Servicemanual

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Hemolyzer 5

This service manual is intended to give detailed information for service engineers of
Analyticon Biotechnologies AG Hemolyzer 5 optical hematology analyzer.

All information contained herein is the intellectual property of Analyticon Biotechnologies AG

and should not be used or reproduced without prior agreement of Analyticon Biotechnologies
AG, the manufacturer.

This manual was written with the intention to give the most precise and up-to-date, detailed
description of operation and use of the analyzer for laboratory purposes.

Despite careful revision and multiple grammar and content control, mistakes can still be
present in this manual. Analyticon may from time to time issue errata, or a new revision of
the manual. Would you find things unclear, please contact
support@analyticon-diagnostics.com for assistance.

User’s manual contains important information about the operation and measurement
principles of Hemolyzer 5. Specifications, definition of parameters and user interface are also
described therein, consequently Service manual does not contain these data.

Use of the Service manual assumes knowledge of the information contained in the User’s
manual.

Analyticon Biotechnologies AG
Technical Support Team

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Table of Contents
TABLE OF CONTENTS .......................................................................................................................... 3
1 INTRODUCTION ............................................................................................................................. 8
1.1 W HO SHOULD READ THIS MANUAL ............................................................................................... 8
2 FOR YOUR SAFETY ...................................................................................................................... 9
2.1 SPECIAL SYMBOLS USED IN THIS MANUAL .................................................................................. 9
2.2 GENERAL PRECAUTIONS ............................................................................................................ 9
2.3 ENVIRONMENTAL FACTORS ...................................................................................................... 10
2.4 ELECTRICAL REQUIREMENTS .................................................................................................... 11
2.5 SUGGESTED ON-LINE UPS ....................................................................................................... 11
2.6 PROPER PLACEMENT OF HEMOLYZER 5 .................................................................................... 12
2.7 W EIGHT REQUIREMENTS .......................................................................................................... 12
2.8 W ASTE DISPOSAL .................................................................................................................... 13
2.9 EMERGENCY SITUATIONS ......................................................................................................... 13
3 STRUCTURE OF THE ANALYZER.............................................................................................. 14
3.1 COMPONENTS LOCATED ON THE FRONT PANEL .......................................................................... 14
3.1.1 Display screen and the touch sensitive surface ................................................................ 14
3.1.2 Start Button and LEDs ....................................................................................................... 15
3.2 COMPONENTS ACCESSIBLE AFTER OPENING THE FRONT PANEL .................................................. 15
3.2.1 Shear Valve Assembly ...................................................................................................... 15
3.2.2 Sample rotor ...................................................................................................................... 15
3.2.3 Main Dilutors ...................................................................................................................... 16
3.2.4 Dilutor opto sensor boards ................................................................................................ 17
3.2.5 Tube organizer................................................................................................................... 17
3.2.6 Temperature Control Unit .................................................................................................. 17
3.2.7 Laser head ......................................................................................................................... 18
3.2.8 Laser Head Assembly + Sample Injector .......................................................................... 19
3.2.9 Laserdiode Driver Board .................................................................................................... 20
3.2.10 Pin Photodiode and Amplifier (OPTSENSOR_2v1) ...................................................... 20
3.3 LEFT SIDE ................................................................................................................................ 21
3.3.1 Valve boards ...................................................................................................................... 21
3.3.2 WBC/BASO Preheater Assembly ...................................................................................... 22
3.3.3 Counting chamber with electrodes and measuring aperture ............................................. 22
3.3.4 HGB Measuring Head ....................................................................................................... 23
3.3.5 Cell counter Amplifier Board .............................................................................................. 24
3.3.6 Pressure sensor board ...................................................................................................... 25
3.3.7 Reagent and Vacuum buffers ............................................................................................ 26
3.3.8 Reagent Sensor Board ...................................................................................................... 27
3.3.9 Opening the valve assembly plate..................................................................................... 27
3.3.10 Vacuum buffer ............................................................................................................... 27
3.3.11 Pneumatic and Power Boards (PPB1 and PPB2) ......................................................... 28
3.3.12 Pump assembly ............................................................................................................. 29
3.4 RIGHT SIDE .............................................................................................................................. 30
3.4.1 XY unit ............................................................................................................................... 30
3.4.2 XYROpto Board ................................................................................................................. 31
3.4.3 Sampling needle ................................................................................................................ 31
3.4.4 Blood sensor ...................................................................................................................... 31
3.4.5 Wash head......................................................................................................................... 32
3.4.6 Processor unit (LS-DACQ board with DimmBoard) .......................................................... 32
3.4.7 Mini-ITX PC mother board (In Hardware block) ................................................................ 37
4 ELECTRONIC BLOCK DIAGRAM ............................................................................................... 38
4.1 HARDWARE BLOCK .................................................................................................................. 38
4.2 DATA ACQUISITION UNIT .......................................................................................................... 40
4.3 AMPLIFIER BOARD .................................................................................................................... 42

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Hemolyzer 5

4.4 OPTICAL HEAD......................................................................................................................... 43

5 OPERATION OF THE FLUIDIC SYSTEM .................................................................................... 44
5.1 THE REAGENT SYSTEM............................................................................................................. 44
5.2 FLOW DIAGRAM OF MEASUREMENT............................................................................................ 45
5.3 INITIALIZATION OF THE FLUIDIC SYSTEM .................................................................................... 47
5.4 REAGENTS PRIMING ................................................................................................................. 47
5.5 PIERCING PROCESS ................................................................................................................. 47
5.6 SAMPLING PROCESS ................................................................................................................ 47
5.7 NEEDLE WASHING PROCESSES ................................................................................................. 48
5.8 DILUTING PROCESSES .............................................................................................................. 48
5.9 LYSING PROCESS ..................................................................................................................... 48
5.10 RBC COUNTING PROCESS ........................................................................................................ 49
5.11 WBC/BASO COUNTING ........................................................................................................... 49
5.12 WBC 4DIFF COUNTING ............................................................................................................ 49
5.13 CHAMBER DRAINING PROCESSES .............................................................................................. 50
5.14 CLEANING (RINSING) PROCESSES ............................................................................................. 50
5.15 STANDBY PROCESS .................................................................................................................. 50
5.16 W AKE UP PROCESS .................................................................................................................. 51
5.17 SHUTDOWN PROCESS .............................................................................................................. 51
6 ADJUSTMENTS ............................................................................................................................ 52
6.1 XY UNIT MECHANICAL ADJUSTMENTS ........................................................................................ 52
6.1.1 XY horizontal movement ................................................................................................... 52
6.1.1.1 Greasing the horizontal rods ................................................................................................... 52
6.1.1.2 Set opto flags for horizontal movement................................................................................... 53
6.1.2 XY vertical adjustment ....................................................................................................... 55
6.1.2.1 Basic operation ....................................................................................................................... 55
6.1.2.2 Adjusting the needle’s vertical position ................................................................................... 56
6.1.3 Washing head settings ...................................................................................................... 56
6.1.4 Needle setting .................................................................................................................... 57
6.1.4.1 Handmade setting ................................................................................................................... 57
6.1.4.2 Software made setting ............................................................................................................ 58
6.2 SHEAR VALVE MECHANICAL SETTING ......................................................................................... 58
6.2.1 Shear valve lower disc position setting ............................................................................. 59
6.2.2 Shear valve upper disc setting .......................................................................................... 59
6.2.3 Setting the opto sensors of the shear valve. ..................................................................... 61
6.3 AMPLIFIER OFFSET SETTING ..................................................................................................... 62
6.4 BLOOD SENSOR CALIBRATION ................................................................................................... 63
6.5 SAMPLE POSITION SETTING....................................................................................................... 65
6.6 PRESSURE SENSOR ADJUSTMENT ............................................................................................. 66
6.7 SET SERIAL NUMBER ................................................................................................................ 67
6.8 WBC PREHEATER .................................................................................................................... 67
6.9 SETTING LASER VALUES ........................................................................................................... 67
6.9.1 Calibration procedure of optical heads .............................................................................. 67
6.9.2 Short guide for laser values ............................................................................................... 71
7 VERIFICATION PROCEDURES ................................................................................................... 74
7.1 SELF-TEST............................................................................................................................... 74
7.1.1 Hemolyzer 5 Self-Test Guide ............................................................................................ 75
7.1.1.1 General information ................................................................................................................ 75
7.1.1.2 Electronic Self-Test parameters .............................................................................................. 75
7.1.1.3 Pneumatic Self-Test parameters............................................................................................. 77
7.2 ERROR MESSAGES .................................................................................................................. 79
7.3 SERVICE MENU ........................................................................................................................ 84
7.3.1 Service functions ............................................................................................................... 86
7.3.1.1 Test functions.......................................................................................................................... 87
7.3.1.2 Low level file management...................................................................................................... 87
7.3.1.3 Low level reboot (DimmBoard)................................................................................................ 87
7.3.1.4 Pneumatical System – Initialize .............................................................................................. 87
7.3.1.5 Network management ............................................................................................................. 88
7.3.1.6 RAW data saving mode .......................................................................................................... 88

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7.3.1.7 Export RAW files ..................................................................................................................... 88

7.3.1.8 Windows Control Status .......................................................................................................... 88
7.3.1.9 TCU fill/drain ........................................................................................................................... 88
7.3.1.10 Flow cell fill/drain..................................................................................................................... 88
7.3.1.11 Blood sensor status ................................................................................................................ 88
7.3.1.12 Reset statistics ........................................................................................................................ 88
7.3.1.13 Hard drive maintenance .......................................................................................................... 88
7.3.1.14 Show advanced DB view ........................................................................................................ 88
7.3.1.15 Small sample mode ................................................................................................................ 89
7.3.1.16 Pre-diluted mode..................................................................................................................... 89
7.3.1.17 Monitoring ............................................................................................................................... 89
7.3.2 Service testing ................................................................................................................... 89
7.3.3 Service calibration ............................................................................................................. 90
7.3.3.1 Enable scatter calibration ........................................................................................................ 90
7.3.3.2 Backup Calibration .................................................................................................................. 90
7.3.3.3 Restore Calibration ................................................................................................................. 90
7.3.3.4 Load Calibration ...................................................................................................................... 90
7.3.3.5 Accept User factors ................................................................................................................. 91
7.3.3.6 Back ........................................................................................................................................ 91
7.3.3.7 Accept ..................................................................................................................................... 91
7.3.4 Stress measure.................................................................................................................. 91
7.3.5 Auto alignment ................................................................................................................... 92
7.3.6 AS (Auto-sampler) ............................................................................................................. 92
7.3.6.1 Go to Pos ................................................................................................................................ 92
7.3.6.2 Reset ...................................................................................................................................... 92
7.3.6.3 Repeat last command ............................................................................................................. 92
7.3.6.4 Go To Mixer ............................................................................................................................ 92
7.3.6.5 Load to sampling position ....................................................................................................... 92
7.3.6.6 Set up Barcode Reader .......................................................................................................... 93
7.3.7 Adjustments ....................................................................................................................... 93
7.3.8 Multiuser Settings .............................................................................................................. 94
7.3.9 MDA view ........................................................................................................................... 94
7.3.10 Software upgrade .......................................................................................................... 95
7.3.10.1 Refresh data ........................................................................................................................... 95
7.3.10.2 Change High Level software ................................................................................................... 95
7.3.10.3 Change Low level software ..................................................................................................... 95
7.3.10.4 Change Low level boot ........................................................................................................... 95
7.3.10.5 Change LSDACQ firmware ..................................................................................................... 95
7.3.10.6 Change Optical Head Firmware .............................................................................................. 95
7.3.10.7 Change TCU software ............................................................................................................ 95
7.3.10.8 Change AutoSampler software ............................................................................................... 95
7.3.11 Reagent Lock................................................................................................................. 96
7.3.12 QC Wizard ..................................................................................................................... 97
7.3.13 Printer installation .......................................................................................................... 97
7.3.14 Factory Settings ............................................................................................................. 97
7.3.15 Service mode OFF......................................................................................................... 97
7.4 SOFTWARE SYSTEMS ............................................................................................................... 98
7.5 GENERAL SW INSTALLATION GUIDE .......................................................................................... 98
7.5.1 Install operating system Windows 2.0 install using pendrive .......................................... 100
7.5.2 Installing a Printer ............................................................................................................ 104
8 INSTALLATION .......................................................................................................................... 105
8.1 CHECK THE DELIVERY ............................................................................................................ 105
8.2 PREPARE FOR INITIAL INSTALLATION ....................................................................................... 105
8.2.1 Select a Suitable Location ............................................................................................... 105
8.2.2 Make Any Special Arrangements .................................................................................... 105
8.2.3 Gather Your Peripherals Devices .................................................................................... 106
8.3 PERFORMING THE INSTALLATION............................................................................................. 106
8.3.1 Move the ‘Hemolyzer 5’ to the Selected Location ........................................................... 106
8.3.2 Visual Inspection.............................................................................................................. 106
8.3.3 Remove the Protective Card from the Shear Valve ........................................................ 106
8.3.4 Connect the Optional Auto-Sampler ................................................................................ 107
8.3.5 Connect the Reagents ..................................................................................................... 107
8.3.6 Connect the Power Cord ................................................................................................. 108

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Hemolyzer 5

8.3.7 Verify the ‘Hemolyzer 5’ Computer Operation ................................................................. 109

8.3.8 Connect Peripherals ........................................................................................................ 109
8.3.9 How to install a printer ..................................................................................................... 110
8.3.10 Initializing the Optional Autosampler ........................................................................... 110
8.3.11 Using the Settings Menu ............................................................................................. 112
8.3.12 Set Up a Laboratory Information System (LIS) ........................................................... 112
8.3.13 Set Up a Serial LIS Connection ................................................................................... 113
8.3.14 Set Up an Ethernet LIS Connection ............................................................................ 114
8.3.15 Running Blank Samples and Blood Samples for the First Time ................................. 114
8.4 CHECKLIST FOR INSTALLING HEMOLYZER 5 HEMATOLOGY ANALYZER ........................................ 115
9 TROUBLESHOOTING ................................................................................................................ 117
9.1 TROUBLESHOOTING CHECKLIST FOR HEMOLYZER 5 HEMATOLOGY ANALYZER .................................. 117
9.1.1 Visual inspection .............................................................................................................. 117
9.1.2 Powering up the system .................................................................................................. 118
9.1.3 Checking the software adjustments................................................................................. 118
9.1.4 Checking the Hardware adjustments............................................................................... 119
9.1.5 Run a Self-test ................................................................................................................. 120
9.1.6 Run Blank measurements ............................................................................................... 120
9.1.7 Run Control measurements ............................................................................................. 121
9.2 MECHANICAL PROBLEMS ........................................................................................................ 122
9.2.1 General guidelines to overcome motor or moving part related problems ....................... 122
9.2.2 Sample Rotor (SR or BOB) failures ................................................................................. 123
9.2.2.1 SR gives grinding noise and / or SW displays SR error messages ....................................... 123
9.2.2.2 SR error appears during initialization process:...................................................................... 123
9.2.2.3 The SR does not turn into the analyzer even with open front panel ...................................... 123
9.2.3 Needle mechanics, Vertical motor (MVert) problems ...................................................... 123
9.2.3.1 The needle carriage keeps dropping back (down) at initialization ......................................... 123
9.2.3.2 MVert cannot reach the optosensor (Up or Down) ................................................................ 123
9.2.4 Shear Valve (SV) related errors ...................................................................................... 124
9.2.4.1 SV error at the first startup .................................................................................................... 124
9.2.4.2 Grinding noise after SV cleaning, (after SV reinstallation) .................................................... 124
9.2.4.3 SV leakage............................................................................................................................ 124
9.2.5 Dilutor errors .................................................................................................................... 125
9.2.5.1 Dilutor is making noise .......................................................................................................... 125
9.2.5.2 Dilutor is leaking.................................................................................................................... 125
9.2.6 A tube comes off of a valve ............................................................................................. 125
9.2.7 Priming problems ............................................................................................................. 125
9.2.7.1 The analyzer would not prime liquids .................................................................................... 125
9.3 ELECTRONICS RELATED PROBLEMS ......................................................................................... 126
9.3.1 Touch screen / display errors .......................................................................................... 126
9.3.1.1 No image on display ............................................................................................................. 126
9.3.1.2 Touch sensitive surface not working ..................................................................................... 126
9.3.1.3 Touch (click) is inaccurate..................................................................................................... 126
9.3.1.4 Screen image is not normal, some parts of the software screen is not visible ...................... 126
9.3.2 Communication errors ..................................................................................................... 127
9.3.3 The analyzer does not power on ..................................................................................... 127
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9.3.4 I C errors displayed at startup ......................................................................................... 128
9.4 USEFUL INFORMATION AND TIPS.............................................................................................. 128
9.4.1 High PLT background ...................................................................................................... 128
9.4.2 Fast Starting up and Shutting down ................................................................................ 128
9.4.3 Removing bubbles from the Flow cell.............................................................................. 128
9.4.4 Removing the DimmBoard .............................................................................................. 129
9.4.5 Listen the sounds of the instrument ................................................................................ 129
9.4.6 Replacing small diameter tubes ...................................................................................... 129
9.4.7 Swapping the pumps ....................................................................................................... 129
9.4.8 Draining the reservoirs .................................................................................................... 129
10 MAINTENANCE .......................................................................................................................... 130
10.1 USER MAINTENANCE .............................................................................................................. 130
10.1.1 Daily maintenance ....................................................................................................... 130
10.1.2 Weekly maintenance ................................................................................................... 130

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10.1.2.1 Shear Valve cleaning ............................................................................................................ 130

10.1.2.2 Cleaning the wash head ....................................................................................................... 130
10.2 PREVENTIVE MAINTENANCE.................................................................................................... 130
10.3 FLOW CELL CLEANING ............................................................................................................ 136
11 REMOVAL AND REPLACEMENT PROCEDURES ................................................................... 139
11.1 OPENING THE INSTRUMENT..................................................................................................... 139
11.2 SHEAR VALVE ASSEMBLY ....................................................................................................... 140
11.3 XY UNIT ................................................................................................................................ 141
11.4 SAMPLE ROTOR ..................................................................................................................... 144
11.5 DILUTORS .............................................................................................................................. 145
11.5.1 Syringe replacement .................................................................................................... 145
11.6 TCU MODULE........................................................................................................................ 146
11.7 VALVE BLOCK ........................................................................................................................ 147
11.8 PRE-AMPLIFIER BOARD .......................................................................................................... 148
11.9 PUMP ASSEMBLY ................................................................................................................... 148
11.10 HARDWARE MODULE .......................................................................................................... 150
11.11 LASER HEAD ASSEMBLY ..................................................................................................... 151
11.11.1 Reinstalling the Laser Head: ....................................................................................... 154
11.12 MEASURING BLOCK............................................................................................................ 154
11.12.1 Aperture removal: ........................................................................................................ 154
11.12.2 WBC aperture removal: ............................................................................................... 155
11.12.3 Measuring Chamber removal: ..................................................................................... 155
11.12.4 HGB head removal ...................................................................................................... 156
11.13 DISPLAY UNIT..................................................................................................................... 156
11.14 HEMOLYZER 5 FLUIDICS V2.1 - SV IN CHAMBER POSITION ................................................... 158
11.15 HEMOLYZER 5 FLUIDICS V2.1 - SV IN NEEDLE POSITION ...................................................... 159
11.16 TUBINGS............................................................................................................................ 160
12 APPENDIX .................................................................................................................................. 171
12.1 RECOMMENDED KIT OF TOOLS ................................................................................................ 171
12.2 HOW TO SEND .RP FILES TO ASSESSMENT OF ANALYZER PERFORMANCE ................................... 171
12.3 HOW TO USE THE „COLLECT” FUNCTION OF THE HEMOLYZER 5 HEMATOLOGY ANALYZER ........... 172

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Hemolyzer 5

1 INTRODUCTION
1.1 Who should read this manual
This Service manual is intended for trained technicians or service engineers to be able to
maintain and repair Hemolyzer 5 automated hematology analyzer. It contains the functional
descriptions of the analyzer, operation of the fluidic system, adjustments and settings, and
very important information for the Service Personnel about the service operations and
possible problems.

If equipment operation is different from the manufacturer’s specifications

and intended use, the protection provided by the equipment may be
impaired.
Misuse of equipment or use other than its intended purpose will invalidate
conditions of warranty. Accuracy and precision may also be impaired.
Follow the service procedures described herein to guarantee functional
operation after repairs and maintenance.

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2 For Your Safety

2.1 Special Symbols Used In This Manual
Label Meaning Explanation

Blood samples and analyzer waste are potentially infectious

Biohazard
materials.

Corrosive Reagents may cause corrosion or skin irritation.

Warning General warning of possible hazard conditions.

Sharp needle warning The sampling needle may be a hazard to the operator.

2.2 General Precautions

The sampling needle and other components inside the analyzer may cause injury, or can
get damaged if handled incorrectly. Only certified personnel should open the covers.
Running measurements with opened cover is not recommended due to the risk of
possible injury. Always wear safety gloves while performing maintenance actions.

The analyzer weighs 35kg (~77lbs). Please do not attempt to move it alone. The analyzer
should always be moved by two persons holding the analyzer by its sides in an upright
position.

Always use safe lifting procedures when lifting the analyzer.

Make sure to retain the original packaging material for safe transportation and storage in
the future.

To prepare the analyzer for shipping, storage or extended periods of inactivity, please
drain the reagents and repackage the Hemolyzer 5 in its original packaging. Do not
expose the Hemolyzer 5 to direct sunlight, extreme temperature or humidity (>80%).

The analyzer operates with chemically and biologically active reagents. Physical contact
with these reagents should be avoided. Please read reagent descriptions carefully for
possible emergency actions.

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Hemolyzer 5

To ensure reliable operation and reliable results:

• Only genuine Analyticon reagents should be used
• Required service maintenance should be performed as recommended in this
manual
• Only genuine Analyticon service materials and spare parts should be used for
repairs

Genuine reagents and service materials and spare parts are available from Analyticon.

Only Analyticon certified service personnel that have successfully completed the
‘Hemolyzer 5 Service Training’ program are qualified to service the Hemolyzer 5 analyzer.

Before operating Hemolyzer 5 analyzer, all operators should complete an ‘Hemolyzer 5

Operator Training’ program. This program is offered by Analyticon or by Analyticon
certified service personnel.

Replacement materials or spare parts (tubes, valves, etc.) which might have been in
contact with human blood or reagents should be handled as a potentially biologically
hazardous and chemically dangerous material. All applicable laws and regulations must
be observed in the handling and disposal of these materials.

Hemolyzer 5 is designed for laboratory operation. Mobile operation is not supported.

Operate Hemolyzer 5 within the ambient temperature range described in User Manual
section 2.4.

The IVD equipment complies with the emission and immunity requirements described in
relevant part of the IEC 61326 series.

This equipment has been designed and tested to CISPR 11 Class A. In a domestic
environment it may cause radio interference, in which case, you may need to take
measures to mitigate the interference.

Electromagnetic environment should be evaluated prior to operation of the device.

This analyzer contains electronic components. Please handle electronic waste

adhering to local or federal regulations.

CAUTION – Use of controls or adjustments or perfomance of procedures other than

those specified herein may result hazardous radiation exposure.

2.3 Environmental Factors

Operate Hemolyzer 5 within the ambient temperature range of 15-30°C (59-86°F) and a
relative humidity range of 10% - 80%. Optimum operating temperature is 25°C (77°F).

Hemolyzer 5 should be stored within the temperature range of 5-35°C (41-95°F). Avoid
exposing the analyzer to direct sunlight or to extreme high or low temperatures. If the
analyzer was subjected to extreme temperatures during shipment or storage, it must be

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placed for at least two hours in a room whose temperature is within the operational range
before installation or use.

Reagents should be stored at a temperature range of 15-30°C (59-86°F). Reagents may

experience a temperature range of at most 5-35°C (41-95 °F) for a maximum of 3 days.

The analyzer should be placed in a well-ventilated location. Operation at an altitude above

2000 meters (6560 ft) is not guaranteed.

2.4 Electrical Requirements

The analyzer should only be operated from a wall outlet meeting these power input
requirements:

• 100-127VAC or 200-240VAC; 47Hz to 63Hz

• Power Consumption: maximum 400 VA (including power of the auto-sampler)
Please ensure that the wall outlet is also capable of supplying the power consumption of any
additional devices (such as a printer).

Use only the power cord supplied with the instrument. Avoid using extension cords.
Hemolyzer 5 comes with a power cord appropriate for your power system. Proper use of the
appropriate power cord assures adequate grounding of the system. If the power is not
reliable, contact your representative for options such as the installation of an external UPS
module.

Failure to properly ground the Hemolyzer 5 bypasses important safety features

and may result in electrical hazard.

The instrument should not be placed near potentially interfering devices capable of emitting
radio frequencies (e.g. radio or television transmitters/receivers, radars, centrifuges, X-ray
devices, fans, etc.).

This analyzer is designed to be safe for transient voltages to INSTALLATION CATEGORY II

and POLLUTION DEGREE 2.

2.5 Suggested on-line UPS

It is recommended to use a UPS (uninterruptible power supply) in line with the power input in
the following circumstances:

• if the main power is fluctuating

• in case of power black out happens frequently

Power consumption of the analyzer and optional Auto-sampler is 400VA max. If there is a
power failure, the analyzer should be able to complete the function in progress and perform a
Windows shut-down to secure data.

In order to provide the necessary power, it is recommended to use a UPS with the following
minimum specifications: 600 VA provides uninterrupted power for 10-15 minutes.

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Hemolyzer 5

Analyticon does not supply UPS for Hemolyzer 5. Therefore, Analyticon is not taking
responsibility or liability for the operation of Hemolyzer 5 running on UPS.
If you need further information, please, contact technical support of the UPS vendor.

2.6 Proper Placement of Hemolyzer 5

It is important to install the instrument in a suitable location, a poor location can adversely
affect its performance:
• Select a well-ventilated location near a power source and close to a suitable drain.
• Place the unit on a clean, level surface. Leave at least 0.5 m (18 inches) space on
both sides and above the instrument to access pneumatics.
• A minimum of 0.2 m (8 inches) must be maintained between the rear panel and the
wall to allow for heat dissipation and tubing clearance.
• Ensure there is enough clearance in front of the analyzer to open front panel. Allow
enough space if you want to use optional external keyboard, mouse or bar code
reader.
• Your selected location should allow placement of the reagents in an unobtrusive
location below the laboratory bench that the instrument is placed on. Placement
below the laboratory bench also allows for storage of a spare set of reagents. Never
place the reagents above the Hemolyzer 5 analyzer.

Placing reagents above the Hemolyzer 5 analyzer could result in reagent overflow and
spilling.
Always put the diluent tank on the floor, never to the same level where the analyzer is.

1. Figure: Spacing of Hemolyzer 5 with Auto-Sampler and reagents

2.7 Weight Requirements

Hemolyzer 5 weighs 35 Kg (77 lb) without the Auto-sampler.

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Hemolyzer 5 with optional Auto-sampler weighs 47Kg (104 lb). Adding an external keyboard,
printer, documents, etc. can bring the total weight up to 60 Kg (132 lb).

Please select a table, laboratory shelf, or other location which can support the weight of the
Hemolyzer 5 with all accessories and it is free from vibration.

To allow reliable operation and to provide a safe working environment, make sure that
the table supporting the unit is stable enough to carry the weight of the instrument and
accessories.

2.8 Waste Disposal

Waste of Hemolyzer 5 analyzer contains human blood and reagents that are chemically and
biologically active, and should be considered to be a potential infection and biohazard threat.
Safe laboratory practices must be followed including the use of personal protective when
operating Hemolyzer 5 and handling blood, reagents, and waste.

System waste should be handled as a potentially bio hazardous material. All

applicable laws, regulations, and laboratory practices should be followed in the
handling and disposal of waste.

2.9 Emergency Situations

Always follow all applicable laws and regulations with regards to emergency situations.

If Hemolyzer 5 needs to be powered off due to an emergency situation (like fire,

thunderstorm, etc.), follow the procedures in User Manual section 7.3.4.

In case of fire, do not use water to extinguish the fire unless Hemolyzer 5 is disconnected
from the electrical network!

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3 Structure of the analyzer

Please, refer to the User’s manual for details on opening the front and side covers, and parts
contained there.

3.1 Components located on the front panel

The display panel and related components are covered with a metal plate, to avoid electronic
interference causing problems, and to protect sensitive electronics.

3.1.1 Display screen and the touch sensitive surface

Hemolyzer 5 uses a color LCD with LED backlight touchscreen as main user interface.

The built-in touchscreen is a 4 wire resistive type. It is interfaced to the mainboard by a USB
controller.

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3.1.2 Start Button and LEDs

START Button board is mounted on the front panel. It contains a start button and two LEDs
to illuminate the START button. The LEDs are bicolor: red and green LEDs. When both red
and green are switched on, the resultant color is yellow.

3.2 Components accessible after opening the front panel

3.2.1 Shear Valve Assembly

Shear Valve assembly consists of the following parts:

• Shear Valve holding plate,

• Moving mechanism,
• Stepper motor,
• Ceramic Shear Valve,
• Shear Valve optoboard.

3.2.2 Sample rotor

Hemolyzer 5 hematology analyzer has a sample rotor for safety and more precise sample
handling.

15
Hemolyzer 5

Sample rotor unit uses a stepper motor, connected to the PPB through the XY opto board.
The rotor has micro switches for positioning.

The unit blocks itself in the home and end position with mechanical parts and has a special
cap that prevents the damage of the electronic and mechanic parts caused by any fluid.

Tube adapter Micro switches for positioning

3.2.3 Main Dilutors

Hemolyzer 5 has two separate main dilutor modules. There are two stepper motors, a
common motor opto board, four syringes and piston rods with gear transmission in each
module.

The software identifies and moves four dilutors (Dil1, Dil2, Dil3, Dil4), each dilutor consists of
two syringes. Dilutor 1 and 2 is in Dilutor module 1, dilutor 3 and 4 is in Dilutor module 2, as
represented in the picture below.

Main Dilutor Module Main Dilutor Module

Dil 1 Dil 2 Dil Dil

16
 Servicemanual

3.2.4 Dilutor opto sensor boards

Dilutors have their own separated opto-boards, located
directly in the units. On the front side of the optoboards
there are 4 optosensors and 4 control LED-s, on the
back side are mounted the motor connectors and the flat
cable connector.

3.2.5 Tube organizer

This is the component that provides arrangement for the tubes going from
the valves to the dilutor, shear valve, optical head and Temperature Control
Unit. It is intended to allow easy identification and access to tubes for
service related cleaning procedures.

Four tubes have metal through tubes to allow easier removal and
replacement when necessary in case the TCU needs to be cleaned and
rinsed.

3.2.6 Temperature Control Unit

Temperature Control Unit provides the necessary temperature for reagents used to create 4-
DIFF sample. It is able to heat or cool the sample and reagents, depending on the ambient

17
Hemolyzer 5

temperature. It contains a massive, molded aluminum block. There are multiple, curved and
interconnected stainless steel tubes (fluid paths) inside the TCU to ensure proper capacity.

Parts of TCU:

• in-line mixer, for mixing and homogenizing sample and specific reagents.
• Temperature Controller Board, to monitor the temperature of the aluminum block by
power transistors (heating elements) or Peltier cooling circuitry
• thermal insulation for temperature stability.

3.2.7 Laser head

Laser head is used for optical measurements of 4-DIFF and BASO parameters.

3
1. LASERDRV BOARD

2. LENS ASSEMBLY

3. OPTSENSE BOARD

4. SAFETY SWITCHES
1
5. SAMPLE INJECTOR

6. OPTICAL FLOW CELL

7. OPTICAL CABLE

2 4
6 7
5

Black anodized aluminum box works as safety cover. Two different micro-switches protect
the technician against direct exposure to beam:

• When cover holder screws are removed laser activity will be switched off by laser
driver board.
• To turn on laser again, put the cover back, and fasten the screws so that both
switches are closed and the low-level SW should be restarted.
Optical measurement unit has a sheath and sample inlet, and a waste outlet from fluidic side,
laser driver cable, analogue output cable and auto-alignment cable from the electronics.

18
 Servicemanual

3.2.8 Laser Head Assembly + Sample Injector

Laser Head Assembly is responsible for detecting the 4diff and BASO cells from the
prepared blood sample.

The laser head is responsible for the precise illumination of the sample. The temperature
controlled laser diode source is mounted on a huge brass basis which holds it tight and also
responsible for the cooling. Just beside the laser diode aspheric and achromatic lenses
performs the focusing of the laser beam.

For accurate and stable adjustment, this

optical unit is mounted on an aluminum
block with a sphere-to-cone contact.
Powerful springs hold the unit in place.
Using stainless steel levers, the direction of
the laser can be rotated around two axes.
This means, the laser spot on the flow-cell
can be tilted in horizontal and vertical
directions. Precise linear motion stepper
motors perform the accurate setting of the
laser.

Coarse adjustment of the laser can be made by setting the rough adjustment screws.

The flow-cell unit is responsible for the

precise flow control and the pre-detection
of the pulses. An optically clear flow-cell
(cross section for flow is 0.25x0.25mm) is
mounted with 2 side cone-to-cone
connection into its holder. Below the flow-
cell an injector helps to insert the sample in
the middle of the main sheath streamline.
The sheath puffer opened to free air
supplies the sheath and the sample flow.

Cross section of the flow cell – sample

injector assembly
The size and position of the sampler needle, the different tube resistance of the sheath and
sampler lines and the applied vacuum result an about 40nm wide sample stream in the
middle of the flow-cell.

Concentric ring shaped optical cable is also mounted to the flow-cell unit. This collects the
scattered light from the cells, and transfers it to the detection unit. Just before the insertion
zone of the optical cable, there is a laser dump for filtering direct laser beam.

19
Hemolyzer 5

3.2.9 Laserdiode Driver Board

The LASERDRV board is based on a PIC 24FJ64GA004
(Microchip) microcontroller that performs all the control
functions of the laser diode and the communication with the
LS-DACQ (DimmBoard).

The LASERDVR board incorporates a laser diode with built-in

APC (automatic power control). The laser power can be set by
a programmable digital potentiometer in the 1.8 – 5.5 mW
range. The laser can be switched on and off from program.

The laser diode temperature can be set, and then the

microcontroller will keep the diode temperature at the preset
value. As the temperature control uses only heating (2 transistors), stable diode temperature
can be maintained only above room temperature.

The LASERDRV board provides laser safety functions too. When removing the laser cover,
the safety switches cut off laser power immediately. In order to turn the laser on the cover
must be in replaced and the instrument must be turned off and back on.

The controlling interface between the LS-DACQ and the LASERDRV is I2C.

3.2.10 Pin Photodiode and Amplifier (OPTSENSOR_2v1)

When a blood cell in the diluted and lysed
blood stream crosses the focused laser
light, the light scatters and two pin
photodiodes sense the scattered light.
The current, generated by the two
photodiodes has to be handled
separately, so two independent analog
channels are used on the OPTSENSOR
board. The photodiode’s current is
amplified by one transimpedance amplifier
per channel.

Then the DC level is removed, and more amplification is applied. The DC level of output 0
and 1 (AOUT0, AOUT1) are clamped to +1V. The output span is 2V, so the output range is
+1V..+3V. This is appropriate for the A/D converter on the LS-DACQ, that has a 2V input
voltage span, only the offset has to be set according to the A/D’s requirement (+1.5V..+3.5V).
The 3rd analog channel (AOUT2) outputs the DC level of channel 0, amplified by 2. It can be
used for the auto alignment of the laser. The OPTSENSOR card contains the connectors and
LEDs for AutoAlignment motors, as well as position sensing.

20
 Servicemanual

3.3 Left side

3.3.1 Valve boards
The Hemolyzer 5 system incorporates 44 valves. The
valve boards are controlled by two Pneumatic and Power
Board (PPB) boards. The used valve boards are the
following:

2x Valve_1-5
2x Valve_6-12
2x Valve_13-18
2x Valve_19-22

4 valves are not used, and thus not installed. Valve coils are not installed on valve driver
boards behind either.

Note: Valves can be replaced individually, also the coils can be unsoldered and replaced but
valve board cannot be replaced individually. We only provide the whole valve assembly 40
valves as a spare part.

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Hemolyzer 5

3.3.2 WBC/BASO Preheater Assembly

WBC/BASO
preheater
assembly

The WBC/Baso preheater assembly is located on the

right side of the impedance measurement block, near
the WBC/BASO counting chamber. It consists of two
stainless steel holding plates, thermal insulation,
heater block (see illustration below) and electronic
board with heating transistors.

Thermostated on 36-37 °C and its function is to heat

the WBC/BASO dilution for better lysing. Diluted blood
and lyse reagent is pushed through the tubing of the
heater block, diluent used for rinsing and cleaning the
chamber
also passes through this assembly thus the chamber
itself is warmer than the ambient temperature.

3.3.3 Counting chamber with electrodes and measuring aperture

Impedance method is used for determination of volume and number of cells. In this method a
known volume of dilution is drawn through a small aperture. Constant current is passed
through the aperture from one side to the other. When a cell passes through the aperture, it
causes a change in resistance, which generates a voltage pulse. The amplitude of the
voltage pulse is proportional to the ratio of cell volume per aperture volume. This is used to
determine the volume of cells. The number of cells can be obtained by counting the pulses.

In the instruments there are two cell-counter chambers: separate for RBC and WBC.

In the RBC chamber the instruments counts red blood cells, and uses no lyse at all in this
chamber. It has a smaller draining outlet made of plastic and its measuring tube contains a
70 µm-sized aperture.

In the WBC chamber the instrument counts all kind of WBC. It has a measuring tube with an
aperture size of 80 µm and a bigger draining outlet made of PTFE (Teflon).

22
 Servicemanual

Both chambers have a reference electrode and a draining outlet. The next picture shows the
chambers and the measuring tubes. The aperture is made of ruby and it is molded into the
measuring tube.

RBC Reference WBC

chamber electrode chamber

Reference
electrode

RBC measuring tube WBC measuring tube

with the aperture (70µm) with the aperture (80µm)
(no grooving) (1 grooving) Aperture

O-ring

3.3.4 HGB Measuring Head

Hemoglobin head is placed around the WBC measuring chamber in the instrument.

It contains: a light source (LED) at 540 nm wavelength and Photo Detector (TSL235). The
Photo Detector converts the light to frequency. The HGB concentration is a logarithmic
function of this frequency measured by the FPGA circuit of the COMB card.

TSL235
LED

Connection to the
amplifier

The analyzer performs enhanced Hemoglobin measurement technology for HGB

23
Hemolyzer 5

measurement. The output of HGB head is frequency (TSL235 detector is light to frequency
converter). A digital counter in the FPGA circuit counts this signal.

This counter counts up while the LED is on and counts down while the LED is off, the LED
and the counter directions are switched with a 250 Hz signal. This method provides “real time
backlight correction”, which makes the HGB measurement more precise in changing
backlight environment situation as well.

There are two kinds of HGB measurements:

• Sample measurement (before RBC counting)

• Diluent measurement (in WBC washing phase)

The HGB result is calculated from these measurements by:

HGB ≅ log (CNTdiluent light / CNTsample light)

Due to backlight correction, Hemolyzer 5 is less sensitive to incident light changes.

3.3.5 Cell counter Amplifier Board

Amplifier board includes its own voltage regulators, connection interfaces to HGB head, to
high voltage board and to LSDACQ board. There is a current generator circuit on this board,
which works from 50V measuring voltage (generated by the High Voltage Board) and the
probe voltage (DC) is amplified with a voltage follower (output: ELV). Nominal measuring
current is 870 µA.

Connection to:
CSA1 on COMB

Connection to:
HVB

Connection to:
COMB (DIGIO)

24
 Servicemanual

Connection to
the electrodes

Offset
potentiometer

Connection to
HGB head

Amplifier board includes one input connector for each measuring chamber (measuring
electrode). There is one opto switch (OPT1) and a relay (REL1) to connect high voltage to
one of the probes with HSW signal and to isolate the input of the amplifier. Test circuit allows
generating test pulses (with TEST and PLS signals through Q1, Q2 FETs) for checking
proper operation of each amplifier channel.

Amplifier board includes a 3-stage main amplifier channel, which gains input signal to the
0...5 V range (this is the input range of the A/D converter (IC10), which is placed on the
LSDACQ card). The RSW signal (with Q8 transistor) changes the input electrode through
REL2 relay. There is an offset potentiometer, P1 in the third amplifier stage, manufacturer
sets the correct offset voltage.

The Amplifier offset adjusted automatically by the SW. The service personnel can adjust it
manually by giving the offset value through the SW in service menu. If the auto offset is

cannot put the value in range the amplifier board is defective needs to be replaced.

3.3.6 Pressure sensor board

1 2 3

The Pressure Sensor Board incorporates three differential pressure sensors. The pressure
values are read out by the LS-DACQ card through I2C interface. The sesors are responsible
for reading pressures of:

25
Hemolyzer 5

(1) vacuum for impedance count (“chamber”)

(2) vacuum used for draining chambers (“drain”)
(3) big puffer vacuum for optical aspiration (“big puffer”)
Upon replacing the pressure meter board, it is recommended to adjust pressure meter
offset

Hemolyzer 5 is equipped with sensitive pressure meters. These pressure meters are used to
monitor and control measurement, and chamber draining processes. In some cases, the
pressure meters can develop an offset value that can cause “Timeout” or “Chamber draining”
errors. The new analyzer software can compensate for this offset value drift.

Locate the “Start adjustment” button in the lower part of the screen – and tap it. The SW will
perform a process, where the pressure meters will be “vented” to atmospheric pressure –
and this value will be noted by the SW. This will minimize the occurrence of the “Timeout” or
“draining” related errors. (On the screen you will see the actual value of the pressure meter,
corrected values can be seen only if a Self-test is performed after the adjustments).

If the above process fails…

1. Perform a Low Level Reboot (service menu, service functions) to get low level PC in
a default known state
2. Run Test Function 11
3. Low Level Reboot 2 times
4. Perform Pressure Sensor Offset function (Service Menu, Adjustments)
5. Perform a 3-measurements based Calibration using normal level control blood

3.3.7 Reagent and Vacuum buffers

The lower part of the assembly plate holds six plastic cylinders, called chambers or buffers.
The last one (marked as ‘1’ in the image) holds vacuum used in the optical measurement

26
 Servicemanual

process (for moving the solution). This vacuum is always adjusted according to measured
atmospheric pressure.

The four next chambers are used as temporary storage volumes for individual reagents for
one measurement cycle. The first two (in the front, marked as ‘5-6’ are linked in parallel to
double the capacity. Chambers 2-5 have internal floating (magnetic) level sensors. The
volume of chambers 2-6 allow one measurement cycle to be performed after the reagent low
warning.

3.3.8 Reagent Sensor Board

The Reagent Sensor Board monitors the liquid level in the reagent puffers continuously. If
the liquid level too high (puffer full), it signals to the PPB2 board and the software can stop
the filling process.

3.3.9 Opening the valve assembly plate

The plate holding the valves and the measurement block can be folded out of the analyzer.
The plate is secured with 2 screws, similar to the ones securing the side panels. The screws
are designed to stay on the analyzer to avoid losing them.

3.3.10 Vacuum buffer

The glass chamber is located on the internal side of the assembly plate, and is used to store
the vacuum for the optical measurements.

27
Hemolyzer 5

3.3.11 Pneumatic and Power Boards (PPB1 and PPB2)

PPB card contains the main power regulator circuits, valve and motor driver circuits and
other connections for the fluidic and pneumatic system’s parts.

Power system generates +5V (Digital power), +8V (Printer power) and +12V (Motor and
valve power) from the single +12V DC input signal.

Motor driver part consists of six separated PIC micro-controllers with power drivers.
Horizontal, Vertical and Sample rotor motors have one combined ribbon cable connection.
Main Dilutor (with two motors) and Micro-dilutor have separated connectors.

Valve driver section is based on the valve driver PIC micro-controller and three 8-bit,
powered output shift registers (with built in protection diodes) and there are two common
ribbon cable connections for the 4 valve boards. The pump assembly has a separated
Darlington driver circuit for more reliable operation.

All microcontrollers have 2 LEDs: a yellow one and a green one.

The yellow one indicates motor moving or holding and active valve or pump moving. (it
means current flows into motors, valves or pump)

The green one has 3 states:

• dark: (after initialization phase) error state,

28
 Servicemanual

• blinking: communication in progress - normal state

• on (just lighting): OK - normal state

PPB boards have a small board on the bottom called PPB CON board. This board connects
the PPB to the LSDACQ board.

3.3.12 Pump assembly

Pump assembly generates regulated vacuum and drains the fluidic system. There are two
pumps in the system. They are connected to the two PPB boards.

For further information see chapter 11.9.

29
Hemolyzer 5

3.4 Right side

3.4.1 XY unit
This unit contains slides to move the sample sampling
needle in Horizontal and Vertical directions, two stepper
motors, XYR opto board, opto wheel, washing head and
the sampling needle. It moves the needle to the desired
position: from sampling position, to washing head, and
by means of the washing head it press the sample tube
during the sampling process.

Both stepper motors have optical end-switch sensors for detecting these positions. These
are required for correct initialization and error detection. All sensors have status LEDs to
show actual conditions.

The Vertical motor works with a special opto wheel for detecting home & end positions. See
the Adjustment section of this manual to place this wheel to the proper position.

Greasing of the horizontal/vertical guiding rods should be done regularly using photolube
A598.

It is recommended to check and repeat greasing of guiding rods every year, or after 30000
measurements. See section 6.1.1.1.

30
 Servicemanual

3.4.2 XYROpto Board

Horizontal and Vertical motors and the Sample Rotor unit have a common Opto-board.

Sample Motor
Rotor opto connections

Horizontal Horizontal Vertical Vertical opto

opto sensors status LEDs status LEDs sensors

The other (rear) side of the board contains the connection for the Sample rotor and a ribbon
cable connection to PPB#

3.4.3 Sampling needle

Sampling needle is assembled in the H&V moving unit and it makes the piercing and the
sample aspirations. Correct setting of sampling needle is necessary and very important (see
Chapter 6. Adjustments).

Be careful, the needle is very sharp and it can cause injury!

3.4.4 Blood sensor

Blood detector is a component that will allow determining if the sampling process was
successful. It is measuring the length of the sample. If the sample is found short, a “sampling
error” is going to be displayed. It also has an emergency mode in case the blood detector
failed. In this case, the analyzer is not going to consider blood detector data, but it will move
the sample to a predefined position. Both parts of the sampling control must be adjusted.

31
Hemolyzer 5

3.4.5 Wash head

Wash head is located at the bottom of the XY unit and it is for cleaning
the outer surface of the sampling needle. This washing process is
made with diluent reagent and the fluid is drained by the pump. The
arrows on the picture show the direction of diluent flow during
sampling needle washing.

Replace washing according Preventive Maintenance procedure .

3.4.6 Processor unit (LS-DACQ board with DimmBoard)

The LS-DACQ board is based on a credit card size embedded PC (DimmBoard). The LS-
DACQ implements the following functions:

- Receiving commands from the Analytical Unit,

- Blood sampling and sample handling control,
- Motor and valve control,
- Measurements control,
- Amplifying and A/D converting of 4 input channels simultaneously,
- Data preprocessing,
- Transmitting data to the Analytical Unit,
- Interfacing the Laser Driver and the TCU,
- Interfacing the Start Button and Status LEDs,

The LSDACQ board incorporates a credit-card sized PC, named DimmBoard. The
processor on the DimmBoard is a 600MHz Pentium-class core, with 256Mbytes on-board
RAM, and SD card controller. This SD card contains the Low Level SW of the system which

32
 Servicemanual

handles all the measuring processes. The Low level SW can be updated from the service
software update menu.

Flash (BIOS)

Vortex86DX
CPU

Edge
MicroSD
Card

Flash (BIOS)

FPGA interface

The FPGA is connected through the ISA bus of the DimmBoard. The FPGA implements
several registers, and the DimmBoard can reach these registers as memory-mapped.

Buffer memory

During optical measurement, a vast amount of data has to be transferred to the Analytical
Unit through the USB connection. It is necessary to use a buffer memory to store the data
temporarily, because the USB transfer speed may not be enough to transfer the data real-
time. The LS-DACQ uses a 2 MB SRAM memory as buffer. The SRAM is organized as FIFO
(first-in first-out memory).

Connection with the Analytical Unit

The Analytical Unit is connected to the Data Acquisition System by a full-speed USB
interface. The USB interface is implemented by a FT2232L USB chip. The USB chip
implements 2 channels, one of them works as a virtual COM port, the other is a parallel data
channel. The VCOM channel is used as a command channel, through which the Analytical

33
Hemolyzer 5

Unit sends commands to the Data Acquisition System. The measurement data are sent to
the Analytical Unit through the parallel data channel.

FPGA

The FPGA is a Xilinx Spartan II type. The FPGA preprocesses the digitized data of the
optical measurement and sends them to the Analytical Unit through the USB. It preprocesses
the volumetric impedance measurement data too, produces data packets, and sends them to
the Analytical unit.

FPGA controls the SRAM, to make a FIFO data buffer of it. Implements an I2C interface to
control the PPB (Pneumatic and Power Board) boards.

Implements a MDA display for service purposes.

FPGA configuration

As the FPGA is SRAM based, it is configured after every power on. The program is stored in
a Xilinx configuration flash memory. The flash memory can be programmed through a JTAG
port by a Xilinx Parallel Cable or in-circuit from the Hemolyzer 5 program.

Analog inputs

The LS-DACQ has 4 analog inputs (AIN0-AIN3). AIN0 and AIN1 for the 2 channel optical
measurement, AIN2 is for the auto alignment, AIN3 is for the volumetric impedance
measurement. The input signal range for AIN0 and AIN1 is 1V..+3V, the DC offset is
programmable, to adapt it to the A/D converter’s input level of +1.5V..+3.5V. The input signal
range for AIN2 and AIN3 is 0V..+5V, and the gain is programmable.

A/D converter

The A/D converter is a THS1007 type, four channel A/D, manufactured by Texas. The input
voltage level is +1.5V..+3.5V, so AIN0 and AIN1 can be connected after DC level setting, but
AIN2 and AIN3 channels require not only level conversion, but attenuation. The input
amplifier and level converter perform these functions. The sampling frequency is 1 MHz on
all input channels.

Temperature and Power Voltage Measurement, I2C Interfaces

The LS-DACQ card incorporates a PIC microcontroller that is connected to the DimmBoard
through the FPGA. The PIC with a built-in I2C controller controls the Laser Driver Board, the
Opto Sensor Board, the Pressure board and the TCU.

The PIC measures the board temperature and there is an input for measuring an external
temperature. The PIC measures the board power voltages and the DimmBoard battery
voltage.

Connectors

POWER Connector

The LS-DACQ board is powered directly by the PC power supply through a standard IDE
power connector. It supplies the board with +5V and +12V.

34
 Servicemanual

Power voltages on the LS-DACQ board:

+12V – Provides +12V to the Cell Counter Amplifier board (AJ5-MEAS), Pin Photodiode and
Amplifier board (OPTSENSOR), High Voltage Board (AJ-HVB) and the Laser Driver board
(LASERDRV).

-12V – Generated by a DC-DC converter. Not used on the LS-DACQ, output to the Cell
Counter Amplifier board (AJ5-MEAS) and the Pin Photodiode and Amplifier board
(OPTSENSOR).

+5V – Supply voltage to the DimmBoard, and to some other logic.

+3V3 – It is generated from the +5V by a low dropout voltage regulator. Supply voltage to the
3.3V logic, among them to the FPGA IO pins.

+2V5 – It is generated from the +5V by a low dropout voltage regulator. FPGA core voltage.

PPB Connector

The PPB connector connects the 2 Pneumatic and Power Boards (PPB) to the LS-DACQ
board.

DIGIT IO Connector

The Cell Counter Amplifier board (AJ5-MEAS) is connected to the LS-DACQ board through
the DIGIT IO Connector.

HVB Connector

The HVB connector connects the High Voltage Board (AJ-HVB).

ANALOG INPUT Connector

The ANALOG INPUT connector connects the Pin Photodiode and Amplifier board
(OPTSENSOR) to the LS-DACQ board.

AINCH2 Connector

The AINCH2 connector is not used in the actual design.

AINCH3 Connector

The AINCH3 connector connects the analog output of the Cell Counter Amplifier board (AJ5-
MEAS) to the LS-DACQ board.

XILINX JTAG Connector (not used on the field)

The FPGA configuration flash memory can be programmed through this connector by a Xilix
Parallel Cable.

DEBUG DISPLAY Connector (not used on the field)

Only for test and debug purposes.

LASER DRIVER Connector

35
Hemolyzer 5

The LS-DACQ board provides power and an I2C interface to the LASERDRV board through
the LASER DRIVER connector.

PRESSURE Connector

The LS-DACQ board provides power and an I2C interface to the PRESSMEAS board through
the PRESSURE connector.

TCU Connector

The LS-DACQ board provides an I2C interface to the TEMPCTRL board through the TCU
connector. As the TCU requires high current power, the TCU is powered directly by an IDE
connector of the PC power supply.

FRONT PANEL Connector

The FRONT PANEL connector connects the Front Panel board (STARTBUT) to the LS-
DACQ board.

FLOPPY Connector

A standard 3.5” floppy drive can be connected. It is used only for test and debug purposes.

KEYBOARD Connector

A standard PS2 keyboard can be connected to the DimmBoard’s keyboard interface by this
connector. It is used only for test and debug purposes.

COM1 Connector

The DimmBoard’s COM1 port is output here. The Auto Sampler is connected to this port.

NTC TEMP Connector

An external temperature measuring NTC resistor can be connected, to measure external

temperature.

USBA Connector

The DimmBoard’s USB upstream port is output here. It can be used for DimmBoard software
upgrade.

USBB2 Connector

It is connected to the USB downstream port of the PIC microcontroller. Not used.

USBB1 Connector

It is the USB interface between the Data Acquisition System and the Analytical System. It is
an USB downstream connector.

36
 Servicemanual

3.4.7 Mini-ITX PC mother board (In Hardware block)

1. PS/2 mouse port (green). This port is for a PS/2 mouse.

2. Serial connector. This 9-pin COM1 port is for serial devices.

3. DVI connector. This 24-pin DVI port connects to a DVI monitor.

4 & 5. LAN (RJ-45) port. This port allows Gigabit connection to a Local Area Network (LAN)
through a network hub.

6. Line In port (light blue). This port connects a tape, CD, DVD player, or other audio
sources.

7. Line Out port (lime). This port connects a headphone or a speaker. In 4-channel, 6-
channel, and 8-channel configuration, the function of this port becomes Front Speaker Out.

8. Microphone port (pink). This port connects a microphone.

9. USB 2.0 ports 3 and 4. These two 4-pin Universal Serial Bus (USB) ports are available
for connecting USB 2.0 devices.

10. USB 2.0 ports 1 and 2. These two 4-pin Universal Serial Bus (USB) ports are available
for connecting USB 2.0 devices.

11. VGA port. This 15-pin VGA port connects to a VGA monitor.

12. Serial connector. This 9-pin COM2 port is for serial devices.

13. PS/2 keyboard port (purple). This port is for a PS/2 keyboard.

37
Hemolyzer 5

4 Electronic block diagram

The analyzer hardware consists of two systems, an Analytical Unit and a Data Acquisition
Unit. The two autonomous systems communicate via an USB interface. A 400W ATX PC
power supply generates the necessary voltages for the two units.

4.1 Hardware Block

The function of the Analytical Unit is to implement the user interface, to start and control the
measurement processes, to receive and process the measurement data, handle the
database, display, store, and print the processed measurement data. Hardware Block is
responsible to communicate with the user, transfer data to the Low Level Software and store
the settings and measured data.

The components of the Analytical Unit are:

- PC mainboard (mini-ITX mainboard).

- Mass storage device (250 GB Winchester)
- Power supply (400W)
- Audio amplifier and speaker
- Keyboard (optional)
- Mouse (optional)
- USB CD/DVD drive (optional)
- Mainboard back panel I/O ports
- LVDS cable
- Touch cable
- Internal USB cable
- LED display cable

38
 Servicemanual

10.4” LCD-
LED 600x800

Touch screen Data and Power connector Back light connector

connector

Touch screen USB

interface board Power supply

USB Power & Video Power supply connector

Mini-ITX main board

PS2 PS2 Mouse

Keyboard IDE 4 USB Audio USB

Keyboard Mouse 3.5” 250GB CD-DVD or Audio

optional HDD other eternal amplifier
optional device like board
printer
(optional)

Speaker

Data acquisition
system

39
Hemolyzer 5

4.2 Data Acquisition Unit

This unit executes the commands of the Analytical Unit. It controls all the processes of the
sampling, sample actuation, motor and valve control, measurement control and the data
acquisition. It preprocesses the raw sampled data and forwards it to the analytical unit.

The components controlled by the Data Acquisition Unit are:

- Laser diode driver and diode

- PIN photodiode and amplifier
- Cell counter amplifier and HGB head
- High voltage board (HVB)
- Pressure sensor
- TCU (Temperature Control Unit)
- 2 PPB boards (Pneumatic and Power Board)
- Stepper motor units with opto boards (dilutors, X-Y module, shear valve)
- 40 Valves
- 2 Pumps
- Reagent sensor board

See Data Acquisition “map” on the next page:

40
 Servicemanual

Reagent Sensor
Auto Alignment
27-33 valves

23-26 valves

12-16 valves

38-44 valves

17-22 valves

34-37 valves

Shear Valve
X-Y module
6-11 valves
1-5 valves

Dilutor 2
Dilutor1
Pump1

Pump2
I2C PPB1 I2C PPB2

PPBIF LS-DACQ board Impedance measurement

(I2C) Analog
connector Cell chamber +
counter electrode
amplifier
DIGITIO HGB head
connector

HVB HVB +50V

JTAG board +150V
connector
connector
(FW I2C Pressure sensor

Parallel
I2C TCU
port
Analog
Floppy IF DimmBoard connector Pin photo diode + amplifier
Debug

Laser driver
USBA Laser driver + laser diode
connector

PS2 Optical measurement

COM1 Start Button USBB
keyboard Connector

Autosampler HW
(optional) block
Start Button
+ LEDs

41
Hemolyzer 5

4.3 Amplifier board

This unit is responsible to gather information during impedance measurements. The amplifier
board receives the signal of cells gathered by the aperture and gains these analog signals
before transferring it to the LSDACQ.

The amplifier is using 50V DC for measurement and 150V DC for cleaning apertures. These
voltages are generated by the HVB (High Voltage Board).

Amplifier unit has a test function. Test generator switches pulses to the input of operation
amplifiers during the automated Self-test program.

HGB signals are distributed by Amplifier unit.

42
 Servicemanual

4.4 Optical Head

Optical head provide WBC differential result applying a hydrodynamic focused flow cell, a
laser light, light detectors and amplifiers to gain the detector signals.

The laser driver unit has two Safety switches on the Laser head cover fixing to turn off the
laser light when the cover is removed. For safety reason the laser diode remains off until the
low level system or the whole system is rebooted.

Three analog signals are provided on the output of Laser Amplifier board. The low angle is
typical of the size of white blood cells, the high angle is typical of the size of the cell
complexity, DC is dependent on of cleanness flow cell.

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Hemolyzer 5

5 OPERATION OF THE FLUIDIC SYSTEM

This section describes the main fluidic steps of Hemolyzer 5 measurement cycle. The
following figures show total measurement flow diagram and detailed descriptions of
processes for understanding the fluidic system work.

In Hemolyzer 5 the cleaning process executed parallel to the measures and the standby
process are executed in the background. It means that the database and other functions
(except pneumatic) are accessible while the analyzer is performing the measurement cycle
and while it is going to standby.

The cleaning process does not block the next measurement cycle, so after getting the results
the next measurement can be started.

5.1 The Reagent system

Name Description Function
Hemolyzer-Diluent Isotonic solution, used to dilute whole dilution of sample,
blood and quantitative and qualitative rinsing and cleaning the
determination of RBC, WBC, PLT and tubing system; it is the
HGB concentration sheath fluidic
Hemolyzer-5-Lyser Reagent for stromatolysis of RBC and BASO and 4-part (LYM,
quantitative determination of WBC 5- MON, NEU, EOS)
part differentiation (LYM, MON, NEU, lysing
EOS, BAS) and HGB concentration
measurement of human blood.
Hemolyzer-5-Diff 5P Quantitative determination of responsible for timed 4-
leukocyte five-part differentiation Diff reaction
(LYM, MON, NEU, EOS, BAS)
Hemolyzer-Hypocleaner Capillaries, tubing and chambers, Cleaning system
removing blood component (external liquid, not part
precipitates. of standard reagent
system)

44
 Servicemanual

5.2 Flow diagram of measurement

START BLANK START Meas.

Needle to SR Sample in

Needle piercing

Cleaning Sampling Preparing for

processes making dilutions
Needle washing
Generating (outside) HGB blank
Vacuums

SV to CP

Generating Dilutions in parallel Needle Pre-

Vacuums WBC, MIX, 4diff washing (Inside)

SV to NP

Note: CP means
Making RBC dilution “Chamber Position”; NP
means “Needle
Position”;
SV means Shear Valve; SR means
Sample SV to CP Rotor

45
Hemolyzer 5

Cleaning Making 4diff RBC

Needle (Inside) dilution + measurement

refilling sheath
puffer

Generating
vacuum SV to NP HGB
measurement
+ reset
vacuum

4diff Cleaning WBC

measurement measurement
MIX, RBC
chambers, TCU
loops 1st time

Taking BASO
Regenerate
sample
vacuum

SV to CP

BASO Cleaning
measurement
WBC, RBC
chambers TCU
loops 2nd time

RESULT SV to NP

START
NEXT

46
 Servicemanual

5.3 Initialization of the Fluidic System

Fluidic initialization process performs the following steps:

• Checking the hardware conditions of the unit.

• Checking of pump and pressures sensor by generating measuring vacuum.

• Positioning all mechanical components by scanning moving range (with end-

switches).

• Checking prime conditions of reagent buffers.

• Cleaning of aperture with high-pressure back-flush and high-voltage burning.

• Preparing for compulsory blank measurement.

5.4 Reagents priming

Sample measurement or most of the fluidic functions is not available if the reagents are not
fully primed. This can be done manually or automatically from the Maintenance menu, but
the instrument also performs automatic priming in several points of the pneumatic functions.
(e.g. starting fill-up process, Preparing for measurement, wake up…etc.)

The fluidic system is connected to the reagent containers in a closed fluidic way. This means
when a syringe is priming reagent from the internal reagent reservoirs, the generated
vacuum will automatically fill them up when the floating sensors detects low liquid level.
Hereby the priming of the reagent during the measurement is automatically.

During measurement the system automatically double-check the reagent levels in the
buffers, and notice the user at the end of that measurement, if any of the reagents are
running low and replacement is needed.

5.5 Piercing process

After the Start Button was pressed and all of the necessary initializations had done, the
measurement cycle starts with the piercing process.

The Sample rotor immediately turns in; the needle comes forward and starts to pierce the
sample.

5.6 Sampling process

When the needle reaches the sampling position, a dilutor syringe takes out 100µl of blood.
The blood sample is separated from the diluent by air bubble. The air bubble was taken right
after the needle washing process of the previous measurement or during the preparing for
measurement or wake-up processes.

When the needle is pulled out of the sample tube and washed by the wash-head from
outside, the primary blood sample will be transferred into the Shear Valve loops.

47
Hemolyzer 5

5.7 Needle washing processes

When the primary sample is taken out, the needle will be washed outside by the wash-head
using diluent and continuous drawing.

During Diluting process, the needle will be washed through twice. First a preliminary flow of
diluent slowly washes out the remnant of the whole blood into the washing head. Finally
2,5ml of diluent cleans out the needle with high speed.

When the needle is clean, the system will take air bubble into the end of the needle preparing
for the next sampling.

5.8 Diluting processes

After the primary blood sample was taken out and transferred to the first 3 SV loops, the SV
rotates to Chamber Position (CP).

The loops in the SV counting from the needle side are:

1st – WBC (~16μl) 2nd – MIX (~16μl) 3rd – 4diff (~40μl) || 4th – RBC (~16μl)

4-diff has a special loop; it is transparent and has higher volume.

The system makes the first step of RBC dilution, WBC dilution and 4diff pre-dilution in
parallel.

WBC dilution is made by 2.5 ml mixture of diluent and lyse. The concentration of the lysing
mixture is approx. 1:4. The WBC dilution is mixed with air bubbles from the bottom of the
WBC chamber.

During 4-diff pre-dilution the primary blood sample is forwarded with diluent into the TCU to
preset of the required temperature.

The first step of RBC dilution made by 2.2 ml of diluent and mixed with air bubbling from the
bottom and the side connector of the Mix chamber.

When the mix dilution is ready, a dilutor syringe moves the mix sample through the SV into
the 4th sampling loop. Then the SV rotates back to Needle Position (NP).

The RBC dilution is made in the RBC chamber with 2.5ml of diluent and mixed with air
bubbling from the bottom.

5.9 Lysing process

The dilution for the WBC and optical BASO count is the same. The WBCs are shrink by the
quick lyse reagent to its nucleus except the BASOPHILES. After the sample dilution
measured in impedance way, the remaining sample is transferred to the optical head for
basophile count.

More complex lysing process is made on the 4diff dilution. It requires precise timing, volume
control and temperature conditions. The accurate temperature control is made by the TCU
module.

48
 Servicemanual

In the TCU unit, there are loops for lyse, stopper, blood + lyse, pre-diluted blood mixture.
Temperature of these loops is controlled accurately.

After the 4-diff primer sample is pre-diluted and its temperature has been set, 3 syringes
(lyse, stop, diluent) make the precise dilution through the TCU unit, the Shear Valve 4-diff
sample loop, ending in the big vacuum puffer. Previously generated vacuum supports the
smooth flow of the mixture.

The pre-diluted blood meets with the lysing reagent by a small “T” connector first. Right after
this point there is an inline mixer part in the TCU module, where the blood and lyse is mixed
in its tube by flowing through. After that the precisely mixed lysing dilution runs through one
of the TCU heater loops for better temperature conditions, and reaches the stopper “T”
connector. The volume between lyse and stopper “T” connectors is about 1ml, and this is the
incubation zone for the lysing.

After adding the stopper reagent the mixture goes through another inline mixer, the SV 4-diff
sampler loop, and flows into the vacuum puffer. The SV 4diff sampler loop is volumetrically
set by the software, so the precisely lysed and stabilized 4diff mixture will be stopped in this
loop, ready for measurement.

The parameters of the lysing process are the temperature of the dilution, the dilution ratios of
the blood-diluent-lyse-stopper mixture and the speed of the flow. These are determining the
quality of the 4diff dilution.

5.10 RBC counting process

The regulated vacuum aspirates RBC dilution (RBC) from the RBC chamber through the
aperture. The instrument counts the cells for 10 seconds in this case.

5.11 WBC/BASO counting

The regulated vacuum aspirates the WBC dilution from the WBC chamber through the
aperture. The instrument counts the cells for 10 seconds in this case.

After the WBC dilution has measured in capillary mode, the system transfers the remnant of
the sample to the BASO loop in the Shear Valve. The last parameter in measurement cycle
is the optical BASO count. The BASO count is measured by the optical head as like the 4-diff
measurement.

5.12 WBC 4Diff counting

The regulated vacuum aspirates the WBC 4diff dilution and the sheath fluid from Sheath
puffer, through parallel tubes (one for sheath flow, one for sample flow), through the flow-cell
into the vacuum chamber. The instrument counts the cells for 6 seconds in this case.

During measurement the core diameter of the sample stream in the flow-cell is approx.
250µm. This is determined by the tube resistance ratio between the sheath and the sampling
lines.

A self-cleaning process is started after the 4-diff measurement ends. The system changes
the insertion point of the vacuum, which starts to wash back the sampler needle and the 4diff

49
Hemolyzer 5

sample loop in the Shear Valve with sheath fluid. This process prepares the optical head for
the following BASO count.

5.13 Chamber draining processes

Chamber draining is made by a special pressure control. Pressure controlled draining starts
with vacuum generation in the puffer reservoir. The liquid aspirated from the chambers while
buffer reservoir and thus the pressure sensor is monitored in the draining tube. The
instrument can detect the empty state of the chamber by drop of vacuum. Error message is
send if the vacuum loss was not detected indicating the measuring chamber draining
procedure was failed.

5.14 Cleaning (rinsing) processes

All cleaning processes during a measurement cycle uses mainly diluent, and for special
cases small volume of lyse, and stopper reagent (e.g.: cleaning the adequate loops in the
TCU).

The instrument performs the cleaning processes parallel to the measurement. When any of
the fluidic part has finished its work with the whole or diluted blood, cleaning process will
start.

The main cleaning processes during measurement are:

- Needle washing outside, 2x inside into washing head

- Mix chamber washing

- RBC, WBC chamber washing, back flush and high voltage burn of apertures

- 4diff diluting loop (Shear Valve + TCU loops) washing

- Optical head and sampling line washing with sheath fluid

5.15 Standby process

Because of the high throughput of the Hemolyzer 5, the measuring cycle ends with empty
WBC chamber, and leaves the BASO sampling line is not cleaned. During continuous
measurement the beginning of the next measurement will automatically clean this loop.

Avoiding the BASO loop contamination the liquid is aspirated automatically from it two
minutes after the last measurement of a sample batch.

However, when there is no more measurement started, the instrument will go to stand-by
mode after some minutes.

Standby process performs cleaning, drains all vacuum chambers, drains all chambers then
refill them with diluent just above aperture level.

50
 Servicemanual

5.16 Wake up process

In this case the instrument prepares itself for the upcoming measurement cycle. Cleaning the
wash head and calibrating the blood sensor.

5.17 Shutdown process

The fluidic shutdown performs the following steps:

- Priming chambers with diluent to avoid drying out of aperture and prevent the
chamber from contamination.

- Needle is in up position and washed.

- All of the syringes are positioned down.

- Sample rotor moved out

51
Hemolyzer 5

6 ADJUSTMENTS
For proper functioning, it is vital to adjust the system correctly. Although Analyticon
production sets the system in house, sometimes these adjustments needs to be done on the
field also. Both mechanical and software adjustments has to be done properly to avoid
measurement results or pneumatic errors.

Please note that the lifetime of the mechanics system is long. If there's a problem with the
mechanical system, most cases a proper adjustment is enough to solve the problem.

6.1 XY unit mechanical adjustments

The XY unit has 4 critical parts to adjust. These 4 adjustments can be done separately, but
some of them can affect other settings. See the 4 attributes of the XY unit which has to be
set properly:

• XY (needle) horizontal movement

• XY (needle) vertical movement

• Needle position

• Washing head position

If any of these four attributions are not set correctly, the system can stop with a pneumatic
error or give improper results. These adjustments can be tested in Service testing menu.

The movements of the XY unit made from Service testing menu are slower than
normally. Some cases the improper hardware settings are not appear during the
movement used by Service testing menu. To make sure that the mechanical part
is working properly, the system has to make an Initialization process (hardware
init). This process moves the mechanical part (XY) faster, highlighting the
problems made by the faulty settings or misalignments. Hardware init can be done
in Service functions screen or the system is making an automatic init process,
after e.g. Washing head setting process is finished. Use these functions to check
mechanical settings also.

6.1.1 XY horizontal movement

The proper horizontal movement is important to make sampling from the Sample rotor and
from the Auto-Sampler. The horizontal movement of the XY unit is made by one of the
stepping motors and positioned by two separate opto flags. The Front and Rear positions are
defined by the settings of these opto flags. The XY unit is moving on metal rods. These rods
have to be greased after a period of time.

6.1.1.1 Greasing the horizontal rods

There are 2 horizontal rods in the XY which is responsible for proper and smooth movement
of the needle and the needle holding block. These rods are cylinder shaped. They have a fix
position in both the front wall and rear metal block in the XY. The rods are not fixed tight,
they're loose and can wobble to move together with the needle block.

52
 Servicemanual

The third rod is squire shaped and responsible to hold the vertical belt for the needle. The
front of this rod is not fixed in a metal block, it “hangs” free.

Guide

Square
shaped
rod

Guide rod

Test the movement of the needle to Front or Rear positions in Service testing menu. If there
is any grinding noise because of the improper lubrication, these three rods has to be
lubricated.

Name (and part number) of the lubricant: Photolube 022 (A598)

6.1.1.2 Set opto flags for horizontal movement

If the XY unit hits the front wall of the mechanics (Front position, above the sample rotor) or
stops in a non centered position above the Auto-Sampler docking station (Rear position).
Use a hexagon 2.0 mm screw to loose the fixing screws holding the opto flags. Align them to
make the XY horizontal movement stop earlier or later, depending on the actual state of the
flags.

53
Hemolyzer 5

Opto flags

Opto LEDs

Opto

Fixing

Front wall

Use handmade horizontal positioning of the needle, place the needle to the correct position,
then align the opto flag to the opto sensor, see that the indication LEDs are turned on when
the flag reached the sensor.

When the needle reached the ‘Front’ position, the gap between the needle holding block and
the front wall of the XY unit should be around 0.5 mm.

When the needle reached the ‘Rear’ position, make sure that the two vertical rods -which are
holding the washing head can push the tube holders to the correct position on the Auto-
Sampler's docking station.

54
 Servicemanual

Needle holding block

Washing

Washing
head

AS docking

Tube

The opto sensors are fixed to the XY PCB and cannot be adjusted.

6.1.2 XY vertical adjustment

This setting is necessary for the vertical motor movements because this adjustment sets the
opto end-switches of the XY unit.

6.1.2.1 Basic operation

During testing the vertical movement of the XY, some strange noise can appear or maybe
the vertical movement is not performed correctly and it's causing the pneumatic error. These
problems can be found if we understand how the mechanics works.

Find the opto wheel (black cogwheel) at the rear side of the XY unit. Note that the vertical
opto sensors -next to the opto wheel- are using negative logics. The sensor is always
triggered by the opto wheel, except when the small holes on the wheel reaches the sensors.
These wholes indicates the Up and Down positions and the needle should stop when the
wholes reaches the sensors. The opto LEDs are always on, except when the needle reaches
the ‘Up’ or ‘Down’ positions. The opto wheel is connected to the vertical belt -by the middle
square shape rod -and they are moving together. The needle is connected to the belt by two
screws. If the opto wheel reaches the ‘Up’ or ‘Down’ position, the needle should also stop.

The problem is that the mechanical structure of the XY is making the needle stop before the
whole on the opto wheel is reaching the opto sensor. This can be happen in 'Down' position,
because the needle mechanics is reaching the position earlier than the opto sensor gets the
signal to stop. Or in 'Up' position, when the Washing head is already reached the highest

55
Hemolyzer 5

position and hits the needle's vertical block, while the opto sensor still didn't received the 'Up'
position signal.

6.1.2.2 Adjusting the needle’s vertical position

The problem can be easily set by losing the
two screws behind the needle and let the
needle "release" the belt and fall down to
"Down" position. Because the screws are
loose, the opto wheel and the belt can move
separately from the needle, the needle itself
is down and not moving.

Disengaged

Now the opto wheel can be set after the

needle, which means the opto wheel should reach Down position. Press 'Down' in Service
testing screen to move the opto wheel to 'Down' position. The needle is already in 'Down'
position. When the opto wheel is in 'Down' position, tight the two screws which makes the
needle "grap" the belt again. Now the vertical system is set together again, press 'Up' and
'Down' buttons in Service testing screen to see that the movements are proper. Test the
movement with Init process also.

Adjustment is successful if LEDs goes on before moving part reaches end of mechanical
range.

Changing the vertical position of the needle on the vertical belt can affect the position of the
washing head and the needle. Please perform a needle and washing head setting after
vertical position is set.

6.1.3 Washing head settings

The position of the washing head is critical
for the system to make the sampling and
needle washing correctly. The washing head
contains two metal tubes to make the
washing process. The bottom is the inlet for
diluent to wash the needle from outside, the
top is the outlet to aspirate the liquid from the
needle to the waste. During the washing
process, the system also pushes diluent to
the needle from the shear valve, ensuring
that the needle will be cleaned from the
inside also. The relative position of the
needle and the washing head is important to make the aspiration properly, otherwise the
diluent from the needle will flow out from the bottom of the washing head.

To set the Washing head’s position, go to Adjustments menu and press ‘Wash head’ button.
The message will appear to confirm that the washing head setting process will start. Press

56
 Servicemanual

‘Ok’. The system will pull the needle and the washing head to Up position. Now the system
holds the XY unit in the Up position until the setting is ready. The washing head is in position
if the distance between the top of the head and the metal block above it is close to 1mm.

1 mm gap

This distance is not strict, but it’s enough to provide space for the washing head when the
needle moves. If washing head’s position is higher, it can hit the metal block when it’s raised
to Up position and it can hit the sample rotor and the tube holders if the position is too low. If
the position is not correct and has to be set, find the two screws on the top of the XY unit.
These two screws are holding the two rods of the washing head. Loosing these screws make
the height settings enable.

1.5 hexagon screws to hold

the washing head leading

2.0 hexagon screws

to hold the needle

6.1.4 Needle setting

The height of the needle is important to make a good aspiration from the blood sample. The
aspiration whole is on the side of the needle, but for height setting, we use the bottom end of
the needle. This end of the needle is sharp, but during the procedure, there is no need to
touch this part. For position checking, the needle can be moved by hand or by the software.

6.1.4.1 Handmade setting

Manually push the needle to down position. Make sure that the needle is not hitting the
sample rotor’s plate. Check that the needle is completely down, then take a look at the end of
the needle. The distance between the sample rotor’s plate and the needle should be 1mm.

57
Hemolyzer 5

If the distance is not correct, find the two

holding screws at the other end of the
needle. Use a hexagon 2.0 mm tool to loose
the screws and set the needle’s position.

1mm

Note that when the

needle is Down, the screws are covered by
the mechanics of the XY. The needle has to
be raised to have access to the screws.

The needle is sharp and it can cause injury! Always use gloves when needle
setting is performed! Make sure that the whole on the needle is facing the sample
rotor.

6.1.4.2 Software made setting

In Adjustments menu, press ‘Needle’ button. The system will ask to confirm that the needle
setting should start. Press ‘Ok’. The needle will move down and up. The software will ask to
confirm that the end of the needle is visible at the bottom of the washing head. If the needle
is not visible or it’s leaning out too much, loose the holding screws to adjust. If setting is
ready, press ‘Ok’.

6.2 Shear valve mechanical setting

This opto setting is necessary for the correct movement of the Shear Valve. Although the SV
is stopped mechanically in its end positions, the opto sensors provide the necessary
feedback signal for the electronics that the movement has been done. The setting of the
mechanics and the opto sensors are made by Analyticon during production, sometimes
these alignments has to be checked or realigned.

58
 Servicemanual

6.2.1 Shear valve lower disc position setting

For adjusting the lower disc, remove the
thumb screw and place the upper disc to a
safe position on the mechanics under the
optical head. The lower disc of the shear
valve is positioned by two metal plates.
Setting up the plate on the right side is

Plate and disc connection

critical.

The plate is fixed by to screws. This is the

basic setting of the valve, if the disc is not fixed correctly, the amount of sample can be
different during each measurement.

The disc and the plate should connect in the full length of the connection surface. The disc
shouldn’t wobble or move. If the setting of the disc is not proper, loosening the two screws on
the bottom and realigning the connection between the plate and the disc should be the first
step. This setting should be set with a hexagon 2.5 mm screwdriver. The two connection
surface should be parallel. When the lower disc is aligned, make sure about the following:

• the disc position is horizontal

• the plate fixing screws are tight
• the sides are parallel
• the disc meets the plate with full
surface
• the lower disc cannot move

While making an alignment and the shear valve is disassembled, make sure that the internal
surface of the ceramics is clean, not scratched. If the plate and disc is aligned make sure that
the second plate on the left side is pushed to the disc. This plate ensures that the shear
valve will not move away from the aligning plate.

After the lower disc is aligned, replace the upper disc and fix the thumb screw back to
position.

6.2.2 Shear valve upper disc setting

The upper disc and the mechanical stoppers (bumpers) are aligned by Analyticon during QC
and End of Line procedures. If this setting is compromised, the mechanics should be aligned

59
Hemolyzer 5

again. To have access to the mechanical stoppers, the metal cover of the shear valve should
be removed. The cover is fixed to its place by the two inner screws behind the thumb screw.

The shear valve’s task is to change position to guide the sample and the reagents to the
correct direction. For this, the tubes should be perfectly aligned which means that the
mechanics should stop the turning of the discs in a correct position.

Bumper fixing

Shear valve upper

Plates holding the

The mechanic part is designed to change the motor’s circular motion to horizontal motion.
There is a horizontal drive behind the ceramic disc which can be shifted left or right by the
stepping motor.

Horizontal

Shear valve moving

Mechanical stoppers

This rod has two nodes which are surrounding and moving the upper disc’s rod. This is how
the disk is moving. The nodes can reach a stopping mechanic block on both sides of the
mechanics. If nodes hit the stoppers, the turning of the shear valve will stop. When the shear
valve is stopped, the small metal tubes on the upper and lower discs should be perfectly
aligned to each other.

The shear valve has a free hole on the edge of each ceramics. This hole is not connected to
the tubing system and it’s easy to access. There is no special tool to check shear valve
alignment; a simple paper clip is enough to check the alignment in both positions. The paper
clip should access both holes on the ceramics. During the test, make sure the shear valve
reached to bumper and cannot turn more.

60
 Servicemanual

The paper clip has a size and straight part just enough to push through the ceramics.

Opto

Opto

Paper clip in alignment

Alignment

The lower disc has two holes to test both positions. Test one position at a time.

If the paper clip can go through both discs, it means the shear valve is in position.

If the paper clip cannot go through the holes the upper discs position has to be realigned.
The bummer fixing screw should be loose to make the bumper move free. Find the correct
position where the paper clip fits into both holes. If the position is ok, push the bumper to
position until it hits the node of the drive. If the positions are set, the bumpers have to be
fixed again by tightening the screw.

Note that the shear valve needs to be pushed to the other position to have access to the
bumper fixing screws. Remove the paper clip to turn the shear valve with the horizontal drive.

Use the paper clip to see alignments in both positions (CP, NP). Make sure that the bumper
holding screws are well tight.

6.2.3 Setting the opto sensors of the shear valve.

There are two opto sensors for the shear valve to sense when the ceramics reached their
positions. The upper disc has a rod called the opto rod. This rod moves inside the opto
sensors when the shear valve is turned. The sensor should give the signal to the software to
stop the motor because the positioning of the shear valve is done.

The opto sensors are placed on a PCB

called Shear Valve OPTO (SVOPTO). The
sensors can be positioned separately; it
doesn’t need to align both if only one sensor
is
Shear valve misaligned.

SVOPTO

61
Hemolyzer 5

The sensors are connected to a LED, which turn on when the sensors are triggered. Use
these LED to check alignment.

Turn the shear valve clockwise to the outer (chamber) position. Make sure that the shear
valve is in the maximal position and cannot turn more. Put the paper clip to the alignment
hole. It should access both holes easily. The outer sensor’s LED should be turned on in this
position. Check that the LED is on, position the LED PCB if it’s needed. Use hexagon 2.5
mm screwdriver.

If the sensor is in position and the LED is on, try to turn the shear valve counter-clockwise.
Because the paper clip is in the alignment holes, the shear valve will only turn in a very small
amount. Find the maximum position until the paper clip lets the shear valve turn. In this
position, the LED should be still on. Make sure that the LED is on and set the SVOPTO to
make the LED light again. Remove the paper clip and turn the shear valve to the inner
(needle) position. Repeat the process to set the opto in this position too. Move the shear
valve by hand when aligning opto sensors, remove the paper clip when done. Check the
alignment by moving the shear valve in Service testing menu.

Note the in needle position, the SVOPTO is fixed with two screws. Loose and tight both
screws during alignments. The SVOPTO PCB screws can be accessed by the holes under
the blood sensor.

6.3 Amplifier offset setting

Values
Offset for of
values Auto-offset
manual offsetting
the channels

Send settings

Field for manual

offsetting

The analyzer contains several amplifier circuits to gain signals during the measurements. An
ideal amplifier gives zero mV output if input is has 0mV. In reality, the amplifier's output
always has some electric potential which is different than zero. This voltage is the offset of

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 Servicemanual

the amplifier and has to be zeroed to avoid any effects on the measurement results. In
Service menu Adjustments screen, it's possible to set these values manually or enable the
checkbox to use the auto-offset option. There are three amplifier channels in the optical
head, all three should be zeroed to avoid noise during optical measurement.

CH0: Channel for Low angle gain

CH1: Channel for High angle gain

CH0 DC: Channel for optical head DC level.

Amplifier offset should be between ±5mV. It's possible to check offset values by pressing
Read data button. Reading the offset continuously will turn the start button red, indicating
that the internal communication is busy. The system cannot command the Low Level
software until the offset reading is Stopped.

Impedance amplifier offset can be adjusted separately, also by filling the potentiometer field
in the middle or by using Auto-offset checkbox.

Always press 'Send settings' button to finish adjustments. Offset setting are done by
LSDACQ. If Auto-offset is not working or values are not close to zero, replace the LSDACQ.

6.4 Blood sensor calibration

Hemolyzer 5 contains a blood sensor to ensure that the value of the sample is the same
during every measurement. After every startup, the system calibrates the blood sensor
automatically by making a Wakeup process.

During wakeup, the system creates a bubble in

the wash head and pulls the bubble inside the
blood sensor. The sensor measures the
number of steps that the dilutor has to make to
pull the bubble into the sensor. The system
repeats the process three times and records
the number of the steps. During the wakeup,
these numbers are displayed in MDA screen if
MdaOn checkbox is enabled.

Result of blood
sensor
lib ti

MdaOn
checkbox has to
b bl d

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Hemolyzer 5

Field to enter number of

test functions

Checkbox to enable or
disable blood sensor

Press MDA to view MDA

screen

If the number of steps are the same for two times (out of three), the sensor calibration is
successful. If all three values are different, the sensor calibration is failed. Failure of the
calibration is displayed as a 'T' flag after a blank, control or human measurement is finished
and warning exclamation mark is also shown on the bottom of the display. If blood sensor
calibration problem appears, it's possible to run Wakeup process directly from Service
functions. See test functions list in section 7.3.1.1.

The sensor can have problems sensing the bubble's position because the sampling tube is
not transparent enough or it's dirty. In this case the tube between the needle and the shear
valve has to be replaced.

Note that the calibration value is strongly depends on the state and position of the sample
tube. This tube in the blood sensor is not fixed and its position can be changed by pulling the
tube during a shear valve adjustment or cleaning. The tube is set correctly if calibration value
is in a range 44-49. If the value is different, it can cause sampling problems, 'W' flag or it can
happen that the sampling tube will be too tense when the needle is piercing a sample from
the Auto-Sampler.

Make sure that the tube between the shear valve and the blood sensor is horizontal, not too
tense and transparent.

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 Servicemanual

6.5 Sample position setting

The measurement starts with a blood sample
aspiration. The blood sample needs to be
moved to a specific location through the shear
valve. Open the front cover of the analyzer and
observe the beginning of the measurement
process. The below adjustment is necessary to
allow the sample reach this location – to avoid
sampling errors and thus avoid optical
measurement errors

During sampling, the blood sample must go

beyond the last loop of the shear valve, as
indicated on the image.

The purple area is a schematic representation of the purple area on the shear valve in the
Hemolyzer 5. Please locate this tube in the analyzer (the tube is connected to the V41/1 tube
in the vertical tube organizer.

Run a control blood sample. If the sample

position is between 2 and 8 mm, then do not
change the default position. If the three loops
are not filled with blood or the sample stops
more than 8mm beyond the shear valve, the
sampling settings has to be set in Adjustments
screen.

Length of sample position

used if blood sensor is
enabled

Default blood position

value is used if blood
sensor is not enabled

In Adjustments screen, the sample position can be set at Needle tube full length/sample
position. If blood sensor is enabled, the system uses the top value (70 by default) to position
the sample. This value can be calibrated by pressing Calib length button.

• If button is pressed, the system will create a bubble in the wash head and pulls it
through the sample tube and the three loops to the top of the shear valve. The
software will ask whether the bubble is visible at the top of the shear valve, this has to
be checked visually.

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Hemolyzer 5

• If the bubble is not arrived to the correct position, press Cancel to make the system
(the dilutor) pulls the bubble higher from the shear valve. The system will ask to
check every new position after Cancel is pushed.

• If the bubble is in position press Ok. The system will overwrite the old sample position
value (default 70) with the newly set value.

• Rerun a control sample. Observe the position. Run calibration again if sample
position is not proper or type in a new value by hand. If value is changed by hand,
press Set length button to save the new value.

If the blood sensor is disabled or not working properly, the system will use the bottom value
so called the default blood position. It is not possible to calibrate this value, but it can be
modified by typing in a new value. After the value is modified, press Set default blood
position button to make new setting accepted. This value should be in a range 0.190-0.220.

Make sure that the format of this entered value is correct and “0.” is visible. It's important to
keep this value under 0.22 because larger values will make the blood sample override the
shear valve and will enter to the reservoir.

Always use blood to test the sample position after the following:

• sample position value was calibrated

• sample position value was changed (with blood sensor)

• default blood position value was changed (without blood sensor)

• blood sensor was turned off or on

• sample tube was replaced or its position was realigned

• shear valve was disassembled

• XY adjustments was realigned (horizontal, vertical, wash head, needle)

• wash head was cleaned

Always test blood position from Auto-Sampler. Make sure that sample position is proper both
from Sample rotor and Auto-Sampler.

6.6 Pressure sensor adjustment

Similar to the amplifiers, the pressure sensors also has offsets. It is also possible to zero the
pressure sensor's offsets in Adjustments menu by pressing the Start adjustment button. The
offset compensating is done automatically, showing the offset results in mBars. These values
must be 0 ± 20 mBars. If one value is higher than 20mBars, the pressure board needs to be
replaced.

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 Servicemanual

The sensors can work with higher offsets than 20mBars, but if values are higher than
30mBars the system will give a pressure sensor offset error and if the values are higher than
40mBars it will cause a pneumatic error.

6.7 Set serial number

It is also possible to enter the instrument's serial number in Adjustments menu. Simply type
in the correct number and press Set serial button. The serial number of the instrument is
stored in the Hardware block, the LSDACQ and the DimmBoard. Serial number is also
indicated in the label on the back of the instrument.

Serial number has to be typed again if:

• Dimmboard was changed
• Low level software was reinstalled
• LSDACQ was changed
• HDD was changed
• High level software was reinstalled

6.8 WBC preheater

In Adjustments screen, it is possible to set the WBC preheater's temperature. The default
value is 375 indicating that the temperature should be 37.5 °C. By pressing Read data
button, it's possible to check the preheater current temperature.

Make sure that the preheater's value is 375 (37.5°C), if it is not possible to set the
temperature or values are too high, check WBC preheater's cable or replace LSDACQ board.

6.9 Setting Laser values

Every laser head has unique values which have to be set in the instrument for proper
working. These values were set by Analyticon, but has to be set again if the laser head was
replaced. In Auto Alignment screen it's possible to check or overwrite the values. The Read
DC button and the laser values are accessible, but other options are password protected.
Password is asked every time when entering Auto alignment menu.

Do not change the laser values unless it's necessary.

6.9.1 Calibration procedure of optical heads

1. Enter to Service/auto alignment menu (password:47715481) and set optical head

values as shown below:

Laser power: 120

Low angle gain: 130

High angle gain: 210

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Hemolyzer 5

2. In service/service calibration menu, set Scatter X and Scatter Y values to 1,1. Press
Accept when done.

These values needs to be set to make a proper start for the laser to calibrate.

3. In settings/system/set menu, select Gravity X and Gravity Y columns on the right list,
and put them to the used columns on the left list by pressing the left arrow. Press
done and save when ready.

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 Servicemanual

4. Do a control measurement using a control blood. In the database find the results of
the measurement. Check the Gravity X and Gravity Y values of the measurement and
compare them with the Gravity values shown on the blood sheet of the actual control
lot.

5. If measured Gravity values (X and Y) are between 0,8 x Lot Gravity values (X and Y)
and 1,2 x Lot Gravity values (X and Y)(+-20%), then the Gravity values can be
calibrated by software.

6. If measured Gravity X is lower than 80% of Lot Gravity X, raise low angle gain in auto
alignment menu to bring the measured Gravity X value closer to Lot Gravity X. If
measured Gravity X is higher than 120% of Lot Gravity X, then lower the low angle
gain to bring the measured Gravity X value closer to Lot Gravity X.

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Hemolyzer 5

7. If measured Gravity Y is lower than 80% of Lot Gravity Y, raise high angle gain in
auto alignment menu to bring the measured Gravity Y value closer to Lot Gravity Y. If
measured Gravity Y is higher than 120% of Lot Gravity Y, then lower the high angle
gain to bring the measured Gravity Y value closer to Lot Gravity Y.

8. Repeat the process until the measured Gravity values are between 80% and 120% of
Lot Gravity values.

9. If values are ok, enter service calibration and check enable scatter calibration.

10. Press ok and browse the AS file for scatter calibration.

11. When ready, go to calibration menu and perform a calibration (min 3 measurements)

12. The new Scatter X and Scatter Y will appear. Press ok.

13. Calibration is done.

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 Servicemanual

6.9.2 Short guide for laser values

This is a short description to give information about the values and settings of the optical
head assuming that user understand the operation of the optical measurement.

Concepts:

Scattergram Gravity X
Scatter scale X Gravity Y
Scatter scale Y Low angle gain
WOC4 High angle gain
WOCB DC level
Laser Power

Scatter diagram (Scattergram):

The scattergram is responsible to view the white blood

cell populations. The 4 diff scatter indicates the 4
differential populations (LYM, MONO, NEU, EO), the
Baso scatter shows the BASOPHIL population. Both
scattergrams are indicated as a square, surrounding all
the populations. In default, the scatter has a size 1.00
x 1.00. This scattergram can be magnified, making the
cells / populations change positions. The size of the
scatter is defined by the scatter X (horizontal) and
scatter Y (vertical) values. These values are 1.00 in
default and can be modified by calibrating the scatter.

The values of Scatter X and Y are shown in service calibration menu or it can also be found
on factory settings menu.

Gravity values:

Gravity values are specific numbers for all type of

control blood for instruments with optical
measurements. These numbers indicates the
center of gravity.
All cells (which is part of a population and not
noise) are counted and added horizontally, line by
line and divided by the number of lines shown in
the scatter. This value is the Gravity X value.
The Gravity Y is created the same way; all cells
attached to a population are added vertically and
divided by the number of columns shown in the scatter.

All controls have its own gravity values, these values are used as target reference during
calibration. The gravity values are stored in an AS file and can be uploaded or added
manually before making a calibration.

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Hemolyzer 5

(After a measurement, the gravity values are indicated in the measurement database.)

WOC4 and WOCB values:

WOC4 (WBC Optical Count for 4 diff scatter): indicates the ratio of WBC cells included in the
4 diff measurement. Min. value: 2.72
WOCB (WBC Optical Count for Baso scatter): indicates the ratio of WBC cells included in the
BASO measurement. Min. value: 5.44
These values are also displayed in the measurement database, showing that the number of
cells during measurement is enough.
If WOC4 is low (and WOCB is ok), it can indicate that the TCU is clogged and only a little
amount of cells entered the flow cell.
If WOCB is low (and WOC4 is ok), it can indicate that there is a partial clogging in the WBC
chamber, not allowing the cells to reach the flow cell.
If both values are low, it means that the flow cell is clogged (both 4diff and Baso cells aren’t
sensed by the laser) and needs to be cleaned by software or manually.

Neutrophil area center point:

If the measurements are displayed with
Analyzer Spy software, there is a chance to
enlarge the image of the actual
measurement’s scatter. There is a small
green cross appeared on the scatter (both
4diff and Baso). This marker is created to help
the laser’s calibration procedure, if there’s no
control blood available for measurement.
The marker indicates the Neutrophil
populations center point. With the use of this
marker, the user can manually set the
scatterX and Y values in the Analyzer Spy
software. By enlarging the scatter with X and
Y scale scatter values, the Neu population field
can shifted to a position where the marker is the middle of the Neutrophil population. This is
a harsh approximate calibration showing the proper Scatter values. This values can be set in
the instrument manually in service calibration menu or factory settings.

Laser Power and gains:

In auto alignment menu, there is a chance to set the optical head values, laser power, low
and high angle gains. These values are set by Analyticon QC, but these values can be
modified to align the optical head operation to the instrument.

Every optical head has an unique setting of values. These values can be set in auto
alignment menu and stored in the instrument’s memory. The values are not stored
inside the laser. If optical head is changed in the instrument, the new laser’s values
have to be set in auto alignment menu to make the new laser’s operation proper.
Also note that these values are reset to default, if the windows is reinstalled or a
hardware block is changed.

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 Servicemanual

Laser power values (both for 4diff and Baso) indicate the current operating the Laser Diode.
The higher the laser power value, the lower the current flows though the diode. If the power
values are increased, the current will be decreased making the scatter smaller in both
dimensions (X and Y).
Laser power value had a range from 54 to 96. Older (2012 and older) type of laser’s must
keep this range (54-96) with a standard low angle gain 48, and high angle gain 112.
In new type of optical heads (created in 2013 and after), the optics, flow cell size and
amplifier is modified.
This modifications increases the ranges both for power and gains. See ranges for new type
of optical heads below:

Laser power: 70 – 130

Low angle gain: 0 – 255

High angle gain: 0 – 255

Note that the lower the laser power value, the higher the Laser diode’s current, which can
create NOISE during laser blank measurements. These NOISE is indicated by warning flags
n, N at the end of a measurement.

The diode’s light is sensed by the detector. The area

of detection is masked by a metal plate to ignore the
LED’s direct light hitting the sensing zone. The zone
is separated to two different subzones. The internal
zone responsible to sense the low angle signals
(size of cells), the outer larger zone is for sensing
the high angle signals (internal structure of cells).
Both incoming signals are very weak and must be
gained by an amplifier. The Low and High angle
gains are the gain values of the laser’s amplifier,
these values also can be set in auto alignment
menu. In older optical heads, this values are
standard 48 and 112, but new optical head’s -with 3
stripes on the side- has a range of gain values.

The gain values are good to make small scatter alignments to improve the Gravity values
and Scatter sizes in small amount. Note that the values are directly proportional, the higher
the value the higher the gain is.

DC level:

The DC level value indicates the amount of light hitting the LOW ANGLE SENSING ZONE
without any cells involved. This value has a minimum and maximum range. Low DC level
could mean that the beam of light is misaligned, high DC level means dirty flow cell or optics.

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Hemolyzer 5

7 Verification procedures
7.1 Self-test
The analyzer has built in test function to check and evaluate operation of internal modules
and systems. The function is accessible from the Main Menu, Diagnostics, Self-test function.
There are two subsets of tests: electronic and pneumatic. Each process takes approximately
1 minute, and provides results of each tested parameter. You can select to run both test sets,
by clicking on the “Start Both” button. Accepted ranges are displayed below.
Big buffer time Small buffer time
Generate 3000 - 13000sec Generate1 1200 - 2800sec
Release 3000 - 6000sec Generate2 1200 - 2800sec
Release 700 - 1300sec
Big buffer drift Small buffer drift
Maximum 540 - 560mBar Maximum 225 - 235mBar
Minimum 530 - 560mBar Minimum 215 - 235mBar
Drift -5 - 15mBar Drift -5 - 15mBar
Pump status Null pressures
Pump1 1-1 Sheath -20 - 20mBar
Pump2 1-1 Capillary -20 - 20mBar
Chamber -20 - 20mBar
TCU Laser temperature/Optical
Reference 25 - 38°C Laser off 0 - 0.05V
Actual Reference +- 0.2 °C Laser on 0.06 - 0.8V
Sink 0 - 70°C
HGB LED Battery
HGB Dark 0 - 3000 pulses Battery voltage 2.7 - 3.3V
HGB light 3000 - 60000 pulses +12V 11.4 - 12.6V
-12V -12.6 - -11.4V
Electrode Noise/Pulse
Voltage 45 - 55V pls/5sec 0 - 2000 pulses
Current 620 – 680μA 20000pls 19990 - 20050 pulses
Offset -5.0 – 5.0mV

Would any value fall outside the above defined range, the SW will indicate it with a red,
“Failed” string. Correct and acceptable results are indicated with a “Passed” string.

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 Servicemanual

7.1.1 Hemolyzer 5 Self-Test Guide

The Hemolyzer 5 Self-Test provides information about the actual status of hardware and
software of the analyzer.
This guide is intended for helping service engineers to correctly interpret Self-test result and
to provide guidelines in troubleshooting the instrument.
It is possible to perform electronic Self-Test only, pneumatic Self-Test cannot be performed
separately.

7.1.1.1 General information

High level SW version: …….
Low Level SW version: …….
• Low and high level SW version must be identical. For proper functioning of the
instrument the two software versions has to be the same.

LSDACQ Firmware; LSDACQ PIC; Optical head; TCU SW versions; LSDACQ

version:
• All these must have version numbers. If version number isn’t displayed that can
indicate failure of part or communication error.

• LSDACQ version number provide information about compatibility with certain

electronic components;

OPT sensor board; TCU board; Pressure board; Laser driver board:
• These are intelligent components which communicate with the low level software via
I2C bus. All boards must be „PRESENT” for correct operation of the analyzer.

• If any of these components is reported „NOT PRESENT” that indicate failure of part,
cable or connection problem.

Corrective action: Check cables and LSDACQ status LEDs

7.1.1.2 Electronic Self-Test parameters

TCU temperature(C°):

• Actual: normal operating temperature of TCU unit is 29+/- 0,2 C°. Lower/higher
temperature indicate failure of heater/cooler circuit.

Troubleshoot accordingly.

• Heatsink: cooling of TCU is done by Peltier elements. Heat generated on the other
side of the elements is dissipated by a heatsink and cooling fan. Failure of fan leads
to overheating and damage of Peltier elements.

Corrective action: check and/or replace TCU

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Hemolyzer 5

• Laser DC level: Laser DC (Dark Current) is the reference value of the optical
measurement circuit. Measurement is performed on diluent. When the optical flow
cell is clean and bubble-free, laser light isn’t scattered by anything and only a very
small signal should be measured by the detectors.

• Laser off: DC level recorded without laser light. If out of range, probably the
Optosensor card is defective. In such case usually the Laser on value is out of range
too.

Corrective action: Check laser head's cables, change Laser Head Assembly

• Laser on: DC level with laser light. If Laser off value is in range but Laser on value
is high, it can indicate: dirty flow cell, bubbles in the flow cell, misaligned laser.

Corrective action:

- run „Flow Cell Cleaning” followed by blank measurement to wash out any air bubble
from the flow cell and repeat Self-test. If DC level is OK => nothing else to do

- manually clean* the flow cell with bleach solution

- wipe the flow cell sides with lint-free lens paper dampened with isoprophyl-alcohol

- change Laser Head Assembly

Laser head must be opened for this operation! Power off the analyzer, and proceed with
precaution; take extra care not to damage or misadjust any internal component of Laser
Head.

Electrode: These are the main parameters of impedance amplifier board.

• Voltage; Current: is out of range, the amplifier board or the high voltage board might
be defective

Corrective action: check or replace HVB board, check or replace amplifier board, check
cables

• Offset: if voltage and current is in range, offset can be adjusted. If the offset cannot
be adjusted or it is unstable, check or replace the amplifier board and /or LSDACQ.

Corrective action: change the impedance amplifier board or LSDACQ

• Battery / Power supply: Monitors the supply voltage of LSDACQ board (+/- 12V)
and the real-time clock battery voltage.

Troubleshoot accordingly

Laser parameters:

• Temperature(C°): temperature of laser diode block, for information purposes only

• Laser Power: the value of laser power setting. It is not percentage (!), just a digital
number.

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 Servicemanual

DO NOT CHANGE THIS VALUE UNLESS IT'S NECESSARY OR YOU INSTALL A NEW
LASER HEAD IN THE ANALYZER. IN THAT CASE LASER POWER VALUE TO BE SET
IS WRITTEN ON THE AUTOALIGNMENT SHEET OF NEW LASER HEAD OR ON THE
SIDE OF THE OPTICAL HEAD.

• HGB Head (electronic): HGB diode and sensor test.

• HGB dark: measured without light, if out of range probably the sensor is defective or
too much external light reached the sensor

• HGB light: measured with HGB diode on, if out of range that can indicate diode or
sensor failure

Corrective action: check chamber and amplifier for salt buildups, replace HGB head

• WBC Preheater: if out of range it can be adjusted in „Service/Adjustments”

• LSDACQ: show the temperature of the Dimmboard

7.1.1.3 Pneumatic Self-Test parameters

• Big buffer time(msec): The time necessary to generate the required vacuum in the
big(sheath) buffer.
• Generate(P1+P2): failed indicate weak pump, leak in vacuum system, bad valve
head or valve coil, kinked tubing, etc.
• Release: time necessary to completely vent the buffer, if failed, valve #5, related
tubing and vent nozzle can be at the origin of failure
• Small buffer time(msec): The time necessary to generate the required vacuum in
the small(capillary) buffer.
• Generate: failed indicate weak pump, leak in vacuum system, bad or valve head or
valve coil, kinked tubing, etc.
• Release: time necessary to completely vent the buffer, if failed, valve #5, related
tubing and vent nozzle can be at the origin of failure
• Big buffer drift(mBar): Failed indicate leakage in the sheath buffer-related vacuum
system. Troubleshoot accordingly.
• Small buffer drift(mBar): Failed indicate leakage in the capillary buffer-related
vacuum system. Troubleshoot accordingly.
• Max vacuum P1(mBar/sec): The maximum value of vacuum that can be generated
by the pump in a given range of time. Failed indicate weak pump or problem in
related valves or tubing.
• Max vacuum P2(mBar/sec): The maximum value of vacuum that can be generated
by the pump in a given range of time. Failed indicate weak pump or problem in
related valves or tubing.
• Pump status: Failed indicate that the pump wasn’t sensed by the electronic system.
Possible pump, connection, cable or PPB board failure
• Pressures – buffers vented(mBar): Show the remaining pressure/vacuum in the
buffers, after the instrument released the vacuum. If (any)failed, check related tubing,

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Hemolyzer 5

valves, and pressure sensor board, run pressure offset adjustment and repeat Self-
test.
• Noise/Pulse: This is an electronic test but it require diluent to be present in the
counting chambers.
• pls/8 sec: if failed either electronic noise is picked up by the electrode or the amplifier
board is noisy. Troubleshoot accordingly
• 20000 pls: a test circuit generate 20000 pulses and the counter number them. Failed
indicate defective amplifier board
• HGB head: Same test as in the electronic section, but with diluent in the counting
chamber.

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 Servicemanual

7.2 Error Messages

The analyzer checks the operations of several mechanic, fluidic and electronic parts during
measurement. The system shows the type of the error on the LCD display if any kind of
malfunction is detected.

When an error message pops up, the details contains the processes were involved when the
error appeared. The error codes also help to identify the problem.

Error code Description

0 EG_NO_ERROR
1 EG_BAD_VALVE_NUMBER
2 EG_BAD_PUMP_NUMBER
3 EG_PNEU_INIT
4 EG_BAD_CHAMBER_NUMBER
5 EG_ALL_VALVES_OFF
6 EG_NO_ANSWER
7 EG_CANCEL
8 EG_ABORT
10 EG_UNKNOWN
11 EG_ERROR_HANDLER
12 EG_NO_CONNECTION
13 EG_PRIME
14 EG_TEST_FUNCTION
15 EG_MEASURE_PUFFER
16 EG_MEASURE_PUFFER_SPEC
17 EG_CALIB_SENSORS
18 EG_TEST_MOTORS
19 EG_TEST_VALVES
20 EG_TEST_PUMPS
21 EG_PREP_FOR_SHIP
22 EG_CLEAN
23 EG_WASHHEAD_WASH
24 EG_BLANK
25 EG_STRESS
26 EG_EMPTYCHAMBER
27 EG_SHUTDOWN
28 EG_HARDWARE_INIT
29 EG_PNEUCONTROL
30 EG_PNEUCONTROL_VAR
31 EG_PNEUCONTROL_THR
32 EG_PNEUCONTROL_INIT
33 EG_MEASURECONTROL
34 EG_SV
35 EG_SEND_EVENT
36 EG_NEXT_MIX

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Hemolyzer 5

37 EG_NEXT_PIERCE
38 EG_INIT_PORT
39 EG_INIT_FPGA
40 EG_INIT_PIC
41 EG_INIT_MDATA
42 EG_LOOP
43 EG_SAMPLER_DELEG
44 EG_MOVING_DELEG
45 EG_NMOVING_DELEG
46 EG_COMM_PARAM
47 EG_TEST_DISLPAY
48 EG_INIT_STATE
49 EG_FILE_NOT_FOUND
50 EG_FILE_NO_INFORMATION
51 EG_FILE_OPEN
52 EG_GET_FILE
53 EG_SEND_FILE
54 EG_CRC_CREATE
55 EG_UPGRADE
56 EG_TEST_SPEC
57 EG_ANSWER
58 EG_COMMUNICATION
59 EG_DRAIN
60 EG_NEEDLESETTINGS
61 EG_HARDCLEANING
62 EG_MAININIT
63 EG_WAITFORCONTROLEVENT
64 EG_S_MSGMLR_TIMEOUT
65 EG_NM_MSGMLR_TIMEOUT
66 EG_M_MSGMLR_TIMEOUT
67 EG_PRESSURE
68 EG_THREADS
69 EG_WAITFOREVENT
70 EG_SENDEVENT
71 EG_DELETE_FILE
72 EG_SETTINGS
73 EG_REAGENTS
74 EG_SAMPLER_CONSTRUCTOR
75 EG_SAMPLER_INIT
76 EG_SAMPLER_STOP
77 EG_SAMPLER_GETSTATE
78 EG_SAMPLER_SETSTATE
79 EG_SAMPLER_GETPOSITION
80 EG_SAMPLER_SETPOSITION
81 EG_SAMPLER_GETCONTAINERTYPE

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 Servicemanual

82 EG_SAMPLER_CANCEL_WAITSTATE
83 EG_SAMPLER_WAITSTATE
84 EG_SAMPLER_ONLINE
85 EG_SAMPLER_SAMPLERDY
86 EG_SAMPLER_ERROR
87 EG_SAMPLER_FATALERROR
88 EG_SAMPLER_SENDPOS
89 EG_SAMPLER_BARCODE
90 EG_SAMPLER_INITDONE
91 EG_SAMPLER_STOPPED
92 EG_SAMPLER_TRAYDONE
93 EG_SAMPLER_PONG
94 EG_SAMPLER_SAMPLEMIX
95 EG_SAMPLER_BAROK
96 EG_SAMPLER_SENDTRAYINFO
97 EG_SAMPLER_SENDRACKINFO
98 EG_SAMPLER_UNKNOWNCMD
99 EG_SAMPLER_CMD
100 EG_SAMPLER_TRAY_DONE
101 EG_SAMPLER_STARTPOS
102 EG_AUTOSAMPLER_MEASURE
103 EG_FILL
104 EG_TEST_PIERCE
105 EG_MOVE_DILUTOR_1
106 EG_MOVE_DILUTOR_2
107 EG_MOVE_DILUTOR_3
108 EG_MOVE_DILUTOR_4
109 EG_BOB
110 EG_HORIZONTAL
111 EG_VERTICAL
112 EG_DILUFULL
113 EG_GET_BUBBLE
114 EG_BUBBLING
115 EG_MICRO
116 EG_MEAPUFF
117 EG_MEAPUFFBIG
118 EG_MEAPUFFSMALL
119 EG_PREDIL
120 EG_DIL_L
121 EG_SAMPLE_MOVE
122 EG_NEEDLE_WASHING
123 EG_WBC_STOP
124 EG_MIX_SAMPLE
125 EG_CHAMBER_MIX
126 EG_CHAMBER_RBC

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127 EG_CHAMBER_WBC
128 EG_HGB_MEASURE
129 EG_BASO_MEASURE
130 EG_BASO_SAMPLE
131 EG_RBC_MEASURE
132 EG_WASHING_DIFF
133 EG_PREDRAIN
134 EG_SENDTHEEND
135 EG_WBC_MEASURE
136 EG_OPT_SAMP_CL
137 EG_SET_POSITION
138 EG_BURNRBC
139 EG_BURNWBC
140 EG_TIMEOUT
141 EG_TOTTI
142 EG_AAMVERT
143 EG_AAMHORI
144 EG_AUTO_ALIGNEMENT
145 EG_STOP_PUFFER
146 EG_LYSE_PUFFER
147 EG_DILUENT_PUFFER
148 EG_SHEATH_PUFFER
149 EG_PRIME_DILU
150 EG_PRIME_SHEATH
151 EG_PRIME_LYSE
152 EG_PRIME_STOPPER
153 EG_AS_ERROR
154 EG_RINSE
155 EG_PNEU_INIT_2
156 EG_DELAY
157 EG_WAKEUP
158 EG_STANDBY
159 EG_CHECKPRIME
160 EG_SELFTEST
161 EG_LASERHEAT
162 EG_LASERHEAT_INFO
163 EG_MACHINEINFO
164 EG_FILELIST
165 EG_SV_CLEAN
166 EG_AUTOSAMPLER
167 EG_EXTRA1
168 EG_EXTRA2
169 EG_EXTRA3
170 EG_UDILUTOR
171 EG_CHAMBERS

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172 EG_CELL_CLOGGING
173 EG_FILL_LASER
174 EG_DEBUG
175 EG_REPAIR
176 EG_CANCEL_ANSWER
177 EG_CANCEL_AT_END
178 EG_PIC_ERROR
179 EG_SET_OFFSET
180 EG_AS_INFO
181 EG_REAGENT_LOCK
182 EG_RV_RD_ERROR
183 EG_RV_WR_FAULT_ERROR
184 EG_RV_WR_PROTECT_ERROR
185 EG_RV_ARG_ERROR
186 EG_RV_UNEXPECTED_ERROR
187 EG_RV_KEY_ERROR
188 EG_RV_CRC_ERROR
189 EG_RV_PERMISSION_ERROR
190 EG_RV_DEVICE_MISSING_ERROR
191 EG_RV_NOT_ENOUGH_MEASUREMENTS
192 EG_SERIALS
193 EG_OFFLINERINSING
194 EG_DC
195 EG_CLEANCELL
196 EG_CLEANDILU
197 EG_QCWIZARD
198 EG_QCTEST
199 EG_CHECK_ALTITUDE
200 EG_RELEASE_AIR
201 EG_AS_COVER
202 EG_BLOODSENSOR
203 EG_BLOODSENSOR_CALIB
204 EG_OVERNIGHT_CLEAN
205 EG_PRESSURE_OFFSET
206 EG_CANCEL_REPAIR
207 EG_DRAIN_TCU
208 EG_FILL_TCU
209 EG_DRAIN_FLOW_CELL
210 EG_FILL_FLOW_CELL
211 EG_XY
212 EG_EMPTYRCHAMBER
213 EG_EMPTYWCHAMBER

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7.3 Service Menu

There is a Service menu for servicing and operation checking purposes; however it is hidden
from the standard user. To access the service menu:

With on screen keyboard active:

• Go to the Main Menu
• Tap and hold the Main Menu icon for appr. 6 seconds
• Accompanied by a “bing” sound, the password entry dialog will be displayed.
• Enter the service code (6484A5)
• The service menu icon will be displayed

With onscreen keyboard inactive

• Connect an external USB keyboard
• Go to the Main Menu
• Make sure the arrow is over the Main Menu icon
• On the external keyboard, type 6484A5
• Press enter
• The service menu icon will be displayed

Enter the following code to access service menu: 6484A5

Password is case sensitive

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Once you typed in the correct service code, you will enter into the service menu. The system
is designed to provide you continuous access to service functions: you will have to enter the
service code once for a specific service session.

The button in the lower right corner says “Service mode OFF”. This is the EXIT point of the
service menu.

Do not forget to end service operation by tapping the “Service mode off” button to prevent
users accessing the service menu.

The following screen displays available operations and functions. Refer to the menu screen
above to locate the description of the feature.

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7.3.1 Service functions

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7.3.1.1 Test functions

This item allows running specific test procedures. You have to enter the “ID” of the required
service and RUN the process. The list of available functions and their expected result is
listed below.

ID Name Expected result

2 Go to Standby The system will go into standby independently of standby
timer status
3 Drain tubing system It is equivalent to tapping the “Drain all” function under Main
Menu / Maintenance / Drain all
4 Wakeup The system performs wakeup function.
15 Skip clean The system will assume Cleaning has been performed
61 Skip (next) Pneuinit The system will omit pneuinit
62 Skip (next) Rinse The system will omit Rinse (tube washing process)
63 Make PneuInit The system will be forced to do a pneuinit (as if it was just
Mandatory powered on)
64 Make Pneuinit and Prime All motors and the tube system is set to uninitialized state.
Mandatory (equivalent to power off)
65 Make Fill Mandatory Equivalent to first startup – the system will assume that all
pneumatical systems are empty.
66 Skip Pneuinit, Clean and Combination of various functions
Wakeup
67 Skip Pneuinit, Wakeup Combination of various functions
68 Skip Pneuinit, Rinse and Combination of various functions
Wakeup

7.3.1.2 Low level file management

Allows accessing files located in the DimmBoard’s SD card.

7.3.1.3 Low level reboot (DimmBoard)

This command allows restarting the Low Level software which controls the pneumatic
system. This might be necessary when the communication is lost between the High and the
Low level systems. Typically: when the Start button remains RED without pneumatically
action and the system does not respond to user commands. This function forces the
DimmBoard controlled system into a known basic state.

7.3.1.4 Pneumatical System – Initialize

When Initialize starts, the system moves all mechanical components to their "standby"
position. This function allows starting up pneumatics after mechanical alignments or a
system startup. The system will perform an Init process after Wash head and Needle
alignment or when Service testing menu was used.

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7.3.1.5 Network management

This is the input area to define network related parameters in connection with LIS
communication. The parameters required for setting up the link should be acquired from the
system operator of the network you want to connect the analyzer to.

7.3.1.6 RAW data saving mode

Allows selection of RAW (unprocessed) data file save mode. Raw data files can be important
for Analyticon support or R&D team to analyze and troubleshoot. Turn on Raw data saving
mode to make the system save measurement data during further measurements.

7.3.1.7 Export RAW files

Allows saving collected RAW data files to a removable storage media, typically USB Flash
memory.

7.3.1.8 Windows Control Status

This setting controls whether the CTRL-ALT-DEL combination can be used to access system
functions or not. This setting is suggested to be turned OFF after installation of the analyzer
at the end user’s site to prevent unauthorized access to system files. This setting requires a
system reboot.

7.3.1.9 TCU fill/drain

Allows to fill the TCU tubing system with reagents or remove all liquid from the tubing.
Recommended to use draining before and fill after TCU removing.

7.3.1.10 Flow cell fill/drain

Fills up or completely removes all liquid from the optical head. Use drain before removing
laser head.

7.3.1.11 Blood sensor status

Turns on and off the blood sensor

7.3.1.12 Reset statistics

This function resets the statistic screen. The statistic contains information about the
instrument's history. It shows the number of startups, shutdowns, errors, etc. See section
16.4 in User Manual.

7.3.1.13 Hard drive maintenance

Makes a defragmentation on the hard disc. It can be used to make the system faster is
database contains too many measurements.

7.3.1.14 Show advanced DB view

Changes the database screen to contain more information

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7.3.1.15 Small sample mode

Enables to use small sample mode if it's installed into the system.

7.3.1.16 Pre-diluted mode

Enables to use pre-diluted blood sample.

7.3.1.17 Monitoring
Allows to connect the system to an external computer by entering its IP address. If
monitoring is enabled, it's possible to see how the unit is used in real time on a PC or laptop
which is located in another area.

7.3.2 Service testing

Service Testing menu provides tools for
checking hardware.

• Valves - In the menu you can see

buttons (each represents a valve). The
state of buttons is similar to the state of
valves.

• Motors - In the menu you can see

buttons (each represents a command
to motor). By pressing a button you can
send the motor to the requested end-
position.

• Pumps - In the menu you can see

buttons (each represents a pump).By
pressing the buttons you can turn on
and off the pumps.

• Also allows to monitor pressures in real time on all three pressure sensors.

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7.3.3 Service calibration

The analyzer provides a menu for Service
calibration purposes. This screen displays the
actual calibration factors, service level calibration
factors and the user level calibration factors.
Service and User level factors are multiplied and
the system is using the result as the actual
calibration factor for each measured value.

Example for RBC:

RBCDisp. = FactRBC User * FactRBC Serv *

RBCMeasured

Service calibration screen displays both factors for

the values measured in the chambers and in the
optical head.

7.3.3.1 Enable scatter calibration

This checkbox has to be enabled to make a scatter calibration. The system will ask
for the scatter calibration file (AS file) which contains the gravity values of the
selected control blood. After the AS file is selected, push calibration to measure with
control blood. After measurements are done, the system will display the new scatter
values.

7.3.3.2 Backup Calibration

It is possible to save the calibration factors to a ‘bak’ file. This option is recommended
before reinstalling the operation system or the High Level software. Save the
calibration file to a pendrive.

7.3.3.3 Restore Calibration

It is possible to restore the saved calibration values from a pen drive by pushing
Restore Calibration.

7.3.3.4 Load Calibration

The system is capable to upload calibration factors made by the Analyzer Spy
software. This is useful when Backup calibration option was missed before software
reinstall and all the factors are reseted to 1.00. The Analyzer Spy software can create
a fact file with all the defined calibration factors. Load the fact file with Load
Calibration and not with Restore Calibration.

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7.3.3.5 Accept User factors

Pushing this button will reset the User factor values to 1.00. Reset values will be
multiplied with Service factors, creating new Service factors.

7.3.3.6 Back
Returns to Service menu screen.

7.3.3.7 Accept
Actual calibration factors can be modified by tapping the touch screen. After new
values are typed in, Accept has to be pushed to make the system use the new
factors.

7.3.4 Stress measure

In Stress mode, the instrument performs
measuring cycles without sample (blank
measurements) continuously. This can be used
for burn-in tests, or to check pneumatic system
after changing any main fluidic parts.

You can have information about stability,

cleanliness, HGB operation, and counting time
stability.

It is possible to Load last stress results to gather

more information of the analyzer.

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7.3.5 Auto alignment

This function allows access to adjusting the
optical head’s laser alignment. The page is
password protected, but some functions are
accessible without entering the password.

• Laser settings can be typed in manually.

After values are entered, press Save
values to confirm the settings.

• By pressing Read DC, it is possible to

check the status of the optical head. DC
level is also indicated in Self-test menu. If
DC level is in range it means that the flow
cell and the laser diode is proper. If the
DC is high or not steady, flow cell
cleaning needs to be done.

Always type in the new Laser settings if optical

head was replaced.

7.3.6 AS (Auto-sampler)
This function allows accessing and testing
various functions of the Auto Sampler.

7.3.6.1 Go to Pos
Pulls the selected rack position -defined
by the RackPos and SamplePos-in front
of the mixer.

7.3.6.2 Reset
Sets the Auto-Sampler to default position

7.3.6.3 Repeat last command

Repeats the previous action.

7.3.6.4 Go To Mixer
Pulls the selected rack position -defined
by the RackPos and SamplePos-into the
mixer.

7.3.6.5 Load to sampling position

Pulls the selected rack position -defined by the RackPos and SamplePos-to the
needle

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7.3.6.6 Set up Barcode Reader

7.3.7 Adjustments
This page contains software and mechanical
adjustments. These adjustments and values
have to be set correctly for proper working.

• Optical channels offset

Reduces the offset voltages in the optical

head. Can be set by hand or
automatically.

• Impedance amplifier offset

Reduces the offset voltages in the

amplifier board. Can be set by hand or
automatically.

• Needle tube full length/sample

position

Sets the correct blood position by default

or by using Blood sensor.

• Pressure offset adjustment

Sets the pressure sensors to reduce the sensed pressure offsets during
measurements.

• Needle & wash head adjustments

Sets the mechanical parts to position for checking and adjusting.

• Also possible to retype the system's serial number after a hardware

(DimmBoard, LSDACQ, Hardware block, HDD) change.

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7.3.8 Multiuser Settings

In this page the Administrator can create new
user profiles or delete existing users.

More than one user can have access to the

analyzer if Multiuser mode enabled checkbox is
set.

The user will have Administrator rights if the

Administrator checkbox is enabled.

7.3.9 MDA view

This screen allows monitoring activity of the Low
Level software in the DimmBoard. Regularly,
communication and pneumatic procedures post
status report on this screen.

Analyticon Support may ask you to open this

window and report messages.

MdaOn checkbox has to be enabled to see the

activity of the Low Level software.

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7.3.10 Software upgrade

The software of the Instrument can be upgraded
using a commercially available USB flash memory
device.

Hemolyzer 5 software can be upgraded with

software releases from Analyticon. It is
recommended to install both upper (Windows XP)
and lower (DimmBoard) software from the same
release package to keep maximum performance
and compatibility. However software releases
come in packages, it is possible to install the
upper and lower software independently.

7.3.10.1 Refresh data

Shows the serial number and all software and
firmware versions installed on the analyzer.

7.3.10.2 Change High Level software

Brings up the screen where the High Level software file (msi file) can be selected (browsed).
Make sure that the file is prepared on a pen drive attached to the instrument.

7.3.10.3 Change Low level software

Brings up the screen where the Low Level software file (lls file) can be selected (browsed).
Make sure that the file is prepared on a pen drive attached to the instrument.

7.3.10.4 Change Low level boot

This button needs to be used when the system's software has to be updated from 1.3.xxx to
1.4.xxx

7.3.10.5 Change LSDACQ firmware

Brings up the screen where the LSDACQ firmware file can be selected (browsed). Make sure
that the file is prepared on a pen drive attached to the instrument.

7.3.10.6 Change Optical Head Firmware

The optical head's (laser) firmware can be updated here.

7.3.10.7 Change TCU software

The TCU board also contains software which can be updated here.

7.3.10.8 Change AutoSampler software

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The Auto-Sampler has software similar to the Low Level software in the DimmBoard. This
software can be controlled by the High Level software. It is possible to update the software
here is new software is enable.

7.3.11 Reagent Lock

The analyzer can keep track of measurements
and will change (decrease) the number of
available measurements accordingly.

Definitely, some service actions require

measurements with reagents from the User’s
licensed tests. The analyzer will thus decrease
the license counter.

To make up for these measurements, the service

engineer can use the dedicated Service Reagent
Key to “give back” the used number of
measurements to the client.

Upon connection of the Service Reagent Key, the

numbers of available measurements on the key
are displayed. You can enter the number of tests
you need to provide for the end user to
compensate them for the sample runs related to
the service operation.

Enter the number of measurements to grant, and

click on the Grant button. The selected number of
tests will be added to the counter of the analyzer,
and at the same time the number of available
measurements on the Service Reagent key will
be decreased with the granted number.

Make sure that the reagent key is connected

properly to the instrument.

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7.3.12 QC Wizard
It's possible to run several automatic tests on the analyzer. QC Wizard is used by Analyticon
production to ensure that all mechanical, pneumatic and electrical settings are correct.

QC wizard requires a 'lim' file containing ranges for all the tests.

7.3.13 Printer installation

Hemolyzer 5 supports all Windows XP
compatible printers. To install a printer or a
printer driver, you are going to need either an
external USB CD or DVD drive for the original
printer driver CD, or a USB flash drive with the
printer driver.

This option allows installing a printer on

Hemolyzer 5. Normally, users are not allowed
to connect and install printers, since all
peripherals must be installed, connected by the
representative of the service provider of the
analyzer. The add printer button initiates the
Add printer Wizard from Windows. Follow
instructions on the screen to install the printer.

7.3.14 Factory Settings

Accessible to the Manufacturer only.

7.3.15 Service mode OFF

Clicking on this button will turn service mode off, and puts you back to the User Menu. To re-
enter Service menu, you need to type in the service code again.

Make sure you finish any service related actions requiring service menu access with clicking
on this button to keep the end user away from these functions.

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7.4 Software systems

Hemolyzer 5 has a complex software
system. This system can be divided into
two parts, low level system and high level
system. The low level system (DimmBoard
SW) is responsible for the moving parts of
the analyzer and the high level system is
responsible for the user interactions. The
high level system is running on a built-in
industrial PC with an operating system
(Microsoft Windows XP Embedded).

7.5 General SW installation guide

• Please contact our support team under
support@analyticon-diagnostics.com to
get the following files:
Hemolyzer5.msi
Upgrade.lls

• Copy all files to a USB memory stick.

• Power on the Analyzer – do not
perform pneumatic operations (like
measurement).
• Connect the USB memory stick to the
Analyzer. Wait a few seconds until the
LED in the memory stick starts flashing.
• Go to Service Menu (enter the code:
6484A5)
• Go to SW upgrade. Press “Refresh
data” to see SW versions of individual
components.
• Write down SW versions to a paper (or
tap Print icon to print the image).
• Upgrade software in the following
order:

Low level SW – tap the “Change Low

Level SW”. Locate the lls file on the “E:”
drive. (By default, the USB stick should be
the E: drive. If not, please browse to the
USB stick (F:, …)

• Select the file by tapping the checkbox next to the file, then clicking OK. The process
will start – you can see the progress on the progress bar.
• High Level SW- Click on “Change High Level SW” – the analyzer will ask you to
locate the Hemolyzer5.msi file on the USB stick. Select the file by tapping the

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checkbox next to the file, then clicking OK. The process will start. Click “next,
next…install”.
• Wait for the process to end.
• Click on “Finish” (the new SW will start).

Note: Software restart (especially if there are more than 1000 samples present in the
database) might take several minutes. During this process, the screen will be blank (black –
with the mouse pointer displayed). Do not interrupt the process by turning the analyzer off.

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Hemolyzer 5

7.5.1 Install operating system Windows 2.0 install using pendrive

Tools needed:

- Pendrive (at least 4 GB)

- Pendrive with high level software
- Windows iso image file 2.0 (winpe_x86_v2.0)
- Rufus v1.2.0(or higher) application
- Additional files directory
- External usb keyboard and mouse

Step 1.
To install windows from pendrive, a bootable pendrive has to be created first.

Copy the additional files directory and the software rufus_v1.2.0. to your hard disk.

Make sure that the windows 2.0 iso file (winpe_x86_v2.0) is also downloaded to the PC’s
hard disk.

Step 2.
Insert the pen drive (4 GB or higher) into the
PC

Step 3.
Run the rufus exe.

„Rufus” will automatically find the external

device attached to the PC.

Select NTFS for File system.

Cluster size is default.

Make sure that the „Quick format”, the

„Create a bootable disk using ISO image”
and the „Create extended label and icon
files” checkboxes are checked/marked. Click
on the disk button to select the windows ISO
file. Browse and find winpe_x86_v2.0.iso file.
You can also set the „New volume label” to a
name of your choice.

If setting is ready, press Start button.

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Step 4.

Let „Rufus” copy the ISO to the

pendrive.

It will take approximately 80-120

minutes, depending on the hardware.

Do not remove the pendrive during

the copy!

Step 5.

When copying if finished, you have to

select the files in the Additional files
directory and copy it to the root of the
pendrive.

The pendrive is now a bootable

windows installer. The Pendrive should
look like in the image on the left.

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Hemolyzer 5

Step 6.
Now we have to set the hematology analyzer to recognize to Pendrive.

Insert the pendrive to the hematology analyzer, also attach the USB keyboard and turn
the analyzer on. While the booting process is going, press „del” button to enter to BIOS.

In Advanced BIOS Features, set the first boot device to Hard disk.

On the same screen you have to enter to Hard Disk Boot Priority. Select the Pendrive
to be first, so the system will use the Pendrive as an external Hard Disk (use + and –
buttons to change the order of HDD).

If setting is ready, press F10 and save to exit from BIOS and restart.

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Step 7.
The system now restarts and a
message will appear on the screen
„Press any key to boot from USB”.
Press any key, than wait until windows
command console window appears. If
you miss pressing any key, the system
will stop with an error. In this case,
restart the system with
CTRL+ALT+DEL. As the windows
console window appears and it’s ready
to receive the commands, type in „e:”.
Warning: In case of a new HDD, it can
happen that the „e” drive is not
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available. In this case, remove the
bootable pendrive and type in the
below commands into the console to
create proper partition on the HDD.
DISKPART
SELECT DISK 0
CLEAN
CREATE PARTITION PRIMARY SIZE=100000
FORMAT FS=NTFS QUICK
ACTIVE
ASSIGN LETTER = C
CREATE PARTITION PRIMARY
FORMAT FS=NTFS QUICK
ASSIGN LETTER = D
EXIT
EXIT
Replace the pendrive then wait until
console window returns.
If „e” drive exists type in „installpen” to
start the windows install. The system
will offer to options, first one is to
recover the windows the second one
is a full format. The recover format will
keep the database, the full format will
erase all data from the HDD (which is
not a problem if the HDD is new).
Choose number 1 or 2 then press
enter to start the process. The
windows install/recovery would take
approximately 30 minutes. If the install
is done, remove the pendrive and type
„exit” to restart the system. If you
didn’t remove the pendrive, don’t
press any key when it’s offered, let
the system start windows from
HDD. If the touch screen is not
calibrated, you have to use a mouse to
find touch screen calibration on the
desktop. Start touchcalib and calibrate
the screen, by pushing the 4 corners
(crosses) on the touchscreen. If touch
is calibrated, insert the second
pendrive with the high level software
installer, start total commander and
run the high level software’s msi file.
Hemolyzer 5

Step 8.

After install is done, the high level software has to be set properly.

Please adjust or set:

- Calibration factors (load or restore calibration factors if it’s saved before)

- Laser setting (power, low and high angle gains have to be set again for proper scatter
values)

- Offsets on amplifiers (optical measurement and impedance measurement offsets

have to be set (zeroed) in adjustments menu)

- Pressure sensor offsetting (also have to be set to make the pressure sensor work
properly)

- Set the serial number of the instrument (the serial number is also stored on the HDD,
after windows install the serial have to be set again. Use adjustments menu to enter
the same serial number as on the DIMMPC/DIMMBOARD or on the sticker on the
back of the instrument).

Windows and high level software install is done.

7.5.2 Installing a Printer

Hemolyzer 5 is using a Windows operating system. To add a new printer on Hemolyzer 5
you have to install the printer specific driver. The operating system has limited possibilities
for user interaction affecting operating system functions. Follow the steps below to install a
printer, or use one of the printer install functions from the service menu (see section 7.3.13).

1. Prepare the printer driver on a USB stick. (Either copy it from the install CD, or
download it from the printer manufacturer’s web site)
2. Connect a USB external keyboard.
3. Connect the USB stick with the printer driver to an available USB slot on the analyzer.
4. Make sure that Windows control function is Enabled in Service functions menu
(section 7.3.1.8).
5. Press CTRL-ALT-DEL on external keyboard to access „Task manager”
6. Select „start new process”
7. A file dialog box appears. Browse the file system for the USB stick and locate the
install package of the printer. Run the application (printer driver). Follow instructions
on the screen.
8. Upon completion the printer becomes available as an installed printer for Hemolyzer
5
9. Exit task manager (close)

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8 Installation
8.1 Check the Delivery
When you receive the ‘Hemolyzer 5’ analyzer delivery, please ensure that the packaging is
not damaged. Check the bill of lading accompanying the package against your order
documents and ensure that the shipment is complete and that all documentation is in order.
If you have ordered an optional Autosampler, it will arrive in its own package. Please contact
your sales representative, service representative, or shipper if there are any discrepancies in
the shipping documentation or any visible damage to any of the packaging.

Please follow all applicable laws or regulations regarding the handling or opening of the
‘Hemolyzer 5’ analyzer packaging.

8.2 Prepare For Initial Installation

Before you start the installation please ensure the following:

• Locate a suitable place for the ‘Hemolyzer 5’ instrument

• Identify any additional laboratory personnel that will observe the installation process
• Have the contact information for your Analyticon representative or service engineer
• Arrange for additional support (IT specialist, electrician, etc.) if necessary during the
installation
• Understand and follow the analyzer General Precautions listed in section 2.2.

8.2.1 Select a Suitable Location

Select a location for the ‘Hemolyzer 5’ analyzer that meets your laboratory requirements for
safety, ergonomics and efficient workflow. The location should also meet the environmental,
electrical, and safety requirements of the ‘Hemolyzer 5’ listed in section 2.

It is important to install the instrument in a suitable location. A poor location can adversely
affect its performance. Consider the space and weight requirements listed in sections 2.6
and 2.7.

To allow reliable operation and to provide a safe working environment, make sure that the
table supporting the unit is stable enough to carry the weight of the instrument and
accessories. Reagents should never be placed above the analyzer to avoid spill hazards.

8.2.2 Make Any Special Arrangements

If you decide to route the reagent tubing through the tabletop, please ensure that any
necessary holes are drilled before the installation process starts.

If you plan to connect the ‘Hemolyzer 5’ analyzer to any external devices (keyboard, mouse,
printer, host computer, etc.), please ensure that all necessary preparations (cable-channels,
cable-binders, drilling through tables, walls etc.) are complete before the installation begins.

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8.2.3 Gather Your Peripherals Devices

Collect any external keyboard, mouse, bar code reader, or printer that you will be attaching
to the ‘Hemolyzer 5’ analyzer. Although the Windows® XP® Embedded operating system
installed on the ‘Hemolyzer 5’ analyzer is capable of automatically recognizing multiple
peripheral devices, please ensure you have available any installation disks or drivers
provided by the device vendor. See section 3.4.7. to learn peripheral connections on the
hardware block.

8.3 Performing the Installation

Now that a location has been selected and all preparations are complete, you are ready to
begin the installation. Initial installation should only be done by Analyticon certified service
personnel. You can find the installation checklist in section 8.4.

8.3.1 Move the ‘Hemolyzer 5’ to the Selected Location

Always have two persons present and use safe lifting procedures when lifting the ‘Hemolyzer
5’ analyzer. Safely move the ‘Hemolyzer 5’ analyzer, the accessory box, and the optional
Autosampler (if ordered) and the Autosampler accessories to the selected location. Keep the
‘Hemolyzer 5’ analyzer in an upright position and gently set it down in its new location.

8.3.2 Visual Inspection

Visually inspect the ‘Hemolyzer 5’ before proceeding with the installation and verify that:
• The front panel is be free of cracks or scratches
• The display screen is free of cracks or scratches
• The top, sides, and back panels are free of dents or scratches

Open the front panel of the unit and visually verify that:
• The syringes are not cracked
• The shear valve has the protective card installed
• There is no fluid inside the tubing
• There is no salt buildup inside the tubing

Remove the side covers of the unit and verify that:

• The tubes on the valves are in position and not popped off from (note that valve # 4
has a free connection)
• Cables are not loose and they are well connected
• The reagent puffers are not cracked and there is no salt buildup on their sides and
bottom
• Chambers are not cracked

Visually inspect the Autosampler and verify that:

• The outside housing of the Autosampler is free of dents or scratches
• The transparent cover opens and closes smoothly
• The sample tray and the sample racks have no visible damage

8.3.3 Remove the Protective Card from the Shear Valve

The shear valve comes equipped with a protective plastic card between the ceramic disks of
the shear valve to prevent damage and adhesion during transportation.

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To remove the protective card, perform the following steps:

• Open the front cover of the ‘Hemolyzer 5’ analyzer

• Locate the white protective plastic card in the shear valve as shown in 2. Figure.
• Gently pull out the card
• Check and tighten the locking screw of the shear valve if necessary

2. Figure: Shear Valve Protective Card

8.3.4 Connect the Optional Auto-Sampler

To connect the optional Auto-Sampler to the ‘Hemolyzer 5’ analyzer, perform the following
steps:

• Unscrew the five screws and remove the small cover plate on the right side of the
‘Hemolyzer 5’.
• Check that the connection surface is clean and there are no cables or other
obstructions blocking the opening.
• Gently push the Auto-Sampler into the ‘Hemolyzer 5’ until the clamps are locked.
• Place the white racks with the tray into the Auto-Sampler.
• Close the Auto-Sampler's cover.
• Pull then push back the Sampler's tray to see that it can move front and back.

8.3.5 Connect the Reagents

Place the reagent containers as shown in section 2.6.

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Open the protective package containing the reagent and waste tubes. When connecting or
changing reagent containers, please ensure that the reagent caps and tubes are protected
and do not touch the floor or other surfaces. This can lead to contamination of the reagents
and the ‘Hemolyzer 5’ analyzer.

To connect the reagents to the ’Hemolyzer 5’ analyzer, perform the following steps:

• Push the color-coded reagent and waste tubes all the way on to the matching color-
coded reagent connectors on the back panel of the ‘Hemolyzer 5’ analyzer.
o Green: Hemolyzer-Diluent
o Orange: Hemolyzer-5-Diff 5P
o Yellow: Hemolyzer-5-Lyser
o Red: waste container
• Route the reagent cap and tube to the matching reagent container, ensuring that the
reagent tubes are not bent, broken, twisted or blocked.

• Place the reagent or waste tube in the matching reagent or waste container and
screw the cap on to the container.

Only genuine Analyticon reagents should be used with the ‘Hemolyzer 5’ analyzer

The analyzer operates with chemically and biologically active reagents. Physical
contact with these reagents should be avoided. Please read reagent descriptions
carefully for possible emergency actions.

8.3.6 Connect the Power Cord

Before connecting the power cord, make sure that all of the ‘Hemolyzer 5’ back panel
switches and the optional Autosampler switches are turned off:

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• Turn off the main power switch (small switch) on the rear panel of the ‘Hemolyzer 5’
analyzer near the power connection to the ‘down’ position labeled ‘0’.
• If the optional Autosampler is installed, turn the power switch on the right side of the
Autosampler to the ‘off’ position labeled ‘0’.
Connect one end of the power cord to the power connection of the ‘Hemolyzer 5’ analyzer,
and the other end of the power cord to an appropriate wall outlet.

The ‘Hemolyzer 5’ analyzer should only be operated from a wall outlet capable of
meeting the electrical requirements listed in section 2.4.

8.3.7 Verify the ‘Hemolyzer 5’ Computer Operation

We are now going to start up, then shutdown the ‘Hemolyzer 5’ analyzer to ensure that the
computer system and software start and shut down correctly.

To power and shut down up the ‘Hemolyzer 5’ analyzer, perform the following steps:

• Turn on the main power switch on the rear panel of the ‘Hemolyzer 5’ analyzer near
the power connection to the ‘up’ position labeled ‘1’.
• Flip the power -on switch near the top of the rear panel of the ‘Hemolyzer 5’ analyzer
to the ‘up’ position.
• If the optional Autosampler is installed, do not turn on its power switch at this time.
• Wait until 'Hemolyzer 5' boots up and the software loads. This will take a few minutes.
• Ensure that the software displays the main menu and that no warning or error
messages are displayed. Warnings are displayed on the bottom of the LCD as a
yellow exclamation mark. Shut down the ‘Hemolyzer 5’ analyzer. DO NOT simply turn
off the power switches to shut down the ‘Hemolyzer 5’ analyzer. The analyzer
requires a specific shutdown sequence. See chapter 7.3.2. in User Manual for
information about the shutdown procedure.

8.3.8 Connect Peripherals

Ensure that the ‘Hemolyzer 5’ analyzer is completely powered down before connecting the
peripherals.

To connect the peripherals, perform the following steps:

• Plug in any external keyboard, mouse, bar code reader into the appropriate port on
the back panel of the ‘Hemolyzer 5’ analyzer.
• If a peripheral device requires its own power supply, plug it in now in a wall socket
belonging to the same socket group for proper grounding. Consult an electrician if
you have any questions about wall socket grounding.
• Turn on the main power switch on the rear panel of the ‘Hemolyzer 5’ analyzer near
the power connection to the ‘up’ position labeled ‘1’.
• Flip the power-on witch near the top of the rear panel of the ‘Hemolyzer 5’ analyzer to
the ‘up’ position.
• If the optional Autosampler is installed, do not turn on its power switch at this time.
• Allow the computer inside the ‘Hemolyzer 5’ analyzer a few minutes to start and
initialize the ‘Hemolyzer 5’ operating software.

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• Perform the software installation of the peripherals devices. The Windows® XP®
Embedded operating system recognizes most of the peripherals without additional
installation steps.
• Peripheral devices that require additional installation steps must be installed by a
Analyticon certified service engineer.

8.3.9 How to install a printer

Before making the printer install, prepare the printer’s driver files to an USB drive. Make sure
that the driver files are for the printer you want to install. If the printer has an USB
connection, there is a simple way to do the installing:

• connect the USB drive containing the printer divers to the analyzer
• make sure that an external keyboard is also connected to the analyzer
• connect the printer to the analyzer via USB
• if windows supports the printer, after a few seconds, the printer install window should
pop up. Windows recognizes the newly attached hardware and it starts the installing
process automatically by popping up the install window. If you press the touch while
the printer install screen is loading, the window will hide behind the 'Hemolyzer 5'
software. Use ALT+TAB to switch between the two screens
• in the popped up printer install screen, browse the driver files from the pendrive
• add all the necessary printer driver files if needed
• if the files are added properly and install is finished, the printer will appear in settings,
printer menu after „Refresh printer’s list” button is pushed (see user manual’s section
15.6).
• select installed printer and press save

If there is a problem during installing procedure or the printer install window is not popping
up, there is a way to install printers from service, printer install menu.

There will be three options for installation:

1. complete setup with SETUP.EXE file from printer driver CD or pendrive. Windows install.
Printer is not connected during installation
2. only driver installation with *.INF file. Will open Windows printer installation wizard
procedure.
Printer connected and turned ON during installation
3. only driver installation with *.INF file. Will open Windows printer installation wizard
procedure.
Printer is not connected during installation

8.3.10 Initializing the Optional Autosampler

If the optional Autosampler is not installed, skip this section. To initialize the Autosampler,
perform the following steps:

• Turn the power switch on the right side of the Autosampler to the ‘on’ position labeled
‘1’.

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• Make sure that the cover of the Autosampler is closed and that the ‘Cover’ led
changes to green;
• Double click the AS state on the left side of the Status Bar at the bottom of the screen
to bring up the ‘Autosampler info’ panel.
• Click the Reset button the ‘Autosampler info’ dialog as shown on the left figure below.
• The Autosampler performs a mechanical initialization. When this completes, ensure
the HOME message and the currently installed software version appears as shown
circled in red on the figure on the right below.
• Click the Ok button to close the ‘Autosampler info’ panel.

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8.3.11 Using the Settings Menu

The settings menu allows modification of various system settings. Click the Settings icon on
the Main Menu to bring up the Settings screen.

The Settings screen contains various buttons that allow the user to change system settings.
Each screen contains a Back button and a Save button. The Back button returns to the
Settings screen. The Save button save any changes made in the screen. If the Back button
is clicked without clicking the Save button first, all changes made in the screen will be
discarded. See description in the User Manual.

8.3.12 Set Up a Laboratory Information System (LIS)

'Hemolyzer 5' analyzer supports uploading of measurement data to an LIS or host computer.
If your laboratory has an LIS system, the ‘Hemolyzer 5’ analyzer can be connected to it using
a serial or an Ethernet connection. An LIS system is not required to operate the ‘Hemolyzer
5’ analyzer.

Your LIS system must be configured to accept measurement results from the analyzer.
‘Hemolyzer 5’ uses the Analyticon 3.1 protocol to communicate over a serial connection, and
the HL7 (version 2.5 or higher) to communicate over an Ethernet connection. See your LIS
vendor to determine if your LIS system is compatible with the ‘Hemolyzer 5’ analyzer.

LIS configuration requires a moderate level of familiarity with computer settings and some
understanding of computer data communications. If you are not comfortable setting up the
‘Hemolyzer 5’ LIS connection, consult your Analyticon certified service engineer.

Use the ‘External devices’ button in the Settings screen to set up LIS connection options.

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8.3.13 Set Up a Serial LIS Connection

To connect the ‘Hemolyzer 5’ analyzer to an LIS system using a serial LIS connection,
perform the following steps:

• Ensure that your LIS system is compatible with the Analyticon 3.1 protocol using a
serial connection.
• Connect a serial cable (null modem or modem eliminator) between the COM 1 port
on the back panel of the ‘Hemolyzer 5’ analyzer and the host system.
• Select the appropriate ‘Sending port baud rate’ on the ‘Hemolyzer 5’ ‘External
devices’ screen.
o Select 9600 baud if your serial cable is longer than 5m (~15’).
o Select either 9600 or 115200 baud if your serial cable is shorter than 5m
(~15’).
• Check the ‘Automatic LIS’ check box if you want every result to be transmitted
automatically to the LIS. Uncheck if you want to manually select and transmit
database records to the LIS.
• Uncheck the LIS check box.
• Uncheck the ‘Bidirectional LIS’ check box.
• Click the Save button to save your changes.
• Click the Back button to exit the External devices screen.
• Configure your LIS system to accept measurement results from the ‘Hemolyzer 5’
analyzer using these settings.
A copy of the ‘Hemolyzer Communication protocols’ description is available from your sales
representative or by download from the Support section of the Analyticon web site
(http://www.analyticon-diagnostics.com/en/service_and_support/partner_sign-in.html).

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8.3.14 Set Up an Ethernet LIS Connection

Connecting the ‘Hemolyzer 5’ analyzer using an Ethernet connection requires connecting the
analyzer to a local area network. Consult your IT administrator about connecting the
‘Hemolyzer 5’ analyzer to the local area network of your laboratory. The ‘Hemolyzer 5’
analyzer is configured at the factory to “Obtain an IP address automatically.” If this setting is
not suitable for your local area network and must be changed, only a Analyticon certified
service engineer can complete the installation.

To connect the ‘Hemolyzer 5’ analyzer to an LIS system using an Ethernet LIS connection,
perform the following steps:

• Ensure that your LIS system is compatible with the HL7 version 2.5 protocol or higher
using an Ethernet connection, and has been configured to accept ‘Hemolyzer 5’
compatible HL7 messages.
• Check the ‘Automatic LIS’ check box if you want every result to be transmitted
automatically to the LIS. Uncheck if you want to manually select and transmit
database records to the LIS.
• Check the LIS check box.
• Enter the IP address of the LIS host computer.
• Enter the Port of the host computer.
• Click the Save button to save your changes.
• Click the Back button to exit the External devices screen.
• Configure your LIS system to accept measurement results from the ‘Hemolyzer 5’
analyzer using these settings.

8.3.15 Running Blank Samples and Blood Samples for the First Time
The ‘Hemolyzer 5’ analyzer requires a blank measurement to be run every day before the
analyzer will allow you to run blood or control samples. This measurement is also called
Background which indicates that the system is clean and ready to measure blood samples.

The transportation and packaging process sometimes causes minor particles to be present in
the pneumatic components of the analyzer. For this reason, five to ten initial blank
measurements should to be run during installation to flush the system.

Click the Measure icon on the top left side of the screen and run a blank measurement. The
Start button will change color to red. The fill procedure and blank measurement take several
minutes to complete. The start button will change color to green and the blank result screen
will be displayed.

After the procedure completes, a blank result screen will be displayed. Click the ‘Start Again’
to run an additional blank measurement. Repeat this procedure several more times until the
blank results are no longer flagged, or until the blank results are low enough to satisfy
laboratory quality standards. If the Blank measurement is satisfactory, press Accept to make
other measurement modes enable.

Change the mode selector to Control and run a control measurement to see that the sample
results are correct. It's important to use a valid, not expired control sample with known target
values and ranges. See chapter 12 in User Manual for additional information about QC on
the ‘Hemolyzer 5’ analyzer.

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Lastly, it's possible that a calibration procedure is needed on the ‘Hemolyzer 5’ analyzer. See
section 11 in User Manual for additional details regarding ‘Hemolyzer 5’ calibration.

8.4 Checklist for installing Hemolyzer 5 hematology analyzer

1. Open the box, carefully take out and place the analyzer on a flat surface. The table or
desk should be able to bear at least 50 kg.
2. If the analyzer was stored in a cooler place than room temperature, allow 2 hours for
acclimatization, otherwise water condensation may happen.
3. Check the analyzer visually. Make sure that there is no visible damage. Open the
front cover and remove the side covers to check the electronics and the tubing.
Replace the covers when done.
4. Remove the plastic card from the Shear Valve and check tightness of the locking
screw.
5. If you have an Auto-sampler unit, remove the plate which covers the AS docking
connector (from the right side cover) and connect the Auto-sampler to the unit.
6. Place reagents preferably on lower level than the analyzer (max. 1 m difference).
Never place reagents to higher level than the unit itself!
7. Assemble and connect reagent and waste tubes to the corresponding containers and
connectors.
8. Connect the power cord.
9. Turn on the analyzer, turn on and initialize the Auto-sampler.
10. Connect other peripherals if needed (keyboard, mouse and printer).

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11. Check that all the software adjustments are proper. Use setting menu to adjust the
software according to the customer needs. Set the LIS connection (if the laboratory
has any).
12. Check that all the hardware adjustments are proper. Use service/service testing
menu to run or test the pumps, valves and motors.
13. From ’Diagnostics/Self-test’ click on ’Start both’ button and wait for the result.
14. Click on ’Measure’. Pneumatic initialization and „fill” cycle will start. Automatic
background cycle will be performed (at first startup several blank runs might be
needed till the results are acceptable)
After two or three blank measurements, results should fall within the acceptable
range, see section 22.7.9 in User’s manual.
15. Run a control blood in ’Control’ mode or run QC procedure.
16. Check if results are within the acceptable range. Run calibration if necessary.
17. The Hemolyzer 5 is ready for routine measurements.

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9 Troubleshooting
This chapter will show how to do a step by step troubleshooting on the 'Hemolyzer 5'
analyzer. Following the troubleshooting process ensures that the problem can be identified
without making any harm on the system. This chapter will helps find the root cause of the
problem and navigate to the page where you can find information how to solve the problem.

9.1 Troubleshooting checklist for Hemolyzer 5 hematology analyzer

1. Visual inspection

2. Powering up the system

3. Checking software adjustments

4. Checking hardware adjustments

5. Run a Self-test

6. Run a Blank measurement

7. Run a Control measurement

9.1.1 Visual inspection

The first step during troubleshooting is to check the instrument visually. Some problems can
be easily defined visually before any sample run test, measurements or even to power up the
system.

1. Check the front panel and the two side panels; look for scratch or any other damage.

2. Check the back panel of the analyzer, see that the reagents are connected properly,
the tubes are not misplaced.

3. See that the power cord is connected to the analyzer and plugged into the wall
socket. The power supply main switch is flipped to off position.

4. Open the front cover and remove the two side covers. See section 11.

5. Make sure that the tubing are not popped off from the valves, the chambers and
reservoirs are not cracked, there is no liquid on the bottom of the instrument and
there are no salt buildups around the pneumatic system. Check tube between blood
sensor and shear valve, see that the tube is transparent and not whites or has any
other color. Replace the tube if it's not clean or transparent enough. If tube was
moved or replaced, the blood sensor and the sampling values should be realigned.
Please see section 6.4 and 6.5 to learn how to calibrate blood sensor and sample
position. Other tube color changes are not so critical, but if there is a tube in the
system with a very huge pigmentation, it should also be replaced. Please see tubing
map in section 11.16.

6. Check all cable connections. Make sure that the cables are in position on the
LSDACQ, PPB boards, HVB panel and the valve PCB boards. Replace any damaged
cable.

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9.1.2 Powering up the system

After the visual inspection, it's time to see that the analyzer can turn on properly. Please
follow the steps below:

1. Make sure that the power cord is well connected to the analyzer and that the socket
can provide the proper electric power. Turn the power supply's switch to on position
and check that the power indicating LED on the motherboard is on. If the LED is not
on, please check the power cord. If the cord is ok, we must assume that the power
supply is not functioning.

2. Flip the power-on switch on the top back of the analyzer to turn it on. Check the five
green voltage indicator LEDs on the LSDACQ. The five LEDs show that the
necessary voltages are present. If one of the LEDs is not lit, check power supply
cable or replace LSDACQ board if needed.

3. Wait until Windows and the High Level Software of the analyzer loads. If there is a
problem during the boot process or the analyzer's software cannot load, please see
section 7.5.1.

4. There is a short audio welcome signal played by the analyzer after the software has
loaded. If you can hear the sound and the software screen is present on the display,
then the powering up was successful. If the display is showing windows, but not the
High Level Software, please see section 7.5.

9.1.3 Checking the software adjustments

Setting the software is important to make proper measurements. Every 'Hemolyzer 5'
software was set by Analyticon, but in some cases (windows recovery, high level sw reinstall)
this setting has to be done again or at least has to be checked. 'Hemolyzer 5' analyzer has
two software levels. The High Level Software is responsible to communicate with the user
and to give the user's commands to the Low Level Software. The Low Level Software
receives the User's commands and controls the pneumatic and mechanics system of the
analyzer. After low and high level analyzer software is loaded, check the following:

1. On the display, the High Level Software is present; the start button on the front panel
is lighting orange. If the start button is off, it means there is no communication
between the two software levels. See section 7.5 for communication error.

2. Enter to Service menu by entering the service password ‘6484A5’, then go into SW
upgrade screen. Press Refresh data. After a few seconds the analyzer should show
all the software and firmware versions in the system. Make sure that the analyzer has
the same version of the Low Level Software and High Level Software installed. If
there is a problem occurring during Refreshing data, please see section 7.3.10.

3. The software gives a warning mark if there is a problem noticed by the system. This
is shown as an exclamation mark in a yellow triangle on the bottom of the display.
Double tap on the mark shows the details of the problem. By pressing 'Go to' button,
the software brings up the screen where the problem can be solved. See section7.2
for detailed warnings.

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4. Go to Service Functions screen in Service menu. Check that the necessary

checkboxes like blood sensor status and windows control are enabled. If blood
sensor is disabled, please ask the user about the reason. For blood sensor settings,
please see section 6.4.

5. Go to Adjustments screen in Service menu. Check that the Auto-offset checkboxes

are enabled in Optical measurement offset and Impedance amplifier offset fields.
Press 'Read data' to see that the offset values are close to 0. Note that if 'Read data'
is pressed, the start button will turn to red, indicating the communication line between
the two software levels are busy reading the offset values. During the reading, no
other commands can be done by the analyzer. Make sure that the 'Stop data' button
is pressed to stop continuous reading of the offset and make the communication line
free again. If offset values are very high during the reading and auto-offset cannot
lower them, it shows an offset error in the LSDACQ. This board has to be changed in
this case.

Check that WBC preheater value is 375 (37,5 °C). Press 'Read data' to see the
current temperature of WBC preheater. If the value is ok, press 'Stop data'.

Press Start adjustment at Pressure sensor adjustment. Adjustment will take the few
seconds. The start button will turn red to indicate that the system is busy. After the
adjustment is done, check that all three offset results are in range. The values
shouldn't be higher than 20 mBars. If one of the values is higher, replace the pressure
sensor board.

6. Go to Auto Alignment screen. The system will ask a password, press cancel to enter
without giving the password. In this case, the password protected setting will be
unable to adjust. Check laser power, low level and high level gains. These are Laser
Optics related values. Changing one of them influents the WBC differential population
positions on the scattergram. These are factory defined values for the optical head
and they should match to default setting of Laser Optics in analyzer.

9.1.4 Checking the Hardware adjustments

The proper settings of the mechanical parts are important to make good measurements and
to increase the lifetime of the system. The mechanics are aligned by Analyticon during
production but some realignment may need when some mechanical parts are replaced or
repaired. These parts can be checked by Service testing menu.

1. Press all 40 valves on. Check that every valve can turn on and off. Make sure that
every valve can be turned on together, than press 'All off' to turn them off. If one of
the valves is not responding, try to replace it with a new one. See section 7.3.2.

2. Press shear valve to Needle position (NP) and Chamber position (CP). Check that
the shear valve discs can turn to the correct position without any grinding noise and
that there is no pneumatic error during the test. For problems related to shear valve,
see section 6.2.

3. Turn the sample rotor In and Out. Make sure that the front cover and the washing
head is not in the way. If you receive a pneumatic error, see chapter 6.1.

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4. Press 'Rear' and 'Front' buttons at MHori test to move the needle back to the Auto-
Sampler station and back to sample rotor position. Listen the sound of the
mechanics, if there is a grinding noise or a pneumatic error, please see section 6.1.

5. Press 'Down' and 'Up' buttons to see that the needle can move down and up properly.
Check that there is not noise during the movement; the moving mechanics parts are
not hitting the not moving parts. See that the opto LEDs can indicate the needle
positions properly. See section 6.1.2 for alignments.

6. Press 'Up' and 'Down' to all Dilutors. Check visually that the syringes can reach the
top and bottom positions without any problems. Look for micro bubbles at the pistons
and for leakage at the syringes. If there is a problem with a syringe and it needs to be
changed, see section 6.1.2.

7. Go to Service Functions screen and press 'Wash head' button to see that the position
of the washing head is proper. The system wants you to confirm that you want to
make a washing head position checking/setting, press 'Ok'. If it is in a good position
press 'OK' to make a mechanical initialization of the XY unit. Press 'OK' when it's
done. See section 6.1.3 for alignment information.

8. Checking the needle's position. There is two way to see that the needle is in a good
position.

o Move the needle down manually without using the software. If the needle is in
down position, check the distance between the end of the needle and the
sample rotor's plate. The distance should be around 1mm.

o In Service functions screen, press the 'Needle' button. The system wants you
to confirm that you want to make a needle position checking/setting, press
'Ok'. The system moves the needle up, the needle tip is inside the washing
head. If the needle is set correctly, the end of the needle should be hanging
out from the washing head. Press 'Ok' if it is aligned well.

For needle setting procedure, see section 6.1.4.

9.1.5 Run a Self-test

Self-test can be run In Diagnostics menu. This test is fast and automatic, very useful for
troubleshooting. For proper functioning of the analyzer, a Passed selftest is as important as
like a clean and acceptable Blank measurement. For selftest results see chapter 16.1 in User
Manual. If selftest is Failed, please see Self-test guide in section 7.1.

9.1.6 Run Blank measurements

The Blank and sample measurement provides valuable information about the fluidics and
electronic system, but some setting may need to receive the information in Database:

1. If Database only provides those parameters that are important to the clinicians, the
Database parameter setting must be changed. In Setting menu go to System and
press 'Set'. Please add extra columns to the database. Make sure that the following
columns are added.

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o PrV RBV

o PrV WBC

o Warnings

o Gravity X

o Gravity Y

o Woc 4

o Woc B

Select these columns and add them from the right to the left column block then
press Accept and Save. If you don't press save the setting were not made and the
result columns will not appear in the database.

2. Perform Blank measurements. NOTE: If it's the first measurement after startup, the
system makes an init process, a wake up process and Rinse process. If there was an
improper shutdown before, the system also asks for cleaning. These processes can
increase the time of the troubleshooting and reagent consumption. That’s why it can
be bypassed if you type in the suitable code (66-69) in Service functions on Test
functions field. See test functions at section 7.3.1.1. Type in the required test
function's number and press 'Run test'. If it is done, the Blank measurements can run
without any other requirements.

3. If a blank measurement is ready, please check that the result is not flagged with
warnings. Check probe voltages. RBC probe voltage (PrV RBC) should be 10-13
Volts, WBC probe voltage (PrV WBC) should be 20-27 Volts. If there are problems
with probe voltages, replace apertures, check measuring chamber and preamplifier;
see section 11.12. If the blank measurement is stopped with a pneumatic error,
troubleshoot as a displayed error codes, see section 7.2. If there is a problem with
popping off tubing in the system, see section 11.16.

9.1.7 Run Control measurements

Finally, a measurement with a sample is the most complex testing from all. A measurement
gives information about sampling, calibration, nonfunctional modules, clogged tubing or
valves. Measurement with blood sample and please check the following:

1. The control blood needs to be run in control mode. Please select proper mode.

2. The control blood shouldn't be expired and should have an exact target and range for
all values.

3. During sampling, please check visually if the sample position is proper at the shear
valve. Please see section 6.5 to learn more about sampling and setting sampling
position.

4. After a measurement is done, check the steps below:

o The results of the control are in range.

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o Cell numbers (Woc 4, Woc B) are proper on normal control. Woc numbers
(White blood cell Optical Count) indicates how many cells are present during
optical measurement. These values have only minimum number.

 Woc 4 min : 2.72

 Woc B min : 5.44

o Gravity values are close to the target. Improper or unstable gravity values can
indicate a calibration or an optical head problem. Scatter calibration must be
performed. See section 7.3.3 to learn more.

o Ignore probe voltages during Control measurement. Probe voltage values are
different in Control mode. To check probe voltages, use Blank or Human
mode.

o Check that impedance measurement results are proper and close to target. If
there is problem with the results, make a calibration (User Manual section 11)
or replace appropriate part of measuring unit (section 11.12).

o Check HGB result. HGB is accomplished by a photometric measurement

technology. Incorrect HGB result can be caused by dilution or mixing failure in
the WBC chamber. Whole WBC (impedance) count is also incorrect in this
case. But it's not related to the apertures and to amplifier board. If there is a
problem with HGB results, please clean the measuring chamber and replace
the HGB head; see section 11.12.4.

o The WBC differential (Ly, Mono, Neu, Eo, Baso) % results are within the
limits, the values are close to target. If there is a problem with the scatter,
please do a scatter calibration, see section 7.3.3, replace the injector in the
optics, see section Hiba! A hivatkozási forrás nem található..

5. Do measurements from the Auto-Sampler if it is attached. Make sure that the sampler
can move in X and Y direction and that the sample position is proper. See section
7.3.6. to learn more about the Auto-Sampler settings.

If the analyzer still has a problem despite of all the points of troubleshooting, please contact
Analyticon Support Team.

support@analyticon-diagnostics.com

9.2 Mechanical problems

9.2.1 General guidelines to overcome motor or moving part related problems
Make sure to follow this simple sequence to be able to locate sources of errors and to
resolve problems easily and correctly.

• Always make sure that the part with the problem can be moved freely and easily.
• Make sure that there is enough (and not excessive) amount of lubricant on the
moving parts.

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• Test the motor with the built in functions in service testing menu. It will always try to
operate all sensors, and will drive the motors with necessary current and power.
• Any Setting or adjusting (mechanical, opto sensor) should be done only after the
previous steps (cleaning, lubricating) did not solve the problem.

9.2.2 Sample Rotor (SR or BOB) failures

9.2.2.1 SR gives grinding noise and / or SW displays SR error messages

• The front panel alignment is not good.
• The front panel is not closed properly, the opening does not match with the sample
rotor door. Fully open or close the front panel to observe correct shear valve
operation.
• There is liquid in the SR. If you can see traces of salt around the SR, then the
switches might have gotten damaged.

9.2.2.2 SR error appears during initialization process:

• Sample adaptor is removed from proper position.
• The cable of the SR is damaged, or not connected, or connection is not good.
• The motor is not working at all. Check motor cable and/or replace the motor.

9.2.2.3 The SR does not turn into the analyzer even with open front panel
• The SR door got stuck in the wash head. The wash head needs to be aligned
correctly.
• Micro switches are not functioning inside the SR. Faulty switch needs to be replaced.
• PPB board is not controlling the rotor. PPB board replacement needed.

9.2.3 Needle mechanics, Vertical motor (MVert) problems

9.2.3.1 The needle carriage keeps dropping back (down) at initialization

• The wash head position -relative to the needle and to the SR- is not correct. The
wash head comes down too much, and even if lifted, leaves no room for the SR door
to turn.
• Make sure that the vertical rod holding the wash head (if removed or modified) is
inserted correctly.

9.2.3.2 MVert cannot reach the optosensor (Up or Down)

• The wash head (when lifted) gets physically blocked by the non-moving parts of the
needle carriage (needle holding block). Set wash head, see washing head
adjustments in chapter 6.1.3.
• The grip of the needle on the timing belt is in a wrong position. Set the needle and
timing belt connection. See chapter 6.1.2.2.
• The opto sensor is damaged, or the light path is blocked. Use a screwdriver, or a
piece of paper to verify operation.
• The timing belt is damaged or became too long, or got torn. In this case the XY unit
has to be removed and the belt should be replaced.

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• The motor gives a strange noise (not “smooth”) even when moving. Check cable or
connection problem
• The problem comes up only when using Stastedt (or similar) sample tubes from
sample rotor. This could happen because the system is set to pierce a monovette
type of tube, not a Stastedt or the incorrect setting of opto flags on horizontal
movement. In this case test that the motor (carriage) can move freely and run MHori
tests. Make sure that the needle height is set correctly. See chapter 6.1.4.
• The problem comes up only when using Stastedt (or similar) sample tubes (AS
position) because the tube holders are not working properly. Check operation of the
tube holders. They must operate symmetrically, both tube holders should move easily
and make sure that the rack can move in and out freely. Also check that needle
height is set correctly.

9.2.4 Shear Valve (SV) related errors

9.2.4.1 SV error at the first startup

• The SV cannot turn. Make sure that the pull tab has been removed, check free
movement of the upper disc and check operation of opto sensors by blocking the light
path with e.g. a screwdriver.
• The SV is stuck because the last draining or preparing for shipment process was not
performed or it could not be finished. See that the motor can move the valve and it is
not blocked “solid”. Try to loosen the central screw closing the two disks and try to
move the motor a few times in service testing menu. If it does not help:
 use warm water to wet the side of the SV (to make some liquid get in
between the disks)
 you can also dip the SV into water if you can
 gently force it apart

9.2.4.2 Grinding noise after SV cleaning, (after SV reinstallation)

• The upper disc cannot reach opto position. In this case DO NOT adjust the
optosensors! See that lower disc is aligned correctly – loosen the fixing lever, and
reseat the lower disc. See section 6.2.1.
• Check that the middle rod on the back of the upper disc is positioned between the two
moving nods. See section 6.2.2.

9.2.4.3 SV leakage
• The upper disc is not sitting well on the lower disc. Disassemble the shear valve,
clean the internal surface. Small particles or dirt can be stuck between the two discs,
making a gap between the ceramics causing a flow.
• The closing screw is not sitting completely on the upper disc. Remove than replace
the screw properly. Make sure there is no gap between the discs.

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9.2.5 Dilutor errors

9.2.5.1 Dilutor is making noise

• Dilutor pistons are not attached correctly to the dilutor’s moving part. The piston has a
different size hole on the bottom; the larger hole has to face the instrument.
• One optosensor on the dilutor PCB is faulty. Try to move the dilutor up and down in
Service Testing menu. If noise is still present, replace the dilutor unit.

9.2.5.2 Dilutor is leaking

• The syringe or the top plastic of the syringe is cracked. In this case replace syringe.
• The “ribs” on the pistons are filled with liquid and they are white. The piston is leaking;
the whole syringe with piston should be replaced or greased with silicon grease. Do
not grease the black pistons, just replace them if needed.

9.2.6 A tube comes off of a valve

Depending on the location (ID) of the valve, it can be caused by:

• One of the valves are not opening well. Check all of the valves in Service Testing
menu. Replace the valve which is not responding.
• Shear valve discs are not aligned well. Adjust the shear valve, see section 6.2.
• Tube on the valve is too wide. Cut off the end of the tube and reconnect it to position.
• TCU tubing is blocked. Drain the TCU by using the option is Service Functions menu.
Fill TCU and see that the clogging in the TCU is removed. If the TCU tubing is still
blocked, remove the TCU and check the tubing inside.
• Laser flow cell is clogged. Perform a flow cell cleaning by software or manually.
• One of the chambers is clogged. Remove the metal plate from the side of the
chamber and clean it. Don't forget to drain the chambers in Maintenance before
removing the front of the chamber.

If a tube comes off from a valve, it can be useful to check the tubing schematics. See the
tubes connected to the valve, follow the route of the tubing, note that the valves involved
were open or close state when the tube popped off. Also see shear valve position when tube
pops off.

By using the schematics and following the route of the tubes, it is possible to find the
clogging in the system.

9.2.7 Priming problems

9.2.7.1 The analyzer would not prime liquids

• The respective reagent is out. Check the reagent status bar on the bottom. Change
reagent if needed.
• The reagent tubing is not connected to the proper inlet. Check both ends of the tube.
• The reagent tube is bended or broken. Check the tube.
• Tube popped off from a valve. It will make the vacuum level dropping immediately, so
priming won’t be successful. Reconnect the tube.

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• There is not enough vacuum to fill up the reservoirs. Check all the valves in Service
Testing menu. Replace faulty or non-opening or closing valves.
• The pressure sensor is faulty. Check sensor offsets, see section 6.6.
• Reagent buffer reservoir is cracked and vacuum is escaping. Replace the reservoir.
• The float is not moving when the reagent is filled. In this case the float sensor is stuck
to the bottom. Gently touch or tap the buffer to make the float free.
• The reservoir is full, priming doesn’t stop, but the float is not sensing, even when it’s
on the top. In this case the reagent sensor board or the float sensor is damaged.
Reset the Low Level Software to stop priming and locate the reagent sensor board.
See that the LED is sensing the float’s signal, or connect the buffer’s cable to another
pair of pins. See that the LED is on. If LED is on, the float is ok and the board can be
faulty and it has to be replaced. If the LED is not turned on, the float is faulty and the
reservoir needs to be replaced.

9.3 Electronics related problems

9.3.1 Touch screen / display errors

9.3.1.1 No image on display

• Display is white. LVDS data cable is removed from the touch screen or from the
motherboard. Reconnect the cable.
• Screen is black. Check the cables behind LCD and on the mother board. See that
BIOS settings are not modified to use different display device. See chapter 7.5.1.,
BIOS settings, Chipset/North Bridge/Onchip/Select Display Device.

9.3.1.2 Touch sensitive surface not working

• When touch is not responding, it can happen that the sw is frozen or the display is
faulty. The touchscreen PCB is located on the back of the LCD. Remove the cover of
the PCB and check the board and the cable connection.
• Connect external USB mouse to the unit and check that the mouse cursor is available
and moving. If mouse is ok, remove and reconnect the Touch USB cable.

9.3.1.3 Touch (click) is inaccurate

• Connect external USB mouse and select touchscreen calibration in Maintenance
menu.

9.3.1.4 Screen image is not normal, some parts of the software screen is not visible
• The analyzer uses a resolution 600x800. If there is a problem with the size of the
screen check the resolution in Windows. Leave the High Level Software by pressing
CTRL+ALT+DEL to enter Windows (only if Windows control checkbox is enabled in
Service Functions).
• It is also possible that the resolution of the screen was changed in BIOS. Enter BIOS
and check the resolution in Chipset/North Bridge/Onchip/Select Display Device.

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9.3.2 Communication errors

Check the communication by going into Service menu/Sw Upgrade and press Refresh
button. If communication is ok, all the available firmware and software will be listed. If there is
a problem with communication, the unit will send message “Pneumatic error” or “USB
communication lost”.

• In most cases, the communication problem is created by the DimmBoard. All the
electronics are working well but the data cannot access the low level software. In this
case check the DimmBoard, locate the SD card inside the board and make sure that
it’s not removed.
• Remove the DimmBoard from the LSDAQCQ, clean the connection surfaces and put
it back. Don’t need to turn off the unit, just restart the Low Level Software in Service
Functions. The Low Level Software will automatically turn on and start
communication, when the connection is available again.
• Check the start button. If it is red all time, it means the low level software is frozen or
stuck in an infinite cycle. Go to Service functions screen and restart/reset the low
level sw. See section 7.3.1.
• If start button is blinking, the communication error is related to the Pneumatic system.
Open the valve block door and locate the two PPB panels. Check the cable
connections; replace the small PPB CON panel on PPB1 (left). If communication is
still not ok, replace the PPB CON panel on PPB 2 (right). If the problem still not
solved, replace PPB1 and then PPB2.
• The error message “Unit is not present” will notice that the communication line inside
the unit is broken. The line is a closed BUS between the LSDACQ (DimmBoard), the
TCU, the pressure sensor, the optical head and the front panel (touch). If one of
these are damaged or not connected by USB cable, the system gives a message
about which unit is present or not. Locate the faulty unit and see that the power
supply is attached to it and check all their cables. See section 9.3.4.

9.3.3 The analyzer does not power on

• If the analyzer is connected to the external power source and the main power switch
is on, an indicator LED on the motherboard should turn on to show that the power
supply is working. If the LED is not on, the power supply has to be changed. Remove
the hardware module from the analyzer and change the power supply. If the LED is
on but the unit is not starting, the problem can be the motherboard or the power-on
switch. Follow the power-on switch’s cable to the motherboard. Remove the cable
from its position. Try to power on the motherboard by applying a short circuit on that
specific jumper of power-on switch with a screwdriver. If it starts, then the switch is
faulty.
• There is a “beep” sound coming from the instrument. Typically the motherboard gives
this sound if the board itself has a problem starting up or the memory card is not in
place. Locate the memory card and check its position. Replace motherboard and/or
memory card if necessary.
• The power supply works, the motherboard starts, but the system would not boot up. If
high level sw and windows cannot start, the operation system has to be reinstalled or
recovered. See section 7.5.1.

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• The power supply works, the motherboard starts, windows starts, but the User
interface SW does not start (just widows desktop appear). In this case the instrument
doesn’t have a properly installed High Level Software. Contact the Analyticon support
via support@analyticon-diagnostics.com to get the right software. Copy the software
to a pen drive and insert it to the instrument. See software installation in section 7.5.
Make sure that the Low and High Level Softwares are the same version.

9.3.4 I2C errors displayed at startup

• Check the power and data connection of the board reported missing
• Most probably the power connector of the missing module is disconnected
• The second most likely cause is a misconnected, or not connected data cable
• A missing TCU power cable can cause a “multiple” I2C error when more than one
modules are reported missing. Check the power connection of the TCU module

9.4 Useful information and tips

9.4.1 High PLT background
After shipping it's possible that the PLT background is higher than normal for the first few
background runs.
• If the PLT level is not normal after a few runs, use a syringe to put Hypoclean CC
inside the RBC chamber and leave it there for a few minutes. Than make stress
measurements.
• If the reagent tube was contaminated, and some bacteria begin to grow inside, once you put
an infected reagent tube into a new tank, by time it can become infected as well, i.e. the
background (PLT blank) becomes high. Wash the reagent tube - which is in connection with
the reagent - with 1% of bleach solution, and then rinse with clean distilled water or diluent.
It can avoid the bacteria to grow inside.
• If tank is open – and cap is not installed or closed - external dust can make reagent dirty.
• Use stress measurements to find out that the problem is dirt inside the aperture or it is
noise. If the stress results are high but slowly decreasing, it most likely dirt inside the RBC
chamber. If results have a large diversity, it's caused by noise.

9.4.2 Fast Starting up and Shutting down

During troubleshooting, it is possible that the unit needs to be turned off and on multiple
times. Before shutdown, the unit has to make a cleaning process and after an improper
shutdown, the instrument requires a cleaning process when turned on again. The cleaning
procedure is not always necessary during troubleshooting and it can take a long time.

The cleaning procedure can be skipped by running program code 66 in Service Testing
menu. Run this program before shutdown to make it faster and to skip the cleaning process
run the program before running background measurement.

9.4.3 Removing bubbles from the Flow cell

The flow in the flow cell is very critical during the measurement. If bubbles appear in the
tubing system (the 4 meter tube and the flow cell), it can make improper scatter values. The
easiest way to check the amount of bubbles is to press valve #1 and #20 together. This will
start the flow inside the 4 meter tube; moving bubbles can be noticed easier. To start the flow

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in the flow cell, press valve #1 and #32 together and check the laser waste tube for bubbles.
If there are too many bubbles in the laser, check the tubing and "T" connections in the tubing
at valve #20 and #32. If bubbles are leaving the laser but not entering into it, the injector
must be cracked. Remove the laser and replace the injector.

9.4.4 Removing the DimmBoard

There is no need to turn off the instrument to remove the DimmBoard. Go to Service
Functions menu and press ‘Low Level Reboot’ button. After a few seconds, the start button
will turn off which means the low level sw is turned off to reboot. It is possible to remove the
DimmBoard or the SD card while the Low Level Software is off. After a few seconds, the
software reboots and the communication will return. If there is not DimmBoard in the
LSDACQ, the communication will be lost until the board is replaced. After replace, it is
possible that the system needs a Low Level Software reboot to wake up.

9.4.5 Listen the sounds of the instrument

The unit keeps repeating the same process during measurements. The sound of the unit is
very telling and can warn the user or service engineer that something is not working properly.
It is also useful to put your ears on the front panel and listen the mechanics. Some noise can
be discovered easier this way.

9.4.6 Replacing small diameter tubes

Some tubes in the unit are connected to a small plastic 'T' fitting. Replacing these tubes can
be difficult because the tube's diameter is smaller than the fitting. In this case a thin metal rod
can help putting back the tube to position. Put the rod's end into the 'T' fitting while the tube is
on the rod. This way the fitting will not broke while the tube is pressed onto it, because the
metal rod is keeping it on position from inside.

9.4.7 Swapping the pumps

For troubleshooting, it can be useful to swap the
two pumps. The instrument can work when the
two pumps are interchanged. It's not necessary
to remove the pumps, simply just remove pump 1
cable from PPB1 and pump 2 cable from PPB2.
Connect pump 1 (outer) cable to PPB2 and
pump2 (inner) cable to PPB1. After this, also
change the tube connections next to the
reservoirs. By this it's possible to find out which
pumps has problems. Self-test results can help.

9.4.8 Draining the reservoirs

If there is a problem with a reservoir and it needs to be changed it has to be drained first.
Draining is made by the unit automatically by pressing drain in Maintenance menu. To save
time, it is possible to remove the tube from the top of the reservoir. The ambient air pressure
will push the reagent out from the reservoir faster than the draining procedure. Use this only
when reservoir needs to be replaced.

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10 Maintenance
10.1 User maintenance
10.1.1 Daily maintenance
Hemolyzer 5 requires automated maintenance during daily routine. It is a user maintenance.

At the end of day a system cleaning procedure is recommended. To perform this cleaning,
prepare a vial containing 2-4 ml Hemolyzer-Hypocleaner and place it in the Sample Rotor.
From Main Menu go to: Maintenance/Functions and press Clean. This will initiate a cleaning
cycle, all chambers, needle, shear valve and the TCU is cleaned with diluted Hemolyzer-
Hypocleaner, than the system is rinsed with diluent.

10.1.2 Weekly maintenance

Weekly maintenance is for cleaning salt build-up from the most contaminated surfaces. It is
recommended to clean the Shear Valve and Needle Wash head after every 1500
samples.

10.1.2.1 Shear Valve cleaning

This procedure is detailed in User Manual section 17.6

10.1.2.2 Cleaning the wash head

This procedure is detailed in User Manual section 17.7

10.2 Preventive Maintenance

The procedures in this section are service maintenance.

Preventive maintenance frequency depends on the daily workload of the customer.

In the Hemolyzer 5 User Manual and Service Manual the maintenance interval of moving
parts and syringes is determined as to be done after every 30.000 measurement cycles or
twice per year.

As a general rule, at least 1 maintenance per year must be performed to ensure

correct functioning and performance according to specification.

Analyticon recommends the following frequency for preventive maintenance by field service:

- for instruments with a workload of up to 100 samples/day

Preventive maintenance by field service should be performed once per year

- for instruments with a workload between 100 and 200 samples/day

Preventive maintenance by field service should be performed 2 times per year

- for instruments with a workload above 200 samples/day

Preventive maintenance by field service should be performed at least 3 times per year

To do list and materials needed for a preventive maintenance intervention

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Note: there is no difference between the „6 months” or „1 year” preventive maintenance. The
same maintenance protocol must be followed and applied every time.

Procedure Duration: ~ 2 hours

Tools needed:
- hex screwdrivers (1.5, 2, 2.5, 3, 4)
- torx screwdrivers (2.5, 3)
- philips screwdriver (2)
- small size flat screwdriver
- forceps
- tweezers
- syringe (at least 20ml)

Materials needed:
- silicone grease (P/N: A599)
- teflon grease (P/N: A598)
- bleach (~200ml, Hemolyzer-Hypocleaner)
- distilled water, ~500ml
- paper towels
- compressed air
- required protective safety equipment (gloves, lab coat, glasses, etc.)

Spare parts needed:

Maintenance KIT for A5

Contains:

Part
number Description Quantity

A5330 Washing head Hemolyzer 5 1

A543 4/1.8 Tygon tube, 1 m 4

A5433 1,27/2,23 Tygon tube (type: S 54-HL) 1

A5439-S 0,78/2,38 Tygon sampling tube for A5, 26 cm 1

A5-AJN014 Piercing needle (Hemolyzer 5) 1

AP251 SCHOTT syringe with piston white (mounted, 2 ml) 6

J5P251 Schott syringe with piston black (mounted, 2ml) 2

Suggestion of spare parts which are good to have but not necessary at a PM visit:

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Hemolyzer 5

- RBC/WBC Chamber J5P421

- RBC/WBC Aperture J5P431
- 2/2 Valve with Coil A504
- 3/2 Valve with Coil A505
- Pressure sensor board A5519

Preventive Maintenance Protocol:

1. First steps / Checking the state of the analyzer

1.1 turn on the analyzer, run background and check if values are within accepted range
1.2 run Self-test (electronic and pneumatic), if it is „successful” check if any value is close
to the accepted limit, if it is „failed” troubleshoot accordingly
1.3 in case of high „laser on” or „laser off” DC level run a background cycle and Self-test
again. If DC level values are still high do a flow cell cleaning, see section 10.3
1.4 from Service/Adjustments run „pressure offset adjustment” and check if values are
within range; change the pressure sensor board (P/N: A5519) if „offset values cannot
be adjusted”, message appears or if adjusted value is very close to the limit (refer to
SM for limits)
Next step is to bring the analyzer into the proper state where maintenance procedures can
be performed without the risk of liquids spilling on parts. DO NOT skip the 3 procedures
listed below:

1.5 from Service menu run „drain TCU” option; follow instructions in the SM regarding this
procedure
1.6 from Service menu run „drain Flow cell” option;
1.7 from Maintenance menu empty all 3 chambers(RBC/PLT, WBC, MIX)
At this point maintenance of parts can be started. Open the front cover and remove side
covers of the analyzer.

Inspect:

2. Valves
2.1 check for any dirt or deposit in the valve; if necessary clean inside of valve by pushing
DI water or bleach through it by means of a syringe
2.2 if any sign show that liquid spilled on the valve, remove the valve head to see if liquid
got also in the coil, if so, replace the coil
2.3 activate each valve from service menu; if switching of valve isn’t firm(smooth
movement of membrane) try to clean it or replace the valve head
2.4 check the exhausting tube/vent nozzle on valve #5 to be free of dust or any deposit;
clean it with DI water if necessary
2.5 special attention on valve #2: this valve and related tubing must be clean. In case of
dirty valve/tubing, flow of laser waste through valve is restricted and it has direct
influence on optical counts (!) Replace the valve and/or tubing if necessary
2.6 special attention on valves #34 and #35 as well; these valves and the related tubing
must also be clean and free of any deposit. Replace the valve and/or tubing if
necessary

Proceed to step 3.

3. Tubes
3.1 all tubes must be clean inside; any deposit must be cleaned with bleach and rinsed
with DI water or replace the tubing

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3.2 check tube connections on valves, chambers, SV, wash head, internal reservoirs etc.
all connection points must be tight, otherwise change that tube portion with new tube
3.3 as a rule if a tube cannot be cleaned sufficiently and/or its’ connection isn’t tight it is
recommended to be changed with new tube

Proceed to step 4.

4. Chambers
4.1 all chambers must be clean, free of scratches or cracks
4.2 removal of chambers is recommended to check if no liquid has spilled behind them
and also to see if the electrode is in good condition; change the chamber if any visible
crack can be seen or if the electrode can be moved by hand
4.3 reinstall the chambers

Proceed to step 5.

5. Dilutors
5.1 from service menu move dilutors one-by-one and check if large air bubbles are visible
in the syringes or if any leakage sign can be seen on or beneath them; mark the
syringe(s) where you saw large air bubbles getting in near the plunger
5.2 perform dilutor pistons cleaning and greasing procedure
- Follow instructions of section 10.2;
Black pistons should NOT be greased (!)

Use a forceps to close the tube above the syringe you are going to remove. This is to avoid
reagent from internal reservoirs spilling back to the reagent bottle. Remove one syringe at a
time only!

5.3 cycle dilutors from service menu again, if any of the syringes does not seal properly
(air bubbles are still getting inside near the plunger) replace the syringe(s)

Analyticon recommendation as preventive maintenance: replace syringes after 50.000

measurement cycles

5.4 clean dilutor optosensors from dust by means of compressed air

5.5 clean the driving pin of dilutors then lubricate them with teflon grease

Proceed to step 6.

6. Shear Valve
6.1 inspect tubes on SV for any deposit or discoloration, especially the „4diff waste” and
„Laser in”(refer to fluidic schematic of the analyzer to identify these tubes) tube ;
lower section of laser waste tube might have black color – it can be cleaned with
bleach or that tube section can be changed.

Note: when removing tubes from the SV ports use a small flat screwdriver to help the tube
slide off from the port; to avoid misconnection remove only 1 tube at a time

6.2 check tightness of tubes on SV ports by hand, all tubes connections must be firm; if
any tube comes off easily if pulled by hand that tube section should be changed
6.3 clean the SV optosensors from dust by means of compressed air
6.4 from service menu cycle the SV several times; if the movement isn’t smooth or noise
is coming from driving mechanism, remove the cover behind the SV and lubricate the

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Hemolyzer 5

cogged wheel/bar with machine grease; apply a thin film of teflon grease to the two
ends of the sliding clutch-bed
6.5 reinstall the driving mechanism cover
6.6 change the blood sensor tube(tube between the needle and SV)

Proceed to step 7.

7. Laser head
The laser head doesn’t need to be opened for regular maintenance. Opening the laser head
will end the warranty period for the optical head!

If „laser on” DC level was high during repeated Self-test cycles, it might be necessary to
clean the Flow Cell manually. This should be done only if „laser on” DC level is still high after
the software given “flow cell cleaning” procedure option was done.

If „laser off” DC level is high that might indicate failure of a component of the laser head.
Contact Analyticon Support Team ( support@analyticon-diagnostics.com ) for further
information and assistance.

If any deposit can be seen in the „laser in” tube or if „laser on” DC level was high during
Self-test than do the following:

7.1 remove the thick, RED coded tygon tube(laser waste) from the tube organizer and
connect a syringe to it
7.2 prepare at least 10ml of 1/1 bleach solution(1 part bleach, 1 part DI water) in a cup
7.3 remove the „Laser in” tube from the SV and immerse it into the bleach
7.4 gently pull the syringe until at least half of the bleach is aspirated or until the „Laser
in” tube is clean
7.5 remove the „Laser in” tube from the bleach and pull ~ 20ml of air through it
7.6 reconnect the „Laser in” and „laser waste” tubes to their ports

Proceed to step 8.

8. TCU
The TCU unit is a key assembly and proper functioning of this part is vital for good
performance of the analyzer. Therefore with the occasion of periodic maintenance the
TCU unit must also be inspected by service engineer. Inspection is only possible if
the TCU unit is removed from the instrument. Follow instructions of the SM for
removal of the TCU.

8.1 clean the fan and heat sink of the TCU from dust with compressed air
8.2 remove the in-line mixer cover and check the 2 tygon tubes for any deposit
8.3 if necessary clean or replace* the 2 tubes with 1,8x4,0 mm tygon tubes cut to the
same length

* Tubes of the in-line mixer are the bottleneck for flow inside the TCU. Any deposit in these
tubes will cause overpressure in the 4diff sample preparation circuit which in worst case will
result in tubes being pushed off from valves and would cause liquid spills inside the analyzer.
Natural ageing of tygon results in loss of elasticity and small decrease of diameter. Ageing is
speeded up by the aggressive reagents (Lyse5P, Diff5P).

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 Servicemanual

Analyticon recommendation as preventive maintenance: change the in-line mixer tubes once
per year.

8.4 reassemble the TCU unit to its place, follow instructions of the SM

Proceed to step 9.

9. Wash head and XY block

9.1 clean the sliding bars of the XY unit with a paper towel and apply a thin film of teflon
grease on them
9.2 clean the optosensor on the XY opto board with compressed air
9.3 verify the metal ports of the wash head are not loose, replace the wash head if any of
the ports can be moved by hand
9.4 verify the vertical movement of wash head neck inside of the XY block by lifting it up
from the needle holder

Attention: Sharp needle! Risk of injury! Biohazard!

9.5 vertical movement of the wash head must be easy without any obstruction, clean the
wash head neck if movement isn’t smooth
9.6 clean the bottom of wash head

Proceed to step 10.

10. Verification/adjustments
From service menu run:
10.1 „pneumatic initialization”
10.2 „fill flow cell”
10.3 „fill TCU”

Run shutdown then switch on the analyzer.

10.4 run background counts until background values are within accepted limit; several
background cycles might be necessary to achieve good values – this is normal
behavior after tubes and subassemblies have been drained and refilled
10.5 run Self-test (both) and check that all parameters are within range
10.6 if DC level is still high contact Analyticon Support (support@analyticon-
diagnostics.com) for further assistance
10.7 from service menu perform wash head and needle position verification; adjust if
necessary
10.8 adjust blood sensor default value(with blood sensor disabled)
10.9 calibrate the blood sensor
10.10 verify calibration with fresh control blood; calibrate the instrument if necessary
10.11 run human samples and check results
10.12 run repeatability test(at least 11 measurements from one fresh human blood with
normal values) and check CV%-s are within specification for all parameters

Preventive maintenance is done!

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Hemolyzer 5

10.3 Flow cell cleaning

The optical measurement system of the Hemolyzer 5 is strictly vacuum-based. Please
do not apply pressure to the flow cell!

Tools needed:

• small flat screwdriver

• Syringe(10-15 ml or bigger)
• small cup with Hypoclean CC or filtered bleach(approx.. 10-20 ml)

Procedure:

1. Open and secure front panel.

2. Run “empty flow cell” function.
3. Remove the laser waste tube from the connector located on left side of inner front
panel. This tube has red strip on it. Use a small flat screwdriver to help the tube come
off from the metal port.
4. Connect the (empty) syringe to the tube.

5. Disconnect the sheath tube from the connector located on left side of inner front
panel. This tube has green strip on it and it is smaller in diameter. Use the
screwdriver to help removal.

136
 Servicemanual

6. Pour Hypoclean CC or filtered bleach into a cup and place the end of the sheath tube
in it.

7. Gently pull the syringe to make the bleach flow through the Flow Cell.
You can increase cleaning efficiency if you let air bubbles in the sheath tube while
pulling.
8. Remove the sheath tube from the bleach and pull some air through the FC.
9. Reconnect sheath tube to its connector.

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Hemolyzer 5

10. Remove the laser sample tube from upper disc of SV. This is the thinnest tube. Use
the small flat screwdriver to help removal from metal port.

11. Place the end of sample injector tube in bleach. Gently pull the syringe to clean the
sample injector tube from the inside.
12. Remove the sample injector tube from bleach, pull some air with the syringe, wipe the
end of the tube and reconnect it to its port on the SV.
13. Remove the syringe from the laser waste tube and connect the tube back to its
connector.
14. Run “fill flow cell” function.
15. Check that background and sample results are acceptable.

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 Servicemanual

11 Removal and replacement procedures

11.1 Opening the instrument
Both side covers of the instrument can be easily removed. This allows reaching of the fluidic
system and the mechanical parts. Other parts of the analyzer can be reached by lifting up the
front panel.

Don’t forget to secure the front cover in the upper position after lifting,
as it may fall down if unsecured!

To take off the left cover:

Loosen the four milled-edge screws in the front and on the back of the analyzer.

Pull the cover to the left to take it off.

To take off the right cover:

The procedure is the same as in the case of the left
cover.

Milled-edge

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Hemolyzer 5

11.2 Shear Valve Assembly

Shear Valve Assembly is located in
middle of front side of Hemolyzer 5
behind the front cover.

Main parts of Shear Valve Unit:

• Ceramic valve
• Driver unit with a stepper motor
• SV Opto sensor board

Ceramic Valve removal

• Drain SV and the tubes on it using Shear Valve cleaning
function in the Maintenance screen
• Prepare a piece of absorbent paper to dry components if
necessary
• Remove the thumb screw on the valve
• Remove the upper ceramic disc
• Remove the lower ceramic disc of the valve pulling it upward

Ceramic Valve install

• Put back lower ceramic disk
• Make sure the fixing plates hold the disc in tight enough,
prevent the lower disk rotating. Please realign the plates if it
needs.
• Install the upper ceramic disk, making sure the longer
horizontal pin is between the two rods of the Shear Valve
drive. So it can move the upper ceramic disk. The other rod
must be able to move into opto sensors freely. Fix the Shear Valve with the thumb
screw. Please do a Shear Valve Opto SNSR alignment if the right side pin hits one of
the opto sensors.
• Check the operation.

140
 Servicemanual

Shear Valve Opto Sensor board replacement

• Shear Valve opto sensors are mounted to the right
side on Shear Valve Assembly with 3 screws in
such a way the sensors can be set separately.
• remove screw behind the circular opening (through
the hole)
• Watch out the plastic washers.
• Remove the screws behind the oval opening
(through the opening)
• pull out the opto board and remove the 2 cables
• Install a new board.
• connect cables
• install big board (2 screws) use plastic washers
• install small board (1 screw) use plastic washers
• Make sure that the lower disc’s flat side is aligned,
and secure. You should not be able to move (twist)
the lower disc at all.
• Please do a SV alignment procedure 6.2.

Shear Valve Assembly removal

• Disconnect cable J7510 from SV opto board
• Disconnect SV motor cable from PPB
• Remove four screws on the front of SV assembly
• Move the SV assembly out of the instrument

11.3 XY Unit
XY unit contains the slides for Horizontal and Vertical movements, two stepper motors, XYR
opto board, opto wheel, sample rotor, wash head holder, wash head and the sampling
needle. With the exception of the sampling needle, wash head, wash head holder and MHori
(stepper motor for horizontal movement), for proper servicing the XY unit needs to be
removed. The procedure is the following:

• Turn off the analyzer.

• Lift and secure the front panel, then remove the right cover.
• If the analyzer is equipped with an Autoloader, disconnect and remove the Autoloader
module.
Loosen the two sampling needle fixing screws and remove the needle.

141
Hemolyzer 5

• Sampling needle is sharp and represents biohazard! Take extra care and wear gloves when
servicing this part of the analyzer.
• Remove the baluster. Its lower screw can be access from the bottom of analyzer.

• Locate and unscrew the four screws

from the bottom of the analyzer,
which hold the Sample Rotor basis.

• Unscrew the two (upper and lower)

screws which hold the rear part of the
XY unit. One screw is located above
the MVert (the bigger stepper motor
for vertical movement and cap
piercing), the other one is located
below the optowheel and sliding
bar, near the same motor.

142
 Servicemanual

• Gently remove the wash head holder

with the wash head, by twisting it
clockwise and pulling it down until
released.
• Disconnect electrical cables
• Remove the XY unit

Sampling needle
fixing screws

Upper

MVert
Washing head and
washing head
MHori

Sample Rotor basis Lower

(the screws are
located on the bottom
of the analyzer).

For mounting back the XY unit, follow the steps listed above in reverse order. Make sure to
perform the Sampling Needle adjustment procedure after reinstallation.

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Hemolyzer 5

11.4 Sample Rotor

Sample rotor holds the sample tube and turns it inside the instrument for cap piercing. In
order to provide its proper operation with XY unit, they
are equipped together.

Sample Rotor removal:

• Remove XY unit with Sample Rotor as it is written

in previous item
• Remove two screws from the front of XY unit that
hold the Sample Rotor rods
• Separate the Sample Rotor
• Pull off the door. Please check rotor arm and the
hole of lower door plate rod position when put
back the door.
• Two end position switches can be removed and
motor of unit are accessible.

144
 Servicemanual

11.5 Dilutors
Hemolyzer 5 has two separate main dilutor modules, located behind the front panel on the
lower part of the front plate. Each modules is secured by four hex screws and has a flat cable
connection to PPB1 respectively PPB2. The removal/replacement procedure is as follows:
1. Turn off the analyzer.
2. Lift and secure the front panel.
3. Remove the tubing from the syringes.
4. Unscrew the four hex screws and put
them in a safe place where you can find
them later.
5. Gently pull the unit toward you until you
can see the flat cable connector on the
rear side of the dilutor optoboard.
Disconnect the cable.
6. Now the dilutor module is released and
available for maintenance or replacement.
To remount the dilutor unit, follow the steps described
above in reverse order.

11.5.1 Syringe replacement

• Remove two thumb screws from the syringe
holder bar and remove the holder bar from the
top of the syringes.
• Remove lower thumb screw from syringe
piston rod.
• Remove the syringe
Installing back a new syringe take care the direction of
piston rod. The wider hole must be turned inside the
system.

145
Hemolyzer 5

Correct Incorrect

11.6 TCU Module

The Temperature Control Unit is located below the Laser Head Assembly. It is connected to
the Shear Valve and to the tube organizer via Tygon tubing. The internal electronics are
connected to the power supply and to the LSDACQ board. In order to remove this unit, follow
the steps below:

- turn off the analyzer

- If autoloader is installed, disconnect and remove the Autoloader module.
- drain the TCU module manually
 disconnect the BLACK tube and connect a 10ml syringe
 disconnect the GREEN tube and aspirate liquid from the TCU module
using the syringe
 disconnect the WHITE tube
and connect a 10ml syringe
 disconnect the RED tube and
aspirate liquid from the TCU
module using the syringe

- remove the screw above the shear

valve (securing the front of the TCU)

146
 Servicemanual

- remove the 4 screws in the back of

the analyzer securing the rear

- open the assembly plate on the left side of the

analyzer to have access to the TCU control
board cables
- locate and disconnect the power cable of the
TCU module
- disconnect the controlling cable coming from
the LSDACQ board
- pull the TCU out towards the back of the
analyzer

To reinstall: follow the procedure in reverse order

11.7 Valve block

3/2 valves
Valves can be
removed together in
one assembly
(valve, coil, board)
or individually one
by one.

To remove the
3/2 valves complete assembly
just unscrew the 6
mounting screw and
disconnect the driver
cables on the back.

A valve has two

main parts: the valve
3/2 valves
unit and
electromagnet coil.

147
Hemolyzer 5

The tubes are connected to the valve pins.

The coil is soldered to valve block board.
A plate fixes the main parts together on the coil
site.

Pull with pliers

To remove individually you’ll need to use a plier to

pull the valve fixing plate out at the back and after
that it is possible to remove only the valve itself.

11.8 Pre-Amplifier Board

Pre-Amplifier Board is located inner side of the
fluidics panel, behind the Measuring Black. It is
under a metal cover that fixed to the fluidics panel
with two screws. See the picture.

11.9 Pump Assembly

1. Open the front cover.
2. Remove the left side cover by loosening the four fixing screws.
3. Loosen the two clamp-screws on the rear panel and open the side pneumatic
board.

148
 Servicemanual

4. Pull off the connected tubes from inner fittings of Waste output and pump inlet
tubes from lower right side of flow Panel.

5. Pull off the connected cables (red-green-black) from

the PPB boards. The pump 1 (outer one) power
cable is connected to PBB1 (left board), the pump 2
(inner one) power cable is connected to PBB2 (right
board).
6. Unscrew the screws at the top of the pump fixing
bar and pull it up with the white plastic bar.
7. Lift off the pumps.

149
Hemolyzer 5

11.10 Hardware Module

The whole removing procedure is easier by opening the front cover and with removed side
covers.

1. Unscrew the five screws connected on the rear plate.

2. The assembly is positioned and pushed down inside by a spring sheet. Gently pull
out the fixing plate until almost the whole module comes out. Be careful not to
strain the power and data cables connected to other parts inside.
3. If you want to completely remove the module you have to disconnect all the power
and data cables connected inside.

150
 Servicemanual

11.11 Laser Head Assembly

To remove the Laser Head:

Turn on the analyzer.

1. Press and hold the Menu icon until the on-screen keyboard pops up, then type in the
service password. Service button appears on the main screen, click on it to enter the
service menu, then click on Service Functions/Drain flow cell and wait until the
process finish.
2. Turn off the analyzer (from rear start switch)
3. Open (lift up) and secure front cover.
4. Remove right side cover.
5. Unscrew the 4 holding screws of the top cover then remove it by lifting and sliding it
backwards.
6. Locate the three tube connections of the Laser Head.
#1 – laser sample tube; #2 – sheath tube; #3 – laser waste tube.

7. Gently remove the tubes from the metal ports. Use a small flat screwdriver to help sliding
tubes off.

151
Hemolyzer 5

8. CLOSE FRONT DOOR

9. Disconnect both cables from the optical head. Refer to picture 4 below.
(#1 – autoalignment cable*; #2 – optosensor board cable; #3 – laserdriver board cable)

Note: it is easier to disconnect the laserdriver board cable from the LSDACQ board. Units
produced after 2013.06.doesn’t have auto alignment cable.

152
 Servicemanual

1
2

10. Locate the four holding screws of the base-plate of the optical head. Refer to Picture
5.below.
Use a 2,5 mm hex screwdriver to remove the
screws. Take extra care of the washers.
11. Gently remove the optical head unit. To avoid
damage of the sample injector needle and
sheath inlets on the base of the flow cell
please always place the laser head
assembly on its’ side or upside-down. Do
not ben tubes too much.

153
Hemolyzer 5

11.11.1 Reinstalling the Laser Head:

(Analyzer is turned off, right side and top covers removed, front door is CLOSED)

1. Connect laser driver board cable to laser head.

2. Place the Laser Head to its’ place. Guide tubes to exit towards the front.
3. Tighten the screws, make sure that ground cable is also in place and washers are
installed.
3. Reconnect autoalignment* and optosensor cables.
4. LIFT UP AND SECURE FRONT COVER.
5. Reconnect tubes to the corresponding ports.
6. Turn on the analyzer; activate the service menu, then click on Service/Auto alignment.
Check the values of “laser power” (4 diff and baso) on “Laser settings” field. Compare
these values with the Auto alignment datasheet received with the new laser head.
Enter new values from the datasheet (only necessary if those are different from the
analyzer’s values) and click on Save values. Exit from service menu.
7. Click on Measure for background count, if necessary repeat background cycles until all
values are in acceptable range.
8. Prepare a freshly opened D-Check3P NORMAL level control. Run “Scatter Calibration
Procedure”.

11.12 Measuring Block

• Remove the left side cover by loosening the four fixing screws.
• Measurement Block is located middle upper side of flow panel, above the
valve blocks. It has WBC measuring chamber, RBC/PLT measuring chamber,
Mix chamber and a drain buffer.

11.12.1 Aperture removal:

WBC, 80µm and RBC/PLT, 70 µm apertures are behind metal front plate of measuring units
mounted by four screws. Two long ones (upper left and lower right) fixes the metal plate to
the measuring chamber, two short ones (upper right and lower left) fix the measuring
chamber the back plate of the unit. See the picture.

154
 Servicemanual

11.12.2 WBC aperture removal:

• Drain the chambers in
maintenance menu.
• Unscrew hex nut on the right site
of front panel that fixes the black
metal shield.
• Remove the black shield.
• Remove four screws from the unit.
• Remove black grounding wire and
the metal plate with two tube
fittings.
• Aperture can be removed. Be
careful with the plastic parts, do
not scratch them.

11.12.3 Measuring Chamber removal:

• After two short screws (upper right and lower
left) and black grounding wire removal, the
measuring unit can be taken out.
• Pay attention: if long screws had been
removed, their square nuts on the back of
measuring chamber may be fallen out from
the unit. See the picture.

155
Hemolyzer 5

11.12.4 HGB head removal

• WBC measuring chamber must be removed, as it is written above.
• Pull off the HGB head from pre-amplifier connector.

11.13 Display unit

Display unit is installed on to the front panel of Hemolyzer 5 with a metal mounting unit. The
LED display is controlled directly by Hardware block, the touch screen is driven by a Touch
Controller board. It is behind the display, under a metal cover.

156
 Servicemanual

Display removal:

• Turn the system off

• Remove the front cover fixing arm and two hinges
• Disconnect the grounding cable
• Take off the front panel and put it on flat surface
• Remove the metal cover of Touch Controller board
• Disconnect the cables
• Remove the metal mounting plate by taking out four
screws
• Remove the LED display from the metal plate

157
Hemolyzer 5

11.14 Hemolyzer 5 Fluidics v2.1 - SV in Chamber Position

158
 Servicemanual

11.15 Hemolyzer 5 Fluidics v2.1 - SV in Needle Position

159
Hemolyzer 5

11.16 Tubings
Preparing of tubings:

= (A556)

= (A545) = (A546)

T0 T1

4 8 MEA V15/1 7 12 V2/2

V12/ 2
PUFFER
10 2

V1/3 V12/3

3,5 3,5
2 V 13/2 V12/1 T2
3,5 2
2 2 2,5 2,5
V4/3 V6/3 V8/3 25
10 6
P 3,5
3,5 3,5
3 2
2 2 2
V3/3 V5/3 V7/3 V23/2

V10/1 T3 T4
8 WBC
4 Cham 2 7 2 SVF12
2,5 22 BASO
Puffer
2
2

16 40 2
V15/2 V9/1 V11/1
V29/1 V11/2

V13/1 T5 T6
V36/2 22 4 V17/3
2
Washing 5 114 4 V14/1 3
head
5
V26/2

V20/2 T7
Dilu I. T8
4 puffer 9.

47 SHEAT
PUFFER 31 V16/1
Dilu II. 6.
1,7 puffer
V32/2

160
 Servicemanual

DILU II. DILU I.

PUFFER PUFFER T9

2 2

V43/1 2,5 18,5 8 20 3 9,3 V36/1

3 2 2

V41/1 2,5 V42/1 V40/1

10

V37/1

T10 RBC T11

MIX
2
2

V42/2 40 V29/2 40

9. 9.

V9/2 V10/2

MEA
T12 T13
PUFFER
V34/2
2,5
2 20 V3/2
MEA Puff
Small 6. 3 V35/2 7
MEA
PUFFER

Dilu I. T14 MEA T15

Puffer 4 Puffer
Small 10
20 V8/2 23 V23/1
. Dilu II 4 MEA
Puffer 10
Puffer
Small

161
Hemolyzer 5

CK1

CL1 CL2 CL3 CL4

Cham MIX RBC BASO

1 Puffer
CF2 CF3 CF4
1 2
2
CA3 CA4
MEA 3
PUFFER

C1 C2 C3 C4

1
1
3
2 2 1 3 2 2 2 2 2 2 2 2
2 1 1 2 1 1 1 1 1 1 1
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 3
V12
V12 V12
V13 V12
V14 V12
V15 V12
V16 V12
V17 V12
V18 V19 V20

2 2 2 2 2 2 2 1 1
4
3 3 3 3 3 3 3 2 2
1 1 1 1 1 1 1

4 5
6
T6

7
T6 T6
5 8
5

2 1 1 3 1 1 1 2 1 3
9
3 3 3 3 1 3
1 2 2 2 2 2 2 1 2
10
T6

V23 V24 V25 V26 V28 V29 V30 V32 V33

V34 V35 V12

V36 VV37
12 V12
V38 V12
V39 V12
V40 V12
V41 V12
V42 VV43
12 VV44
12 11
1 1 2 2 2 2 2 2 2 2 2
2 2 3 3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1 1 12
T6
34

13
40

T12
14
T12

40
4 3 3 3 3 3 34 4 3 15

16

17

18

19
Mea
Sheath Stop Lyse Dilu I. Dilu II.
Puffer
Puffer Puffer Puffer Puffer Puffer
Small
40
34

1 1 1 1 1 1
2 2 2 2 2 2
40

34
40

162
 Servicemanual

CK1
= Kicsi
CL1 CL2 CL3 CL4
= Nagy
Cham MIX RBC BASO

1
Puffer
CF2 CF3 CF4
1 2
2
CA3 CA4
MEA
PUFFER 3
C1 C2 C3 C4
T3
19 cm
T2

T3
3 T2
T3 T3

T2

T2

T2

T2
T3

T2
T2

1
1
3
2 2 1 3 2 2 2 2 2 2 2 2
2 1 1 2 1 1 1 1 1 1 1

V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 3

T3
V12
V12 V12
V13 V12
V14 V12
V15 V12
V16 V12
V17 V12
V18 V19 V20

2 2 2 2 2 2 2 1 1
4
3 3 3 3 3 3 3 2 2
1 1 1 1 1 1 1

4 5
T2 6
T6

T2
7
T2

16 cm

T2
T3
T6 T6
T2
5 8
5

8
11
5

3
2 1 1 3 1 1 1 2 1 3
9
3 3 3 3 1 3
1 2 2 2 2 2 2 1 2
10
T6

V23 V24 V25 V26 V28 V29 V30 V32 V33

V34 V35 V12

V36 VV37
12 V12
V38 V12
V39 V12
V40 V12
V41 V12
V42 VV43
12 VV44
12 11
1 1 2 2 2 2 2 2 2 2 2
2 2 3 3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1 1 12
T6
11
34

13
40

T12
14
T12

40
4 3 3 3 3 3 34 4 3 15

16

17

18

19
Mea
Sheath Stop Lyse Dilu I. Dilu II.
Puffer
Puffer Puffer Puffer Puffer Puffer
Small
40
34

1 1 1 1 1 1
2 2 2 2 2 2
40

34
40

163
Hemolyzer 5
12
CK1

CL1 CL2 CL3 CL4

12
Cham MIX RBC BASO

1
Puffer
CF2 CF3 CF4
1 12
2 2
CA3 CA4
MEA 3

19
33
PUFFER

C1 C2 C3 C4
T3

T2

T3
3 T2

33 T3 T3

T2

T2

T2

T2
28 T3

T2
T2

19
1
3
2 2 1 3 2 2 2 2 2 2 2 2
2 1 1 2 1 1 1 1 1 1 1
3

19
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11

T3
V12
V12 V12
V13 V12
V14 V12
V15 V12
V16 V12
V17 V12
V18 V19 V20

2 2 2 2 2 2 2 1 1
4
3 3 3 3 3 3 3 2 2
1 1 1 1 1 1 1

4 5
T2 6
T6

40 19 T2
7
T2
28

T2
T3
T6 T6 19
5 8
T2
33

8
11
5

3
2 1 1 3 1 1 1 2 1 3
9
3 3 3 3 1 3
1 2 2 2 2 2 2 1 2
10
T6

V23 V24 V25 V26 V28 V29 V30 V32 V33

V34 V35 V12

V36 VV37
12 V12
V38 V12
V39 V12
V40 V12
V41 V12
V42 VV43
12 VV44
12 11
1 1 2 2 2 2 2 2 2 2 2
2 2 3 3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1 1 12
T6
11
34

28 13
40

T12
14
T12

40
4 3 3 3 3 3 34 4 3 15
40

16

17

18

19
Mea
Sheath Stop Lyse Dilu I. Dilu II.
Puffer
Puffer Puffer Puffer Puffer Puffer
Small
40
34

1 1 1 1 1 1
2 2 2 2 2 2
40

40 34
40

164
 Servicemanual

12 CK1

CL1 CL2 CL3 CL4

12
Cham MIX RBC BASO
Puffer
1 CF2 CF3 CF4
1 12
2 2
CA3 CA4
MEA

19
36
33
PUFFER 3

42
C1 C2 C3 C4
T3

T2

T3
3
36 T2

33 42 T3 T3
28

T2

T2

T2

T2
T3

T2
T2

19
1
3
2 2 1 3 2 2 2 2 2 2 2 2
2 1 1 2 1 1 1 1 1 1 1
3

19
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11

T3
V12
V12 V12
V13 V12
V14 V12
V15 V12
V16 V12
V17 V12
V18 V19 V20

2 2 2 2 2 2 2 1 1
4
3
1
3
1
3
1
3
1
3
1
3
1
3
1 2 2 A5433
4 5
T2 6
36
42

T6

40 19 T2
14 7
T2
28

HF STOP 2 (20)

T2
T3
T6 T6 19
5 8
T2
33

14 5

8
11
5

3
2 1 1 3 1 1 1 2 1 3
9
3 3 3 3 1 3
1 2 2 2 2 2 2 1 2
17
14

10
T6

V23 V24 V25 V26 V28 V29 V30 V32 V33

14

V34 V35 V12

V36 VV37
12 V12
V38 V12
V39 V12
V40 V12
V41 V12
V42 VV43
12 VV44
12 11
1 1 2 2 2 2 2 2 2 2 2
2 2 3 3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1 1 12
T6 14
11
34

28 14 13
14
40

T12
14
T12

40
4 3 3 3 3 3 34 4 3 15
40

16

17

18

19
Mea
Sheath Stop Lyse Dilu I. Dilu II.
Puffer
Puffer Puffer Puffer Puffer Puffer
Small
40
34

1 1 1 1 1 1
2 2 2 2 2 2
40

40 34
40

165
Hemolyzer 5

12
CK1

CL1 CL2 CL3 CL4

12
Cham MIX RBC BASO
Puffer
1
CF2 CF3 CF4
1 12
2 2
CA3 CA4
MEA

19
36
33
PUFFER 3

42
C1 C2 C3 C4
T3

T2

T3
3 36 T2
T3 T3
33 42

T2
28

T2

T2

T2
T3

T2
T2

19
1
3
2 2 1 3 2 2 2 2 2 2 2 2
2 1 1 2 1 1 1 1 1 1 1
3

19
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11

T3
V12
V12 VV13
12 V12
V14 V12
V15 V12
V16 V12
V17 V12
V18 V19 V20

2 2 2 2 2 2 2 1 1
4
3
1
3
1
3
1
3
1
3
1
3
1
3
1 2 2 A5433
4 5
T2 14 6
36
42

T6
14
40 19 T2
14 7
T2
28

HF STOP 2 (20)

T2
15

T3
12

T6 T6 19
5 8
T2 HF LYSE 2 (20)
33

14 5

8
11
2
14
5

3
5

2 1 1 3 1 1 1 2 1 3
9
3 3 3 3 1 3
1 2 2 2 2 2 2 1 2
17
14

10
T6

V23 V24 V25 V26 V28 V29 V30 V32 V33

14

V34 V35 V12

V36 VV37
12 V12
V38 V12
V39 V12
V40 V12
V41 V12
V42 VV43
12 VV44
12 11
1 1 2 2 2 2 2 2 2 2 2
2 2 3 3 3 3 3 3 3 3 3
1 1 1 1 1 1 1 1 1 12
T6 14 14
11
34

28 14 13
14
40

T12
14
14
T12

40
T15

4 3 3 3 3 3 34 4 3 15
40

16

17

18

19
Mea
Sheath Stop Lyse Dilu I. Dilu II.
Puffer
Puffer Puffer Puffer Puffer Puffer
Small
40
34
T15

1 1 1 1 1 1
2 2 2 2 2 2
T15
40

40 34
40

166
 Servicemanual

1
2
3

4
5
6
7

9
10

11

12 38

13 37
37
37
35
14 35
35

15 17

16
L y se
L Lyse
- EO
L - EO
17 D D D D

18

19

167
Hemolyzer 5

1
2
3

4
5
6
7

2 1
3
1
3
1
3
1
3 1
3
1
3
1
3
1
3
2 1
3
8
1 2 2 2 2 2 2 2 2 1 2

V2 3 V24 V2 5 V26 V27 V2 8 V29 V30 V3 1 V3 2 V33

9
V 34 V3 5 VV36
12 37
VV12 VV38
12 VV39
12 V1
V420 VV41
12 VV12
42 VV12
43 VV4
124

1 1
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
2 10
2 2 1 1 1 1 1 1 1 1 1

11

38
37
38 12

37
37
13
35
37
35

37 14
35

17
37 15
35
16

35 17
35
18

19

168
 Servicemanual

169
Hemolyzer 5

Note: 400cm tube from V20 to SV upper disc is type A5433 1.27/2.23

170
 Servicemanual

12 Appendix
12.1 Recommended kit of tools
• PC standard keyboard (USB)
• Screwdrivers:
Slot Screwdrivers
Cross Slot Screwdrivers (Philips)
Hexagon Screwdrivers (3.5, 2.5, 2.0, 1.5 mm sizes)

• Pocket digital multimeter

• Diagonal Cutter (plier)
• Nipper

12.2 How to send .rp files to assessment of analyzer performance

Insert a pendrive (USB stick) in one of the USB ports. From ’Database’ press ’multiselect’
then select the results you want to save( It is very important to save some human blood
measurement results not just controls), then press ’manage records’. A window will appear,
press ’export’. The analyzer will search for the pendrive, usually it will be displayed as drive
E:.

Double click on the folder icon (just like in windows), the content of the pendrive will appear.
Press ’OK’.

rp files will be saved. You can send these files on to Support for investigation of analyzer
performance.

171
Hemolyzer 5

12.3 How to use the „Collect” function of the Hemolyzer 5

hematology analyzer

When is it needed?

- After servicing the analyzer (for documentation purposes)

- When requested by the service engineer (user can do it)
- When requested by Analyticon Support

How to do it?

- Run a blank measurement*

- Run a patient sample*
- Run a control measurement*
- From ’Menu/Diagnostics/Self-test’ click on ’Start both’ button and wait for the result.
- Insert a USB Stick in one of the USB ports on back of the analyzer
- From ’Diagnostics/Information’ click on ’Refresh data’ then on ’Collect’ button.
- When the window with drive E:/ appears select the drive then click on ’OK’ button
- This function saves the following information in a .gz file:
o Self-test result
o Stress Blank result
o Last 10 Human measurement rp-file
o Last 3 Control measurement rp-file
o Last Blank measurement rp-file
o Event log
o Statistics
o User/Service/calibration factors
o SW – PIC – Firmware versions

Keep the file for your records or send it to support@analyticon-diagnostics.com if asked by

support staff.

* Not mandatory

end of document

172