controls that contain
human blood or serum (calibrators, etc.) and contaminated instruments as potentially infectious. Wear
gloves, lab coats, and safety glasses, and follow other biosafety practices as specified in the OSHA
Bloodborne Pathogen Rule (29 CFR Part 1910.1030) or other equivalent biosafety procedures.
Needles
Needles are sharp and potentially contaminated with infectious materials. Avoid any contact with
needles.
Handling spills
Consider all samples, reagents, calibrators, and controls that contain human blood or serum as
potentially infectious. Clean up spills of potentially infectious materials in accordance with established
biosafety practices. A generally accepted procedure for cleaning such spills is to absorb the spill with
toweling or other absorbent material, wipe the area with a detergent solution, and then wipe the area
with an appropriate tuberculocidal disinfectant such as 10% chlorine bleach solution.
Handling Waste and Waste Containers
Dispose of all clinical specimens, reagents, controls, calibrators, standards, cuvettes, and other
disposables that may be contaminated, in accordance with local, state, and federal regulations
governing the treatment of regulated medical waste. Sharps, such as contaminated probes, must be
placed in an appropriately marked, puncture-resistant container prior to treatment and disposal.

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 HAZARDS iv
Decontamination Procedures
The OSHA Bloodborne Pathogen Rule (20 CFR 1910.1030) requires the decontamination of
laboratory equipment prior to servicing or shipment. (Note: see Operations Manual, Section 9, Service
and Maintenance)
Needles
Flush the needles with a disinfectant solution, if possible, or a buffer or water solution used in the
assay system.
Fluid Pathway
Cycle the pathway with a disinfectant solution, if possible, or a buffer or water solution. If during
maintenance or repair the lines will be disconnected or changed, purge the waste reagents out of the
lines.
Instrument Surfaces
Wipe the surface of the instrument with a detergent solution to remove any soiling. Then wipe the unit
down with a hospital disinfectant such as 10% chlorine bleach solution.
Waste Container
Empty and rinse all waste containers with disinfectant or water prior to shipment.
Disposables
Remove all samples, reagents, controls and disposables from the unit prior to shipment.

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 HAZARDS v
Electrical Shock Hazard
WARNING: Electrical Shock Hazard. Basic electrical hazard awareness is essential to the safe
operation of any electrical device. Personnel must practice good habits of electrical safety such as the
following:
• Periodically inspect electrical cabling into and on the system for signs of wear or damage.
• Do not disconnect any electrical connection while the power is on.
• In the event of a blown fuse or thrown circuit breaker, determine and correct the cause before
attempting to resume operation of the equipment.
• Keep liquids away from all connectors of electrical or communication components.
• Keep the floor and countertop dry and clean under and around the system.
Laser Hazard
DANGER: Class 3B Laser System. Avoid direct exposure to beam. Wear approved laser eye
protection and observe procedural controls.
Electrostatic Discharge
Many of the electronic components on the CELL-DYN circuit boards are susceptible to electrostatic
discharge (ESD). To prevent ESD damage, follow these guidelines:
1. Place the static protective work mat on a solid surface close to the instrument. Allow the ground
strap to reach the instrument.
2. Attach the ground clip to the instrument chassis.

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 HAZARDS vi
3. Attach the other end of the ground clip cable and the connector from the wrist strap to the work
mat. (Exception: Some wrist strap cables provide a clip to connect to the same ground source as
the mat cable.)
4. Attach wrist strap to your wrist, make sure the metallic button on the inside of the wrist strap is in
direct contact with your skin.
5. Place PC Boards, removed from the instrument, on the work mat.
6. Replacement PC Boards should be placed on the work mat before removing from the protective
bag and remain on the mat until installation.
Defective PC Boards should be placed in the static-protective bag before removal from the work mat
area.
END

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 How to Identify a CE MARK Loader vii
How to Identify a CE MARK Loader
The previous version of the Guide (ISA 95-049 Attachment) used[NEW] and [OLD] references. These
have been replaced with [CE MARK] and [NON-CE MARK].
To determine if the Loader is CE MARK Certified, look for the CE Label affixed to the front cover near
the Power Input Panel (See ).
If the Loader is CE MARK Certified, follow the [CE MARK] instructions throughout the Guide. Follow
the [NON-CE MARK] instructions for all other configurations.
NOTE:The CE MARK Loader is also referred to as Sample Loader 96 in some ISA/TSB Documenta-
tion.

CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
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28 Oct
1997 20:44 How to Identify a CE MARK Loader viii
Figure i - 1 CE MARK Label Location
END
Power Input
Panel
SL-276
CE MARK
Label

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1 - 1
1
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CHAPTER 1 TABLE OF CONTENTS
1.1 OVERVIEW
1.2 ERROR MESSAGES
1.3 ISOLATION PROCEDURES
IP - 1 Blood Detected In Sample Line
IP - 2 Erratic Results
IP - 3 Mixin
g
Fault
IP - 4 Incomplete Aspiration
IP - 5 No Li
g
hts, Some Other Functions Work
IP - 6 Sample Loader Dead, No Li
g
hts, No
sounds
IP - 7 Alarm 4 (a) Needle Home & Limit Sensors
IP - 8 Alarm 4 (b) X-Axis Home And Limit
Sensors
IP - 9 Alarm 4 (c) Mixin
g
Home And Contact
Sensors
IP - 10 Alarm 4 (d) Mixin
g
Home And Limit
Sensors
IP - 11 Alarm 4 (e and j) Time-out Movin
g
X-Axis
IP - 12 Alarm 4 (f) Time-out Movin
g
Pusher
Y-Axis
IP - 13 Alarm 4 (
g
and k) Time-out Movin
g
Needles
IP - 14 Alarm 4 (h) Time-out Movin
g
Mixin
g
Paddle
IP - 15 Alarm 4 (i) Time-out Movin
g
X-Axis
IP - 16 Alarm 4 (l) Time-out Movin
g
Mixin
g
Paddle
IP - 17 Rack Fault or Alarm 4 (m, n, o, p, q, r)
Rack Sensors
IP - 18 Alarm 4 (s) Sample Tube Not Sensed
Properly
IP-19Covers OpenorAlarm 4 (t)SafetyCover
Removed
IP - 20 Alarm 4 (u) Rack Number Misread
IP - 21 Alarm 1 (v, w, y, z) Communications
Problem
IP - 22 Alarm 2, Mixin
g
Failure
--- END ---

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.1 OVERVIEW 1 - 2
1
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1.1 OVERVIEW
This chapter contains the followin
g
information
for Type E, F, & G Sample Loaders:
• 1.2 Error Messa
g
es
• 1.3 Isolation Procedures (IPs)
Troubleshooting Approach
Troubleshootin
g
is required whenever an
Observed Error or a Displayed Error occurs.
Sample Loader Displayed Errors can be
viewed on the Bulletin Line of the Data Station
screen. (The Bulletin Line is down about 3/4
way on the screen.)
When a malfunction occurs, follow these
recommended procedures:
1. Decontaminate the Sample Loader and the
Analyzer accordin
g
to General Biosafety
Procedure.
2. Use this Troubleshootin
g
Guide as follows:
a. If possible, be
g
in by verifyin
g
the
reported error. Perform the exact pro-
cedure that produced the error condi-
tion.
b. When an error occurs, either observed
or displayed, look up the error in Sec-
tion 1.2, Error Messa
g
es table.
c. Perform the Corrective Action.
d. If directed to an IP, flip pa
g
es while look-
in
g
on ed
g
e of sheets for the desired IP
Number.
e. Turn to pa
g
e 1 of x, and be
g
in at the
START box.
f. Follow the directions in the IP.
g
. If directed to perform a Verification Pro-
cedure (VP), flip pa
g
es while lookin
g
on
ed
g
e of sheets for the desired VP Num-
ber.
h. If a part is adjusted or replaced,
g
o to
Section 3.2, Interrelationship Matrix.
i. Find part in left column.
j. Perform VPs in order
g
iven (i.e. 1, 2, 3,
4, etc.)
3. Perform Total Call.
--- END ---

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.2 ERROR MESSAGES 1 - 3
1
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1.2 ERROR MESSAGES
Table 1 - 1 Error Messages
MESSAGE CORREC- TIVE
ACTION
Alarms Fault Messa
g
eNone
Alarm 1 (v) Last messa
g
e sent to Analyzer was acknowled
g
ed ne
g
atively
(improper format or improper information. IP - 21
Alarm 1 (w) Time-out - CELL-DYN did not Acknowled
g
e last messa
g
e from
Sample Loader. IP - 21
Alarm 1 (x) Analyzer sent F command to Sample Loader, and Sample Loader
responded. None
Alarm 1 (y) Time-out durin
g
aspiration. Sample Loader and Analyzer maybe
out of Sync. IP - 21
Alarm 1 (z) Time-out durin
g
mixin
g
. Sample Loader and Analyzer maybe out of
Sync. IP - 21
Alarm 2 Mixin
g
Failure IP - 22
Alarm 3 Not Used None
Alarm 4 (a) Z Ventin
g
/Samplin
g
Needle’s Ori
g
in and Limit Sensors BOTH ON
at Power-On. IP - 7

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.2 ERROR MESSAGES 1 - 4
1
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Alarm 4 (b) X Ori
g
in and Limit Sensors BOTH ON at Power On. IP - 8
(X Transport Home and Limit Sensors both active durin
g
initialization of Sample Loader.)
Alarm 4 (c) Mixin
g
Paddle’s Ori
g
in and Position Sensors BOTH ON at Power
On. IP - 9
Alarm 4 (d) Mixin
g
Paddle’s Ori
g
in and Limit Sensors BOTH ON at Power On. IP - 10
Alarm 4 (e) X Home Sensor Failure. IP - 11
Time-out in an attempt todrive X-axis mechanism to/from its ori
g
in.
A test performed durin
g
initialization and Run where the particular
mechanism is moved sli
g
htly past a particular sensor then back
and forth several times. The Sensor operation is verified each
time.
Alarm 4 (f) Y Home Sensor Failure. IP - 12
Time-out in an attempt todrive Y-axis mechanism to/from its ori
g
in.
A test performed durin
g
initialization and Run where the particular
mechanism is moved sli
g
htly past a particular sensor then back
and forth several times. The Sensor operation is verified each
time.
Table 1 - 1 Error Messages(continued)
MESSAGE CORREC- TIVE
ACTION

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.2 ERROR MESSAGES 1 - 5
1
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Alarm 4 (
g
) Time-out in an attempt to drive the Ventin
g
/Samplin
g
needle’s axis
mechanism to/from its ori
g
in. IP - 13
Alarm 4 (h) Time-out in an attempt to drive the Mixin
g
Z2-axis mechanism
to/from its ori
g
in. IP - 14
Alarm 4 (i) Time-out in an attempt to drive the X-axis mechanism to its
Slowdown Sensor. IP - 15
Alarm 4 (j) X Limit Sensor Time-out in an attempt to drive the X-axis
mechanism to/from its limit sensor. IP - 11
Alarm 4 (k) Z1 Limit Sensor Time-out in an attempt to drive the
Ventin
g
/Samplin
g
needle’s axis mechanism to/from its ori
g
in. IP - 13
Alarm 4 (l) Time-out in an attempt to drive the Mixin
g
Paddle’s axis
mechanism to its Position Sensor. IP - 16
Alarm 4 (m) Rack-B Sensor did not detect a Rack. IP - 17
Alarm 4 (n) At least 2 Rack Sensors A throu
g
h D not in correct state durin
g
phases of rack rotation. IP - 17
Alarm 4 (o) Rack Sensor A not in correct state durin
g
rotation phase. IP - 17
Alarm 4 (p) Rack Sensor B not in correct state durin
g
rotation phase. IP - 17
Alarm 4 (q) Rack Sensor C not in correct state durin
g
rotation phase. IP - 17
Alarm 4 (r) Rack Sensor D not in correct state durin
g
rotation phase. IP - 17
Table 1 - 1 Error Messages(continued)
MESSAGE CORREC- TIVE
ACTION

28 Oct
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CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.2 ERROR MESSAGES 1 - 6
1
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Alarm 4 (s) Sample Tube not sensed correctly. IP - 18
Alarm 4 (t) Safety Cover removed durin
g
sample processin
g
.IP - 19
Alarm 4 (u) Rack Number Misread. Barcode reader did not properly read a
rack barcode. IP - 20
Autosampler Command Ne
g
atively Acknowled
g
ed Reseat
RS232
Cable At
Both
Ends
And
Restart
Auto Stand-by Mode None
Blood Detected
in Sample Line If system automatically rinses, and error does not recur. None
If "Blood Detected in Sample Line" error displays on bulletin line. IP - 1
If FATAL error displays on bulletin line. Cycle
Power,
then
IP - 1
Check Rack Alarm None
Cover Open IP - 19
Table 1 - 1 Error Messages(continued)
MESSAGE CORREC- TIVE
ACTION

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.2 ERROR MESSAGES 1 - 7
1
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Emer
g
ency STOP Switch Pressed None
End Ma
g
azine (Rack) Detected None
Erratic Results IP - 2
Incomplete Aspiration (or Samplin
g
Error) IP - 4
Laser OFF None
Laser ON None
Manual Mode None
Mixin
g
Fault for 1st pre-mixer on E-Loader, or F-Loader. Mixin
g
1 Overloaded. IP - 3
Mixin
g
Fault for 2nd pre-mixer on E-Loader. Mixin
g
2 Overloaded. IP - 3
Mixin
g
Faults IP - 3
No Li
g
hts on Control Panel - Other Functions Work IP - 5
Pause Executed None
Re-Mixin
g
Off None
Repeat Auto-Run None
Table 1 - 1 Error Messages(continued)
MESSAGE CORREC- TIVE
ACTION

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.2 ERROR MESSAGES 1 - 8
1
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--- END --
Request to Clean Ventin
g
Needle Clean
Ventin
g
Needle
Per
Operator
Manual
Reset Started None
Sample is at Mixin
g
Position None
Sample Loader Dead - No Li
g
hts -No Sound IP - 6
Samplin
g
Error (or Incomplete Aspiration) IP - 4
Start Key Pressed or Initialize started. None
Start: Send Barcode, CKSUM, RACK, Tube Numbers None
Vertical Barcode Number for Dia
g
nostics. DA=Ali
g
nment, DV=Verification None
Table 1 - 1 Error Messages(continued)
MESSAGE CORREC- TIVE
ACTION

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING 1.3 ISOLATION PROCEDURES 1 - 9
1
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1.3 ISOLATION PROCEDURES

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING IP - 1 Blood Detected In Sample Line, 1 of 3 1 - 10
1
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IP - 1 Blood Detected In Sample Line, 1 of 3
Blood in
Line
?
Check for Blood in
Sample Line Near
Blood In-Line
Sensor
1
No
START
From the Data Station Main Menu
- Go to Special Protocols and Press
CLEAN NEEDLE Key
- Check All Tubing, T-Connectors, and
Y-Fittings leading Through SOL #96
and #92 Ending at Waste Chamber
#2
- Check 12" (82.7 kPa) Vacuum Used
for Evacuating Leftover Sample
- Check Diluent Line leading Through
SOL #91 along With 4 PSI (27.6 kPa)
Used to Flush the Line
- Check Vacuum Connection from
Waste Chamber #2 to Sample
Loader Wash Block
YES

28 Oct
1997 20:45
CELL-DYN®3/35 Sample Loader TS Guide 9140234B-June 1997
TROUBLESHOOTING IP - 1 Blood Detected In Sample Line, 2 of 3 1 - 11
1
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IP - 1 Blood Detected In Sample Line, 2 of 3
Problem
Corrected
?
Perform Total
Call
Yes
1
- Turn OFF
Sample Loader
- Reseat CN5 on
CPU Main Bd
- Reseat
Connector on
Blood In-Line
Sensor Bd
- Perform Blood
In-Line Sensor
Check (VP-12.1)
Replace Sample
Line (PL-7.8)
Problem in
Line
?
Pull Sample Line Through
Sensor About 1/2 "
(1.27cm), and Inspect Line
For Dark Spots and Kinks
That Might Cause Error
Yes
No
No
2
Blood
In-Line
Sensor
SL-267