ct500维修手册

CLINITEK 500 SERVICE MANUAL

Section Description Section number

Rev.1199H Table of Contents Page 1 of 4

General Description 1

Methods Overview 2

Installation 3

Operation / procedures 4

Preventive Maintenance 5Introduction 5-0

Cleaning 5-1

Lubrication 5-2

Functional Diagrams / Theory 6Introduction 6-0

General Operation 6-1

User Interface 6-2

Power Distribution 6-3

Mother PCB 6-4

Motor Drive Circuits 6-4-1

Optical Sensors 6-4-2

Printer Interface 6-4-3

Serial Ports 6-4-4

Moving table 6-5

Main PCB 6-6

Touch Screen Display 6-7

Read-head System Overview 6-8

Read-Head Movement 6-8-1

Pre-amp PCB 6-9

Pre-amp A/D PCB 6-10

Strip Detector 6-11



Page 2 of 4 Table of contents Rev. 1199H

Exercise / Diagnostics Troubleshooting 7Troubleshooting Chart 7-1

Explanation of Error Codes 7-2

Introduction 7-2-0

Error Handling 7-2-1

Error Summary 7-2-2

Explanation of Instrument Test Card 7-3

Introduction 7-3-0

Self Checks 7-3-1

Ready Screen 7-3-2

Level 1 instrument Tests 7-3-3




Detailed Troubleshooting and Testing 7-4

Introduction 7-4-0

Pre-amp PCB 7-4-1

A/D PCB 7-4-2

Mother PCB 7-4-3

Sensor Tests 7-4-5

Display Testing 7-4-6

Main Processor PCB 7-4-7

Alignments / Adjustments 8Introduction 8-0

Voltage adjustments 8-1

Readhead alignment 8-2

Horizontal plate adjustment 8-3

Printer cleaning 8-4

Cleaning print mechanism 8-5-1

Cleaning the printer platen 8-5-2

Sensor adjustments 8-6

Push Bar slide lubrication 8-7



Rev.1199H Table of Contents Page 3 of 4

Repair / Replacement 9Introduction 9-0

Pusher Bar 9-1

PCMCIA 9-2

Printer Module 9-3

Bezel 9-4

Fixed Table 9-5

Moving Table 9-6

Upper Case 9-7

Fan 9-7-1

Table Guide Left 9-8

Table Guide Right 9-9

Power Supply 9-10

Processor PCB 9-11

SIMM PCB 9-11-1

Electronics Bracket 9-12

The Mother PCB 9-13

Strip Detector 9-14

Lamp 9-15

Preamp & A/D 9-16

A/D PCB 9-16-1

Preamp PCBs 9-16-2

Drive Housing 9-17

Crank Arm 9-18

Baseplate Mechanism 9-19

Lower Case Assembly 9-20

Lower Case 9-20-1

Touch Screen 9-21

Printer Interface PCB 9-22

Illustrated Parts Breakdown 10

Schematics 11

Release Testing 12



Page 4 of 4 Table of contents Rev. 1199H

Appendices CLINITEK 500 Instrument Release Test Data Collection Software A

Hard Standards Maintenance B

CLINITEK 200 Emulation Output Format Support C

CLINITEK 200+ Emulation Output Format Support D

Printer Report Formats E

Test Mode 2 and Altered Ranges F

GENERAL DESCRIPTION

Rev. 1199H CLINITEK 500 Service Manual Page 1.1

1-0 IntroductionThe CLINITEK 500 Urine Chemistry Analyzeris capable of processing in excess of 500-urine chemistry reagent test strips per hour. Itwas developed as the next generationreplacement system for Bayers CLINITEK200+ Urine Chemistry Analyzer and differsprimarily from this system in its higherthroughput (over 500 tests per hour), non-pacing operation and enhanced touch-screenbased user interface. In addition to directsupport for a wide range of MULTISTIXReagent Strips, the Clinitek 500 instrumentcan make and report a qualitativedetermination of urine color.

1-1 FeaturesThe major improvement over previoussystems has been in workflow reduction.Customers can reduce their technician timespent on processing urine samples. Toachieve this overall benefit, the followingfeatures were implemented:

Touch screen display for easier andfaster operation,

Non-pacing operation mode toprocess samples at the users pace,

Increased throughput for completingwork faster,

Automatic urine color determination tospeed up data entry,

Confirmatory Sieve with Batch ResultsEditing to eliminate time consumingmainframe editing,

Memory Recall which allowscustomers to display the test resultsfrom specific samples,

Interactive Bar Code Reader Support(optional) to enter patient ID and colorand clarity more efficiently,

Internal Automatic Calibration toimprove reliability of results.

No warm-up time for starting a batch.

User Interface available in English, German,French , Italian, Spanish and Kanji withapplicable help screens The generaldescription of the CLINITEK 500 UrineChemistry Analyzer can be found on pages 1.0to 1.5 in the Operating Manual.

1-2 General Specifications

Size:Depth-32.4 cm (12.8 in.)Width-37.7 cm (14.8 in.)Height-28.2 cm (11.1 in.)

Weight:7.4 Kg (16.3 lb)

Input voltage:Auto Ranging 90 VAC to 264 VAC50 60 Hz

Maximum Power Input-72VA

Thermal output:246 BTU/hr

Line Leakage Current:< 0.5 milliamperes in normal condition< 3.5 milliamperes in single fault condition

(Testing protocol and allowable limits as specified bythe safety standards for laboratory equipmentoutlined in UL 3101-1, CSA 22.2 No. 1010.1 and IEC1010-1)

Ambient Operating Temperature Range:18C to 30C (64F to 86F

Ambient Operating Humidity Range:20% to 85% relative humidity

Optimum Operating Conditions:22C to 26C (72F to 86F)

35% to 55% relative humidity

CHAPTER ONE - GENERAL DESCRIPTION

GENERAL DESCRIPTION

Page 1.2 CLINITEK 500 Service Manual Rev. 1199H

METHODS OVERVIEW


Chapter Two - Methods Overview

2-0 IntroductionThe CLINITEK? 500 Urine Chemistry Analyeris a scanning reflectance photometer, whichreads the change in color on Bayer MultistixReagent Strips. Please refer to the productinsert that comes with the specific MultistxReagent Strips being used for a descriptionof the its methods.

METHODS OVERVIEW


INSTALLATION


3-0 IntroductionRefer to the installation section of theOperating Manual.

CHAPTER THREE INSTALLATION

INSTALLATION


OPERATIONS / PROCEDURES

Rev.1199H CLINITEK 500 Service Manual Page 4.1

4-0 IntroductionRefer to sections 3 and 4 of the OperatingManual for instructions on the operation ofthe CLINITEK500 Urine ChemistryAnalyzer.

CHAPTER FOUR OPERATIONS / PROCEDURES

OPERATIONS / PROCEDURES

Page 4.2 CLINITEK 500 Service Manual Rev.1199H

PREVENTIVE MAINTENANCE


5-0 IntroductionThis section describes cleaning and preventativemaintenance test procedures that should beperformed as a matter of routine anytime that aCLINITEK 500 instrument is in Bayer Diagnosticspossession. Following these procedures will helpidentify possible system weaknesses prior tothem manifesting themselves as field failures.

5-1 Cleaning

Reference

CLINITEK 500 Operating Manual, Section 5CARE OF THE INSTRUMENT for cleaninginstructions.

5-2 Lubrication

Push Bar Slide Arm Shaft

1. Clean the Push Bar Slide Arm Shaft withalcohol.

2. Apply a thin coat of Lubriplate 630-AA Multi-purpose Grease, part number 50336008.

Introduction-------------------------------------------------------------------------------------------------------5-0Cleaning ----------------------------------------------------------------------------------------------------------5-1Lubrication--------------------------------------------------------------------------------------------------------5-2

CHAPTER FIVE - PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE


FUNCTIONAL DIAGRAMS / THEORY


6-0 IntroductionThe CLINITEK 500 Instrument is a stand-alone,semi-automatic urine chemistry analyzer. Theinstrument is a scanning reflectance photometercapable of outputting clinically significantdiagnostic results when used with a variety ofBayer reagent strips.

Primary features of the system include the abilityto automatically detect the presence of a Bayerreagent test strip which has been presented forprocessing, a throughput in excess of 500reagent tests per hour and an advanced touch-screen based user interface which gives thecustomer considerable control over the operationof the system.

The instrument has several functional sub-systems: Reagent Transport, Readhead system,Data processing and User interface. Within eachof these sub-systems there are specific electrical,mechanical and software components. Theoverall operation of the instrument is controlled bytwo independent processors, the first managingdata I/O and the user interface. The secondcontrolling basic instrument hardware functions.

6-1 General OperationThe general operation of the instrument is asfollows:1. (Refer to figure 6-1)

2. The user dips a Bayer urine test strip into aurine sample and places it onto the load zoneof the CLINITEK 500 instruments Fixed Table.

3. A strip detector senses the presence of areagent strip on the Fixed Table.

4. Detection of a reagent strip activates the Pushbar that pushes the reagent strip to the rightside of the load zone on the Fixed Table.

5. When the Push bar reaches the far right endof its travel, the strip detector verifies thepresence of a reagent strip. If a strip ispresent, the test sequence number isincremented and the Moving Table isactivated to move the reagent strip into theReadhead area in preparation for analysis.(This area is encased under a permanenthood to prevent ambient light from interferingwith the system's reflectance measurements.)

6. The Moving Table continues to be activatedevery 7 seconds and advances the strip tothe right each time by approximately.45 inches (1.143 cm).

Section

Introduction-------------------------------------------------------------------------------------------------------6-0General Operation----------------------------------------------------------------------------------------------6-1User Interface----------------------------------------------------------------------------------------------------6-2Power Distribution ----------------------------------------------------------------------------------------------6-3Mother PCB ------------------------------------------------------------------------------------------------------6-4Motor Drive Circuits --------------------------------------------------------------------------------------------6-4-1

Optical Sensors -----------------------------------------------------------------------------------------6-4-2Printer Interface -----------------------------------------------------------------------------------------6-4-3Serial Ports -----------------------------------------------------------------------------------------------6-4-4

Moving table -----------------------------------------------------------------------------------------------------6-5Main PCB---------------------------------------------------------------------------------------------------------6-6Touch Screen Display -----------------------------------------------------------------------------------------6-7Readhead System Overview---------------------------------------------------------------------------------6-8

Readhead Movement ----------------------------------------------------------------------------------6-8-1Pre-amp PCB ----------------------------------------------------------------------------------------------------6-9Pre-amp A/D PCB ----------------------------------------------------------------------------------------------6-10Strip Detector ----------------------------------------------------------------------------------------------------6-11

CHAPTER SIX FUNCTIONAL DIAGRAMS / THEORY



7. The Moving Table advancement places a stripunder either Readhead (at approximately 25or 67 seconds after dipping),if a strip is undereither readhead then the Readhead will scanthe strip taking measurements in the Red,Blue, Green and IR wavelengths.

8. After a Strip has been read under bothreadheads the data will be analyzed and theresults passed to processor 1 for output todevices based upon system configurationoptions selected by the user.



Instrument Operation Overview Block Diagram

Figure 6-1

Strip placed on load zone

Push Bar moves strip to verificationposition

Strip present at right side detector

Pusher moves strip to Moving tablepick-up and stays at far rightposition

Moving table advances 3 positions(3 instrument cycles, 21 seconds)

Push Bar returns to left position

NO

Readhead 1 detects strip present

Strip at either readhead

Initialize readhead position

Calibrate

Read strip(s)

Select readings

Calculate reflectances

NO

Push Bar returns toleft position

Ready

YES

NO

YES

NO

Have12 moving table cyclesoccurred without detecting a stripunder readhead 1

NO

YES

yes

Push Bar moves strip to themoving table pick up

Push Bar returns to the far leftand waits for next strip

Moving table advances stripevery 7 seconds

yes



6-2 User InterfaceThe user interface consists of: a touch screendisplay, audible and visual alarms, internal andexternal printer options, a serial RS232 input forbar-coded sample ID, a second RS232, data portfor interface with an external customersinformation system (computer) and a third RS232serial port for future customer options. All userinterface functions are controlled by processor#1.

6-3 Power DistributionThe AC line input for the instrument first passesthrough the power entry module. This module is acombination of an on/off switch and line cordreceptacle. Note that the AC line fusing for thisproduct is located inside of the power supplymodule and is not considered a serviceable item.

The power supply is a switching power supply.The AC input voltage is automaticallycompensated for and has a range of 90-264 VAC,50-60 Hz. The outputs of this supply are +5 VDCand +12 VDC, -12 VDC and -5 VDC. The exactvoltage level of the +5 VDC output can beadjustable by use of potentiometer V1 adjacent toterminal block TB2 (refer to figure 8-1). Thepower supply is protected from overload by useof fold-back current protection and an internalfuse. An internal over-temperature protectioncircuit with automatic reset provides additionalprotection. Output noise and ripple will be less

than .3% RMS (noise) and 1% peak-to-peak(ripple) for the main +5 VDC output.

Power is distributed throughout the instrument viathe MOTHER PCB. A cable connects the powersupply to connector P12 of the MOTHER PCB.Connector P12 is a six pin connector and has thefollowing pin out: Pins 2 and 3 of this connectorare the DC ground, pin 1 is -12 VDC, pins 4 and 5+5 VDC and pin 6 +12 VDC.

There are two auto reset fuses F1 and F2 whichare soldered into the MOTHER PCB and providecurrent protection for the external Bar codereader. Fuse F1 is for the +5 VDC and fuse F2 isfor +12 VDC

Power to the internal printer is supplied viaconnector P7 on the MOTHER PCB, Pins 1 and 2are +5 VDC, Pin 3 is DC Ground.

The strip detector circuit operates off both+12 VDC and 12 VDC. This power is suppliedthrough connector P8 of the MOTHER PCB. Pins1,4 and 5 are GND while pin 3 is +12 VDC andpin 2 is 12 VDC

6-4 Mother PCBThe MOTHER PCB serves primarily as aninterconnection board for many of the systemsI/O functions and contains a portion of theinstruments control circuitry. Each of thefunctions performed by the MOTHER PCB isdescribed below.

Main PCB

Processor #1

Mother PCBPrinter Bar-code reader RS232

RS232 Ports

InternalPrinter

ExternalPrinter

Bar-CodeReader

RS232RJ45

RS232DB25

TouchScreenDisplay

Figure 6-2



6-4-1 Motor Drive Circuits

The drive circuits for the moving table, Push barand readhead all utilize the same circuit design.U5, U6 and U7 are motor controller ICs whichconvert the instructions from Processor #2(connector J2) to drive signals for the steppermotors. The input signals are Step (pin 11), OE(pin 15), and Direction (pin 14). The half stepcontrol line is tied high to the +5 VDC thusdisabling this function on all ICs. U6 also has pin11 tied to the +5 VDC which fixes the motordirection to clockwise rotation.

The output of the motor controller IC drives a fourphase stepper motor. The outputs are: pin 8 (Aoutput), pin 1 (B output), pin 6 (C output) and pin3 (D output). Each of the outputs is clamped toground through a reversed bias schottky diodes(D1-D12).

The stepper motors are four phase and havetypical coil resistances as follow:

Readhead motor 24 ohmsPush Bar motor 53 ohmsMoving Table motor 32 ohms

6-4-2 Optical Sensors

There are three optical sensors that are used toconfirm the following:

1. Fixed Table is in place (PN 40453222)

2. Push Bar interrupt sensor (PN 40453233)

3. Moving Table interrupt sensor (PN 40453221)

All of the sensor outputs are routed to the MainPCB through connector J1

The Fixed Table in place optical sensor is locatedon the left support of the fixed table guide and isused to determine if the fixed table is fully seated.The sensor plugs into connector P10 on theMother PCB. If the signal is not present it willresult in a general system error 26 and will haltoperation.

The Push bar interrupter is used to determine ifthe push bar has cycled completely. The sensorplugs into connector P9 on the MOTHER PCB. Ifthe signal is not present it will result in a generalsystem error 24 and will halt operation.

The Moving Table interrupter is used to determineif the strip transport is working properly. Oncethe system initiates a test cycle and activatesthose mechanisms used to advance a regent teststrip, it expects to see a signal change from thissensor within a certain time window. This sensorplugs into connector P1 on the MOTHER PCB. Ifa signal is not seen, the system interprets this asa problem with the moving table and reports ageneral error 23 which will halt operation.

6-4-3 Printer interface

The external printer port J3 is located on theMother PCB. In addition to providing the routingfrom Main PCB connector J1, to connector J3mounted to the rear of the instrument, the datalines are clamped for noise suppression withdiodes D14 through D24.

6-4-4 Serial Ports

The Mother PCB also provides interconnectionfrom the Main PCB (connector J2) to the threeRS232 serial ports J5, J6 and P4. Connector J6 isa RJ45 8 pin modular jack and connector P4 is a25 pin female D-Connector. These are for serialcommunication with external equipment.

The remaining port J5 is an 8 pin RJ45 connectorthat is dedicated for use with a bar code reader.On this jack, pins 1 & 3 are tied to ground, pin 4is serial output from the Main PCB, pin 5 is serialinput. Pin 6 provides +5 VDC output and pin 7provides a +12 VDC output for the reader.

6-4-5 Moving table

Following confirmation of reagent strip presenceby the strip detector, movement of the reagenttest strip is then performed by the moving tableassembly. This assembly is driven by a steppermotor which is under the direct control ofProcessor 2 (Refer to figure 6-3).



Processor #2 sends control signals for directionand a pulse train to the stepper motor controllerchip on the mother PCB. The controller convertsthe pulse train into four outputs; phase A, phaseB, phase C, phase D, for the windings of thestepper motor. An optical interrupter detector isused to establish a home location for the movingtable and provides a means of timing its operationto detect errors in its motion. (Refer to section 6-4-1 for more details on the motor drive circuits)

6-5 Main PCBThe Main PCB contains the instruments twoProcessors and all of their associated supportcircuitry. Processor #1 (U21) is an 80C517A(8051 family) which is a surface mount IC.Processor #2 (U1) is a Dallas DS2253T and ismounted as a SIMM in a socket. The systemutilizes the Processors as follows:

Processor #1 is used for serial communications,bar code communications, internal and externalprinter functions, converting decode values toclinical levels, and provides all user interfacefunctions. It communicates with Processor #2and includes the ability to program Processor #2.

Processor #2 is used to control strip movement(strip detector, push bar motor, moving tablemotor), readhead movement, perform errorchecking, read the strip, perform calculations onstrip data, store one set of results (reflectance,decodes and color) and maintain real time anddate.

The PCMCIA card is used to store the CT 500software and to retain the user configurationsettings.

IC U24 is the system RAM (128K) that is used tostore patient results.

ICs U13 &U14 are quad comparators used inconjunction with DAC U29 and processor 2 forthe strip detector control.

Data for the internal printer is sent to latch U17where it is output through an octal ferrite to theprinter on connector J3.

Data for the external printer is sent to U19, abuffer, where in conjunction with a response to astrobe signal it is sent out connector P1.

The Touch Screen Display is connected to theMain PCB at connector J5. Data from Processor#1 is sent to a latch U15 where it is then clockedto the display. Information is entered from thetouch screen keyboard and is passed throughconnector J5 to Processor #1. Power is suppliedto the display via connector J5 pins 16 & 17 forthe +5 VDC and pins 18 & 19 for the +12 VDC.Pins 4,5,20,21,24,29 and 30 are grounded.

6-6 Touch Screen DisplayThe touch screen display assembly consists offour main components: The bezel assembly,touch screen, display and the interface PCB.

The Display is a 320 by 240 dot matrix (15 linesby 40 characters) and is controlled by the displaycontroller U1 (SED133SF) on the interface PCB.The information is presented to the controller inan eight bit parallel format from the Main PCB viaprocessor #1. It is then converted to a videoformat and sent to the display as pixels.

The touch screen is an Analog Resistive TouchScreen (ARTS). It consists of two layers (oneorientated along the X-axis and one layerorientated along the Y-axis) of a transparentresistive film separated by a spacer. The activeaxis of the screen is selected via two controlsignals which switch one of two pair of MOSFETS(U4) on to apply a fixed voltage across the axis ofthe resistive element. The inactive elementbecomes the input for the A/D convert. R1 is apull down resistor for the vertical axis and R2 is apull down resistor for the horizontal axis. Whenthe screen is pressed a unique voltage isgenerated for both the X layer and the Y layer.These two voltages are converted to a digital

Processor #2

Mother PCBStepper motordrive circuits

Optical sensor(PN 40453221)

Moving tableAssembly

Stepper motor

Figure 6-3



representation of the location on the screen bythe A/D converter in Processor #1.

6-7 Readhead System OverviewThe Readhead system consists of the followingcomponents: Two Pre-amps, an A/D convertersubsystem, two independent illumination sources,a drive subsystem and a system controller. Theinstrument uses two readheads that are spacedto allow for two readings of a strip. The firstreading occurs approximately 25 seconds afterthe strip has been dipped and the secondreading at about 67 seconds. Each of thereadheads consists of a light source and fourdetectors. The detectors each have an opticalfilter that passes a broad bandwidth of energy tothe detector. The four bands passed to thedetectors are Infrared, Red, Green and Blue. Theoutput of each detector is passed to a two-stageamplifier. (See section 6-9 Pre-amp theory)

The four outputs (IR, Red, Green and Blue) fromeach of the two pre-amps PCBs are routed to acommon A/D PCB. The A/D PCB contains aneight-channel A/D converter that is multiplexed toselect which of the eight channels will beconverted. Its output is sent in a serial format toProcessor #2 (Refer tosection 6-10 A/D theory).Processor #2 controls the operations of readingthe strips and calculating the results. Once theresults are calculated, they are sent to Processor#1 which controls the User Interface.

6-8 Readhead Movement

The two readheads of the CLINITEK 500 aremounted to a Readhead carrier that rides on aprecision ball slide and is driven by means of astepper motor. The process of taking a readinginvolves moving this assembly over the reagentstrip(s) and scanning each reagent strip takingone or more readings at every pad location.Processor #2 controls the position of theReadhead carrier (See section 6-4-1 motorcontrol theory).

The actual process of reading a strip issummarized below:

The scan cycle is 7 seconds.

1. Strip presence is verified by the stripdetector.

2. Processor #2 activates the moving table toadvance the reagent strip into the Readheadarea. It takes three cycles for a reagent stripplaced on the load area to be brought underReadhead #1.

3. If a strip was under Readhead #1 during theprevious scan cycle, a control code is sent toprocessor #2. (A strip is verified as beingpresent at Readhead #1 if the IR channelreflectance between pads 9 and 10, and pads2 and 3 is above 65% is present in the lastdata set)

4. If a strip was present at Readhead #2 duringthe last cycle, the data set, which includeserror code, is sent to processor #1. The errorflags are reset after the error code is sent. (Ifboth events 3 and 4 occur a code will be sentfirst)

5. At 3.0 seconds into the 7 second scan cycle,the actual read operation begins:

A. Move the Readheads to find the edge ofthe cal-chip under readhead #1 andmove to the center of the cal chip. Thisis arbitrarily set as location 0.

B. Perform a dark value reading on allchannels.

C. Turn the lamps on and perform acalibration of all channels on the whitecal chip.

D. Move the Readheads out 0.017 andread each of the eight channels after theReadheads have moved. Thesereadings consist of the A/D convertervalues associated with each channel. Allof the readings are stored in the ordertaken in temporary memory.

E. Repeat this until 1488 readings of 2 byteseach are read, dark values subtractedfrom this and the resultant values storedfor each Readhead during the scancycle.

F. The Readheads are returned to the calchip location.



6. Calculations are performed based on thespecifics of the reagent strip being tested.Not all data is used in these calculations (forexample, for most MULTISTIX reagents, onlythe reading closest to the center of thereagent pad is used in the determination ofresults for that analyte).

Calculations are done to obtain reflectances,which, after processing in the specificalgorithm for a reagent, is compared to adecode point, and converted into a reportableclinical level. Each of the interim and finalresults is stored in the appropriate data set.

After all individual pad calculations arecompleted the color calculations are doneand stored. The date, time and sequencenumber, are sent in the data set. Thesequence number is then incremented.

7. The system then waits until the 7-second scancycle is completed. The process thenrepeats until there are no more reagent stripsunder the hood area.



Figure 6-4

Block Diagram of Process of Scanning a Strip

Strip has been moved underReadhead 1

Have 12 Cycles occurred withoutdetecting a strip under eitherreadhead

Readhead #1 finds the edge of theCal chip, then moves to chip center

Read dark values for all channels

Turn lamps on and calibrate allchannels

Scan reagent strip read all 8 channels(1488 readings taken)

Readheads return to cal chip position

Calculations performed reflectance,decode, clinical levels

Color calculation done date and timestored in data

Wait for cycle to complete and repeatoperation

NO

ENDYES

Select readings

CycleMovingtable



6-9 Pre-amp PCBThe CT500 has two functionally identicalReadheads. The heart of each Readhead is thesurface mounted detector package. This devicehas four separate channels each with its ownoptical filter: one green, one infrared, one blueand one red. Each of the channels has its ownphoto detector output. The output of the detectoris passed through a two-stage Pre-amp and itsoutput through connector P1.The op-amps used on the Pre-amp operate from a+5VDC and -5VDC power supply located on theA/D PCB. When the lamp in the readhead is onand it is over the calibration chip the output ofeach of the Pre-amp channels should beapproximately +4VDC. With the Readhead lampoff, the outputs of the pre-amp channels shouldbe approximately 0VDC (because the op-ampsoperate from the both a positive and negativesupply up to a.4 positive or .4 negative voltagemay be observed).

CAUTION

Cotton gloves must be worn whenhandling the Preamp PCBs.

ESD percautions must be taken wheneverthe upper case of the instrument isremoved.

A dirty Preamp PCB can cause errors 02-1 and 02-2.

6-10 Pre-amp A/D PCBThe Pre-amp A/D PCB receives the analogsignals from both Pre-amp PCBs and convertsthese voltages to digital values. This count is theraw value that is used in the algorithms tocalculate reflectance.

The Analog to Digital conversion is performed byIC U1 an eight channel analog multiplexing A/Dconverter with serial output. There are also fourvoltage regulators on the PCB. Voltage regulatorVR1 provides a +4 VDC reference for the A/Dconverter. Voltage regulator VR2 provides the +5VDC used by both readheads pre-amp PCB andthe A/D board. Voltage regulator VR3 providesthe 5 VDC used by both readhead pre-ampPCBs and the A/D board. Voltage regulator VR4provides the + 6 VDC for the lamps in bothreadheads. Power is supplied to the A/D PCB

from the processor PCB via connector P3; pins 9&10 provide +12 VDC and pin 6 provides -12VDC.

6-11 Strip DetectorThe strip detector contains 5 high output redLED's and 4 detectors spaced between theLED's. (Presently, the LED at the left of thedetector is not used.) Every 100 milliseconds,when the Push Bar is at the left most position, oneof the LEDs is pulsed ON for about 16microseconds. The five strip detectors LEDs areturned ON one at a time, sequentially from thetimer interrupt routine. The LED's are disabledduring the time the Push Bar is moving orlocated at the right side.

Light reflected back by the presence of a strip ispicked up by an associated detector and triggersa level sensitive circuit connected to an input porton the processor. Each detector has two"detection level-setting" circuits associated with it,one for each of the two LED's with which itoperates. The detection levels are calibrated onlywhen the instrument power is turned on, when nostrip is on the table (The fixed table needs to bein place when the instrument is powered on forproper detector calibration). For each of the 8detector-LED pairs, the detection level count isfound where light from the table just causesdetection. Then the setting is increased by apercentage of the count for low level signals andfor high level signal it adds a constant, so that astrip is necessary to cause detection. When thestrip detector setup is printed out using theInstrument test card (Refer to section 7-3-4-4) theprintout will show the detector calibration valuesfor both of its LEDs

Notice that L5D5 is printed twice. The secondcalibration level is used for the Strip Verificationposition and has a lower detector gain setting toprevent false verification.

Example of Strip Detector Set-up print-out

L1D1 L2D1 L2D2 L3D2

L3D3 L4D3 L4D4 L5D5 L5D5



Note

On early units, a 5th LED on the far left may bepresent but disabled. The Set-Up value L1D1 iscalculated but is not used by the software.

The calibration compensates for variations in LEDoutput, detector sensitivity, and table reflectancechanges. The strip detector is AC coupled, toreduce the effect of ambient light.

The detector circuits require both +12 volts and 12 volts for operation which is supplied viaconnector P1: pin 3 (+12 VDC), pin 2 (-12 VDC)and pins 1, 4 and 5 are ground.

The instrument only calibrates the strip detectorduring the power on cycle.

EXERCISE / DIAGNOSTICS TROUBLESHOOTING


7-0 IntroductionThis chapter is divided into four distinct sections.Each of the sections has its own table of contentsat its beginning.

CHAPTER SEVEN EXERCISE / DIAGNOSTICSTROUBLESHOOTING

Section

Troubleshooting Table-----------------------------------------------------------------------------------------7-1Explanation of Error Codes-----------------------------------------------------------------------------------7-2Explanation of Instrument Test Card-----------------------------------------------------------------------7-3Detailed Troubleshooting and Testing---------------------------------------------------------------------7-4



7-1 Troubleshooting table

The following chart is provided to assist introubleshooting the CLINITEK 500 system. Thefirst three columns are similar to those found inthe Troubleshooting Section of the OperatingManual.

The fourth column, labeled Service Remedycontains more advanced troubleshooting whichshould only be performed by / or under theguidance of trained Bayer Service Personnel.The items in the forth column are listed in increasingorder of technical difficulty

Symptom orError Displayed

Possible Cause Customer Remedy Service Remedy

Display is blank No power.

Improperly insertedprogram card.

Defective programcard or defectivesystem electronics.

Listen for the fan; if it is notrunning, turn the instrumentpower off. Check that thepower cord is firmly pluggedinto the instrument and into alive AC electrical outlet.Turn the power back on.

Turn the instrument power offthen remove the programcard and reinsert it firmly,making sure that the label isfacing forward, with thearrows pointing in and up.When properly inserted, theedge of the card will be flushwith the instrument case.Turn the power back on.

Contact your BayerCustomer Service office.

Remove the Bezel Assemblyand check that all cables areproperly seated. (Refer tosections 9-4).

Verify input and outputvoltages to the power supply.(Refer to section 7-4-3-1).

Use the instrument test cardto verify that the problem isnot related to the customersprogram card.Troubleshoot the Display(Refer to section 7-4-5).

Trouble-shoot the MainProcessor PCB (Refer tosection 7-4-6).

Fixed Tablecan not beinstalled

The Moving Table isnot in the lowestposition

Turn power ON and let thesystem initialize, then switchthe power off. Repeat 3times.

Inspect the Fixed and MovingTables for damage. Usingthe Instrument Test Card, testthe Drive Housing andstepper motor for properoperation.

Printout doesnot contain allreports

Missing reportshave been flaggedfor confirmatoryreport, and Editflagged result is ON

The list of the flaggedreports will be displayedwhen the run is completeand the report will be printedafter the End-of-Run Reportscreens have been exited.

Perform printer tests usingthe Instrument Test Card.(refer to section 7-3-4-2)


Page 7.4 CLINITEK 500 Service manual Rev.1199H



Push bar doesnot move to theright after astrip is placedonto theplatform.

Other strips arebeing moved alongthe platform.

Strip Detectorproblem.

Allow up to 7 seconds toelapse before movement ofthe push bar. The time lapsedepends upon the timingcycle for movement of thestrips across the platform.

From the Ready/Run screen(and with the run complete),turn the instrument power off,wait several seconds, thenturn it back on. If theproblem continues, contactyour Bayer Customer Serviceoffice.

Verify that the Strip DetectorLEDs are turning on.

Verify that the customerssystem is in the Ready/Runstate.

Check that the cable from thepush arm motor is seatedinto connector P14 on themother PCB.

Use the instrument test cardto check operation.(Refer to section 7-3-6-3).

Verify strip detector operation(Refer to section7-3-4-4).

Verify that the strip detectorhas correct voltages (Refer tosection 7-4-3-2).

Replace the strip detector(Refer to section 9-14).

Trouble shoot the MAIN PCBfor a broken trace andreplace if necessary (Refer tosection 7-4-6).





Push bar doesnot move backto the left aftermoving a strip(other than atthe end of aload-listed runor while waitingfor entry of anID).

The last strip hasbeen placed in aloadlist run, or theinstrument is waitingfor entry of an ID.

A very dark urine isbeing tested; thestrip detector isunable to verify thepresence of the stripuntil it reaches thefirst readhead.

The instrument is functioningproperly. Begin a newloadlist run (after the currentrun is complete) or enter theID Number being requested.

Presence of the strip will beverified at the first readhead,requiring an additional 3cycles (21 seconds). Thepush bar should then moveback to the left. Continuetesting in the normal manner.

If occurs repeatedly oroccurs with non-dark urines,verify proper Strip Detectoroperation as outlined below.


Use the instrument test cardto check operation(Refer to section 7-3-6-3).




Trouble shoot the MAIN PCBfor a broken trace andreplace if necessary (Refer tosection 7-4-6).

Check that the cable from thepush bar motor is seated intoconnector P14 on the motherPCB

Defective push barmechanism troubleshoot(Refer to section 7-3-6-3 and9-18).





Push barmoves to theright when itshouldnt (astrip has notbeen placed onthe platform)

The strip detectorwas accidentallytriggered by a hand,sleeve or otherforeign object.

Ambient light haschanged significantly

Strip detectorproblem.

The push bar will move backto the left after 3 cycles (21seconds); continue testing inthe normal manner. Be sureyou do not place your handor other objects on theplatform, as these can bemistaken for a Reagent Strip.

From the Run/Ready screen(with the run completed andthe strip loading station clearof all strips and foreignobjects), turn the instrumentpower off, wait severalseconds, then turn it back onto recalibrate the stripdetector. If the problemcontinues, contact yourBayer Customer Serviceoffice


Use the instrument test cardto check operation.(Refer to section 7-3-6-3).




Troubleshoot the MAIN PCBfor a broken trace andreplace if necessary(Refer to section 7-4-6).

Test results arenot beingprinted by theinternal printer

Internal printer is setto OFF.

No paper installed inprinter.

Paper installedbackwards orincorrect paperbeiing used.

Loose electricalconnection to theprinter.

Defective printer.

Set the internal printer to ONthrough the Setup Routine(Refer to section 3, Step A-4).

Install a new roll of paper asinstructed in Section 5,Periodic Maintenance.

Remove the paper and installper the direction of theOperating Manual. Use onlyBayer thermal printer paper.

Carefully remove andreinstall the interface cableto the printer (See section 7,Printer Replacement, steps4 and 5).

Run the printer test (seeSection 3, Step J-2f).Contact your BayerCustomer Service office if itdoes not print correctly.

Verify that all cables areproperly seated.

Verify that the internal printerhas power. (Refer to section7-4-3-3).

Perform printer tests usingthe instrument test card onboth internal and externalprinters.(Refer to section 7-3-4-2).

Clean internal printer drivemechanism with isopropylalcohol and cotton tipapplicator or equivalent.(Refer to section 8-4).

Replace internal printer(Refer to section 9-3)

Replace printer driver PCBMain PCB (Refer to section 9-11).

Mother PCB (Refer to section9-13).





Touch Screendoes notrespondcorrectly

Screen needs to berecalibrated.

Defective screen.

Recalibrate as instructed inSection 7, Calibrating theTouch Screen of theOperating Manual.


Refer to Figure 7-1-1 fordetailed troubleshootingflowchart.

Reset instrument to defaultsettings (ReferenceOperating Manual chapter 3section J).

Install Instrument Test Cardand recalibrate touch screen.

Remove the Bezel Assemblyand check that all cables areproperly seated. (Refer tosections 9-8).

Verify input and outputvoltages to the power supply.(Refer to section 7-4-3-1).

Use the instrument test cardto verify that the problem isnot related to the customersprogram card.

Troubleshoot the TouchScreen (Refer to section 7-4-5)

Troubleshoot the MainProcessor PCB (Refer tosection 7-4-6)

Error 01Error 02Error 03Error 04Error 05

Instrument opticalerror.

Turn the instrument poweroff, wait several seconds,then turn it back on.

Problem with the pre-amp orA/D PCB (Refer to section 7-2-2).

Troubleshoot Readheadsubassembly (Refer tosections:7-4-1, 7-4-2,7-3-5-1 and 7-3-5-2).

Replace BOTH Lamps(Reference 9-15).

Replace Pre-amp (Refer tosection 9-16-2).

Replace A/D PCB (Refer tosection 9-16-1).





Error 06-2 A reagent strip thathad been detected atthe first readheadwas not detected atthe secondreadhead.

Touch the Return toReady/Run button to cancelthe run and return to theReady/Run screen, then turnoff the instrument power.Remove Push Bar and theFixed Table to locate thestrip (Refer to section 5,Daily Cleaning). Check thepins on the Moving Table toensure that none are bent orbroken. Perform the DailyCleaning and WeeklyCleaning procedures insection 5. Check yourprintout of results, or theResults Error Reportdisplayed at the end of therun, to determine thespecimen(s) for which thereare no results; retest thosespecimens.

Verify that Fixed Table seatscorrectly (Refer to section 9-5).

Verify that Moving Tableseats correctly (Refer tosection 9-6).

Perform Strip Walk Test(Refer to section 7-3-3-6).

Replace Drive housing(Refer to section 9-17).

Replace Fixed Table andMoving Table (Refer tosection 9-5, 9-6).

Replace Table Guides (Referto sections 9-8, 9-9).

Error 07-1 A reagent strip eitheris not fully wetted oris upside-down onthe platform.

If the error is because of anupside-down strip, removeand clean the Push Bar,Fixed Table, and Holddown(see Section 5, DailyCleaning). Then check yourprintout of results, or theResults Error Reportdisplayed at the end of therun, to determine thespecimen(s) for which thereare no results. Retest theappropriate specimen,ensuring that the strip isdipped completely into thespecimen and is placed ontothe platform with the padsfacing up.

Inspect Push Bar, FixedTable and Holddown forphysical damage. Replaceas necessary.(Refer to section 9-1, 9-5, 9-6).





Error 08-1Error 08-2

A Reagent Strip hasbecome misalignedduring processingdue to the tip of thestrip walking closerto the cal chip orfarther away from thecal chip. This errorindicates that a stripposition correctionfactor of 0 or 8 wasdetermined forreadhead 1 orreadhead 2 .

Check your printout ofresults, or the Results ErrorReport displayed at the endof the run, to determine thespecimen(s) for which thereare no results. Retest thosespecimens, ensuring that theend of the strip is placedagainst the rear wall of theplatform (with Error 08-1)and not touching the bottomof the strip loading station. Ifthe error repeats, removeand clean the Push Bar,moving table, Fixed Table,Holddown, (see section 5,Daily Cleaning) Check theMoving Table to ensure thatno pins are bent or broken,then reinstall the parts.Make sure that the tables arefully seated and that theHolddown is snapped intoplace.

Inspect Push Bar, FixedTable and Holddown forphysical damage. Replaceas necessary (Refer tosection 9-1, 9-5, 9-6).

Make sure that the instrumentis level.

Verify that Fixed Table seatscorrectly(Refer to section 9-5).



Realign horizontal table(Refer to section 8-3).

Replace Drive Housing(Refer to section 9-18).


Replace Table Guides (Referto section 9-8,9-9).

Check that drive housing flagis positioned in sensor (Referto section 8-6).





Error 09-1Error 09-2

A Reagent Strip hasbecome skewedduring processing

Check your printout ofresults, or the Results ErrorReport displayed at the endof the run, to determine thespecimen(s) for which thereare no results. Retest thosespecimens, ensuring that theend of the strip is placedagainst the rear wall of theplatform and not touchingthe bottom of the striploading station. If the errorrepeats, remove and cleanthe Push Bar, moving table,Fixed Table, Holddown, (seesection 5, Daily Cleaning)Check the Moving Table toensure that no pins are bentor broken, then reinstall theparts. Make sure that thetables are fully seated andthat the Holddown issnapped into place.

For Error 09-1, havecustomer check to see ifreagent strips have stackedup near the outfeed area inthe waste bin. If so, clearany jams and push strips toright in waste bin to clear theoutfeed area

Inspect Push Bar, FixedTable and Holddown forphysical damage. Replaceas necessary (Refer tosection 9-1, 9-5, 9-6).

Make sure that the instrumentis level.

Verify that Fixed Table seatscorrectly(Refer to section 9-5).



Realign horizontal table(Refer to section 8-3).

Replace Drive Housing(Refer to section 9-18).


Replace Table Guides (Referto section 9-8,9-9).

Check that drive housing flagis positioned in sensor (Referto section 8-6).

.





Error 10 1 10 2

Instrument opticalerror.

Turn the instrument poweroff, then remove and cleanthe Fixed Table, taking careto carefully clean thecalibration bars (see Section5, Daily Cleaning). Checkyour printout of results, orthe Results Error Reportdisplayed at the end of therun, to determine thespecimen(s) for which thereare no results; retest thosespecimens.

Troubleshoot Pre-ampsubassembly (Refer tosections: 7-4-1, 7-4-2, 7-3-5-1, 7-3-5-2).



Error 20-1

NOTE: Thiserror onlyapplies to Kanjiiunits.

The instrument wasnot able toautomatically detectthe strip type (if AutoDetect has beenselected through theSetup Routine).(Refer to section 3,Step C).

Ensure that you are using arecognized strip typeRetest the specimen using anew strip. If the errorcontinues to occur, contactyour Bayer Customer Serviceoffice.

Troubleshoot Pre-ampsubassembly (Refer tosections: 7-4-1, 7-4-2, 7-3-5-1 and 7-3-5-2).



Error 21 Internal memory error Turn the instrument poweroff, wait several seconds,then turn it back on.

Replace program card.

Replace Processor #1module(Refer to section 9-11-1).

Replace Main PCB (Refer tosection 9-11).





Error 23 Moving Table ismisaligned

Instrumentmechanical error

Turn the instrument poweroff. Check to see if themoving table is installed.Inspect the instrument forany obvious signs ofmisalignment or incorrectinstallation of the movingtable or fixed table. Removeand reinstall the fixed andmoving table, see Section 5,Daily Cleaning. Turn thepower back on.


Inspect Drive Housing andFixed Table Guides for wearor damage. Replace asnecessary.(Refer to section 9-5, 9-6,9-8,9-9, 9-18).

Verify that moving table isaligned correctly(Refer to section 8-3).

Verify that optical sensoroperate correctly(Refer to section 7-4-4).

Check stepper motor drivecircuits for proper operation(Refer to section 7-4-3-4).Use instrument test card tocycle motors(Refer to section 7-3-3-2 and7-3-6).

Replace Mother PCB ifdefective (Refer to section 9-13).





Error 24 Misalignment orincorrect installationof the push bar orfixed table


Turn the instrument poweroff. Inspect the instrumentfor any obvious signs ofmisalignment or incorrectinstallation of the push bar orfixed table. Remove andreinstall, if needed, asdirected in Section 5, DailyCleaning. Turn the powerback on.


Push Bar is not finding homein the proper time.

Verify that optical sensoroperate correctly(Refer to section 7-4-4)

Check stepper motor drivecircuits for proper operation(Refer to section 7-4-3-4).

Use instrument test card tocycle motor (Refer to section7-3-3-2 and 7-3-6).

Clean Push Bar Shaft andlubricate (Refer to section 5-5-3).


Check to see that left-handPREAMP PCB is not hittingany of the mechanicalassemblies as the readheadsmove back and forth whilecycling all motions. If hitting,carefully loosen the screwholding the PREAMP, lift upon the rear end of the PCBand retighten screw.





Error 25 Readhead could notfind the Cal Chip.


Turn the instrument poweroff. Inspect the instrumentfor any obvious signs ofmisalignment or incorrectinstallation of the FixedTable, or Holddown.Remove and reinstall, ifneeded, as directed inSection 5, Daily Cleaning.Turn the power back on.


For error 25, perform 3 on/offcycles of instrument power,ignoring any errors receivedprior to the 3rd cycle.

Check to see that left-handPREAMP PCB is not hittingany of the mechanicalassemblies as the readheadsmove back and forth. Ifhitting, carefully loosen thescrew holding the PREAMP,lift up on the rear end of thePCB and retighten screw.

Check that Flex cable is fullyseated in connector J7 onMain PCB. Insure that flexcables are fully seated in theconnectors on the PreampPCBs and that the lampcables are locked in place onthe A/D PCB.

Verify that the lamps operate,replace if necessary.(Refer to section 7-3-5-1, 9-15)

Test Preamp operation bypositioning readheads overcal chips and obtaining A/Dcounts (Refer to section 7-3-5-2).

Replace Preamp(Refer to section 9-16-2).

Check stepper motor drivecircuits for proper operation(Refer to section 7-4-3-4).

Use instrument test card tocycle motors (Refer tosection 7-3-3-2 and 7-3-6).






Error 26 Fixed Table ismissing or notinstalled properly.

Install the table and platform,if missing (see Section 5,Daily Cleaning). If alreadyinstalled, carefully push in onthe sides of the platform tomake sure it is fullyengaged. If the errorcontinues, remove andreinstall the platform, asinstructed in Section 5.

Inspect Drive Housing andFixed Table Guides for wearor damage. Replace asnecessary (Refer to section9-5,9-6,9-8,9-9, 9-18).

Verify that all connectors areseated.

Use instrument test card totest individual sensors.(Refer to sections 7-4-4).

Confirm that the Fixed Tableenters the photo sensor onthe table guide. (refer tosection 8-5 for adjustment)

Replace sensor as necessaryMOTHER PCB defectivereplace (Refer to section 9-13).

Processor #1 is defective onthe MAIN PCB - Replace(Refer to section 9-11-1).





Error 27 Holddown isimproperlyinstalled,or missing,or is dirty.

Touch the Return toRUN/READY button ifnecessary to cancel the run.Remove the Fixed Table asinstructed in Section 5,Daily Cleaning. Install theHolddown if missing, orclean if it appears dirty.Reinstall the Holddown,ensuring it is properlyinstalled, then replace theplatform onto the instrument(if the Holddown appearsdamaged or discolored,replace with a newHolddown). Check yourprintout of results, or theResults Error Reportdisplayed at the end of therun, to determine thespecimen(s) for which thereare no results and retestthose specimens.

Refer to section 7-2-2-1.Inspect Fixed Table andHolddown for wear anddiscoloration. Replace asnecessary (Refer to section9-5).

Verify Readheadperformance and alignment(reference 7-3-5-3, 8-2)





Error 28 A Reagent Strip thatwas detected, asbeing placed on theplatform, was notdetected at the firstreadhead.

Moving Table is notinstalled.

A strip was never placed orwas removed after beingplaced: Check your printoutof results, or the ResultsError Report displayed at theend of the run, to determineif a result set is missing and,if so, retest the specimen.Be sure you do not placeyour hand or other objectson the strip loading station,as these can be mistaken fora Reagent Strip. If the erroroccurs repeatedly, turn theinstrument power off, waitseveral seconds, then turn itback on to recalibrate thestrip sensor.If a strip was present,remove and clean theMoving Table, Fixed Table,Holddown (Referenceoperating manual section 5,Daily Cleaning andWeekly Cleaning).

Remove the Fixed Table andcheck for the presence ofthe Moving Table. If missinginstall.

Refer to section 7-2-2-1.Confirm strip detectoroperates properly usinginstrument test card(Refer to section 7-3-3-4).

Verify that the cable comingfrom the strip detector has itsconnector properly seatedinto the mother PCB.


Check for proper readheadperformance by runningreflectance test withinstrument test card.(Refer to section 7-3-5-4)

Replace Pre-amp PCB(Refer to section 9-16-2).





Error 29 Calibration bar error. Turn the instrument poweroff, then remove the FixedTable (see Section 5, DailyCleaning) and inspect thecalibration bars for damageor misalignment. Clean theplatform and calibration barsand reinstall the platform.Turn the power back on.

Refer to section 7-2-2-1.Make sure that the customerhas installed the fixed tablecompletely (to the stops).

Cycle instrument poweron/off three times ignoringany errors reported prior tothe 3rd cycle.

Check for damage to theFixed Table cal chips.

Use the instrument test cardto verify stepper motor driveoperation for readheadcarrier and that carrier ismoving with the belt. (Referto section 7-4-3-4, 7-3-6-

Remove upper case andverify that all connectors(signal and lamp) on thereadhead and A/D PCB arefully seated. Verify that thelamps turn on.

Use instrument test card toverify operation of Pre-ampsand A/D PCB(Refer to section 7-3-5-1, 7-3-5-3, 7-4-1, and 7-4-2).

Error 30 Instrumentmechanical error

(Readhead alignmenterror)



Error 30-check alignment ofreadheads (Refer to section8-2).

Check for proper operation ofPre-amps & A/DPCBs.(Reference 7-3-5-3)





Error 31 Instrumentmechanical error.

(Strip Detector SetUp Error)


Refer to section 7-2-2-1.Make sure that the customerhas installed the fixed tablecompletely (to the stops)

Error 31-verify strip detectoroperation(Reference 7-3-4-4).

Error 34 Instrumentmechanical error(Strip Centering Error/ instrument factorerror)



Perform strip centering test(Reference 7-3-3-4).

Error 40 Not an assigned errorfor the customersoftware.

Verify that the propersoftware is installed.

Communications errorbetween processor #1 andprocessor #2.Replace processor #1 (seeSection 9-11-1).

Replace MAIN PCB (seesection 9-11).

Error 50 Printer Error Check that your externalprinter is turned on and ison-line. Verify that bothends of the interface cableare securely connected andcheck that your printer haspaper

Re-verify proper installationof interface cable.

Possible defective PrinterMother PCB (see Section 7-3-4-2, 9-13).

Possible defective PrinterCable.

Possible defective MAIN PCB(see Section 9-11).





Error 51Error 52

Control resultsmemory (51) orsample resultsmemory (52) isalmost full.

Nearly 200 control result setsor nearly 500 patient resultssets have been stored inmemory without beingtransferred to a computer.Check that your computer isturned on, that the interfacecable is securely connectedat both ends, and that thesetup parameters for thecomputer interface arecorrect. Transfer at leastsome of the record. Ifunable to transfer records,print the records and thendelete the results frommemory. Contact your BayerCustomer Service office

Verify that customer setup iscorrect

Verify that CT500 ExternalPort is turned ON

Verify that external computeris connected to the serialcommunication RS 232 port

Possible defective MotherPCB (See section 7-3-4-1, 9-13)

Possible defective MAIN PCB(See section 9-11)

Error 53Error 54

Control resultsmemory (53) orsample resultsmemory (54) iscompletely full

Two hundred control resultsets or 500 patient resultssets have been stored inmemory without beingtransferred to a computer.Check that your computer isturned on, that the interfacecable is securely connectedat both ends, and that thesetup parameters for thecomputer interface arecorrect. Transfer at leastsome of the record. Ifunable to transfer records,print the records and thendelete the results frommemory. Contact your BayerCustomer Service office.

Verify that customer setup iscorrect

Verify that CT500 ExternalPort is turned ON

Verify that external computeris connected to the serialcommunication RS 232 port

Possible defective MotherPCB (See section 7-3-4-1, 9-13)

Possible defective MAIN PCB(See section 9-11)

Error 55 System was unableto store Setupchanges to theProgram Card;default values havebeen stored instead.Displayed whenAnalyzer is firstturned on.

After clearing the errorscreen, print both setupconfigurations, if desired, todetermine which you want touse, then select that option.(the Analyzer memory willusually contain the latestSetup changes). If the errorrepeats the next time theinstrument is turned on,contact your Bayer CustomerService office.

Possible defective programcard (see section 9-2).

Possible defective MAIN PCB(see section 9-11).





Error 56 System error Turn the instrument poweroff, wait several secondsthen turn it back on. If theerror repeats, contact yourBayer Customer Serviceoffice.

General error code forinternal communicationserrors.

Possible defective Processor#1 (See section 9-11-1).

Possible defective MAIN PCB(See Section 9-11).

Possible defective programcard (see section 9-2).



Is the DisplayBlank?

Trouble shoot per servicemanual.

Report error: DT001

Is character stringcorrect?Do adjacent areas

around the keysrespond?

Cycle power andrecalibrate touch

screen.Does this correct

Cycle Power. Does touchscreen respond?

Report Error:DT008

Cycle power andrecalibrate touch

screen.Does touch screen

Report Error:DT009

Is Pusher Bar to the left?Trouble shoot PerService Manual

Report Error: DT010

Will strip detectordetect strip and cycle

pusher bar

System Locked upReport Error: DT012

Does the Displayupdate to run mode

Report Error:DT013

Replace touch ScreenReport Error: DT014

Does Data Print

Is display operatingcorrectly?

Are lines scrollingon the screen? Display Bad

Report Error: DT002

Is touch screenresponding?

No problem

No problem

Cycle power. Doesthe problem correct

itself?

Trouble shootDisplay, Main

PCB andProgram Card.

Report Error:DT005

Problem correctedReport error: DT003

Report ErrorDT007

Report Error:DT006

Perform the following

1) Reset memory withInstrument test card.

2) Reset the customersettings to theinstrument defaults.

Is the problem corrected?

Problem correctedReport Error: DT004

Trouble shoot PerService Manual

Report Error: DT011

YES

NO

YES

YES

YES

YES

NO

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

NO

NO

YES

NO

NO

NO

Perform the following

1) Print out instrument setup.

2) Reset the customersettings to theinstrument defaults

NO

ReportError:DT015

YES

Failure Identification Flow Chart For Display and Touch Screen Problems

Figure 7-1-1


Rev 1199H CLINITEK 500 Service Manual Page 7.23

7-2 Explanation of Error Codes

7-2-1 Error Handling

The Errors on the instrument are divided into:1) General Errors2) Data Set Errors.

A General Error is defined as an error resultingfrom hardware input, e.g., a ROM checksumError, RAM checksum error, Processor #2programming error or a sensor error. Theseerrors are detected by processor #2.

A Data Set Error is defined as an errordetected by analyzing the data collected fromthe readheads during the read process.

7-2-1-2 Error Number Display

The Instrument Test Card and Customer Carddisplay only those errors defined as "generalerrors" on the screen. These general errors aregenerated by processor #2 as a two-digitnumber and sent to processor #1 to display onthe screen (refer to Table 7-2-1 for completelisting).

7-2-1-3 Error Numbers Printed

The Data Set errors are printed or sent with thedata sets. The Data Set errors are displayed indifferent forms depending upon if anInstrument Test Card is being used or theCustomer Card. When the Customer Card isinstalled in the instrument, the error code willbe printed or displayed on the screen ( seefigure 7-2-1) as 1-xx or 2-xx. The first digit

represents the readhead associated with the errorand the xx is the two-digit error code..

When the Instrument Test Card is installed in theinstrument, the error code is a four-digit code.The first two digits are the error code for the firstreadhead and the second two digits are the errorcode for the second readhead (see figure 7-2-2).

The two digits to the right of POS: are the striptip locations. The first digit is the location of thestrip under the first readhead with respect to thefirst calibration chip and the second digit is thestrip tip location under the second readhead ascompared to the second calibration chip.

Table 7-2-2, in the section 7-2-2, is a listing ofData Set error codes and their meanings as wellas a cross-reference between the error codesgenerated from the Customer Card and theInstrument Test Card.Note that the error codes in the sample output(Figure 7-2-2) can combine based on column

position (for non zero columns) and error codepriorities in Table 7-2-2.

Note

This means that only the higest piroty erors will bedisplayed even if mutipal error exist.

For example, if the system detects both a skewedstrip error on RH #2 (Error Code 0009) and areflectance > 100% on RH #2 (Error Code 0010),the error reported in Figure 7-2-2 might be 0018.If the system generates a Low Dark Value error

The Analyzer has reported Error N-XX

Figure 7-2-1

#00008 19940426125800ERRORS: 0000 POS: 34COL A B L CD -020 +014 +209 +002SRV I R G B DCDGLU 787 793 809 074 0744BIL 737 663 457 124 0900KET 785 752 685 432 3847SG 727 692 322 112 5061pH 125 041 026 067 0562PRO 618 588 589 767 0790URO 322 322 316 242 0980NIT 063 096 053 530 0836BLO 024 045 056 124 0900LEU 820 771 560 355 5612LE1 637 698 876 907 7500

First readheaderror code

SecondReadheaderror code

Figure 7-2-2



for RH #1 (Error Code 0100) and a MissingStrip error for RH #2 (Error Code 0006) thenthe error code output would be 0106.However, if the system generates two errorswith digits in the same column only the higherpriority error is displayed. For example, aReflectance > 100% error on RH #1 (ErrorCode 1000) and a Auto Strip Type Error onRH #1 (Error Code 2000), then the system willoutput Error Code 2000 since the Auto StripType error (Priority = 10) is a higher priorityerror then Reflectance (Priority = 11).



7-2-2 Error Summary

General Error Codes

Instrument Test Card Error DefinitionError CodeGenerated

Customer Card Error Definition

ROM Checksum Error 21 ROM Checksum ErrorTable Movement Error *23 Table Movement ErrorPush Bar Movement Error *24 Push Bar Movement ErrorRead-head Scan Movement Error *25 Read-head Scan Movement ErrorTable Not in Place 26 Table Not in PlaceHold-downs Not in Place *27 Hold-downs Not in PlaceFalse Strip Detect *28 False Strip DetectCal Chip NOT Found Error 29 Cal Chip NOT Found ErrorRead-head Alignment Error *30 Read-head Alignment ErrorStrip Detector Setup Error 31 Strip Detector Setup Error

(unassigned) 32 (unassigned)(unassigned) 33 (unassigned)

Strip Centering Error 34 Strip Centering ErrorCommunication 40 (unassigned)

(unassigned) 50 Printer error(unassigned) 51 Control results memory is almost full(unassigned) 52 Sample results memory is almost full(unassigned) 53 Control results memory is completely full(unassigned) 54 Sample results memory is completely full(unassigned) 55 System was unable to store Setup

changes in program card

(unassigned) 56 System error

**Special Instrument Release TestData Set Errors

61 thru 93

Notes: *Indicates that these error are checked for and reported only during a run** Refer to table 7-2-2-1 Refer to section 7-3 Trouble shooting guide for corrective actions

Table 7-2-1



7-2-2-1 General Errors

ROM Checksum Error (21)

If the calculated checksum for the ROM doesnot equal 0, then this error is set.

Table Movement Error (23)

The table sensor is checked for "no sensor" at2.5 seconds into the cycle when the table flagshould not interrupt the optical sensor and againafter 3.0 seconds in the cycle for "sensorpresent" when the table flag should interrupt theoptical sensor. If either condition fails, the erroris set.

Push Bar Movement error (24)

The push bar sensor is checked for "no sensor"at about 2.5 seconds in the cycle if the Push Barwas to move and again at about 3.8 secondswhen it should be at the sensor. If eithercondition fails, the error is set.

Readhead Scan Movement Error (25)

This error is set in RUN, during readheadposition initialization, when the readhead is notpositioned on the cal chip as it should be.

Table Not In Place (26)

The table sensor is not activated.

Holddowns Not In Place (27)

When a strip is read at the first readhead, thereflectance between pads 10 and 11 is checked( this is actually between the tip of the strip andthe calibration chip). If no reflectance readingis below 40%, the error condition is set. (Withthe hold-downs in place the reflectance is onthe order of 15% to 20% and with no hold-downs it is above 80%).

False Strip Detect (28)

If a strip is detected and verified by the stripdetector but is not sensed as being present atthe 1st readhead when it should be, this error isset. A strip is sensed as being present asfollows: Two areas of the strip are checked,between pads 2 and 3 and between pads 9 and10.. If both areas did NOT have a reading>65%, the false strip detect error is set.

Cal Chip NOT found error (29)

During initialization of the readhead position, eitherat power ON or during RUN, the cal chip underreadhead 1 could not be found (IR reflectance



NOTE:

The following error codes definitionsare only for the Customer Program Card

Printer Error (50)

The external printer has an error, or is out ofpaper.

Control Results Almost Full (51)

The Controls database has space left for only 10more results. Sample Results Almost Full (52)

The Sample database has space left for only 10more results.

Control Results Full (53)

The Controls database is full, no more samplescan be run.

Sample Results Full (54)

The Sample database is full, no more samplescan be run.

Setup Information Problem (55)

One of the setup information files was found tobe corrupted during the data integrity check atpower ON

System Error (56)

A serious system error has occurred. Thesystem must be powered OFF. Allcommunication problems between Processor 1and Processor 2 are reported as system errors.

NOTE

Special Instrument Release Test Errors(Only when generated while using theInstrument Test Card) (61 to 90)

When the instrument release test is performed,data is collected from each readhead andevaluated against ten error conditions. Normally noerror is found and the data is transmitted. If anerror is detected during evaluation, one of the errorcodes from the table 7-2-2-1 below will be printedout on the instruments internal printer. When adata set error is detected no data will be sent outthe serial port to the computer that is running theRelease Test Data Collection software.

The definitions of these errors are the same as the

data set error described in section 7-2-2-2.

ERROR GeneratedError Code

RH1 RH2Low Dark Value 61 81High Dark Value 62 82

A/D Converter OverRange

63 83

Low Lamp Level 64 84Low Channel Output 65 85

Missing Strip (NA) 86Upside-down / Dry

StripSeenote 1

Seenote 1

Misaligned Strip 68 88Skewed Strip 69 89

Reflectance > 100% 70 90Auto Strip Type

ErrorSeenote 1

Seenote 1

Result DataIntergrity

(NA) 93

Notes1) These error are not checked while theinstrument is performing the release test

Table 7-2-2-1Special Instrument Release Test Errors



7-2-2-2 Data set Errors

RH.1 RH.2Low Dark value (0100) (0001)

A dark value is < 1 count for any channel.

RH.1 RH.2High Dark value (0200) (0002)

A dark value is >= 400 counts on any channel.

RH.1 RH.2Read Overrange (0300) (0003)

A-D Converter Overrange. A read value is at fullscale (i.e. > 2040 counts) on any channel.

RH.1 RH.2Low Lamp Output (0400) (0004)Low Lamp Level. All channels read < 200counts above dark value at calibration.

RH.1 RH.2Low Channel Output (0500) (0005)

Low Channel Output. One or more channels ona readhead, but not all, read < 200 countsabove dark at calibration.

R.H1 R.H2Missing Strip (NA) (0006)

Two areas of the strip are checked, between pads2 and 3 and between pads 9 and 10. If both areasdid NOT have a reading >50%, the "missing strip"error is set.

RH.1 RH.2Upside-down or Dry Strip

(0700) (NA)

Reflectance reading was > 70% for the GLU padon the RED channel or the reflectance reading was> 76% for the LEU1 pad on the GREEN channel.Both are at the 1st readhead.

NOTE:

This is the only error generated using a padreflectance.

Data Set Error Codes

Error Priority Instrument Test CardError Code

Customer Card ErrorCode

Readhead 1 Readhead2 Readhead 1 Readhead2Low Dark Value 3 0100 0001 01-1 01-2High Dark Value 2 0200 0002 02-1 02-2

A/D Converter Over Range 4 0300 0003 03-1 03-2Low Lamp Level 5 0400 0004 04-1 04-2

Low Channel Output 6 0500 0005 05-1 05-2Missing Strip 7 N/A 0006 N/A 06-2

Upside-down / Dry Strip 12 0700 N/A 07-1 N/AMisaligned Strip 9 0800 0008 08-1 08-2

Skewed Strip 8 0900 0009 09-1 09-2Reflectance > 100% 11 1000 0010 10-1 10-2Auto Strip Type Error 10 2000 N/A 20-1 N/AResult Data Intergrity 1 N/A 0030

Table 7-2-2Data Set Error Codes



RH.1 RH.2Misaligned Strip (0800) (0008)

When doing the strip position correction, theend of the strip nearest the cal chip is locatedby finding the position where the reflectancegoes above 30% as the readhead moves towardthe front of the instrument. Steps are countedand a number of "0" through "8" is assignedindicating relative position for each readhead.A number "4" is the nominal position where thestrip is in perfect alignment. A smaller numberindicates the strip is closer to the cal chip, alarger number shows it is farther. If the numberis "0" or "8", the error code for that readhead isset. The positions "1" through "7" will result incorrect reflectance for the strip. Each digitindicates a shift of 0.01716 inchs so that correctreadings will be obtained for shifts of0.051 inchs

RH.1 RH.2Skewed Strip (0900) (0009)

The reflectance in the areas between pads 2and 3 and between pads 9 and 10 are scannedthrough 8 step positions. If a reflectance is>65% at one area but 100% (1000) (0010)

The reflectance for any pad on the stripmeasures more than 100%. This may be due toa bad calibration value.

RH.1 RH.2Auto Strip Type error (2000) (NA)

If the strip type is set to Japan Auto Strip, then thestrip type being used is determined by checkingfor the GLU pad (reflectance



7-3 Explanation of Instrument TestCard

7-3-0 Introduction

The Instrument Test Card is a special programcard used during the manufacturing andservicing of the CLINITEK 500. The followingsection of the manual explains the function ofeach test.

To use this test card, first turn theinstrument power off, then remove the CustomerProgram Card (all customer setup options aresaved in this card). Next, insert the test card intothe program card socket. When the instrumentpower is turned back ON, the test software willstart.

Following the startup screen if the touch sscreenis not calibrated, the user will be prompted tocalibrate the touch screen by pressing the areasindicated on the following screens.

+ TOUCH SCREEN HERE

CALIBRATE THE TOUCH SCREEN

CALIBRATE THE TOUCH SCREEN

TOUCH SCREEN HERE +

CLINITEK 500

INSTRUMENT TEST PROGRAM

Copyright 1997 Bayer Corporation

Power ON message:



When the program card is first installed, theinstrument compares the software version in inthe card for processor 2 with that runningprocessor 2. If the software versions do notmatch, the two version numbers will be displayedand the system will prompt ReprogramProcessor #2. Pushing the YES key on thetouch screen reprograms the processor whilepushing the NO key does not.

AAAAA: Represents the version o processor #2software being used by the instrument.

BBBBB: Represents the version of processor #2software on the PCMCIA card.

Processor #2 version is: AAAAAA The new card version is: BBBBBB Reprogram Processor #2?

YES

NO



7-3-1 Self Checks

After the system has checked that bothprocessors are using the same software versionthe instrument performs the following self checks.

Self Check Screen

Software Version:

Displays the version of software runing inprocessor 1 and in processor 2

ROM checksum test:

The ROM of processor #1 is checked for apredetermined checksum. If the expectedchecksum value is not found, a FAIL messagewill be shown on the screen.

XRAM test for data corruption:

XRAM memory is checked for a predeterminedchecksum value. If that value is not found, then aFAIL message is displayed on the screen.

Hardware homing test:

The moving table, blotter and readhead arehomed by processor #1.

If any of these functions result in an errorgeneration then, a FAIL message is displayedon the screen with the appropriate two digit errorcode.

7-3-2 Ready Screen

Once all of the self checks are completed withoutfailure, the instrument will display the readyscreen:

Ready Screen

When the instrument is displaying this screen it isready to detect a test strip and process it as inthe customer mode. The difference being thatinstrument is always in Test Mode #1, whichoutputs reflectance and decode data for theresults.

Set the sequence number:

This displays the sequence number entry screenand allows the sequence number to be set. Thepresent sequence number is displayed with acursor under the first digit. The number entrykeys are active and when the ENTER key ispushed, the number is accepted and returns tothe READY screen. A reset key provides meansof resetting the sequence number to "00001".

Print Setup:

This prints the current setup for the instrumentusing the internal thermal printer.

Use: AAAAAAAAAAAAAAAAPlace Strip.

SEQUENCE #:BBBBB

PRINT SETUP

SETUP

INSTRUMENT TEST

Performing the Self Check...

Software version: AAAAAAAAAA

ROM check - BBBBBBBBB

XRAM check - CCCCCCCCCCCCCCCCCCCCC

Homing hardware check - DDDDDDDDD



Setup:

Selecting this option presents a new screen thatdisplays the functions that can be set.

Setup sub-menu

Set the Date:

This selection allows the date to be set.

Set the Time:

Selecting this key allows the time to be set.

Clear Memory:

If this selection is chosen, the following displaywill appear:

Yes:

If this is selected all test results stored in thesystem are purged.

Reset System Memory:

If selected the fixed memory locations are reset todefault values. This must be performed afterusing the instrument Test Card before installingthe customer card.

Printer:

This key toggles the internal printer on or off. Thedefault setting is ON.

Strip Type:

This option allows the user to select what type ofreagent strip will be used. MULTISTIX 10 SG isthe default strip.

7-3-3 Instrument Tests

The diagnostic tests provided by the InstrumentTest Card are grouped in 4 levels or sub menus.Each level of test is displayed as a separatemenu on the display

Level 1 tests all complete subsystem tests.

Level 2 tests are interface tests.

Level 3 tests are all related to data collection.

Level 4 tests operations which are specific toprocessor 1.

SELECT ITEM TO SPECIFY ITSOPTION

Set the Date AA-BB-CC (M-D-Y)

Set the Time DD:EE (24 hr)

Clear Memory

Printer: FFF

Strip Type: GGGGGGGGGGGGGGGGG

Clear all results from the CLINITEK memory ? Are you sure ?

YES

NO

Reset System Memory

Setup sub-menu Clear Memory Screen

Instrument Tests, Level 1

INSTRUMENT RELEASE TEST

EXERCISE ALL MOTIONS

SENSOR STATUS

SETUP STRIP CENTERINGREBOOT

STRIP WALK TEST SYSTEM

LEVEL 2 TESTS

Instrument Test Level 1 Screen



7-3-3-1 Instrument Release Test

Equipment Required:

PC with the following minimumconfiguration:486 33MHz processor, 8 (16)Megabytes of Memory, 1 free serial port

Windows 3.11 or 95 Serial test cable (Null modem DB25 to DB9)

(p/n 40453255) Instrument Release Test Software

(p/n SR00169X) Release Test limits file (p/n SR00170X) Floating Rail Hold-down (p/n 71647013) Hard Standards Test Strip (p/n 95002262) Thermal Printer Paper Instrument Test Card (p/n SR00081X) Refer to the RSL 024E6470 (Recommended

Spare Parts List) for the current part numbersfor the fixtures

The Instrument Release Test uses a special teststrip and a PC running the Release test softwareto perform a quality check on the operation of theinstrument. In this test, data is outputed fromthe instrument and col lected by the PCrunning the release software. Next, the data isanalyzed and compared to predefined limits, andif the results are within the limits, the instrumentpasses the test. The PC screen will display if theinstrument passed or failed.

The Test Hard Standard strip used for the releasetest has pads in the following positions P4, P9,P10 and P11.

The procedure for performing the Release Test isas follows:

1. With the power off install the Instrument TestCard and connect the CT 500 via the DB25serial port to the test cable from the PC.Install the Floating Rail Hold-down on th

ct500维修手册

Documents