Service Manual

360
Fully Automatic Hematology Analyzer Service

Vapi, Gujarat

Web: www.merillife.com Phone: +91 260 305 2100

Chapter 1 Foreword 1

Chapter 2 Function and operation 2

2.1 Simple operation 2
2.2 Founction Introduction 3
2.2-1 Founction Module Diagram 4
2.2-2 Connection Port of Complete Machine 7

Chapter 3 Maintenance 14
3.1 Routine Maintenance 14
3.1.1 Clean the Appearance 14
3.2 Daily Maintenace 15
3.3 Weekly Maintenance 15
3.4 Monthly Maintenace 15
3.5 Yearly Maintenance 16
3.6 Maintenance Before Transport or For the Instrument that will not be used for
along time 16

Chapter4 Troubleshooting 17

Chapter5 Liquid System diagram 25

Chapter6 Mechanical Assembly 26

 Chapter 1 Foreword

This manual includes the information about functionality, daily operation and
maintenance. To achieve the optimal performance, be sure to operate and maintain the
instrument according to this manual.

Functionality
Operation
Maintenance.

In the chapter 2
There are diagrams related to express function and operation.

In the chapter 3
Maintenance is mentioned.

In the chapter 4
This includes Errors encountered during operation of the machine and trouble shooting.

1
 Chapter 2 Function and operation

2.1 Simple Operation

First: Front panel

Display

Sample Needle

Power Light

Aspiration Switch
Printer Cover

2-1 Diagram Front Panel

2
 Chapter 2 Function and operation

Second：Operation Process

1) Test blank once，after that it will show the data for the background check .Repeat
blank test till the values of all the five parameters namely WBC, RBC, HgB,PLT and
MCV are within the acceptable range.

2) Once Blank is in acceptable range patient samples can be tested . Put the patient
sample under the sample probe and press the start key . Ensure that bubble is not
entering during the aspiration procedure . Move the sample tube along with the
sample probe so that sample enters correctly into the measuring chamber.

3) Before the test is completed no other operation can be executed . After completion the
needle come back to the home position and is ready for the next sample aspiration.

4) Press the key “print”. The results are printed on the thermal printer paper

5) After finishing measure sample click the right key，the menu will pop-up
last bar of the menu is “shutdown” key，press this key，it will show “please
shutdown power “ a few minutes later, operator can turn off the power.

3
 2.2 ) Function Introduction

2.2-1. Function Module Diagram

1. Interface board

P104 bus

Motor control CPLD--->printer driver Printer driver

and One-way
CPLD total
WBC-RBC
drive unit control unit CPLD<--- W¡¢R
enlarge
(PC104 Board)

Electromagne c
CPLD<---HGB HGB ·enlarge
Two-way
Valve drive

Analog power supply

4
 2.2 ) Function Introduction

Simple Introduction

1) CPLD (PC104 board) total control unit.

Control every function module how to communicate with PC104 board.

2) Motor control and driver

Control motor working and amplify signals.

3) Electromagnetic valve driver.

Amplify the signals of electromagnetic valve driver.

4) Printer driver.
Amplify the signals of printer driver.

5) WBC-RBC amplify
Amplified WBC-RBC signal that can be earlier to change it to digital signal.

6) HGB amplify
i)Amplified HGB signal that can be earlier to change it to digital signal.
ii)Supply power to the HGB lamp.

7) PC104 bus.
The bus that Connect computer board with CPLD of interface board.

8) Analog power supply.

1) Supply power to each part, +48V, +12V, +8V, 8V.
2) Protect each part supply power.

5
 2.2 ) Function Introduction

2) Mechanism Fasten Board Module Introduction

1) Function Diagram

Sampling pump
TWO WAY

Sampling
Liquid
needle Two way

and road
And flow
bracket
Vacuum
Sensor
Two way
Measure pump
board
cup

·
2 . Simple Introduction
1) Liquid tubing board and flow sensor board.
I)Liquid tubing board.
Each valve control the liquid tubing in measurement.
ii)Flow sensor board.
Precise ration for the measured volume.
2) Sample needle.
Aspirate outer sample.
3) Measurement cup
The place where measuring sample is kept.
4) Vacuum pump
Let the related liquid from measured cup to vacuum room.
5) Sampling pump
Create force when aspirating sample.

6
2.1. Connection part of complete machine

2.1.1. Interface Board:-

A) Motor & Opto-Interrupter:-

I) JP28:- For motor A connection; to vertical assembly movement.

ii) Jp29:- For motor A Opto-interrupter; is used to make optical detection of vertical assembly
movement.
iii) Jp30:- For motor B connection; to horizontal assembly movement.
iv) Jp31:- For motor B Opto-interrupter; is used to make optical detection of horizontal
assembly movement.
v) Jp24:- For motor C connection; to Diluter assembly movement.
vi) Jp25:- For motor C Opto-interrupter; is used to make optical detection of diluter assembly
movement.
vii) Jp27:- For motor D connection; to pressure pump assembly movement.
viii)Jp26:- For motor D Opto-interrupter; is used to make optical detection of pressure pump
assembly movement.

7
2.1. Connection part of complete machine

B) PC104 Board Connection:- Compose with two connector ie,J22 & J23. For connection
between interface board and PC104 board.
C) Valve Input:- For Valve connector ie, JP19. To on/off valve connection for V1-V12.
D) Connection for Liquid sensor board:- JP10 is input connection for liquid sensor board.
E) Reagent sensor:-
I) J32:- Opto-interrupter to detection of diluent’s empty.
ii) J33:- Opto-interrupter to detection of rinse’s empty.
iii) J34:- Opto-interrupter to detection of lyse’s empty.
F) Aspiration Key:- ASP switch is sense by ASP switch by pressing Aspiration key.
Connected with interface board connector JP8.
G) Power input:- Input supply which comes from SMPS is 5Vdc & 12Vdc directly connected
with interface board JP32.
H) Analog power control:-
I) JP5:- To provide supply for transformer to generate high voltages at the time of
troubleshooting of board.
ii) Jp3:- Check voltages at the time of troubleshooting, i.e.
At 1&2 voltage is +16Vdc
At 3&4 Voltage is +12Vdc
At 5&6 Voltage is -12Vdc
At 7&8 Voltage is +42Vdc
I) HGB amplifying module:-
I) VR6:- Used to gain adjust HGB signals.
ii) Vr5:- Used to offset adjust HGB signals.
iii) Jp1:- For used to connect LED & Photo-diode in chamber.
J) WBC-RBC amplifying module:-
I) VR1, VR2 & Vr7:- Used to adjust resistance of WBC-RBC-PLT signal.
ii) J1 & J2 :- For input signals for WBC-RBC-PLT signal.
iii) J4 :-110V voltage input from transformer to burn clotting in chamber.

K) Printer Board:- For given signals (connector JP17) to printer board. To print results.

L) LCD back-light :- To provide input signals (connector JP12) to LCD Back-light PCB.

8
2.1.2. PC104 Board:-

PC104 is an embedded industrial main-board developed in 96×115mm size with low-power

multi-function 586 grade AMD LX800 500Mhz CPU integrated. There’re VGA/LCD, two
10/100Mbps LANs, 4 serial ports, 1 parallel port, 4 USB2.0, audio, 65536 Watch-dog, 16
routes digital I/O, PC/104 BUS and 256M Bytes DDR SDRAM on board. A 2.5”notebook
hard-disk connector can support 2 IDE hard-disks.Since AMD low-power consumption
LX800 CPU with BGA package used in this board, it can work under
0～60C without cooling-fan. Onboard CPU and memory enhance its stability and
reliability.
The LCD connector on board can support TFT LCD screen by those resolution like
640×480, 800×600,1024×768, LVDS supported too. 44-pin IDE connector can support
DOM or CF on board. 8 layers PCB design enhance its EMI\EMC ability. PC104 can be widely
used in all kinds of embedded application field, such as medical equipment, internet
terminal, communication application by its multi-function, small dimension.

9
2.1.2. PC104 Board:-

Corresponding Port Introduction:

1) CN1: connect to VGA
2) CN2: connect to LVDC or TFT
3) CN3: For CF Card connection
4) CN4: To Interface with interface board
5) CN5: For USB 1 & 2 connection
6) CN6: For USB 3 & 4 connection
7) CN7: To provide Reset
8) CN8: For Audio connection
9) CN9: For LAN2 connection
10) CN10: For LAN1 connection
11) CN11: For Input supply connection which comes from SMPS is 5Vdc & 12Vdc.
12) CN12: For RS485 connection
13) CN13: For Keyboard/Mouse connection
14) CN15: For Digital I/O connection
15) CN16: For parallel port interface connection
16) CN17: For COM1-2 connection
17) CN18: For COM3-4 connection

10
2.1.2. PC104 Board:-

Corresponding Port Introduction:

1) CN1: connect to VGA

2) CN2: connect to LVDC or TFT
3) CN3: For CF Card connection
4) CN4: To Interface with interface board
5) CN5: For USB 1 & 2 connection
6) CN6: For USB 3 & 4 connection
7) CN7: To provide Reset
8) CN8: For Audio connection
9) CN9: For LAN2 connection
10) CN10: For LAN1 connection
11) CN11: For Input supply connection which comes from SMPS is 5Vdc & 12Vdc.
12) CN12: For RS485 connection
13) CN13: For Keyboard/Mouse connection
14) CN15: For Digital I/O connection
15) CN16: For parallel port interface connection
16) CN17: For COM1-2 connection
17) CN18: For COM3-4 connection

11
2.1.3. Liquid sensor board:-

Supply & signals connector J1 is for Start-Stop action. To start counting of WBC, RBC & PLT.
Start-Stop action means data send from ADC to controller.After counting of cells stop signal
is send to controller.
LEDs are use for volumetric indication of start & stop signal.

2.1.4. Printer Board:-

12
2.1.5. SVC Board:-

SVC(Solenoid valve control) board is used for Solenoid valve on-off functions.
Connector P15:- Communicate with Interface board to SVC board.
Connector P1 to P14:- For connect solenoid valves.

13
 Chapter 3- MAINTENANCE

Chapter 3- MAINTENANCE

As other precision instrument, only careful daily service and periodic maintenance
can keep the instrument in a good working status, and can we get the reliable results and
have few errors.
This chapter introduces some preventive methods for service and maintenance.
If you want to have more information, please contact the customer service department of
MERIL DIAGNOSTICS PVT LTD.
According to the requirements for maintenance of the instrument during the procedures, we
divide the preventive service and maintenance into the following types: daily, weekly,
monthly, yearly and maintenance according to actual need.

Warning:
It is important for the hospital or organization that employs this instrument to carry out a
reasonable maintenance schedule. Neglecting of this may result in machine breakdown.

3.1 ROUTINE MAINTENANCE

3.1.1 Clean the Appearance
Wipe the appearance of the instrument with neutral detergent or distilled water.

Caution:

Avoid using corrosive acids, alkali, and volatile organic solvent such as: acetone, ether,
chloroforms to wipe the appearance of instrument. Only neutral detergent should be used.
Avoid wiping the inner of the instrument.

14
 Chapter 3- MAINTENANCE

3.2 Daily Maintenance

It can be divided into two types: run and shutdown.

Run
The instrument has installed daily maintenance procedure. On running, it can execute auto
cleaning procedure according to the quantity of the sample to keep the instrument in good
working status.
The general setting principles are:
Working time > 8 hours, auto-cleaning time=8 hours;
4 hours<Working time<8 hours, auto-cleaning time=4 hours;
Working time< 4 hours, auto-cleaning time=2 hours;
The auto-cleaning time will decrease 1 hour year by year.

Shutdown
When the instrument is shutdown, it will run daily shutdown auto cleaning procedure. You
only need to clean the workbench and wipe the appearance of instrument when the power-
off.
3.3 Weekly Maintenance
This instrument has installed weekly maintenance procedure.
Act as follows:
a) Prepare E-Z cleanser and probe cleanser.
b) In the main operation window, press the right key of the mouse. In the menu area, select
"Service/Maintenance". Operate as the screen shows.
c) Turn off the power supply.

3.4 Monthly Maintenance

It is necessary to clean the dust of the instrument monthly.
Operate as follows:
a) Turn off the power supply, and pull out the power line.
b) Hold up the air filter cover with slotted screwdriver. Take off the cover and the
net.
c) Clean them with neutral detergent brush and put them in the shade.
d) Airing naturally. Brush away the dust clinging on the air filter grid at the rear
panel of instrument.
e) Put the air filter grid on the air filter net carefully. Spanish them.

15
 Chapter 3- MAINTENANCE

Notice:

Only can use the neutral detergent cleaning the air filter. Avoid airing it with heat.
3.5 Yearly Maintenance
It's necessary to perform preventive maintenance once every year. Because of
the high -requirements of yearly maintenance, the maintenance should be performed by the
authorized engineer of MERIL DIAGNOSTICS PVT LTD. Please contact the customer service
department MERIL DIAGNOSTICS PVT LTD of before yearly maintenance.

3.6 MAINTENANCE BEFORE TRANSPORT OR FOR THE INSTRUMENT THAT WILL

NOT BE USED FOR A LONG TIME
If the instrument is not going to be used in 2 weeks or longer, or needs to be packed and
transported, perform he following procedures:
In the main operation window, press the right key of the mouse, choose "Service/Park" in the
menu.
Operate as screen shows.
Rotate the bottle covers of reagents and store them in proper condition . User should
perform efficient action to prevent the material from deteriorating.
Plug the stopples which were pulled out at the first installation into the corresponding tube
connector.
Pull out diligent connection tube, rinse connection tube, lyse connection tube and waste
connection tube and clean them with distilled water. Dry them in shady place,then packing
them into plastics.
Pull out the power wire, packing it in plastics after cleaning with neutral detergent.
Put the instrument and parts packed in plastics into packing cases.

16
 Chapter-4 TRAUBLESHOOTING

Notice:

Only can use the neutral detergent cleaning the air filter. Avoid airing it with heat.
3.5 Yearly Maintenance
It's necessary to perform preventive maintenance once every year. Because of
the high -requirements of yearly maintenance, the maintenance should be performed by the
authorized engineer of MERIL DIAGNOSTICS PVT LTD. Please contact the customer service
department MERIL DIAGNOSTICS PVT LTD of before yearly maintenance.

3.6 MAINTENANCE BEFORE TRANSPORT OR FOR THE INSTRUMENT THAT WILL

NOT BE USED FOR A LONG TIME
If the instrument is not going to be used in 2 weeks or longer, or needs to be packed and
transported, perform he following procedures:
In the main operation window, press the right key of the mouse, choose "Service/Park" in the
menu.
Operate as screen shows.
Rotate the bottle covers of reagents and store them in proper condition . User should
perform efficient action to prevent the material from deteriorating.
Plug the stopples which were pulled out at the first installation into the corresponding tube
connector.
Pull out diligent connection tube, rinse connection tube, lyse connection tube and waste
connection tube and clean them with distilled water. Dry them in shady place,then packing
them into plastics.
Pull out the power wire, packing it in plastics after cleaning with neutral detergent.
Put the instrument and parts packed in plastics into packing cases.

17
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon

WBC, RBC bubble A)

The situation which 1) Checking the tube connector whether
liquid ow into the is it leakage.
ow sensor board. 2) Enter into sub menu : Mechanic:
A. When the liquid (password:6800)
ow too fast. checking each solenoid valve whether it
WBC,RBC B. When liquid ow is normal , if not, change it.
bubble into ow sensor, both B) When taking count of measurement
lamp is always on or time, check the lamp: when there is
bottom lamp is liquid the lamp will be on, no liquid the
always on. lamp will be off. If the lamp is always on,
press several pieces of gummed papers
until it is normal. for other reason,
change the board.

Detecting the situation A) The most possible is aperture clog :

which liquid ow into B) 1) Enhance ush
the ow sensor board. 2) Cauterant (aperture damaged by
A)The liquid ow caustic reagent )aperture
along wall. 3) Clean the ruby and reassemble the
B)The liquid ow is measurement cup module
WBC and normal. B) Use EZ cleaner to clean wall of ow
RBC clog C )The liquid ow sensor board module.
slowly. C) check whether the two lamp is on, if
D) Whether is the the lamp is always off, change the the
second foot Of board.
interface board D) Resulting from leakage in the vacuum
connector J50 is pump E connect the second foot to the
connected with ground.
ground
Detecting the situation A) Use E-Z cleaner to clean wall of ow
in which liquid ow sensor board module
into the ow sensor B) Change the ow sensor board
board module
A) The liquid ow C) Enter into special (password: 6868),
WBC or along wall the setting time is always 9.5 S
RBC clog B) The liquid ow is
normal
C) The liquid ow
slowly.

18
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon
A) Ground line state A) Detect the voltage of the ground wire
B) whether it is shared and zero curve whether it is less than
socket with large 5V.if it is more than 5V ,reassemble.
efcient machine B) It is separated from the large efcient
C) whether machine.
environment C) Environment temperature is suit for
temperature is suit for the request of the machine
the request of the D) If not, use the function “park” clean
machine all the tubing.
D) The constant E) Change the reagent
maintenance:once F) Descaling ,reassemble
every week
E)Whether the reagent
is expired date or
sordid
PLT unstable F) Check every
module especially the
test cup module
whether it is rusting,
whether the fasten
board is separated
from ground.(how to
check the separation:
unx the signal wire,
check whether the
fasten board is
separated from
cabinet. The right
assemblage is
separation

20
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon
A) Whether the HBG A) If the lamp is off , check whether the 1
lamp is on. feet of U57 is 5V, if not ,change the
B) Whether the HGB interface board
receiver line have B) Reconnecting the receiver line
HGB Malfunction problem. C) Adjust the resistance VR6 to normal
HGB bubble C) Enter into range 4.25—4.31V
mechanic
(password:6800),
check whether the
HGB voltage is normal
range 4.25—4.31

A) Detect whether A) If it is stable,follow B step. If it is

others items is stable unstable, check the sampling volume.
B) Enter into B) If the HGB blank voltage is larger
Hemoglobin mechanic than 0.2V, change the HGB lamp.
unstable (password:6800)
check the HGB blank
voltage uctuation

A) Ground line state. A) Detect the voltage of the ground wire

B) Whether it is shared and zero curve whether it is less than
socket with large 5V.if it is more than 5V, reassemble
efcient machine B) It is separated from the large efcient
C)whether environment machine.
temperature is suit for C) Environment temperature is suit for
the request of the the request of the machine.
machine D) If not, use the function “park” clean
D)The constant: all the tubing.
maintenance once E) Change the reagent.
every week F) Descaling ,reassemble.
E) whether the reagent
PLT value is is expired date or
too high in sordid
ground test F)check every module
especially the test cup
module whether it is
rusting, whether the
fasten board is
separated from
ground.(how to check
the separation: unx
the signal wire, check
whether the fasten
board is separated
from cabinet. The right
assemblage is
separation 19
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon
A) Ground line state A) Detect the voltage of the ground wire
B) whether it is shared and zero curve whether it is less than
socket with large 5V.if it is more than 5V, reassemble.
efcient machine B) It is separated from the large efcient
C) whether machine.
environment C) Environment temperature is suit for
temperature is suit for the request of the machine.
the request of the D) If not, use the function “park” clean
machine all the tubing.
D) The constant E) Change the reagent.
Maintenance :once F) Descaling, reassemble.
every week.
E) Whether the
reagent is expired date
All the items or sordid.
unstable F) Check every
module
E) Specially the test
cup.module whether it
is rusting, whether the
fasten board is
separated from
ground.(how to check
the separation: unx
the signal wire, check
whether the fasten
board is separated
from cabinet.The right
assemblage is
separation.

A) The vacuum pump A) Check whether the voltage in the rst

move in the same foot of connector J36 is 1.2V.if not,
direction. change the sensor. Check the voltage of
B) The vacuum pump three foot in connector, when the sheet
skid. metal enter into sensor, the voltage is
C) when the vacuum 4.0-5.0V; when the sheet metal is out of
Vacuum pump
pump stop moving, sensor, the voltage is 0.0-1.0V.
skid and noise
the piston bounce. if not ,change it
separation. B) As the rack and the gear suffer wear
and tear ,change them.
C) The waste tubing ow
disuency, dredge it.

21
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon
A) If the value of HGB A) Change the piston gasket ring
is zero, the lyse is not of sampling room, and prime lyse.
enough in the tube. B) Reconnect the cup board, if no use,
B) Enter into mechanic change the interface board.
(password: 6800), C) If the screen show the pulse diagram,
check whether the adjust the resistance VR8 clockwise or
WBC no value function “sampling” anticlockwise.
or the value is”*” “break” is normal.
C) If the value of HGB
is not zero,check the
pulse of WBC, RBC,
PLT(enter into special,
the password is 6666,
press F5 to watch the
pulse of WBC )

A) If the value of HGB A) Reconnect the cup board, if no use,

is zero, the lyse is not change the interface board.
enough in the tube. B) If the screen show the pulse diagram,
B) If the value of HGB adjust the resistance VR8 clockwise or
is not zero, check the anticlockwise.
RBC no value pulse of WBC, RBC,
PLT (enter into special,
the password is 6666,
press F6 to watch the
pulse of RBC )

A) Enter into mechanic A) Reconnect the cup board, if no use,

(password:6800), change the interface board.
check whether the B) If the screen show the pulse diagram,
function “sampling” the same solution as “PLT TOO HIGH”
“break” is normal
PLT no value B) If the value of HGB
is not zero, check the
pulse of WBC, RBC,
PLT (enter into special,
the password is 6666,
press F7 to watch the
pulse of PLT ).

22
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon
A) Check the voltage A) If not, the sensor have broken,
of 1 feet of J33 change it.
whether it is 1.2V. B) If the voltage far from the abnormal
B) Whether the voltage range, change the sensor\Opposite,
Distort no lyse of 3 feet is greater than adjust the resistance R153 or R144
3.8 when the tube
have liquid or less
than 2.7V when it have
not liquid

A) Check the voltage A) If not, the sensor have broken,

of 1 feet of J33 change it.
whether it is 1.2V B) If the voltage far from the abnormal
B) Whether the voltage range, change the sensor\Opposite,
Distort no Diluent of 3 feet is greater than adjust the resistance R151or R142.
3.8 when the tube
have liquid or less
than 2.7V when it have
not liquid

A) Check the voltage A) If not, the sensor have broken,

of 1 feet of J33 change it.
whether it is 1.2V B) If the voltage far from the abnormal
B) Whether the voltage range, change the sensor\Opposite,
Distort no Rinse of 3 feet is greater than adjust the resistance R152 or R143.
3.8 when the tube
have liquid or less
than 2.7V when it have
not liquid.

23
Chapter-4 TRAUBLESHOOTING

Malfunction Treatment program

Reason
Phenomenon
A) Inappropriate A) Use the quality control to adjust the
magnication. diagram of WBC.
B) Inappropriate B) Check the sampling.
sampling. C) Detect the store time.
Not be good
C) Inappropriate store
at classication
of blood.

A) No display but A) The connector of screen have poor

other normal. contact.
Only blank B) No display and B) The cup board have poor contact or
in the screen others is abnormal was broken.

A) Alarm when it is not A) There are some problem in the

use the waste sensor. interface board.
B) No alarm when it is B) The waste sensor broken or the
Full waste alarm not use the waste waste sensor have bubble.
sensor.

Printer paper running A) Check if there is printer paper.

out or not Properly B) Check if the printer is well installed.
installed
REC No Paper

24
Chapter- 5 Liquid System diagram

25
 Mechanical Assemblies

A) Fluid Path Mounting Plate Assembly

B) Middle Partition Assembly

26
 Mechanical Assemblies

C) Rear Panel Assembly

D) Probe Shield Box Assembly

27
 Mechanical Assemblies

E)Transverse Assembly

F) Vertical Assembly

28
 Mechanical Assemblies

G) WBC Chamber Assembly

H) RBC Chamber Assembly

29
 Mechanical Assemblies

I) Volumetric PCB Assembly

J) Vacuum Pump Assembly

30
 Mechanical Assemblies

K) 3-Channel Syringe Module Assembly

L) Display Bracket Assembly

31