Analyticon Hemolyzer 5 User manual

ServicemanualServicemanual
11

Hemolyzer 5Hemolyzer 5
22
This service manual is intended to give detailed information for service engineers ofThis service manual is intended to give detailed information for service engineers of
Analyticon BAnalyticon B
iotechnologieiotechnologie
s AG Hemolyzes AG Hemolyze
r 5 optical hematolor 5 optical hematolo
gy analyzer.gy analyzer.
All information All information
contained hecontained he
rein is the intellrein is the intell
ectual properectual proper
ty of Analyticon Bity of Analyticon Bi
otechnologies otechnologies
AGAG
and should not be used or reproduced without prior agreement of Analyticon Biotechnologiesand should not be used or reproduced without prior agreement of Analyticon Biotechnologies
AG, the manufactureAG, the manufacture
r.r.
This manual was written with the intention to give the most precise and up-to-date, detailedThis manual was written with the intention to give the most precise and up-to-date, detailed
description of operation and use of the description of operation and use of the
analyzer for laboratory purposes.analyzer for laboratory purposes.
Despite careful revision and multiple grammar and content control, mistakes can still beDespite careful revision and multiple grammar and content control, mistakes can still be
present in this manual. Analyticon may from time to time issue errata, or a new revision ofpresent in this manual. Analyticon may from time to time issue errata, or a new revision of
the manual. Would you find tthe manual. Would you find t
hings unclear, please contacthings unclear, please contact
[email protected][email protected]
for assistance.for assistance.
User’s manual contains important information about the operation and measurementUser’s manual contains important information about the operation and measurement
principles of Hemolyzer 5. Specifications, definition of parameters and user interface are alsoprinciples of Hemolyzer 5. Specifications, definition of parameters and user interface are also
described therein, consequently Service manual does not contain these data.described therein, consequently Service manual does not contain these data.
Use of the Service manual assumes knowledge of the information contained in the User’sUse of the Service manual assumes knowledge of the information contained in the User’s
manual.manual.
AnAn
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AGAG
Technical Support TeamTechnical Support Team

ServicemanualServicemanual
33
TaTa
ble of ble of
ContentsContents
TABTAB
LL
E OF E OF
CONTENTS CONTENTS
......................................................................................................
..........................................................................................................................
.......... 3.......... 3
11
INTRODUCTION .....................................................................................INTRODUCTION .....................................................................................
........................................ ........................................
88
1.11.1
WW
HO SHOULD READ THIS MANUALHO SHOULD READ THIS MANUAL
........................................................................................................................................
........................... ...........................
88
22
FOR YOUR FOR YOUR
SAFETSAFET
Y ..............................................................................Y ..............................................................................
........................................ 9........................................ 9
2.12.1
SS
PECIALPECIAL
SS
YMBOLSYMBOLS
UU
SEDSED
II
NN
TT
HISHIS
MM
ANUALANUAL
.................................................................................. 9.................................................................................. 9
2.22.2
GG
ENERALENERAL
PP
RECAUTIONSRECAUTIONS
....................................................................................................................................................................................
.................. ..................
99
2.32.3
EE
NVIRONMENTALNVIRONMENTAL
FF
ACTORSACTORS
...................................................................................................... 10...................................................................................................... 10
2.42.4
EE
LECTRICALLECTRICAL
RR
EQUIREMENTSEQUIREMENTS
..........................................................................................................
............................................... ...............................................
1111
2.52.5
SS
UGGESTED ONUGGESTED ON
--
LINELINE
UPS .............................................................................UPS .............................................................................
.......................... ..........................
1111
2.62.6
PP
ROPERROPER
PP
LACEMENT OFLACEMENT OF
HH
EMOLYZEREMOLYZER
5 .....................................................................5 .....................................................................
............... ...............
1212
2.72.7
WW
EIGHTEIGHT
RR
EQUIREMENTSEQUIREMENTS
..........................................................................................................................................
..................................... .....................................
1212
2.82.8
WW
ASTEASTE
DD
ISPOSALISPOSAL
..................................................................................................................................................................................
........................... ...........................
1313
2.92.9
EE
MERGENCYMERGENCY
SS
ITUATIONSITUATIONS
..............................................................................................................................................................
.......................... ..........................
1313
33
STRUCTURE OF THE ANALYZER.............................................................................................. 14STRUCTURE OF THE ANALYZER.............................................................................................. 14
3.13.1
CC
OMPONENTS LOCATED ON THE FRONT PANELOMPONENTS LOCATED ON THE FRONT PANEL
.......................................................................... 14.......................................................................... 14
3.1.13.1.1
Display screen and Display screen and
the touch sensitive the touch sensitive
surface .....................surface .....................
........................................... ...........................................
1414
3.1.23.1.2
Start Start
Button Button
and LEand LE
Ds Ds
................................................................................................................
............................................... 15............................................... 15
3.23.2
CC
OMPONENTS ACCESSIBLE AFTER OPENING THE FRONT OMPONENTS ACCESSIBLE AFTER OPENING THE FRONT
PANELPANEL
.................................................. 15.................................................. 15
3.2.13.2.1
Shear VaShear Va
lve Assembly lve Assembly
..............................................................................................................
............................................... 15............................................... 15
3.2.23.2.2
Sample Sample
rotor ......................................................................rotor ......................................................................
................................................ 15................................................ 15
3.2.33.2.3
Main Main
Dilutors .........Dilutors .........
..........................................................................................................................
................................................ 16................................................ 16
3.2.43.2.4
Dilutor opto seDilutor opto se
nsor boards ................................................................................................ 17nsor boards ................................................................................................ 17
3.2.53.2.5
Tube Tube
organizer..............................................................................organizer..............................................................................
..................................... 17..................................... 17
3.2.63.2.6
Temperature Temperature
Control Control
Unit ......................Unit ......................
........................................................................................................................
................ 17................ 17
3.2.73.2.7
Laser Laser
head ............head ............
..........................................................................................................................
................................................ 18................................................ 18
3.2.83.2.8
Laser Head Laser Head
Assembly + Assembly +
Sample Injector .............................................................Sample Injector .............................................................
............. 19............. 19
3.2.93.2.9
Laserdiode Laserdiode
Driver Driver
Board Board
............................................................................................................
.............................................. 20.............................................. 20
3.2.103.2.10
Pin Photodiode anPin Photodiode an
d Amplifier (OPTd Amplifier (OPT
SENSOR_2v1) ............SENSOR_2v1) ............
.......................................... ..........................................
2020
3.33.3
LL
EFT SIDEEFT SIDE
..........................................................................................................................................
........................................................... ...........................................................
2121
3.3.13.3.1
Valve Valve
boards .........boards .........
..........................................................................................................................
................................................ 21................................................ 21
3.3.23.3.2
WBC/BASO WBC/BASO
Preheater Preheater
Assembly Assembly
..........................................................................................................................
......................... 22......................... 22
3.3.33.3.3
Counting chamber Counting chamber
with electrodes with electrodes
and measuring and measuring
aperture aperture
............................................. .............................................
2222
3.3.43.3.4
HGB Measuring HGB Measuring
Head .................................................................................................Head .................................................................................................
...... 23...... 23
3.3.53.3.5
Cell counCell coun
ter ter
Amplifier Amplifier
Board Board
....................................................................................................................
.................................... 24.................................... 24
3.3.63.3.6
Pressure Pressure
sensor boarsensor boar
d ........................................................d ........................................................
.............................................. 25.............................................. 25
3.3.73.3.7
Reagent Reagent
and and
Vacuum Vacuum
buffers buffers
................................................................................................................
.................................... 26.................................... 26
3.3.83.3.8
Reagent Reagent
Sensor Sensor
Board ....................................Board ....................................
........................................................................................................................
...... 27...... 27
3.3.93.3.9
Opening the Opening the
valve assembly valve assembly
plate............................................................plate............................................................
......................... 27......................... 27
3.3.103.3.10
Vacuum Vacuum
buffer ..............................................................................................buffer ..............................................................................................
................. 27................. 27
3.3.113.3.11
Pneumatic and Power Pneumatic and Power
Boards (PPBoards (PP
B1 and PPBB1 and PPB
2) 2)
............................................................................................................
... 28... 28
3.3.123.3.12
Pump Pump
assembly ...............................................................assembly ...............................................................
.............................................. 29.............................................. 29
3.43.4
RR
IGHT SIDEIGHT SIDE
..................................................................................................................
..........................................................................................................................
........ ........
3030
3.4.13.4.1
XY XY
unit .....................................................................unit .....................................................................
.......................................................... 30.......................................................... 30
3.4.23.4.2
XYROpto XYROpto
Board ...................................Board ...................................
..........................................................................................................................
................. 31................. 31
3.4.33.4.3
Sampling Sampling
needle ..................................needle ..................................
..........................................................................................................................
................. 31................. 31
3.4.43.4.4
Blood Blood
sensor .........sensor .........
..........................................................................................................................
................................................ 31................................................ 31
3.4.53.4.5
Wash Wash
head head
........................................................................................................
..........................................................................................................................
........ ........
3232
3.4.63.4.6
Processor unit (LProcessor unit (L
S-DACQ board with S-DACQ board with
DimmBoard) .......................................................... DimmBoard) ..........................................................
3232
3.4.73.4.7
Mini-ITX PC motMini-ITX PC mot
her board (In her board (In
Hardware block) .........................................Hardware block) .........................................
....................... 37....................... 37
44
ELECTRONIC BLOCK DIAGRAM ............................................................................................... 38ELECTRONIC BLOCK DIAGRAM ............................................................................................... 38
4.14.1
HH
ARDWAREARDWARE
BB
LOCKLOCK
......................................................................................................................................................................................................................
....... .......
3838
4.24.2
DD
ATAATA
AA
CQUISITIONCQUISITION
UU
NITNIT
......................................................................................................................
............................................... 40............................................... 40
4.34.3
AA
MPLIFIER BOARDMPLIFIER BOARD
............................................................................................................................................................
...................................... ......................................
4242

Hemolyzer 5
4
4.4
O
PTICAL
H
EAD
.....................................................
............................................................
........
43
5
OPERATION
OF THE
FLUIDIC
SYSTEM
...........................................................
......................... 44
5.1
T
HE
R
EAGENT SYSTEM
................................
............................................................
.................
44
5.2
F
LOW DIAGRAM OF
MEASUREMENT
........................................................
....................................
45
5.3
I
NITIALIZATION OF THE
F
LUIDIC
S
YSTEM
.................................................................................... 47
5.4
R
EAGENTS PRIMING
................................................................................................
.................
47
5.5
P
IERCING PROCESS
........................................................
......................................................... 47
5.6
S
AMPLING PROCESS
.......................................................
......................................................... 47
5.7
N
EEDLE WASHING PROCESSES
................................................................................................. 48
5.8
D
ILUTING PROCESSES
.........................................................................
.....................................
48
5.9
L
YSING PROCESS
.....................................................................
................................................
48
5.10
RBC
COUNTING PROCESS
...................................................................
.....................................
49
5.11
WBC/BASO
COUNTING
.................................................................................
..........................
49
5.12
WBC
4D
IFF COUNTING
...................................................
......................................................... 49
5.13
C
HAMBER DRAINING PROCESSES
...............................................................................
...............
50
5.14
C
LEANING
(
RINSING
)
PROCESSES
............................................................................................. 50
5.15
S
TANDBY PROCESS
..............................................
.............................................................
.......
50
5.16
W
AKE UP PROCE
SS
........................................................
..........................................................
51
5.17
S
HUTDOWN PROCESS
.....................................................
......................................................... 51
6
ADJ
USTMENTS
.......................................................
.............................................................
........ 52
6.1
XY
UNIT MECHANICAL ADJUSTMENTS
.....................................................
................................... 52
6.1.1
XY horizonta
l movement
.....................................................
.............................................. 52
6.1.1.1
Greasing the horizontal rods
..............................................................
..................................... 52
6.1.1.2
Set opto
flags for horizontal
movement
.........................................................
.......................... 53
6.1.2
XY
vertical
adjustment
........................................................
............................................... 55
6.1.2.1
Basic operation ....................................................................................................................... 55
6.1.2.2
Adjusting the needle’s vertical position
.........................................................
.......................... 56
6.1.3
Washing
head settings ...................................................................................................... 56
6.1.4
Needle
setting .................
.............................................................
...................................... 57
6.1.4.1
Handmade setting
...................................................................
................................................ 57
6.1.4.2
Software made setting ............................................................................................................ 58
6.2
S
HEAR VALVE MECHANICAL SETTING
..........................................................................
...............
58
6.2.1
Shear valve lower
disc position setting
.....................................................
........................ 59
6.2.2
Shear valve
upper disc
setting .................................................................
......................... 59
6.2.3
Setting the opto
sensors of
the shear valve. ........................................................
............. 61
6.3
A
MPLIFIER OFFSET SETTING
.......................................................
.............................................. 62
6.4
B
LOOD SENSOR CALIBRATION
.........................................................................
..........................
63
6.5
S
AMPLE POSITION SETTING
....................................
.............................................................
......
65
6.6
P
RESSURE SENSOR ADJUSTMENT
........................................................................................
.....
66
6.7
S
ET SERIAL NUMBER
.........................................................................................................
.......
67
6.8
WBC
PREHEATER
....................................................................
................................................
67
6.9
S
ETTING
L
ASER VALUES
............................................................
...............................................
67
6.9.1
Calibration procedure
of optical
heads
......................................................
........................ 67
6.9.2
Short
guide for
laser
values
...........................................................
.................................... 71
7
VERIFICATION
PROCEDURES
.....................................................
.............................................. 74
7.1
S
ELF
-
TEST
..........................................................
.............................................................
........
74
7.1.1
Hemolyzer 5
Self-Test Guide ............................................................................................ 75
7.1.1.1
General information ................................................................................................................ 75
7.1.1.2
Electronic Self-Test parameters
.........................................................
.....................................
75
7.1.1.3
Pneumatic Self-Test parameters
...................................................................
.......................... 77
7.2
E
RROR
M
ESSAGES
.................................................................................................
.................
79
7.3
S
ERVICE
M
ENU
....................................................
............................................................
........
84
7.3.1
Service
functions ....................................................................................
........................... 86
7.3.1.1
Test functions
...............................................................
...........................................................
87
7.3.1.2
Low level file management...................................................................................................... 87
7.3.1.3
Low level reboot
(DimmBoard)
...........................................................
..................................... 87
7.3.1.4
Pneumatical System – Initialize .............................................................................................. 87
7.3.1.5
Network management
.............................................................
................................................
88
7.3.1.6
RAW data saving mode .......................................................................................................... 88

Servicemanual
5
7.3.1.7
Export RAW files
..........................................................
...........................................................
88
7.3.1.8
Windows Control Status
..........................................................
................................................
88
7.3.1.9
TCU fill/drain ........................................................................................................................... 88
7.3.1.10
Flow cell fi
ll/drain
..........................................................
...........................................................
88
7.3.1.11
Blood sensor status ................................................................................................................ 88
7.3.1.12
Reset statistics
.............................................................
...........................................................
88
7.3.1.13
Hard drive maintenance
..........................................................
................................................ 88
7.3.1.14
Show advanced DB view
...................................................................
..................................... 88
7.3.1.15
Small sample mode ................................................................................................................ 89
7.3.1.16
Pre-diluted mode
..........................................................
...........................................................
89
7.3.1.17
Monitoring ............................................................................................................................... 89
7.3.2
Service
testing ...................................................................
................................................ 89
7.3.3
Service
calibration ..................................................................................
........................... 90
7.3.3.1
Enable scatter calibration
...................................................................
..................................... 90
7.3.3.2
Backup Calibration
..................................................................
................................................
90
7.3.3.3
Restore Calibration ................................................................................................................. 90
7.3.3.4
Load Calibration
...........................................................
...........................................................
90
7.3.3.5
Accept User factor
s
.................................................................
................................................ 91
7.3.3.6
Back
..................................................................
..................................................................
.... 91
7.3.3.7
Accept
...............................................................
..................................................................
.... 91
7.3.4
Stress
measure..................................................................
................................................ 91
7.3.5
Auto alignment
.........................................................
..........................................................
92
7.3.6
AS (Auto-sampler) ..
............................................................
...............................................
92
7.3.6.1
Go to Pos ................................................................................................................................ 92
7.3.6.2
Reset ...................................................................................................................................... 92
7.3.6.3
Repeat last command ............................................................................................................. 92
7.3.6.4
Go To Mixer ............................................................................................................................ 92
7.3.6.5
Load to sampling position ....................................................................................................... 92
7.3.6.6
Set up Barcode Reader .......................................................................................................... 93
7.3.7
Adjustments
.............................................................
..........................................................
93
7.3.8
Multiuser
Settings ...............................................................
............................................... 94
7.3.9
MDA
view
......................................................
.............................................................
........
94
7.3.10
Software
upgrade ..........................................................................................
................ 95
7.3.10.1
Refresh data ........................................................................................................................... 95
7.3.10.2
Change High Level software
..............................................................
..................................... 95
7.3.10.3
Change Low level software
................................................................
..................................... 95
7.3.10.4
Change Low level boot ........................................................................................................... 95
7.3.10.5
Change LSDACQ firmware
................................................................
..................................... 95
7.3.10.6
Change Optical Head
Firmware
.........................................................
..................................... 95
7.3.10.7
Change TCU software ............................................................................................................ 95
7.3.10.8
Change AutoSampler software
..........................................................
..................................... 95
7.3.11
Reagent
Lock
........................................................
......................................................... 96
7.3.12
QC
Wizard ................................................................................
..................................... 97
7.3.13
Printer
installation ............................................................
.............................................. 97
7.3.14
Factory
Settings .
.............................................................
............................................... 97
7.3.15
Service mod
e OFF......................................................................................................... 97
7.4
S
OFTWARE SYSTEMS
......................................................
......................................................... 98
7.5
G
ENERAL
SW
INSTALLATION GUIDE
.......................................................................................... 98
7.5.1
Install operating system
Windows 2.0
install using pendrive ..........................................
100
7.5.2
Installing
a
Printer ............
.............................................................
................................... 104
8
INSTALLATION .......................................................................................................................... 105
8.1
C
HECK THE
D
ELIVERY
...............................................................
.............................................
105
8.2
P
REPARE
F
OR
I
NITIAL
I
NSTALLATION
.................................
......................................................
105
8.2.1
Select a
Suitable Locat
ion .
............................................................
.................................. 105
8.2.2
Make Any
Special Ar
rangements ...............................
..................................................... 105
8.2.3
Gather
Your
Peripherals D
evices
.............................................................
....................... 106
8.3
P
ERFORMING THE
I
NSTALLATION
...........................................................
..................................
106
8.3.1
Move the ‘Hemolyzer
5’ to the
Selected Location ......................................
..................... 106
8.3.2
Visual
Inspection................................................................
.............................................. 106
8.3.3
Remove the Protective Card from t
he Shear Valve ........................................................
106
8.3.4
Connect
the
Optional
Auto-Sampler
.........................................................
....................... 107
8.3.5
Connect
the
Reagents
........................................................
............................................. 107
8.3.6
Connect the
Power Cord .............................................................................................
.... 108

Hemolyzer 5
6
8.3.7
Verify the
‘Hemolyzer 5’
Computer Operat
ion
......................................................
........... 109
8.3.8
Connect
Peripherals ...........................................................
............................................. 109
8.3.9
How to
install a
printer .......
............................................................
.................................. 110
8.3.10
Initializing the
Optional Aut
osampler .............
............................................................
.. 110
8.3.11
Using the
Settings Menu ............................................................................................. 112
8.3.12
Set Up a Laboratory I
nformation System (LIS) ...........................................................
112
8.3.13
Set Up
a Serial
LIS Connection
............................................................
....................... 113
8.3.14
Set Up an
Ethernet LIS
Connection ............................................
................................ 114
8.3.15
Running Blank Samples and Blood Samples for the First Time ................................. 114
8.4
C
HECKLIST FOR INSTALLING
H
EMOLYZER
5
HEMATOLOGY ANALYZER
..............................
..........
115
9
TROUBL
ESHOOTING .....................................
............................................................
............... 117
9.1
T
ROUBLESHOOTING CHECKLIST FOR
H
EMOLYZER
5
HEMATOLOGY ANALYZER
.........................
.........
117
9.1.1
Visual
inspection ....
............................................................
.............................................. 117
9.1.2
Powering up
the system ....................................................................................
.............. 118
9.1.3
Checking the
software adjustments................................................................................. 118
9.1.4
Checking the
Hardware adjustments............................................................................... 119
9.1.5
Run
a
Self-test .................
.............................................................
................................... 120
9.1.6
Run Blank
measurements .............................................................
.................................. 120
9.1.7
Run
Control
measurements
...........................................................
.................................. 121
9.2
M
ECHANICAL PROBLEMS
........................................................................................................ 122
9.2.1
General guidelines to overcome
motor or moving part r
elated problems .......................
122
9.2.2
Sample Rotor
(SR or
BOB) failures
..........................................................
....................... 123
9.2.2.1
SR gives grinding noise and
/ or SW displays SR error messages
....................................... 123
9.2.2.2
SR error appears during initialization
process:
...................................................................... 123
9.2.2.3
The SR does not
turn into the anal
yzer even with open front panel
...................................... 123
9.2.3
Needle mechanics,
Vertical motor
(MVert)
problems
.....................................................
. 123
9.2.3.1
The needle
carriage keeps dropping back
(down) at initialization
.........................................
123
9.2.3.2
MVert cannot reach
the optosensor (Up or
Down)
..............................................................
.. 123
9.2.4
Shear Valve (
SV) related er
rors .....................................................
................................. 124
9.2.4.1
SV error at the
first startup
.................................................................
................................... 124
9.2.4.2
Grinding noise after SV cleaning, (after SV reinstallation) .................................................... 124
9.2.4.3
SV leakage............................................................................................................................ 124
9.2.5
Dilutor
errors .................................................
.............................................................
...... 125
9.2.5.1
Dilutor is making noise
............................................................
.............................................. 125
9.2.5.2
Dilutor is l
eaking
...........................................................
.........................................................
125
9.2.6
A tube comes off of a valve .........
............................................................
........................
125
9.2.7
Priming
problems ...
............................................................
.............................................. 125
9.2.7.1
The analyzer would not prime
liquids
............................................................
........................ 125
9.3
E
LECTRONICS RELATED PROBLEMS
...................................
......................................................
126
9.3.1
Touch screen
/ display
errors .....................................
.....................................................
126
9.3.1.1
No image on display ............................................................................................................. 126
9.3.1.2
Touch sensitive surface not working
.............................................................
........................ 126
9.3.1.3
Touch (click) is inaccurate..................................................................................................... 126
9.3.1.4
Screen image is not n
ormal, some parts of the software
screen is not visible
...................... 126
9.3.2
Communication er
rors .............................................................................
........................ 127
9.3.3
The analyzer
does not
power on ....................................................
................................. 127
9.3.4
I
2
C errors
displayed at
startup .........................
.............................................................
... 128
9.4
U
SEFUL INFORMATION AND TIPS
..............................
............................................................
....
128
9.4.1
High
PLT
background .......
............................................................
................................... 128
9.4.2
Fast Starting up
and Shutting
down .....................................
...........................................
128
9.4.3
Removing bubbles from
the Flow cell.............................................................................. 128
9.4.4
Removing the
DimmBoard ..........................................................................................
.... 129
9.4.5
Listen the sounds
of the ins
trument ..............................................................................
.. 129
9.4.6
Replacing small di
ameter tubes ......................................................................................
129
9.4.7
Swapping
the
pumps ............................
............................................................
............... 129
9.4.8
Draining the
reservoirs ................................................................................................
.... 129
10
MAINTEN
ANCE ......................................................................................
.................................... 130
10.1
U
SER MAINTENANCE
.......................................................
....................................................... 130
10.1.1
Daily
maintenance ...........................................................
............................................ 130
10.1.2
Weekly
maintenance .................................................................
.................................. 130

Servicemanual
7
10.1.2.1
Shear Valve cleaning ............................................................................................................ 130
10.1.2.2
Cleaning the wash head ....................................................................................................... 130
10.2
P
REVENTIVE
M
AINTENANCE
........................................................
............................................
130
10.3
F
LOW CELL CLEANING
.....................................................
....................................................... 136
11
REMOVAL
AND REPL
ACEMENT
PROCEDURES
.......................................................
............ 139
11.1
O
PENING THE INSTRUMENT
........................................................
.............................................
139
11.2
S
HEAR
V
ALVE
A
SSEMBLY
..........................................................
.............................................
140
11.3
XY
U
NIT
.................................................................................
...............................................
141
11.4
S
AMPLE
R
OTOR
.............................................................
........................................................
144
11.5
D
ILUTORS
.................................................
.............................................................
................
145
11.5.1
Syringe
replacement
........................................................
............................................ 145
11.6
TCU
M
ODULE
............................................
............................................................
................
146
11.7
V
ALVE BLOCK
......................................................
............................................................
......
147
11.8
P
RE
-A
MPLIFIER
B
OARD
.............................................................
.............................................
148
11.9
P
UMP
A
SSEMBLY
..........................................................................................
.........................
148
11.10
H
ARDWARE
M
ODULE
.........................................
............................................................
.....
150
11.11
L
ASER
H
EAD
A
SSEMBLY
..............................................
.......................................................
151
11.11.1
Reinstalling the L
aser Head: .......................................................................................
154
11.12
M
EASURING
B
LOCK
...........................................
............................................................
.....
154
11.12.1
Aperture removal:
............................................................
............................................
154
11.12.2
WBC
aperture
removal: ...............................
.............................................................
... 155
11.12.3
Measuring Chamber
removal: ....................................................
................................. 155
11.12.4
HGB he
ad r
emoval .....................................
.............................................................
.... 156
11.13
D
ISPLAY UNIT
.............................................................
........................................................
156
11.14
H
EMOLYZER
5
F
LUIDICS V
2.1
-
SV
IN
C
HAMBER
P
OSITION
................................................... 158
11.15
H
EMOLYZER
5
F
LUIDICS V
2.1
-
SV
IN
N
EEDLE
P
OSITION
.................................
.....................
159
11.16
T
UBINGS
.....................................
.............................................................
..........................
160
12
APP
ENDIX .......................
............................................................
...............................................
171
12.1
R
ECOMMENDED KIT OF TOOLS
............................................................................................
....
171
12.2
H
OW TO SEND
.
RP FILES TO
ASSESSMENT OF ANALYZER PERFORMANCE
................................... 171
12.3
H
OW TO USE THE
„C
OLLECT
”
FUNCTION OF THE
H
EMOLYZER
5
HEMATOLOGY ANALYZER
........... 172

Hemolyzer 5
8
1 INTRODUCTION
1.
1
Who
sho
uld rea
d
this manual
This Service manual is intended for trained technicians or service engineers to be able to
maintain and repair Hemolyzer 5 automated hematology analyzer. It contains the functional
descriptions of the analyzer, operation of the f
luidic system, adjustments and settings, and
very important information for the Service Personnel about the service operations and
possible problems.
If e
quipm
ent opera
tion is di
fferent from the manufacturer’s specific
ations
and intended use,
the protecti
on prov
ided by the equipment may be
impaired.
Misuse of equipment or use other than its intended purpos
e
will i
nvalidate
condit
ions of w
arranty. Accuracy and precision may also be impaired.
Follow the service procedures describ
ed here
in to g
uarantee
funct
ional
operation after
repa
irs
and maintenance.

Servicemanual
9
2
For
Your
Sa
fety
2.1
Special S
ymbo
ls Used
In
This M
anual
Label
Meaning
Explanation
Biohazard
Blood samples and analyzer waste are potentially infectious
materials.
Corrosive
Reagents
may
cause
corrosion
or
skin
irritation.
Warning
General
warning
of
possible
hazard
conditions.
Sharp
needle
warning
The
sampling
needle
may
be
a
hazard
to
the
operator.
2.2
Ge
neral
Precautio
ns
The sampling needle and other components inside the analyzer may cause injury, or can
get damaged if handled incorrectly. Only certified personnel should open the covers.
Running measurements with opened cover is not recommended due to the risk of
possible injury. Always wear safety gloves while performing maintenance act
ions.
The analyzer weighs 35kg (~77lbs). Please do not attempt to move it alone. The analyzer
should always be moved by two persons holding the analyzer by its sides in an upright
position.
Always use safe lifting procedures when lifting t
he analyzer.
Make sure to retain the original packaging material for safe transportation and storage in
the future.
To prepare the analyzer for shipping, storage or extended periods of inactivity, please
drain the reagents and repackage the Hemolyzer 5 in its original packaging. Do not
expose the Hemolyzer 5 to direct
sunlight, extreme temperature or humidity (>80%).
The analyzer operates with chemically and biologically active reagents. Physical contact
with these reagents should be avoided. Please read reagent descriptions carefully for
possible emergency actions.

Hemolyzer 5
10
To ensure reliable operation and reliable
results:
•
Only genuine Analyticon reagents should
be used
•
Required service maintenance should be performed as recommended in t
his
manual
•
Only genuine Analyticon service materials and spare parts should be used for
repairs
Genuine reagents
and service materials and spare parts are
available from Analyticon.
Only Analyticon certified service personnel that have successfully completed the
‘Hemolyzer 5 Service Training’ program are
qualified to service the Hemolyzer 5 analyzer.
Before operating Hemolyzer 5 analyzer, all operators should complete an ‘Hemolyzer 5
Operator Training’ program. This program is offered by Analyticon or by Analyticon
certified service personnel.
Replacement materials or spare parts (tubes, valves, etc.) which might have been in
contact with human blood or reagents should be handled as a potentially biologically
hazardous and chemically dangerous material. All applicable laws and regulations must
be observed in the handling and
disposal of these materials.
Hemolyzer 5 is designed for laboratory operation. Mobile operation is not supported.
Operate Hemolyzer 5 within the ambient temperature range described in User Manual
section 2.4.
The IVD equipment complies with the emission and immunity requirements described in
relevant part of the IEC 61326
series.
This equipment has been designed and tested to CISPR 11 Class A. In a domestic
environment it may cause radio interference, in which case, you may need to take
measures to mitigate the interference.
Electromagnetic environment should be evaluated prior to operation
of the device.
This analyzer contains electronic components. Please handle electronic waste
adhering to local or federal regulations.
CAUTION – Use of controls or adjustments or perfomance of procedures other than
those specified herein may result hazardous radiation exposure.
2.
3
Environ
mental
Fa
cto
rs
Operate Hemolyzer 5 within the ambient temperature range of 15-30°C (59-86°F) and a
relative humidity range of 10% - 80%. Optimum operating temperature is 25°C (77°F).
Hemolyzer 5 should be stored within the temperature range of 5-35°C (41-95°F). Avoid
exposing the analyzer to direct sunlight or to extreme high or low temperatures. If the
analyzer was subjected to extreme temperatures during shipment or storage, it
must be

Servicemanual
11
placed for at least two hours in a room whose temperature is within the operational range
before installation or use.
Reagents should be stored at a temperature range of 15-30°C (59-86°F). Reagents may
experience a temperature range of at most 5-35°C (41-95 °F) for a maximum of 3 days.
The analyzer should be placed in a well-ventilated location. Operation at an altitude above
2000 meters (6560 ft)
is not guaranteed.
2.4 Elect
ri
cal
Re
qui
rements
The analyzer should only be operated from a wall outlet meeting these power input
requirements:
•
100-127VAC
or
200-240VAC;
47Hz
to
63Hz
•
Power
Consumption: maximum
400
VA
(including pow
er
of
the
auto-sam
pler)
Please ensure that the wall outlet is also capable of supplying the power consumption of any
additional devic
es (such as
a printer).
Use only the power cord supplied with the instrument. Avoid using extension cords.
Hemolyzer 5 comes with a power cord appropriate for your power system. Proper use of the
appropriate power cord assures adequate grounding of the system. If the power is not
reliable, contact your representative for options such as the
installation of an external UPS
module.
Failure to properly ground the Hemolyzer 5 bypasses important safety features
and may result in electrical hazard.
The instrument should not be placed near potentially interfering devices capable of emitting
radio frequencies (e.g. radio or
televisio
n t
ransmitters/recei
vers, radars, centrifuges, X-ray
devices, fans, etc.).
This analyzer is designed to be
safe for transient voltages to I
NSTALLATION CATEGORY II
and POLLUTION DEGREE 2.
2.5
Suggest
ed
on-l
ine
UP
S
It is recommended to use a UPS (uninterruptible power supply) in line with the power input in
the f
ollowin
g
circumstanc
es:
•
if
the
main
power
is
fluctuat
ing
•
in
case
of
power
black
out
happens
frequent
ly
Power consumption of the analyzer and optional Auto-sampler is 400VA max. If there is a
power failure, the analyzer should be able to complete the function in progress and perform a
Windows shut-down to secure data.
In order to provide the necessary power, it is recommended to use a UPS with the following
minimum specifications: 600 VA provides uninterrupted power for 10-15 minutes.

Hemolyzer 5
12
Analyticon does not supply UPS for Hemolyzer 5. Therefore, Analyticon is not taking
responsibility or liability for the operation of Hemolyzer 5 running on UPS.
If you need further information, please, contact
technical support of the UPS v
endor.
2.6
Prop
er
Placement
of He
mol
yze
r 5
It is
important to install the instrument in
a suitable location, a poor location can adversely
affect its
performance
:
•
Select a
well-ventilat
ed
location near
a
power
source and
close
to a
suitable drain.
•
Place the
unit on
a clean,
level surface. Leave
at least
0.5 m
(18 inches)
space on
both sides and above the instrument to access pneumatics.
•
A minimum
of 0.2
m (8
inches) must be
maintained between the
rear panel
and the
wall to allow for heat dissipation and tubing clearance.
•
Ensure the
re is en
ough c
learance
in front o
f the an
alyzer to
open
front panel
. Allow
enough space if you want to use optional external keyboard, mouse or bar code
reader.
•
Your
selected location
should
allow
placement of
the
reagents in
an
unobtrusive
location below the laboratory bench that the instrument is placed on. Placement
below the laboratory bench also allows for storage of a spare set of reagents. Never
place the reagents above the Hemolyzer 5
analyzer.
Placing reagents above the Hemolyzer 5 analyzer could result in reagent overflow and
spilling.
Always put the diluent tank on the floor, never to the same level where the analyzer is.
1. Figure: Spacing of Hemolyzer 5 with Auto-Sampler and reagents
2.7
We
ig
ht
Re
qui
rements
Hemolyzer 5 weighs 35 Kg (77 lb) without the Auto-sampler.

Servicemanual
13
Hemolyzer 5 with optional Auto-sampler weighs 47Kg (104 lb). Adding an external keyboard,
printer, documents, etc. can bring the total weight up to 60 Kg (132 lb).
Please select a table, laboratory shelf, or other location which can support the weight of the
Hemolyzer 5 with all accessories and it
is free from
vibration.
To allow reliable operation and to provide a safe working environment, make sure that
the table supporting the unit is stable enough to carry the weight of the instrument and
accessories.
2.8
Wa
st
e
Dispo
sal
Waste of Hemolyzer 5 analyzer contains human blood and reagents that are chemically and
biologically active, and should be considered to be a potential infection and biohazard threat.
Safe laboratory practices must be followed including the use of personal protective when
operating Hemolyzer 5 and handling blood, reagents, and waste.
System waste should be handled as a potentially bio hazardous material. All
applicable laws, regulations, and laboratory practices should be followed in the
handling and disposal of waste.
2.
9
Eme
rgency
Situation
s
Always follow
all applicab
le laws and regu
lations wi
th regards to emerge
ncy situations.
If Hemolyzer 5 needs to be powered off due to an emergency situation (like fire,
thunderstorm, etc.), follow the procedures in User Manual section 7.3.4.
In case of fire, do not use water to extinguish the fire unless Hemolyzer 5 is disconnected
from the electrical network!

Hemolyzer 5
14
3
S
tru
ctu
re
of the
a
nalyze
r
Please, refer to the User’s manual for details on opening the front and side covers, and parts
contained there.
3.
1
Components located
on the
fro
nt pa
nel
The display panel and related components are covered with a metal plate, to avoid electronic
interference causing problems, and to
protect sensitive electronics.
3.
1.
1
Display
scr
ee
n
and
the
touc
h
sensiti
ve
sur
face
Hemolyzer 5 uses a color LCD with LED backlight touchscreen as main user interface.
The built-in touchscreen is a 4 wire resistive type. It is interfaced to the mainboard by a USB
controller.

Servicemanual
15
3.
1.
2
Start
Butt
on
and
LEDs
START Button board is mounted on the front panel. It contains a start
button and two LEDs
to illuminate the START button. The LEDs are bicolor: red and green LEDs. When both red
and green are switched on, the resultant color is yellow.
3.
2
Components accessibl
e
after
opening the
fro
nt pane
l
3.2
.1
Shear
Valve
Ass
embl
y
Shear
Valve
assembly
consists
of
the
following
parts:
•
Shear
Valve
holding
plate,
•
Moving
mechanism,
•
Stepper
motor,
•
Ceramic
Shear
Valve,
•
Shear
Valve
optoboard.
3.2
.2
Sample
ro
tor
Hemolyzer 5 hematology analyzer has a sample rotor for safety and more precise sample
handling.

Hemolyzer 5
16
Sample rotor unit uses a stepper motor, connected to the PPB through the XY opto board.
The rotor has micro switches for positioning.
The unit blocks itself in the home and end position with mechanical parts and has a special
cap that prevents the
damage of the electronic and mechanic parts caused by any f
luid.
Tube adapter
Micro switches for positioning
3.2
.3
Main
Dilu
to
rs
Hemolyzer 5 has two separate main dilutor modules. There are
two stepper motors, a
common motor opto board, four syringes and
piston rods with gear transmission in each
module.
The software identifies and moves four dilutors (Dil1, Dil2,
Dil3, Dil4), each dilutor consists of
two syringes. Dilutor 1 and 2 is in Dilutor module 1, dilutor 3 and 4 is in Dilutor module 2, as
represented in the picture below.
Main Dilutor Module
Main Dilutor Module
Dil
1
Dil
2
Dil
Dil

Servicemanual
17
3.
2.
4
Diluto
r
opto
sensor
boards
Dilutors have their own separated opto-boards, located
directly in the units. On the front side of
the optoboards
there are 4 optosensors and 4 control LED-s, on the
back side are mounted the motor connectors and the flat
cable connector.
3.2
.5
Tube
or
gani
zer
This is the
component that provides arrangemen
t for
the tubes going from
the valves to the dilutor, shear valve, optical head and Temperature Control
Unit. It is intended to allow easy identification and access to tubes for
service related cleaning procedures.
Four tubes have metal through tubes t
o allow easier removal and
replacement when necessary in case the TCU needs to be cleaned and
rinsed.
3.
2.
6
Te
mperature
Control
Unit
Temperature Control Unit provides the necessary temperature for reagents used to create 4-
DIFF sample. It is able to heat or cool the sample and reagents, depending on the ambient

Hemolyzer 5
18
1
2
3
4
6
7
5
temperature. It contains a massive, molded aluminum block. There are
multiple, curved and
interconnected stainl
ess steel tubes (fluid paths)
inside the TCU to
ensure proper capacity.
Parts of TCU:
•
in-line
mixer,
for
mixing
and
homogenizing sample
and
specific reagents.
•
Temperatur
e
Controller Board,
to
monitor the
temperatu
re
of
the
aluminum
block
by
power transistors (heating elements) or
Peltier cooling circuitry
•
thermal
insulation
for
temperature
stability.
3.2.7
Las
er
head
Laser head is used for
optical measureme
nts of 4-DIFF
and BASO parameters.
1. LASERDRV BOARD
2. LENS ASSEMBLY
3. OPTSENSE BOARD
4. SAFETY SWITCHES
5. SAMPLE INJECTOR
6. OPTICAL FLOW CELL
7. OPTI
CAL CABL
E
Black anodized aluminum box works as safety cover. Two different micro-switches protect
the technician against direct exposure to beam:
•
When
cover holder
screws
are removed
laser activity
will
be
switched off
by
laser
driver board.
•
To turn
on l
aser a
gain, pu
t the co
ver ba
ck, and
fasten the
screws so
that bo
th
switches are closed and the low-level SW should be restarted.
Optical measurement unit has a sheath and
sample inlet, and a waste
outlet from fluidic side,
laser driver cable, analogue output cable and auto-alignment cable from the electronics.

Servicemanual
19
3.2
.8
Laser
He
ad
Assem
bl
y
+
Sample
Inject
or
Laser Head Assembly is responsible for detecting the 4diff and BASO cells from the
prepared blood sample.
The laser head is
responsib
le for t
he precise illumination of the sample. The t
emperature
controlled laser diode source is mounted on a huge brass basis which holds it tight and also
responsible for the cooling. Just beside the laser diode aspheric and achromatic lenses
performs the focusing of the
laser beam.
For accurate and stable adjustment, this
optical unit is mounted on an aluminum
block with a
sphere-to-co
ne contact.
Powerful springs hold the unit in place.
Using stainless steel levers, the direction of
the laser can be
rotated around two axes.
This means, the laser
spot on the f
low-cell
can be tilted in
horizontal and vertical
directions. Precise linear motion stepper
motors perform the accurate setting of the
laser.
Coarse adjustment of the laser can
be made by setting the
rough adjustment screws.
The flow-cell unit is responsible for the
precise flow control and
the pre-detection
of the pulses.
An optically clear flow-cell
(cross section for flow is
0.25x0.25mm) is
mounted with 2 side cone-to-cone
connection into its holder. Below the flow-
cell an injector helps to insert the sample in
the middle of the main sheath streamline.
The sheath puffer opened to free air
supplies the sheath and the sample flow.
Cross section of the flow cell – sample
injector assembly
The size and position of
the sampler needle, the different tube resistance of
the sheath and
sampler lines and the applied vacuum result an about 40nm wide sample stream in the
middle of the flow-cell.
Concentric ring shaped optical cable is also mounted to t
he flow-cell unit. This collects the
scattered light from the cells, and transfers it to the
detection unit. Just before the insertion
zone of the optical cable, there is a laser dump for f
iltering direct laser beam.