BS-120 Service Training

International Service Dept.

Mindray Co.,Ltd.
Agenda

 Work flow
 Machine structure
 Hardware system
 Liquid system
 Optical system
 Test results
 Software upgrade
 Maintenance
 Work Flow
Yes
claim a assistance from
Find a Troubleshooting Mindray and inform •Find out causation
Got a serial number and
problem solution? No details of problem

Yes
Need to change
Yes parts?

Under
No
Yes warranty? No
Have spare Adjust and repair it
parts? Contact salesman for
No
ordering new parts
Repair or replace And ask for RMA
defective parts from Mindray service
department
No Get new parts
Test
Return defective parts
OK? Yes and inform the
Repair or replace
And ask for RMA from tracking number
defective parts
Mindray service department
No

Return defective parts Test

and inform the OK?
tracking number

Get new parts

Yes
End
 Work principle

•Work flow

•Machine structure MACHINE STRUCTURE

•Hardware system
(MECHANISM)
•Liquid system

•Optical system Structure

•Test results Work Principle
•Software
Troubleshooting
•Maintenance
 Basic configuration

The Biochemistry analyzer consists

of the analyzing unit (Analyzer), op
Work flow eration unit (PC) and output unit (P
rinter).
Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

The analyzing unit and operation

are connected by communicatio
n cable of serial port.
 Structure

BS-120 Front View

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Structure

BS-120 Left Panel View

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Question

Work flow

Machine structure

Hardware system

Liquid system

Optical system How to install a new analyzer?

Test results

Software

Maintenance
 Structure
Reagent and sample tray of BS-120

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance 36 position

1~8 sample position
9~36 reagent position
 Structure
Mixer and Syringe of BS-120

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

Mixer Sample&Reagent Syringe

 Structure
Pump&Valve of BS-120

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
•Interior Wash Pump
•Exterior Wash Pump
•EM Valve
 Basic assembly

Work flow

Machine structure
Reagent/sample probe drive assembly
Hardware system

Liquid system
Mixing bar drive assembly
Optical system Reagent and Sample compartment assembly
Test results
Reaction compartment assembly
Software
Light Source Assembly
Maintenance
 Structure

Mechanical structure of BS-120

Sample and Reagent Probe Drive Mixing bar drive assembly
ISE Assembly Assembly

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

Reaction Tray Assembly

Reagent and Sample Tray Assembly
 Structure

Probe Drive Assembly

Work flow

Machine structure
① Movement is driven by two step motors
Hardware system ② Signals are feed back by two home
Liquid system position sensors
Optical system ③ LLD function
Test results ④ Collision detection
Software ⑤ Reagent preheating
Maintenance
 Structure

Mixing Bar Drive Assembly

Work flow

Machine structure
① Movement is driven by two step motors
Hardware system ② Signals are feed back by two home
Liquid system position sensors
Optical system ③ LLD function
Test results ④ Collision detection
Software ⑤ Reagent preheating
Maintenance
 Question
Probe and mixing bar drive assembly

Work flow

Machine structure

Hardware system
How to adjust the position of the mixing bar and
Liquid system
probe?
Optical system

Test results

Software

Maintenance
---------By DEBUG software

Let’s try to adjust the position!

 Structure

Reagent/Sample probe drive assembly

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results Arm Base Assembly Reagent pre-heater assembly

Software

Maintenance
4~15 ℃ around 35℃
Reagent Reagent bottle Reagent Reaction Cuvette in
in reagent tray pre-heater reaction tray (37 ℃)
 Troubleshooting

Temperature problems in Reagent pre-heater

Symptom Probable Cause

Work flow Corrective Action
Machine structure

Hardware system
① The 24V from Power driv
Liquid system e board is abnormal ① Check the 24V power
② The temperature control p supply
Optical system arameters are improper ② configure the parameters
The temperature could ③ The heater is defective (2. ③ Replace the heater
Test results
not reach 45 ℃ and 46~2.85K Ohm) ，
keep stable ④ Replace temperature
Software ④ The temperature sensor is
sensor
（ 1100 ~1190 Ohm ） def
Maintenance ective
⑤ The cable is not well con ⑤ Reconnect the cable
nected
 Structure
Reagent compartment drive and refrigeration

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

Step motor Peltier

Radiator
 Troubleshooting

Temperature problems in Reagent compartment

Symptom Probable Cause Corrective Action

Work flow

Machine structure

Hardware system ① The cable is not well ① Reconnect the cable

connected
Liquid system ② Replace 12V/5V board
② The 12V/5V board is
defective ③ Replace Reagent
Optical system The reagent refrigeration board
compartment could not ③ The Reagent refrigeration
Test results be cooled. board is defective ④ Replace the Peltier
④ The Peltier is defective ⑤ Replace temperature
Software sensor
Maintenance ⑤ The temperature sensor is
defective
 Question

Work flow

Machine structure

Hardware system
How can I disassemble the Peltier?
Liquid system

Optical system

Test results

Software

Maintenance
Click here!
 Structure
Reaction compartment assembly

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software
Maintenance
•Offer positions for reaction cuvette
•Provide proper temperature for reaction
•Provide positions for photoelectric measurement
 Structure

Reaction compartment drive assembly

Step motor
Step sensor
Work flow

Machine structure

Hardware system

Liquid system

Optical system Home position

sensor
Test results

Software

Maintenance
• Rotary movement is driven by one Step Motor
• Signals are feed back by Home Position Sensor and Step
Sensor
 Structure

Reaction compartment

Work flow

Machine structure
220/110VAC, 125W 220/110VAC,350W
Hardware system

Liquid system

Optical system 1 temperature transducer 2 fans 3 photoelectric seat

Test results
4 heat insulating plate 5 top heater 6 cover
Software
7 temperature-control 8 bottom
Maintenance chamber heater
 Troubleshooting

Temperature problems in Reaction tray

Symptom Probable Cause Corrective Action

Work flow
① The 220V/110 input is ab
Machine structure normal
② The ambient temperature
Hardware system is over 37 ℃
① Check the power supply
Liquid system ③ The temperature control p
② Install air condition.
arameters are improper
Optical system ③ configure the parameters
④ The heater is defective (T
The temperature op heater:437.8~483.8 Ohm ， ④ Replace the heater
Test results could not reach 37 Bottom heater:131.4~145.2 O ⑤ Replace temperature
℃ and keep stable hm )
Software sensor
⑤ The temperature sensor is ⑥ Reconnect the cable
Maintenance （ 1100 ~1190 Ohm ） def
ective

⑥ The cable is not well con

nected
 Troubleshooting

Light Source Assembly

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Work principle

Work flow

HARDWARE SYSTEM
Machine structure

Hardware system

Liquid system (Printed Circuit Boards)

Optical system
Connection,
Test results
Function,
Software Typical troubleshooting.
Maintenance
 Work principle

Hardware Frame
NOTE:
Red: PCB Boards;
Blue: Field Components; PC Fans Peltiers
Black: Outside Parts.
Work flow

Machine structure Refrigeration

Position Sensors ISE Power
Board Board
Hardware system
Sensors in Tanks

AC Power Supply
Reaction Disk
Liquid system Temp Transducers Temperature
Main Power Supply Boards

(110/220V)
Sampling Board

Optical system
Probes LLD Boards
Board PFC Board
12V&5V Board
24V Board
Test results
Photo-electric
A/D Board
Boards
Software Reac. Tray
Lamp
Heaters
Maintenance

Power Drive Board

Step Reagent
Pumps Valves DC Motor
Motors Preheater
 Work principle

Main Board (CPU Board)

Functions:
Work flow
 Control center of chemistry analyzer.
Machine structure  Multi-CPU processor system.
Hardware system  Temperature control loop.
 Power drive board control.
Liquid system
 A/D conversion board control.
Optical system  Signal collection of sensors.
Test results

Software

Maintenance
 Work principle
AD Conversion Board Liquid level sensor
Position Sensors

FPGA Download Interface

LLD Interface

Power supply

Power
Feedback signal of Drive
Fans Board

Serial Port ISE Module

Reaction Temp
Sampling Board
 Work principle

Jumper on Main Board

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results
Keep embedded program. Upgrade embedded program.
Software

Maintenance
Change the jumper’s position to enable modification to each units.
 Work principle

Power Drive Board (PDB)

Work flow

Machine structure
Functions:
 Power drive components.
Hardware system
 Receive control signals for pumps, valves, motors and
Liquid system temperature switch from main board.
Optical system  Drive pumps, valves, motors and temperature switch
directly according to the signals.
Test results

Software
Maintenance
 Motor of Filter Wheel
Work principle

Power Drive Board of BS120

Motor of Syringe

Motor of Reaction
Compartment
H-Motor of Probe

FPGA
Motor of Download Interface
Reagent
Compartment

Reagent
Motor of Preheated
Mixer Main Board

Valves&Pumps
V-Motor of Probe Power Control Signal of Lamp Mix Motor
Supply
 Work principle

Reaction-Temperature Sampling Board

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results
Functions:
Software
 Collect the Temp signal.
Maintenance  Convert them into digital signal.
 Transform the signal to main board.
 Work principle

A/D Conversion Board

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results
Functions:
Software
 Filter, amplify and adjust the gains of different channels
Maintenance of photo-electric signal.
 Convert analog signal to digital signal.
 Multi-selective gating system.
 Work principle

Photoelectric Conversion Board

Work flow
Functions:
Machine structure
 Also called pre-amplification board.
Hardware system  Convert optical signal to electric signal.
Liquid system  Amplify electric signal.
 Each photoelectric channel with one photoelectric
Optical system
conversion board.
Test results

Software

Maintenance
 Work principle

Photoelectric Conversion Board

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results
Photodiode
Software
 Convert optical signal to electric signal
Maintenance
 Signal filter and amplification
 Work principle

Reagent Refrigeration Board

Work flow
Functions:
Machine structure  Provide Power of the two peltiers.
Hardware system  Loop control of reagent refrigeration.
 Supply power to fans
Liquid system
 Fans feedback from reaction disk.
Optical system

Test results

Software

Maintenance
 Work principle

Reagent Refrigeration Board (BS-120)

Work flow J71~74 Fans for J89 Peltiers

Reaction Disk
Machine structure
J15 Fogbroom /
Hardware system J77 Lamp Fan Temp Protective Swich
Liquid system
J75 Drive
Optical system Board Fan J88 Reagent Tray
Temp Sensor
Test results
J87 Main Board
Software J84,85 Refrigeration
Fans
Maintenance

J86 12V/5V Board

12VFan 12V 12V
GNDFan GND GND
 Work principle

Reagent Refrigeration Board

Description
Meaning Marker Color
On Off
12V goes
Work flow 12VLED Green 12V works normally
wrong
Power supply
12VFAN works 12VFAN goes
Machine structure 12VFAN_LED Green
normally wrong
Hardware system Peltiers work Peltiers go
Peltiers PELTIER_LED Green
normally wrong
Liquid system FAN1_LED Red
Corresponding
Temperature FAN2_LED Red Corresponding fan
Optical system fan works
control fans FAN3_LED Red goes wrong
normally
Test results FAN4_LED Red
Refrigeration Refrigeration
Software GREEN_LED Green temperature is temperature is
within 0-15℃ beyond 0-15℃
Maintenance
Refrigeration Refrigeration
Refrigeration
YELLOW_LED Yellow temperature is temperature is
temperature
below 0℃ above 0℃
Refrigeration Refrigeration
RED_LED Red temperature is temperature is
above 15℃ below 15℃
 Work principle

Liquid Level Detection Board (LLD Board)

Work flow

Machine structure
Functions:
Hardware system
 Detect liquid level (reagent probe, sample probe).
Liquid system  Supply power of pre-heating module.
Optical system  Anti-collision function.

Test results

Software

Maintenance
 Work principle

Liquid Level Detection Board

VR1 Adjust Point

J66 Reagent /
Work flow LED

Anti-Collision
Sample Probe

LLD Signal
Machine structure

GND

12V
Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Work principle

Liquid Level Detection Board

Caution: The voltage between TP2 and TP4 should be
around 4.5V. Otherwise, adjust VR1 to match it.
Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software TP2 Voltage TP6 Anti-Collision

TP4 GND
Testing Point Signal
Maintenance
 Work principle

Power supply assembly

AC
Top heater
&Bottom heater

Work flow

Machine structure 110V/220V

AC input
Hardware system

Liquid system
24V
Optical system

Test results 24V board

Software APFC

Maintenance
C12V,5V

LAMP A12V B12V 24V PFC 12V&5V

BOARD BOARD BOARD
PFC board 12V/5V board
 Trouble Shooting

General


Importance of the three boards:
Work flow PFC Bd.>12V&5V Bd.>24V Bd.
Machine structure

Hardware system 
Important symptoms:
Liquid system
Fans or refrigeration function/communication with PC/
Optical system instrument self-checking /analyzer unit switch indicator
Test results

Software

Maintenance
 Work principle

PFC Board

P3 Analyzer power switch

Work flow

Machine structure
P1 AC input
Hardware system

Liquid system
P4
Optical system 390V output P6 Lamp control signal

Test results P2 VDD P5 Output for lamp

Software

Maintenance • EMI filter network

• AC/DC conversion, supplying the +390V and VDD voltage to 24V board and 12V&5V
board;
• Supplying stable 12V(4.5A) voltage for the lamp;
• Control the C12V, 5V and 24V outputs through the analyzing unit switch.
 Trouble Shooting

Possible symptoms of PFC board failure

• Fans do not work.

Work flow
• No click sound in the Power Supply when switching on the
Machine structure
main switch.
Hardware system
• Indicator of analyzer unit switch is off when switching on.
Liquid system
• No power input on Main Board and Power Drive Board.
Optical system

Test results

Software

Maintenance
 Work principle

24V Board

P404 AC input
Work flow

Machine structure P406 Heater power

output
Hardware system

Liquid system
P6 heater control
Optical system
P4 390V input
P5 24V output
Test results
P2 VDD input
Software

Maintenance

• Transferring AC to the heater and controlling the heater

• Converting the 390V to 24V
 Trouble Shooting

Possible symptoms of 24V Board Failure

• Power is switching on, fans are working and cable

Work flow communication are normal.
Machine structure • Error messages such as XXX can not reach its initial position
Hardware system while instrument self-checking.
Liquid system • All motors/pumps/valves do not work.
Optical system

Test results

Software

Maintenance
 Work principle

12V&5V Board

P353 B12V /C12V

Work flow output

Machine structure P406 C12V/5V output

(PDB)
Hardware system
P352 C12V/5V output
Liquid system (Main board)
P351 power fan
Optical system
P301 390V input
Test results
P2 VDD &SW
Software

Maintenance
Convert the 390VDC to B12V(10A), C12V(4.7A) and 5V
 Trouble Shooting

Possible symptoms of 12V&5V Board Failure

•Case 1
Work flow • Works of fans are failed
Machine structure • Work of refrigeration is failed
Hardware system • Work of pumps and valves is failed
Liquid system • Mechanic reset is ok
Optical system • Indicator of analyzer unit switch is normal
Test results
•Case 2
Software
• Works of fans are normal
Maintenance
• Work of cable communication with PC is failed
 Trouble Shooting

ISE Power Supply Board

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
Convert 12V to 24V
Provide the 24V to the ISE Assembly
 Work Principle

Work flow

Machine structure Liquid System

Hardware system

Liquid system
Introduction
Principle
Optical system
Typical troubleshooting.
Test results

Software

Maintenance
 Work Principle

LLD (Liquid Level Detection ) Principle:

Probe tip touches

liquid level
Work flow

Machine structure
Capacitance between
Hardware system inner and outer probe
tube is changed.
Liquid system

Optical system The change is

converted to
Test results
voltage change.
Software

Maintenance Voltage signal is

transmitted to main
board
 Work Principle

Syringe ,Pumps and valves for BS-120

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

1.Sample volume/precision: 1.Reagent&Sample valve

3-45μl / 0.5μl 2.Interior wash pump
2.Reagent volume/precision 3.Exterior wash pump
30-450μL/ 1μL
 Work Principle

Liquid flow for BS-120

Syringe
Work flow Probe wash well Mixing bar
wash well Probe
Machine structure Reagent valve

Hardware system
Reagent/sample
Liquid system Interior wash compartment
pump Exterior wash
Optical system pump

Test results

Software

Maintenance

Deionized water Waste water

tank tank
 Work Principle

Liquid flow for BS-120

Syringe
Work flow Probe Mixing bar
wash well
Machine structure
Reagent valve
Hardware system
Reagent/sample
Liquid system
compartment
Interior wash Exterior wash Probe wash well
Optical system pump pump

Test results

Software

Maintenance

Deionized water Waste water

tank tank
 Troubleshooting

LLD (Liquid Level Detection ) Error Messages:


There are four kinds of LLD errors:
Work flow – LLD error in reagent/sample disk (when aspirating)
Machine structure – LLD error in reaction disk (when dispensing)
Hardware system – LLD error of the reagent/sample probe in wash well
Liquid system – LLD error caused by little bottle
Optical system

Test results

Software

Maintenance
 Troubleshooting

LLD errors in reagent /sample tray.

Symptom Probable Cause Corrective Action

① LLD board is faulty
Work flow ① Replace the LLD board
② LLD voltage(TP2) is too
② Adjust the LLD voltage to about
Machine structure high or too low 4.5 volts
The detection
③ No liquid or liquid ③ Add reagent or sample into the
Hardware system indicator (LED) is
volume is too little bottle or tube
off or always on.
Liquid system ④ Probe is broken ④ Replace the probe
⑤ 12V of LLD is not ⑤ Check the 12V on main board
Optical system available or 12V/5V power supply board.
Test results
① The cable between LLD ① Measure the signal on LLD
Software The detection and Main board is ill board, Probe connection board
indicator is normal connected and CPU board, and reconnect
Maintenance but the probe is the cable.
failed to aspirate
② Main board is faulty.
and dispense
② Replace Main board.
 Troubleshooting

LLD error in reaction tray

Symptom Probable Cause Corrective Action

Work flow

Machine structure

Hardware system ① Probe detect level by • Check probe , connection

mistake so that probe
cable ,main board and LLD
Liquid system aspirate air
board
No liquid surface ② There are bubbles in
Optical system reagent bottle • Remove the bubbles
detected when
Test results sample probe ③ Reagent leakage • Syringe is not fixed well or
dispensing replace the piston of reagent
Software ④ The sample adding syringe and EM valve
position and reaction
Maintenance vertical limit position need • Adjust the corresponding
to be adjusted. parameters or upgrade
software
 Troubleshooting

LLD error in wash well

Symptom Probable Cause Corrective Action

Work flow No water in wash well
① The deionized water tank is not ① Click “Probe stop” and add
Machine structure enough or empty deionized water
Hardware system ② The exterior wash pump is ② Replace exterior wash pump
defective
③ Check and replace the
Liquid system ③ The tubing or the single-way blocked parts
No liquid surface valve or the 3-way connector is
Optical system detected when ④ Connect the tubing
blocked;
washing probe ④ The tubing is disconnected
Test results

Software
Water available in wash well
Maintenance The same as LLD on reagent tray
① LLD function is abnormal
 Work Principle

Work flow

Machine structure
Optical System
Hardware system
Principle
Liquid system
Typical troubleshooting.
Optical system

Test results

Software

Maintenance
 Work Principle

Optical system

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Wavelength of Filters: 340nm, 405nm, 450nm, 510nm, 546nm,
578nm 、 630nm, 670nm.
 Lamp: 12V, 20W
 Troubleshooting

Background checking for BS-120

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Troubleshooting

Adjustment of Optical System

Work flow Sequence of Optical Adjustment:

Machine structure
1. Photometric Position of Reaction Disk
Hardware system
2. Filter Offset
Liquid system 3. Photoelectric Gain
Optical system 4. Confirm Light Source Background and Dark Current
Test results

Software

Maintenance
 Troubleshooting

Photometric Position of Reaction Disk

1. Turn off analyzing unit

Work flow 2. Connect two probes of oscillograph to AD start signal R

C and the analog signal V3 respectively, both earth termi
Machine structure
nals connected to GND.
Hardware system
3. Turn on both power
Liquid system
4. Enter Debug software, select Setup button on the up-rig
Optical system
ht of the window and input password of bs120
Test results
5. Place 8 new segments to the reaction compartment.
Software
6. Select the Command-Main Unit-Ordinary Rotate&Mea
Maintenance
sure Instruction, and then select Run. At the same tim
e, press Start on the oscillograph and collect signals.
7. Snap the waves
 Troubleshooting

Photometric Position of Reaction Disk

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software
AD start signal should be in the
Maintenance
middle of the photometric analog
signal.
 Troubleshooting

Photometric Position of Reaction Disk

AD start signal not in the middle

Work flow of photometric analog signal

Machine structure

Hardware system Move coder sensor of reaction

disk to adjust the start signal
Liquid system

Optical system

Test results AD start signal to the AD start signal to the

left of the Middle left of the Middle
Software

Maintenance

move the sensor along move the sensor

clockwise counter-clockwise
 Troubleshooting

Filter Offset

1. Enter debug software

Work flow 2. Select Photoelectric-Filter Offset, and then click Star
t
Machine structure
3. Wait for 3-4 minutes till the process finished
Hardware system 4. Click ok, then a pink line will be at the center of the firs
Liquid system
t peak, calculated by the software itself
5. the offset of the filter equals to the value in the text box
Optical system
minus 100
Test results 6. Confiugure the filter offset in PARA and Speed-Reacti
Software
on Unit.

Maintenance
 Troubleshooting

Filter Offset

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Troubleshooting

Photoelectric Gain

1. Enter Debug software, select Photoelectric-Others-Test Gain, then Start.

2. After finished, gain value will performed in the Gain column. The order is 340
Work flow
nm, 405nm, 450nm, 510nm, 546nm, 578nm, 630nm, 670nm.
Machine structure
3. During the test, the software will configure the gain value to the reaction unit.
Hardware system
4. After the test, select PARA and Speed-Reaction Unit-Query to confirm the con
Liquid system figuration.
The order on the reaction unit is 670nm, 630nm, 578nm, 546nm, 510nm, 450n
Optical system
m, 405nm, 340nm.
Test results
5. Run background test to confirm the gain configuration. The recommended ran
Software ge for background is 48000-62000.

Maintenance 6. If the gain values of a channel are not reasonable, adjust them manually. Chang
e the gain value of the specific channel on PARA and Speed-Reaction Unit. Yo
u will get low background value by configuring large gain value. Similarly, yo
u will get high background value by configuring low gain value. The input ran
ge for gain value is 1-255.
 Troubleshooting

Photoelectric Gain

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

Note:
1. Remove the Jumper to VDD in main board;
2. Enable modifying parameters in Debug software is necessary
 Troubleshooting

Relative range of optical system parameters

• Light intensity
Light intensity >80% 70%~80% 60%~70% <60%
Work flow
Status Normal Caution of low intensity Caution of changing Test
Machine structure
lamp prohibition
Hardware system
• Dark current
Liquid system

Optical system Normal value 0~200

Test results
• Background
Software

Maintenance Backgrounds 60,000~65,000 50,000~65,000 43,000~50,000 <43,000

Status Initial value Normal value Need to be Need to change

increased lamp
 Troubleshooting

Insufficient Light Intensity

Symptom Probable Cause Corrective Action
① Abnormal gain
Work flow ① Adjust the parameters b
parameters y Debug software
Machine structure ② Photoelectric signal ② Adjust the correspondin
collecting position is g parameters
Hardware system Only certain background is improper
Liquid system
very low ③ Abnormal optical path ③ Clean the head of little
④ Defective pre- Fibre or replace it
Optical system amplification assembly ④ Replace pre-
⑤ Defective A/D amplification assembly
Test results
conversion board ⑤ Replace A/D
Software conversion board
All backgrounds are on the
Increase the gains by Debug
Maintenance lower side but bigger than
software
43,000
The background of 340nm or The lamp is aged
reference light is lower than
Change the lamp
43,000, and other backgrounds
are also very low
 Troubleshooting

Abnormal dark current

Symptom Probable Cause Corrective Action

Work flow ① The reaction tray is not
covered
Machine structure • Cover the reaction tray
② The cable between Main
• Reconnect the cable
Hardware system board and A/D conversion
The value of dark board is not connected. • Replace Pre-amplification
Liquid system current is more than assembly
③ Defective Pre-amplification
200 • Replace A/D conversion
assembly
Optical system board
④ Defective A/D conversion
Test results board • Eliminate all Interference
⑤ Interference from outside source
Software

Maintenance
 Troubleshooting

The status of reaction cuvette is unknown

Symptom Probable Cause Corrective Action

Work flow

Machine structure

Hardware system

Liquid system
① Reduce the backgrounds
Optical system
① The background is too through changing the gains
The status of
high (65535)
reaction cuvette is ② Adjust start position of
Test results
unknown ② Photoelectric signal photoelectric collection
collecting position is not (normal range 19~23)
Software
proper
Maintenance
 Work Principle

Work flow

Machine structure

Hardware system
Test Results
Liquid system

Optical system

Test results

Software
Troubleshooting
Maintenance
 Troubleshooting

Reaction Curve
F
Absorbance •Adding R1 ： Pont A
Work flow •Preheating R1 ： Process B
E •Adding sample ： Point C
Machine structure
C •Incubating ： Process D
Hardware system •Adding R2 ： Point E
A •Reaction ： Process F
Liquid system B
Optical system D
Measuring cycle
Test results

Software
• The vertical axis indicates the absorbance
Maintenance Real value = curve value /10000
• The horizontal axis indicates the measuring cycle ： 12s
 Troubleshooting

Point A: Reagent 1 is added

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software
• In the first cycle, R1 is added into the reaction cuvette, so the
absorbance value here is the reagent blank of R1.
Maintenance
•Absorbance values at Point A vary with different reagents.
If the absorbance is much smaller than the value specified
in the reagent instruction, the reagent may has expired
 Troubleshooting

Phase B: Preheating time

Usually, absorbance does

Work flow
not change when the
Machine structure reagent is heated
Hardware system

Liquid system

Optical system

Test results
Some reagents may have a
Software
increase/decrease of about 200
Maintenance (0.02A) in this process, but
normal, fluctuation of absorbance
between two consecutive cycles is
no more than 20.
 Troubleshooting

Phase B: possible problems

Symptom Probable Cause Correction

Work flow
Absorbance fluctuates in some There are Bubbles or Remove bubbles or
Machine structure
Curves, but not all curves. contamination in cuvettes check the cuvette
Hardware system

Liquid system The collecting time matches t Adjust the parameter

he photoelectric conversion no of “Start position of
Optical system t well photoelectric
collection” by Debug
Test results Absorbance fluctuates in almost software
all Curves
Software

Maintenance The lamp is aged Change lamp

 Troubleshooting

Phase C: Sample is added

Work flow

Machine structure

Hardware system

Liquid system

Optical system
Point C
Test results

Software

Maintenance

• Obvious change in absorbance showing that sample is added into the

reaction cuvette.
• Adding distilled water is different, it’s may cause 200 decrease.
 Troubleshooting

Phase C: possible problems

Symptom Probable Cause Correction
Check the DC motor of
Work flow Mixing bar does not work
Mixing bar

Machine structure Adjust the parameter of

Mixing bar is over high “Mixing bar V-position for
mixing”
Hardware system
Little change The sample syringe is not properly tightened Mount the syringe again
Liquid system
Check the probe and liquid
Liquid dropping from sample probe
system
Optical system
Bubbles in sample tube Remove the bubble
Test results
Fluid tubing leakage Change the tubing
Software
Bubbles in reagent bottle Remove the bubbles
Maintenance No change
Check the LLD
Liquid level detection of sample probe is failed
function
 Troubleshooting

Phase D: Incubation

Work flow Phase D

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance • Incubation reaction at 37℃ circumstance

• The reaction curve in this phase is supposed to be smooth or
changing smoothly. The fluctuation should not be greater than 50 in
consecutive sampling cycle
 Troubleshooting

Phase D: possible problems

Symptom Probable Cause Correction

Work flow
Absorbance fluctuates in some There are Bubbles or Remove bubbles or
Machine structure
Curves, but not all curves. contamination in cuvettes check the cuvette
Hardware system
The sampling time matches t Adjust the parameter of
Liquid system “Start position of
he photoelectric conversion n
ot well photoelectric
Optical system
collection” by Debug
Test results software
Absorbance fluctuates in almost
Software Adjust the position of
all Curves The mixing bar strikes Cuvette
mixing bar
Maintenance

The lamp is aged Change lamp

 Troubleshooting

Phase E: Adding sample

Work flow

Machine structure

Hardware system
Point E
Liquid system

Optical system

Test results

Software

Maintenance
• Absorbency is theoretically the summation of double reagent blank and
sample blank
• Similar situation as point A and point C.
• Considered as the starting time of the reaction in the software.
 Troubleshooting

Phase E: Possible problems

Work flow
Symptom Probable Cause Correction
Machine structure
Check the dispensing system /
No change or little change Failure in adding R2 / Bubbles
Hardware system remove bubbles

Liquid system

Optical system
Too much Change R2 is expired or contaminated Change R2
Test results

Software

Maintenance
 Troubleshooting
Phase F: Reaction process

Work flow

Machine structure
increase decrease
Hardware system

Liquid system

Optical system

Test results

Software

Maintenance • The trend of reaction change is decided by the measure method.

• It’s the base of absorbency measurement and concentration
calculation.
• Normally it should be smooth, with no obvious fluctuation.
 Troubleshooting
Phase F: Possible problems

Symptom Probable Cause Correction

Work flow R2 is expired or not properly Check R2 or dispensing
The degree of reaction is added system
Machine structure
not enough
The mixing bar is over high or
Check the mixing bar
Hardware system does not work
Liquid system
Remove bubbles ， test it a
Bubbles in mixture
Optical system gain

Test results
Fluctuation is greater Change R2
Contamination in R2
Software than 100 in each cycle
Maintenance
The mixing bar Strikes the cuvette Adjust the position of
mixing bar
 Troubleshooting

Different reaction type has different curve shape.

So a nearly invisible fluctuation here may impact
Work flow test results much.
Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Troubleshooting

Summarization

 Analyzing the reaction curve sectionally and find the rea

Work flow
son of problem
Machine structure
 Comparing the current questionable Curves with former
Hardware system
good ones and find difference
Liquid system
 Repeating the test is very important. It can help you find
Optical system
the difference among the curves of the same test.
Test results

Software

Maintenance
 Troubleshooting

Abnormal results analysis


All results are abnormal
Work flow ­ All results are low
Machine structure ­ Some are high, and some are low, resulting in bad
Hardware system repeatability
Liquid system 
Certain results are abnormal
Optical system ­ Certain applications, e.g. ALT
Test results ­ Certain tests using same filter
Software 
Accidental result is abnormal
Maintenance
 Troubleshooting

All results are low

Symptom Probable Cause Correction

Work flow
The added sample is insufficient ① Unclog the sample probe
Machine structure
or replace the probe
① The sample probe is clogged
② Replace the defective
Hardware system ② Fluid tubing has leakage tubing
Liquid system ③ The Sample syringe work ③ Make the syringe work
improperly normally
Optical system
ALL results The reaction is insufficient ① Adjust the mixing
Test results position of mixing bar
are low ① The mixing bar is over high
Software
② The mixing bar does not work ② Check the DC motor

Maintenance ③ Inspect the temperature

③ The reaction temperature is
abnormal
① Increase all backgrounds
The light intensity is too low by debug software
② Replace the lamp
 Troubleshooting

Some results are high, some are low

Symptom Probable Cause Correction

Work flow The mixing bar strikes the
reaction cuvette Adjust the position of mixing bar
Machine structure

Hardware system
① Check Halogen lamp
Liquid system ② Check Optical Fibre
Some results Some backgrounds are ③ Check Filter
Optical system
are high, some abnormal ④ Check the Photoelectric sign
Test results are low al sampling position

Software

Maintenance Liquid system has

problems Check Syringe , tubing, Valve, Probe and
so on
 Troubleshooting

Certain item results is abnormal

Symptom Probable Cause Correction

Work flow

Machine structure
Good repeatability
Calibrate this item again
Hardware system
Improper calibration parameters
Liquid system Certain item
results is Poor repeatability
Optical system ① Reagent is disabled
abnormal ① Change new reagent
② Bubbles in reagent bottle
Test results ② Remove bubbles

Software

Maintenance
 Troubleshooting

Accidental result is abnormal

Symptom Probable Cause Correction

Work flow

Machine structure

Hardware system Normal in the repeated tests

① Reaction cuvette is dirty ① Do not use cuvette
Liquid system repeatedly
② There are bubbles aspirated
Optical system into reagent probe ② Remove the bubbles
Accidental
Test results result is
abnormal
Software

Maintenance
Abnormal in repeated tests. Chang the sample
The sample is abnormal
Work flow

Machine structure

Hardware system

Liquid system
Software
Optical system

Test results

Software
Introduction
Maintenance
 Introduction

Software frame

System software/Debug software PC

Work flow

Machine structure

Hardware system
Main Unit
Liquid system
Refrigeration Unit
Optical system

Test results Sample Temperature Photoelectric mixing Unit

Reagent
Software Unit control Unit Unit
Unit
Maintenance
Control software
Analyzer
 Introduction

Control software
•Functional Unit
 Main Unit
 Loading/mixing Unit
Work flow  Reagent Unit
Machine structure  Sample Unit
 Temperature control Unit
Hardware system  Photoelectric Unit
Liquid system •Upgrade
Optical system

Test results

Software

Maintenance
 Introduction

Debug software

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance

• Single-step instruction and macro instruction operation

• Parameter enquiry and modifying
• Temperature monitor
• Photoelectric measurement
 Introduction

Operation software

Work flow

Machine structure

Hardware system

Liquid system

Optical system

Test results

Software

Maintenance
 Work Principle

Work flow

Machine structure

Hardware system
Maintenance
Liquid system

Optical system

Test results

Software

Maintenance
 Trouble Shooting

Daily maintenance

1. Clean sample disk and reagent disk

Work flow

Machine structure
2. Clean surface of probe and mixing bar
Hardware system 3. Clean all the covers
Liquid system
4. Check deionized water tank and waste water t
Optical system
ank
Test results

Software

Maintenance
 Trouble Shooting

Maintenance

Every 3 months: Every 6 months: Every year:

Work flow
① Check the ① Unclog probes ① Replace
Machine structure syringe plunger; with needle; washers for
② Check all the ② Replace check probe and
Hardware system valves valve if it is syringe;
very dirty.
Liquid system ② Replacing
③ Replace 100μL
plunger probe is
Optical system
assembly in recommended
Test results sample syringe .
④ Replace 500μL
Software ③ Replacing
plunger tip in
mixing bar is
Maintenance reagent
preferred
syringe
 End

Thanks