Maintenance Checklist 24 Months HumaStar 100 and 200

Required Material

Hardware:
1 x 168902 "HumaStar 100/200 Service Manual"
1 x 16890/250-24 "Maintenance kit 24 month for HS100 and 200"
4 x 17400/56 “HC-Acute (50ml)”
1 x 1000 ml Vessel for preparation of the decontamination solution

Operational Qualification (OQ):

1 x Serodos® (13951) or HumaTrol N (13511)
1 x Serodos®plus (13151) or HumaTrol P (13512)
1 x Autocal - multi calibrator (13160)
1 x Glucose liquicolor Multipurpose reagent
1 x GOT (ASAT) IFCC mod. liquiUV Multipurpose reagent
1 x Calcium liquicolor Multipurpose reagent

Content of Maintenance kit 24 month for HS100 and 200

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
Page 1 of 10
Maintenance Checklist 24 Months HumaStar 100 and 200

Step 1: Decontamination of the hydraulic System (5)

 Remove the floats from the wash tanks (blue and green) and run empty tubes (OS-F5-F5-3).
 Prepare a special vessel (1 liter) with 1 to 4 diluted HC-Acute (add 600 ml of distilled water to
200ml of HC-Acute).
 Insert the flow tanks/floating blue (system solution) and green (wash solution) into the special
vessel prepared previously.
 Run fill tubes procedure (OS-F5-F5-2). All tubes and needles will be decontaminated by the
special solution.
 Perform the empty tubes procedure (OS-F5-F5-3).
 Flush the two wash tanks (blue and green) with the remaining cleaning solution (1 to 4 HC-
Acute).
 Flush the wash tanks 3 times with fresh distilled water and refill them afterwards.
 Place / Replace the check valves (5) at the tubing sets (close after the tubing protection at the
floats; see picture below; white side in direction to the floats).

 Reinsert both flow tanks/floating blue and green as default configuration.

Step 2: Wash station needles (3) and drying tip (4)

Note: There are only two wash station double needles in the maintenance kit.
 Replace the first (most right) wash station double needle (3).
Note: The deposit on the needles depends on the type of reagent employed. Clean them with the
special wash solution (base) to remove protein or lipid deposits. Use an acid solution to
remove salt deposits.
 Check also the other 4 positions (range 2 to 5; seen from right) if they are clogged or damaged.
Replace one (8) if necessary.
 Replace the wash station drying tip (4) in position 8 (leftmost position).
 Check that all needles and the drying tip are not bent and are well centered in the cuvettes (OS-
F2-17).

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
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Maintenance Checklist 24 Months HumaStar 100 and 200

Step 3: Pinch valve tubing (1)

 Replace the outer tube and the inner tube (1) of the pinch valve, labelled as B3.
 Stretch both tubes (3 to 4 times), just on the part inserted into the pinch valve (Do not stretch the
ends. Stretching this part will weaken the connection to the fitting).
 Ensure that the new tubes are inserted to the very bottom of the insertion slots.

 The length of the inner tube between the pinch valve and the silicon-to-TEFLON adapter must be
approx. 10 mm.

Step 4: Wash well tubing (7) including check valve.

 Replace the tubing "7" labelled as B4 between the wash well of the sampling arm, bottom output
connector and the input connector (inner side) "14" of the peristaltic pump 7. This tubing includes a
check valve.

Step 5: Reaction waste tube (6) and Y-fitting (8)

 Replace the tubing “6” labelled as A3 from the wash station manifold to the inlet of pump 6, fitting
11.
 Replace the Y-fitting silicon tubes (4) labelled as B1 which are connected to the fittings 12 and
13 (inner side of the pump panel) to the fitting 7 of the pumps panel manifold. Please check the
Service Schematic in the Service Manual.
Note: The tubing labelled as B2 is not required.

Step 6: Vacuum pump crystal tubing labelled as A1 (2)

 Replace the tubing between the wash station manifold, connector "A" and the input connector of
the vacuum pump 1 (the left one seen from the back side).
 Replace the tubing between the wash station manifold, connector "AS" and the input connector of
the vacuum pump 2 (the right one seen from the back side).
 Replace the Y-tubing between the output connectors of the vacuum pumps and the input
connector of the pumps panel manifold.

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
Page 3 of 10
Maintenance Checklist 24 Months HumaStar 100 and 200

Step 7: Diluter piston gasket (9)

Note: Detailed instructions can be found in the Service Manual.
 Replace the diluter piston gasket.

Step 8: Peristaltic pump heads (10)

 Replace all (7 or 8) peristaltic pump heads.
 Ensure the proper click-in when the heads are seated.

Step 9: Reaction cuvettes (11)

Note: Don't touch the reading window with the fingers.
 Replace the 80 cuvettes of the reaction tray. Follow exactly the instructions in the accompanying
document.

Step 10: Vacuum pump membrane valves (12, 13, 14)

Detailed instructions can be found in the Service Manual.
 Replace the two membrane valves of each vacuum pump.
 Use the membranes kit corresponding to each vacuum pump type. Please refer to the HSB
0046.

16890/81 16895/81 16930/81

Note: If the hydraulics hardware upgrade took place, you will find two different pumps in the
HumaStar 100, i. e. you need both types of membrane valves (12 and 13).

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
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Maintenance Checklist 24 Months HumaStar 100 and 200

Step 11: Waste tubing check valve (15) and air filters (16)
 Place/replace the check valve (15) at waste tubing, with the black O-ring side in direction to the
instrument connector (see the picture below).

 Replace the air filters (16) on top of the blue (system solution) and green (wash solution)
containers (see the picture below).

Step 12: Halogen Lamp replacement (17)

Note: Don't touch the halogen lamp with the fingers.
 Replace the halogen lamp (17) when the lifetime exceeds the 1000 hours and confirm the
replacement.

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
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Maintenance Checklist 24 Months HumaStar 100 and 200

Step 13: Sampling needle (18), needle holder (19) and O-ring (20)
Note: It is necessary to check all the adjustments for the mechanical calibration. A detailed
instruction can be found in the Service Manual.
 Replace the needle (18), needle holder (19) and black O-ring (20) (see SM "12.5 Needle
replacement").

Step 13: Firm- / Software and settings

Note: In case an update is necessary a detailed instruction can be found in the Service Manual.
 Check the actuality of the current firm-, software and settings (please scan the QR-code below).

Step 14: Cover

 Check if the instrument is correctly levelled.
 Check if the top cover correctly pushes down the cover detection switch when being closed (only
old cover version).
 Check if the pair of gas springs keeps the top cover in the upper position when opened up.

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
Page 6 of 10
Maintenance Checklist 24 Months HumaStar 100 and 200

Step 15: Test and adjustment procedures in the Terminal program

Note: The following menus must be called from the TERMINAL SERVICE menu to execute
the test procedures.

Note: In case of any needed support please do screenshots of the result pages and sent them to
Human.

A) F1 Hardware Test
 Check the vertical collision sensor by moving the needle manually up and down and watching the
second indicator (marked red) for changing between 0 and 1. OS-F1-F5

Level Sw.:10110001

 Check liquid level sensing by touching/untouching the needle manually close to the tip and watch
the first indicator (marked red) for changing between 0 and 1. OS-F1-F5

Level Sw.:10110001

 Check the dilutor assembly by the following procedure:

1. See the red marked areas in the status of the home position sensors
Mot.L. Sw.:1101001X .
2. Press up-arrow once to go to the “DS Diluter” row.
3. Press left-arrow to move to the “IX-STEPS” column which visualize the number 1300 and
write 10<enter> .
4. Press F1 twice .
5. Keep an eye on the last digit of the upper right field Mot.L. Sw.:11010011 .
6. Press F2 several times, slowly, and stop immediately when this digit goes to
Mot.L. Sw.:11010010 .
7. Press and count F3 several times, slowly, until this digit goes to 1 again
Mot.L. Sw.:11010011 .
8. The first count will be COUNT1. Repeat the sequence from 4 to 7 to have a second
measure that will be called COUNT2.
9. Use the flow-chart to determine the actions to be taken (next page).

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
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Maintenance Checklist 24 Months HumaStar 100 and 200

Flow-chart of the procedure to determine actions to be taken

YES
IF the difference between Asymmetrical backlash
COUNT1 and COUNT2 is > 2

NO

the GAP is equal to the maximum between

COUNT1 and COUNT2

YES
IF GAP < 4 No actions to be taken

NO

NO YES
IF GAB = 4 re-schedule test in 6
months

NO

Then GAB >4 Replacement of the diluter

assembly

 The mechanical GAB is < 4

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
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Maintenance Checklist 24 Months HumaStar 100 and 200

B) F2 MECHANICAL CALIBRATION
 Check all the mechanical calibrations.

C) F3 MECHANICAL CHECK
 Verify the belts and the mechanics therefore run. OS-F3-F4

D) F5 WASHINGS MENU
Note: perform fill tubes up to 3 times to restore the normal condition. (OS-F5-F5-2)
 Pumps test. OS-F5-F5-1
 Adjust pumps. OS-F5-F5-5

E) F4 READING TEST MENU

 OP reading offset check. OS-F4-F6-1
 FS filter wheel offset adjustment. OS-F4-F7-2
 Autozero test. OS-F4-F5-2

Step 16: Start-up procedure

 Run the start-up procedure.
 Check the status of the lamp, pumps and cuvettes in the maintenance module (HI-Software).

Step 17: Do the OQ

Note: Please use the printed out OQ-form (Operational Qualification) included in the Maintenance
kit, or you can also download it from our Homepage. Afterwards add the filled form to this
protocol.

Step 18: Closing documentation.

 Fill in all fields in the next page as requested and submit a scanned copy of all pages to Human.
 Place the maintenance label at the instrument and mark the next maintenance period on it.

Additional notes

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
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Maintenance Checklist 24 Months HumaStar 100 and 200

Instrument data
Following mandatory data can be found in the INFO window of the HI program.

 Fill in the serial number. 

 Fill in the HI software version. ...
 Fill in the hardware version. .
 Fill in the hardware date (DD/MM/YY). //
Maintenance confirmation

Add label here

 Place the maintenance kit serial label.

 Date and signature service technician/engineer

 Date and signature customer

After the maintenance has been performed, please submit a scanned copy of this checklist
page duly signed and stamped to extend or confirm the warranty of your device. Conditions
apply.

Maintenance Checklist 24 Months HumaStar 100/200 Form 6.3-01.04-32

Vers. 05
Valid from 20.03.2024
Page 10 of 10