Documente Academic
Documente Profesional
Documente Cultură
Cat. 04005374
©2002 Bayer Corporation
All rights reserved
Flow Chart
CALIBRATE?
yes
ANALYZE SAMPLE?
yes no
LIFT SAMPLER TO
ANALYZE
Whole Blood, Serum, or Plasma Analysis no
DAILY CLEANER?
ANALYZE QC?
CALIBRATE?
Calibration yes no
SECOND MENU?
yes no
ANALYZE URINE?
STANDBY?
REPLACE
COMPONENTS?
Replace: Valve Module, Replace Others yes no
DIAGNOSTICS?
STORED
INFORMATION?
View: Patient Results, QC Results, Calibration Data,
Reagent Module Status; yes no
Print: Setup
SETUP MENU?
Set: User Options, Configuration,
Calibration Options, Reference Limits; yes no
Delete: Patient/QC Data;
Adjust Display
Table of Symbols
▲ Important information
Biohazard warning
Electrical hazard
i
Service Manual Contents
Product Description
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Sensor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Sampler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Printer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CPU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Pre-Amp PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Contact Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Display Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Valve Module Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Rear Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Replacement List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Troubleshooting
Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
AC Power Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DC Power Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Display Assembly Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Flash Device Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Printer Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Pump Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Valve Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Sensor Signal Input Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Serial Communication Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Repair
System Overview
T he repairs and procedures in this manual are intended for authorized field service
engineers. Instructions describe the repair or replacement of all modular internal
components. It is recommended that the field service engineer also refer to the Operator’s
Manual for detailed instructions on operating and troubleshooting the analyzer to determine
if repair or replacement is necessary for an internal component. The Replacement List
indicates assemblies and components available to the field service engineer. Refer to the
Repair section of this manual for the CPU schematics.
1
P R O D U C T D E S C R I P T I O N N
Sensor Module
Contains sampler position sensors, bubble detector,
door sensor, sampler, and compression plate. The
Sensors Na+, K+, Cl-, spacer, and reference sensors
are housed in the sensor module.
Sampler
Attached to sensor module. Contains sample probe
with probe wiper. The sampler is removable from the
sensor module as a replacement part.
Valve Module
Controls reagent (from reagent module) or air
selection. The valve module contains a ceramic valve,
motor, position detector. There are no serviceable
parts inside the valve module.
2
P R O D U C T D E S C R I P T I O N
Printer Assembly
Contains the printer mechanism, printer software, and
printer electronics. Prints analysis, calibration and
diagnostic data.
CPU Assembly
Contains transformer, software, inputs (sensors),
motor control circuitry, and 2 serial ports.
Pre-amp PC Board
Connects contact housing to the CPU assembly and
amplifies sensor signals.
Pump Assembly
Contains peristaltic pump with wire connector.
3
P R O D U C T D E S C R I P T I O N N
Contact Housing
Contains all contacts from the sensors, as well as the
contact housing cable for connection to the CPU
assembly.
Display Assemblies
(Analyzer operator interface.) Contains operator
keypad and LCD display.
Graphic display
(required for certain languages)
Numeric display
4
P R O D U C T D E S C R I P T I O N
5
P R O D U C T D E S C R I P T I O N N
Replacement List
The items on this list are available for purchase from
Bayer Corporation.
6
T R O U B L E S H O O T I N G
Troubleshooting Overview
Troubleshooting Guide
Determine the problem and corrective action
needed.
Action Steps
Problem/Description Problem Source Corrective Action Steps
7
T R O U B L E S H O O T I N G G
AC Power Verification
When the power is first turned on, the Rapidchem
analyzer will “beep,” and the display will light up. If
this fails to happen, follow the verification procedure
in this section. Review this entire section before
replacing any components. First confirm that the
power cord is inserted securely inside the AC power
cord socket.
220
220
110
11
or
X2 GND Reference 4 Verify the voltage at each test point listed in Table 1.
X3 + 8.5V +– 1.00V 5 Connect the reference side of the voltmeter to X2
Table 3 on the CPU board.
TP9 GND Reference 6 Verify the voltage at each test point listed in Table 2.
TP10 + 2.000V +– .003V
7 Connect the reference side of the voltmeter to TP9
TP12 - 15.00V +– 0.25V on the pre-amp PC board.
TP13 - 5.00V +– 0.25V
8 Verify the voltage at each test point listed in Table 3.
TP14 + 5.00 +– 0.25V
TP15 + 15.00V +– 0.25V
★ No adjustments are permitted. Failed boards
should be replaced. See CPU Assembly
Removal / Installation in the Repair section for
instructions.
9
T R O U B L E S H O O T I N G G
10
T R O U B L E S H O O T I N G
11
T R O U B L E S H O O T I N G G
Printer Verification
If the printer is not actively printing:
12
T R O U B L E S H O O T I N G
Pump Verification
DIAGNOSTICS?
For suspected pump problems, proceed to PUMP
TEST?. under TEST COMPONENTS? in the
DIAGNOSTICS? section of the SECOND
yes MENU. Press YES. The screen displays
ROTATING.... Look for pump rotation. When
TEST COMPONENTS?
full pump rotation occurs, FULL ROTATION? is
displayed. Press YES and PASS is displayed.
yes
When there is no pump movement or partial pump
PUMP TEST?
movement, press NO and FAIL is displayed.
Remove the pump tubing and repeat the PUMP
yes TEST?. If the test passes, install a new pump
tubing and resume operation. If the test fails, install a
new pump assembly. See Pump Assembly Removal /
Installation in the Repair section for instructions.
Valve Verification
13
T R O U B L E S H O O T I N G G
14
T R O U B L E S H O O T I N G
15
RR EE PP A
A II RR RR
Repair Overview
To replace Rapidchem assemblies, disassemble the STORED
INFORMATION?
analyzer in the order described in this section, PATIENT yes
referring to the photographs for assistance. After RESULTS?
USER OPTIONS?,
CONFIGURATION?,
PATIENT LIMITS?,
PATIENT INFORMATION?
Required Tools
Only 4 tools are required to remove or install the
Rapidchem electronic and mechanical assemblies:
16
R E P A I R
17
R E P A I R R
18
R E P A I R
19
R E P A I R R
20
R E P A I R
★ Before changing the flash device on the Rapidchem, follow these steps:
21
R E P A I R R
★ After changing the flash device on the Rapidchem, power up and follow
these steps:
22
R E P A I R
23
R E P A I R R
★ Before changing the Pre-amp PC board on the Rapidchem, follow these steps:
Pre-amp PC Board/Contact
Housing Removal
Remove the screw which connects the grounding strap
to the pre-amp PC board.
24
R E P A I R
★ After changing the Pre-amp PC board on the Rapidchem power up and follow
these steps:
Pre-amp PC Board/Contact
Housing Installation
Align the opening on the pre-amp PC board with the
CPU board mounting post. This will align the screw
holes. Insert the 6 screws to secure. Do not
overtighten. Connect the grounding strap to the pre-
amp PC board.
25
R E P A I R R
26
R E P A I R
27
R E P A I R R
Sampler Removal
If the sampler requires replacement, it can be
removed from the sensor module. Using a coin or
fingers, remove the retaining screw from the sensor
module.
Sampler Installation
Install the new sampler (includes sample probe and
wiper) in the sensor module. Insert the sampler
alignment pin into the sensor module. Rotate the
sampler into the closed position.
28
R E P A I R
PC Setup
Open Hyper Terminal under Programs > Accessories
> Communications.
Select File, then Save As, and enter a new file name.
29
R E P A I R R
Select Send Text file under transfer menu from the tool
bar in Hyper Terminal windows.
30
R EO P T AE I S R
N
+12V
X1
L1
1 2
U1 VCC
BEAD C4
3 1
IN OUT
Y1
C1
C2
22pF
.1uF
GND
C5
2
MIC2950
12MHz
1
2.2uF-16V
35
VCC
VCC
AGND
VCC
GND
XTAL1
38
AVREF-
VBATT EA
RESET 46 A15 46 29 D0
RESET P27-A15 PA0
45 A14 45 28 D1
EW P26-A14 PA1
A13
2
P25-A13 PA2
BUB_TOP 1 A12 D3
P50-ADC0 P24-A12 PA3
C6
U4 BUB_BOT 68 A11 D4
2
P23-A11
U6A
TEMP1 P52-ADC2 P22-A10 A10 A10 PA5 D5
TEMP2 P53-ADC3 A9 A9 PA6 D6
1 TEMP3 A8 D7
P20-A8
VCC
BAT/AC 64 PSD834F
P55-ADC5
4 7 PROB_OUT 63 AD7 37 7 SERIAL_E
PFI /RST P56-ADC6 AD7-A7 PB0
PROB_HM 62 50 AD6 36 6
P07-AD7
8 6 AD5 RTS
VBAT WDI P06-AD6 AD5-A5 PB2
P05-AD5 AD4 AD4-A4 PB3 HEATER2
5 RAM_ENA
GND
PACK_RD
1
PFO P04-AD4 AD3-A3 PB4
3VBAT AD_CLK P11-CT1I P03-AD3 AD2 AD2-A2 PB5 LATCH
AD_WR AD1
3
P12-CT2I P02-AD2 AD1-A1 PB6
+
P13-CT3I P01-AD1 AD0 AD0-A0 PB7
AD_RD 57
P14-T2 P00-AD0
PACK_PRG U3 20 JTAG_T
P15-RT2 PC0
B1
3V LITH
-
EE_DATA P16-SCL CPU-ALE ALE-PD0 PC1
PUMP_STP 23 48 CPU-PSEN PC_2
P17-SDA ALE PSEN PC2
CPU-RD JTAG_T
CPU-PSEN 47
PSEN CPU-WR WR PC4
PHASE1 7 48
P40-CSR0 /RST RESET PC5
PHASE2 8
VALVE_EN 9 RTC_SEL 11 JTAG_JEN
P42-CSR2 PC7 P8:1
PUMP_EN 10 30
P43-CSR3 P36-WR RAM_SEL
11
PC_2 29
GND
GND
P47-CMT1 P33-INT1
26
P32-INT0 PRNT
T
P30-RXD R
VCC C64 VCC
C8
JTAG_JEN
.1uF
GND
.1uF JTAG_TST
74HC14 80C552AZ VCC
JTAG_TDI
HEAT_PWM
U6P DGND JTAG_TCK
14 7 JTAG_TDO
VCC GND
JTAG_TER
NAME
DGND
9 POWER SUPPLY
I CI R
S
A
VCC
/RST P1::19
PRNT_RDY P1::6
VBATT
PRNT_STB
P1::10
.1uF P1::12
D7
C11 D6
D5
D4 P1::7
D2
D1
D0
U7
18
AD3 11 /RST
D3
AD2 12 15
D2 CS1
VCC
AD1 13
AD0 14
D0
1
A3 NC P2::11
6
5
A1
4
A0
9
GND
RTC-62421
CPU-ALE ALE P2::1
8 VCC
/RD P2::2
CS0
/WR
2
P2::18
DISP_EN P2::17
DISP_REG
RTC_SEL DISP_R/W
DIS_ADJ
DISP_SL1
/RST P2::24
CPU-RD
CPU-WR
GND
P2::12
P2::14
DGND
DGND
B
T1
3 4
2 5
1 6
ISOXFMR
VCC
U12
4
1
6
1uF
2
5
4N26N
DGND U10
14
U11 1 NC P3:1
U13
TXD 4 4
TXD
VCC
2 1 3
AC
D1 T1DIN P3:4
/RTS 5 12
RTS TXD
D2 T2DIN
RXD1 9 6 11
RXD RTS P3:5
5
CTS 12 10
CTS RXD
3 2 6
T1LDR R2LDR P3:2
5
6 4N26N 9
SERIAL_E T2LDR CTS
8 7
EN BYP P3:3
10 13
R1DIN V-
1 8
11 5 4N26N 2 ISO_V+
R2DIN V+ P3:6
7 2 14
GND RGND
MAX250 MAX251
6
C13
DGND
1uF
C14
4.7uF
1
4
U14
5 4N26N
2
1
4
DGND
U15
REMOTE-GND
C9
.1uf
C
X3
ISO_V+
C16
X2
10uF-16V
/RTS
U6D
RTS 9 8 1
REMOTE-GND
NC P4:1 VCC
74HC14 2
PS2505
P4:5
C17
R5
R4
P4:2
VCC
DGND
G
8
D2
74HC157
DGND
REMOTE-GND
D
+24V-FUS
VCC
22uF-50V
.001uF
C19 U8
DGND
9
I12
DGND
I02
17
I11
VALVE_EN 20 3
I01
23
PHASE2 P2
PHASE1 16
P1 SEN1
VREF2
RC2 VREF1
14
RC1
5
13
LS 2A
1B
24
C24
S 1A
.001uF
R15
UDN2916B
C20
.001uF
DGND
DGND
VALVE
P6:4
P6:5
P6:8
P6:7
+24V-FUS
U20
2
VSUP1
16
VCC
VCC
7
VSUP2
15 PUMP_EN
PSA EN
OUT-A PUMP_STP
11
PSB STEPS
3
C25
OUT-B
14
PSC DIR
6
OUT-C
PSD HALF
8
OUT-D
9
PHASE
.1uF
DGND
UCN5804B
DGND DGND
PUMP
P7:1
P7:6
P7:5
P7:4
P7:3
P7:2
E
P5:13 CAPI_MOD
P5:10 PROB_HM
P5:12 PROB_OUT
VCC
P5:11 MOD_DOOR
5.6v znr
5.6v znr
5.6v znr
5.6v znr
R16
U19A
1M 2
+5V
1 BUB_BOT
P5:6
R17
1M
3
.01uf
DGND
P5:7 TLC2272A
P5:9
AGND
8
R18
VANA+
1M U19B BUB_TOP
6
.1uF
U19PB
TLC2272A
7
1M
GND
.01uf
4
HEATPWM +5V
TLC2272A
DGND
AGND AGND
HEAT_PWM
R21 HEATCON
W1
C30
P5:2
.1uF
U9C
P5:4
.1uF 9
P5:1
8
P5:14
P5:5 C31
R27 10
AGND
HEAT_DAC TLC2274A
U9B
AGND 6
C32
.1uF
7 TEMP1
5
TLC2274A
BUBBLE DETECTOR & HEATER #1
R25 R26
+5V
AGND
F
VALVE_HM
12
VCC
U6F
74HC14
VCC
13
P6:11
VALVE P6:13
R34
U27
5.6V znr
U9A
1 2 2
IN OUT
1
GND
TEMP3
3
C34
LM35 +5V
TLC2274A
L3
1 2
BEAD
+24V .1uF
DGND
R37
4
9.09K
VANA+
Q2
.1uF
W2
RXE075
U9PB
TLC2274A
HEATER2
GND
F15N05L
R29
11
P6:14
P6:12
DGND
R33
AGND
U9D
DGND
R30
13
14 TEMP2
12
TLC2274A
HEATER 2 & TEMP SENSORS
R31 R32
+5V
AGND
G
VCC
+12V
-18V
P9:9
+18V D14
P9:7
AD_WR
P9:3
AD_RD
P9:2
AD_CLK
P9:1
ADC_ENA
Q6
P9:5
VP0300L
EE_DATA
2N7000
P9:6
PACK_RD P13:1
GND
P9:4
AGND Q5 Q4
P9:8 P13:2
PACK_PRG
C71
D13
2N7000
DGND AGND
DGND
H
-12V +12V
X9 X10
C53
U24 U23
2 3 1
IN OUT IN OUT
GND
GND
C40
.1uf
X5 ENTRY MO
1
2
79L12 78L12
7 GND-EARTH
5
6
A1
+18V
DGND 1 2
L8
AC-CHOKE
L7
X6
C60
L9
C54
3
4
+24V
+24V-FUS
X4
-18V P15
JUMPER
1000uF 35V
1
2
MNT-HOLE
AC MAINS
W8
GND-EARTH GND-EARTH
THROUGH HOLE PAD
C55
RXE075 TO SHIELD OF CHASSIS
S1
ON \ OFF
VCC 12 6
X7
11
3
4
4 S2
9 3
3 4
110/220
N1 8
U30 2 1
4
L5
7 1
2 1
VOUT VIN 63SPS
FB
100uh XFMR56VA
1N5819
GND
ON
C59
.1uF
D17
3
5
L4
4700uF 10V
3300uF 35V
1 2
BEAD
X8
BAT/AC
AGND
DGND DGND
+18V
BATTERY
GND-EARTH
I
U22A
2
1 VCC
3
C46
OPA2131P VBATT
+24V
.1uf
C47
28
U21
4
L6 .1uf A14
2 1 A13 DGND
VCC
FB
100uh
A10
GND
ON
A9
20
U28
LM2575ADJ
3
5
1N5820
AD7 19 A7 3 HM62256B
VCC
C37
AD5 A5
AD4 A4
AD2 A2
330uf 35v
AD1 A1
8D 8Q A0 A0
+12V U26 19
I/O8
CPU-ALE
C
DGND 1
GND
DGND
10
GND
I/O1
14
DGND
8 4
VANA+ VANA-
HEATCON R41 R40
U22PA CPU-WR
DGND
6
7
-12V
RAM_ENA
-1.25V
Q1 5
OPA2131P
CPU-RD
DGND
J
Contacting Bayer Diagnostics
For technical assistance, contact your local authorized representative. For customer service or
additional information, contact your local authorized distributor.
K
Bayer Diagnostics Limited Bayer As
20/F Gee Chang Hong Centre Brennaveien 18
65 Wong Chuk Hang Road N-1483 Skytta, Norway
Hong Kong + 47 67 06 86 00
852-28147337
Bayer Sp. z o.o.
Bayer Diagnostics India Limited Al. Jerozolimskie 158
589, Sayajipura 02-326 Warszawa, Polska
Ajwa Road +48(0)225723500
Baroda – 390019
Gujarat, India Bayer Portugal S.A.
91 265 46 2720 Divisao PH / DS
Rua da Quinta do Pinheiro, 5
Bayer S.p.A. 2795-653 Carnaxide, Portugal
Divisione Diagnostici 351.21.416.50.22
Via Grosio 10/4
20151 Milano, Italia Bayer Puerto Rico Inc.
+39/023978.1 Diagnostics Division
Victoria Industrial Park
Bayer Medical Ltd. Building #1
Unosawa Tokyu Building 3F Carolina, Puerto Rico
1-19-15, Ebisu 787 752-8989
Shibuya-Ku
Tokyo 150-0013, Japan Bayer (Pty) Ltd.
81.3.3440.4881 Healthcare Division
27 Wrench Road
Bayer Diagnostics Korea Limited Isando 1600, South Africa
4/F Kyemyung Building 27 11 921-5048
48-7 Myungil-Dong
Kangdong-Ku Química Farmacéutica Bayer, S.A.
Seoul, Korea 134-070 División Diagnósticos
82-2-428-5980 Calabria, 268
08029 Barcelona, España
Bayer de México, S.A. de C.V. + 34 93 495.65.00
Division Diagnósticos
Ave. Colonia del Valle No. 615 Bayer AB
Col. del Valle Drakegatan 1
Delegación Benito Juárez S-402 24 Göteborg, Sweden
México, D.F. C.P. 03100 + 46 31 83 98 00
525 7283301
Bayer (Schweiz) AG
Bayer B.V. Geschäftsbereich Diagnostika
Division Diagnostics Grubenstrasse 6
Energieweg 1 8045 Zuerich, Switzerland
3641 RT Mijdrecht, The Netherlands 0041/1/465 81 11
+31 (0)297 280 666
M
Bayer Taiwan Company Limited
Diagnostics Division
8/F No. 109 Sec. 2
Keelung Road
Taipei, Taiwan R.O.C.
886-2-23777520
Bayer plc
Diagnostics Division
Bayer House
Strawberry Hill
Newbury, RG14 1JA
United Kingdom
+44 (0)1635 563000
Bayer Corporation
Diagnostics Division
511 Benedict Avenue
Tarrytown, NY 10591-5097 USA
914 631-8000
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005521-001 R0