Human Humastar 180 - Service Manual PDF

HumaStar 180
| Service Manual
Cat No. 16900/200

REVISION LIST OF THE MANUAL
Rev. /DATE. REVISION DESCRIPTION
01/2004-07 First edition
02/2005-07 Addition of Chapter 8
03/2010-11 Adaption to new Corporate Design
04/2011-01 Addition of Chapter 5
SYSTEM VERSION
COPYRIGHT
Copyright 2010, Human GmbH, Wiesbaden, Germany. All rights reserved.
No part of this documentation may be reproduced in any form, nor processed, copied or distribut-
ed by means of electronic systems, without prior permission of Human GmbH in writing. Since all
precautionary measures were taken into account in producing these operating instructions, the
manufacturer accepts no responsibility for any errors or omissions. This includes any liability for
damage that could arise from possible incorrect operation based on this information. Subject to
changes without notice as result of technical development.
SERVICE UND SUPPORT

CONTENTS
TABLE OF CONTENTS
1 SAFETY INSTRUCTIONS 5
1.1 INTRODUCTION 5
1.2 USER WARRANTY 5
1.3 INTENDED USE OF THE INSTRUMENT 5
1.4 GENERAL SAFETY WARNINGS 6
1.5 DISPOSAL MANAGEMENT CONCEPT 6
1.6 BIOHAZARD WARNING 7
1.7 INSTRUMENT DISINFECTION 7
2 SYSTEM INTRODUCTION 11
2.1 INTRODUCTION 11
2.2 CHARACTERISTICS 11
2.3 SPECIFICATIONS 12
2.4 FUNCTIONAL DESCRIPTION 13
2.4.1 Process Management 13
2.4.2 Liquid Handling 14
2.4.3 Carousels, Temperature Control and Cooling 17
2.4.4 Measurement System 20
3 ELECTRONICS 23
3.1 INTRODUCTION 23
3.2 SCHEMATIC DIAGRAM OF ELECTRONICS 23
4 SERVICE SOFTWARE “EULY SERVICE” 25

4.1 INTRODUCTION 25
4.2 INSTALLATION OF EULY SERVICE 25
4.3 SERIAL SETTINGS 25
4.4 SCRIPT 25
4.4.1 Example for a reading through Euly Service Script 31
4.5 REAGENTROTOR 31
4.6 CUVETTEROTOR 31
4.7 BELT 31
4.8 PIPETTOR 32
4.9 EULYTEST 32
4.10 ENDURANCE TEST 32
4.11 DEVICE DATA 32
4.12 FW UPDATE 32
4.13 PHOTO 32
4.14 PUMPS-VALVES 32
4.15 INFO 32
5 MAINTENANCE 33
5.1 INTRODUCTION 33
5.2 SYRINGES 33
5.3 SYRINGE VALVES 33
5.4 TUBINGS 33
5.5 PHOTOMETER 34
5.6 X-DRIVE 34
5.7 Z-DRIVES 34
5.8 LIQUID DETECTION 35
5.9 MAGNETIC VALVES 35
5.10 PROBES 35
5.11 MEMBRANE PUMPS 35
6 TESTS/TROUBLESHOOTING 37
6.1 INTRODUCTION 37
6.2 FUNCTIONAL TESTS 37
6.3 TROUBLESHOOTING 39
6.3.1 Reagent Rotor 39
6.3.2 Cuvette Rotor 40
6.3.3 Belt 42
6.3.4 Pipettor 44
6.3.5 Liquid Detection 45
6.3.6 Liquid Flood 47
6.3.7 Communication 48
7 REPLACEMENT 49
7.1 INTRODUCTION 49
7.2 CAROUSEL UNIT WITH NEW REAGENTROTORSENSOR 49
7.3 CAROUSEL UNIT WITH OLD REAGENTROTORSENSOR
(POTENTIOMETER) 54
7.4 CENTERING MAGNET 59
7.5 COVER 64
7.6 CUVETTE DRIVE MOTOR ASSEMBLY 67
7.7 CUVETTE ROTOR BOARD 71
7.8 MASTER BOARD 72
7.9 PHOTOMETER 74
7.10 PIPETTOR ARM 76
CONTENTS
7.11 PROBES 80
7.12 REAGENT ROTOR CONTROL BOARD 82
7.13 REAGENT ROTOR POTENTIOMETER 83
7.14 SYRINGE PUMPS 89
7.15 WASHING PUMPS 92
8 ADDITIONAL INFORMATIONS 95
8.1 INTRODUCTION 95
8.2 PIPETTOR ARM 95
SAFETY INSTRUCTIONS 5
1 SAFETY INSTRUCTIONS
1.1 Introduction
This manual is considered part of the instrument and must be available to the
operator and the maintenance personnel. For accurate installation, use and
maintenance, please read the following instructions carefully.
In order to avoid damage to the instrument or personal injury, carefully read
the ”GENERAL SAFETY WARNINGS”, describing the appropriate operating pro-
cedures. Please contact your HUMAN authorised local Technical Service in the
event of instrument failure or other difficulties with the instrument.
1.2 User Warranty

HUMAN warrants that instruments sold by one of its authorised
representatives shall be free of any defect in material or workmanship, provided
that this warranty shall apply only to defects which become apparent within
one year from the date of delivery of the new instrument to the purchaser.
The HUMAN representative shall replace or repair any defective item within this
warranty period at no charge, except for transportation expenses to the point
of repair.
This warranty excludes the HUMAN representative from liability to replace
any item considered as expendable in the course of normal usage, e.g.: lamps,
valves, syringes, glassware, fuses, tubing etc.
The HUMAN representative shall be relieved of any liability under this warranty
if the product is not used in accordance with the manufacturer‘s instructions,
altered in any way not specified by HUMAN, not regularly maintained, used with
equipment not approved by HUMAN or used for purposes for which it was not
designed.
1.3 Intended Use of the Instrument

The instrument must be used for its intended purpose (see paragraph 2). It must
[IVD]
be operated in perfect technical conditions, by qualified personnel, in such
working conditions and maintained as described in this manual, in the GENERAL
SAFETY WARNINGS. This manual contains instructions for qualified professional
operators.
6
1.4 General Safety Warnings

Use only chemical reagents and accessories specified and supplied by
HUMAN and/or mentioned in this manual. Place the product so that it has
proper ventilation.
The instrument should be installed on a flat, stationary working surface, that is
free of vibrations.
Do not operate in area with excessive dust.
Operate at temperature and at a humidity level in accordance with the
specifications listed in this manual.
Do not operate this instrument with covers and panels removed.
Use only the power cord specified for this product, with the grounding
conductor of the power cord connected to earth ground.
Use only the fuse type and rating specified by the manufacturer for this
instrument.
The use of fuses with improper ratings may pose electrical and fire
hazards.
To avoid fire or shock hazard, observe all ratings and markings on the
instrument.
Do not power the instrument in environments that are potentially explosive or
at risk of fire.
Prior to cleaning and/or performing maintenance on the instrument, switch off
the instrument and remove the power cord.
Only cleaning materials described in this manual may be used, as other mate-
rials may damage parts. It is recommended to always wear protective clothing
and eye protection while using this instrument.
All warning symbols that appear in this manual must be carefully observed.
1.5 Disposal Management Concept

The applicable local regulations governing disposal must be observed. It
is the user‘s responsibility to arrange for proper disposal of the individual
components.
All parts which may contain potentially infectious materials must be
disinfected by suitable, validated procedures (autoclaving, chemical treatment)
prior to disposal. Applicable local regulations for disposal must be carefully
observed. The instruments and electronic accessories (without batteries, power
packs etc.) must be disposed of according to the applicable local regulations
for the disposal of electronic components.
HumaStar 180 | Service manual

Batteries, power packs and similar power sources must be removed from
electric/electronic parts and disposed of in accordance with applicable local
regulations.
1.6 Biohazard Warning

Analytical instruments for in vitro diagnostic application involve the handling
of human samples and controls which should be considered at least potentially
infectious. Therefore every part and accessory of the respective
instrument which may have come into contact with such samples must equally
be considered as potentially infectious.
The „BIOHAZARD“ warning label must be affixed to the instrument prior to first
use with biological material!
FIGURE 1
Biological Hazard
Symbol
1.7 Instrument Disinfection

Before performing any servicing on the instrument it is very important to
thoroughly disinfect all possibly contaminated parts. Before the instrument is
removed from the laboratory for disposal or servicing, it must be
decontaminated. Decontamination must be performed by authorised well-
trained personnel, and in observance of all necessary safety precautions.
8

Notes:
10

SYSTEM INTRODUCTION 11
2 SYSTEM INTRODUCTION
- Characteristics, Specifications & Performance
- Functional Description
2.1 Introduction
HumaStar 180 is a fully automated, random access Clinical Chemistry Analyser
for wet chemistry applications. It has an open structure, so that reagents from
most manufacturers can be used on the system.
HumaStar 180 is computer controlled and uses the Software Package „DETect“
for data reduction and result evaluation.
HumaStar 180 has been developed in a way as to maximise throughput at
maximum comfort, and at the same time to minimise maintenance efforts to be
taken by the user.
HumaStar 180 is fitted with a patented, maintenance free measuring street,
featuring 20 photometer channels for individual wavelength selection and
maximum flexibility.
2.2 Characteristics
Access Modes: - Random Access

- Stat (immediate access and execution)
Processing Modes: - Patient by Patient
- Test by Test
Analysis Modes: - Endpoint (Substrates)
- Kinetic (Enzymes)
- Initial Rate (fixed time kinetics)
- Serum Blank (differential)
- Turbidimetric (immunoturbidimetry)
- Multi Standard (quantitative)
- Bichromatic
- Multi Chemistry
- Intermethodes Calculation (mathematical)
12
2.3 Specifications
TABLE 1
Throughput: - around 150 Tests/hr under speed – optimised
conditions
Carousel: - 25 reagent positions (with SW update up too
50 positions)
- 25 sample positions (random access)
- 25 serum cup positions (minimum 300μl
volume)
- 300 test positions (75x4 cuvettes)
- Customized carousels available !
Liquid Handling: - 2 independent Syringes:
Sample: 1 - 200μl in 1μl steps
Reagent: 1 - 900μl in 1μl steps
- CV less 2,0% for Volumes > 10μl
- High pressure washing
- Autocleaning
- Backflush function
- Easy maintenance
Measurement System: - Maintenance Free !
- Light sources: LED
- Detectors: Photodiodes
- Temperature controlled
- 5 inbuilt photometers, 4 channels each
- 20 independent channels
- up to 20 different wavelegths at a time
- Wavelength range: 340 – 900 nm
- Standard filters:
- 340, 405, 505, 546 & 620nm (4 each)
- Resolution: 0,0001 ABS
- Accuracy: <1% CV at 1ABS / 405nm
- Linearity: 0.0000 – 3.0000 OD better than +/- 1%
- Drift: less than 0.001 OD / hr
Temperature Control: - Reagent cooling (ambient minus 10°C)
- (water circulation w/ external cooler)
- Cuvette heating (electrical) in carousel and
- reading path: 37°C
- Liquid heating (electrical) in probes

Power Requirements: - 85-264V, 50/60 Hz (autodetecting)

- Power Consumption: max 150 VA
- Mains Fuse: 2 x 2A T (slow blow)
Measures: - Dimensions: 810 x 550 x 550 (w x d x h)
- Weight: 28kg
Environmental: - Operation: 18 - 35°C, 10 - 90% rel. Hum.
- Storage: -40°C – 70°C, 5 – 95% rel. Hum.
Options: - External ISE module f. electrolytes
- Handheld Barcode Reader f. pos. Sample ID
Disposables: - Cuvette block for 4 tests each
(typical reading volume 200μl)
- Reagent bottles
- Serum Cups (1,5ml-minimum volume 300μl)
Overvoltage Cat.: II
Pollution Degree: 2
Method of Disposal: - Contaminated Waste
Usage: - Commercial
2.4 Functional Description

The Clinical Chemistry Analyser “HumaStar 180” comprises the following main
functional units:
- Process Management
- Liquid Handling
- Carousels
- Temperature control
- Cooling (optional)
- Measurement System
- DETect Software package
The following explains the functions of all these units, as well as their
interference within eachother.
2.4.1 PROCESS MANAGEMENT

The working principal of HumaStar 180 is based on a
modular system, which is controlled by a PC via the Process Manager (inbuilt in
HumaStar 180).
14
Each module is fitted with it’s own “intelligence” and functions as a slave to the Process
Manager. The process manager is connected to a PC via RS 232 and receives his orders from DETect
Software package running on the PC. When a process is started on DETect (e.g.: testing a sample
for certain paramters), DETect cuts the complete process into the required steps:
- Washing the probes

- Pipetting the reagent(s)
- Pipetting the sample
- Mixing
- Incubating
- Reading
These process steps are sent to the process manager in the instrument, one at a time, exactly
whenappropriate. The process manager himself distributes the necessary commands to the
modules. The modules “fulfill the order” and report back to the process manager, which himself
provides DETect with the actual status accordingly.
2.4.2 LIQUID HANDLING

The functional unit “Liquid Handling” consists of two independent Liquid paths, one for Sample
pipetting and one for Reagent pipetting. All involved electrical components such as drive motors,
valves and syringes are connected to and controlled by the central Process Manager.
FIGURE 2
Liquid Path
Z Movement Valve Positions:
VP a
X Movement
3
VP b
6 4
VP c
13 11 5 2
10 7
9 8
12
Waste System
14 Liquid 1

Explanation:
1 System Liquid Bottle 6 Probe w. liquid detection 11 Wash Station

2 Membrane Pump 7 Cuvette 12 Splitting Valve
3 Syringe 3-way Valve 8 Reagent Container 13 Waste Membrane Pump
4 Syringe Pump & Syringe 9 Primary Sample Tube 14 Waste Bottle
5 Syringe Pump Drive 10 Serum Cups
Both liquid paths are built up identical, with the only difference of the size of the
syringes and the probes:
Syringe: 1ml for Reagent path Probe: 0.5 mm inner diameter for Reagent path
250 μl for Sample path 0.4 mm inner diameter for Sample path
X- and Z – movement are realised by the pipetting arm, which holds the
probes and the probes drives, together with all necessary motors, sensors and
electronics.
2.4.2.1 Pipetting cycle

The system is able to pippete reagents in either single- or multi pipetting mode.
Multipipetting mode means that, a multiple of the required reagent volume per
test of one reagent will be aspirated and then be distributed into the different
target containers (cuvettes) accordingly.
A complete pipetting cycle incorporates the following steps:
Single Pipetting (Sample or Reagent)
Wash probe
- move probe in Z direction into wash station
- flush with System liquid for a pre-defined time span
- lift probe in Z direction to top position
Pick up source liquid

- move probe in X direction to source container (reagent container, sample
tube or serum cup)
- move probe in Z direction into source container until liquid is detected
- aspirate the required test volume (driven by syringe pumps)
16
REAGENT Pipetting:
Pipette liquid into target container
- move probe in X direction to target container (Cuvette)
- move probe in Z direction into target container
- pipet required test volume into target container
SAMPLE Pipetting:
Pipette liquid into target container
- move probe in X direction to target container (Cuvette)
- move probe in Z direction into target container until liquid is detected
- pipet required test volume into target container
- mix by aspirating and re-pipetting
Move probe in X direction to home (Washstation)
Multi Pipetting (Reagent only)

Wash probe
- move probe in Z direction into wash station
- flush with System liquid for a pre-defined time span
Pick up source liquid

- move probe in X direction to source container (reagent container)
- Move probe in Z direction into source container until liquid is detected
- aspirate a multiple of the required test volume (driven by syringe pumps)
Pipet liquid into target container

- move probe in X direction to target container 1 (Cuvette)
- move probe in Z direction into target container 1
- pipet required test volume into target container 1
- move probe in X direction to target container 2 (Cuvette)
- Move probe in Z direction into target container 2
- pipet required volume into target container 2
- repeat for target containers 3 - n
Move probe to home (Washstation)

2.4.3 CAROUSELS, TEMPERATURE CONTROL AND COOLING

HumaStar 180 is using two Carousels, the Inner and the Outer Carousel. Both
carousels are directly connected to and controlled by the central Process
Manager.
- The INNER Carousel for carrying Samples, Reagents, Standards,
Calibrators and Controls. The inner carousel can optionally be cooled. This
option comprises an external cooling unit and cooled liquid is circulated
underneath the inner carousel.
- The OUTER Carousel for carrying the disposable Cuvettes. The outer carousel
is temperature controlled to 37° C (standard).
FIGURE 3
Carousels, loaded, inside
Instrument
Inner
Outer Please refer to Chapter 2 for

instructions on how to re-
move, load and replace the inner
carousel.
2.4.3.1 Inner Carousel
The inner carousel can easily be removed for loading.
*2 Controls, marked as C1 and C2

FIGURE 4
1
10 Standards / Calibrators marked Inner Carousel
2 as S1, S2 ... S10 (if less or no Std/
3 Cal are used, these positions can
The Inner Carousel features:
be used for additional Samples)
1 25 Positions for Reagents,
marked as 1, 2 ... 25
13 free positions marked as 26,
2 25 Positions for Primary
27 ....... 48
Sample Tubes, marked as
1, 2 ... 25
3 25 Positions for Serum
Cups for:*
18
FIGURE 5 Empty Bottles can be ordered from Human:

Reagent bottle Cat. number 16900/2
FIGURE 6 1.5 ml Serum Cups can be ordered from Human:

Serum cup Cat. number 16904
max 10,5 mm
2.4.3.2 Outer Carousel

The outer carousel can not be removed for loading. Graph 1.17 just gives a better
impression of what the outer carousel is like.
FIGURE 8
Cuvette Block
FIGURE 7
Outer Carousel
The Outer Carousel features Each Cuvette Block contains 4 Cuvettes, for
75 Positions for Cuvette Blocks one test each.
Total loading volume: Cuvettes for 300
Tests. These Cuvette Blocks are unique
and can only be ordered from Human:
Cat number 16900/1
2.4.3.3 Functions of the Carousels

Temperature control of Outer Carousel
The temperature control of the outer carousel is effected by thermo resistors,
connected to an electronic regulating circuit. Together with temperature
sensitive sensors connected to the same regulating circuit, a stable temperature
is provided to the cuvettes throughout the whole test run.

Cooling Option of Inner Carousel

The cooling of the inner carousel is effected by cooled water circulating un-
derneath the inner carousel, within a closed spiral copper tube. This copper
tube is connected to an external cooling generator, the system is closed and
independent from a tap water connection.
Insulation
In order to prevent temperature – interferences between the (optionally) cooled
inner and the temp. controlled outer carousel, an insulation ring is dividing the
two carousels.
Rotation
Both Carousels are controlled and rotated independently, within a co-axial
mechanical system.
Besides keeping samples, reagents and test containers in stable temperature
environment, actually the main function of the carousels is to provide the
Y – movement of the source and target containers within the pipetting and
measuring system of HumaStar 180.
The carousels are rotated while other processes within the complete system are
being performed. By doing so, the time required for rotating and positioning the
carousels is not a critical factor in terms of process time and throughput.
The Inner Carousel is only to be rotated during pipetting steps, as described

under 2.4.3.
It is rotated in either clockwise or counter clockwise direction and provides the
source containers required for a specific pipetting step to be positioned precisely
underneath the probes.
The Outer Carousel is to be rotated during pipetting steps as described under

2.4.3.
Additionally, the outer carousel is to be rotated during measurement steps as
described under 2.4.4
For pipetting, it is rotated in either clockwise or counter clockwise direction
and provides the target containers required for a specific pipetting step to be
positioned precisely underneath the probes.
For measurement steps, it is rotated in either clockwise or counter clockwise
direction and provides the target containers required for the measurement step
to be positioned precisely at the entrance position of the Linear Photometer
street.
20
2.4.4 MEASUREMENT SYSTEM

HumaStar 180 is fitted with a unique Linear Photometer, featuring 20 independent measurement
channels for fast and accurate reading of test results in the cuvettes.
These 20 channels are organised in 5 groups of 4 channels each, whereas each group of 4 channels
is controlled by two electronic boards: One light emitting board and one detection board. These
are directly connected to the central Process Manager
Each of the 5 light emitting boards is fitted with 4 light sources (LED, light emitting diodes) and
the respective control electronics.
Each of the 5 detection boards is fitted with 4 detectors (Silicon Diodes) and the respective signal conver-
ter electronics, as well as with a RS 232 port which connects it with the Process Manager.
Cuvettes in 1 Cuvette block in

FIGURE 9 Cuvette Transport Cuvette Transport
outer carousel Reading Position
Measurement Notch Belt
system
Cuvette
Transport
Motor
Detection board
Detector
Interference Filter Cuvette Block
Optics (lens)
Light beam
Optics (lens)
Light source "LED"

Light emitting board

For reading, the cuvette block is transported from the outer carousel through the
linear photometer by a transport belt.
Depending on the wavelength required for the measurement, the cuvette block
will be positioned into the 4 light beams of the respective photometer block.
The light emitted by the LED’s is directed through a focusing lens. This lens
ensures a light beam, which is as parallel as required for having homogenous
measurement conditions.
While passing the cuvettes, respectively the liquid in the cuvettes, a part of the
light energy is being absorbed by the liquid in the cuvette. The remaining light
energy is now passing another lens and the respective interference filter and is
then being measured by the detectors.
22

ELECTRONICS 23
3 ELECTRONICS
- Schematic Diagrams
3.1 Introduction
This chapter gives information on the electrical and electronical components of
the Human system.
FIGURE 10
3.2 Schematic Diagram of Electronics
24
FIGURE 11

SERVICE SOFTWARE “EULY SERVICE” 25
4 SERVICE SOFTWARE “EULY SERVICE”
4.1 Introduction
This chapter gives the instructions on how to test functionality of all
independent modules of HumaStar 180 by using the Service Software
“EulyService”.
4.2 Installation of Euly Service

EULY SERVICE REQUIRES EXCEL 2000 ™ and will not work with older versions !
Copy the Service-Software-Folder to your local harddrive.
Start Microsoft Excel ™.
Open the file “EulyService.xls”.
Activate macros (set the security-level accordingly).
Microsoft Excel ™ will display a new Menu point “EulyService”.
4.3 Serial Settings

Set the serial port by selecting the menucommand “EulyService” -> “Serial
Settings”.
4.4 Script
A script consists of a string of commands, which are explained in this section of
the Service manual.
26
The menucommand “EulyService” -> “Script” launches displays the following

screen.
FIGURE 12
EuLy Service Script
Screen
List of prede- Contents of Result window of

fined saved predefined tests performed
scripts, if saved scripts,
there is any if there is any
In the list „Scripts:“ a script can be selected.

In the field „Scripttext:“ the text of the selected script is shown.
In the field „Iterations:“ the number of iterations can be entered.
By clicking „Start“ the selected script is started.
In the field „Result:“ the results are shown.
By clicking „Stop“ the script is stopped.
Script features a command set that allows service personnel to check and
confirm functionality of modules of HumaStar 180. Every single module and it’s
sub-functions can be checked independently.
When processing commands, Script requires command strings that determine the module, the subfunction
Euly Service does not check and the actual command for the respective function.
for sensors ! It is the responsibili-
ty of the Service engineer to make A command – string consists of:
sure, that only command strings - Module Code
are being entered, that can not - Command
damage mechanical parts. - Parameter
The Module codes, Commands and Parameters are explained on the following
pages (all letters are case sensitive !)

IMPORTANT NOTES:
Before starting X-movement of the pipetting arm, both probes must be in top
position !
Commands: “ Zi “ (initialises left Probe) and “ Zj “ (initialises right Probe)
Before starting Cuvette Rotor movements, make sure the Belt drive is
initialised! Command: “ Mi ”
Photometer Belt Movements: positioning within the photometer is only

possible after switching all LED’s on, and initialise Belt.
Command: Xh (where X here stands for the photometer number 1 – 5)

Command: Mi to initialise Belt
28

FIGURE 13
Module Mod. Code Module Function Command Parameter Command String: Effect
Master 0 (zero) Reset all modules r 0r performs a reset on all modules

Get State g 0g gives status of module
Get Version v 0v gives firmware version of module

Get Sensors s 0s gives status of all sensors
Wait W xxxxx Wxxxxx system "Rest" for xxxxx milliseconds

Washer Pumps w 0 (zero) 0w0 MV off WP off AP off (*) (*) MV = Magnetic Valve
WP = Wash Pump
1 0w1 MV off WP off AP ON AP = Aspiration Pump
2 0w2 MV off WP ON AP off
3 0w3 MV off WP ON AP ON
4 0w4 MV ON WP off AP off
5 0w5 MV ON WP off AP ON
6 0w6 MV ON WP ON AP off
7 0w7 MV ON WP ON AP ON
Sample Pipettor d1 ZR 0d1ZR Initialise

IR 0d1IR Move Valve to Input position
OR 0d1OR Move Valve to Output position
These steps always
require initialisation first ! BR 0d1BR Move Valve to Bypass position
AxxxxR 0d1AxxxxR Move syringe to position xxxx (0-1000)
PxxxxR 0d1PxxxxR Move syringe down for xxxx steps
DxxxxR 0d1DxxxxR Move syringe up for xxxx steps
pR 0d1pR start syringe prime cycle
Reagent Pipettor d2 ZR 0d2ZR Initialise

IR 0d2IR Move Valve to Input position
OR 0d2OR Move Valve to Output position
These steps always
require initialisation first ! BR 0d2BR Move Valve to Bypass position
AxxxxR 0d2AxxxxR Move syringe to position xxxx (0-1000)
PxxxxR 0d2PxxxxR Move syringe down for xxxx steps
DxxxxR 0d2DxxxxR Move syringe up for xxxx steps
pR 0d2pR start syringe prime cycle
Photometer drive M Get State g Mg gives status of module
Get Version v Mv gives firmware version of module

Initialise i Mi position belt in valid position
Position x a,b Mxa,b (with comma !) move cuvette to a (0-6) from b (0-5) (*) (*) 0 = Rotor
1 = Photometer 1
2 = Photometer 2
3 = Photometer 3
4 = Photometer 4
5 = Photometer 5
6 = Waste disposal
Before cuvettes can be
Pipettor X drive X Get State g Xg gives status of module moved / positioned within
the photometer, the LED's
must be turned on:
SERVICE SOFTWARE “EULY SERVICE”
Get Version v Xv gives firmware version of module

-> See following page
Initialise X-drive i Xi Initialises X - drive to wash position
This step requires (*) 10 = Spl probe at serum cup pos.
initialisation first X-position n a Xna move arm to X-Position (0 - 10) (*)
9= Reag probe at Reag bttle
Probe Z drive Z 8= Spl probe at prim. tube
Get State g Zg gives status of module 7= Reag probe at CuvPos 4
6= Reag probe at CuvPos 3
Get Version v Zv gives firmware version of module 5= Reag probe at CuvPos 2
4= Reag probe at CuvPos 1
Initialise Left Probe i Zi Initialises left probe to top position Spl probe at CuvPos 4
3= Spl probe at CuvPos 3
Initialise Right Probe j Zj Initialises right probe to top position 2= Spl probe at CuvPos 2
1= Spl probe at CuvPos 1
Left Probe to liquid m a,b Zma,b (with comma !) left probe to liquid, a steps into liquid, 0= both probes at Washpos
but max b steps (1mm = 10 steps)
These steps require
initialisation of the Right Probe to liquid n a,b Zna,b (with comma !) right probe to liquid, a steps into liquid,
respective module first but max b steps (1mm = 10 steps)
Z-position left Probe l xxxx Zlxxxx move left probe to pos. xxxx (0 - 1200)
Z-position right Probe r xxxx Zrxxxx move rigth probe to pos. xxxx (0 - 1200)
Cuvette rotor C Get State g Cg gives status of module
Get Version v Cv gives firmware version of module

Get Position p Cp gives position of Cuvette Rotor (1 - 75)
Goto Position x a Cxa moves Cuvette Rotor to pos a (1 - 75)
Reagent Tray R Get State g Rg gives status of module
Get Version v Rv gives firmware version of module

Get Position p Rp gives position of ReagTray (1 - 25)
Goto Position x a Rxa moves ReagTray to pos a (1 - 25)
29
FIGURE 14
30
FIGURE 15

Photometer 1 - 5 1-5 Get State g Xg gives status of Photometer X (1-5)
Get Version v Xv gives firmware ver. of Photometer X (1-5)

Wait W xxxxx Wxxxxx (NO module code !!) wait for xxxxx millisec
In this table, the module Photometer Offset o Xo Offset Photometer X (1-5)
is determined by a number
Dark Reading c Xc Read and store dark value of Photom X (1-5)
from 1 - 5, which stand for
Photometer 1 to Photometer 5 LED power on h Xh turns on LED's of Photometer X (1-5)
The table shows an "X" for
the respective photometer Read OD m Xm read OD in Photometer X (1-5)
number Get OD values a Xa gives reading of all 4 channels of
Photometer X (1-5)
LED power off d Xd turns off LED's of Photometer X (1-5)
This command set allows to make readings "manually".

In order to make a reading, the following steps must be perormed in exactly this order (for each photometer individually):
1. LED power off

2. Sleep for 500 milliseconds (this is required to ensure there is no more light emitted)
3. Photometer Offset
4. Dark Reading
5. Sleep for 300 ms (required to finish dark reading)
6. LED power on
7. Sleep for 60000 milliseconds (this is required to make sure the LED's are stable)
8. Read OD
9. Get OD values
To repeat a reading, only steps 8 and 9 need to be repeated.

4.4.1 EXAMPLE FOR A READING THROUGH EULY SERVICE SCRIPT

The following commandset can be entered line after line, before starting the
actual reading. When saving the commandset as a script, this commandset will
be available for later tests as well:
FIGURE 16
Commandset for reading
with Photometer 1.
After the command set has been entered and maybe stored as a script, select the
“Start”, button and one command after the other will be sent to the instrument.
During processing all steps, the feedback from the instrument will be displayed
in the Result Window of Euly Service.
4.5 ReagentRotor
Menucommand for adjusting and testing the Reagent Rotor.
4.6 CuvetteRotor
Menucommand for adjusting and testing the Cuvette Rotor.
4.7 Belt
Menucommand for adjusting and testing the Belt.
32
4.8 Pipettor
Menucommand for adjusting and testing the Pipettor.
4.9 EulyTest
Menucommand for testing the liquid detection.
4.10 Endurance Test

Menucommand for testing the instrument.
4.11 Device Data

Menucommand for reading and saving the Device Data.
4.12 FW Update
Menucommand for updating the firmware.
4.13 Photo
Menucommand for testing the Photometer.
4.14 Pumps-Valves
Menucommand for testing the Pumps and Valves.
4.15 Info
Menucommand for displaying program information.

MAINTENANCE 33
5 MAINTENANCE
5.1 Introduction
This chapter gives information on maintenance procedures for the Eurolyser sy-
stem. The required maintenance varies with usage of the Eurolyser system. The-
refore the following recommendations are only general guidelines and should
be adapted according to the needs.
5.2 Syringes
Reasons to change the part:
- The Syringe Seal looks worn.
- Leakage of the Syringe.
- At least once a year.
Remarks:
You can either change the Syringe Seal or the complete Syringe. If you change
only the Syringe Seal change the whole Syringe every forth time.
5.3 Syringe Valves

- Leakage of the Syringe Valve.
- Continued formation of drops on the corresponding probe.
5.4 Tubings
- The Tubings look worn.
- Leakage of the Tubings.
34
5.5 Photometer
Reasons for maintenance of the part:
- The Photometer is dirty.
- At least once every 6 months.
Instructions:
1. Clean the wall of the photometer with a small amount of glass cleaner on a
cotton wool stick.
2. Perform a Belt Adjust (either with the Service Software or with the
Application Software).
5.6 X-Drive
- The X-Positioning is not accurate (e.g. small (unwanted) movements on a
certain position).
Instructions:
1. Clean the spindle and the two axis (use only alcohol) with a cotton wool stick.
2. Lubricate spindle and axis with a small amount of the Special Lubricant
(BE1072).
5.7 Z-Drives
- The Z-Positioning is not accurate (e.g. small (unwanted) movements on a
certain position).
Instructions:
1. Clean the spindle (use only alcohol) with a cotton wool stick.
2. Lubricate spindle and axis with a small amount of the Special Lubricant
(BE1072).

MAINTENANCE 35
5.8 Liquid Detection

- The Liquid Detection is not accurate (e.g. sometimes aspiration of air due to
a too high position).
Instructions:
1. Clean the leads of the probe cables and use an electronic contact spray in
order to have a low resistant contact.
2. Perform a Liquid Detection Adjust with the Service Software.
5.9 Magnetic Valves

- Leakage of the Magnetic Valve.
- Magnetic Valve does not open.
- Preventive Maintenance.
- At least every second year.
5.10 Probes
- Probe is blocked.
Instructions:
1. Use the Cleaning Set Reagent & Sample Probe.
5.11 Membrane Pumps

- Leakage of Membrane Pump .
- Bad performance of Membrane Pump.
- Preventive Maintenance.
Instructions:
1. Disassemble the pump header.
2. Replace the Membrane.
3. Clean the parts of the pump header.
4. Assemble the pump header.
36

TESTS/TROUBLESHOOTING 37
6 TESTS/TROUBLESHOOTING
6.1 Introduction
This chapter gives information on testing components of the Human system.
6.2 Functional Tests

General EulyService-Scripts for Testing:
- AllState: Shows the State of all moduls.
- AllVersion: Shows the firmware-version of all moduls.
- Reset: Resets the instrument / stops all movements.
Sensors:
Start EulyService-Script “SensorTest” with 1000 iterations. Check the state of the
doorsensor, cuevettesensor, button and liquidsensors.
Reagentrotor:
Insert empty tray on the reagentrotor.
Select menucommand „EulyService“ -> „ReagentRotor“ and click „Test Digital“.
Start EulyService-Script „ReagRotorTest1“.
Insert full tray on the reagentrotor.
Cuevtterotor:
Select menucommand „EulyService“ -> „CuevetteRotor“ and click “Test Digital”.
Start EulyService-Script „CuvRotorTest1“. All positions are positioned in both
directions.
Select menucommand „EulyService“ -> „CuevetteRotor“ and click „Test Sensor“.
Cuevettesensor is tested with and without cuevettes.
Insert a cuvette on position 1 (marked with 2 dots) and remove all other cuvettes.
Start EulyService-Script „CuvRotorTest5“.
38
Pipettor:
Start EulyService-Script „PipettorSensorTest“ with 1000 Iterations. Open and
close the pipettor and check the results.
Start EulyService-Script „PipettorXTest“. Positions the X-drive.
Fill traypositions R2 and S2 with water (traypositions R1 and S1 have to be
empty). Select menucommand „EulyService“ -> „EulyTest”.
Enable “LiquidDetection”.
Click „Start“.
Check results on sheet „EulyTest“.
Dispenser:
Start EulyService-Script „DispenserTest“. Initalizes the dispenser.
Pumps and Valves:

Select menucommand “EulyService” -> “Pumps-Valves”.
Switch the pumps and valves on and off.
Photometerstreet:
Start EulyService-Script „PhotoLEDsOn“. Switches on the photometer-LEDs.
Insert a cuvette on position 1 (marked with 2 dots).
Start EulyService-Script „BeltTest1“. The cuevette is positioned to all
photometer-modules.
Endurance Test:
Fill traypositions R2 and S2 with water. Empty all other sample-positions and R1.
Insert a cuvette filled with water to position 1 (marked with 2 dots) of the
cuvette rotor.
Select menucommand „EulyService“ -> „EnduranceTest“.
Click „Start“.
Check results on sheet „EnduranceTest“.

6.3 Troubleshooting
6.3.1 REAGENT ROTOR

TABLE 2
Step Check Result Action
1 Is the green LED on? No Switch on the instrument. Switch off the power before
No Control the mains cable.
changing any electronicmo-
No Control the mains voltage.
dule or connecting or disconnec-
No Control the mains fuses.
ting any cable. Wait 5 seconds
No Control the master board fuses.
after switching on the power
Yes Proceed with step 2.
before starting any command.
2 Start EulyService-Script AllState.
Is the message displayed on Yes Go to Communication Trouble-
Result: „Error occured processing shooting Table
0g: Timeout...“?
No Proceed with step 3.
3 Is the message displayed on Yes Replace reagent-flat-cable.
Result: „... R: State: BUSY ...“?
Yes Replace reagent rotor control board.
Is the message displayed on Yes Proceed with step 4.
Result: „... R: State: READY ...“?
4 Yes Start EulyService-Script Reset.
Try to move the rotor manually.
Is manual movement possible? No Remove possible blocking.
No Replace carousel unit.
5 Start EulyService-Script ReagFastCW.
Does the rotor move in clockwise No Replace reagent rotor control board.
direction?
Yes Start EulyService-Script ReagSlowCW.
Does the rotor move in No Replace reagent rotor control board.
counter-clockwise direction?
Yes Start EulyService-Script ReagSlowCCW.
Does the rotor move in No Replace reagent rotor control board.
counter-clockwise direction?
40

6 Select menucommand EulyService-
>ReagentRotor and click Test Digital.
Is the test ok? No Replace carousel unit.
>ReagentRotor and click Adjust. (not
required with new Reagentrotorsensor)
Does the adjustment fail? Yes Replace carousel unit.
>ReagentRotor and click Adjust Digital.
Does the adjustment fail? Yes Replace carousel unit.
9 Start EulyService-Script ReagRotorTest1.
Result: "R: State: READY R- Yes Replace carousel unit.
Timeout"
No If the error occurs from time to time
replace carousel unit.
6.3.2 CUVETTE ROTOR

TABLE 3
1 Is the green LED on? No Switch on the instrument.
Is the message displayed on Result: Yes Goto Communication
„Error occured processing 0g: Timeout...“? Troubleshooting Table


3 Is the message displayed on Result: "... C:
Yes Replace cuvette-flat-cable.
State: BUSY ..."?
Yes Replace cuvette rotor board.
Is the message displayed on
Result: "... C: State: READY ..."?
Start EulyService-Script Reset.
4 Yes
Try to move the rotor manually.
Is manual movement possible? Yes Proceed with step 5.
No Remove possible blocking.
Put the cuvette rotor motor 2
No
mm away from the rotor.
Is manual movement possible? No Remove possible blocking.
Replace cuvette drive motor
Yes
assembley.
Start EulyService-Script CuvFast-
5
CW.
Does the rotor move in clockwise direc-
No Replace cuvette rotor board.
tion?
No
assembley.
Start EulyService-Script CuvSlow-
Yes
CW.
Does the rotor move in clockwise
direction?
No
assembley.
Start EulyService-Script Cuv-
Yes
FastCCW.
Does the rotor move in counter-clock-
wise direction?
No
assembley.
Start EulyService-Script
Yes
CuvSlowCCW.
Does the rotor move in counter-clock-
wise direction?
No
assembley.
42

6 Select menucommand EulySer-
vice->CuvetteRotor and click Test
Digital.
Is the test ok? No Replace cuvette rotor board.

7 Select menucommand EulySer-
vice
->CuvetteRotor and click Adjust.
Does the adjustment fail? Yes Replace cuvette rotor board.
Yes Replace carousel unit.
8 Start EulyService-Script Cu-
vRotorTest1.
Result: Yes Replace carousel unit.
„C: State: READY C-Timeout“
No If the error occurs from time to
time replace carousel unit.
6.3.3 BELT

TABLE 4 No Control the mains cable.
Is the message displayed on Yes Goto Communication
Result: „Error occured processing 0g: Time- Troubleshooting Table
out...“?
3 Is the message displayed on Yes Replace photometer-flat-cable.
Result: „... M: State: BUSY ...“?

Yes Replace photometer.

Is the message displayed on Result: „... M: Yes Proceed with step 4.
State: READY ...“?
4 Start EulyService-Script BeltFast-
CW.
Does the belt move in clockwise No Remove possible blocking.
direction?
No Replace photometer.
Yes Start EulyService-Script BeltSlow-
CW.
Does the belt move in clockwise direction? No Remove possible blocking.
Yes Start EulyService-Script
BeltFastCCW.
Does the belt move in counter-clockwise No Remove possible blocking.
direction?
Yes Start EulyService-Script
BeltSlowCCW.
Does the belt move in counter-clockwise No Remove possible blocking.
direction?
5 Select menucommand
EulyService->Belt and click Adjust
and check results on sheets Belt1
and Belt2.
Does the adjustment fail? Yes Replace photometer.
6 Insert cuvette in outer carussel
position 1. Start EulyService-
Script BeltTest1.
Result: „M: State: READY M-Timeout“ Yes Replace photometer.
No If the error occurs from time to
time replace photometer.
44
6.3.4 PIPETTOR

TABLE 5
Is the message displayed Yes Goto Communication
on Result: "Error occured Troubleshooting Table
processing 0g: Timeout..."?
3 Is the message displayed Yes Replace x-flat-cable.
on
Result: "... Z: State: BUSY X:
State: BUSY ..."?
Yes Replace pipettor arm.
Is the message displayed Yes Replace z-flat-cable.
on
State: READY ..."?
Is the message displayed Yes Replace pipettor arm.
on
Result: "... Z: State: READY
X: State: BUSY ..."?
Is the message displayed Yes Proceed with step 4.
on
Result: "... Z: State: READY
X: State: READY..."?
4 Yes Start EulyService-Script Reset.
Try to move the needles
manually.
Is manual movement easily Yes Proceed with step 5.
possible?
No Clean the spindles (use only alcohol)
with a cotton wool stick and lubricate
the spindles with a small drop of thin
oil.
No Replace pipettor arm.


5 Be sure to have the arm in the front-
most position. Start EulyService-Script
PipettorTest1.
Is the message displayed Yes Clean the spindles (use only alcohol)
on Result: "... Z: State: with a cotton wool stick and lubricate
READY Zx-Timeout"? the spindles with a small drop of thin
oil.
6 Yes Try to move the z-carriage manually.
Is manual movement Yes Proceed with step 7.
possible?
No Clean the spindle and the two axis (use
only alcohol) with a cotton wool stick
and lubricate spindle and axis with a
small drop of thin oil.
No Replace pipettor arm.
7 Start EulyService-Script PipettorTest2.
Is the message displayed Yes Clean the spindle and the two axis (use
on Result: "... Z: State: only alcohol) with a cotton wool stick
READY X-Timeout"? and lubricate spindle and axis with a
small drop of thin oil.
No If the error occurs from time to time
replace pipettor arm.
6.3.5 LIQUID DETECTION
Step Check Result Action TABLE 6

46

Is the message displayed on Yes Goto Communication Troubleshooting
Result: "Error occured processing Table
0g: Timeout..."?
3 Is the message displayed on Yes Replace x-flat-cable.
State: BUSY ..."?
Is the message displayed on Yes Replace z-flat-cable.
State: READY ..."?
Is the message displayed on Yes Proceed with step 4.
Result: "... Z: State: READY ..."?
4 Make sure to have a low resistant contact
of the probe-cables (clean the leads and
use a electronic contact spray).
5 Select menucommand EulyService
->Pipettor and click Adjust
Liquidsensor....
Is the adjustment successful? No Replace pipettor arm.
6 Start menucommand EulyService ->Euly-
Test. Select Liquid Detection. Click Start
and check the results on sheet EulyTest.
Are the results ok? No Replace pipettor arm.
Yes If the error occurs from time to time
replace pipettor arm.

6.3.6 LIQUID FLOOD
Step Check Result Action TABLE 7

1 Are there any traces of leakage No Proceed with step 2.
obvious from outside?
Syringe or valve leakage? Yes Replace the syringe with piston or the
whole syringe pump.
Did a wrong pipettor position Yes Goto Pipettor Arm Troubleshooting
cause the liquid flood? Table.
2 Disassemble the cover.
Are there any obvious leakages Yes Replace the particular tube or whole
in the tubes? tubing system.
Are there any obvious leakages Yes Replace the washing pumps.
in the washing pumps?
>Pumps-Valves and test the pumps
and valves.
Any obvious leakage? Yes Replace the involved part(s) (tube or
tube system, connector,...).
Overflow at wash station after Yes Try to clean the tubes inside with a
some time? longer wash cycle (some minutes) and
cleaning solution.
Yes Replace the whole tubing system.
Yes Replace the washing pumps.
No
48
6.3.7 COMMUNICATION
TABLE 8 Step Check Result Action

Is an error message displayed: Yes The serial port is opened by another
„...Dll-Error: 5...“? application. Close all applications.
Restart the computer and try again.
3 Is the message displayed on Yes Control the serial or USB cable.
Result:
„Error occured processing 0g:
Timeout...“?
Yes Control the serial port settings.
Yes Close all applications. Restart the
computer and try again.
Yes Replace master board.

REPLACEMENT 49
7 REPLACEMENT
7.1 Introduction
This chapter gives information on replacing components of the Human system.
7.2 Carousel Unit with new Reagentrotorsensor

Disassembling the Carousel Unit
1. Disassemble the cover (see “Disassembling the Cover”).
2. Disconnect the tubing for cooling from the liquid connection block.
FIGURE 17
Tubing for cooling
Liquid connection
block
3. Disconnect the reagent-code-flat-cable from the reagent control board.

50
4. Disconnect the reagent-position-cable from the reagent control board
FIGURE 18
Reagent-code-flat-cable
Reagent-position-cable
5. Disconnect the cuvette-temperature-cable (white and brown) from the

master board.
FIGURE 19 Cuvette-
temperature-cable
6. Disassemble the cuvette rotor board (see “Disassembling the Cuvette Rotor
Board”).

REPLACEMENT 51
7. Remove the 5 screws on the bottom of the instrument fixing the carousel
unit.
FIGURE 20
Screws for
carousel unit
8. Remove the carousel unit.
Assembling the Carousel Unit

1. Assemble the carousel unit (tubing for cooling right, all cables back).
2. Fix the carousel unit with 5 screws.
3. Assemble the cuvette rotor board (see “Assembling the Cuvette Rotor Board”).
4. Connect the cuvette-temperature-cable (white and brown) to the master
board.
5. Connect the reagent-position-flat-cable to the reagent control board.
6. Connect the tubing for cooling to the liquid connection block.
7. Adjust the carousel unit (see “Adjusting the Carousel Unit”).
8. Assemble the cover (see “Assembling the Cover”).
Adjusting the Carousel Unit

1. Adjust the centering magnet (see “Adjusting the Centering Magnet”).
2. Select menucommand „EulyService“ -> „CuevetteRotor“.
3. Click „Adjust“.
4. Disconnect the centering-magnet-cable.
5. Start EulyService-Script „CuvRotorTest1“.
52
6. Adjust the cuvette rotor board until the cuvette rotor position is aligned with
the photometer.
FIGURE 21
Open screws for

adjusting cuvette
rotor position
Centering-magnet-
cable
7. Tighten the 2 screws.

8. Connect the centering-magnet-cable.
9. Execute functional test for cuvette rotor.
10. Make sure the Reagentrotor-FW-Version is 22 or higher (check with
EulyService-Script “AllVersion”). If not update the firmware and start the
EulyService-Script “ReagRotor_V2x_EEPROM”.
11. Select menucommand „EulyService“ -> „ReagentRotor“.
12. Click “Adjust Digital” and follow the instructions. See picture for alignment
(e.g. position 1).

REPLACEMENT 53
FIGURE 22
13. Execute functional test for reagent rotor.

54
7.3 Carousel Unit with old Reagentrotorsensor

(Potentiometer)
Disassembling the Carousel Unit
2. Disconnect the tubing for cooling from the liquid connection block.
FIGURE 23 Tubing for cooling
Liquid connection
block
3. Disconnect the reagent-code-flat-cable from the reagent control board.

4. Disconnect the reagent-position-cable from the reagent control board.
FIGURE 24
Reagent-code-flat-cable
Reagent-position-
cable

REPLACEMENT 55
5. Disconnect the cuvette-temperature-cable (white and brown) from the

master board.
Cuvette-tempera-
ture-cable FIGURE 25
6. Disassemble the cuvette rotor board (see “Disassembling the Cuvette Rotor
Board”).
7. Remove the 5 screws on the bottom of the instrument fixing the carousel
unit.
FIGURE 26
Screws for carousel

unit
56
8. Remove the carousel unit.

Assembling the Carousel Unit
1. Assemble the carousel unit (tubing for cooling right, all cables back).
2. Fix the carousel unit with 5 screws.
3. Assemble the cuvette rotor board (see “Assembling the Cuvette Rotor Board”).
4. Connect the cuvette-temperature-cable (white and brown) to the master
board.
5. Connect the reagent-position-cable to the reagent control board.
6. Connect the reagent-position-flat-cable to the reagent control board.
7. Connect the tubing for cooling to the liquid connection block.
8. Adjust the carousel unit (see “Adjusting the Carousel Unit”).
Adjusting the Carousel Unit
2. Select menucommand „EulyService“ -> „CuevetteRotor“.
3. Click „Adjust“.
FIGURE 27
Centering-magnet-
cable
4. Disconnect the centering-magnet-cable.

5. Start EulyService-Script „CuvRotorTest1“.

REPLACEMENT 57
6. Adjust the cuvette rotor board until the cuvette rotor position is aligned with
the photometer.
FIGURE 28
Open screws for

adjusting cuvette rotor
position
7. Tighten the 2 screws.

8. Connect the centering-magnet-cable.
9. Execute functional test for cuvette rotor.
10. Make sure the Reagentrotor-FW-Version is 11 (check with EulyService-Script
“AllVersion”). If not update the firmware (select the file “R25_V11_Adr22.
hex”) and start the EulyService-Script “ReagRotor_V11_EEPROM”.
11. Start EulyService-Script “ReagRotorPosition“ with 1000 Iterations.
58
12. Insert tray and align border between position 1 and 25 with photometer.
FIGURE 29
13. Remove tray.

14. Adjust the centerring until the position shown by EulyService-Script
“ReagRotorPosition” is on the threshold between 1 and
FIGURE 30

REPLACEMENT 59
15. Tighten the screws.

16. Insert the tray and test position 1 and 25.
18. Click “Adjust Digital” and follow the instructions.
19. Remove the tray.
21. Click “Adjust” and follow the instructions.
7.4 Centering Magnet

Adjusting the Centering Magnet
1. Adjust the distance between the carousel unit and the photometer to a
minimum of 0.3mm. The distance can be varied by moving the carousel unit
and/or by moving the photometer within the holes for the corresponding
screws.
FIGURE 31
> 0.3mm
2. Adjust the height of the cuvette ring to 0.3mm above the photometer. To
change the height open all 6 screws, rotate the spacing bolts 1/6-rotation
each and tighten the screws. Repeat this until the height is as desired.
60
FIGURE 32
Top of cuvette ring
0.3mm
Top of photometer

REPLACEMENT 61
FIGURE 33
Open screws for adjusting

the height of the cuvette
ring
62
FIGURE 34
Spacing bolts for adjusting

the height of the cuvette
ring

REPLACEMENT 63
3. Adjust the height of the centering magnet to the centre of the fixing area on
the cuvette rotor.
FIGURE 35
FIGURE 36
64
Adjust the position of the centering magnet so that the cuvette rotor position is
aligned with the photometer.
FIGURE 37
Alignment
7.5 Cover
Disassembling the Cover

1. Disassemble the pipettor arm (see “Disassembling the Pipettor Arm”).
2. Disassemble the inlet tubing from the sample syringe pump.
3. Disassemble the inlet tubing from the reagent syringe pump.
Inlet tubing sample Inlet tubing reagent

FIGURE 38 syringe syringe

REPLACEMENT 65
4. Remove the 6 screws on the bottom of the instrument fixing the main cover.
FIGURE 39
Screws for main

cover
5. Lift the main cover.

6. Disconnect the doorlock-cable (yellow-brown).
FIGURE 40
Doorlock-cable
7. Disconnect the syringe-pump-cable from the master board.

66
8. Disconnect the doorsensor-LED-key-flat-cable from the master board.
FIGURE 41
Syringe-pump-
cable
Doorsensor-LED-key-
flat-cable
9. Remove the inlet tubings from the main cover.

10. Remove the main cover.
Assembling the Cover

1. Lead the inlet tubings through the main cover.
2. Connect the doorsensor-LED-key-flat-cable to the master board.
3. Connect the syringe-pump-cable to the master board.
4. Connect the doorlock-cable (yellow-brown).
5. Put the main cover on the instrument.
6. Fix the main cover with 6 screws.
7. Assemble the inlet tubing to the reagent syringe pump.
8. Assemble the inlet tubing to the sample syringe pump.
9. Assemble the pipettor arm (see “Assembling the Pipettor Arm”).

REPLACEMENT 67
7.6 Cuvette Drive Motor Assembly

Disassembling the Cuvette Drive Motor Assembly
2. Disconnect the cuvette-motor-cable from the cuvette rotor board.
FIGURE 42
Cuvette-motor-
cable
68
3. Unscrew the slug.
FIGURE 43
Slug

REPLACEMENT 69
4. Disassemble the cuvette drive motor assembly (1 screw on the bottom of the instrument).
FIGURE 44
Screw for cuvette drive

motor assembley
Assembling the Cuvette Drive Motor Assembly

1. Assemble the cuvette drive motor assembly.
70
2. Adjust the cuvette drive motor assembly to a pressure of 8N by rotating.
FIGURE 45
Pressure = 8N
3. Tighten the slug.

4. Connect the cuvette-motor-cable to the cuvette rotor board.

REPLACEMENT 71
7.7 Cuvette Rotor Board

Disassembling the Cuvette Rotor Board
FIGURE 46
Cuvette-flat-cable
Screws for cuvette

rotor board
Centering-magnet-
Cuvette-motor-cable cable
2. Disconnect the cuvette- flat-cable from the cuvette rotor board.

3. Disconnect the cuvette-motor-cable from the cuvette rotor board.
4. Disconnect the centering-magnet-cable from the cuvette rotor board.
5. Remove the cuvette rotor board (2 screws). Avoid scratching the bottom
surface of the carousel unit.
Assembling the Cuvette Rotor Board
1. Assemble the cuvette rotor board (2 screws).
2. Connect the centering-magnet-cable to the cuvette rotor board.
3. Connect the cuvette-motor-cable to the cuvette rotor board.
4. Connect the cuvette-flat-cable to the cuvette rotor board.
5. Adjust the cuvette rotor (see “Adjusting the Carousel Unit”).
72
7.8 Master Board

Disassembling the Master Board
FIGURE 47 24V-cable Outer-temperature- Washing- Doorlock-

cable pumps-cable valves-cable
X-flat-cable
X-15V-cable
Cuvette-tempera- Photometer-tem- Z-24V-cable
ture-cable perature-cable Cuvette-
sensor-cable
Photometer-
flat-cable
Reagent-flat-cable Cuvette-flat-cable
2. Disconnect the 24V-cable from the master board.

3. Disconnect the cuvette-temperature-cable from the master board.
4. Disconnect the outer-temperature-cable from the master board.
5. Disconnect the photometer-temperature-cable from the master board.
6. Disconnect the washing-pumps-cable from the master board.
7. Disconnect the doorlock-valves-cable from the master board.
8. Disconnect the Z-24V-cable from the master board.
9. Disconnect the x-flat-cable from the master board.
10. Disconnect the X-15V-cable from the master board.
11. Disconnect the cuvette-sensor-cable from the master board.
12. Disconnect the photometer-flat-cable from the master board.
13. Disconnect the cuvette-flat-cable from the master board.
14. Disconnect the reagent-flat-cable from the master board.

REPLACEMENT 73
FIGURE 48
Screws for master

board
15. Remove the master board (4 screws on the bottom of the instrument).
Assembling the Master Board

1. Assemble the master board (4 screws on the bottom of the instrument).
2. Connect the reagent-flat-cable to the master board.
3. Connect the cuvette-flat-cable to the master board.
4. Connect the photometer-flat-cable to the master board.
5. Connect the cuvette-sensor-cable to the master board.
6. Connect the X-15V-cable to the master board.
7. Connect the x-flat-cable to the master board.
8. Connect the Z-24V-cable to the master board.
9. Connect the doorlock-valves-cable to the master board.
10. Connect the washing-pumps-cable to the master board.
11. Connect the photometer-temperature-cable to the master board.
12. Connect the outer-temperature-cable to the master board.
13. Connect the cuvette-temperature-cable to the master board.
14. Connect the 24V-cable to the master board.
74
7.9 Photometer
Disassembling the Photometer
FIGURE 49 Photometer-tempe-
rature-cable
Photometer-flat-cable
2. Disconnect the photometer-flat-cable from the master board.

3. Disconnect the photometer-temperature-cable (red and black) from the
master board.
4. Remove the centering magnet.

REPLACEMENT 75
FIGURE 50
Screws for photometer
5. Remove the 8 screws on the bottom of the instrument fixing the photometer.
6. Remove the photometer.
Assembling the Photometer
1. Assemble the photometer.
2. Fix the photometer with 8 screws.
3. Assemble the centering magnet.
5. Connect the photometer-temperature-cable (red and black) to the master
board.
6. Connect the photometer-flat-cable to the master board.
8. Execute functional test for photometer.
76
7.10 Pipettor Arm

Disassembling the Pipettor Arm
1. Remove the top cover (5 screws below the top cover).
FIGURE 51
Screws for top cover
2. Disassemble the outlet tubing from the sample syringe pump.

3. Disassemble the outlet tubing from the reagent syringe pump.
FIGURE 52 Outlet tubing sample Outlet tubing reagent

syringe syringe

REPLACEMENT 77
4. Remove the safety ring.
Cable driller for FIGURE 53

Z-24V-cable
Saftey ring
5. Disconnect the Z-24V-cable (red and black) from the Z–drive board.
6. Open the cable driller fixing the Z-24V-cable behind the X-drive board.
7. Disconnect the X-15V-cable (yellow and black) from the X-drive board.
8. Disconnect the X-flat-cable from the X-drive board.
FIGURE 54
Z-24V-cable
X-flat-cable
X-15V-cable
9. Remove the pipettor arm.

78
Assembling the Pipettor Arm

1. Assemble the pipettor arm.
2. Connect the X-flat-cable to the X-drive board.
3. Connect the X-15V-cable (yellow and black) to the X-drive board.
4. Lead the Z-24V-cable behind the X-drive board to the Z-drive board and
connect the Z-24V-cable (red and black) to the Z–drive board.
5. Fix the Z-24V-cable with a cable driller behind the X-drive board.
6. Assemble the safety ring.
7. Assemble the outlet tubing to the sample syringe pump.
8. Assemble the outlet tubing to the reagent syringe pump.
9. Assemble the top cover (5 screws).
Adjusting the Pipettor Arm
1. Select menucomand „EulyService“ -> „Pipettor“.
2. Press „Adjust X“ (adjust the needles centred above the holes in the washing-
device).
FIGURE 55
Needles
Holes in washing-
device

REPLACEMENT 79
3. Press „Adjust Z“ (adjust the needles just above the cuvette rotor).
FIGURE 56
Needles
Top of cuvette
rotor
4. Execute functional test for the pipettor.

80
7.11 Probes
Disassembling the Probe
1. Remove the top cover (5 screws below the top cover).
FIGURE 57
Screws for top cover
2. Disconnect the Z-24V-cable (red and black) from the Z–drive board.
FIGURE 58
Reagent-probe-cable Sample-probe-cable
3. Disconnect the probe-cable.

4. Open the screws fixing the probe and remove the probe.

REPLACEMENT 81
Assembling and Adjusting the Probe

1. Connect the probe-cable (shield is middle-connector).
2. Insert the probe into a water-bath with 39°.
3. Switch on power-supply.
4. Select menucomand „EulyService“ -> „Pipettor“.
5. Click „Switch off Temperaturecontrol“.
6. Connect the Z-24V-cable (red and black) to the Z-drive board.
7. Wait 2 minutes.
FIGURE 59
Shield (middle)
Liquidsensor-sample-
probe-potentiometer
Liquidsensor-reagent-
probe-potentiometer
Temperature-sample-
probe-potentiometer
Temperature-reagent-
probe-potentiometer
8. Click “Adjust Temperature Sample/Reagent Probe”.

9. Switch off power-supply.
10. Take the probe out of the water-bath and assemble on the Pipettor Arm.
11. Switch on power-supply.
12. Click “Adjust Liquidsensor Sample/Reagent Probe”.
13. Assemble the top cover (5 screws).
14. Select menucomand „EulyService“ -> „EulyTest“.
15. Enable “LiquidDetection”.
16. Click “Start”.
17. Check results on sheet “EulyTest”.
82
7.12 Reagent Rotor Control Board

Disassembling the Reagent Rotor Control Board
FIGURE 60
Reagent-flat-cable Reagent-code-flat-
cable
Screws for reagent

rotor control board
Reagent-position-
cable (not present on
all instruments)
2. Disconnect the reagent-flat-cable from the reagent rotor control board.

3. Disconnect the reagent-code-flat-cable from the reagent rotor control board.
4. Disconnect the reagent-position-cable from the reagent rotor control board
(if present).
5. Remove the reagent rotor control board (4 screws). unit.
Assembling the Reagent Rotor Control Board
1. Assemble the reagent rotor control board (4 screws).
2. Connect the reagent-position-cable to the reagent rotor control board (if pre-
sent).
3. Connect the reagent-position-flat-cable to the reagent rotor control board.
4. Connect the reagent-flat-cable to the reagent rotor control board.
5. Adjust the reagent rotor (see “Adjusting the Carousel Unit”).

REPLACEMENT 83
7.13 Reagent Rotor Potentiometer

Disassembling the Reagent Rotor Potentiometer
1. Remove the cover from the centerring.
FIGURE 61
2. Remove the 4 screws from the centerring.

84
FIGURE 62
Screws
Centerring
3. Disassemble the centerring.
FIGURE 63
Coupler
4. Disassemble the coupler.

REPLACEMENT 85
Reagent rotor potentio-

meter ring FIGURE 64
Slug
5. Disassemble the reagent rotor potentiometer ring (fixed with a slug).
FIGURE 65
Reagent rotor poten-
tiometer
86
6. Disassemble the reagent rotor potentiometer (by removing the silicon).

Assembling the Reagent Rotor Potentiometer
New reagent rotor

FIGURE 66 potentiometer
Wires
Old reagent rotor

potentiometer
1. Disconnect the wires from the old reagent rotor potentiometer and connect
to the new reagent rotor potentiometer one by one.
2. Assemble the reagent rotor potentiometer and fix it with silicon.
3. Assemble the reagent rotor potentiometer ring (as low as possible).
4. Assemble the coupler.
5. Assemble the centerring.
Adjusting the Reagent Rotor
1. Start EulyService-Script “ReagRotorPosition“ with 1000 Iterations.
2. Insert tray and align border between position 1 and 25 with photometer.

REPLACEMENT 87
FIGURE 67
3. Remove tray.
4. Adjust the centerring until the position shown by EulyService-Script
“ReagRotorPosition” is on the threshold between 1 and 25.
FIGURE 68
5. Tighten the screws.

6. Insert the tray and test position 1 and 25.
7. Assemble the cover of the centerring.
88
9. Click “Adjust Digital” and follow the instructions.

10. Remove the tray.
12. Click “Adjust” and follow the instructions.

REPLACEMENT 89
7.14 Syringe Pumps

Disassembling the Syringe Pump
Tubings FIGURE 69
Screws for syringe

pumps
Sample syringe Reagent syringe

pump pump
1. Disassemble the tubings from the syringe pump.

2. Disassemble the syringe pump (2 screws each).
90
FIGURE 70
Syringe-pumps-
cable
3. Disconnect the syringe-pumps-cable from the syringe pump.

REPLACEMENT 91
Assembling the Syringe Pump
Reagent syringe Sample syringe FIGURE 71

pump pump
Jumper
1. Install the jumpers on the syringe pump according the figure.Connect the
syringe-pumps-cable to the syringe pump.
2. Assemble the syringe pump (2 screws).
3. Assemble the tubings to the syringe pump.
92
7.15 Washing Pumps

Disassembling the Washing Pumps
2. Disconnect the washing-pumps-cable from the master board.
Washing-pumps-
FIGURE 72 cable
3. Disconnect the tubings from the washing pumps.
FIGURE 73
Tubings

REPLACEMENT 93
4. Disassemble the washing pumps (4 screws on the bottom of the instrument).
FIGURE 74
Screws for
washing pumps
Assembling the Washing Pumps

1. Assemble the washing pumps (4 screws).
2. Connect the tubings to the washing pumps.
3. Secure the tubings with cable drillers.
4. Connect the washing-pumps-cable to the master board.
ADDITIONAL INFORMATIONS 95
8 ADDITIONAL INFORMATIONS
8.1 Introduction
This chapter gives additional information on the components of the Human
system.
8.2 Pipettor Arm

1. Z-Motors:
There are two types of Z-motors, which are from different manufacturers (escap
and maxon)
- Both motors have to be from the same manufacturer
- After either changing the Z-drive-board or the Z-motors start one of the
following EulyService-Script:
- “Z_Enc16_EEPROM” for motor from manufacturer escap
- “Z_Enc32_EEPROM” for motor from manufacturer maxon
2. X-Motor:
There are two types of X-motors, which are from different manufacturers (escap
and maxon)
- After either changing the X-drive-board or the X-motor start one of the
following EulyService-Script:
- “X_Enc16_EEPROM” for motor from manufacturer escap
- “X_Enc32_EEPROM” for motor from manufacturer maxon
There are two types of sensor systems for the reagent rotor:
- No hardware-change of the Reagent Rotor Control Board
1. Potentiometer and reflective sensors:

- Firmware has to be V11
2. Magnet and hallsensors:

- Firmware has to be V22 or higher
96

97
HUMAN
Gesellschaft für Biochemica und Diagnostica mbH
Max-Planck-Ring 21 • 65205 Wiesbaden • Germany
Tel.: +49 6122/9988 0 • Fax: +49 6122/9988 100
eMail: human@human.de • www.human.de

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HumaStar 180

Cat No. 16900/200

Copyright 2010, Human GmbH, Wiesbaden, Germany. All rights reserved.

SERVICE UND SUPPORT

4 SERVICE SOFTWARE “EULY SERVICE” 25

1.2 User Warranty

1.3 Intended Use of the Instrument

1.4 General Safety Warnings

1.5 Disposal Management Concept

HumaStar 180 | Service manual

1.6 Biohazard Warning

1.7 Instrument Disinfection

HumaStar 180 | Service manual

HumaStar 180 | Service manual

Access Modes: - Random Access

HumaStar 180 | Service manual

Power Requirements: - 85-264V, 50/60 Hz (autodetecting)

2.4 Functional Description

2.4.1 PROCESS MANAGEMENT

- Washing the probes

2.4.2 LIQUID HANDLING

HumaStar 180 | Service manual

1 System Liquid Bottle 6 Probe w. liquid detection 11 Wash Station

2.4.2.1 Pipetting cycle

Single Pipetting (Sample or Reagent)

Pick up source liquid

Move probe in X direction to home (Washstation)

Multi Pipetting (Reagent only)

Pick up source liquid

Pipet liquid into target container

HumaStar 180 | Service manual

2.4.3 CAROUSELS, TEMPERATURE CONTROL AND COOLING

Outer Please refer to Chapter 2 for

*2 Controls, marked as C1 and C2

FIGURE 5 Empty Bottles can be ordered from Human:

FIGURE 6 1.5 ml Serum Cups can be ordered from Human:

2.4.3.2 Outer Carousel

2.4.3.3 Functions of the Carousels

HumaStar 180 | Service manual

Cooling Option of Inner Carousel

The Inner Carousel is only to be rotated during pipetting steps, as described

The Outer Carousel is to be rotated during pipetting steps as described under

2.4.4 MEASUREMENT SYSTEM

Cuvettes in 1 Cuvette block in

Interference Filter Cuvette Block

Light source "LED"

HumaStar 180 | Service manual

HumaStar 180 | Service manual

HumaStar 180 | Service manual

4 SERVICE SOFTWARE “EULY SERVICE”

4.2 Installation of Euly Service

4.3 Serial Settings

The menucommand “EulyService” -> “Script” launches displays the following

List of prede- Contents of Result window of

In the list „Scripts:“ a script can be selected.

HumaStar 180 | Service manual

Photometer Belt Movements: positioning within the photometer is only

Command: Xh (where X here stands for the photometer number 1 – 5)

HumaStar 180 | Service manual

Master 0 (zero) Reset all modules r 0r performs a reset on all modules

Get Version v 0v gives firmware version of module

Wait W xxxxx Wxxxxx system "Rest" for xxxxx milliseconds

2 0w2 MV off WP ON AP off