CD Compact Disk
OS Operating System
Day 2 Tuesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 09:00 QC / Customer Maintenance Classroom
09:00 11:30 QC & Sample Programming / Processing Exercises Laboratory
11:30 12:30 Lunch
Event Logs, QNX, and Boot Sequence
12:30 1:30
Instrument Control Subsystem
Event Logs, QNX, Boot Sequence and Instrument
1:30 5:00 Control Computer Exercises Laboratory
Troubleshooting Exercises
Day 3 Wednesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 10:00 Power Subsystem, Smart Modules & Classroom
Communications Subsystems
10:00 11:30 Power & Fans Exercises Laboratory
11:30 12:30 Lunch
1:00 5:00 Smart Modules & Communications Exercises Laboratory
Troubleshooting Exercises
Day 5 Friday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 10:00 Sample Rack Handling Subsystem Theory Classroom
Reserved Racks
TS-CTS Cap Piercer
10:00 11:30 Sample Rack Handling Exercises Laboratory
11:30 12:30 Lunch
12:30 5:00 Sample Rack Handling Exercises Laboratory
Troubleshooting Exercises
Day 7 Tuesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 10:00 ISE Theory Classroom
10:00 11:30 Preventive Maintenance Minor (ISE/MC) Laboratory
11:30 12:30 Lunch
12:30 5:00 PM continued Laboratory
Day 8 Wednesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 11:30 PM completion Laboratory
Decontamination Procedure Overview Exercise
Troubleshooting Exercises
11:30 12:30 Lunch
12:30 5:00 Troubleshooting Exercises, Cont... Laboratory
Day 9 Thursday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 11:30 Troubleshooting Exercises Laboratory
11:30 1:00 Lunch
1:00 2:00 Lab Cleanup Laboratory
2:00 5:00 Student Survey Classroom
Mentoring Period Requirements
Instructions The Personal Progress Report is your way of monitoring your skill
development. At the end of each exercise, monitor your progress by
comparing your answers or reports to the Reference Key. Initial your
Personal Progress Report and ask your Instructor to do the same.
ITEMS PERTINENT TO INSTALLATION ARE IN BOLDFACE
Day 1 Monday
Student Instructor
Exercise Objectives
Initials Initials
System Overview Identify major system components
and locations _______ _______
Software Overview Software operation, menus, icons
and options _______ _______
System Set Up Set up / review all System
Parameters _______ _______
Metering Activate Service Mode using
Password Generator program
Initialize Metering
Disable Service Mode
Accessing Metering Information
Utilize Meter-Use Manual _______ _______
MC Reagent Identify preparation requirement
Preparation & AUTO load MC reagents
Loading MANUAL load of MC reagents
Edit volumes _______ _______
MC Reagent Assign calibrator IDs
Calibration Calibrate MC and CC Reagents
With barcodes
Without barcodes
Reprint (recall) previous calibration
reports _______ _______
DxC IFU Read Chapter 13: Troubleshooting
Calibration and Result Errors _______ _______
Day 3 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
Power Locate Power Subsystem components
Subsystem Remove and reinstall power supply
Observe normal power up sequences
Identify LED display codes
Adjust power supplies
Power supply measurements Min Max _______ _______
Smart Modules Locate the Smart Modules on the DxC
Fiber Optics Troubleshooting Fiber Optics _______ _______
Day 5 Friday
Student Instructor
Exercise Objectives
Initials Initials
Cap Piercer Remove and reinstall bar code reader
TS-CTS Remove and reinstall TS-CTS
Blade and wick removal and replacement _______ _______
Auto gloss pump repair and replacement
One blade TS-CTS functional alignment
Sample Rack Shuttle latch solenoid removal and
Handling replacement
Remove and reinstall onload tray _______ _______
assembly
Remove and reinstall offload tray
assembly
Remove and reinstall shuttle assembly
Perform sample rack handling alignment
procedures
Verify alignments
Review TS-CTS event log entries
Day 7 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
MC ISE Replace Carbon Bridge
Strike the Carbon Bridge _______ _______
Preventive Perform PMC Minor (ISE/MC)
Maintenance
Procedure _______ _______
Day 8 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
Decontamination Locate, review and understand the
Procedure system decontamination procedures. _______ _______
Overview the software to become familiar with the icons and menus
for more detailed operation.
Reference:
DxC In-Lab Training Manual
Chapter 1 System Components
System Read the above chapter reference and identify all components and
Components locations on your instrument.
When you have completed the above move on to the next section.
References:
DxC In-Lab Training Manual:
Chapter 2 Software Overview
Software Read the above chapter reference and identify the sections of the
Overview main screen on your instrument.
Objectives Select options on the Setup Menu and review their purpose.
1) Auto Serum Index / ORDAC
2) Chem Config / Sample Type
3) Date/Time
4) Demographics Setup
5) Immediate Report
6) Panels
7) Replicates
8) Report Setup
9) Reportable Ranges
10) Reference / Critical Ranges
11) Sample Comments
12) Special Calculations
13) Setup Summary
14) Units / Precision
15) User-Defined Chemistries
16) Bar Code
17) Reserved Racks / Obstruction Detect
18) Disable Service Monitor
19) External Water Monitor
20) Host Communication
21) Language / Keyboard
22) Printer Setup
23) Service Setup (Password Generator Program)
24) System Configuration (password)
25) Version Upgrade
26) Status Alarm / Annunciator
27) Chem Update
28) Password Setup
29) Auto Generation of Control
References:
DxC Reference Manual:
Chapter 3 Detailed System Setup
DxC Information For Use Manual
Chapter 4 System Setup Operations
Date/Time
Set up the date and time information on your instrument
3 using PST.
Demographics
4
Setup
Review menu with the references.
5
Immediate Set up Module Chemistries for ALL to Printer only and
Report Immediate Report of Reruns
Review this menu and take note of Default Panel feature.
The Default Panel of tests is automatically run if the host
6 Panels fails to respond within the designed time period to a host
query.
Why The metering function is used to keep track of reagent usage on the
instrument for accounts that are on a reagent-metering program.
Metering data is to be collected via modem; copying metering data to
a floppy diskette can be used as a backup procedure.
For this exercise, you will need the Password Generator Program,
which allows you access to Service Mode. Once the metering feature
has been initialized, contact Systems Technical Support with meter
read day and modem phone number. When verifying an instrument
repair or performing troubleshooting chemistry tests, the Service Mode
should be enabled so that the customer is not charged for those tests.
Reference:
DxC Metered Use Manual:
Operational Overview
Reference:
DxC Metered Use Manual:
Metering Data Transfer Procedure
- Operating in Service Mode
Disable Read the above reference
Service Disable Service Mode:
Mode System Setup Menu - [18] Disable Service Monitor
Reference:
DxC Metered Use Manual:
Metering Data Transfer Procedure
Adjustments to Standard Replenishments
Part Replenishment/Adjustment
472481 - CO2 Acid [HOLD]
445865 - WASH CONCENTRATE Decrease by 1 box
Question If your customer transmits their Metering Report via modem to BCI,
how will they be informed that the transmission was successful?
___________________________________________
___________________________________________
Why: When installing the DxC one of the first things you will need to do is
place the MC reagents on the DxC. Some require preparation.
Load Once placed on the DxC you will need to load them on the system.
The term loading reagents on an DxC means that we are loading
the following information into the system parameters memory:
The test or reagent name
The lot number
The expiration date
The serial number
The only way that you can be sure that the information has been
loaded is to watch the Reagent Load Screen to see that the data
changes.
Edit When the bulk reagents are scanned the system assumes 100%
Volume volume.
This can cause serious problems with ISE results if it is not accurate.
References:
Reagent Preparation Quick Reference Card:
Supplied with all DxC instruments. (P/N A18595)
DxC Instructions For Use
DxC Chemistry Information Manual
MC Reagent The MC reagents for your training instrument have already been
Preparation prepared and placed on the CAU (Chemistry Analytical Unit).
Take special note of the numbers and letters that are on the tubing
that is attached to the MC reagent straws.
MC Reagent Load:
References:
DxC Instructions For Use:
Chapter 5 Reagent Load / Calibration
DxC In-Lab Training Manual:
Chapter 3 Procedures and Processes
AUTO Using the bar code reader, load all of the MC reagents in the bulk
(Reagent) reagent compartment and the Wash Concentrate II. Load the No
Load Foam and, if your DxC has a cap piercer installed, the CTS Auto-
Gloss. They are located in the middle section of the instrument in
the Hydropneumatics compartment.
References:
DxC Instructions For Use Manual:
Chapter 1- General Information
- Precautions
- Insufficient ISE Reagents
DxC Instructions For Use Manual:
Chapter 5 Reagent Load/Calibration
Edit Volume If the volume displayed does not match the actual reagent volume,
enter the correct % estimate for each reagent in the Vol field on the
Reagent Status side of the Rgts/Cal screen.
Warning:
This is an extremely important step for the ISE reagents! There
is no other mechanism for the system to warn of insufficient
ISE reagents the system will report erroneous results. In
some cases, results will be obtained without reagents.
Why: This exercise guides you through the steps that you will need on an
installation to calibrate the instrument in preparation for precision and
carry over tests.
As with the other exercises some steps are slightly out of order so
that you can see the pop up messages that indicate what you need to
do first.
References:
DxC Chemistry Information Manual
Chemistry Information Sheets
-Specific Chemistry Tab
-Calibration
-Calibrator Required
Cal Status Check the calibration status of all the reagents currently loaded.
Requesting Press the appropriate button in the Chemistry or Position column
Calibration on the Reagent Status side of the Rgts/Cal Screen to select the
following chemistries for calibration:
DxC 800 Na, K, Cl, CO2, Calc, BUNm, CREm, GLUCm, PHOSm,
TPm, ALBm and Mg
DxC 600 Na, K, Cl, CO2, Calc, GLUCm and Mg
1. ______________________________________________
2. ______________________________________________
List of You can find out which calibrator parameters have been loaded on
Calibrators the instrument by checking the List of Calibrators menu.
Press the Assign [F7] button.
On the Assign Barcode/Rack Menu press or click on the pull down
arrow next to the Calibrator Name. If the calibrator(s) you need are
not on this list, you will need to load the calibrator diskette.
Assign Now that the calibrator parameters have been loaded on the
Calibrator ID system, the instrument needs to know where the calibrator samples
will be located when they are run. We can do that in three ways:
1. Assign a calibrator ID barcode.
2. Assign a rack number and position number to the calibrator.
3. Assign a barcode ID and a rack and position number.
Assign the calibrator ID for AQUA CAL (and PROTEIN CAL if your
instrument is a DxC 800). You will find the IDs on the sample
container barcodes located in the labeled gray racks on your
workstation.
Assign
Calibrator Multi Calibrator does not have a barcode for this exercise, so
Rack assign it a rack and position number
.
Reserved Since barcodes labels are too long for the sample cups, we have to
Racks place them in a container long enough to accommodate them.
These cups are referred to as Nested Cups. The details will be
discussed later in the course, but for now, we need to reserve any
racks that have nested cups.
List Press [F5] List to identify the calibrators required for the selected
chemistries.
Calibration Pour the calibrators into either a 0.5 ml sample cup or a 2.0 ml
using bar sample cup and nest these cups into their respective bar code
code labels labeled containers.
Calibration Pour the calibrator for Mg into a 0.5 ml sample cup and place it in
without bar position on the rack assigned for Multi Calibrator.
code labels
Initiate calibration!
Printing While your instrument is calibrating, press [F6] Options on the
Calibration Rgts / Cal screen and select option number 10 to familiarize
Reports yourself with printing of current and previous cal reports.
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Lab Exercise: QC and Sample
Programming/Processing
Objective This laboratory exercise will guide you and your partner through:
Define quality control files
Assign control ids
Programming and processing of qc
Programming and processing patient samples with and
without bar code labels
Requesting load lists
Clear rack assignments
Recall results
Sample replicates and test replicates
Statistical summary report
Absorbance versus time plots and tables.
Knowing how to request load lists and clearing rack assignments will
help in determining whether there is a test still pending or the rack is
unavailable for programming in some problem situations.
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QC and Sample Programming/Processing
Reference:
DxC Instructions For Use Manual:
Chapter 6 Quality Control
-Defining a Control
DxC In-Lab Training Manual:
Chapter 3 Procedures and Processes
-Program / Process QC
Define Using the information found in the table below, define the following
Quality quality control files:
Control
Files
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QC and Sample Programming/Processing, cont
Reference:
DxC Instructions For Use Manual:
Chapter 6 Quality Control
Control ID Assignments
Assign Using the information found in the table below, assign bar code IDs
Control ID for the 2 QC files you had just defined.
Reference:
DxC Instructions For Use Manual:
Chapter 6 Quality Control
- Running Control Samples
-- Running Control Samples With Bar Code
Labels and Auto Generation of Control
Enabled
Program and
Process Program and process Unicel Controls, Levels 1 and 2.
Quality
Control
WITH bar
code labels
Reference:
Chapter 3 Preparing Samples for Analysis
- How to Use Reserved Racks
-- Processing Bar Coded Samples
Patient Using the information that is provided in the table below, process
Samples simulated patient samples.
WITH Bar NOTE: These samples have readable barcodes.
Code labels Using the Sampling Template, verify adequate sample volume!
Request a Load List and print it.
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QC and Sample Programming/Processing, cont
Reference:
DxC Instructions For Use Manual:
Chapter 3 Preparing Samples for Analysis
- How to Use Reserved Racks
-- Processing Unreadable Bar Coded
Samples
Chapter 7 Sample Programming
-Identifying Samples
--Manually Assigning Rack and Position
Patient Using the information that is provided in the table below, program
Samples and process simulated patient samples.
WITHOUT NOTE: These samples do not have readable bar code labels!
bar code Request a Load List and print it.
labels
Sample ID Sample Type Patient Name Chemistries
101526 Serum George Jetson NA, K, Cl, CO2, CALC
101638 Serum June Cleaver NA, K, Cl, CO2, CALC
Reference:
DxC Instructions For Use Manual
Chapter 7 Sample Programming
- Prior to Programming
-- Rack Status
Clear Racks When all the results have printed, CLEAR racks of any manually
assigned samples!
Reference:
DxC Instructions For Use Manual
Chapter 9 Results Recall
Results Recall and reprint the results for the following samples:
Recall
Arthur Edwards Sample ID: 101264
George Jetson Sample ID: 101526
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QC and Sample Programming/Processing, cont
Reference:
System
Replicates Program the following samples in the same rack choosing the
and Test options listed:
Replicates
Sample ID SYNC L1
Chemistries K, CL
Sample Replicates 5
Reps leave blank
Sample ID SYNC L2
Chemistries K, CL
Sample Replicates 1
Reps K 5
CL 5
Using Unicel Controls Levels 1 & 2 as samples, run them.
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QC and Sample Programming/Processing, cont
SYNC L2 __________
Reference:
DxC Instructions For Use Manual
Chapter 9 Results Recall
- Results Recall
-- Statistical Summary Report
Recall Print a Statistical Summary report for the precision tests SYNC L1
Results and and SYNC L2.
Print This feature provides all of the statistical results needed for the
Statistical precision tests on an installation.
Summary
Report
Reference:
DxC Instructions For Use Manual
Chapter 8 Results Recall
- Results Recall
- Absorbance Versus Time
Absorbance Recall the Absorbance Plot and Table for one of the above results
vs. Time and print the Plot.
Compare it to the plot for that chemistry on the next page.
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Generated by ABS vs Time Macro V1.0 JAD - June 1998
0
0 5 10 15 20 25 30 35 40 45
-1000
-2000
-3000
ISE-ADC
-4000
-5000
-6000
-7000
-8000
t / sec
4000
3500
3000
2500
ISE-ADC
2000
1500
1000
500
0
0 5 10 15 20 25 30 35 40 45
t / sec
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Lab Exercise: Customer Maintenance
Objective This laboratory exercise guides you through the following maintenance
procedures:
Review Customer Maintenance Procedures
Reference:
DxC Instructions For Use Manual:
Chapter 10 Maintenance
- Maintenance Overview
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Lab Exercise: Software Boot Sequence
Objectives This exercise will guide you and your partner through the following
procedures:
Proper power down and power up
Initiate a Hyper Terminal session
Observe boot process in Hyper Terminal window
Identify the information in Hyper Terminal window
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Software Boot Sequence
Reference:
DxC In-Lab Training Manual
- Chapter 3: Procedures and Processes
- Power Down and Power Up
DxC Instructions For Use Manual
- Chapter 11: System Status and Commands
- Instrument Commands
Reference:
Unicel DxC Service Manual on Lotus Notes
- Chapter 20: Service Tools
-ICC Hyperterminal
- Items 1, 2 & 3
Question What event on the Hyper Terminal window indicates that the ICC is
ready to communicate with the DxC?
__________________________________________________
Observing
the CAU Power on the DxC console.
Boot Notice that new lines begin to appear in the HyperTerminal screen.
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Software Boot Sequence, Cont...
Reference:
Unicel DxC Service Manual on Lotus Notes
- Chapter 20: Service Tools
- CAU Boot Errors
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Lab Exercise: Instrument Control Subsystem
Objective This lab exercise guides you and your partner through the following
procedures:
Removal and replacement of the ICS components
Boot to "Console Only"
Instrument serial number and Ethernet address entry
Why By performing the procedures in this lab exercise, you will familiarize
yourself with the system's electronic architecture and how the
components interact with one another.
When installing a DxC or replacing the ICS or ICC, the QNX software
on the Multi-Product Console (MPC) needs to know the Ethernet
address of the new ICC in order to communicate with the Chemistry
Acquisition Unit (CAU).
If this number is not entered into the console, the console will not be
able to proceed beyond the Hardware Diagnostics Bar Graph. The
system will continue trying to communicate for 10 minutes before
popping a red Severe Error Message 0X13AC000B requiring a reboot
or shutdown, which, of course will not help.
To prevent this attempt to communicate with the CAU, the MPC must
be booted into the 'Console Only Mode,' which will bypass the
connection with the instrument (CAU).
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ICS Removal and Replacement
Reference:
Unicel DxC Service Manual on Lotus Notes on Lotus Notes
- Chapter 10 ICS/Dual Motor Drivers/Smart Modules
- Removal and Replacement
- Items 1 through 3
- Diagrams and Schematics
- The ICS Expanded View
Power down the instrument.
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ICS Removal and Replacement, Cont...
Reference:
Unicel DxC Service Manual on Lotus Notes
- Chapter 18: Software Troubleshooting
- Item 6 Booting Into Console Only Mode
Note:
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Lab Exercise: QNX Procedures
Objectives This exercise will direct you and your partner to the QNX procedures
that can be useful in resolving corrupted database problems.
There are 3 ways to access QNX - the method used will depend on
the status of the DxC console.
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QNX Procedures, cont
Reference:
Unicel DxC Service Manual on Lotus Notes
- Chapter 18: Software
- Software Troubleshooting
- Operating System & Network Communication
Resolution It would be best to let the instrument finish its process if at all possible,
since it might be finished in five minutes and often is before you even
arrive at the account.
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Lab Exercise: Event Logs
Objectives This exercise will guide you and your partner through the following
procedures:
Viewing information displayed in the Event Log.
Identifying information found in the Event Log
Why Because the Event Log records both error and normal conditions that
occur within the instrument, it is a valuable source of information while
troubleshooting.
Event Log Error Codes are referred to throughout the service manual
for troubleshooting specific problems.
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Event Logs
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 18: Software
Software Troubleshooting - Event Log
Chapter 21: System Troubleshooting
Event Log Error Codes
DxC Instructions For Use Manual
Chapter 12 Utilities- Event Codes
Event Logs Read the above references while reviewing each event log on your
instrument.
Load an empty sample rack with the bar code label facing the
wrong direction. Observe the information presented on the DxC
monitor.
What were the Event ID and Class Number (for the pop-up message
on the DxC monitor)?
________________________________________________
Event Logs
Locate the error message in the Event Log. Print the screen that
displays the event log information regarding this event.
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Event Logs, Cont
Event Logs Locate the error message in the Event Log. Print the screen that
displays the event log information regarding this event.
Questions In the table below, match the severity code with its correct
Cont... description.
System Error All significant events that are not errors are assigned
this severity code.
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Power
Smart Modules
Fiber Optics
Exercises
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Lab Exercise: Power Subsystem
Objectives This lab exercise will guide you and your partner through the following:
Location of Power Subsystem components
Remove and replace power supply
Observe normal power up sequence
Identify LED display codes
Power supply adjustments
Power supply measurements
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Power Subsystem
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 4: Installation
Item 4 Computer Setup
Chapter 14: Power Subsystem
Removal and Replacement
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 14: Power Subsystem
- Troubleshooting
- Item #3 The diagnostic four digit display
- Item #6 The Power Distribution
Initialization / Startup
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Power Subsystem, Cont...
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 14: Power Subsystem
Fluke 187 & 189 Users Manual
Power Measure the inputs to the Isolatran and power supplies and the
Measurements outputs of each power supply and fill in the information below.
Inputs
Ground (G/Y) to Ground (G/Y) to Neutral (BLU) to
Supply
Neutral (BLU) Load (BRN) Load (BRN)
Isolatran
+24.5vdc
+36.0vdc
Outputs
+24.5vdc
+36.0vdc
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Power Subsystem, Cont...
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 14: Power Subsystem
- Adjustment
Fluke 187 & 189 Users Manual
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Power Subsystem, Cont...
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 14: Power Subsystem
- Electronics
- Removal and Replacement
Power Distribution Board
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Lab Exercise: Smart Modules & Fiber Optics
Objective This lab exercise guides you and your partner through the following
procedures:
Location of the various smart modules in the DXC
Troubleshooting Fiber Optics
Why By performing the procedures in this lab exercise, you will familiarize
yourself with the system's electronics components and how they
communicate with one another.
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Smart Modules & Fiber Optics:
Reference:
Unicel DxC Service Manual on Lotus Notes:
Chapter 10: ICS/Dual Motor Drivers/Smart Modules
- Diagrams and Schematics
- Smart Module Locations
DxC Basic Service Training CD
- Fiber Optics Diagrams
- Troubleshooting Fiber Optics
Smart Remove the covers and locate all the smart modules on your
Module training instrument.
Identification Identify the address switch locations on the smart modules.
Compare your instrument with the Fiber Optics Diagram.
Fiber Optic Perform MSMC Loop-back Test located on Service Setup Menu.
Checks Main Menu
Select Setup on the Icon Menu Bar
Select [23] Service Setup
Obtain password using Service Password Generator
Enter password on Password Screen and select [OK}
If you have generated and entered the correct password, you will
be in the Service Setup Screen, if not repeat the process.
On the Service Setup Menu select [8] MSMC Loopback Test
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Hydropneumatics
Exercises
Objectives This exercise will guide you and your partner through the following
procedures:
Component identification
Observe instrument status during routine hydro operation
Valves:
Removal & replacement of valves
Perform the following diagnostics tests:
Vacuum and air pump test
Float switch tests
Hydro valves tests
Pump Box access
Review PMC procedures
Review decontamination procedure
Why The hydropneumatics system is essentially the heart & lungs of the
instrument.
Diagnostics allows the operator the ability to test the functionality of a
component (pump, float switch, etc.) without having to shut down the
system. In addition, diagnostics provides the operator with real-time
feedback while they are adjusting pressures.
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 9: Hydropneumatics
Components Remove the center section and the left section air ducts from the
Location back of the DXC.
Rear of Unplug the center fan and both left fans.
Instrument Remove the fans to access the frame compartment s.
Inspect the following hydropneumatic components on your training
instrument.
Gravity drain assembly
Restrictor Reservoir A19456
Waste connections
DI water connections
Pump Box Locate the Pump Box Stop Bracket with pump on/off switch from
front of the DxC.
Pull out the Pump Box per procedure.
Remove the cover and identify the components using the Pump
Box Diagram provided.
Reinstall the Pump Box and associated assemblies,
Reinstall the fans.
Reinstall the air ducts.
Power up the DxC
Components Observe the operation of the hydro drawer while the instrument is
Location homing, when the pumps come on, valve operation, etc.
Hydro On the DxC, locate all of the components depicted on the Master
Drawer and Hydropneumatic Schematic in the above reference.
System Do the same with the major assemblies on DxC 600/800 Hydro-
Pneumatic Diagram P/N A18111.
Questions When the DI Water Reservoir float switch reaches the 'EMPTY'
position, which valve and LED turns on to fill the canister?
Valve(s) #: ___________________LED(s) #:
___________________
FYI
While manually filling the DI Water Reservoir, it is important NOT to
turn the gray button while pushing in. Doing so will cause it to
remain open.
Questions Which valve(s) and LED(s) are responsible for filling this canister?
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 9: Hydropneumatics
- Troubleshooting
Note:
List the 3 possible readings/conditions that you may see for float
switches:
_________________________________
_________________________________
_________________________________
Instrument Verify that the instrument is in Standby mode and that all the
Verification instrument status is within specifications.
Calibrate all Modular Chemistries
Reference:
DXC Service Manual on Lotus Notes
Chapter 9: Hydropneumatics
- System Decontamination Procedure
(ISE/MC/HYDRO)
Chapter 11: ISE Module
- DxC 600/800 System Decontamination
Procedure (MC/ISE/HYDRO)
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Lab Exercise: Cap Piercer TS-CTS
Objectives This exercise will guide you and your partner through the following
procedures:
Bar-code reader removal and replacement
TS-CTS removal and replacement
Blade & wick removal and replacement
Autogloss pump repair and replacement
One blade TS-CTS functional alignment
Why We have discussed some of the problems you might see in the field
regarding the cap piercer. Use this opportunity to become familiar with
the operation, repair and alignment of the TS-CTS.
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Cap Piercer TS-CTS:
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 17: Sample Handling
- Removal and Replacement
- The Barcode Reader
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 6: Cap Piercer
- Removal and Replacement
- The Blade, Wick removal and
replacement Procedure
-The Linear Pump Replacement and
Alignment
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 6: Cap Piercer
- Cap Piercer Removal and Replacement
Procedure
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Lab Exercise: Sample Rack Handling
Objectives This exercise will guide you and your partner through the following
procedures:
Shuttle latch solenoid removal and replacement
Onload tray assembly removal and replacement
Offload tray assembly removal and replacement
Shuttle assembly removal and replacement
Sample rack handling alignment procedures
Why The Sample Rack Handling subsystem is one of the subsystems within
the DXC. Its primary function is to introduce sample racks containing
sample containers. The shuttle mechanism guides the sample rack to
the bar code reader, the cap piercing stations (if present), and onto the
sample wheel. Once the rack is on the sample wheel, the MC and CC
sample probes can access the samples in order to process any
requested test(s). At the completion of a run, the rack is off loaded
from the sample wheel to the offload tray.
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Sample Rack Handling:
Reference:
Unicel DxC 600/800 Service Manual on Lotus Notes
Chapter 17: Sample Handling
- Arm/Latch Solenoid
- Onload Tray
- Offload Tray
- Shuttle Assembly
Onload Tray Remove the Onload Tray and inspect the replaceable components.
Removal Compare the DxC 600 Onload Tray with the DxC 800 Onload Tray.
Offload Tray Remove the Offload Tray and inspect the replaceable components.
Removal
Reinstall all Reinstall all Sample Rack Handling Components on your training
SRH instrument:
Components Shuttle Assembly
Offload Tray
Onload Tray
TS-CTS Cap Piercer
Barcode Reader.
Sample Rack Perform the following Functional Area alignment procedures
Handling Sample Carousel
Alignments Sample Rack Handling
Cap Piercer
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Sample Rack Handling, Cont...
Event Log Find each instance where the run button was pressed, highlight it
#10 and review the subsequent events, such as pierce status, when it
Information is loaded on the sample wheel, etc. .
Compare the <container type> on the printout with the table on the
next page.
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Sample Rack Handling, Cont...
Description Codes
Event Message Event or Log Description
Description
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MC Sample
MC Cups
Exercises
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Lab Exercise: MC Sample Syringe Drive Assembly
Objectives This exercise will guide you and your partner through the removal and
reinstallation of MC Sample Syringe Drive Assembly.
Why The Syringe Drive Assembly can become noisy. Replacement of the
Syringe Drive Shaft Assembly may be necessary.
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MC Sample Syringe Drive Assembly
Reference:
Unicel DXC Service Manual on Lotus Notes
No reference in the Service Manual.
Consult an instructor when necessary.
Notice the spring on the shaft. Together with the offset pin on the
motor shaft, it forms a key which prevents the valve from being
placed on the motor shaft incorrectly.
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MC Sample Syringe Drive Assembly, Cont...
Syringe The following will bring the syringes to a position where an operator
Replacement can replace them without shutting the instrument down or pressing the
Maintenance stop button to move them manually.
Procedure Utilities
[2] Maintenance
[7] Syringe Rod Replacement
[Continue]
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Lab Exercise: DxC Sample Cranes
Objectives This exercise will guide you and your partner through the following:
Removal and replacement of (MC) Crane
Inspect the Triple Crane Assembly
Removal and replacement of (MC) probe
Perform MC Crane Alignments
Why Occasionally the MC Sample Crane shaft assembly rails (3) require
cleaning with isopropyl alcohol.
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DxC 800 MC Sample Crane
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 17: Sample Handling
DxC 800 MC Sample Crane (Diagram)
No reference in the Service Manual.
Consult an instructor when necessary.
DxC 800 Dirt and dust, which may accumulate along the guide rails of a crane
MC Sample assembly, can affect the timing and motion of the probe travel
Crane (triggering motion errors and/or level sense errors). It is therefore
important to clean these guide rails periodically with alcohol pads.
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 17: Sample Handling
DxC 600 Triple Crane Overview
DxC 600 Remove the covers from the MC Sample Crane and observe the
Triple Crane replaceable components.
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MC Sample Crane, Cont.
Reference:
Unicel DXC Service Manual:
Chapter 17: Sample Handling
- Alignment and Adjustment
- CC and MC Sample Probe Alignments
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Lab Exercise: Modular Chemistry - Cups
Objectives This exercise will guide you and your partner through the following:
Identification of LED status/colors
Removal and reinstallation of an MC cup module
Removal and reinstallation of reagent pump and valves
Removal and reinstallation of stir motor
Adjustment of temperature via diagnostic
Removal and reinstallation of an MC lamp via diagnostics
Lamp calibration
Why Each cup must go through the fill, stir and drain process during normal
operation. Inadequate cup filling, stirring or draining can lead to
erroneous patient results. Should these events occur, it might become
necessary to replace components within the cup module assembly.
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Modular Chemistry Cups
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 8: Cup Modules
- Items #1 through # 9
MC Manifold Locate MC Manifold on both a DxC 600 and 800 and note the
differences.
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 8: Cup Modules
- Alignment and Adjustments
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Modular Chemistry Cups, Cont
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 8: Cup Modules
- Removal and Replacement
- MC Modules Lamp Replacement
DxC 800 Remove and replace a cup module lamp per the procedure above.
Lamp Calibrate all lamps and the GLUm sensor.
Removal and
Replacement
Utilities Icon
[2] Maintenance
[8] CUPs Lamp/Sensor Calibration
Select all available entries.
DxC 600 Follow the above steps to calibrate the Glucose Sensor.
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MC/ISE
Preventive
Maintenance
Exercises
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Lab Exercise: MC/ISE & Preventive Maintenance
Objectives This exercise will guide you and your partner through the following:
Remove the Flow Cell and replace the Carbon Bridge.
Strike carbon bridge
Preventive Maintenance ISE & MC
Why This is your opportunity to take a closer look at the ISE and review the
PMC checklist / procedures.
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Carbon Bridge Replacement Exercise:
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 11: ISE Module
- The Carbon Bridge
- Replacing of the Carbon Bridge
- Carbon Bridge Striking
Striking the Striking the carbon bridge on the DXC is part of the installation
Carbon procedure. Please take the time and review the procedure as
Bridge described in the reference above. A striking tool is available for
you to inspect and/or use while here in training.
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Preventive Maintenance
Reference:
Unicel DxC Service Manual on Lotus Notes
Chapter 5: Preventive Maintenance
- UniCel DxC 600/800 Preventative Maintenance
Checklists.
- UniCel DxC 600/800 PMC Schedule and Kit Part
Numbers
- UniCel DxC 600/800, PM A Kit, (Major CC), P/N
A22681
- UniCel DxC 600/800 PM B Kit, (Major MC/CC),
P/N A22683
- UniCel DxC 800, PM Minor Kit, (ISE/MC), P/N
A37245
- UniCel DxC 600, PM Minor Kit, (ISE/MC), P/N
A37244
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DxC 600/800
System
Decontamination
Exercise
Objectives This exercise will guide you and your partner through the following:
Decontamination Procedures
Why There are occasions when the same symptoms seem to be recurring
in a periodic manner.
This might be the result of repairing the symptom rather than the root
cause.
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 11: ISE Module
- DxC 600/800 System Decontamination
Procedure (MC/ISE/HYDRO)
DxC 600/800 You have already demonstrated the skills required to perform this
System procedure, so practice is unnecessary.
Thoroughly read the following document and using your
instrument as a reference, familiarize yourself with the
procedures involved.
Note 4: Have the customer soak a Potassium tip and Calcium tip in LX ISE
Reference Solution for 24 hrs before starting procedure.
-Dummy ISE electrodes (P/N 668077), or old used electrodes for the ISE, Glucose
and BUN
-One kit of Chlorine Dioxide (P/N A22197 Kit contains 2 packets)
-Fresh bottles of Electrolyte Buffer, Electrolyte Reference and CO2 Acid
-One clamp (hemostat)
-One four-liter container
-One 1L beaker
-Degasser (471650)
-0.2 Micron Filter (949898)
-Potassium Tip (669117)
-Calcium Tip (467769)
-NA Electrode (668295)
2. Dry prime by using All ISE command 20 times to remove reagent fluid from
ISE module. Remove reagent bottles when complete.
3. Remove reagent tray. Note: Removing reagent tray is used to install lines
11,12,13,14, and 15 for better access.,
,
4. Remove/disassemble ISE tubing, flowcell/electrodes, ratio pump chambers,
Alkaline Buffer damper, and EIC assy. Note: When disassembling ratio pump
and EIC remove the solenoid valves, leaving the electrical connections alone.
Make sure the o-rings on the solenoids are still in place.
7. Wipe the face of the solenoids (ratio pump and EIC) with Acetic Acid then
Hydrogen Peroxide solution, and finish with DI water.
8. Reassemble and install ratio pump with new seals, damper, flowcell, EIC Cup
with new spacer and o-ring. Note: When replacing electrodes use NEW QUAD
RINGS. Install for now, old/dummy electrodes in flowcell, Glucose, and BUN
modules.
10. Replace the Buffer and Reference caps and straws with new.
12. Remove straws from the Acetic Acid solution; wipe straws dry and prime once
for an air slug. Put straws in the Hydrogen Peroxide beaker that was used
earlier and repeat the priming procedure as same as Acetic Acid.
13. Remove straws out of the Hydrogen Peroxide and wipe clean. Put straws in a
beaker of DI water and prime 25 times All ISE. Prime 5 times with the straws
out of the DI water to drain tubing of fluids.
2. Clamp off Wash Concentrate line #145. This line is coming out of the top of
the wash concentrate canister.
3. Prime hydro 10 times to remove all wash concentrate out of the system.
Waste reservoir should not have suds at the end of the priming cycles.
4. Put the straws from the electrolyte buffer, reference and CO2 acid bottles into
a 1L beaker with prepared chlorine dioxide solution. Make sure there is
enough solution (approx. 200ml) for 20-30 primes. ISE will turn a greenish
color.
5. With rest of the four-liter container, shut off customer outlet valve and remove
the DI water line from that point and put line into four liter container. Note: The
0.2 micron filter will remain with DI water line, but will be replaced at a later
step in the procedure.
a. You will need to follow the document "Filling the DI Water Reservoir
using V3 Vacuum," in Chapter 9: Hydropneumatics of the DxC 600/800
Service Manual.
6. Prime all 15 times. You should see the greenish Chlorine Dioxide solution in
the DI water and the wash solution canisters.
7. After prime, let the solution sit for one hour in the system. (Very Important).
9. Reattach the DI water line to customer outlet valve along with the new 0.2
Micron filter (949898) and put the ISE buffer, ISE reference reagent and CO2
acid reagent straws into a beaker of DI water.
10. Prime the ISE 20 times with the straws in the DI water, then remove the straws
and prime with air 5 times.
11. Install new K and Calc tips. Clean the CO2 and NA Reference Electrode
glass ends with alcohol pads several times. Note: When replacing electrodes,
use NEW QUAD RINGS. Replace NA and Chloride Electrodes, and re-
membrane the CO2 Electrode. Install original BUN and Glucose electrodes.
Strike the flowcell carbon bridge.
12. Next, put on new bottles of ISE electrolyte buffer, ISE electrolyte reference
and CO2 acid. Replace the Degassers (471650). Reset reagent volumes to
current values.
14. Remove wash solution canister, empty contents, clean and reinstall.
17. Prime all 5 times, calibrate MC side tests and then program a run of 20
Potassium samples to coat the flow cell.
The most important aspect of the mentoring process is the training that the mentors
provide by example. Mentors are selected because they have shown a commitment
to quality and a track record for doing the right thing. Demonstrating by example is
the best training that can be provided to ensure the success of engineers new to the
instrument or product line.
When enrolling the trainee for class, the manager assigns a mentor.
The manager sets the goal for mentoring completion based on workgroup needs.
Mentoring requirements are based on demonstration of the knowledge and skills needed to service
the instrument in the field. The requirements should be determined by the mentor in consultation with
the manager and will depend upon the individual trainee's ability and the type of instrumentation.
Minimum requirements are suggested in the Mentoring Packet for the individual instrument. The
packet can be downloaded from the Chemistry/Immunoassay link in the Training Resources Database
on BirchNotes/BII.
The trainee and the mentor arrange time to complete mentoring requirements. This is best done in
person, with the mentor and the trainee performing service calls together. If it is not possible for the
mentor and trainee to meet in person in a timely manner, the mentor, with the manager's approval,
may designate another engineer who has been certified on the instrument. Whenever possible a
variety of call types should be selected PMs, installations, trouble calls, etc. to broaden the learning
experience.
If the trainee has been certified on the instrument by Professional Development, the
mentor can elect to assign calls to the trainee when he determines that the situation
warrants it. The mentor should review all call assignments for the product by
telephone with the trainee before the trainee goes on site. An action plan for the
call should be devised and the trainee should know how to reach the mentor quickly
if the plan is not appropriate. The trainee must update the mentor at the close of the
call.
By completing and e-mailing the Mentor Validation Form on page 2, the Mentor
confirms that:
1) The trainee has mastered the skills required to:
o Operate the instrumentation as a system
o Perform Preventive Maintenance Procedures on the instrument
o Troubleshoot and repair basic hardware problems on the instrument
2) Plans have been formulated to provide assistance and support in those areas where the
trainee may need additional practice.
3) The trainee has demonstrated the ability to assess, review and resolve instrument problems
and customer concerns independently.
4) The trainee has the required tools and test equipment needed to service the instrumentation
and has demonstrated a working knowledge of their use and function.
5) The mentor and the trainee have reviewed documentation related to servicing the product,
including:
o Location and use of the service manual
UNICEL DxC 600/800 Pro Basic Service, Mentoring Documentation Page 3 of 10
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o Location of Service Memos/Modifications, Technical Updates and other relevant
information on Lotus Notes, Odyssey and electronic media in use by the field.
o Location and use of the North America Commercial Operations (NACO) Database on
Lotus Notes and the documents contained in the Service Section. (Call Closeout,
Installation, DOA reporting, Escalation, ESD, etc.)
6) The mentor confirms that the trainee has a basic car stock for the instrument.
Address
City
State
Zip
Instructor
Class
RM
Mentor
Mentor (sign)
Date
The trainee and the mentor arrange time to perform service calls
together. It is important that the trainee accompany a mentor on a
daily basis on all service calls scheduled for that day, including
if necessary instruments other than DxC 600/800.
POST SESSIONS The major goal for Post Sessions Mentoring is for the trainee to be
MENTORING able to perform independently when servicing the DxC 600/800.
Since the trainee has been certified on the instrument, the mentor
INDIRECT can elect to assign calls to the trainee when he determines that
SUPERVISION the situation warrants it.
The mentor should review all call assignments for the product by
telephone with the trainee before the trainee goes on site. An
action plan for the call should be devised and the trainee should
know how to reach the mentor quickly if the plan is not
appropriate. The trainee must update the mentor at the close of
the call.
Post Sessions Mentoring Trainee should complete the following with the mentor or a
designated certified engineer on-site:
Direct Supervision
3 DxC CC Service Calls
1 UniCel DxC 600/800 PM B, Major MC/CC.
1 UniCel DxC 600/800 PM A, Major CC.
Post Sessions Mentoring Trainee should successfully complete the following without on-
site supervision:
Indirect Supervision
6 DxC MC/ISE or CC Service Calls
1 UniCel DxC 600/800 PM B, Major MC/CC
1 UniCel DxC 600/800 PM A, Major CC
1 Unicel DxC 600/800, PM Minor, ISE/MC
The mentor may require more than or less than what the above
guidelines recommend when evaluating an individual trainee.
Servic
Event
e Trouble-
Reason for Problem Log Successful?
Order shooting
call Observed Error If not, explain.
# Process
Code
& Date
*Save this document as 'Your Name DxC Log Week # (as appropriate)
E-mail the completed form weekly to your instructor.
Day 11 Wednesday
Time Event Location
Group Summary and QC Interpretation
08:00 11:30 Presented by Stan Johnson Classroom
Questions & Answers
11:30 12:30 Lunch
Program QC using Group Summary
12:30 5:00 ISE Preamp Test Box Laboratory
Troubleshooting Exercises
Day 12 Thursday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 09:30 Refrigeration Subsystem Classroom
09:30 11:30 Refrigeration Exercises Laboratory
11:30 1:00 Lunch
1:00 5:00 Troubleshooting Exercises Laboratory
Day 13 Friday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
CC Sample Aspiration & Delivery
08:30 09:30 Classroom
CC Reagent Aspiration & Delivery
09:30 11:30 CC Sample & Reagent Exercises Laboratory
11:30 12:30 Lunch
12:30 5:00 Troubleshooting Exercises Laboratory
Day 15 Tuesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 11:30 Reaction Subsystem / PVT2, PVT3 & PVT5 Laboratory
11:30 12:30 Lunch
12:30 5:00 Troubleshooting Exercises Laboratory
Day 16 Wednesday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
10:00 11:30 Preventive Maintenance Major Laboratory
11:30 12:30 Lunch
12:30 5:00 PM continued Laboratory
Day 17 Thursday
Time Event Location
08:00 08:30 Review: Questions & Answers Classroom
08:30 11:30 Troubleshooting Exercises Laboratory
11:30 1:00 Lunch
1:00 2:00 Lab Cleanup Laboratory
2:00 5:00 Student Survey Graduation Classroom
Instructions The Personal Progress Report is your way of monitoring your skill
development. Initial your Personal Progress Report and ask your
Instructor to do the same.
ITEMS PERTINENT TO INSTALLATION ARE IN BOLDFACE
Day 10 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
Calibrate and Troubleshoot MC/ISE.
Tools Perform precision tests using ChemAssistant.
Test instrument communications using LISA ______ _______
Day 11 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
QC
Program & process QC using Group
Summary. ______ _______
ISE
Troubleshoot ISE using ISE Preamp Test ______ _______
Box.
Day 12 Thursday
Student Instructor
Exercise Objectives
Initials Initials
Locate all refrigeration components
Remove and reinstall Cooler Assembly
Refrigeration Remove and reinstall Thermistors
Remove and reinstall cooler fan
Remove and reinstall Peltier Drivers ______ _______
Day 13 Friday
Student Instructor
Exercise Objectives
Initials Initials
Identify reagent handling components
CC Sample Remove and reinstall reagent carousels home
& sensors and motors
Reagent Remove and reinstall bar code readers
Handling Perform belt adjustment
_______ _______
Perform alignment procedures
Day 14 Monday
Student Instructor
Exercise Objectives
Initials Initials
Remove and reinstall reaction drive
assembly & its associated components
Remove and reinstall of photometer _______ _______
Reaction module & its associated components
Wheel & Remove and reinstall of cuvette wash
Photometer manifold and valves
Identify components and part numbers
Perform Diagnostic tests
Perform alignment procedures
Day 15 Tuesday
Student Instructor
Exercise Objectives
Initials Initials
Performance Perform PVT2 Wash Station Test
Verification Cuvette Dryness
Tests Perform PVT3 Carryover Tests
Wash Station
Reagent Probes
CC Sample Probe
CC Mixer Paddles
Perform PVT5 Precision Tests
Normal Precision
On-Line Dilution
Review PVT5 Sample Probe Precision
Day 16 Wednesday
Student Instructor
Exercise Objectives
Initials Initials
Preventive Perform Major PM
Maintenance
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Lab Exercise: ISE Preamp Test Box
Objectives This exercise will guide you and your partner through the following
procedures:
Use of the ISE Preamp Test Box
Why To familiarize the engineers with the procedures for using the ISE
Preamp Test Box to eliminate the preamp board as a possible cause
for ISE problems.
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ISE Preamp Test Box:
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 20: Service Tools
- ISE Electrode Simulator Box
1. Using the ISE Electrode Simulator to
help troubleshoot the ISE
2. Troubleshooting
3. Important Notes
4. Specifications
5. ADC Count Verification Using ISE
Simulator Module
6. Box Description/Part Number
7. Box Drawing
8. Board Description
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Refrigeration
Exercises
Objectives This exercise will guide you and your partner through the following
procedures:
Removal of the Cooler Assembly
Removal of Peltier Driver Assembly
Why To familiarize the engineers with the procedures for replacement of the
cooler assembly and its associated components
TOP of Cable
Bracket DxC
1 8
P J159
Peltier Banks Thermal
Switch
COLD 1 2 3
PLATE
4 5 6
IN AIR J156B J156A
J155 TECFAN2 TECFAN4
Thermistors
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 16: Reagent Handling
- Removal and Replacement
- Item 7 Peltier Assembly Removal and
Replacement Procedure
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 16: Reagent Handling
- Removal and Replacement
- Item 7 Peltier Driver A Assembly
- Item 8 Peltier Driver B Assembly
UNICEL DxC 600/800 Pro Basic Service, CC Subsystem Sample & Reagent Page 1 of 8
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UNICEL DxC 600/800 Pro Basic Service, CC Subsystem Sample & Reagent Page 2 of 8
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Lab Exercise: CC Sample Handling
Objectives
This exercise will guide you and your partner through the following
procedures:
Locate & identify sample handling components
CC Sample Syringe Assembly
Sample & Mixer Module
Remove and reinstall rotational motor
Perform alignment procedures
Why To become familiar with the components and assemblies that may
require repair or replacement.
UNICEL DxC 600/800 Pro Basic Service, CC Subsystem Sample & Reagent Page 3 of 8
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CC Sample Handling:
Reference:
Unicel DXC Service Manual on Lotus Notes
Sample Remove the covers from the CC Sample Crane Arm and the CC
Handling Mixer Crane Arm
System
Locate the vertical and rotational motors, sensors and belts or
gears for each.
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Lab Exercise: CC Reagent Handling
Objectives This exercise will guide you and your partner through the following
procedures:
Locate & identify reagent handling components
Remove & reinstall the following components:
A/B Valve Assembly
Bubble Generator Assembly
Reagent Carousel Home Sensors Assembly
Reagent carousel motors
Bar code readers
Perform belt adjustments
Perform alignment procedures
Why To become familiar with the components and assemblies that may
require repair or replacement.
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CC Reagent Handling:
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 16: Reagent Handling
1. Reagent Probe A and B Installation Procedure
2. Collar Wash Removal and Replacement Procedure
3. Reagent Crane Vertical Motor Removal and
Replacement Procedure
4. Reagent Carousel Removal and Replacement
Procedure
5. Reagent Carousel Dual Drive Assembly Removal and
Replacement Procedure
6. Reagent Carousel Home Sensor Assembly Removal
and Replacement Procedure
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CC Reagent Handling, cont...
Reagent Carousel:
1. Reagent Carouse Load
2. Reagent Probe A& B Rotary to Cartridge (post requisite to 1.)
3. Reagent Probe A Height in Cartridge
4. Reagent Probe B Height in Cartridge
Instrument Verify that the instrument is in Standby mode and that all the instrument
Verification status is within specifications.
Calibrate Mg.
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Reaction Wheel
&
Photometer
Exercises
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 1 of 12
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Lab Exercise: Reaction Wheel and Photometer
Objectives This exercise will guide you and your partner through the following
procedures:
Removal and replacement of cuvette wash manifold
assembly
Removal and replacement of cuvette wash drive assembly
Testing the wash station valves
Removal and replacement of reaction drive assembly & its
associated components
Removal and replacement of photometer module & its
associated components
Perform Diagnostics tests
Perform alignment procedures
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 3 of 12
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Reaction Wheel Subsystem
Reference:
Training CD:
Quick Reference Diagrams:
DxC Cuvette Wash Valve Manifold A11106
Cartridge Chemistries
Reaction Wheel Subsystems
A11106-AC DxC Cuvette Wash Valve
Manifold Assy.+
Cuvette Perform the following steps to remove the Cuvette Wash Manifold
Wash
Power down the system.
Manifold
Assembly Remove Sample Carousel evaporation cover.
Disconnect Sample Mixer Wash Cup fluid line and drape to center
section.
Remove the retaining screw from manifold bracket.
Loosen Wash Head captive retaining screws and lift Wash Head
from Cuvette Wash Drive.
Lift Cuvette Wash Manifold and Wash Head to gain access to
Manifold fluid connectors.
Disconnect fluid lines 134, 135, 151 and 175.
NOTE: Some fluid will leak from the Manifold. Capture with paper
towels.
Disconnect solenoid connectors 71P1, 71P2, 71P3, 71P4 and
71P5.
Disconnect heater power cables 71P6 and 71P7.
Lift assemblies away from instrument.
Using the above references, become familiar with the components
in the Cuvette Wash Manifold Assembly, valves, heaters, fluid
lines, probes, etc.
Remove and reinstall valve V2.
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 4 of 12
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Reaction Wheel Subsystem, cont...
Cuvette Perform the following steps to remove the Cuvette Wash Drive.
Wash Drive
Assembly
Remove Smart Modules Center Cover.
Disconnect Cuvette Wash Drive motor connector 71PM1 from
Smart Module 71.
Remove (2) Phillips retaining screws from Drive base.
Lift Drive from instrument while carefully guiding motor cable
through harnesses and tubing maze.
Reinstall both the cuvette wash manifold and cuvette wash drive
assembly.
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Reaction Wheel Subsystem, cont...
Wash Valve Remove cuvette probe assembly from wash tower.
Check
Place probes 1, 2 & 3 in separate test tubes/cuvettes.
Select start cycle in the diagnostics routine.
Probes 1, 2 and 3 will each deliver fluid.
At some point, the fluid level in each tube rises to the probe tip
where it will be evacuated.
If the fluid valves are delivering a consistent volume and the waste
valves are evacuating a consistent volume, the level in all three
tubes will stay the same.
If probes 2 & 3 are working properly, check the wiper probe (4) to
insure that it is aspirating fluid.
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 15: Reaction Subsystem
- Reaction Subsystem Removal and Replacement
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Reaction Wheel Subsystem, cont...
Reaction While the reaction drive assembly is off the instrument, remove,
Drive inspect and reinstall the following components from the reaction
Assembly drive assembly:
Slip ring assembly
Drive motor
Home sensor
Flash encoder
Drive shaft
(Plastic) gear
Reinstall the reaction drive assembly. Do not replace the reaction
wheel trough at this time.
Alignments Because the reaction wheel platter has been removed, the probes
and the cuvette wash station need to be realigned to the reaction
carousel.
Perform the following Alignments:
Functional Area Reaction Carousel
1. Reaction Carousel Home
2. Cuvette Wash Station
3. CC Sample Probe Rotary to Cuvettes
4. CC Sample Probe Cuvette Height
5. CC Sample Mixer Rotary
6. CC Sample Mixer Height
7. Reagent Probe A Rotary to Cuvettes
8. Reagent Probe A Height in Cuvette
9. Reagent Probe B Rotary to Cuvettes
10. Reagent Probe B Height in Cuvette
11. Reagent Mixer Rotary
12. Reagent Mixer Height
471803 Rx Wheel Align Tool 476211 Cuvette Wash Probe Align Tool
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Photometer Subsystem
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 15: Reaction Subsystem
- Photometer Removal and Replacement
Photometer Note:
Removal and Do not loosen or remove the reaction wheel platter. Doing
Replacement so will require the Reaction Carousel alignments to be
repeated!
Photometer Loosen the three long screws on the back of the preamp housing
Preamp which extend through the internal spacers one turn.
Removal
Note:
The diagram on the next page show where these screws are.
The reason they are loosened is to allow the 4 captive thumb
screws that hold the preamp to the base plate to be loosened
by hand.
Disconnect the three fiber optic cables between the Photometer
Controller and the Lamp Power Supply. Leave the fiber optics
connected to the Lamp Power Supply.
Loosen all 4 captive screws which secure the Preamp Assembly to
the monochromator housing.
Gently lift the Preamp Assembly from the monochromator. Set
aside.
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 8 of 12
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Photometer Subsystem, cont...
Photometer Loosen the three long screws on the replacement Preamp
Preamp Assembly which extend through the internal spacers one turn.
Removal and
Note:
Replacement
The reason they are loosened on a new preamp is that the
thumb screws must be tightened by hand to avoid placing
torque on the box which will misalign the wavelength diodes
causing failure of the diagnostic tests.
Gently install the replacement Preamp onto the monochromator
base plate, being careful to guide the reference detector into the
cavity in the fiber receptacle. Take note that the edges of the
Preamp housing are inside the channels in the base plate.
By hand, tighten the 4 captive screws which secure the Preamp
Assembly onto the monochromator base plate.
Tighten the three long screws which extend through the internal
spacers.
Reconnect the fiber optic cables from the Lamp Power Supply to the
Photometer Controller.
Re-install the Photometer Assembly on the instrument.
Loosen these 3
screws 1 turn
and 1 turn only!
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 9 of 12
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Photometer Subsystem, cont...
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 15: Reaction Subsystem
- Alignment and Adjustment
1. The Photometer Lamp Calibration
2. The Photometer Flash Encoder Test
3. The Photometer Lamp Alignment and Power
4. The Photometer Flash Lamp Power Supply
5. The Photometer Smart Module & Preamp Test
6. The Reaction Wheel Temperature Test
7. The Reaction Wheel Heater Controller
8. The Reaction Wheel Home Alignment Test
To prevent damage to the instrument (during power up &
homing process):
Position the wash head off to the side with the probes
placed into a large plastic beaker.
UNICEL DXC 600/800 Pro Basic Service, Reaction Wheel & Photometer Exercises Page 10 of 12
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Photometer Subsystem, cont...
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 12: LPIA
Alignment and Adjustment
1. The Cuvette Centering Alignment Procedure
2. The LED DAC Setting
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Cleaving
Exercise
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Lab Exercise: Cleaving
Why Sometimes there are installations that require the DxC 600/800 to be
reduced in size in order to fit through doorways or elevators that are
too small to accommodate the complete instrument.
SYNCHRON, DxC 600 / 800 Pro Basic Service, Cleaving Exercise Page 1 of 4
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DxC Cleaving:
Reference:
Unicel DXC Service Manual on Lotus Notes
Chapter 4: Installation
- DxC 600 Cleaving
- DxC 800 Cleaving
SYNCHRON, DxC 600 / 800 Pro Basic Service, Cleaving Exercise Page 2 of 4
Version A 05042007 Brea Training Center