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Service Manual For CHEM 5X V2012 01 01
Service Manual For CHEM 5X V2012 01 01
For
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.
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Service Manual CHEM-5 X
Legal Information
All rights are reserved by manufacturer of this product.
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.
No part of this document can be copied or reprinted, in whole or in part, without prior
written permission from the manufacturer.
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CONTENTS
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Service Manual CHEM-5 X
1. OVERVIEW OF ANALYZER
1.1. INTRODUCTION
The CHEM5X (hereafter referred as an analyzer) is a low cost, low power,
compact, high performance 16-bit micro controller based Biochemistry analyzer,
which is used for Routine Chemistries, Electrolytes, Hormones and Drug tests.
There are 9 modes of operation. Programming, Reading and Reporting operations
are user friendly.
The analyzer is provided with memory for storage of Quality Control Data, Reagent
Blank Absorbance, Factor, and Non-linear Calibration Data and up to last 1000
results with Patient ID. Operation is through a non-tactile Keyboard with quick shift
from one function to another without going through complex sequential operations.
The analyzer is provided with a 240 X 64 dots backlit liquid crystal display with
alphanumeric and graphic capabilities.
A Patient ID wise or Date wise or Patient ID with Date wise collated report can be
generated upon request. Exhaustive Quality Control Data at 2 levels, for any of the
tests can be stored and printed.
The software is complete with the device diagnostic self-test function capable of
providing timely flag / error messages related to Test results or analyzer
malfunctioning.
The State-of-the-Art features, advanced optics, versatile analytical capabilities and
economy of 33μl flow cell make 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 as mentioned above.
By the trained personnel in controlled environment and continuously
monitored operation.
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DISPLAY KEYPAD
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2. SAFETY
Operator’s and Service personnel safety is a primary concern. 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.
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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.
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3. ANALYZER FEATURES
3.1. HARDWARE SPECIFICATIONS
1 SYSTEM TYPE Open, Flow cell.
2 MEASUREMENT Colorimetry (Rate/End Point)
PRINCIPLE
3 APPLICABLE ANALYTES Photometric assays – Substrates, Enzymes, Lipid,
Protein, Sugar, Inorganic Substances
4 SETUP Bench top.
5 LIGHTSOURCE Quartz Halogen Lamp, 12V, 20 Watts.
6 PHOTOMETRIC RANGE 0 ~ 2.5 O.D. (Range 340~630nm)
Resolution 0.0001.
7 OPTICS 6 wavelength static photometric group with following
interference filters: 340, 405, 505, 546, 578, 630 nm.
8 DETECTORS 6 UV / VIS Silicon photodiodes.
9 CUVETTE Unique triple cuvette system:
33 µl flow cell
10 mm rectangular polystyrene cuvette
10 THERMOSTAT Peltier temperature control for 25, 30 and 37°C ± 0.1° C.
11 FLOWCELL VOLUME 33 µl
12 SAMPLE ASPIRATION By means of a peristaltic pump, Aspiration Volume
programmable from 350µl to 999µl.
13 PRECISION Better than 1% CV.
14 KEYBOARD Rugged water proof, , non-tactile legend membrane panel
25 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 240x64 dots, with backlit.
View area 134mm x 40 mm.
18 INTERFACES USB B type port for host computer and USB A type port
for External USB DeskJet Printer.
External PC/AT keyboard.
19 PROCESSOR: 16-bit with 384KB Flash Memory
20 MEMORY: 2MB Serial Flash and 2MB EEPROM
21 REAL TIME CLOCK: Built in.
22 REPLACEABLE BATTERY Lithium Battery CR2032 (3V)
ON PCB:
23 WASTE COLLECTION Waste collected in closed container.
24 INCUBATOR: Optional external incubator.
25 OPERATING 20 – 40 Degree Celsius
TEMPERATURE
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Daily QC
Monthly QC
Rate calculation by least square regression method.
Automatic zeroing of Water OD during Run Test.
Total reaction time: Selectable delay time between 5 seconds to 999
seconds. Selectable read time between 5 seconds to 999 seconds.
Non-linear calibration (6 standards).
On-line reagent stability check.
Substrate depletion / Non-linearity check.
In built reaction non-linearity check.
Monochromatic as well as bichromatic measurements possible.
Calibration of peristaltic pump.
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 or Automatic.
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KEY DESCRIPTION
These are multi-function keys. Each key is used for
entering a number seen on the key, and three alphabets
in upper and lowercase. E.g. The numeric key ‘1’ is
used to select or enter an alphabet or the number ‘1’ in
the sequence: ‘A’, ‘B’, ‘C’, ’a’, ’b’, ’c’, ‘1’ following every
press.
This is a dual function Key.
It is used as <YES>key to save changes in parameters.
It is used as <DECIMAL>key when entering numerical
parameters.
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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 110082 STANDARD ACCESSOIRES 1 SET
2 110348 DUST COVER 1 NOS
3 110347 RECTANGULAR POLYSTYRENE MICRO CUVETTE 5 NOS
4 112458 OPERATOR MANUAL for CHEM5X (Version 1 NOS
2012.01.01)
5 106046 POWER CORD (3 PIN) 6A, 250V, LENGTH 1.5 1 NOS
METER, BLACK COLOR, PLUG AS PER IS-6538,
CABLE AS PER IS-694, SOCKET IEC APPROVED AS
PER SAMPLE APPRO
6 110309 THERMAL PRINTER PAPER ROLL (57MM X 30M) 1 KIT
7 102948 AC POWER ADAPTER (OP:18 VDC:70W) PPS70A-16 1 NOS
L TYPE
8 110326 ALLEN KEY SIZE: 2.5 MM 1 NOS
9 110035 ASSEMBLY WASTE BOTTLE 1 NOS
10 103936 P.M. KIT 1 NOS
11 110018 ASSEMBLY LAMP 1 NOS
12 110353 SYRINGE 5 ML (CAT NO 300850 MAKE B-D) 1 NOS
13 110354 TUBING PVC (ID 2.8 MM, OD 4.3 MM) 0.55 M
14 111213 TUBE TEFLON 0.75MM X 1.5 MM (442-5409-4) 0.21 M
15 110194 TUBE TEFLON (ID 1 MM, OD 2 MM, PTFE - M0004) 0.027 M
16 112546 PERISTALTIC TUBE ASSEMBLY 1 NO
17 110356 SILICON TUBING (ID 2 MM, OD 4 MM) (IMPORTED) 0.36 M
18 110355 TUBE SILICON (ID-0.8 MM, OD-2.4 MM) 0.012 M
NOTE: Please refer to dispatch note for detailed checklist.
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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.
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.
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4.6.3. PC COMMUNICATION
NOTE: USB Connectivity to PC requires operating system 2000/XP or above.
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5. BLOCK DIAGRAM
The major blocks of the Chem-5 x 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 240x64 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.
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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.
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6.6. PRINTER
The printer is 40 column graphic printers, able to give a very high printing quality,
high speed and a considerable noiselessness on thermal paper without having to
move the printing head.
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7. WIRING DIAGRAM
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5. If any of the parameter is not ok, then the following message will be
displayed PROCEED…<YES>. Press YES key if you want to proceed.
6. If all the hardware tests are OK then the Home Screen will be displayed.
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Press <→ > key to go to the next page or < ← > to go back to the previous page.
Press numeric keys <1> to<6> get PRE CHANNEL and LOG CHANNEL readings
for 6 filters.
Press < → > key to display the next page.
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The numeric keys 1, 2, 3, 4 and 5 are used to set the date, time, data output mode,
laboratory information, and Blank Deduction option respectively.
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The cursor is positioned on the DATE field on the SYSTEM SETUP: DATE
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 any year from 00 to 99
After appropriate entry is made, press the <fn> key to save date and return to the
System Setup screen or press < PREV. > to quit without saving and return to the
System Setup screen.
NOTE: If the date is entered wrong, the user will be prompted with the message,
"INVALID DATE. PLEASE ENTER AGAIN".
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Press <YES> or <NO> to select or deselect Thermal printer or USB Printer for
auto print options or printout on Thermal printer/USB Printer after pressing
<PRINT> key.
Tick mark <√> will be displayed in front of selected option & it will disappear if any
option deselected.
The user can enter laboratory information (25 characters each on 5 lines) with
external PC/AT keyboard or the analyzer keypad. This is stored in the memory.
Example of Using analyzer Keypad to Enter Lab information:
Item Description
Each key can be used for entering three alphabets in upper
and lowercase. And followed by the number seen on the key,
e.g. ‘A’, ‘B’, ‘C’, ’a’, ’b’, ’c’, ‘1’
to
‘Y’, ’Z’, ’y’, ’z’, ’-‘, ’9’
‘*’, ', '(', ')', '.', '0'
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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
450μl.
However, Air Purge is optional if the aspiration volume value is between 450 – 999
µl.
If Air Purge is enabled extra 150 μl air is aspirated after displaying the result.
If Air Purge is disabled, extra 150 μl air will not be aspirated
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-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
-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
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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.
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4. Slide out the washer and ‘O’ ring of the old aspiration tubing.
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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. Insert the one end of new peristaltic tubing assembly into the tubing coming
from the flow cell.
6. Position the new tubing around the rotor.
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7. Insert the other end of peristaltic tubing into the waste tube and direct the
waste tube towards waste bottle.
8. Perform pump calibration with 1 ml DI water.
NOTE: Perform WASH with 3 ml DI Water to fill the tube up to Peristaltic
pump before proceeding for Pump Calibration
9. Put the cover of the peristaltic pump housing.
12. Before the old lamp is removed, note the exact manner in which it is
positioned.
13. Unscrew the two lamp terminals using (--) screw driver.
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16. Place a new lamp and connect the lamp terminals and fix thumbscrews.
17. Refit the lamp cover.
18. 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.
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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.
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.
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6. Press PAPER FEED key provided on the keypad to advance the paper.
Warning: BE CAREFUL - SHARP PAPER CUTTER.
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15. The result printout is accompanied by the warning “RX ABS LIM
OVER” in all Chemistries.
Probable Cause Corrective Action
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.
Probable Cause Corrective Action
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!!”
Probable Cause Corrective Action
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.
Probable Cause Corrective Action
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.
Probable Cause Corrective Action
1. Absorption Switch is pressed. Release ASP switch.
Reset the analyzer using ON/OFF switch.
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12. APPENDIX
12.1. REVISION HISTORY
Revision Date Revision Description Author
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