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Chemray 240
Auto Chemistry Analyzer
Service Manual
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Contents
3. FUNCTIONAL DESCRIPTION.................................................................. 16
4.1 INSTRUMENT ASSEMBLY...............................................................................................31
4.2 LIGHT SOURCE LAMP REPLACEMENT .............................................................................31
4.3 REACTION CUP REPLACEMENT .....................................................................................34
4.4 PUMP\VALVE REPLACEMENT ........................................................................................35
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1. Instrument Introductio n
2. 38 reagent positions, position of single and double reagent can be set randomly.
3. Display and print results in different styles, including the storage of test results and info of
patients.
4. End point, two point and kinetic method, test with double-wavelength is supported.
6. 8 standard filters: 340nm, 405nm, 450nm, 510nm, 546nm, 578nm, 630nm, 670nm, Other
7. The system will continuously detect and control during the operation, to avoid errors, Error
message will be displayed when detected errors, provide instruction to the user to choose
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The instrument mainframe is mainly composed of sample/reagent processing system, mixing system,
reaction system, and photoelectric detection system. The structure of each function module is as
following:
The sample and reagent disc are located in a same big plate body, and there are 40 sample positions
The sample bracket supports the standard test tube, the original blood sampling tube, and the micro
Original blood sampling tube: Ф12×68.5, Ф12×99, Ф12.7×75, Ф12.7× 100, Ф13×75, Ф13×100;
The reagent disc can hold two sizes of reagent bottles (one big, another small), the volumes are 40ml
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and 18ml, and the reagent bottles of different sizes can be used together.
The system will automatically detect the positions of the working reagents. Before each operation, you
can check the position of each reagent should be placed, as well as the total volume of reagent
The core functional components of the reagent/sample disc cooling system is composed of fan,
radiator, Peltier and other component parts. The cool side of peltier is close to the bottom of the
refrigeration cabin but the hot side should be close to the radiator.
1.2.2 Sampling system
The driver component of the sampling system has two optical couplers, one located at the vertical
direction, another at the horizontal direction, to determine the original mechanical position of the
vertical and horizontal directions precisely. The system also has two stepping motors on the vertical
and horizontal directions to control the accurate movement of the sampling needle at the vertical and
The sampling needle with liquid sensor function will contact with the liquid, to aspirate the required
volume. When the reagent or sample is not enough, the instrument will give prompt message
automatically. During the operation of Chemray 240, the aspiration cycle of the sampling needle is as
follows:
1. The sampling needle enters the bottle of the reagent 1, aspirate reagent with required volume, and
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2. The sampling needle moves to the reaction cup and dispense reagent 1;
3. The sampling needle moves to the washing station, and perform washing;
4. The sampling needle moves to the sample cup to aspirate sample with preset volume, and eliminate
6. Transfer the sample and reagent into the Reaction disc wells;
7. The mechanic arm moves back to the washing station, to wash the sampling needle and mixer;
8. A bit of air and 100 μL distilled water is aspirated into the flowcell, rinse the flowcell to clean the
9. The sampling needle aspirate 80μL reaction liquid and a bit of air into the flowcell, rinse the flowcell
10. Aspirate the remaining reaction liquid into the flowcell for measurement;
11. The mechanic arm moves back to its original position (the washing station); clean the sampling
Generally, when testing with end-point method items and double-reagents items, you can set the
stirring time as 1 ~ 2 seconds.
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When pre-heating the reagent, if the required volume of the reagent is more than 250 micro liters, the
frozen reagent should be treated with the pre-heating module, and the temperature is 30 ~ 35 ℃ after
pre-heating.
Before adding into the reaction cup, the reagent mainly obtains heat from the tube of the middle
heating section, perform the pre-heating by the mixing of high temperature reagent and low
temperature reagent.
In order to ensure the accuracy and repeatability of test results, the suggested sample volume should
The sampling washing system and the stirring washing system use the same materials, called
"Washing station"; use water-spring-type washing method to wash the surface of needle and the
stirring rod.
When the operator has performed an illegal operation or errors of procedure occurred, make the
instrument perform wrong actions, the waste liquid in the waste bottle may overflow, it will be drained
from the mandatory drainage holes at the bottom of instrument.
reaction cup, this structure is simple and practical, and the risk of movement has also been reduced in
a certain degree. Oar-shaped mixing head can achieve rapid mixing effect through the micro DC
motor.
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Using air bath, three fans inside, to make internal hot air rotate and circulate up and down;
Using high quality insulation materials externally will effectively resist the interference to the
using over-temperature protection, the system will cut off the power if the heating air exceeds
The Reaction disc pot body is the same with the reagent/specimen disc body with external insulation,
but the external insulation is mainly to ensure that the Reaction disc internal temperature control easy
to be implemented, because if the effect of insulation is not good, the reaction disc outside will be
featured with fast heat exchange and it is not good to the implementation of constant temperature.
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entrance
External insulation
optical assembly
linked structure, each row has 9 cups; the optical path is 5 ± 0.02mm;
Standard configuration: 340, 405, 450, 510, 546, 578, 630, 670 nm filters, total of 8 wavelengths.
Interference filter, front spectrum, has a separate dark current detection channel. Using 2,000 hours
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Photodiode component
Optical block
The light source uses a direct thermal fan, without any separate air path, use the negative
The whole machine heat emission adopts downdraught system, the whole machine can aspirate
Chemray 240 uses color LCD screen to display WINDOWS software, with friendly user interface.
Operator can operate the software step by step according to the related instructions.
and double-wavelengths
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Reagent positions 40
Specimen positions 40
Sensitivity 0.0001Abs
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Unpack the package of the instrument and remove the materials for transport. Save the packing box
and the packaging materials well, for your convenience in the future of re-packaging the instrument.
2) Take away the packaging materials, and take out the instrument from the plastic packaging bag.
3) Check the items in the box and confirm that the following items are within the box:
User’s Manual
Packing List
Warranty certificate
Accessories: power cord, printer, print cable, LCD monitor, mouse, keyboard, RS-232 serial
Note: If the items are inconsistent with the packing list or have any defects, please contact with
the supplier.
must be installed in a clean dust-free operation room, to avoid shock, humidity, strong magnetic fields
and direct light. The working environment is of 15 ℃~30℃, the relative humidity is 35~85%
(non-condensing).
The power supply must be 220V/50 Hz, and should be well grounded. If the laboratory voltage change
is greater than +10%, it is recommended to install an external regulator above 1500-watt. As this
The back-face of the instrument should be 0.5 m to the wall at least, in order to ensure the heat
dissipation requirements.
If it is a desktop machine, the water bucket should be placed at the right lower adjacent to the analyzer,
pay attention to ensure that the waste liquid pipe should always be downward, to avoid the situation
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such as upward wrap (it can be resolved by adjusting the tube length).
In order to ensure the normal operation of the instrument, it is prohibit to placing the instrument in the
following places:
Note:
●
The AC power supply must be well grounded (zero ground voltage <5V).
●The AC power must be stable and it is prohibited to share power supply with the appliances of
●When unplugging the power cord, please seize the plug itself, rather than the power cord.
●If the instrument is found to have smoke, smell or abnormal sounds, immediately turn off the
Ground Interface
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CPU
If the color mark is still remained, you can connect according to the color mark, if the color
identification is missed, then connect in line with the following figure to ensure proper connection.
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3. Functional Description
3.1 Chemray240 funct ion box
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The main board is machine's central control unit, including the mid-position machine, and five
The mid-position machine is responsible for the channel scheduling of the five control modules;
Module 1 is for the movement control of the reagent disc motor and the filter wheel motor;
Module 2 is for the movement control of the reaction disc motor and the auto-rinsing motor;
Module 3 is for the control of the sampling needle up and down movement motor, the sampling needle
Module 4 is for the control of the stirring rod up and down movement motor and the stirring rod rotation
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DC motor;
complete the temperature control for the reaction disc constant temperature heating, sampling needle
JM4: Auto-rinsing motor
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J1: The interface to serial port transfer board, communicate with computer;
U15: The interface to the temperature control board, and communicate with it;
JP4: The interface to the liquid feeding and dispensing alarming board;
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U15 J1 J2 HP
OC1~OC10
P1~P8
JP4
BUZZER1 V1~V4
BUZZER2
JM1~JM8
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Temperature Control Board performs the whole machine temperature control, it can complete the
temperature control for the reaction disc constant temperature heating, sampling needle pre-heating,
The control parameters will be loaded through the serial port by the main board, and the temperature
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RS0 PX1~PX3
PW3
T1
H_COLD
H_HEAT1
H_HEAT3
PWCN
J1 PW1 J3 J5
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J1
The photoelectric amplification board is for the second stage amplification of the photoelectric signal,
the magnification is adjusted by the digital potentiometer, the specific regulation should follow the
Number/1k);
Input the former two stage amplified signal into the AD conversion chip for analog-digital conversion,
the control signal is from the main board, and the output signal will return back to the main board;
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J2
J1
optic-coupler;
The 10 correlation-type infrared photoelectric sensors will be fixed on board, connected to the main
board by 3pin cable, supporting the main board for collecting the position signals of various fixed
optic-couplers.
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J1
This board will connect to the alarm sensors of the wash bottles and the waste bottle, the connector is
designed as audio interface, connect to the main board through the 10pin flat cable, for the alarm
It is designed with two-way cleaning liquid bottle alarm inputs, two-way waste liquid bottle alarm inputs,
JP1
WASH
WASH2 WASTE1 WASTE2
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The liquid level detection board is to perform the liquid level detection when the sampling needle is
aspirating the reagent or specimen, and the test principle is capacitance. When moving the sampling
needle up and down, from up and down movement to contact with the liquid surface, the capacitance
of the sampling needle will change, the adjusted voltage signal will change, refers to the liquid surface
information;
The crash-proof signal detection of the sampling needle up and down movement will be completed by
The liquid level detection signal and the up and down crash-proof signal will be connected to the main
TP1
It is the Serial Port transfer board of the whole instrument, one end will be connected to the main board
serial converter with 3 pin cable, and the other end will be connected to the computer serial port
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RS232
J1
J1
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4. Parts Replacement
4.1 Instr ument assembly
Chemray 240 is a high- precision instrument, if the instrument has trouble and can not be resolved with
the method in this manual, it should be repaired by professionals; If it is confirmed that the internal
parts of the instrument have some troubles which should be replaced for repairing, please follow the
1. Turn off the instrument power switch (unplug the power cord to prevent from turning on the
2. Remove the eight screws which fix the rear-board of the machine with a screwdriver and
remove the rear board, pay attention to protect the board, avoid falling damage.
3. After removing the rear-board, you can see the instrument's internal hardware boards, pump
valves, the board sockets of the cable at a glance, so it is convenient for electrical maintenance.
system has given out alarm message, or the total working time is estimated to be over 1000 hours,
1. Turn off the power to make the lamp and lamp box cool for 30 minutes.
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Note:
Must wait more than 30 minutes after shutdown, even after 30 minutes, you must be careful to touch
the shell body of the light source lamp, because the hot lamp and lamp box will cause skin burns.
3. Unscrew the three cross screws on the top of the light source body shell.
4. Wait until the light source shell will not burn your skin because of high temperature, pinch the light
5. Remove the light source components, replace new light source lamp, connect the light source line
well, and then put back the supporting base and lock the three cross screws unscrewed before.
Note:
When assembling or disassembling the light source, even if the lamp has no heat, please do
not touch the translucent lamp surface with your hands, because this may change the
characteristics of the light source due to grease, dirt and other reasons, if inadvertently make
the translucent surface stained with grease, dirt, you can wipe it with a clean cotton swab
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screw
Light source
connection cable
6. The light source lamp has been positioned by screws, no need for fine-tuning, but because of the
differences of various lamps, you need to adjust the received light energy, it is recommended to
replace all the reaction cups here, in order to avoid the large differences between the old and new
cups. Method 1: turn on the instrument, enter into the "Chemray 240 auto chemistry analyzer
management software" → "Status" → "Reaction disc", click on “Change Cuvette”" button, and then you
can replace it based on prompt, (method 2: or from the " Chemray 240 auto chemistry analyzer
management software," → "Maintenance" → "Blank" and then click on "Change Cuvette" button, but
note that this method requires a user authorization; Method 3: "Engineering debugging software" →
7. Users usually operate only with method 1 and 2, after correct replacement of the reaction cup, from
the " Chemray 240 auto chemistry analyzer management software" → "Maintenance" → "Blank" and
then click on “Check Blank” button, record the proximate light intensity AD value of each wavelength,
and then enter into "Maintenance"→ “Configure”, adjust the magnitude ratio of each wavelength, make
the light intensity AD value of each wavelength to be about 55000, but for the wavelengths over 510nm,
its AD value could be about 57000 (if it can not successfully auto-configure the magnitude ratio, you
must configure it manually, the AD value is proportional to the configured value), after completing the
configuration, please perform the blank check once more, please observe whether it is appropriate or
not, you may need to repeat several times before it meets the requirements.
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8. After confirming that there is no problem, you can tighten the light source cover of the worktable.
Note: When adjusting the location of the light source lamp, do not let the light directly shine your eyes,
2) The method to replace the reaction cup is the same with the steps mentioned in section 4.2. Method
1: turn on the instrument, enter into the "Chemray 240 auto chemistry analyzer management software"
→ "Status" → "Reaction disc", click on “Change Cuvette”" button, and then you can replace it based on
prompt, (method 2: or from the " Chemray 240 auto chemistry analyzer management software," →
"Maintenance" → "Blank" and then click on "Change Cuvette" button, but note that this method
Cuvette".
3) If the instrument is with auto-rinsing system, when replacing the reaction cup, carefully unscrew the
reaction cup fixing screw; do not let it slide inside. If it has been slid inside, the proposed operation is to
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shutdown firstly, and rotates the reaction disc in place by hand or takes the falling screw out with
4) If the instrument is not with auto-rinsing system, when replacing the reaction cup, pay attention to
take it out vertically to prevent the reaction cup orientation column breaking accidently; when
placing the new reaction cup, please put it vertically, after it has been positioned well, press the cup
5) Because that the reaction cups may have differences in different batches, it is proposed that you
should observe the Cuvette blank after replacing the reaction cup; from " Chemray 240 auto
chemistry analyzer management software," → "Maintenance" → "Blank" and then click on “Check
Blank” button, observe the proximate light intensity AD value of each wavelength, to determine
entrance cover-plate
4.4 Pump\valve Replacement
Firstly, disassemble all the pump\valve components requiring for replacement, and then replace the
specific pump\valves.
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fixing component
Note: Pay attention to the bonding wire on the pump valve, so as not to break; be careful of liquid
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When replacing the cables, please pay attention to the labels on them, do not replace them with the
cable of incorrect labels, if you really have no correct label on the cables, you can write the correct
label on a piece of paper and cover it onto the original label, then twist it with transparent tape.
When plug and unplug the cables, please do not shake around.
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Chemray 240 is a precise clinical analyzer, in order to maintaining the instrument in a good condition;
you must do the routine maintenance work well. The maintenance of Chemray 240 is very simple, but
The cleaning of the instrument surface must be performed with some neutral detergents and damp
cloth.
Check the sampling needle to make sure that it is in good condition, no impairment, and no dirt;
Check the stirring rod to make sure that it is in good condition, no impairment, and no dirt; wipe it
the connection of the pipeline is normal, and whether need to add water or drain.
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Rinse the washing station of the cleaning needle and the stirring rod
Clean the ball spline shaft and the ball bearing of the sampling needle component (with grease
lubrication)
Clean the guide rail of the stirring rod component (with grease lubrication)
Rinse the washing station: Add several milliliter of diluted bleach (5:1000), clean the inner surface
2. Pull out the connector piece between the valve and the transferring jointer, as shown in the following
picture.
3. Prepare a syringe of 10ml and aspirate the distilled water, install a cuvette head on the syringe and
insert it into the pipeline just pulled out, push the syringe to inject the water into the washing station
(the needle must be on the top of the washing station at this time), repeat the above step for more
times until the water flow from sampling needle of cuvette head smoothly.
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washing tank
washing stations of the sampling needle and the stirring rod) regularly. Infuse the diluted bleach liquid
of 5:1000 into the washing station and keep it for 15 to 20 minutes, then wipe it with a medical swab,
after wiping, rinse with plenty of distilled water to ensure that there is no cotton residue in the washing
station.
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station
Sampling needle
washing station
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6. Trouble Shootin g
6.1 Comm on Troub le Shoot ing s
Trouble Solutions
Analyzer can not start up - Check whether the power plug is loose
Operating software can not be - Shutdown and wait for about 10 seconds, then restart the
initialized machine
properly connected
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Bubble and spattering liquid gush - If the liquid-path is not used for a long-term, this happens
Absorbency/blank AD value is
- Check whether the light source is emitting light normally
displayed incorrectly
error
Poor reproducibility of the results -Some reaction cup may be contaminated, replace it
not good
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pipeline
Quality control is not within the - Check the period of validity of the quality control liquid, and
target value verify that the quality control liquid is not contaminated
There are a lot of air bubbles in - Check the connection air-tightness of the syringe T-way
the speed)
There are bulbs in syringe - Confirm that the piston is tight and no-leak.
distilled water)
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pipeline
needle
contaminated
one-off cup
Liquid leaks from the analyzer - Check whether the draining pipeline of the waste liquid is
● If there is any instrument failure, please contact with the dealer in time to obtain technical support!
As for the calculation item, recommend to use the following codes to fill in its item name and item
code.
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7. LDL (Low Density Lipoprotein) = CHO (Total Cholesterol)-HDL (High Density Lipoprotein)-TRIG
(Triglyceride)/2.2
Note:
This manual may contain other proprietary notices and copyright information, and the related
provisions must be observed. The information in this manual may contain some technical
This manual may be changed or updated without notice. Rayto can also improve and/or change
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