Beckman Coulter Power Express Installation guide

Power Express In-Lab Training Manual Page 1 of 147
Version 2.0 (July 2016) Beckman Coulter Professional Development
Power Express
In-Lab Training Manual
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Power Express In-Lab Training Manual Page 2 of 147
Version 2.0 (July 2016) Beckman Coulter Professional Development

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Version 2.0 (July 2016) Beckman Coulter Professional Development
Power Express
WARNINGS AND PRECAUTIONS
Read all product manuals and consult with Beckman Coulter-trained personnel before
attempting to operate the instrument.
Beckman Coulter, Inc. urges its customers and employees to comply with all national
health and safety standards such as the use of barrier protection. This may include,
but is not limited to, protective eyewear, gloves, suitable laboratory attire when
operating or maintaining this or any other automated laboratory equipment.
INTENTION FOR USE
This document is not intended to replace the information in your Instrument
Instructions for Use Manual (IFU). Information in the Instructions for Use Manual
supersedes information in any other manual. For operational information for
connected analyzers on the Power Express system, refer to the analyzer specific
manual.
SCOPE
The scope of this manual is the Power Express sample handling system and the
modules that can be configured on the system. For information on connected
analyzers, refer to the analyzer specific manual.
REVISION STATUS
Version 2.0 (July 2016)
Based on:
Cennexus software version 3.0
Line Control software version 3.0
Power Express General System Operation IFU PN B31448AF
Power Express Aliquot Module IFU PN B31449AD
Power Express Decapper and Recapper Modules PN B31450AD
Power Express Inlets and Outlets Modules IFU PN B31451AD
Power Express Storage Modules IFU PN B31452AD
Power Express Direct Track Sampling Module IFU PN B31453AC
Power Express Rack Builder Modules IFU PN B31455AE
Power Express Centrifuge Module IFU PN B31456AD
Cennexus IFU PN B19606AE

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Power Express
TRADEMARKS
The following Beckman Coulter trademarks are registered in the USPTO and may be
used in this manual:
Beckman Coulter and the Beckman Coulter logo
Access
Synchron
UniCel
DxC
The following are additional Beckman Coulter trademarks used in this manual:
Power Express
Cennexus
AU
All other trademarks are the property of their respective owners.
SAFETY NOTICE
The Instructions for Use for each Power Express module contains a Safety Notice
section.
Read all product manuals and consult with Beckman Coulter-trained personnel before
you operate the system. Do not perform any procedure before you carefully read all
instructions. Always follow the product labels and the manufacturer’s
recommendations. Contact your Beckman Coulter Representative if you have any
questions.
The Safety Notice for each Instructions for Use includes:
Alerts for Warning, Caution, Important, and Note
General Warnings and Cautions
Power Express Hardware Labels
Restrictions of Hazardous Substances (RoHS) Labels
Refer to the Instructions for Use manuals for the complete contents of the Safety
Notice.

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Power Express
In-Lab Training Manual
Table of Contents
Chapter 1 System Overview ......................................................................................... 7
System Description......................................................................................................7
Hardware .....................................................................................................................8
Sample Tube Processing Overview...........................................................................29
Chapter 2 Software Overview..................................................................................... 31
Introduction................................................................................................................31
Switch Between Cennexus and Line Control Software..............................................33
Cennexus Screen Description....................................................................................34
Line Control Main Screen...........................................................................................39
Control Panel Buttons................................................................................................42
Chapter 3 System Operations .................................................................................... 45
Introduction................................................................................................................45
Bar Code Labels........................................................................................................46
Loading Sample Tubes into the Inlet Racks...............................................................47
Loading Racks into the Inlet Module..........................................................................49
Removing Sample Tubes from the Error Lane...........................................................51
Unloading Outlet Racks .............................................................................................53
Removing a Rack from a Storage Module .................................................................57
Cennexus Operations – Loading Pause ....................................................................61
Cennexus Operations – System ................................................................................63
Cennexus Operations – Sample................................................................................64
Cennexus Operations – Setup...................................................................................73
Cennexus Operations – Data Management...............................................................75
Daily Shutdown/Startup .............................................................................................77
Chapter 4 Maintenance ............................................................................................... 81
Introduction................................................................................................................81
Daily Maintenance .....................................................................................................83
Weekly Maintenance..................................................................................................93
Monthly Maintenance...............................................................................................101
Chapter 5 Error Recovery and Troubleshooting .................................................... 107

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Introduction..............................................................................................................107
Alarms......................................................................................................................108
Error Codes..............................................................................................................108
Sensor Diagrams.....................................................................................................111
Function Codes........................................................................................................113
Error Recovery Procedures......................................................................................119
Cennexus Error Recovery........................................................................................121
Chapter 6 Resources ................................................................................................ 125
Chapter 7 In-Lab Training Competency Exercise................................................... 127

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Chapter 1
System Overview
System Description
Power Express is a scalable sample tube processing system that automates pre-
analytical, analytical, and post-analytical processes in the clinical laboratory. You can
configure Power Express to perform pre-analytical sample tube preparation, sort sample
tubes directly to the required analyzers for analysis, and then route tubes to an outlet
rack or to storage.
Power Express handles and routes sample tubes as determined by system defaults,
pre-assigned destinations, or LIS instructions. The system supports the following tubes:
13x75 mm, 13x100 mm, and 16x100 mm Becton Dickinson (BD) tubes and Greiner
tubes
13x75 mm and 13x100 mm aliquot tubes
The system can help manage routine sample preparation and minimize biohazard
exposure to laboratory personnel.

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Hardware
The Power Express system consists of modules configured to accommodate the needs
of your laboratory. This section identifies the common hardware components and
modules of the basic configuration along with the optional modules available for the
Power Express. Your system may not be configured with all modules.
Component Description
Computer:
Cennexus Software
Line Control Software
Houses the following software applications
for Power Express:
Cennexus – Process control software
for Power Express
Software works with hardware to
automate processing and manage
patient sample tubes through pre-
analytical, analytical, and post-
analytical processes
Receives sample programming
from the LIS and then downloads
routing information to Line Control
Line Control – Controls sample
movement through the entire system
Sends and receives information
from Cennexus and the Power
Express track system
Provides status of connected
modules
NOTE: If your Power Express is not on V3.0 or higher, the Cennexus and Line Control
are on separate computers. In this case, the Cennexus and Line Control computers are
generally set up to share the same monitor, mouse, and keyboard. Use the Print
Screen key on the keyboard to switch between the two computers.

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Basic Track System
Uses a series of conveyor belts and sample tube carriers to move sample tubes
through your Power Express configuration
Conveyer belts move sample tube carriers along the Through Lanes (I-Lanes) as
they transport sample tubes to other modules
T-Lanes permit sample tubes to be routed to the module, or bypass the module if it
is not required for processing
Routes empty sample carriers to the Return Lane and back to the Inlet module
Uses compressed air system to control movement of sample tube carriers and
gripper fingers on the system
Can be configured to stop the conveyor belts automatically when there are no tubes
to process

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Track Components
The table below identifies components that are used to identify and route samples along
the Power Express track system.
Component Description
Sample
Tube
Carrier
A test tube holder that conveys a
sample tube along the automation track
A unique RFID chip is housed in the
bottom of each carrier
Carrier
Sensor
Small black sensors that detect sample
tube carriers along the track
Sample
Tube
Sensor
A fiber optic sensor that detects the
presence of sample tubes using a
beam of light
Bar Code
Reader
A laser device that scans and decodes
bar code labels on sample tubes in
sample tube carriers on the track

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Track Components, continued
Component Description
RFID
Sensor
A sensor that detects the RFID chip in
the sample tube carrier
Stopper
A pneumatic mechanism that holds a
sample tube carrier at specific locations
on the track
Diverter
A pneumatic mechanism that diverts
sample tubes carriers from the main
track into the Error Lane, Buffer Area,
Bypass Lane, or modules
Lane
Changer
Controls the movement of sample tube
carriers between the conveyor belts of
the track

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Common Module Components
The table below identifies components that are common to all connected modules on
the Power Express system.
Component Description
Control Panel
Available at each module to display
module status and enter commands
The color of the control panel indicates
the following module status:
GREEN: Running
YELLOW: Module requires
attention or module is paused
RED: Malfunction or module is
stopped
WHITE: Setup or Maintenance
Stop Button

Yellow or white button available at
each module and T-lane
NOTE: The Abbott i2000SR DTS
Connection has a black Stop Button.
Use to halt any hazardous condition
When pressed at any module (except
the Centrifuge and i2000SR DTS
Connection), disconnects power to the
Power Express system
Line Control and Cennexus remain on
Follow steps in Stop Button Recovery
procedure when button is pressed
Beacon
Flashes when an error condition occurs
at the module
Audible alarm also activated with
flashing beacon

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Dynamic Inlet Module
Transfers sample tubes from Inlet racks to sample tube carriers on the conveyor
track at the beginning of the sample handling process
The two rack drawers each have four positions for Inlet racks
Uses transfer arm with 5-grippers to alternately transfer five sample tubes from Inlet
racks onto two 5-position sample holder sets of carriers
Activates an audible alarm and flashing beacon when the Inlet racks are empty
All samples must be loaded onto the Power Express system via Inlet racks;
manually loading a sample tube into a sample tube carrier will sort the tube to the
Error Lane
Includes the power ON/OFF switch for the system

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Dynamic Inlet Module, continued
Inlet Racks
Two versions
Standard Inlet Racks: Hold 13mm tubes only (pictured above)
Inlet Universal Racks: Hold 13mm and 16mm tubes
NOTE: Do not mix Standard and Universal Inlet racks.
Four rack types available to place in any position in the rack drawer
Power Express processes the racks in the following priority order:
RED: Priority. The system always loads sample tubes in red racks first
BLUE: Routine. Use these racks for sample tubes with no special requirements
WHITE: Centrifuge Bypass. Use these racks for sample tubes that do not
require centrifugation
YELLOW: Remap. Use these racks to return a sample tube to a storage
module after it has been properly removed
Each rack is keyed to identify the rack type and to fit in the Inlet rack drawers in only
one direction
Each rack holds 50 tubes
Rack positions in the Inlet rack drawer are numbered as shown below:
1 3 5 7
2 4 6 8
Left Drawer Right Drawer

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Dynamic Inlet Error Lane
Houses components that detects tube size (13x75 mm, 13x100 mm, or 16x100 mm)
NOTE: The optional Inlet Tube Sizer is required for detection of 16 mm tubes.
Houses initial bar code readers that scan a sample tube bar code label for
associated sample processing requirements on the line
The sample ID (bar code) of the sample tube is also linked to the carrier with a
unique RFID chip at this point
Sample tubes with errors are routed here from the Inlet
Up to 10 tubes can route to the Error Lane before operator intervention is required
Activates an audible alarm and flashing beacon when ten samples accumulate in
Error Lane
Option available to have the module activate the audible alarm and flashing beacon
when the first tube arrives in the Error Lane
Identify the reasons for tubes in the Error Lane from Cennexus

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Centrifuge Module
Power Express system can include up to four Centrifuge modules
Configured for a single tube size (13x75 mm, 13x100 mm, or 16x100 mm) and
discipline (Chem/IA, Coag, or both)
Two types of centrifuges: ambient or temperature controlled
Accepts up to 40 tubes per load
Uses transfer arm with 5-grippers to transfer sample tubes from carriers on the track
into one of four sample holders within the centrifuge
Uses water-filled balance tubes, as needed, to create a balanced centrifuge load;
centrifuge will automatically turn off if there is a 20 gram load imbalance
Can be operated in Auto or Manual mode
Auto: Use for normal processing to load tubes automatically from Power Express
Manual: Use in error recovery to load sample tubes directly at the centrifuge
Centrifuge default spin time and speed is 4 minutes at 3000 rpm; adjustable at
centrifuge Control Panel
Temperature controlled centrifuge
Temperature control panel located on the front panel of the module; activates an
audible alarm and flashing beacon when temperature is outside of acceptable
range for more than the preset timer value (default is 30 minutes)
Maintains centrifuge bowl set point temperature of 21ºC +/- 3ºC
Loads sample tubes into the centrifuge until it is full or until load timeout expires
before another sample tube arrives at the module; use Priority button on D-Lane
Control Panel to override load timeout and start centrifugation immediately

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Decapper Module
Contains two assemblies that remove the sample tube caps or stoppers from
individual sample tubes
Decapper assembly grasps the cap and spins it to remove the cap from the tube
Activates an audible alarm and flashing beacon if unable to remove a cap
Drops cap down a chute into a customer-provided biohazard container
Activates an audible alarm and flashing beacon when number of disposed caps
reaches a threshold
Dual decapper assemblies allow processing to continue when one has an error

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Aliquot Module
Transfers sample from a primary sample tube into a maximum of nine separate
aliquot sample tube
Creates aliquots before or after primary tube is routed to connected analyzers,
based on sample programming
Includes three main hardware components:
Level Detector
Labeler
Aliquotter
Level Detector
Measures the red cell layer or clot in the primary sample tube
Grippers lower up to five tubes into an optical well to measure the height from the
bottom of the tube to the top of the red cells; uses the measurement to later
calculate the volume of serum or plasma available in the primary tube
If it does not detect a red cell layer, assumes the entire tube is serum or plasma only
Waits until five primary tubes are available for measurement or until load timeout
expires before transferring tubes into optical well; use Priority button on Control
Panel to override load timeout and start measurement immediately
Routes primary sample tubes to Labeler

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Aliquot Module, continued
Labeler
Prints bar code labels that correspond to the primary sample tube and applies them
to secondary tubes
Bar code reader reads primary sample tube bar code label to identify from Cennexus
how many secondary tubes the sample programming requires
Thermally prints and applies bar code label for each secondary tube and checks the
bar code on each label; assigns secondary tubes the primary sample ID followed by
a decimal from 1 to 9, or uses an LIS-assigned sample ID
Discards secondary tubes with unreadable bar codes into defective secondary tube
container
Activates an audible alarm and flashing beacon if it is unable to create a
secondary tube with a readable bar code after three tries
Routes secondary tubes with acceptable bar codes to Aliquotter

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Aliquot Module, continued
Aliquotter
Transfers sample from the primary sample tube to the secondary sample tubes
Uses a new aliquot tip for each primary sample tube and disposes used tips into a
biohazard container
The minimum/maximum volume aspirated and transferred is 300µL/5000µL (in
100µL increments)
If primary sample tube does not contain sufficient volume to create all requested
secondary tubes, the Aliquotter uses one of the user-defined priority settings:
1) Create as many secondary tubes as possible regardless of aliquot priority
2) Create as many secondary tubes as possible according to aliquot priority
3) Create all empty secondary tubes and route the primary tube and empty tubes
to the Aliquot Error Rack
Based on Cennexus setting, option is available to let the primary tube continue
processing on connected analyzers even though there may be insufficient volume to
create all requested secondary tubes for all requested tests
If clot is detected during transfer process, returns the aspirated sample volume to
the primary sample tube and routes the primary and secondary sample tubes to the
Aliquot Error Rack in the Outlet
Dual aliquot nozzles allow processing to continue when one has an error