Norma Icon-5 Operating manual

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Icon-5 Maintenance Guide
Kit description and procedures
This document describes the contents of the maintenance kit and list the corresponding
maintenance procedures for Norma Icon-5 automated hematology analyzer.
Special tool required: UNF tool (not included in the kit)
Please contact our support team at [e-mail] if further information or
clarification is required.
Icon-5 Maintenance Kit (HAT827A) –for 1-year/10.000 sample period
Item
Part#
pcs
Aperture maintenance kit
HAT809A
1
Peristaltic pump tube set for “gray” and “orange”
pumps
HAT800B
HAT800C
1 pair of each
Lubricants (in small containers)
-Shell Retinax lubricant (red)
HAT829A
1
-Teflon based grease (white)
HAT829B
1
-Silicone grease (clear)
HAT829C
1
Piercing needle with UNF screw and “O” ring
HAT165A
1
Greiner BIO Vacutainer NO add w/o rubber in cap
(White)
HAT823B
1

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Maintenance procedure on Icon-5 analyzers
These steps must be performed by trained service engineer! Please note the following
warnings:
WARNING
Risk of personal injury. Movements of motors are controlled by limited
current. Do not override built-in safety measures, do not short circuit fuses
BIOHAZARD
Risk of biological infection, contamination
WARNING
The analyzer should only be operated without covers with extreme
caution, moving parts can cause injury. High Voltage board HVDCDC
produces 180VDC.
Service marked components only when the power source is disconnected.
WARNING
Risk of personal injury. The ceramic shear valve has a sharp needle
installed. Avoid touching the needle
To prepare the Icon-5 for the maintenance, please, shut down the analyzer and pinch
the reagent pickup tubes using the clamps provided in the reagent pickup tube set,
and remove both side covers to get easy access to the inner components.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 1: Peristaltic pump tube replacement
Frequency:
1 year or 10,000
samples
part#: HAT800B or HAT800C (Included in kit)
Pump tubes must be replaced regularly. The tube material will wear with time and use of
the analyzer.
Failure to replace the tubes will results in deepening cracks on the tube material which will
eventually lead to leaks and reduction or failure in liquid movement.
The wash head will slowly fail to remove waste from the sampling needle washing
procedure. RBC sample processing errors (variation, instability of results) and in extreme
cases waste collector overflow may be the consequences.
Remove the pump module (open the
two screws fixing the module to the
assembly plate)
Remove the pump cassette by
pressing it on its sides and then
pulling it away from the pump.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Remove the pump tubes (gently pull
on the adapter to release it from the
groove)
Pull the tubes off the tube adapters.
The kit contains two different sets of pump tubes.
Different tubes must be used for different pumps.
HAT800B
Use it for the pump with ORANGE cassette
HAT800C
Use it for the pump with GREY cassette

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Install tubes, make sure they run parallelly,
they must not cross each other.
Reinstall the pump tubes. The adapter
heads will sit in the grooves at the pump
body. Slightly pull on the tubes to make
them sit properly in the pump over the
rollers.
Reinstall the cassette. Both ends must CLICK upon insertion. Make sure that the cassette
is level with the pump body. Incorrect alignment of the cassette will not allow the pump to
operate properly, it will fail to move liquid. If the cassette shows only a little gap, simply
push on the top of the cassette to push it in place.
Wrong cassette installation Good cassette alignment

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Reinstall the pump. Watch out for the
external silicone tubes. Avoid pinching
the tubes and cables between metal
plates.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 2: Replacement of aperture rubber valve
Frequency:
1 year or 10,000
samples
part#: HAT809A (Included in kit)
The rubber valve keeps the measuring apertures free of unwanted air and regulates liquid
flow during different stages of the measurement process.
If the rubber valve gets contaminated, then it will not be able to close properly, and false
air may enter the aperture module that will result in erroneous measurements and “Noise”
errors.
Remove the metal shield
Pull the aperture module away from the
amplifier block

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Remove the black screw cap and
remove the rubber valve with a small
forceps
Gently install the rubber valve in its socket with the flat side down
Push the black screw cap
through the internal o-ring, and
screw it in. Observe when the
rubber valve base lays flat on
the base of its socket.
Overtightening the screw cap
will deform the valve and make
its operation impossible.
Reinstall the aperture module. The two pins must go into their sockets. Do not force the
insertion, the pins go in easily.
Pay attention when installing the aperture module. The waste tube must be inside the
waste collector. Do not simply push the aperture in, first align the tube to be inside the
waste collector, then you can push the aperture.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Reinstall the metal shield.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 3: Replacement of the sealing silicon ring of the
apertures
Frequency:
If necessary
(It is suggested to perform
every 24 month)
part#: HAT809B (Included in kit)
The silicone sealing element provides safe and easy installation of the ruby aperture.
A worn silicone sealing ring will allow the aperture to leak and will form contamination
around the module and can even cause errors during measurement due to air or liquid
leaks.
Leaks on aperture housing
Aperture seal sizes:
orange: old, deformed; green: new
Take out the aperture module. Perform Step 2. Replacement of aperture rubber valve
related steps.
Prepare a sheet of paper or paper wipe.
You will need it to avoid losing the
aperture. When working with the
aperture, make sure you work on this
sheet.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Open the two aperture halves by
removing the two screws.
The ruby is inside the silicone seal. Carefully remove
it from the aperture half using a tweezer.
Use a damp cloth (immersed into DI water) to clean the sides of the aperture housings.
Make sure all residuals are removed.
Remove the ruby and seat it into the new seal.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
The ruby is not symmetrical: one side is flat,
the other side has a spherical dent. The
spherical side must face the LEFT side
aperture housing. See picture above. There is
a cut out in the plastic housing where the
aperture can fit. The flat side of the aperture
must face up at this point.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Gently put the RIGHT side onto the LEFT side with the
aperture and sealing ring applied–you will feel how the ruby
sits into its seat.
Put the two screws carefully into their place. (The aperture is
still on its side)
Install the two screws. Tighten them gradually and evenly: turn one screw at a time, then
follow with the other.
Tighten the two screws with “two fingers” torque. Overtightening may cause the silicon to
flat out fast again and start leaking.
The aperture halves must have a small even gap between them. Do not flatten out the gap
between the aperture halves. Doing so will break the plastic halves.
The gap must be even both in the top and in the bottom
Reinstall the aperture module. Perform Step 2. Replacement of aperture rubber valve
related steps.
After performing this procedure check the MCV value with control sample. Perform
calibration if necessary. If the MCV calibration factor is not between the 0.96 to 1.04 range
the MCV gain may need to be adjusted. For more details refer to the Service manual’s
related topic.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 4: Cleaning of the sample rotor brake
Frequency:
1 year or 10000 samples
part#: N/A
The sample rotor movement is dampened by the so-called “brake” component. If the brake
is tight or dirty, then vial position cannot be guaranteed, and the system will report “Sample
rotor errors”.
The sample rotor brake is tightened at a predefined torque in
the factory. It is mandatory to set the brake to the same
position.
To be able to do so, use a marker to mark the brake’s
actual position on two places.
By doing so, it will be easy to find the proper positioning
during reassembling.
Loosen the two small hex screws of the brake.
Unscrew the brake from the axle.
Remove the white plastic part. Use a clean cloth to wipe it
dry. You can use some alcohol-based cleaning liquid to clean
the parts. Make sure the two O-rings and the brake are clean,
too.
Reassemble the brake. Install the o-rings, and the plastic washer. Screw on the steel nut.
Use the pre-marked line as guide and tighten the screws to secure the position of the nut.
Use the Sample Rotor test functions in Service level to check proper operation.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 5: Replacement of piercing needle
Frequency:
1 year or 10,000
samples
part#: HAM165AE (Included in kit)
This component is mandatory to replace during maintenance visit as this part may get
worn out by the time and use of the analyzer. In case of missing out this step the risk of
sampling errors will be high. In case the needle tip gets worn out the needle can rip a bit
from the sample vials rubber cap and can get clogged.
Use the Norma UNF tool (not included) to manipulate the sampling needle
To access the piercing needle, the closed wash
head must be pushed away from the needle. Use
a 2mm hex key to secure the wash head in its
open position.
Now the UNF tool fits in between the shear valve
and the sample rotor. Unscrew and remove the
piercing needle.
Install the new needle. Make sure when it is tightened, the needle opening (the
cut tip) faces towards the right side; towards and into the wash head. This way
liquids leaving the needle will be captured by the wash head. If you install the
needle in the wrong position, you may experience waste drops around the
shear valve.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 6: Leakage detector check
Frequency:
1 year or 10,000
samples
part#: HAE053A (NOT included in kit)
Replace the pins if they are corroded, or damaged.
To check the pins, remove the connection from the shear valve waste collector at the right
side of the shear valve.
Reinstall new pins in the shear valve waste collector.
Step 7: Closed wash head check
Frequency:
1 year or 10,000
samples
part#: N/A
As the wash head is exposed it is now visible if there is any dirt, residuals are on it. Use a
brush to clean the wash head in and out.
Use the white grease from the KIT to lubricate the axis the wash head is turning. It is
possible to put a little drop between the moving and the still plastic part of the was head as
well.
Check the wash head alignment. In case the needle is not in the middle of the wash head
in all directions when the head is closed adjust its position by the two screws. See picture
Check if the wash head is closing back firmly. If it seems it is not moving freely loose its
fixing screw a bit.
Also make sure the wash head closed state sensor is operating the adjustment is proper
as well.
For further details please refer to the service manual.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 8: UNF connectors check
Frequency:
1 year or 10,000
samples
part#: N/A
To make sure that all connections are secure, go through all UNF screws and check their
tightness.
-Use your fingers and the UNF tool if
needed.
-Overtightening may cause damage to
the threads, but loose connection will
cause leakage in the fluidic system
which will show up in erroneous
results.
-If there are visible white salt deposits on the connector, it is a sign of leakage.
-Unscrew this UNF and clean off the residuals. Check the condition of the UNF
screw and the other part as well.
If the UNF connector of the tube or the other part (for example valve manifold) is damaged
or cracked, then replace it.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 9: Check Injectors
Frequency:
1 year or 10,000
samples
part#: N/A
There are two injector blocks equipped with 3 injectors each and one super micro injector
in the system.
Check the state of all injectors look for salt deposits
around their bottom fixing plate. In case there is any it
is maybe a sign of a slight leakage of that injector or of
the related valves.
Check the state of the injectors piston if there is any visible crack around it.
In case of any issue with the microinjector replace the complete part. The part# is
HAM151A.
In case of injector replacement refer to the service manual as new injector will need to get
addressed.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 10: Verify Mixer operation
Frequency:
1 year or 10000 samples
part#: N/A
Get access to service level and check if the mixer is working
properly.
In case of any error, replace the mixer.
Step 11: Reagent sensors and connections
Frequency:
1 year or 10000 samples
part#: N/A
Make sure all tubes are properly placed in
the reagent sensors.
It should “click” in.
In case there is a liquid detection problem, clean the sensors with a brush. Run priming
sequence to see if the sensors are working properly.
Check reagent pickup tube connections to analyzer and reagent containers. In case a
connection is loose damaged cut 10mm from the end of tubing and reconnect.

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TDMG0002 Icon-5 Maintenance Guide –Version: 02 –Release date: 2020-04-27
Step 12: CMOS battery replacement
Frequency:
2 year or 20000 samples
part#: HAT809A (Included in kit)
After every 2-3 years the RTC battery will drain.
Battery maintains the operation of the system
clock (RTC).
-Replace the battery on the Liliom board
every 2 years.
-Do not use metal tools when replacing
the battery, you may cause short circuit
and a damage the board or the battery.
-Do not touch the surface of the new
battery by fingers, because
contamination, salt or moist may speed
up draining process or prevent proper
electrical connection between the battery
and its holder.
-Use of rubber gloves is recommended.
-After replacing battery, do not forget to
set actual date and time.
In case the battery is drained the date will set to default: 1st May 2009.
All measurements with drained battery will run on this date.