Service Manual For Semi-Automated Clinical Chemistry Analyzer

Service Manual
For
Semi-Automated Clinical Chemistry Analyzer
Document Version: 2012.01.01
Last Updated: February 5, 2013

Service Manual CHEM-7
Foreword
This manual is organized in a progressive sequence for easy study and reference. It is an
instructional aide to provide a reference for easy servicing and maintenance of the
analyzer. It contains detailed description of the analyzer features, specifications, PCB
layouts, wiring diagrams, trouble shooting and replacement procedures.
Use of this manual along with proper training will ensure better serviceability,
maintenance and trouble free analyzer operation with optimum performance.
Before servicing the analyzer, service engineer should:
1. Read and understand this manual.
2. Be trained by authorized person.
3. Be familiar with the operation of the analyzer.
NOTE: Keep this manual in an easily accessible place.
II
Legal Information
All rights are reserved by manufacturer of this product.
Manufacturer is the copyright owner of this document.
The contents of this document are subject to change without prior notice and without legal
obligation.
This document and the information herein are provided for the sole use of the intended
recipient(s) and for information purposes only.
This document contains contents which are the confidential and proprietary information of
the manufacturer.
This document cannot be modified, reproduced, translated or transmitted in any form or

by any means for any purpose, without prior written permission from the manufacturer.
No part of this document can be copied or reprinted, in whole or in part, without prior
written permission from the manufacturer.
This document was written and produced with the utmost care. However, errors cannot
be fully excluded. Manufacturer does not take any responsibility and accepts no liabilities
of any kind that may occur because of errors in the document.
III
Contents
1. OVERVIEW OF ANALYZER...................................................................................... 1-1

1.1. INTRODUCTION ................................................................................................. 1-1
1.2. ANALYZER VIEW................................................................................................ 1-2
2. SAFETY ..................................................................................................................... 2-1
3. ANALYZER FEATURES ........................................................................................... 3-1
3.1. HARDWARE SPECIFICATIONS ......................................................................... 3-1
3.2. SOFTWARE SPECIFICATIONS.......................................................................... 3-2
3.3. KEYBOARD DESCRIPTION ............................................................................... 3-4
3.4. ASPIRATION SWITCH ........................................................................................ 3-5
4. INSTALLATION ......................................................................................................... 4-1
4.1. INSPECTION....................................................................................................... 4-1
4.2. UNPACKING ....................................................................................................... 4-1
4.3. INSTALLATION REQUIREMENTS ..................................................................... 4-2
4.4. ELECTRICAL REQUIREMENTS......................................................................... 4-3
4.5. INSTALLATION PROCEDURE ........................................................................... 4-3
4.6. PRINTER HOUSING AND PRINTER PAPER INSTALLATION........................... 4-3
4.6.1. INTERNAL PRINTER................................................................................................. 4-3
4.6.2. EXTERNAL PRINTER................................................................................................ 4-4
4.6.3. PC COMMUNICATION .............................................................................................. 4-4
4.7. EXTERNAL KEYBOARD INSTALLATION........................................................... 4-4
5. BLOCK DIAGRAM .................................................................................................... 5-1
6. FUNCTIONAL DESCRIPTION OF PCB .................................................................... 6-1
6.1. POWER SUPPLY SECTION ............................................................................... 6-4
6.2. CONTROL LOGIC SECTION .............................................................................. 6-7
6.3. MOTOR CONTROL AND MEMORY ................................................................. 6-10
6.4. PHOTOMETRIC UNIT ....................................................................................... 6-12
6.5. USB PCB ........................................................................................................... 6-14
6.6. PRINTER ........................................................................................................... 6-16
6.7. KEYPAD AND DISPLAY SECTION:.................................................................. 6-16
7. TESTING AND PARAMETERS ................................................................................. 7-1
7.1. TESTING OF SMPS ............................................................................................ 7-1
7.2. TESTING OF CPU PCB ...................................................................................... 7-1
7.3. POWER ON SELF-TEST..................................................................................... 7-2
7.4. SELF TEST.......................................................................................................... 7-3
7.5. SETTING PARAMETERS.................................................................................... 7-4
7.5.1. SYSTEM PARAMS .................................................................................................... 7-4
8. ADJUSTMENT AND CALIBRATION ........................................................................ 8-1
8.1. OFFSET AND GAIN CALIBRATION OF PHOTOMETER ................................... 8-1
8.2. TEMPERATURE CALIBRATION......................................................................... 8-1
8.3. PUMP CALIBRATION ......................................................................................... 8-2
8.4. MULTILINGUAL OPTION .................................................................................... 8-2
8.5. ADJUSTING LCD DISPLAY BRIGHTNESS ........................................................ 8-3
IV
9. MAINTENANCE......................................................................................................... 9-1
9.1. DAILY MAINTENANCE ....................................................................................... 9-1
9.2. QUARTERLY MAINTENANCE............................................................................ 9-1
9.3. REPLACEMENT OF TUBING ............................................................................. 9-2
9.3.1. ASPIRATION TUBE REPLACEMENT ....................................................................... 9-2
9.3.2. REPLACEMENT OF PERISTALTIC PUMP TUBINGS.............................................. 9-3
9.4. REPLACEMENT OF LAMP ASSEMBLY ............................................................. 9-5
9.5. REPLACEMENT OF PRINTER PAPER .............................................................. 9-6
10. TROUBLE SHOOTING GUIDE.............................................................................. 10-1
11. SPARE PARTS...................................................................................................... 11-1
11.1. SPARES DETAILS AND ORDERING INFORMATION.................................... 11-1
11.2. LIST OF CONSUMABLES............................................................................... 11-2
12. ANNEXURE – 1 ..................................................................................................... 12-1
13. APPENDIX ............................................................................................................. 13-1
13.1. REVISION HISTORY....................................................................................... 13-1
V
This Page is Intentionally Left Blank
VI
1. OVERVIEW OF ANALYZER
1.1. INTRODUCTION
The CHEM-7 hereafter referred as an analyzer is a Compact, High performance,
16-bit micro controller based semiautomatic biochemistry analyzer for Routine
Chemistries, Electrolytes, Immunoassays, Hormones, Coagulation and Drug tests.
There are 10 modes of operation, including the coagulation mode. Programming,
reading and reporting operations are user friendly.
Operation is through a soft-touch keyboard with quick shift from one function to
another without going through complex sequential operations.
The analyzer is provided with a 320x240 dots LCD with LED backlight display with
alphanumeric and graphic capabilities.
A patient-wise collated report is obtained upon request. Exhaustive quality control
data at 3 levels, for any of the tests is also stored in the memory of the analyzer.
The software is complete with the device diagnostics self test function, capable of
providing timely flag / error messages related to test results or analyzer
malfunctioning.
The State-of-Art features, advanced optics, versatile analytical capabilities and
economy of 18µl (33µl optional) flowcell makes it the analyzer of choice for all
laboratories.
This analyzer is intended to be used:
 For In-vitro quantitative and qualitative determination of wide range of
analytes in body fluids.
 By the trained personnel in controlled environment and continuously
monitored operation.
1-1
1.2. ANALYZER VIEW
PHOTOMETER COVER PRINTER COVER
DISPLAY KEYPAD
ASPIRATION TUBE ASP SWITCH
1-2
PC TRANSMISSION PORT INCUBATOR CONNECTOR
EXTERNAL KEYBOARD
EXTERNAL PRINTER
PORT
DC INPUT SUPPLY
PERISTALTIC PUMP COVER
CONNECTOR
ON/OFF SWITCH SERIAL NO. PLATE
1-3
1-4
2. SAFETY
This section provides safety information about analyzer. Use this product properly
and safely to prevent injuries and or damage to property. User must read these
safety precautions before installation/use and follow the directions.
 Only qualified personnel should use the analyzer.
 While operating, maintaining, servicing or repairing the analyzer, follow all
the procedures described in this manual.
 Always ensure that mains switch is OFF while connecting or removing or
servicing the analyzer.
 Observe all WARNINGS and CAUTIONS posted on the system or
described in this manual.
 Avoid contact with all electrical circuits of analyzer; observe CAUTIONS
posted on the analyzer.
 Never use substitute parts on the analyzer or modify it in any way.
 Analyzer should not be exposed to rain or water in any form. Avoid
operating on an inclined surface or any form of shock and vibration to the
analyzer.
 During the operation photometric lamp becomes extremely hot. DO NOT
look directly into the light path of the lamp when it is ON. DO NOT touch
the lamp when it is ON.
 If the lamp needs to be changed, always switch off the lamp by switching off
the analyzer and then wait for minimum 10-minutes/until lamp has cooled
down.
 Auxiliary 18Vdc supply available on the back side of Instrument (Incubator
connector) for optional incubator only. Do not connect any other equipment
to this connector
 Avoid using dangerous flammable material around the analyzer. Fire or
explosion may be caused by ignition.
 Avoid areas that are adversely affected by atmospheric pressure,
temperature, humidity, ventilation, sunlight, dust and air containing salt,
sulfur, etc.
 Operator is responsible for taking all necessary precautions against hazards
associated with the use of clinical laboratory chemicals. Specific
recommendations for each reagent used with the analyzer are normally
found on the manufacturer’s package inserts or on product information
sheets for each chemical. Wipe up any reagent spillage on the analyzer
immediately.
2-1
 Pay attention not to exceed time and volume necessary for diagnosis. Keep
monitoring the behavior of whole system in order to detect any malfunction.
 Take immediate corrective measures including shutdown of operation when
any malfunction is detected in the analyzer.
 In the event of trouble, do not play with the analyzer and leave any repair
work to an authorized expert.
Caution: NEVER OPERATE ON A WET OR DAMP SURFACE.
2-2
3. ANALYZER FEATURES
3.1. HARDWARE SPECIFICATIONS
1 SYSTEM TYPE Open, Flowcell.
2 MEASUREMENT Colorimetry (Rate/EndPoint), Turbidometry, Immunoassay
PRINCIPLE
3 APPLICABLE ANALYTES Photometric assays – Enzymes, lipid, protein, Sugar,
Inorganic substances & others.
Turbidometric Assay – IgG, IgA, C3, C4, RF etc.
4 SETUP Benchtop.
5 LIGHTSOURCE Quartz Halogen Lamp, 12V, 20 Watts.
6 PHOTOMETRIC RANGE 0 ~ 2.5 O.D. (Range 340~670nm)
Resolution 0.0001.
7 OPTICS 8 wavelength static photometric group with following
interference filters: 340, 405, 450, 505, 546, 578, 600, 670
nm.
8 DETECTORS 8 UV / VIS Silicon photodiodes.
9 CUVETTE Unique triple cuvette system:
 18 l Flow cell or 33 l (optional)
 10 mm square cuvette
 6 mm round Glass Tube with adapter for
Coagulation and Elisa tests.
10 THERMOSTAT Peltier temperatures control from 20-40C ±0.1C
11 MEASUREMENT VOLUME 18l (33 µl optional)
12 SAMPLE ASPIRATION By means of a peristaltic pump, Aspiration Volume
programmable from 200l to 999l.
13 PRECISION Better than 1% CV.
14 KEYBOARD Rugged water proof keyboard.
41 fixed and 6 dynamic keys.
15 SMPS EXTERNAL (18/24V DC; 70/100W)
16 PRINTER High resolution, 384 dots per line, thermal type with full
graphics facility and option for connecting external USB
printer
17 DISPLAY: High resolution Graphics LCD 320x240, with LED
backlight. View area: 120x92 mm
18 INTERFACES USB B type port for host computer and USB A type port
for External USB Desk Jet Printer.
External PC/AT keyboard.
19 PROCESSOR: 16-bit with 384KB Flash Memory
20 MEMORY: 2MB serial flash and 2MB EEPROM for storage of Patient
data, QC and Chemistry Parameters
21 REAL TIME CLOCK: Built in.
22 REPLACEABLE BATTERY Lithium Battery CR2032 (3v)
3-1
ON PCB:
23 WASTE COLLECTION Waste collected in closed container.
24 INCUBATOR: Optional external incubator.
25 OPERATING 20 – 40 C
TEMPERATURE
26 STORAGE TEMPERATURE -10 to + 50 C.
27 HUMIDITY Max.80% RH, non-condensing.
28 MAINS SUPPLY 115/230V AC (±10%), 50/60 Hz (converted to 18~24V DC
using External Universal Power adapter, power
70W~100W.
29 SIZE: 410(L) x 292 (W) x 195 (H) mm
30 WEIGHT: Approximately 7 kg.
NOTE:
 Above specifications subject to change without prior notice.
 The manual is based on the software version 2012.01.
3.2. SOFTWARE SPECIFICATIONS

 10 analytical modes of operation:
 1-point Linear.
 2-point Linear.
 Rate A Linear.
 1-point Non-Linear (Cubic Spline / Point to point / Logit Log).
 2-point Non-Linear (Cubic Spline./ Point to point / Logit Log).
 Rate A Non-Linear (Cubic Spline / point to point / Logit Log).
 1-point Sample Blank Linear.
 1-point Sample Blank Non-linear (Cubic Spline / point to point / Logit
Log).
 Absorbance.
 Coagulation.
 200 totally “open” test programs selectable through keypad.
 Parameters can be viewed, edited, and printed.
 Facility to memorize reagent blank O.D., Standard O.D., Factor and Non-
linear curve for 10 Standards including Standard 0.
 Facility to set replicates (1-3) for standard and sample. Final result
calculation is done by averaging replicate results.
 Patient report for last 1000 results stored in memory are obtained by
3-2
 Date.
 I.D.
 By Date and I.D.
 By Date and Test Name.
 Graphic presentation of Non Linear calibration curves.
 QC (Levy Jennings Chart available for three controls per test)
 Daily QC.
 Monthly QC.
 Facility to view and edit control values of 3 levels (C1/C2/C3) at a glance for
each chemistry.
 Facility to view and edit Normal ranges of 3 sample types (Male/Female/
Infant) at a glance for each chemistry.
 Five fixed calculation items for calculation of certain parameters from the
previously run chemistry results.
 Rate calculation by linear regression method.
 Online reaction graph for Rate and Two point Assays
 Automatic zeroing.
 Total reaction time:
 Selectable Delay Time between 5 seconds and 999 seconds.
 Selectable Read Time between 5 seconds and 999 seconds.
 Selectable Read Number between 5 seconds and 999 seconds.
 Non-linear calibration (10 Standards including Zero Standard) with 3
methods.
 Point to Point.
 Spline.
 Logit Log.
 Variable temperature range. (20-40C) in steps of 1C with accuracy of 
0.1C.
 On-line reagent stability check.
 Substrate depletion / Non-linearity check.
 Monochromatic as well as bichromatic measurements possible.
 Calibration of peristaltic pump.
3-3
 On-line display of cuvette temperature.

 On-line help.
 Self-diagnostics.
 Help messages on erroneous entry.
 Reports can be printed on USB Printer or Thermal Printer by either using
PRINT key.
3.3. KEYBOARD DESCRIPTION
KEY DESCRIPTION
There are 6 dynamic keys, which are LCD display
screen specific.
These keys are used for entering a number from 0 to 9

as seen on the key.
TO
This key is used to enter negative sign or decimal point

when required. If pressed once the ‘-’ sign can be
entered. If pressed twice the decimal point ’.’ gets
entered.
The paper feed key is used to advance the printer paper
by 1 line.
This is a software reset key used to reset the analyzer

without resetting the memory.
3-4
This is an indication LED which blinks when Wash or

Asp key are pressed. It indicates that the peristaltic
pump is in action. The LED stops blinking after 5ml of
water is aspirated or when the programmed volume of
liquid is aspirated.
There are 28 multifunction keys, which act as 56 direct
chemistry access function keys. The function of this key
depends on number of times the key is pressed. If
pressed once chemistry written on the top of the key
gets activated and if pressed twice chemistry mentioned
at the lower part of the key gets activated.
E.g. If pressed once GLU will activate and if pressed
twice GHb gets activated.
The same key is used to enter the alphabets from ‘A’ to
TO
‘Z’ and ‘a’ to ‘z’ indicated on the right top corner of the
direct chemistry access key. These alphabets can be
utilized to enter laboratory information or sample ID.
E.g. If pressed once capital letter ‘A’ to ‘Z’ will be
entered and when pressed twice small letters ‘a’ to ‘z’
gets entered for the corresponding key.
3.4. ASPIRATION SWITCH

The Switch Actuator is located at right hand side below the aspiration tube which is
provided for aspiration of liquid into the flow cell and for washing flow cell.
3-5
3-6
4. INSTALLATION
4.1. INSPECTION
The analyzer is tested before shipment and is packed carefully to prevent any
shipping damage. It is user’s responsibility to inspect all cartons upon arrival and
notify the carrier of any apparent damage. Follow the steps described in the
paragraphs below to install the analyzer.
4.2. UNPACKING
The main unit and accessories are packed in single carton; other additional
accessories such as power cord may be packed in another carton. The
representative is responsible for unpacking, installing and initial setting up of the
analyzer.
Serial Item Code Description Quantity
Number
1 102948 AC POWER ADAPTOR (O/P: 18V DC: 70 W) 1 No.
2 110951 POWER CORD 3 PIN 250V/6A (For Domestic)
OR
1 No.
110343 TYPE E / F PLUG - M2511 / U16CS3 V1625 HO5
VVF 3 X 1SQ.MM 2MTR. LENGTH(For Export)
3 110309 THERMAL PRINTER PAPER ROLL (57 mm x 30 1 No

METERS) 3Nos (Export)
4 110035 WASTE BOTTLE ASSEMBLY. 1 No..
5 110956 DUST COVER FOR CHEM-7 1 No..
6 112498 OPERATOR MANUAL FOR CHEM7 NS
(Domestic) v2012.01.01
OR 1 No..
112450 OPERATOR MANUAL FOR CHEM-7 NS (Version
2012.01.01) (Export)
7 110973 TEST TUBE HOLDER 1 No..
8 ROUND GLASS MICROCUVETTES 5 Nos
110945
10Nos(Export)
9 RECT.POLY MICROCUVETTES 5 Nos
110347
10Nos(Export)
10 110661 ALLEN KEY 3 MM 1 No.
11 111063 TEST TUBE STAND 1No. 
12 110978 PIPETTE STAND (PLASTIC) 1 No. 
13 110943 T200y PIPETTE TIPS 200 µl (YELLOW) 100 Nos. 
14 110944 T1000b PIPETTE TIPS 1000 µl (BLUE) 100 Nos. 
15 111654 PROLINE SC. VV. MECH. PIPETTE 5 µl - 50 µl 1 No. 
4-1
Serial Item Code Description Quantity

Number
16 111655 PROLINE SC. VV.MECH.PIPETTE 100 µl - 1000 µl 1 No. 
17 120232 ERBA WASH KIT 1 No.
110020 PM KIT – CHEM-7 PH II WITH 2 x 5.5 1 NO.
PERISTALTIC TUBE ASSEMBLY
1 110018 ASSEMBLY LAMP 1 NO.
2 110353 5 ML SYRINGE (CAT NO 300850 MAKE B-D) 1 NO.
3 110354 TUBING PVC ID 2.8 MM X OD 4.3 MM 1 NO.
4 111213 TUBE TEFLON ID 0. 75 MM X OD 1.5 MM 1 NO.
5 110194 TUBE TEFLON ID 1 MM X OD 2 MM PTFE – 1 NO.
M0004
6 110021 PERISTALTIC TUBE ASSEMBLY 1 NO.
7 110356 TUBING SILICON ID 2 MM X OD 4 MM 1 NO.
(IMPORTED)
8 110355 TUBE SILICON ID 0.8 MM X OD 2.4 MM 1 NO.
OPTIONAL ACCESSORIES
1 110008 BATTERY BACK-UP ASSEMBLY FOR CHEM-7 1 NO.
2 111654 AUTO PIPETTE 5- 50  L 1 NO.
3 111655 AUTO PIPETTE 100-1000 L 1 NO.
4 110978 AUTO PIPETTE STAND 1 NO.
5 110943 DISPOSABLE TIPS (YELLOW) 100 NOS.
6 110944 DISPOSABLE TIPS (BLUE) 100 NOS.
7 110001 INCUBATOR ASSEMBLY 1 NO.
8 111063 TEST TUBE STAND 1 NO.
9 120233 DEMO KIT 1 NO.
NOTE: Please refer to dispatch note for detailed checklist.
 NA for Export
4.3. INSTALLATION REQUIREMENTS

The proper location is an important consideration; an improper location can lead to
malfunction of the analyzer. Please follow our environmental and electrical
suggestions to ensure the accuracy and precision of analyzer and to maintain high
level of safety for your personnel.
Since the analyzer is comparatively smaller, it can be comfortably accommodated
on any standard sized table.
Remember that minimum 30cm. space is maintained between the rear panel and
the wall to allow for heat dissipation. The waste bottle should be placed on the
same level or below the level of analyzer.
Please ensure while taking any electrical measurement, the multimeter used must
have been calibrated and should possess valid calibration identification traceable
to National/International standard.
4-2
Also ensure that the power supply should be placed near to the analyzer in such a
way that ON/OFF switch is easily accessible to the user. This will help the user to
switch OFF the instrument immediately in case malfunctioning is detected.
PROBLEM resulting from the relocation of the analyzer done by
unauthorized service representative are not covered under warranty.
4.4. ELECTRICAL REQUIREMENTS

Voltage and Frequency Single phase continuous stabilized AC 110/230 V ± 10%, 50 / 60 Hz.
Grounding Perfect earthing must be provided at power source with all
applicable local requirement (A grounded, power plug only should be
used). The voltage between earth and neutral should not exceed
more than 5 V.
Plug Points 3 Nos. of 5 Ampere outlet sockets should be available near the
installation desks. (Normally only one socket is required per analyzer
and 2 extra sockets are recommended for using any measuring
equipment and engineering tool if required while servicing. Failure to
properly ground the analyzer bypasses important safety features
and may result in an electrical hazard. Heavy-duty electrical devices
like Air conditioners, refrigerators, oven’s etc., should not be
operated on the same electrical lines as the analyzer.
4.5. INSTALLATION PROCEDURE

1. Unpack the accessory box.
2. Remove the waste bottle and place it on the table.
3. The Analyzer comes equipped with an external AC power adapter and one
three/two pin power cord (with earth terminal) for external AC power
adapter.
4. Proper use of the appropriate power cord assures adequate grounding for
the system. Failure to properly ground the analyzer bypasses important
safety features and may result in an electrical hazard.
5. Connect the 3/2 pin cord (with earth terminal) of the external SMPS to the
mains socket and check the output of the SMPS, it should be 18~24V DC ±
1V DC.
6. Connect the Peristaltic Pump tubing correctly and place the end of the
peristaltic pump tubing coming out of the analyzer into the waste bottle
provided for collecting the Waste.
4.6. PRINTER HOUSING AND PRINTER PAPER

INSTALLATION
4.6.1. INTERNAL PRINTER
There is a Thermal printer mounted inside the cabinet. It is extremely low noise
printer. The non-presence/improper installation (printer lever is not pressed
4-3
downward) of the thermal paper is detected and it is alarmed by 4 continuous

beeps.
Refer below Figure 1 for proper routing of Thermal Printer Paper roll.
NOTE: The thermal paper used must match the specification of the original one,
since the calibration of the working temperature is optimized for that kind of paper.
Failure to use proper quality of paper may permanently damage the printer.
4.6.2. EXTERNAL PRINTER

1. Switch off the analyzer before connecting printer.
2. HP DeskJet USB Printer can be attached to the analyzer to print reports,
graphs etc.
3. USB A Type connector is provided at the rear of the analyzer. Connect the
printer cable to this port before switching ON the analyzer.
4.6.3. PC COMMUNICATION
NOTE: USB Connectivity to PC requires operating system 2000/XP or above.
4.7. EXTERNAL KEYBOARD INSTALLATION

Switch off the analyzer before connecting PS2 keyboard. Then connect to the port
provided at the rear of the analyzer.
4-4
5. BLOCK DIAGRAM
The major blocks of the Chem-7 New Scheme consists of CPU PCB, thermal
printer, external DeskJet printer (external printer can also be connected)
Photometer, Keypad and liquid crystal display (LCD), Peltier Assembly, Peristaltic
Pump and External keyboard which can be connected to the analyzer.
Soft key functions are designed in such a way that it operates with single touch
with quick shift from one function to another without going through complex
sequential operations.
The LCD is a 320x240 dots, LED backlight display with alphanumeric and graphic
capabilities with backlit feature which enables the user to read in case of less
ambient light. This is most sensitive device to get damaged, which require careful
handling, which is interfaced with keypad using a interface card. External keyboard
can be connected to the analyzer using PS/2 connector provided on the rear of the
analyzer.
5-1
Photometer is a device to measure the intensity of the light. Where the absorbance
of the radiation from the colored substances are measured by means of
photodiode. It can serve 8 different wavelengths. The filter defines the
wavelengths.
CPU PCB as the name suggests is the heart of the analyzer, which controls all the
hardware & software functions of the analyzer. Refer the details of main board in
the operation section.
5-2
6. FUNCTIONAL DESCRIPTION OF PCB

As shown in block diagram analyzer CPU PCB is the heart of this analyzer. This
CPU PCB gives necessary commands and controls the operation of other
peripheral such as Keyboard, LCD, Printer and Photometer. Major blocks are
explained below.
6-1
CPU PCB COMPONENT LAYOUT
6-2
6-3
6.1. POWER SUPPLY SECTION

The instrument is operated at 115/230V AC ±10%, 50/60Hz power supply which
acts as an input for the internal devices.
This instrument uses three power supply sections designed to provide power to
electronic circuit, lamp & photometer and the thermal printer.
Power Supply -> External SMPS provides +18V/24V DC, then the following
Voltages are generated by the Power distribution Board, +5V, +12 V DC and ± 5V
DC.
+5 V DC,-5 V DC, +12 V DC is given as input to the CPU PCB (which generates +
3.3 V DC for microprocessor and other logic ICs.) + 5V & -5V DC isolated supply
for photometer and ADC.
+12 V DC to motor and Incubator.
Any defect in the section will lead to any of the following problem(s):
1. Lamp/Fan voltage fluctuation
2. Lamp/Fan not working.
3. Printer not working.
4. Backlight of LCD is OFF.
5. Analyzer is not getting switched ON.
Action to be taken
 Check ON/OFF switch; any loose connection of cable assy.
 Check 18V DC ±1V DC; if NOT OK then replace power adaptor.
 Check 5V, 12V & ±5V supply (±5%); if not OK then replace DC-DC Power
Supply PCB assy.
6-4
POWER SUPPLY COMPONENT LAYOUT
6-5
POWER SUPPLY SCHEMATIC DIAGRAM
6-6
6.2. CONTROL LOGIC SECTION

The operations for controlling the instrument are performed by the CPU PCB. This
section is provided with MB90F334A microcontroller, 2MB of EEPROMs, a serial
interface RS 232C for interfacing Thermal Printer. The logic is all in CMOS
technology to guarantee low consumption and high reliability. The RTC is provided
with 3V coin battery.
1. Communication is not taking place between processor and peripheral
devices.
6-7
2. External printer is not working.

3. Calibration data is not getting stored.
Action to be taken:
 Replace CPU PCB.
6-8
CONTROL LOGIC SCHEMATIC DIAGRAM
6-9
6.3. MOTOR CONTROL AND MEMORY

This section controls the motion of motor using IC A3979. It is a DMOS Fully
Integrated Stepper Motor driver features a non-dissipative over current protection
on the high side Power MOSFETs and thermal realized in Multipower-BCD
technology. It includes a constant off time PWM current controller. When the
voltage drop across the sense resistor becomes greater than the voltage at the
reference input (VREFA or VREFB) the sense comparator triggers the monostable
switching the motor off. When the monostable times out the motor will again turn
on.
To store different types of data IC three 128 K bytes IC 24c1024 are used to store.
IC U4 is used for chemistry parameters, patient reports, values of standards and
blank for non-linear chemistry, for quality control data and U6 is used for default
parameter.
IC 1338Z is a Real Time Clock plus RAM. The function includes a nonvolatile time
of day, calendar. The time of day and memory are maintained even in the absence
of power.
1. Water, standard, solution is not getting aspirated after pressing ASP switch.
2. Motor is not running or not stopping.
3. Chemistry parameters are not stored.
4. Patient report or quality control data is not stored.
5. Date and time is not correct.
6. Default parameters are incorrect
7. Quality Control Data is not stored.
Action to be taken:
 For defect number 1 and 2, replace CPU PCB.
 For defect number 3 and 4, replace U4.
 For defect number 5, replace U16.
6-10
MOTOR CONTROL AND MEMORY SCHEMATIC DIAGRAM
6-11
6.4. PHOTOMETRIC UNIT

It is one of the major blocks of the instrument & it contains 8 different narrowband
optical interference filters of wavelengths 340, 405, 450, 505, 546, 578, 600, and
670 nm for specific chemistry tests. When ray of light is passed through the
reaction cell part of it gets absorbed by the reaction solution and then passes
through the filter. This filtered light is detected by photodiodes, which is amplified,
and send to the multiplexer CD 4051which selects the one signal and
communicates to processor for further processing.
1. Absorbance values not displayed.
Action to be taken:
 Check that the flowcell is clean and scratch free.
 Replace Photometer PCB.
PHOTOMETER COMPONENT LAYOUT
6-12
PHOTOMETER SCHEMETIC DIAGRAM
6-13
6.5. USB PCB

USB PCB having USB ‘A’ type connection for external USB printer (selected
models only). USB ‘B’ type connection for PC communication. IC CP2102 is used
to convert the serial data (Result) being dumped by the microcontroller to the PC in
USB format.
1. USB printer not printing instrument chemistry test results.
2. Communication between PC and USB not established.
Action to be taken:
 Check USB A-B cable and if found faulty, replace with new.
 Check CP2102 driver in PC.
 Check software communication settings in PC.
 Replace USB PCB assembly.
USB PCB COMPONENT LAYOUT
6-14
USB PCB SCHEMATIC DIAGRAM
6-15
6.6. PRINTER
The 384 dots thermal type graphic printer which is able to give a very high printing
quality, at high speed and a considerable noiselessness on thermal paper without
having to move the printing head.
6.7. KEYPAD AND DISPLAY SECTION:

The liquid crystal graphics display 320 x 240 dots with alphanumeric and graphic
capability.
A 47 key, membrane keyboard is provided.
6-16
7. TESTING AND PARAMETERS

The instrument assemblies are factory adjusted and does not require any field-
testing, adjustment or settings. It is advisable not to change setting unless
necessary.
If it is necessary, the testing, adjustment or setting must be carried out by trained
and authorized personnel only.
7.1. TESTING OF SMPS

1. Check the mains power supply .It should be within 115/230V AC, 50/60Hz,
±10%.
2. Connect one end of 2/3-pin power cord to the analyzer and another to the 3
pin power socket.
Check the outputs of the SMPS using a calibrated Multimeter, it should be
18/24V DC (±1V). DC-DC power supply PCB on J2 connector Output
voltages are as follows:
Pin Number Normal Condition TP Details
1 5V To CPU Board
2 GND Digital Ground
3 +12V Supply to Motor
4 GND Digital ground
5 5V Supply to Printer
7 +5Va +Vcc Analog
8 GND Analog GND
9 -5V -Vcc Analog
10 +12V Supply to FAN
11 GND Digital Ground
12 +12 V Supply to LAMP
14 NC
7.2. TESTING OF CPU PCB

1. Give power supply at J1 connector (on the CPU) from SMPS and measure
voltages at various test points with respect to common ground point using a
calibrated Multi-meter.
Pin Number Normal Condition TP Details
TP1 0V GND
TP19 +5V Vcc
TP20 +12VR Vcc to Motor
7-1
TP22 -5 VANA -Vcc analog

TP23 +5 VANA Vcc analog
TP24 +3.3V Vcc to µC
7.3. POWER ON SELF-TEST

1. Switch ON the analyzer by pressing the ON/OFF switch provided on the
rear of analyzer.
2. On switching ‘ON’ the analyzer, ERBA MANNHEIM logo is displayed and
analyzer will do self-diagnostic it will automatically check all the important
devices and will show the status on display.
3. If all the hardware tests are OK then the analyzer directly goes to the home
screen if one of the parameter is not correct the screen will be displayed as
follows. The user can still go to the home screen by pressing the YES key
4. This is routine test will be performed every time the analyzer is switched
ON.
If any of the parameter is not ok then it will be indicated by ‘x ’sign and a message
‘PROCEED… < YES > will be displayed on the bottom of the screen. In this case,
you have to press <YES> to proceed. If all the hardware tests are OK then the
Home Screen will be displayed.
7-2
7.4. SELF TEST

This key is used to check the analyzer in “Self Diagnostic” mode and is mainly
used by the Service Personnel. This option is available in the SYSTEM SETUP
screen. Following things can be done or checked in this menu.
1. Pump Calibration can be done.
2. Default parameters can be downloaded.
3. Flowcell temperature can be checked.
4. Pre and Log channel values for each filter can be checked.
 Thermal Printer can be checked.
 Unit keypad can be checked.
To minimize error in pump calibration the initial air gap in the peristaltic tube is
removed by giving compulsory wash. The aspiration key is active only after wash
is performed.
7-3
7.5. SETTING PARAMETERS

7.5.1. SYSTEM PARAMS
This option allows the user to view, edit and print the system date, time and the
data output mode. It is available in the SYSTEM STEUP > SYSTEM PARAMS.
To view or edit system parameters, press key <SYSTEM PARAMS> and following
screen will be displayed.
7-4
The dynamic keys <LAB INFO>, <SET DATE>, <SET TIME>, and < MODE> are
used to set the laboratory information, date, time and the data output mode
respectively.
To use the above mentioned dynamic keys refer to the details given below.
7.5.1.1. SETTING THE LAB INFORMATION

Choose the option ‘<LAB INFO>’ from the System Parameter screen and the
following screen appears:
The user can enter laboratory information (25 characters each on 5 lines) with
external PC/AT keyboard as well as with unit keypad. This is stored in the memory.
7-5
The laboratory information is printed as header in Thermal and External Printouts.
7.5.1.2. SETTING THE DATE

The analyzer incorporates a built-in calendar function, which is maintained by a
battery, and once set; the date and time will be printed every time at the beginning
of the test or along with the Lab Header.
Choose the option <SET DATE> from the System Parameters screen and the
following screen appears.
7-6
The cursor blinks at the first digit of the ‘Date’ option on the screen. Enter an
appropriate data in the following format.
DAY: Enter a day from 01 to 31
MONTH: Enter a month from 01 to 12
YEAR: The last 2 digits of year (from 00 to 99)
After appropriate entry is made, press the dynamic key <SAVE> to save date and
return to the system setup screen or press <QUIT> to quit without saving and
return to the system setup screen.
7.5.1.3. SETTING THE TIME

Choose the option <SET TIME> from the system setup screen and the following
screen appears.
7-7
The cursor blinks at the first digit of the ‘Time’ option. Enter an appropriate time in
the format as stated below:
HOUR: Enter an hour from 00 to 23
MINUTE: Enter minutes from 00 to 59
Again, a colon ‘:’ separates each entry sign, which appears automatically after the
entry of the 2nd digit.
After appropriate entry is made, press the dynamic key <SAVE> to save and
return to the system setup screen or press <QUIT> to quit without saving and go
back to the system setup screen.
7.5.1.4. SETTING THE DATA OUTPUT MODE

Choose <MODE> on the system setup screen to set the data output mode.
User can enable/Disable following options in this menu:
1. Thermal printer/USB printer (i.e. Turn ON/OFF printer/s).
2. Result transmission to PC.
3. Specify the number of standard and Sample replicates to be run.
4. Blank Deduction.
5. Air Purge
7-8
Five modes of output are available. Use the soft arrow keys to move between
selections and press <YES> or <NO> to select or deselect the options. Press <GO
BACK> to return to the system setup screen.
The results are printed on the analyzer’s thermal printer or external ‘HP’ make
deskjet printer or both printers as well as transmitted to the computer through the
USB interface.
BLANK DEDUCTION :
If this is selected this will subtract Reagent Blank O. D. from all the test O. D. for all
modes of kinetic and 2 – point assays as well as for One point mode. If this is not
7-9
selected then Blank O. D. will be subtracted only for One point mode. This can be
selected or de-selected by pressing <YES> or <NO> respectively.
STD REPLICATE :
Up to three replicates for the standard can be selected by using numeric keys. By
default it is one.
SAMPLE REPLICATE:
Up to three replicates for the sample can be selected by using numeric keys. By
default it is one.
AIR PURGE
The user can select or deselect Air Purge option from this menu. For Rate A and
Two Point mode, Air Purge must be enabled if aspiration volume is less than
400µl. However, Air Purge is optional if the aspiration volume value is between
400–999µl.
Air Purge can be enabled / disabled from System Setup Menu.
If Air Purge is enabled extra 150 µl air is aspirated after displaying the result.
If Air Purge is disabled, extra 150 µl air is not aspirated.
With the flow cell capacity being 18 μl, a minimum 350 μl volume is recommended
to eliminate errors due to carry over.
7-10
8. ADJUSTMENT AND CALIBRATION

8.1. OFFSET AND GAIN CALIBRATION OF
PHOTOMETER
1. Go to the SYSTEM SETUP > SELF TEST menu.
2. Bring the cursor down by pressing ‘DOWN’ arrow key to the PRE
CHANNEL & LOG CHANNEL option.
3. Press dynamic key ‘F1’ for 3 times.
4. Block the light and then press YES.
5. On pressing YES, the instrument will take the readings and store the offset
automatically.
6. Now the instrument will display the message PLEASE INSERT FLOWCELL
WITH DI WATER AND THEN PRESS <YES> on the screen.
7. Insert the flowcell filled with DI water and then press <YES> key.
8. The instrument will automatically calibrate the gain of photometer and then
display the gain values on the LCD & store these values in memory. It will
also be printed on thermal printer.
NOTE: Refer Dynamic keys, from left first key is F1 and second F2 and likewise.
8.2. TEMPERATURE CALIBRATION

1. Go to self test.
2. Bring the cursor down by pressing ‘DOWN’ arrow key to the FLOWCELL
TEMPERATURE option.
3. Press dynamic key ‘F1’ for 3 times.
4. The message ‘SELECT TEMP. FOR 2 PT. CALIBRATION’ will be displayed
with options as:
 25˚C
 37˚C
5. Press key 1 or 2 depending on the temperature for which calibration is to be
performed.
6. Now let the cuvette housing to attain the selected temperature (25˚C if
option 1 is selected else 37˚C, if option 2 is selected).
7. Check the physical temperature using temperature indicator/jig (allow it to
settle).
8-1
8. Enter the temperature displayed by the temperature indicator/jig. (Refer

resistance vs temperature chart in Annexure-1)
9. Press ENTER to save.
10. Repeat the procedure until the required temperature achieved on the
indicator/jig (after RESET > SELF TEST).
11. Verify the temp once again after switch off / on the analyzer.
8.3. PUMP CALIBRATION

This function of the analyzer is used to calibrate the pump for aspirating specific
volumes from 200-999 µl. This facility is available in the SELF TEST mode of
operation.
To perform Pump Calibration got to SYSTEM SETUP > SELF TEST and then
select PUMP CALIBRATION using the up/down arrow key.
Take 1 ml of distilled water in a test tube. Press ASP switch to start aspiration and
when the last drop is left in the tube, press ASP switch again. Now the peristaltic
pump is calibrated to aspirate any volume from 200 µl up to 999 µl.
8.4. MULTILINGUAL OPTION

1. Go to SYSTEM STEUP.
2. Press SYSTEM PARAMS key.
3. Press F1 key three times
The list of languages will be displayed for selection.
8-2
4. Select language required.
8.5. ADJUSTING LCD DISPLAY BRIGHTNESS

Open the analyzer’s cabinet and rotate the R12 provided on the Main PCB as per
required brightness.
8-3
8-4
9. MAINTENANCE
The analyzer is designed for trouble free operation and requires minimum
maintenance. For good functioning of the analyzer it is advisable to follow the
instructions given below
1. Handle the analyzer with care and keep it clean.
2. When not in use, cover the analyzer with the dust cover to avoid
accumulation of dust.
3. Though air conditioning is not a must, it is advisable to keep the analyzer in
a dust free, cool atmosphere, away from direct sunlight.
9.1. DAILY MAINTENANCE

1. Wipe off any reagent spills on the analyzer immediately.
2. After every chemistry run, wash the flowcell thoroughly with good quality DI
water using the dynamic key <WASH> or <ASP> switch.
3. Always leave the flowcell filled with DI water. Never leave any reaction
mixture in it.
4. At the end of each day, aspirate neutral cleaning solution into the flowcell
and leave it filled overnight. Every morning aspirate DI water 5 ml to
thoroughly rinse the flowcell.
5. Empty the waste solution bottle every evening.
Caution: DO NOT USE STRONG ACIDIC OR ALKALINE
SOLUTIONS WHICH CAN CAUSE IRREPARABLE DAMAGE TO
THE ANALYZER.
Caution: DO NOT LEAVE THE FLOWCELL DRY. ALWAYS LEAVE

IT FILLED WITH DEIONIZED WATER DURING THE DAY AND
WITH CLEANING SOLUTION AT NIGHT.
NOTE: It is advisable to carry out the peristaltic pump calibration every week in
order to compensate for the change in elasticity of the tubing.
9.2. QUARTERLY MAINTENANCE

Replace the aspiration tubing and peristaltic pump tubing once every 3 months (as
explained below) or earlier if it shows signs of wear and tear.
Warning: Failure to change the peristaltic pump tubing in time
can cause serious errors of aspiration volumes and can also
damage the analyzer due to the leakage of corrosive reagents
through torn tubing.
9-1
Besides the above, certain other simple maintenance operations have to be

performed as and when required.
These are:
 Replacement of the paper roll
 Replacement of tubing
9.3. REPLACEMENT OF TUBING

Warning: THE REPLACEMENT OF ASPIRATION AND
PERISTALTIC TUBINGS SHOULD BE PERFORMED BY THE
TRAINED PERSON ONLY.
The replacement has to be carried out once in THREE months, or whenever an
alteration in the aspiration volume occurs. Disconnect the tubing from the
peristaltic pump if the analyzer is not going to be operated for a few days or longer.
9.3.1. ASPIRATION TUBE REPLACEMENT

1. Open the Photometer Cover.
2. Gently remove the flow cell from cuvette housing.
3. Unscrew the aspiration tubing from the flow cell.
9-2
4. Slide out the washer and ‘O’ ring of the old aspiration tubing.
5. Discard the old aspiration tubing onto an appropriate location, as it is bio-

hazardous.
6. Slide the washer and ‘O’ ring into the new aspiration tubing.
7. Lock it to the flow cell with the plastic screw available.
8. Place the flow cell back into its slot.
9. Pass the end of the aspiration tube through the holder and pull it out so that
the length is adequate.
10. Aspirate the DI water.
11. Close the Photometer Cover.
NOTE: Take care to see the side of the flow cell with the arrow mark is in light path
& to your left. and always leave it filled with distilled water whenever not in use.
9.3.2. REPLACEMENT OF PERISTALTIC PUMP TUBINGS

1. Remove the Cover of the peristaltic pump housing.
9-3
2. Before the old tube is removed, note the exact manner in which it is
positioned around the pump.
3. Release the peristaltic pump tubing.
4. Detach both the ends of the tubing from Aspiration tubing and Waste tubing
respectively.
5. Discard the old tubing onto an appropriate location, as it may be bio-

hazardous.
6. Position the new tubing around the rotor in right manner (as previous).
7. Insert the one end of new peristaltic tubing assembly into the tubing coming
from flow cell.
8. Insert the other end of peristaltic tubing into the waste tube and direct the
waste tube towards waste bottle.
9. Put the free end into the waste solution bottle.
9-4
10. Perform pump calibration with 1 ml DI water.

11. Put the Cover of the peristaltic pump housing.
9.4. REPLACEMENT OF LAMP ASSEMBLY

Warning: THE REPLACEMENT OF LAMP ASSEMBLY SHOULD
BE PERFORMED BY THE TRAINED PERSON ONLY.
12. Open the Photometer Cover.
13. Unscrew the thumbscrew and remove lamp cover.
14. Before the old lamp is removed, note the exact manner in which it is
positioned.
15. Unscrew the two lamp terminals using (--) screw driver.
16. Unscrew the thumbscrew provided on the lamp holder.
9-5
17. Pull out the lamp.
18. Place a new lamp and connect the lamp terminals and fix thumbscrews.
19. Refit the lamp cover.
20. Close Photometer Cover.
NOTE: Due to the aging effect the lamp intensity may get reduced and results may
be improper, it is advisable to replace the lamp after every six month.
Warning: SWITCH OFF THE POWER SUPPLY BEFORE
REMOVING THE COVER.
9.5. REPLACEMENT OF PRINTER PAPER

Warning: THE REPLACEMENT OF PRINTER PAPER SHOULD
BE PERFORMED BY THE TRAINED PERSON ONLY.
Before starting the instrument, make sure that enough printer paper is on the roll.
The paper roll is located under the printer cover. To check and / or replace the
paper roll lift off the printer cover. For inserting a new paper roll do as follows.
1. Lift off the printer cover and take the roll out of the paper roll housing.
2. Then take a new paper roll and lay down into the paper roll housing.
3. Release the printer lever by pulling it upward.
9-6
4. Cut the paper in ‘V’ shape and feed this paper tongue into the slot of the
paper feeder. Smoother side should face up.
5. Close the printer lever by pressing it down and close the printer cover.
6. Press PAPER FEED key provided on the keypad to advance the paper.
Warning: BE CAREFUL - SHARP PAPER CUTTER.
9-7
9-8
10. TROUBLE SHOOTING GUIDE

The following list is an extension of the troubleshooting section outlined in the
operator’s manual. The reader should familiarize with the setup, operation and
troubleshooting section of the operators manual before attempting to service the
unit.
In all cases of problem that are not described in this chapter and that cannot be
solved by you according to the given remedies, it is strongly recommended to
contact your technical product specialist.
NOTE: It is very important while diagnosing problem to look at the non-
instrumental aspects of troubleshooting. This will save time and efforts for reaching
to the correct solution.
Please ensure the following before opening the instrument.
 The Quality of reagents and samples used is good.
 There are no voltage fluctuations or stabilization problems in mains voltage.
 There are no pipetting errors.
 While re-programming new/old tests for instrument, ensure the parameters
entered are as per the reagents brands used.
 There are no environmental problems
FIXING A PROBLEM:
1. Analyzer is not turning ON.
Probable Cause Corrective Action
1. No supply voltage. Check supply voltage.
2. Defective SMPS. Replace SMPS.
3. Test point voltages are not OK. Replace CPU PCB.
4. Loose connection. Firmly connect the loose connector.
5. SMPS output is not OK. Replace SMPS adapter.
2. Blank or Black Display.
1. Loose Connection. Remove all connectors on CPU PCB and
Power Distribution PCB. Tighten all the
connections.
2. Defective Display assembly. Replace display assembly.
3. Intensity control for display not set. Adjust display intensity Pot R12 on the
CPU PCB.
10-1
3. No Back Light Effect.

1. +5 V DC at inverter PCB assembly not Possible loose connection of the connector
present. on CPU PCB assembly and inverter
assembly.
2. Defective inverter PCB Assembly. Replace inverter PCB assembly.
3. Defective CPU PCB. Replace main board.
NOTE: Inverter PCB is not required for LED backlight type LCD display
assembly.
4. Liquid is not aspirated when the “ASP” switch is pressed.
1. Peristaltic tube elongated. Replace peristaltic tube with new one.
2. Loosely fitted tubing. Tighten the tube joints and flowcell
connector.
3. Loosely fitted flowcell connector. Tighten the flowcell connectors.
4. Blockage in tubing’s flow cell. Check and remove blockage. Replace
tubing if blockage is not removed.
5. “ASP” switch is defective. Replace “ASP” switch.
6. Defective motor assembly. Replace defective motor assembly.
7. Defective keyboard assembly. Replace keyboard PCB assembly.
8. Defective main board. Replace main board assembly.
5. Liquid is not aspirated when the Dynamic key “WASH” switch is
pressed.
1. Check all the above-mentioned points Check the all above mentioned points
6. Liquid is aspirated continuously.
1. Peristaltic pump not calibrated. Carry out pump calibration.
7. Air bubbles in flowcell.
1. Peristaltic pump wrongly calibrated. Carry out pump calibration.
2. Leakage/cut/pinched flowcell Replace aspiration tube.
connectors.
3. Loosely fitted flowcell connectors. Tighten the flowcell connectors.
4. Flowcell damaged. Replace flowcell.
8. Dripping or Leakage from Aspiration tube.
1. Peristaltic tube reversed. Fix the peristaltic tube in the correct
position.
2. Hole in tubing before peristaltic pump. Replace tubing.
3. Flowcell damaged. Replace flowcell.
10-2
9. Erratic results/poorly reproducible results/peaks in graphs.

1. Inconsistence aspiration of solution. Replace peristaltic tube assembly and
recalibrate peristaltic pump.
2. Dripping or leakage from aspiration Refer point 8 as mentioned above.
tube.
3. Dirty flow cell. Aspirate ERBA wash and clean flowcell.
4. Air bubbles in flow cell. Refer point no.7 as mentioned above.
5. Brownish/Defective lamp assembly. Replace with new lamp assembly.
6. Peristaltic tube elongated. Replace peristaltic tube assembly.
7. Lamp voltage fluctuation. Check and replace power supply PCB
assembly.
8. Loosely fitted Photometer Box. Fix the photometer box properly.
9. Defective photometer assembly. If the gain is abnormal replace photometer.
10. NO Paper Feed.
1. Printer lever is open (release position). Push the printer lever down to lock paper.
2. Loose or poor contact Check for any loose connections to printer
cables and connectors
3. Defective keypad assembly Replace keypad
4. Defective printer assembly Replace printer PCB assembly
11. NO Printout.
1. Paper roll is installed reverse way. Install paper in right way.
2. Printer lever is open (released) Press lever down and lock paper.
position.
3. Defective Printer PCB assembly. Replace printer PCB assembly.
4. Printer is not selected. Select printer option in system setup.
12. Faint printout/some characters missing.
1. Dirty printer head. Clean the printer head with alcohol.
2. Defective printer PCB assembly. Replace with new printer PCB assembly.
13. Continuous Buzzer.
1. Aspiration switch stuck. Release the aspiration switch.
2. Printer lever is open. Close printer lever by pressing it down.
10-3
14. External Printer not working.

1. Printer is not selected in output mode. Select external printer in output mode.
2. USB cable is loose. Tighten USB cable.
15. The result printout is accompanied by the warning “RX ABS LIM
OVER” in all Chemistries.
1. The initial reaction of mixture is more Check the RX ABSLIM value has been
than ABS MIN value in test correctly entered. Prepare fresh reagent
parameters. and check the values.
16. The result printout is accompanied by the warning “RX ABS LIM
UNDER” in all Chemistries.
1. The initial reaction of mixture is more Check the RX ABSLIM value has been
than ABS MIN value in test correctly entered. Prepare fresh reagent
parameters. and check the values.
17. The result printout is accompanied by a warning message
“HYPERACTIVE SAMPLE!!”
1. The change in the absorbance per set. Verify the limit.
minute (∆A/min) pf the sample is
greater than the value fed as “LIN,
LIM”.
2. Kinetic reaction is still in lag phase. Amount of enzyme in the measurement
solution is very low, dilute the sample and
perform the test again.
3. Check if the initial absorbance is OK. Lamp intensity is low /flow cell is not
blocked.
18. All the readings are zero.
1. The lamp is not ON If lamp is fused replace lamp assembly
2. Flowcell is not inserted properly Place the flowcell properly in light path
19. Keypad is locked.
1. Absorption Switch is pressed. Release ASP switch.
Reset the analyzer using ON/OFF switch.
20. Date and time is not OK.

1. Analyzer is not switched ON for more Set date and time by going through the
than 3 to 4 weeks. system setup option.
2. 3V battery may be drained out. Replace 3V battery.
10-4
21. Memory/Data storage error.

1. Chemistry parameters not stored. Replace CPU PCB.
2. Patient report and values for non linear Replace CPU PCB.
chemistry not stored.
3. linear chemistry not stored Quality Replace CPU PCB.
Control Data not stored.
22. Hardware Check shows SMPS Voltage NOK.
1. Heavy fluctuation in mains power Do not operate the analyzer.
supply.
2. Defective SMPS. Replace SMPS.
23. Hardware Check shows Photometer NOK.
1. Light path is blocked. Remove obstacle if any in light path.
2. Flowcell is empty. Aspirate distilled water.
3. Bubbles in flow cell. Remove bubbles by aspirating water.
4. Loose connection of mains Properly insert the mains cord/DC jack
socket/cord/DC jack connector. connector.
5. DC jack PCB faulty. Replace DC jack PCB.
24. The temperature attained in the flow cell is not within ± 0.1º C of the
selected temperature.
Flowcell is not completely inserted Insert flowcell completely in proper way
Refrigerated reagent is used. Bring the temp. of reagent to room
temperature and then use it. Replace
thermister still persists, replace peltier
Additional Troubleshooting Points
Sl. No. SYMPTOM LIKELY CAUSE/CORRECTIVE ACTION

1 Machine Dead/Not Check I/P supply at customer end AC
switching on 230V±10%.
Proper earthing voltage which should be 0-5V
between N&E.
Check power cord continuity. (If NOK then
replace it).
Check 18 V±10% at SMPS dc jack pin.
If output is not ok (18±10%V dc) then replace
the SMPS (AC Adaptor).
Switch ON the instrument by ON/OFF switch.
Change the switch in case it is not working.
If switch is OK then check the supply on dc jack
10-5
pcb in instrument, If there is no supply then

change the dc jack pcb.
If DC jack pcb is ok, check the input voltage at
power supply pcb TP5 w.r.t. TP6 (gnd) ,if
voltage 18 V not coming, replaced the power
supply pcb.
Please follow all the above mentioned steps
before changing any pcb.
2 Lamp not glowing Remove the lamp cover from instrument.
Check the lamp voltage on terminal strip
(11.70v).
If the voltage is OK, check the lamp visually if it
is fused then replace it.
If lamp is ok, then check the same voltage on
P/S pcb (TP2 & TP6).
If voltage is not coming then change the P/S
pcb.
3 No Backlight /Flickering Open the instrument & check the FRC cable
/Low Intensity in Display connection at J12 & Backlight cable connection
at J40 on CPU pcb.Refix it (In case of display
flickering).
Adjust display intensity from pot R12 at CPU
pcb.( In case of low intensity display)
Check display visually by removing from
instrument (soldering of FRC cable & others
components along with visual of Aux pcb).
In case of 'NO Backlight' check the supply of (5v
dc) at J40 connector by removing it from CPU,
if there is no supply then change the CPU
Check another display, if it is ok then replaced
with faulty display.
If not ok with new display then change the CPU
pcb.
4 Keypad not working Check the ASP switch; if stuck then release it by
proper fitment of cabinet.
Check the keypad cable visually & refix the
same on J7 & J7A connector.
Check another keypad without fixing on cabinet.
If new keypad is ok, then replace faulty keypad
with new one.
In case if new keypad is also not working then
change the CPU pcb without changing the
keypad.
5 Offset error Do the offset calibration and observe that
channel at which the error is showing.
10-6
Now open the instrument & detector box. Then

remove the photometer pcb from detector box.
Check the power supply & signal cable of PH.
pcb for proper connection either on PH. Pcb or
on CPU pcb.
Check the RTV application on photometer pcb.
Every single point should be cover with RTV
glue. If found such point then apply the RTV
glue on it.
If RTV is OK but no effect on problem then
change the PH. Pcb.
6 Printer lever error Check thermal paper roll is present or not.
If lever is open then close it towards down
wards.
Reconnect the printer pcb cables (both supply &
signal).
Check the printer pcb visually, if found any
component damage, then change the printer
pcb.
Check the thermal printer tail which should be
properly connect with printer pcb.
If software version is 2010.03 instead of
2011.01(at present) or older ver. Then replace
the cpu pcb.
7 No Print Out & Faint Print Check if paper roll is installed in reverse way; if
Out so then install it correctly.
Check the settings in output mode (system
setup), if thermal printer not selected then select
it.
In case of faint print out, check for any dust
particle on printer head.
Check the printer pcb visually, if found any
component damage, then change the printer
pcb.
Check the thermal printer tail which should be
properly connect with printer pcb.
8 Improper aspiration/No Clean the flowcell by aspirate with ERBA wash
aspiration then with DI water. (Especially in case of any
bubble in working area).
Check the complete peristaltic tube assy.
visually for any cut mark, pinched, fitment of
tubing, loose fitment of straight through
connector & loose fitment of rotor base assy.
In case of slow aspiration check the peristaltic
tube (9cm) for elongation, If found elongated
10-7
then change the same.

In case of "No" aspiration check the motor
assembly, if found defective then replace the
motor assy.
Perform pump calibration again.
9 Leakage from peristaltic Check the complete peristaltic tube assy.
pump/Aspiration tube visually for any cut mark, pinched, fitment of
tubing, loose fitment of straight through
connector & loose fitment of rotor base assy.
Check any loose connector on flowcell & any
cut mark on flowcell tubing.
10 External Keyboard/printer Check at rear side of instrument the ext.
not working keyboard/ printer connectors should be centrally
aligned.
Check for any fault in printer & keyboard of
customer itself by confirming it on any PC.
Check the connector visually from rear side for
any bend or broken of any pin if yes then
change the USB pcb.
Check for any particle dropped on USB pcb.
Check for any loose connection of cables either
on USB pcb (J2 & J4) or on CPU pcb (J13 &
J39).
If not ok with above steps then change the CPU
pcb.
Please follow all above mentioned steps before
changing any pcb.
11 Gain saturation Check the lamp voltage at the lamp terminal
(11.7 V)
Change the lamp & confirm the lamp image.
Do the offset calibration & gain calibration, if not
ok then change the PH. pcb.
12 Filter gain not ok/low gain Check the flowcell visually any finger prints, any
impression, dust particle in working area.
Check for any cuvette chip or foreign particle in
flowcell housing.
Check for any bubble in working area. If there is
bubble then aspirate with DI water.
Check the lamp image. It should be clear in
round form. If not then make its proper
alignment or change the lamp.
Check the alignment of detector box. Also check
the screw tightening on detector box & clamp.
Clean the 9.5 mm condensing lens with optical
grade tissue if any dust or finger prints found.
Clean the photodiode with acetone or alcohol
with optical grade cloth.
If not ok then change the PH. pcb.
10-8

13 ASP switch not working Check if aspiration switch get stuck with cabinet.
Release it firmly.
Check the loose connection of ASP key/LED
cable at J5 connector on CPU pcb.
Check the CPU pcb visually for any dropage of
any foreign particle, chips etc.
If not ok with above steps then change CPU
pcb.
14 ON/OFF switch not Check if switch is tightly pressed while
working/Intermittent functioning, if so then change it.
operation Check for any loose & improper crimping of
wire.
Check if switch connector is not having contact
with power supply cable connector.
If NOK with above steps then change the
ON/OFF switch.
15 Erratic result/Improper Do the offset & gain calibration.
result/Negative result Check the reagents (expiry) & contamination.
Check the flowcell housing area for any foreign
particle or cuvette chip (to avoid zero result).
Properly clean the flowcell with ERBA wash &
then with DI water mandatory (to avoid negative
result).
In case of slow aspiration check the peristaltic
tube (9cm) elongation, If found elongated then
change the same, then Recalibrate the
peristaltic pump.
Check pump calibration & test parameters
thoroughly.
If the graph is erratic then change the lamp. Be
sure that the lamp image is clear. Also check
the Lamp voltage fluctuation. In such case
change the P/S pcb.
If graph still not ok then change the 9.5 mm
condensing lens.
If all above case not resolved then change the
CPU pcb.
16 Pump calibration not ok Recalibrate the pump with 1 ml DI water (pump
count should be 1800 to 2700)
10-9
10-10
11. SPARE PARTS

11.1. SPARES DETAILS AND ORDERING
INFORMATION
It is recommended that all the spares and accessories used in or along with the
equipment are critical and original supplied by the manufacturer. In case
requirement of these parts for trouble free working of analyzer. Kindly mention
below details while ordering spares.
SERIAL ITEM CODE DESCRIPTION QUANTITY
NUMBER
1 110956 DUST COVER FOR CHEM 7 1
2 110973 TEST TUBE HOLDER 1
3 110945 ROUND GLASS MICROCUVETTES 10
4 110943 T200Y PIPET TIPS SERIES 200uL(YELLOW) 100
5 110944 T1000B PIPET TIPS SERIES 1000uL(BLUE) 100
6 111063 TEST TUBE STAND 1
7 110347 RECTANGULAR POLYSTYRENE MICRO 10
CUVETTE
8 103651 PIPETTE STAND WITH BASE STICKER 1
9 110661 ALLEN KEY 3 MM 1
10 OPERATOR MANUAL FOR CHEM7 NS OM 1
112498
(Domestic) v2012.01.01
11 181675 USER MANUAL FOR NEW CHEM-7 (for Export) 1
12 111654 ELECTRONIC PIPETTE 5 - 50 ul (CAT NO. 1
710011ET )
13 111655 ELECTRONIC PIPETTE 50 TO 1200ul (CAT NO. 1
710041ET )
14 120233 DEMO KIT FOR CHEM-7 1
110308 CORD POWER 2 PIN GERMAN TYPE 1
15 110951 CORD POWER 3 PIN 6A, 250V, LENGTH 1.5
METER , COLOR BLACK, PLUG AS PER IS-6538,
CABLE AS PER IS-694, SOCKET IEC
APPROVED
16 120233 ERBA WASH KIT (4 X 50ml) 1
17 110309 PRINTER PAPER ROLL KIT (3 ROLLS) 57mm 1
x30mtr
18 111456 WASTE BOTTLE STAND 1
110020 PM KIT – CHEM-7 PH II WITH 2 x 5.5 1 NO.

PERISTALTIC TUBE ASSEMBLY
1 110018 ASSEMBLY LAMP 1
2 110353 SYRINGE 5 ml ( for cleaning ) 1
11-1
3 110354 TUBE PVC (ID: 2.8mm; OD: 4.3mm)( WASTE 0.55

TUBE)
4 111213 TUBE TEFLON ID 0. 75 MM X OD 1.5 MM 0.21
5 110194 TUBE TEFLON ( ID: 1mm; OD: 2mm ) 0.04
6 110021 PERISTALTIC TUBE ASSEMBLY 2
7 110356 SILICON TUBING ID 2 MM X OD 4 MM 0.36
(USED WITH SYRINGE FOR CLEANING)
8 110355 Tube Silicon (ID-0.8mm, OD-2.4mm) (to be used 0.012
with 40mm flanged Teflon tube)
11.2. LIST OF CONSUMABLES

For a continuous and trouble free working of analyzer, it is a recommended to
keep certain spare consumables handy.
One set of the items mentioned below is also supplied along with the instrument as
standard accessories
SERIAL ITEM CODE DESCRIPTION QUANTITY
NUMBER
1 110021 PERISTALTIC TUBE ASSY 02
2 111213 TUBE TEFLON ID 0. 75 MM X OD 1.5 MM 0.21MTR
3 110018 ASSEMBLY LAMP 1
4 110309 PRINTER PAPER ROLL 57 MM X 30 M (SET OF 3
3)
5 110347 RECTANGULAR POLYSTYRENE MICRO- 10
CUVETTE
6 110945 ROUND GLASS MICRO-CUVETTE 10
7 120232 ERBA WASH KIT (4 X 50ML) 1
11-2
12. ANNEXURE – 1
The annexure consist of following wiring diagram.
12-1
RESISTANCE VERSUS TEMPERATURE -40˚C to +150˚C

Temp RES in Temp RES in Temp RES in Temp RES in Temp RES in Temp RES Temp RES
˚C Ω ˚C Ω ˚C Ω ˚C Ω ˚C Ω ˚C in Ω ˚C in Ω
-40 3356k -10 565.5k 20 125.5k 50 34.70k 80 11.54k 110 4427 140 1914
-39 3147k -9 535.6k 21 119.0k 51 33.44k 81 11.15k 111 4297 141 1865
-38 2951k -8 507.5k 22 114.5k 52 32.15k 82 10.70k 112 4172 142 1817
-37 2769k -7 481.0k 23 109.4k 53 30.82k 83 10.42k 113 4051 143 1770
-36 2599k -6 456.0k 24 104.5k 54 29.74k 84 10.08k 114 3933 144 1725
-35 2440k -5 432.4k 25 100.0k 55 28.61k 85 9744 115 3820 145 1681
-34 2292k -4 410.0k 26 95.51k 56 27.53k 86 9424 116 3711 146 1639
-33 2154k -3 389.2k 27 91.34k 57 26.50k 87 9117 117 3605 147 1598
-32 2025k -2 369.4k 28 87.38k 58 25.50k 88 8821 118 3502 148 1558
-31 1904k -1 350.7k 29 83.60k 59 24.58k 89 8536 119 3403 149 1519
-30 1791k 0 333.1k 30 80.00k 60 23.65k 90 8281 120 3307 150 1481
-29 1685k 1 316.4k 31 76.58k 61 22.77k 91 7996 121 3214
-28 1588k 2 300.6k 32 73.32k 62 21.94k 92 7741 122 3124
-27 1494k 3 285.7k 33 70.22k 63 21.14k 93 7496 123 3038
-26 1407k 4 271.6k 34 67.26k 64 20.37k 94 7259 124 2953
-25 1326k 5 258.3k 35 64.44k 65 19.63k 95 7030 125 2872
-24 1250k 6 245.7k 36 61.75k 66 18.93k 96 6810 126 2793
-23 1178k 7 233.8k 37 59.19k 67 18.25k 97 6598 127 2717
-22 1111k 8 222.5k 38 56.75k 68 17.60k 98 6393 128 2643
-21 1049k 9 211.9k 39 54.42k 69 16.97k 99 6195 129 2571
-20 989.8k 10 201.7k 40 52.19k 70 16.37k 100 6005 130 2501
-19 934.6k 11 192.2k 41 50.07k 71 15.80k 101 5821 131 2434
-18 882.7k 12 183.1k 42 48.04k 72 15.25k 102 5643 132 2369
-17 834.0k 13 174.5k 43 46.11k 73 14.72k 103 5472 133 2306
-16 788.2k 14 166.3k 44 44.26k 74 14.21k 104 5307 134 2244
-15 745.2k 15 158.6k 45 42.50k 75 13.72k 105 5147 135 2185
-14 704.7k 16 151.3k 46 40.81k 76 13.25k 106 4993 136 2128
-13 666.7k 17 144.3k 47 38.20k 77 12.79k 107 4844 137 2072
-12 630.9k 18 137.7k 48 37.66k 78 12.36k 108 4700 138 2018
-11 597.2k 19 131.4k 49 36.19k 79 11.94k 109 4561 139 1965
12-2
13. APPENDIX
13.1. REVISION HISTORY
Revision Date Revision Description Originator
2011.00.01 15-February-2011 First Release Sarang Dumbre
2012.01 10-March-2012 Updated section Self-Test & Trouble Prasad Patil
shooting points
2012.01.01 5-February 2013  Added Air Purge feature PS
 Introduced Section wise page
numbering style ,Standardized
forward & legal information
 Analyzer’s dimensions updated
in Hardware specification
13-1

Service Manual For Semi-Automated Clinical Chemistry Analyzer

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Service Manual For Semi-Automated Clinical Chemistry Analyzer

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Service Manual

Semi-Automated Clinical Chemistry Analyzer

Document Version: 2012.01.01

Last Updated: February 5, 2013

Before servicing the analyzer, service engineer should:

1. Read and understand this manual.

2. Be trained by authorized person.

3. Be familiar with the operation of the analyzer.

NOTE: Keep this manual in an easily accessible place.

Manufacturer is the copyright owner of this document.

This document cannot be modified, reproduced, translated or transmitted in any form or

1. OVERVIEW OF ANALYZER...................................................................................... 1-1

This Page is Intentionally Left Blank

1.2. ANALYZER VIEW

PHOTOMETER COVER PRINTER COVER

ASPIRATION TUBE ASP SWITCH

PC TRANSMISSION PORT INCUBATOR CONNECTOR

ON/OFF SWITCH SERIAL NO. PLATE

This Page is Intentionally Left Blank

3.2. SOFTWARE SPECIFICATIONS

 On-line display of cuvette temperature.

3.3. KEYBOARD DESCRIPTION

These keys are used for entering a number from 0 to 9

This key is used to enter negative sign or decimal point

This is a software reset key used to reset the analyzer

This is an indication LED which blinks when Wash or

3.4. ASPIRATION SWITCH

This Page is Intentionally Left Blank

3 110309 THERMAL PRINTER PAPER ROLL (57 mm x 30 1 No

Serial Item Code Description Quantity

4.3. INSTALLATION REQUIREMENTS

4.4. ELECTRICAL REQUIREMENTS

4.5. INSTALLATION PROCEDURE

4.6. PRINTER HOUSING AND PRINTER PAPER

downward) of the thermal paper is detected and it is alarmed by 4 continuous

4.6.2. EXTERNAL PRINTER

4.7. EXTERNAL KEYBOARD INSTALLATION

6. FUNCTIONAL DESCRIPTION OF PCB

CPU PCB COMPONENT LAYOUT

6.1. POWER SUPPLY SECTION

POWER SUPPLY COMPONENT LAYOUT

POWER SUPPLY SCHEMATIC DIAGRAM

6.2. CONTROL LOGIC SECTION

2. External printer is not working.

CONTROL LOGIC SCHEMATIC DIAGRAM

6.3. MOTOR CONTROL AND MEMORY

MOTOR CONTROL AND MEMORY SCHEMATIC DIAGRAM

6.4. PHOTOMETRIC UNIT

PHOTOMETER COMPONENT LAYOUT

PHOTOMETER SCHEMETIC DIAGRAM

6.5. USB PCB

USB PCB SCHEMATIC DIAGRAM

6.7. KEYPAD AND DISPLAY SECTION:

7. TESTING AND PARAMETERS

7.1. TESTING OF SMPS

7.2. TESTING OF CPU PCB

TP22 -5 VANA -Vcc analog

7.3. POWER ON SELF-TEST

7.4. SELF TEST

7.5. SETTING PARAMETERS

7.5.1.1. SETTING THE LAB INFORMATION

The laboratory information is printed as header in Thermal and External Printouts.

7.5.1.2. SETTING THE DATE