AVL 9130 User manual

MEDICAL INSTRUMENTS
AVL 9120, 9130,
9140, 9180, 9181
ElectrolyteAnalyzers
Service Manual

Tenth Edition
November 1997
Copyright, 1997, AVL Scientific Corporation. All rights reserved. Unless otherwise noted, no part of this
publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into
any language in any form without the written permission of AVL Scientific Corporation.
For information contact:
AVL Scientific Corporation AVL MEDICAL INSTRUMENTS AG AVL LIST GmbH
50 Mansell Court Stettemerstrasse 28 Kleiststrasse 48
P.O. Box 337 CH-8207 Schaffhausen A-8020 Graz
Roswell, Georgia USA 30077 Switzerland Austria
1-800-526-2272 41-848-800-885 43-316-787-0
Printed in USA
US0285 REV K
ii

ThisOperator´sManualcontainsimportantwarningsandsafetyinformationtobeobservedbythe
user.
This instrument is only intended for one area of application which is described in the instruc-
tions. The most important prerequisites for application, operation and safety, are explained to
ensure smooth operation. No warranty or liability claims will be covered if the instrument is
applied in areas other than those described or if the necessary prerequisites and safety
measures are not observed.
The instrument is only to be operated by qualified personnel capable of observing these
prerequisites.
Only accessories and supplies either delivered by or approved by AVL are to be used with the
instrument.
Due to the operating principle of the instrument, analytical accuracy not only depends on
correct operation and function, but also upon a variety of external influences beyond the
manufacturers control. Therefore, the test results from this instrument must be carefully
examined by an expert, before further measures are taken based on the analytical results.
Instrument adjustment and maintenance with removed covers and connected power mains are
only to be performed by a qualified technician who is aware of the dangers involved.
Instrument repairs are only to be performed by the manufacturer or qualified service personnel.
Symbol Explanation
Attention symbol - Refer to the Operator's Manual or Service
Manual for further instructions. This symbol is located on the
inside of the instrument.
Type B instrument symbol - An instrument of the B type falls under
safety categories I, II, or III, or has an internal power supply providing
the required insulation against discharge current and reliable ground
connections.
ImportantInformation!
iii
ImportantInformation!

•This instrument falls under Safety Category I.
•This instrument is a Class B instrument.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference’s, and (2) this device must accept
any interference received, including interference that may cause undesired operation.
Warning: Changes or modifications to this unit not expressly approved by the party
responsible for compliance could void the user’s authority to operate the equipment.
Note: This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation.
This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause harmful interference to
radio communication. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does not cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the following
measures:
•Reorient or relocate the receiving antenna
•Increase the separation between the equipment and receiver
•Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
•Consult the dealer or an experienced radio TV technician for help
Caution:
•The instrument is designed as a conventional device (closed, not waterproof type).
•Do not operate the instrument in an explosive environment or in the vicinity of
explosive anesthetic mixtures containing oxygen or nitrous oxide.
•This instrument is suitable for continuous operation.
•The power plug is to be plugged into a ground socket only. When using an extension
cord, make sure that it is of the proper size and is properly grounded.
•Any breakage of the ground lead inside or outside the instrument or a loose ground
connection can cause a hazardous condition when operating the instrument.
Intentional disconnection of the grounding is not permitted.
•When replacing the fuses, make sure that they are of the same type and rating as the
original fuses. Never use repaired fuses or short-circuit the fuse holders.
Operating Safety Information
iv
Operating Safety Information

Contents
1 Introduction............................................................................................ 1
2 General Description .............................................................................. 2
2.1 Reported Parameters .................................................................. 2
2.2 Operating Parameters ................................................................. 2
3 Software ................................................................................................. 5
3.1 System Software Flow Charts 9120, 30, 40............................... 7
3.2 System Software Flow Charts 9180......................................... 17
3.3 System Software Flow Charts 9181......................................... 29
3.4 Service Functions .................................................................... 42
4 Description of Modules....................................................................... 48
4.1 Mechanical Assemblies ............................................................ 48
4.2 Fluidic Module ........................................................................ 52
4.3 Electronics............................................................................... 56
5 Maintenance and Troubleshooting ..................................................... 59
5.1 Maintenance Procedures......................................................... 59
5.2 Error Messages and Troubleshooting ...................................... 60
6 Adjustments ......................................................................................... 71
6.1 Sample Sensor Adjustment ...................................................... 71
6.2 Temperature Adjustment .......................................................... 71
7 Electronic Diagrams ............................................................................ 72
System Block Diagram 9120, 30, 40, 80 ........................................ 74
System Block Diagram 9181 .......................................................... 75
System Interconnect 9120, 30, 40 .................................................. 76
SBC PCB - Power Supply 9120, 30, 40 ........................................ 77
SBC PCB - Valve Drivers 9120, 30, 40 ......................................... 78
SBC PCB - Pump Motor Driver/Door Detect 9120, 30, 40............ 79
SBC PCB - Input Amplifiers 9120, 30, 40...................................... 80
SBC PCB - Temperature Circuit 9120, 30, 40 ............................... 81
SBC PCB - Analog Selector and A/D Converter 9120, 30, 40 ....... 82
v

SBC PCB - Microprocessor 9120, 30, 40 ..................................... 83
SBC PCB - Printer/Display Drivers 9120, 30, 40 ........................... 84
Printer Daughter PCB 9120, 30, 40, 80, 81 .................................... 85
Lamp PCB 9120, 30, 40 ................................................................ 86
Display Daughter PCB 9120, 30, 40............................................... 87
System Interconnect 9180/9181 ..................................................... 88
SBC PCB - Power Supply 9180/9181 ........................................... 89
SBC PCB - Valve Drivers 9180/9181 ............................................ 90
SBC PCB - Pump Motor Driver/Door Detect 9180/9181............... 91
SBC PCB - Input Amplifiers 9180/9181......................................... 92
SBC PCB - Temperature Circuit 9180/9181 .................................. 93
SBC PCB - Analog Selector and A/D Converter 9180/9181 .......... 94
SBC PCB - Microprocessor 9180/9181 ........................................ 95
SBC PCB - Printer/Display Drivers 9180/9181 .............................. 96
SBC PCB - Fluid Pack Detector 9180/9181 .................................. 97
Lamp PCB 9180/9181 ................................................................... 98
Display Daughter PCB 9180........................................................... 99
8 Parts List ........................................................................................ 100
Main Assembly Front ................................................................... 101
Main Assembly Rear .................................................................... 102
Electrode Holder Assembly .......................................................... 103
Needle Unit Assembly .................................................................. 104
Rear Panel Assembly .................................................................... 105
Front Door Assembly ................................................................... 106
9 Interface Specifications ..................................................................... 107
9.1 Interface Information.............................................................. 107
9.2 Example Data String Information............................................ 108
9.3 Data Link Information............................................................ 108
vi

1Introduction
The Service Manual for the 9120, 30, 40, 80, and 81 Electrolyte Analyzers
contains the technical information needed to ensure easy fault identification.
This manual is intended to be complementary to the Operator's Manual where
detailed instructions for operation, maintenance and troubleshooting are
provided.
As for all clinical instrumentation, a thorough understanding of the principles
of operation is prerequisite to attempting service of this product. Training
along with experience will enhance the use of this manual.
Service and repair of 9120, 30, 40, 80, and 81 analyzers should be performed
only by qualified repair technicians. Care should be taken when removing the
covers as hazardous voltages are exposed. Use only accepted electronic test
procedures and static protection when replacing and handling all electronic
parts.
This manual is divided into 9 chapters to facilitate location of technical infor-
mation. Chapter 2 provides specifications and operating parameter informa-
tion. Chapter 3 includes flow charts for all system functions and detailed
operation of system test procedures. In Chapter 4, all mechanical, fluidic and
electronic assemblies are described. Chapter 5 outlines routine maintenance
and troubleshooting procedures. Chapter 6 includes electronic adjustments
and Chapter 7 provides the system block diagram and all circuit schematic
diagrams and wiring interconnection information. In Chapter 8, part identifica-
tion, location and description is provided by the illustrated parts list.
Finally, in Chapter 9 interface specifications are provided for the RS232
output.
1

2
2 General Description
Specifications
2.1 Reported Parameters Measuring Range Resolution
Whole Blood
Serum
Plasma
Sodium Na+40 - 205 mmol/L 0.1 mmol/L
Potassium K+1.5 - 15 mmol/L 0.01 mmol/L
(0.8 - 15 mmol/L dialysate)
Chloride Cl-50 - 200 mmol/L 0.1 mmol/L
Calcium Ca++ 0.2 - 5.0 mmol/L 0.01 mmol/L
Lithium Li+0.1 - 6.0 mmol/L 0.001 mmol/L
Urine
Sodium Na+1 - 300 mmol/L 1.0 mmol/L
Potassium K+4.5 - 120 mmol/L 0.1 mmol/L
(60 - 120 mmol/L w. addit. dilution)
Chloride Cl-1 - 300 mmol/L 1.0 mmol/L
Calcium and Lithium are not measured in urine samples.
Lithium is not measured in dialysate samples.
2.2 Operating Parameters
Sample type Whole blood, serum, plasma, urine,
dialysate (acetate or bicarbonate)
Sample device Syringe, sample cup, collection tube, capillary
Sample size 95 µL
Analysis time 50 seconds
Sample rate 45 per hour with printout
60 per hour without printout

3
Measurement
Sodium (Na+) sensor Ion-selective, flow-through, glass capillary
electrode
Potassium (K+) sensor Ion-selective, flow-through, liquid membrane
electrode
Chloride (Cl-) sensor Ion-selective, flow-through, liquid membrane
electrode
Calcium (Ca++) sensor Ion-selective, flow-through, liquid membrane
electrode
Lithium (Li+) sensor Ion-selective, flow-through, liquid membrane
electrode
Reference System Open liquid junction, flow-through electrode
Calibration Fully automatic
1 point with each sample
2 point every 3 hours (9180/9181 every 4 hrs.)
Standby Mode suspends calibrations
Warm-up time 1 minute
Temperature Room temperature, 15 - 32° C, 60 - 90° F
Humidity maximum 85% relative humidity,
non-condensing
Data management Quality Control memory storage, 3 levels,
35 values; calculation of mean, standard
deviation, and coefficient of variation (CV)
Diagnostic Programs user-controlled diagnostics,
YES/NO operation via the display
Electronics Microprocessor-controlled
Display LCD dot-matrix, 2 line, 16 characters per line
Printer Integral thermal printer, 16 character width
Autosampler (9181 only) Integral turntable - 18 positions,
2 mL or 0.25 mL sample cups

4
Interface RS232C Serial Port
Data Link Data link to Compact 2/3 (9180/9181)
Electrical requirements 100 - 240 V~, 50/60 Hz,
1.4 A max.
Self-adjusting
Nominal power
consumption 30 W
Dimensions
height 12.2"; 335mm
width 12.4"; 315m
depth 12.0"; 295mm
weight approx. 13 lbs; 6kg
Classifications
Safety category I
Device type B (according to ÖVE-MG/EN 60601-1,
IEC 601-1)
Mode of operation continuous operation
Protection classification IP 20
Explosion protection the device is not designed for operation in
explosive environments.
Approvals CSA, CE, FCC Class B
CLIA Complexity Category: Moderate
Test System Code: 04739
FDA 510(k) number: K972673
Analyte Codes: Na+:5805
K+:4910
Cl-:1018
iCa++:1004
Li+:3712
Data subject to change without notice. Technical information is
supplied for general informational purposes only.

5
3 Software Operation
3.1 Software Operation - 9120, 9130, 9140
Software operation of the 9120, 9130, 9140 analyzers can be accessed by YES/
NO selection on the analyzer front panel. The following flow chart diagrams are
provided to identify operating sequences of the 9120, 9130, 9140 Analyzers:
1. Overall Program Operating Flow
2. Main Menu
3. Measurement Sequence
4. Print Functions Menu
5. QC/Standard/Urine Sample Menu
6. Daily Maintenance Menu
7. Operator Functions Menu
8. Program Instrument Menu
9. Service Functions Menu
10. Calibration Sequence
3.2 Software Operation - 9180
1. Overall Program Operating Flow
2. Main Menu
3. Measurement Sequence
4. Print Functions Menu
5. QC/Std/Dialysate/Urine Sample Menu
6. Daily Maintenance Menu
7. Operator Functions Menu
8. Program Instrument Menu
9. Service Functions Menu
10. Calibration Sequence
11. Power-up Sequence

6
3.3 Software Operation - 9181
1. OverallProgramOperatingFlow
2. MainMenu
3. MeasurementSequence
4. PrintFunctionsMenu
5. QC/Std/Dialysate/UrineSampleMenu
6. DailyMaintenanceMenu
7. OperatorFunctionsMenu
8. ProgramInstrumentMenu
9. ServiceFunctionsMenu
10. CalibrationSequence
11. Power-upSequence
TheServiceFunctionsMenuisalsoprovidedwithamoredetaileddescription
ofeachtestparameterforuseintestinginstrumentsubassemblies.

7
3.1 Software Operation - 9120, 30, 40
1 Overall Program Operating Flow - 9120, 30, 40
NoNoNoNoNoNoNoNo
Yes
READY 12:45 PRINT
FUNCTIONS? QC/S T ANDAR D/
URINE SAMPLE? DAILY
MAINTE NANCE? OPE R AT OR
FUNCTIONS? SERVICE
FUNCTIONS? CALIBRATION?
Test
E lectrodes?
Test
SampleSensor?
Test
S ample Door?
Test
Pump?
Test
Valves?
TestInterface?
Jump Pins 2 & 3
Test
Amplifier?
Enter
S ervice Code?
R emain in
ServiceFunc.?
P rint last
SampleReport?
Print
Cal. Report?
PrintQCValues
and S tatis tics ?
Remain in Print
Functions?
QC Level 1
Sample?
QC Level 2
Sample?
QC Level 3
Sample?
Standard
Sample?
Urine
Sample?
RemaininQC/
Std/UrineSample?
Daily
Cleaning?
Daily
Conditioning?
R emain in Daily
Maintenance?
CALIBRAT E
Check/Change
SnapPak?
Go to
S tandby Mode?
Set
Time/Date?
Reset
SampleNumber?
TakeOutof
Operation?
Remain in
Operator Func.?
PROGRAM
INS T RU ME NT ?
EnterCode:
AAA
Program QC
Level 1 Ranges?
Program QC
Level 2 Ranges?
Program QC
Level 3 Ranges?
Program
NormalRanges?
Program
Corr. Factors?
Program
P rinter S etup?
Remain in
Program Func.?
CALIBRAT E..
.
No
Yes
No No
No No No No No No
No No No
No No No No No
No No No No No No No No
No No No
No No No No No No
Yes Yes Yes Yes Yes Yes
Yes
No
Yes Yes
No
Yes
Yes

8
2 Main Menu - 9120, 30, 40
READY 12:45
PRINT
FUNCTIONS?
QC/STANDARD/
URINE SAMPLE?
DAILY
MAINTENANCE?
OPERATOR
FUNCTIONS?
PROGRAM
INSTRUMENT?
SERVICE
FUNCTIONS?
CALIBRATION?
MAIN MENU
LEGEND
Display prompt
Action performed by analyzer
2-second display prompt
Decision-making by analyzer
NO
NO
NO
NO
NO
NO
NO
NO

9
3 Measurement Sequence - 9120, 30, 40
READY 12:45
DOOR OPENED
WITHIN 2s?
Remove Sample
and Wipe Probe
PRINT
FUNCTIONS?
Open Sample Door
Introduce Sample
Please
Introduce Sample
CHECK SS
VOLTAGE
Remove Sample
and Wipe Probe
Please Close
Sample Door Please Close Sample Door
Serum Sample
in Process 49 Blood Sample in Process 49
Na K Cl
151 5.1 114 Na K Cl 151 5.1 114
NO
YES
OPEN
FLAP
NO
YES
< air
voltage
> air
voltage
2s 2s
FLAP
CLOSED FLAP CLOSED
YES/NO
1 min.
YES/NO
1 min.

10
4 Print Functions Menu - 9120, 30, 40
PRINT
FUNCTIONS?
PRINTING
...
QC/STANDARD/
URINE SAMPLE?
Print Last
SampleReport?
Print
Cal. Report?
Print QC Values
andStatistics?
Remain in Print
Functions? READY 12:45
READY 12:45PRINTING
...
PRINTING
...
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES

11
5 QC/Standard/UrineSampleMenu-9120,30,40
QC/STANDARD/
URINE SAMPLE? DAILY MAINTENANCE?
YES
NO
QC Level 1
Sample? Open Sample Door Introduce Sample
Introduce
Sample Wipe Probe/Close
Sample Door QC Level 1 in Process 49
READY 12:45
Na K Cl
99.65.34 88.2
Store
Values?
VALUES
REJECTED!
VALUES
ACCEPTED!
YES OPEN SAMPLE
IN
CLOSED
2s
2s
2 min
2s
2s YES
NO
QC Level 2
Sample? Open Sample Door Introduce Sample
Introduce
Sample Wipe Probe/Close
Sample Door QC Level 2 in Process 49
READY 12:45
Na K Cl
99.6 5.34 88.2
Store
Values?
VALUES
REJECTED!
VALUES
ACCEPTED!
YES OPEN SAMPLE
IN
CLOSED
2s
2s
2 min
2s
2s YES
NO
QC Level 3
Sample? Open Sample Door Introduce Sample
Introduce
Sample Wipe Probe/Close
Sample Door QC Level 3 in Process 49
READY 12:45
Na K Cl
99.6 5.34 88.2
Store
Values?
VALUES
REJECTED!
VALUES
ACCEPTED!
YES OPEN SAMPLE
IN
CLOSED
2s
2s
2 min
2s
2s YES
NO
NO
NO
NO
Standard
Sample? Open Sample Door Introduce Sample
Introduce
Sample Wipe Probe/Close
Sample Door Standard Sample in Process 49
YES OPEN SAMPLE
IN
CLOSED Na K Cl
158.8 5.82 113.2
1 min. NO/
YES
NO
Urine
Sample? Open Sample Door Introduce Sample
Introduce
Sample Wipe Probe/Close
Sample Door Urine Sample in Process 49
YES OPEN SAMPLE
IN
CLOSED Na K Cl
238 18.8 198
1 min. NO/
YES
NO
Remain in QC/
Std/Urine Sample? READY 12:45
NO/
2 min.
5s
5s
YES
2 min.
2 min.
2 min.
2 min.
2 min.

12
6 Daily Maintenance Menu - 9120, 30, 40
DAILY
MAINTENANCE? OPERATOR FUNCTIONS?
NO
Daily
Cleaning? Open Sample Door Introduce Sample Wipe Probe/Close Sample Door Cleaning Solution detected? CLEAN
Cleaning Solution
not detected!
YES
YES
OPEN
OPEN CLOSE YES
NO
Daily
Conditioning? Open Sample Door Introduce Sample Wipe Probe/Close Sample Door Condition. Solution detected? CONDITION
Condition. Solution
not detected!
NO
YES
OPEN
OPEN CLOSE YES
NO
Remain in Daily
Maintenance?
YES
CLEANING AND/OR
COND. PERFORMED?
Calibration
due?
NO/1min.
NO
30 SECOND
STABILIZATION CALIBRATE READY 12:45
NO
YES
YES

13
7 Operator Functions Menu - 9120, 30, 40
OPERATOR
FUNCTIONS? PROGRAM INSTRUMENT?
Check/Change
SnapPak? 37% remaining Change SnapPak? New SnapPak installed? Fluid Counter reset to 100%
Go to
Standby Mode ***STANDBY!*** YES-> READY Maint.due?
New Pack
Prime...
CALIBRATE
READY 12:45
Leave
Standby Mode?
PRESSYES
WITHIN 2s
IS
CALIBRATION
DUE?
Daily
Cleaning? Daily Conditioning? Remain in Daily Maintenance?
CONDITIONCLEAN IS
CALIBRATION
DUE?
Date: 01-FEB-94
Time: 12:00ok?
Set
Time/Date?
Date: 01-FEB-94
Time: 12:00 ok 30SECOND STABILIZATION
CALIBRATE
READY 12:45
Areyousure?Reset
Sample Number? SET SAMPLE NUMBER TO 0
Takeoutof
Operation? Shutdown Plug/ Waterinstalled? Transp Housing Ref installed? Remove Water andPressYES All Electrodes & Plug Removed?
4 Relief Clamps
Inserted?
Pump Windings
Relieved?
DoYouWishto
DELETE all Data?
ShutdownComplete
Turn Power Off
Remain in
Operator Func?
NO
NO
NO
YES YES
NO
YES
NO
YES
NO
YESYES
YES/NO
YES
NO YES NO
YES
YES
NO NO
YES
YES
1min/NO
NO
YES
NO
NO
NO
YES YES
YES
NO
NO
NO YES
YES
YES
YES NO
YES/
YES YES YES
YES
YES
YES
YES

14
8 Program Instrument Menu - 9120, 30, 40
PROGRAM
INSTRUMENT? SERVICE FUNCTIONS?
EnterCode:
AAA CODE ERROR! RETRY?
Program QC
Level 1 Ranges? Current Lot: 0000 Change Lot? Print old Values and Statistics? New Lot! Delete old Data? Enter last 4 Dig of Lot#: 0000
LotNumber
ok?
Na low = 040
Na high = 205
K low = 3.50
K high = 5.50
Cl low = 050
Cl high = 200
Program QC
Level 2 Ranges?
Program QC
Level 3 Ranges?
Program
Normal Ranges?
Program
Corr Factors
Program Printer
Setup?
Remainin
Program Func?
READY 12:45
PatientReport
off? Print two Patient Reports?
Reset Corr
Factor(default)? Remainin Corr Factors?
Input/Verify
Corr Factors?
Na low = 135.0
Na high = 150.0 Cl low = 95.0 Cl high = 108.0
K low = 1.5
K high = 15.0
Na (b) = +00.0
Na (m) = 1.000
K (b) = +00.0
K (m) = 1.000
Cl (b) = +00.0
Cl (m) = 1.000
Automatic
Cal Report?
NO
NO
YES YES
IN-
CORRECT
CORRECT
YES YES NO YES
NO
YES
NO
YESYESYESYES
NO
NO
"see Level
1"
"see Level
1"
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES YES YES YES
YES
NO
YES
NO
YESYES
NOYES
YES
YES
YES
YES
NO YES/
NO YES/
NO