06 ServiceManual Rev03 PDF

HumaStar 100/200
| Service Manual
Cat. No. 168902

REVISION LIST OF THE MANUAL
Rev. /DATE. REVISION DESCRIPTION
01/2013-02 First edition
02/2013-10 Review of first edition
03/2014/01 Revised version
SYSTEM VERSION
VERSION DESCRIPTION
0.44.2.15 HI Application software
1.34G HumaStar 100 Firmware
1.34K HumaStar 200 Firmware
COPYRIGHT
Copyright 2013, Human Gesellschaft fr Biochemica und Diagnostica mbH, Wiesbaden,

Germany. All rights reserved.
No part of this documentation may be reproduced in any form, nor processed, copied or distri-
buted by means of electronic systems, without prior permission of HUMAN in writing. Since all
precautionary measures were taken into account in producing these operating instructions, the
manufacturer accepts no responsibility for any errors or omissions. This includes any liability for
damage that could arise from possible incorrect operation based on this information. Subject to
changes without notice as result of technical development.
SERVICE UND SUPPORT

CONTENTS
TABLE OF CONTENTS
1 SAFETY INSTRUCTIONS 9
1.1 INTRODUCTION 9
1.2 USER WARRANTY 9
1.3 INTENDED USE OF THE INSTRUMENT 9
1.4 GENERAL SAFETY WARNINGS 10
1.5 DISPOSAL MANAGEMENT CONCEPT 10
1.6 BIOHAZARD WARNING 11
1.7 INSTRUMENT DISINFECTION 11
2 THE ANALYZER HUMASTAR 100/200 13

2.1 GENERAL DESCRIPTION 13
2.2 MAIN CHARACTERISTICS 13
2.3 INSTALLATION 13
2.3.1 Shipping and delivery 13
2.3.2 Packaging 13
2.3.3 Responsibilities 14
2.3.4 Prior to setting-up 14
2.3.5 Installation 16
2.3.6 Moving 21
2.4 ANALYZER COMPONENTS 21
2.4.1 Function group identification 21
2.4.2 Mechanical functions 22
2.4.3 Sampling arm 22
2.4.4 Needle wash station 23
2.4.5 Reagent tray 24
2.4.6 Sample tray and cuvette rotor 24
2.4.7 Optical group 25
2.4.8 Cuvette wash station 26
2.4.9 Hydraulic system 28
3 COMPONENT PARTS 31
3.1 CPU BOARD 31
3.2 POWER SUPPLY BOARD 31
3.3 LEVEL AND SHOCK SENSOR BOARD 32
3.4 POWER SUPPLIES 24 V AND 12 V 32
3.5 GROUND CONNECTIONS 33
3.6 OPTICAL LAMP 34
3.7 HYDRAULICS PANEL 34
3.7.1 Front side 34
3.7.2 Rear side 35
3.7.3 Diluter and valve tubing 36
3.7.4 Manifold 37
3.8 WASH STATION 37
3.9 EXTERNAL TANKS 39
4 TERMINAL PROGRAM 41
4.1 HOW TO USE THE TERMINAL PROGRAM 41
4.2 SERVICE MENU 42
5 HARDWARE TEST MENU (F1) 43

5.1 COLUMNS OF THE HARDWARE TEST TABLE 44
5.2 LOGICAL POSITIONS 45
5.3 PUMPS, VALVE AND LAMP TEST (F4) 47
5.4 CONTINUOUS INPUTS DISPLAY (F5) 47
6 MECHANICAL CALIBRATIONS MENU (F2) 49

6.1 OPERATIONS 49
6.2 CALIBRATION ROWS 50
7 MECHANICAL CHECKS MENU (F3) 55

7.1 RN/IP CHECK (F1) 55
7.2 SN/OP CHECK (F2) 55
7.3 AN/SN/OP CHECK (F3) 56
7.4 OP+FS HOME CHECK (F4) 56
7.5 ALL CHECK (F5) 56
7.6 OP READING CHECK (F6) 57
7.7 DS CHECK (F7) 57
8 OPTICAL READING TEST MENU (F4) 59

8.1 SET O.D. REFERENCE (F1) 60
8.2 SELECT CUVETTE (F2) 60
8.3 CHANGE CUVETTE F3) 61
8.4 READ ALL FILTERS (F4) 61
8.5 AUTOZERO (F5) 62
8.5.1 Autozero (F5-1) 62
8.5.2 Test (F5-2) 64
8.6 OUTER PLATE READING OFFSET (F6) 65
8.6.1 Search fine reading offset (F6-1) 65
CONTENTS
8.6.2 Adjust cuvette rough offset (F6-2) 66

8.7 FILTER WHEEL TEST (F7) 67
8.7.1 Test FS home repeatability (F7-1) 67
8.7.2 Test filter wheel offset + peak (F7-2) 68
8.8 CLEAR ERRORS (F8) 70
8.9 STATUS OF CUVETTES (F9) 70
8.10 G AND Z CUVETTES SELECTION SHORTCUTS 71
9 WASHINGS (F5) 73
9.1 WASHINGS MENU 73
9.2 WASH POSITION (F1) 74
9.3 EXECUTE WASHES (F2) 74
9.4 FILL WASH CUVETTE (F3) 75
9.5 STARTUP (F4) 75
9.6 SPECIAL PUMP TESTS (F5) 75
9.6.1 Pumps test (F5-1) 76
9.6.2 Fill hydraulic tubes + Pumps self test (F5-2) 77
9.6.3 Empty tubes (F5-3) 78
9.6.4 Check residues (F5-4) 78
9.6.5 Adjust pumps (F5-5) 79
9.7 WASH NEEDLE (F6) 80
9.8 WASH STATION TEST (F7) 80
9.9 CLEAR ERRORS (F8) 80
9.10 RINSE CUVETTES (F9) 80
10 SYSTEM PARAMETERS 81
10.1 EDIT PARAMETERS (F7) 81
10.2 PARAMETERS PAGES 82
10.3 FIND PARAMETER (F5) 83
10.4 BACKUP PARAMETERS (F6) 83
10.5 RESTORE PARAMETERS (F7) 83
10.6 SAVE THE PARAMETERS LIST AS A TEXT FILE 84
11 ADJUSTMENTS 85
11.1 A/D VOLTAGE REFERENCES ADJUSTMENT 85
11.2 REACTION PLATE TEMPERATURE ADJUSTMENT 86
11.3 OPTICAL OFFSET AND GAIN ADJUSTMENT 87
11.3.1 Necessary tools 88
11.3.2 Offset adjustment 88
11.3.3 Gain adjustment 88
11.3.4 Cuvettes selection shortcut 89
11.3.5 Interference filters 89
11.3.6 Readings out of range 89
11.4 FILTER WHEEL ADJUSTMENT 90
11.4.2 Optical home switch adjustment 90
11.4.3 FS belt adjustment 91
11.4.4 Offset adjustment 91
11.5 REACTION PLATE BELT ADJUSTMENT 91
11.5.2 OP belt tightening 91
11.5.3 Access to the OP motor screws 92
11.6 NEEDLE VERTICAL ADJUSTMENT IN THE WASH WELL 93
11.7 WASH STATION DOWN ADJUSTMENT 94
11.7.1 Rough automatic calibration 94
11.7.2 Fine calibration 94
11.8 ADJUSTMENT OF THE COVER DETECTION SWITCH 94
12 SERVICING 95
12.1 LAMP REPLACEMENT 95
12.2 SAMPLE TRAY REPLACEMENT 96
12.3 SINGLE REACTION CELL REPLACEMENT 98
12.4 REACTION ROTOR REPLACEMENT 99
12.5 NEEDLE REPLACEMENT 101
12.6 INTERFERENCE FILTERS REPLACEMENT AND EQUALIZATION 103
12.7 VACUUM PUMP REPLACEMENT 105
12.8 VACUUM PUMP WEARING PARTS REPLACEMENT 106
12.8.1 HumaStar 100 106
12.8.2 HumaStar 200 107
12.9 PERISTALTIC PUMP HEAD REPLACEMENT 108
12.10 DILUTER REPLACEMENT 108
12.11 DILUTER SEALING GASKET REPLACEMENT 111
12.12 SAMPLING ARM REPLACEMENT 111
12.13 LEVEL SENSOR WIRING REPLACEMENT 112
12.14 EXTERNAL TANKS FLOATS REPLACEMENT 113
12.15 OPTICAL PREAMPLIFIER REPLACEMENT 114
12.16 CPU BOARD REPLACEMENT 118
13 FIRMWARE UPDATING EPROMS REPLACEMENT 119

13.1 EPROMS REPLACEMENT COMPILATION CHANGE 119
CONTENTS
13.2 EPROMS REPLACEMENT VERSION CHANGE 120

13.3 REPLACEMENT OF VERY OLD EPROMS DATA SYNCHRONIZATION 121
14 TROUBLESHOOTING 123
14.1 ANALYZER DOESN'T CONNECT 123
14.2 BAD PRECISION OF OPTICAL READINGS 124
14.2.1 Noise on the optical signal 125
14.2.2 Imprecision of the reaction plate positioning 125
14.2.3 Imprecision of the filter wheel positioning 125
14.2.4 Dispensation problems 125
14.2.5 Incorrect vertical positioning of the needle 125
14.3 BAD REPEATABILITY OF AUTOZERO, UNSTABLE OPTICAL SIGNAL 126
14.4 REACTION PLATE TEMPERATURE OUT OF CONTROL 126
14.5 DIRTY AND QUICKLY EXCLUDED REACTION CUVETTES 128
14.5.1 First checks 128
14.5.2 Check the reaction cuvettes 128
14.5.3 Check the cause of the high absorbances 128
14.5.4 Execute the pump test 129
14.5.5 Execute the cuvettes special wash 130
14.6 DROPLET FORMS ON NEEDLE TIP 130
14.6.1 Droplet formes at the end of the needle tip 130
14.6.2 Droplet hangs at the side of the needle 131
14.7 ABERRANT/NULL RESULTS, REAGENT BOTTLES WRONGLY DETECTED
FULL 131
14.8 ERROR "NEEDLE SHOCK DETECTOR IS STUCK" 131
15 PERIODICAL CHECK-UP, SERVICE PROCEDURE 133

15.1 TWELVE MONTHS PROGRAMMED MAINTENANCE 133
15.1.1 Update firmware and software 133
15.1.2 Cover 133
15.1.3 Lamp 133
15.1.4 Sampling needle 133
15.1.5 Wash station needles 133
15.1.6 Wiring, connectors 134
15.1.7 Hydraulic tubes, floats 134
15.1.8 Diluter 134
15.1.9 Pumps 134
15.1.10 Reagents cooling 135
15.1.11 Sample plate 135
15.1.12 Reaction plate cuvettes 135
15.1.13 Test and adjustment procedures in the service menu 135
15.1.14 Diluter and pipetting 136
16 SYSTEM PARAMETERS LIST 137

16.1 EPROM PARAMETERS TABLE 137
16.1.1 Inner plate (IP) motor 137
16.1.2 Outer plate (OP) motor 138
16.1.3 Filters selection (FS) motor 138
16.1.4 Sampling needle (SN) motor 138
16.1.5 Diluter syringe (DS) motor 139
16.1.6 Needle rotation (RN) Motor 140
16.1.7 Wash station (AN) motor 140
16.1.8 Motor speeds, home tolerances 141
16.1.9 Pumps 142
16.1.10 Various parameters 143
16.1.11 Barcode 144
16.1.12 Level sensor, floats 144
16.1.13 Temperatures 146
16.1.14 Dilutions, pipetting 146
16.1.15 Reading 147
17 ERROR CODES 149

17.1 HI SOFTWARE ERROR CODES 149
17.2 FIRMWARE EXECUTION ERROR CODES 154
17.2.1 Execution errors 155
17.2.2 Resources errors 155
17.2.3 Off-line predilutions errors 155
17.2.4 Errors caused by firmware/software mistakes 156
18 HI SOFTWARE INSTALLATION/UPDATE 157

18.1 SETTINGS 157
18.2 HI SOFTWARE UPDATING RELEASE 0.4X 157
18.2.1 Logging on 157
18.2.2 Creation of a backup copy of the data folder 158
18.2.3 Installation of the new software 158
18.2.4 Installation steps 158
18.3 HI DATA FOLDER 159
18.4 COMPATIBILITY WITH WINDOWS 7 160
18.5 DEVICE DRIVERS 160
CONTENTS
19 LIS ASTM INTERFACE SOFTWARE 161
20 SERVICE SCHEMATICS 163

20.1 INSTRUMENT BLOCK DIAGRAM 163
20.2 CPU BOARD LAYOUT 164
20.3 POWER BOARD LAYOUT 165
20.4 SAMPLING ARM BOARD LAYOUT 166
20.5 HIGH VOLTAGE WIRING 167
20.6 LOW VOLTAGE WIRING 168
20.7 INTERNAL RS232 SERIAL CABLE 174
20.8 OPTICAL PREAMPLIFIER CABLE 174
20.9 SAMPLING ARM CABLE 174
20.10 SAMPLING ARM CABLE CONSTRUCTIVE SCHEMA 175
20.11 HYDRAULICS DIAGRAM HUMASTAR 100 176
20.12 HYDRAULICS DIAGRAM HUMASTAR 200 177
20.13 HYDRAULICS PANEL LAYOUT (FRONT SIDE) 178
20.14 HYDRAULICS PANEL LAYOUT (REAR SIDE) 179
20.15 PUMPS PLATE HYDRAULICS MANIFOLD 180
20.16 WASH STATION 181
20.17 WASH STATION HYDRAULICS MANIFOLD HUMASTAR 100 182
20.18 WASH STATION HYDRAULICS MANIFOLD HUMASTAR 200 183
20.19 FLOATS AND TUBES CONNECTION ASSEMBLY 184
20.20 FLOATS AND TUBES ELECTRICAL CONNECTIONS 185
20.21 REFRIGERATION PLATE 186
20.22 MAIN POWER INPUT PANEL 187
20.23 CENTRAL MECHANICAL ASSEMBLY 188
20.24 MECHANICAL DESIGN INTERNAL VIEW 191
20.25 FRAME BASE 192
SAFETY INSTRUCTIONS 9
1 SAFETY INSTRUCTIONS
1.1 Introduction
This manual must be available to the service personnel. For accurate service, use
and maintenance, please read the following instructions carefully.
In order to avoid damage to the instrument or personal injury, carefully read
the GENERAL SAFETY WARNINGS, describing the appropriate operating pro-
cedures. Please contact your HUMAN authorised local Technical Service in the
event of instrument failure or other difficulties with the instrument.
1.2 User Warranty

HUMAN warrants that instruments sold by one of its authorised representa-
tives shall be free of any defect in material or workmanship, provided that this
warranty shall apply only to defects which become apparent within one year
from the date of delivery of the new instrument to the purchaser.
The HUMAN representative shall replace or repair any defective item within this
warranty period at no charge, except for transportation expenses to the point
of repair.
This warranty excludes the HUMAN representative from liability to replace
any item considered as expendable in the course of normal usage, e.g.: lamps,
valves, syringes, glassware, fuses, tubing etc.
The HUMAN representative shall be relieved of any liability under this warranty
if the product is not used in accordance with the manufacturers instructions,
altered in any way not specified by HUMAN, not regularly maintained, used with
equipment not approved by HUMAN or used for purposes for which it was not
designed.
1.3 Intended Use of the Instrument

The instrument is intended for laboratory application by professional users. It
must be operated in perfect technical conditions, by qualified personnel, in such
working conditions and maintained as described in this manual, in the GENERAL
SAFETY WARNINGS. This manual contains instructions for qualified professional
operators.
10
1.4 General Safety Warnings

Use only chemical reagents and accessories specified and supplied by HU-
MAN and/or mentioned in this manual. Place the product so that it has proper
ventilation.
The instrument should be installed on a flat, stationary working surface, that is
free of vibrations.
Do not operate in area with excessive dust.
Operate at temperature and at a humidity level in accordance with the specifi-
cations listed in the User Manual.
Do not operate this instrument with covers and panels removed.
Use only the power cord specified for this product, with the grounding conduc-
tor of the power cord connected to earth ground.
Use only the fuse type and rating specified by the manufacturer for this
instrument.
The use of fuses with improper ratings may pose electrical and fire hazards.
To avoid fire or shock hazard, observe all ratings and markings on the
instrument.
Do not power the instrument in environments that are potentially explosive or
at risk of fire.
Prior to cleaning and/or performing maintenance on the instrument, switch off
the instrument and remove the power cord.
Only cleaning materials described in this manual may be used, as other mate-
rials may damage parts. It is recommended to always wear protective clothing
and eye protection while using this instrument.
All warning symbols that appear in this manual must be carefully observed.
1.5 Disposal Management Concept

The applicable local regulations governing disposal must be observed. It is
the users responsibility to arrange for proper disposal of the individual
components.
All parts which may contain potentially infectious materials must be
disinfected by suitable, validated procedures (autoclaving, chemical treatment)
prior to disposal. Applicable local regulations for disposal must be carefully
observed. The instruments and electronic accessories (without batteries, power
packs etc.) must be disposed of according to the applicable local regulations
for the disposal of electronic components.
Batteries, power packs and similar power sources must be removed from
electric/electronic parts and disposed of in accordance with applicable local
regulations.
HumaStar 100/200 | Service manual

SAFETY INSTRUCTIONS 11
1.6 Biohazard Warning

Analytical instruments for in vitro diagnostic application involve the handling
of human samples and controls which should be considered at least potentially
infectious. Therefore every part and accessory of the respective instrument
which may have come into contact with such samples must equally be consi-
dered as potentially infectious.
The BIOHAZARD warning label must be affixed to the instrument prior to first
use with biological material!
FIGURE 1
Biological Hazard Symbol
1.7 Instrument Disinfection

Before performing any servicing on the instrument it is very important to tho-
roughly disinfect all possibly contaminated parts. Before the instrument is
removed from the laboratory for disposal or servicing, it must be decontamina-
ted. Decontamination must be performed by authorised well-trained personnel,
and in observance of all necessary safety precautions.
12

THE ANALYZER HUMASTAR 100/200 13
2 THE ANALYZER HUMASTAR 100/200
2.1 General description
HumaStar 100/200 performs both clinical chemistry and turbidimetric immu-

nochemistry tests. The compact and fully random automated analyzer is espe-
cially suited for medium- and small-size laboratories.
2.2 Main characteristics
Small desktop space, 680 x 760 x 550 mm (width x depth x height). 940 mm
height with open top cover.
Light weight, 51 kg.
127 tests per hour, typical reagent mix.
Method, needle and cuvette management of incompatible tests.
Easy PAUSE request to add samples and reagents. Automatic recovery from em-
pty reagent bottles. Multiple reagent bottles management.
Extends range of kinetic tests through a dynamic processing of the readings.
Simple access to hydraulic pumps system for easy maintenance.
Run-time sample predilution in reaction well. Automatic standards predilution.
2.3 Installation
2.3.1 SHIPPING AND DELIVERY

The new analyzer and its accompanying accessories have been shipped in two
separate containers designed to provide adequate protection during transport
under normal conditions.
2.3.2 PACKAGING
The analyzer is wrapped in stretch-plastic and securely fixed within a strong
wooden container mounted on a lift-pallet.
The required accessories are placed in a well-packed, heavy cardboard carton.
14
2.3.3 RESPONSIBILITIES
The shipment of the analyzer generally is the responsibility of the distributor
and delivery is often made in person by an agent of the distributor.
FIGURE 2
Shipment damages
If the shipment arrives by private or commercial carrier, immediately inspect the

condition and if there is any damage to either containers report it immediately
to both transporter and distributor.
If the damage is extensive, it may be best to refuse the shipment to avoid any
doubt in the attribution of responsabilties.
2.3.4 PRIOR TO SETTING-UP

Prepare a location for your analyzer based on maximum laboratory efficiency
and adequate work space. Keep in mind the patterns of work and staff circulati-
on to ensure a trouble-free lab operation.
2.3.4.1 Site
The laboratory bench for the analyzer work-station should be a level surface of
solid construction to avoid vibration.
A space of 15 cm on both sides and behind the instrument is the minimum re-
quirement to allow adequate ventilation.
An additional work area on one or both sides of the instrument will contribute
greatly to the work efficiency of the technician during operation.
FIGURE 3
Workbench

If sufficient space is available a surface 90 cm deep by 200 cm in working width

will allow a generous surface for the analyzer and the necessities of work (e.g.
tubes, reagents, samples, calibrators, controls, pipettes, user manuals but also
monitor, keyboard, mouse and printer if necessary).
2.3.4.2 Environment
The location of the analyzer should be dust-free, away from drafts, heat sources
and direct sunlight.
Satisfactory operations may be conducted with temperature ranges from 16C
to 30C and with a variation during the testing process not to exceed 2C. Tem-
peratures outside this range may cause erroneous operation.
Air conditioning may be required to ensure result quality if temperatures exceed
these limits.
Relative humidity should not fall below 10% or rise above 80% with no conden-
sation.
Ensure that the electromagnetic standards are met. Refer to European directive
on electromagnetic compatibility (see Document 89/336/CEE of 03/05/89).
2.3.4.3 Storage
If for any reason the instrument has been subjected to prolonged storage under
unfavorable conditions a revision by specialized technicians may be required be-
fore proceeding with installation.
2.3.4.4 Unpacking
The analyzer arrives in a wooden container, the top of which is secured with
screws.
The four walls are fixed to the lift-pallet with screws at the bottom line. Taking The top cover should be lifted
off the bottom line screws allows to lift up the complete box to get easy access up by two persons.
to the analyzer inside.
FIGURE 4
Wooden container
16
As you have already been told, and as HUMAN suggests, it is best to wait for the
arrival of a representative of the distributor to remove the analyzer from the
container (keep the wooden container in case you need to return the analyzer
for adjustment or repairs).
FIGURE 5
Shipment contents
However, the cardboard carton of miscellaneous items and accessories may be

opened and checked for the following:
- User manual,
- Software installation CD,
- Water tank,
- Waste tank,
- Cleaning solution tank,
- Tank connections group (boxed),
- Accessories kit (boxed).
See also complete "Shipment list" provided.
2.3.5 INSTALLATION
After selecting an appropriate site for the instrument and for the PC (inclusive
monitor, keyboard and mouse), you can proceed with the necessary connections.
Connections required are located in two points on the sides of each instrument.

2.3.5.1 Left side
FIGURE 6
Left side connections
Liquid sensors connection plug snap-on connectors for water tank, cleaning so-
lution tank and waste tank.
2.3.5.2 Right side
FIGURE 7
Right side connections
USB port type B; power cord fitting (incuding fuses compartment).

18
2.3.5.3 PC connections
FIGURE 8
USB connections type A
Connect the USB mouse to a PC port (1).

Connect the USB touch-screen (optional) to a PC port (1).
Connect the USB keyboard to a PC port (1).
FIGURE 9
VGA connection
Connect the monitor to PC with a VGA cable (2).
FIGURE 10
Power connection
Connect a power cord to the monitor (3) and to the power outlet (4).
Connect a power cord to the PC (3) and to the power outlet (4).

FIGURE 11
Schuko connection
Adaptors may be required for

local power outlets.
Typically instruments are delivered with 'Schuko' connections (4).
2.3.5.4 Instrument connections
FIGURE 12
USB cord
FIGURE 13
USB connection type B
Connect a USB cord (5) to the PC port (1) and to the analyzer port (6).
Connect a power cord to the instrument (3) and to the power outlet (4).
20
2.3.5.5 Hydraulic connections
FIGURE 14 Place the three tanks below the work

Tank positions surface. Water and cleaning should be
positioned as high as possible under the
work surface.
Waste should be positioned as low as
possible.
Position connecting tubes as straight as

FIGURE 15 possible to avoid the creation of air bub-
Connection tubes bles.
FIGURE 16 Insert and rotate the BLACK connector

Hydraulic connections to secure the three liquid level sensors
(2).
Hydraulic tubes have easy-to- Connect the three tanks to the corre-
use snap-on connectors each sponding hydraulic tube connections
with a special valve to prevent li- on the analyzer.
quid loss when disconnecting Hydraulic connections are color coded
tubes. as follows:
Ensure that the metal tab of - BLUE: Water (3).
each connector is released - GREEN: Cleaning solution (4).
and ready to be snapped in place - RED: Waste (5).
to ensure a safe attachment.
The presence of bubbles in
the system may be caused by
liquid leakages. Check that the
connectors are correctly snapped
in place.

2.3.6 MOVING
The movement of an instrument after it has been put into operation should be
handled with extreme care. One person should never try to move an analyzer
alone. If the instrument needs to be moved over a large distance in or out of the
laboratory please follow the instructions in the sequence below:
- Execute the "Empty entire system" procedure (see User Manual / Mainte-
nance).
- Switch-off the analyzer, the computer and the reagent refrigeration, and
disconnect all lines and tubes connected to the instrument. Be sure to avoid
contact with potentially infectious liquid waste when disconnecting tubes.
- Fix the sampling arm in the uppermost position using the foam protection
tube provided with the shipment.
- At least two persons are now required for moving the analyzer. Lift the in-
strument slowly holding the metal base and in such a way that the cover
remains in the closed position.
- When the analyzer has been located in its new position, reconnect all lines
and tubes according to the installation procedure contained in this manual.
2.4 Analyzer Components
2.4.1 FUNCTION GROUP IDENTIFICATION
1. Sampling arm. FIGURE 17

2. Needle wash station. Function groups 1
3. Reagent tray.
4. Sample tray.
5. Cuvette rotor with ope-
ning for cuvette access.
6. Optical group.
7. Cuvette wash station
(shown for HumaStar
200).
22
FIGURE 18 8. Diluter syringe.

Function groups 2 9. Peristaltic pumps
(shown for HumaStar
200).
10. Pinch valve
2.4.2 MECHANICAL FUNCTIONS

The principal mechanical movements of HumaStar 100/200 are powered by
stepper motors which are activated when the analyzer is switched on and re-
main on until power-off or stand-by. The liquid movements are controlled by
peristaltic pumps and vacuum pumps powered by direct current motors and
activated when required.
2.4.3 SAMPLING ARM
FIGURE 19
Sampling arm
Rapid action sampling arm. (Up, down and rotational movement, controlled by
stepper motors with optical limit switches.)

High-precision coated sampling needle.

Liquid level sensor.
Vertical needle shock sensor.
A single arm is positioned to serve all sampling functions (reagents, samples

and dilutions).
The needle stroke permitted by the vertical movement of the sampling arm al-
lows the use of sample tubes of up to 100 mm in height.
The arm rotates 360 beginning and ending at the midpoint of the reagent tray.
During this cycle the needle passes over all reagent bottles, the reaction cells
and the sample tubes or cups. Test mix preparation begins first with the selec-
tion of the reagent (R1) to be used. Then, depending on the type of test to be
performed, a sample (S) or a second reagent (R2) is collected in the sequence
required for that test. Reagent(s) and samples are deposited in a reaction cell in
reverse order. This action mixes the liquids as they are deposited. The sampling
needle is washed after each individual pipetting.
2.4.4 NEEDLE WASH STATION
FIGURE 20
Needle wash station
Following each sampling operation the needle is washed internally and exter-
nally to remove reagent and sample residues.
24
2.4.5 REAGENT TRAY
FIGURE 21
Reagent tray
Removable tray (29 bottle positions for reagents and 1 for diluent).
Power independent refrigeration.
Refrigerated plate.
Independent refrigeration permits reagents to remain on-board when the ana-

lyzer is switched off. Multiple assortments of reagents can be prepared in ad-
vance of testing needs using additional trays.
This section consists of a recessed semicircular compartment adjacent to the
rotating sample arm. The bottom of the compartment is lined with a continuo-
us refrigerated plate. When in position the tray permits bottles to rest directly
on the plate. Refrigeration is provided by three 30W Peltier cells mounted direct-
ly under and in contact with the plate. A heat sink and fans located below cool
The removable tray is suitable the lower heated surfaces of the Peltier cells.
for bottles of either 50 ml or
20 ml.
2.4.6 SAMPLE TRAY AND CUVETTE ROTOR
FIGURE 22
Sample tray and cuvette rotor

Sample tray (inner plate)

Removable 60 position sample tray (tubes of 12-13 mm or cups of 0.5-1.5 ml).
Optional: Tray with 20 small and 20 large diameter positions to accommodate
20 tubes of 12-16 mm (using adjustable clips) or 20 cups of 3.5 ml.
Cuvette rotor (outer plate)

80 reaction cells.
Plastic rotor.
Rotor safety cover.
High quality reaction cells permit the execution of 30.000 tests before replace-
ment is required.
The rotational movements of both components are controlled by stepper mo-
tors with optical limit switches.
The cuvette rotor aligns a reaction cell to receive the collected test mix for incu-
bation. Needle access to individual cells is through an opening in the rotor cover.
The rotor safety cover ensures safe management of dangerous liquids, protects
the near environment and lessens the chance of contamination. During the on-
going testing process results are read as individual cells align with the optical
group. Test readings are taken over the entire reaction process. As the testing
process continues, programmed wash procedures are performed to the cells just
under the wash station.
The incubation temperature is controlled at 37 C by the means of a heating
strip, a temperature sensor and a thermostate.
2.4.7 OPTICAL GROUP

FIGURE 23
Optical group
26
Halogen lamp assembly with heat sink.

Rotating filter disk.
8/9 interferential filters of various wavelengths.
2 focusing lenses.
Photoelectric detector.
Signal amplifier.
The execution of 20 readings for each test ensures full monitoring of test results.
A self contained unit with a rotating disk positioned to enable an interferential

filter of the wavelength required to be placed in the optical path between the
halogen light source, the aligned reaction cell and the photoelectric detector for
the test reading.
Optical group diagram
FIGURE 24
Optical group diagram
2.4.8 CUVETTE WASH STATION
2.4.8.1 Needle mounting
FIGURE 25
Needle mounting HumaStar 100

FIGURE 26
Needle mounting HumaStar 200
2.4.8.2 Wash station
FIGURE 27
Wash station HumaStar 200
Shown for HumaStar 200 (safety cover removed).

For HumaStar 100 the needles and tubes in position 3 and 6 (right to left) are not
installed.
HumaStar 100
10 wash needles (4 dispensation, 5 aspiration, 1 drying)
HumaStar 200
13 wash needles (5 dispensation, 7 aspiration, 1 drying)
28
2.4.9 HYDRAULIC SYSTEM
2.4.9.1 Syringe assembly
FIGURE 28
Diluter and pinch valve
These elements provide aspiration and dispensation functions central to the

entire hydraulic system. During operation the sampling needle is immersed in
the liquid (reagent, sample, diluent) to be collected and the plunger in the di-
luter moves backward to aspirate the specified amount of liquid. The sampling
needle then moves to its destination (tube, cup, reaction cell) and the plunger
moves forward to dispense that volume of liquid. Following completion of each
liquid movement the sampling needle is rinsed internally by water diverted
through the diluter and externally by water diverted through the needle wash
station.
Vacuum pumps: Located in the rear of the panel behind the manifold.
Diluter syringe: Self-contained micro-metering pump with long-life plun-
ger, stepper motor and optical limit switch.
Pinch valve: To divert the flow of water for either the internal or the
external needle wash.

2.4.9.2 Pump set
FIGURE 29 FIGURE 30
Peristaltic pump Vacuum pump
The pump set provides the power for all washing functions.
6 (HumaStar 100) / 8 (HumaStar 200) self-priming peristaltic pumps are located
in the hydraulic panel. (The peristaltic pumps provided with this analyzer have
replaceable cassettes with neoprene tubes that ensure long life.) Two high-effi-
ciency vacuum pumps are located inside the analyzer.
2.4.9.3 Liquid flow
FIGURE 31
Manifold
This element collects and channels all the ingoing flow of water and cleaning
solution and the outgoing flow of waste between the analyzer and the external
liquid tanks. Snap-on connectors and release buttons permit easy and rapid at-
tachment and removal. Safety valves are provided to avoid liquid loss during the
operations.
30
2.4.9.4 Schematic diagram of the hydraulic system

HumaStar 100 does not have The diagram on the following page shows how the elements of the hydraulic
washing needles / peristaltic system link to perform the liquid functions required (i. e. sampling needle wash,
pumps 3 and 6. cuvette wash, waste disposal and the control of liquid flow).
FIGURE 32
Hydraulic system

COMPONENT PARTS 31
3 COMPONENT PARTS
3.1 CPU board
FIGURE 33
CPU board
A: Firmware EPROM1.
B: Firmware EPROM2.
C: J10, Reaction plate temperature sensor connector.
D: J6, Optical signal connector.
E: J1, Serial communication flat cable connector.
F: Instrument parameters EPROM.
3.2 Power supply board
FIGURE 34
Power board
OP-IP: Outer plate Inner plate motor control.

FS-RN: Filters selection Needle rotation motor control.
SN==: Sampling needle Not used motor control.
DS-AN: Diluter syringe Wash station motor control.
32
3.3 Level and shock sensor board
FIGURE 35
Level and shock sensor board
A (Red): Level sensor connection

B (Black): Ground connection
3.4 Power supplies 24 V and 12 V
FIGURE 36
Power supplies
A: Instrument power supply. Input 100-240 Vac, 50-60 Hz.

Output 24Vcc 500W.
B: Refrigerated plate power supply.
Input 100-240 Vac, 50-60 Hz.
Output 12Vcc 40W.
Output voltage to be adjusted from 12.1 Vcc to 12.2 Vcc.

COMPONENT PARTS 33
3.5 Ground connections
FIGURE 37
Ground connection 1
Ground terminal
The ground terminal combines:

- Connection to main plug.
- Connection to central mechanical assembly.
FIGURE 38
Ground connection 2
The proper grounding is very

important for the correct ope-
ration of the photometer pre-
amplifier and the liquid level sen-
sing.
Central mechanical assembly ground connection

34
3.6 Optical lamp
FIGURE 39
Optical lamp
A: Lamp fastening knob.

B: Lamp connector.
C: Lamp holder.
3.7 Hydraulics Panel
3.7.1 FRONT SIDE
FIGURE 40
Hydraulics panel, front side

COMPONENT PARTS 35
D1-D6: Dispensing pumps for wash station needles 1-6.

(HumaStar 100 is not having D3 and D6.)
AW: Aspiration pump to wash needles mounting.
DW: Dispensing pump to wash needles mounting.
DS: Complete diluter assembly.
EV: Valve switching internal (ON) / external (OFF) needle wash, using DW.
Spare head for peristaltic pump: Peristaltic pump head.
3.7.2 REAR SIDE
FIGURE 41
Wiring and tubing
FIGURE 42
Wiring
FIGURE 43
Electrical connections
36
Electrical Description Device destination

connector
PM2B Valve switching internal (ON) / external EV
(OFF) needle wash.
PM1 Needle wash dispensing pump. DW
MDS Diluter syringe stepper motor. DS motor
SDS Diluter syringe limit switch. DS limit switch
interface board
PM2 Needle wash aspiration pump. AW
EV1 EV6 Wash station dispensing pump 1-6. D1-D6 (HumaStar
100 doesn't have D3
and D6.)
FIGURE 44
Diluter and valve tubing
3.7.3 DILUTER AND VALVE TUBING

A Input from the needle wash dispensing pump.
B Outout to the external needle wash nozzle.
C Wash input to the diluter.
D Wash output from the diluter to the sampling needle.
E Output to the sampling needle.
EV Valve switching internal (ON) / external (OFF) needle wash.

COMPONENT PARTS 37
3.7.4 MANIFOLD
FIGURE 45
Hydraulic panel manifold
The hydraulic connections are feeding the pumps with the system solution.
3.8 Wash station

Wash station figures 46 to 50 show HumaStar 200 wash station.
FIGURE 46
Wash station unit
38
FIGURE 47
Wash station wiring
FIGURE 48
Needles manifold and needles
assembly, top view
FIGURE 49
Needles assembly
FIGURE 50
Manifold to hydraulics panel
tubing
A = Aspiration
B = Dispensation

COMPONENT PARTS 39
Wash station up/down limit switches
U = UP limit switch.
D = DOWN limit switch.
FIGURE 51
Wash station up/down limit
switches
3.9 External tanks
FIGURE 52
External tanks
Floats and tubes connection assembly

A Wash solution tank, 2 liters
B Waste tank, 20 liters
C System solution tank, 20 liters
40
The hydraulic tubes have snap-in connectors. They can be unplugged pressing
on the lateral metal button.
FIGURE 53
Floats and hydraulic tubes
connectors
FIGURE 54
Snap-in connector
1. Floats connector
Waste float (open = full)
System and wash solution floats (open = empty)
2. BLUE System solution tube
3. GREEN Wash solution tube
4. RED Waste tube

TERMINAL PROGRAM 41
4 TERMINAL PROGRAM
4.1 How to use the terminal program

You can have direct access to the HumaStar 100/200 for service or diagnostic
purposes, using the TERMINAL program.
FIGURE 55
TERMINAL main screen
To access to the service TERMINAL you must be logged on to the HI software as

a Service or Installer user.
Press the CLOUD icon in the lower middle part of the screen and select
TERMINAL to open it.
The tab Log can be used to save a parameters list (see 10.6 Save the parameters
list as a text file).
The tabs Printer Buffer and Settings ar not active.
To operate the TERMINAL, touch the TERMINAL window or click with the mouse
inside the TERMINAL window to focus on it. When the TERMINAL window is fo-
cused, it is framed by a thin black line.
With the right mouse key, or touching the screen for two seconds, the
SCREENSHOT/PRINTSCREEN window will be opened:
- Select to save the current screen as a JPG
file.
- Select to print the current screen or to
Press the CAPS LOCK key to

show a preview first. A printer has to be installed before. set the upper case on the key-
board. This is mandatory for the
TERMINAL operation.
42
4.2 Service menu

The command OS allows to access to the SERVICE MENU.
All submenus are accessible from here, pressing the appropriate function key on
the keyboard (the mouse pointer is visible but deactivated).
FIGURE 56
Service menu

HARDWARE TEST MENU (F1) 43
5 HARDWARE TEST MENU (F1)

TERMINAL OS F1 HARDWARE TEST.
Each line in the table in the middle of the screen represents a particular stepper
motor. Use the UP and DOWN arrow keys to select a motor.
FIGURE 57
Hardware test menu
44
F1 MOTOR ZERO To reach the home position of the selected motor.

Shows an "H" followed by the number of lost steps
(ideally "0") on the right side of the motor line.
When the home position is reached, the appropriate
green LED above the connectors J10 and J11 on the
power supply board switches on.
F2 MOTOR FWD To move the selected motor forward.
F3 MOTOR BWD To move the selected motor backward.
If F1, F2 or F3 causes an error of the motor movement,
"S.Err" is shown on the right side of the motor line.
F4 PUMP,VALVE,LAMP To go to the pumps, valve and lamp test.
F5 DISPLAY INPUTS To activate the continuous display of the inputs.
M To continuously move the selected motor forward and
backward, for stress test.
... To edit system parameters, press the "." key three
times.
5.1 Columns of the hardware test table

MOT Motor number.
DESCRIPTION Motor description.
ENAB To enable/disable the motor current (0 = current off,
FREE / 1 = current on, HOLD).
SPEED Motor speed, in steps/second. This value is read, by
default, from the motor speed system parameter and
can be changed in the hardware test, only for dia-
gnostics, without affecting the normal work of the
analyzer. The lower the speed, the stronger the motor.
IX.STEPS Number of steps that will be executed with the F2
(forward) and F3 (backward) commands.
LOG.POS. To go to a logical position (see "5.2. Logical positions").
ABS.POS. Absolute motor position in steps. (-32768 = motor not
initialized.)
Every stepper motor needs 200 steps for one comple-
te revolution.
The diluter syringe can perform 2.600 step max.

5.2 Logical positions

INNER PLATE 1-60 or 1-40 to move the corresponding sample tube
under the sampling needle.
OUTER PLATE 1-80 To move the reaction cell 1-80 in the
reading position.
101-180 To move the reaction cell 1-80 under the
wash station needle 1 (the rightmost
needle).
201-280 To move the reaction cell under the
sampling needle.
NEEDLE ROTATION 1-29 (depending on the bottles configuration) to
rotate the needle over the corresponding reagent
bottle.
The other logical positions are the corresponding
system parameter numbers:
RNWASH 86 Wash needle well position.
RN1_OP 92 Reaction plate dispensing hole.
RN_IP0 90 External ring of sample plate.
RN_IP1 91 Internal ring of sample plate.
RNDILC 95 Diluent position.
RNWRAP 85 Wrap position.
It is a position, close to the anti-
clockwise stroke and outside of a
reagent bottle opening. It is used
by the software to decide how to
access to a reagent bottle, clockwise
or anti-clockwise.
FILTER SELECTION Logical positions 0-9 move to the corresponding
filter.
46
SAMPLING NEEDLE The logical positions are the corresponding system pa-
rameter numbers:
SN1HIG 44 Needle high, 5mm over the rea-
gents bottles.
SN1MID 43 Needle 5mm over the sample tubes.
SN1LOW 42 Needle 5mm over the reaction cells.
SN1REA 49 Needle at the bottom of the reagent
bottles.
SN1WEL 46 Needle inside the wash well for
internal needle wash.
SN1PTU 51 Needle at the bottom of sample
primary tubes.
SN1CUP 50 Needle at the bottom of sample
cups inserted on the cups adapter.
SN1CU2 54 Needle at the bottom of sample
cups on the inner ring of the 20+20
sample tray.
SN1DS2 53 Needle inside the reaction cell for
the second dispensation.
SN1DLC 57 Needle at the bottom of the diluent
bottle.
WASH STATION The logical positions are the corresponding system
parameter numbers:
ANHOME 0/111 Home position.
ANHIGH 0/112 Under the home position
for fast home search.
ANTUBE 1 Low immediately over the
OP reaction tube
ANWA2D 2 Down: quote for second pause
in aspiration.
ANWA1D 3/113 Down: quote for first pause in
aspiration.
Up: quote for restart of aspira-
tion.
ANWASP 4/115 Needle at the bottom of the re-
action cells for aspiration.
DILUTER SYRINGE The logical position indicates the microliters (l) to
dispense.

5.3 Pumps, valve and lamp test (F4)
FIGURE 58
Pumps, valve and lamp test
For testing the peristaltic

pumps, unmount the wash
arm and place the needles in a be-
Go with the cursor to the pump or valve to be activated and type the number of aker. This is to avoid flooding the
hundredths of second it must remain activated. reaction tray because the vacuum
The valve that switches the needle wash between the internal wash and the aspiration pumps are not wor-
external wash is parallel to the wash well aspiration pump. So the well dispen- king.
sation pump dispenses internally or externally according to the state of the as- When peristaltic pumps or va-
piration pump. cuum pumps are activated,
Activation of the wash well aspiration pump empties the wash well only. the appropriate red LEDs above
Activation of the needle wash dispensing pump performs an external wash only. the connectors J3 or J5 on the po-
The optical lamp is ON with 0 and OFF with 1. wer supply board are switching
on.
5.4 Continuous inputs display (F5)
FIGURE 59
Display inputs
48
Mot.L.Sw. Indicates the status of the eight home position sensors

(1=engaged, 0=free).
Level Sw. Indicates the status of the level sensor (1=no sense, 0=sense
level).
Level switches (left to right):
1 Liquid level sensing.
0 Vertical shock.
1 Not used.
1 Not used.
0 Waste tank (red).
0 System wash tank (blue).
0 Special wash tank (green).
1 Cover safety switch.
OP temp. Temperature of the OP reaction plate, in tenths of degrees
Celsius.
Reading Instant A/D reading of the optical group.
PWM R indicates the percent voltage supplying the heating
resistance of the outer plate temperature control (0-70 %).

MECHANICAL CALIBRATIONS MENU (F2) 49
6 MECHANICAL CALIBRATIONS MENU (F2)
6.1 Operations
The mechanical calibration allows to adjust the group of quotes that define all
the main operative points of the analyzer.
In the table the system parameters are listed that are affected in every calibra-
tion point.
The calibration points can be selected by direct address, typing the two digits of
the row, or with the PAGE UP and PAGE DOWN keys, for sequential access.
When one quote of the calibration point is temporary modified, it is shown in
reverse. With F2 SAVE POSITION, the new value is recorded and the quote value
returns normal.
When a calibration point has been saved with F2, on the far right a "v" character
appears.
Before access, the names of the involved parameters are shown in the table (see
FIGURE 60).
After the access to the calibration point, the values of the involved parameters
are displayed in the table.
FIGURE 60
Mechanical calibrations
50
--IP-- Column for inner plate parameter names and values.

--OP-- Column for outer plate parameter names and values.
--RN-- Column for needle rotation parameter names and values.
--SN-- Column for needle vertical parameter names and values.
--AN-- Column for aspiration needle parameter names and values.
--F6-- Column for special functions parameter names and values.
F1 CHECK POSITION Return home and check position.

F2 SAVE POSITION Record positions in the system parameters.
F3 CALIB. BAR CODE Not active (for future use).
F4 EDIT PARAMETERS Cell parameters edit.
F5 MOTORS HOME Search home for all the motors and return to po-
sition.
F6 SPECIAL FUNCT. Allow to check relative movements, levels, water
flow, etc.
Enabled only if the column F6 is not void.
Calling F4 EDIT PARAMETERS, the cursor is positi-
oned on the parameter listed in the F6 column.
Special functions are helpful UP, DOWN IP/OP MOVE UP and DOWN arrows move IP or OP motors step
in case of remote access to by step.
the instrument. LEFT, RIGHT RN MOVE LEFT and RIGHT arrows move RN motor step by
step.
+ - SN/AN MOVE + and move SN or AN motors down and up.
M MOTORS OFF Turns motors OFF. It is recovered with F5 MOTORS
HOME.
6.2 Calibration rows

21 calibration rows are defined, each one calibrating a specific mechanical posi-
The sample needle needs ap- tioning.
prox. 7 steps to move 1 mm.
The vertical collision flag in the REAGENT BOTTLES
sample arm starts moving 5 to 10 01 Sampling needle high, 4 mm over reagent position 1, large bottle.
steps before SHOCK is displayed. F6 checks the liquid level in the large reagent bottle.
02 Sampling needle low at the bottom of reagent position 1.
When touching the bottom (SHOCK displayed), move 10 steps up.
03 Sampling needle high, 4 mm over the last reagent position 29, small
bottle. F6 checks the liquid level in the small reagent bottle.

04 Sampling needle low at the bottom of reagent position 29.

05 Sampling needle low at the bottom of reagent position 1, cup.
DILUENT BOTTLE
06 Sampling needle high, 4 mm over diluent bottle.
F6 checks the liquid level in the large diluent bottle.
07 Sampling needle low at the bottom of diluent bottle.
NEEDLE WASH WELL

08 Sampling needle 5 mm over the wash well for vertical sampling needle
1 access.
F6 checks the needle rotation position over the wash well nipple and
the side position for the needle flush.
09 Sampling needle inside the wash well.
F6 checks:
- The needle internal wash inside the white nipple.
- The needle position over the nipple, inside the water drop (needle must
enter inside the drop down to the top of the white nipple).
- The external wash of the needle (the water jet has to hit the needle).
- The up movement to check if a droplet remains on the tip of the needle.
Important for tests using low sample volume (max. 4 l).
SAMPLE TUBES AND CUPS
10 Sample inner plate barcode offset.
F6 checks sample inner plate barcode offset.
Adjustment for sample position 1: The beam must meet the middle
of the tray handle.
Adjustment for inner ring: The beam must be in the
middle between positions 31 and 60.
11 Sampling needle 5 mm over sample primary tube 1.
F6 checks the liquid level in the primary tube 1.
12 Sampling needle at the bottom of the sample primary tube 1.
52
13 Sampling needle 5 mm over sample position 21 or 31 (first tube of inner

circle, depending on tray type).
F6 checks the liquid level in the sample cup in position 21 or 31.
14 Sampling needle at the bottom of sample cup 1 (cup placed on the
adapter).
15 Sampling needle at the bottom of the cup 21 (only for the 20+20
samples tray).
READING POSITION
16 Reaction cell 1 of the outer plate in the reading position.
Place cuvette 41 at the center of the cuvettes window. In this way,
cuvette 1 is placed in front of the reading position.
This position is roughly calibrated. The accurate calibration is made by
F6 SPECIAL FUNCTION.
F6 finds the fine offset of the reading (same as OS F4 READING TEST
F6-1 OP READING OFFSET-Fine offset).
WASH STATION, NEEDLE DISPENSATION
17 Wash needle 1 (the rightmost) over reaction cell 1.
F6 moves the needles down just over the reaction cells.
Used to calibrate precisely the reaction cells offset so that the cleaning
needle can descend in the next step inside the reaction cells.
In this position also the sampling needle must be just over the
dispensing position.
See also the description in "11.7. Wash station down adjustment".
18 Wash needles down, at the bottom of the reaction cells (ANWASP, one
step over the bottom contact).
In this calibration row the outer plate position cannot be calibrated.
F6 is a calibration procedure that finds out approximately the ANWASP
quote for correct aspiration. After auto-search of quote ANWASP with
the F6 key, on the right of row 18 the suggested value of ANWASP is
displayed. Use the lowest value (i. e. 208 as shown in FIGURE 61).
FIGURE 61
Wash needle down test result

19 Sampling needle down at the bottom of the reaction cell, inside the
dispensing hole, used by the 2nd dispensation.
F6 checks with the shock sensor the vertical position for the 1st
dispensation, to give a rough adjustment of the SN1DDS parameter.
- If there is shock within 5 steps from SN1DDS, the message "ErLow"
is displayed.
- If there is no shock within 20 steps, the message "NoShk" is displayed.
- Otherwise the message "SHOCK:nn" with the number of nn steps to
the shock is displayed.
FIGURE 62
Wash needle bottom test result
20 Sampling needle over the rotation wrap position.

It is a position close to the anti-clockwise stroke and outside of a
reagent bottle opening (between 15 and 16).
It is used by the software to decide how to access to a reagent bottle:
clockwise or anti-clockwise.
F6 does the following in three steps:
- Move the sampling needle to reagent bottle 15.
- Move the sampling needle clockwise to reagent bottle 16.
- Move the sampling needle counter-clockwise to the position bet-
ween 15 and 16.
21 Sampling needle low at the bottom of reagent bottle 1, tube.
54

MECHANICAL CHECKS MENU (F3) 55
7 MECHANICAL CHECKS MENU (F3)
FIGURE 63
Mechanical check
Some precision and stress tests are executed, using one or more motors at the
time.
The duration of test in seconds is predefined but changeable. (The tests are par-
tially long lasting.)
At the end of the test or when aborting the test by pressing ESC, a report of the
errors is displayed.
7.1 RN/IP check (F1)

Moves forward and backward the motors of the needle rotation and the inner
plate.
FIGURE 64
Correct example
FIGURE 65
Erroneous example
A loss of 1-2 steps is acceptable while bigger losses of steps are critical and erro-
neous (see FIGURE 65 above).
7.2 SN/OP check (F2)

Moves forward and backward the motors of the sample needle and the outer
plate.
A loss of 1-2 steps is acceptable while bigger losses of steps are critical and erro-
neous (see FIGURE 65 above).
56
7.3 AN/SN/OP check (F3)

Moves forward and backward the motors of the aspiration and sample needle,
and the outer plate.
At the end displays the difference between the nominal position and the real
position. A loss of 1-2 steps is acceptable while bigger losses of steps are critical
and erroneous (see FIGURE 65 above).
7.4 OP+FS home check (F4)

This is an important check for Executes the home search of the outer plate and filter selection motors starting
the co-operation of compon- from all their positions.
ents. After positioning of the outer plate, before starting the home search, the test
moves the wash station down and up.
800 cycles = 80 cycles of the outer plate * 10 filters.
7.5 ALL check (F5)

Executes the sequence of the F1, F2, F3 and F4 tests.
At the beginning requests the duration of the F1 to F3 tests (in seconds).
FIGURE 66
Report of the ALL function with
the results of the tests F1, F2, F3
and F4
Number of tests.
Number of total errors.
Total number of lossed steps for the filter wheel.
Number of AN (wash station up/down movement) errors.
Pre-home position (reduce speed to approach the outer plate home
sensor).
Position limit switch.
Number of lossed steps of every filter.

MECHANICAL CHECKS MENU (F3) 57
FIGURE 67
Speed reduction in the reference
zone
Losses of steps are not allowed in the reference zone (positions 61 to 67).
7.6 OP reading check (F6)

Test of the outer plate reading movement for all 80 cuvettes.
FIGURE 68
Outer plate reading test result
7.7 DS check (F7)

Stress test of the diluter syringe movement for 10 l, 20 l, , 990 l and 1000 l.
A variation of 1 step for each different movement is acceptable, 4 steps are erro-
neous.
FIGURE 69
Diluter syringe test result
58

OPTICAL READING TEST MENU (F4) 59
8 OPTICAL READING TEST MENU (F4)
FIGURE 70
Optical reading test
Filter (09) Type 0 to 9 to select the operating filter.

... To edit system parameters, press the "." key three times.
A/D in mV*10.
Real time display.
From last fixing with F1 (Set O.D. reference).
Column Description
1 Filter number
2 Filter wavelength in nm
3 Previous reading of the filter in Abs.
4 Current reading of the filter in Abs.
5 Difference in Abs. between the previous and the current readings
6 V = valid value,
Err = error, value out of valid range,
Dif = error, non repetitive,
Ovf = reading overflow.
7 Ratio between current autozero and factory initial value of the au-
tozero. It helps to evaluate the filters downgrade.
The factory initial autozero value is stored in TERMINAL with the
command OZ9.
60
8.1 Set O.D. reference (F1)
FIGURE 71
O.D. reference
Stores the current A/D reading value in the reference value.

The O.D. value is the optical density calculated between the current A/D value
and the stored reference value.
The column in parentesis shows following values for an autozero after a lamp
replacement:
F0: 25
F1-F8: 1000
8.2 Select cuvette (F2)
FIGURE 72
Cuvette selection
Type in the Reading Cuvette field the reaction cell number (1 to 80) which must
be used for the reading test. The default value is 32. In this position, the two
holes for the adjustment of the GAIN and the OFFSET of the optical preamplifier
are placed over the two trimmers to allow the access with a screwdriver.

8.3 Change cuvette F3)

Position the selected cuvette at the center of the cuvette replacement hole, for
cuvette inspection or replacement.
8.4 Read all filters (F4)

FIGURE 73
Reading of selected cuvette for
all filters
Read and display only all the autozero values of the filters, measured in empty
cuvettes (i. e. not real autozero, because measured in air).
Allows getting the reading of the selected cuvette for all filters.
Filter and cuvette = 0 performs a simulation of autozero (reading between the
cuvettes to eliminate the influence of cleanness of the cuvettes).
It is faster then F5 AUTOZERO because of 10 consecutive gap readings.
FIGURE 74
Reading of cuvette 32
62
If a cuvette 1 to 80 is selected, the reading is executed through the cuvette, so

the A/D value is lower because of the cuvette absorbance.
Then, the reading through cuvette 0 is higher.
8.5 Autozero (F5)
FIGURE 75
Autozero menu
Execute the autozero of the optical group.

At the end of the autozero processing, a confirmation is requested. 1 stores the
current values in the old values, 0 restores the old values.
Acceptable range for autozero values: 12.000 to 18.000.
8.5.1 AUTOZERO (F5-1)
FIGURE 76
Autozero

Column Description
1 Filter number
2 Filter wavelength in nm
3 Previous reading of the filter in Abs.
4 Current reading of the filter in Abs.
5 Difference in Abs. between the previous and the current readings
V = valid value,
Err = error, value out of valid range,
6
Dif = error, non repetitive,
Ovf = reading overflow.
Ratio between current autozero and factory initial value of the
autozero. It helps to evaluate the filters downgrade.
7
The factory initial autozero value is stored in TERMINAL with the
command OZ9.
Example of autozero with Dif error:
FIGURE 77
Autozero with Dif error
The analyzer could not obtain two autozero readings with the same value. In
case of Dif error, it is necessary to find out the origin of the unreliability:
1. Defective lamp, loose lamp screw.
2. Lamp connections.
3. Defective or broken or loose interference filter.
4. Filter wheel offset (Reading test F72).
5. Reaction plate offset (Reading test F61).
6. Filter wheel belt (7. Mechanical check F4).
7. Reaction plate belt (7. Mechanical check F4).
64
The test to be performed for checking is noted inside the parentesis.

If only filter 1 has the Dif Error, check points 1 and 3.
If generally only one filter has the Dif Error, check point 3.
Point 3 can also be verified with the autozero repeatability test (F52).
8.5.2 TEST (F5-2)
FIGURE 78
Autozero repeatability
Repeats 10 times the autozero, calculates the average and the CV% for every
filter.
FSOP Should always be zero.
Home sensor stops at different positions (1 step). Unscrew/screw
the stirrup to fix the problem.
Dark Offset should be 20-30.
Even an offset of 100 requires no trimming.
O.D. Lamp stability.
Maximum variation = 0.001 mAbs.
CV% Good values are lower then 0.1000 for all the filters (manufacturing
and refurbishing) and lower then 0.2000 for filter 1.
If the CV% value is higher, check the following points:

1. Filter wheel FS offset (F72): If the filters are not centered on the light beam
the light variation increases and the CV% increases.
2. Reaction plate OP offset (F6-1): If the cuvettes are not centered, the light
variation and the CV% increases.
3. Defective lamp, loose lamp screw.
4. Lamp connections.
5. Defective or broken or loose interference filter.
6. Filter wheel belt (7. Mechanical check, F4).
7. Reaction plate belt (7. Mechanical check, F4).

8.6 Outer plate reading offset (F6)
FIGURE 79
Reaction plate reading offset
To center the cuvettes for best optical reading in two steps: Rough and fine.
A/D:
Value stable OK.
Value increasing wait for finishing warm-up.
Value oszillating problem.
1 - Fine offset
The procedure verifies if the current reaction plate reading offset is correct
or must be modified. It verifies only the fine tuning and it is supposed that
the offset is already set within the range of the reaction cell (cuvette) 1
(see next procedure "Rough offset").
2 Cuvette 1 rough offset
It is used to find the rough reading offset of cuvette 1.
The purpose is to adjust the reaction cuvette 1 position in the center of the
small opening of the reaction plate cover.
8.6.1 SEARCH FINE READING OFFSET (F6-1)

FIGURE 80
Current reading offset
The test shows the current value of the reading offset (parameter 022 OPOFRD) The +1/2 step is just to show
and the value suggested, supposing that the rough offset of the reaction cell 1 the exact offset. It must of
is matched. course be ignored when updating
the 022 OPOFRD parameter.
66
FIGURE 81
Different reading offset
If the value is different, the operator can type Y to store the new value or N to
keep the old value.
FIGURE 82
Fine reading offset finding
8.6.2 ADJUST CUVETTE ROUGH OFFSET (F6-2)
FIGURE 83
Rough cuvette offset adjustment
The distance between two cu- It is used to find the rough reading offset of cuvette 1.
vettes is 20 steps. The purpose it to adjust the reaction cuvette 1 position in the center of the small
opening of the reaction plate cover.

With the LEFT and RIGHT keys, move the reaction cuvette 1 to the center of the
opening.
With the F2 key, save the adjusted offset.
This positioning is a rough adjustment. The fine adjustment has a scope of +/-
half cuvette. So the rough adjustment is used to be sure that the cuvette 1 will
be employed by the fine adjustment procedure.
8.7 Filter wheel test (F7)

FIGURE 84
Filter wheel test
To test the filter wheel home repeatability and also the offset + peak settings.
8.7.1 TEST FS HOME REPEATABILITY (F7-1)

FIGURE 85
FS home repeatability
The home positioning is repeated a 100 times and a correlation check is perfor-
med.
The first two numbers are only for reference and must not be considered.
All the numbers in the rows with eight columns must be higher than 0.9990.
In this case the result is marked as -OK-.
68
If the result is lower than 0.9990, the result is failing.

In the example two values are failing. The final result is then FAIL.
8.7.2 TEST FILTER WHEEL OFFSET + PEAK (F7-2)
FIGURE 86
Filter wheel offset+peak test
The first row shows the current value of the filter wheel (FS) offset value FSOFFS.
For each filter it is displayed if there is a correction to apply to the offset parame-
ter FSOFFS:
FSOFFS: +1 / -1
This message indicates that the peak for this filter should be incremented by 1 /
decremented by 1.
The suggested FSOFFS correction is based on the calculated average of the de-
tected corrections.
It any correction of FSOFFS is suggested, enter in the EDIT PARAMETERS proce-
dure, typing three times the "." key.
The FSOFFS parameter is already selected. Press F4 to unlock the parameters and
insert the new value. Press ESC and then confirm the variation with the F2 key.

Run again the FS OFFSET + PEAK test to match the mechanical middle with the
absorbance peak.
FIGURE 87
Filter wheel offset+peak test
repeated
Now, if everything is right, there is no suggested FSOFFS variation.
In this case it is possible to make a fine correction of the filter 1, which is the
more sensitive to the beam centering.
It is possible to add a specific offset only to the filter 1. Set the filter 1 correction
value to parameter FSDOF1.
In the picture example, set FSDOF1 = 2.
Finally repeat "Search fine reading offset (F6-1)".
FIGURE 88
Alignment of filter wheel and
cuvette for best reading
70
Summary
To achieve the best optical condition for precise readings perform following
steps in given order:
- Search fine reading offset (F6-1)
- 2 x Test filter wheel offset + peak (F7-2)
- Search fine reading offset (F6-1)
8.8 Clear Errors (F8)

To delete error messages.
8.9 Status of cuvettes (F9)
FIGURE 89
Cuvettes status
The first table is the current reading (unit 0.1 mAbs) of the 80 cuvettes at the
filter 1 wavelength of 340 nm.
The second table is the difference of the current reading to the start-up refe-
rence reading (unit 0.1 mAbs) of the 80 cuvettes at the filter 1 wavelength.
At the bottom are some statistics on the 80 cuvettes:

- Minimum reading.
- Average reading.
- Difference between minimum and average.
- Standard deviation.

8.10 G and Z cuvettes selection shortcuts

In the Reading test menu the "G", "Z" and "S" keys can be used to shortcut the
operations for the optical gain and offset adjustments (see "11.3. Optical offset
and gain adjustment").
Press the "G" key to select cuvette 32 for the trimmer's adjustment with a scre-
wdriver.
Press the "Z" key to select cuvette 0 to check the reading at the true range. Cu-
vette 0 means reading between two cuvettes for a real autozero.
Press the "S" key to set the optical gain to 30.

72

WASHINGS (F5) 73
9 WASHINGS (F5)
9.1 Washings menu
FIGURE 90
Washings menu, shown for
HumaStar 100
Press the "." key 3 times to edit system parameters.
1. The wash position is the position of the reaction carousel that is assigned to
operate under the first needle (from the right) of the wash station. It ranges
from 1 to 80.
2. On the upper right corner temperature, floats and cover door are continuo-
usly monitored.
3. The reaction cells wash status bar displays the status of the 80 reaction cells:
0 Clean cell.
1 Dirty cell.
2-9 Cell passed wash station 1-8 wash cycle.
F Wash failed 1 or 2 times (cell didnt pass the reading test after fill in
position 6).
W Cell in warning to be excluded (wash failed 3 or 4 times).
X Cell excluded (wash failed 5 times).
The white-on-blue-background group of eight cells represents the eight posi-
tions of the wash station. The first on the right is position 1 of the wash station,
the last on the left is position 8 of the wash station.
4. The pumps and lamp work hours.
5. The pumps dispensation in l (last, average, flow rate, timers, pump status).
74
9.2 Wash position (F1)

To select the current wash position, enter its number.
9.3 Execute washes (F2)
FIGURE 91
Execution of continuous
washings
To activate the continuous wash function.

Press Esc to stop the washing function.
The reaction cells of the rotor are washed in sequence. For each reaction cell the
new reading value of water at 340 nm after the wash cycles is displayed ("Tubes
zero filter 0" table). Unit: 0.1 mAbs.
Press a number (1-80) to set a number of reaction cells as dirty. When the cell
passes under the wash station and if is dirty (status 1) the wash procedure is
activated. If the cell is already clean (status 0), the wash station operations are
skipped.

WASHINGS (F5) 75
9.4 Fill wash cuvette (F3)

Fill the reaction cuvette selected by the wash position with water through the
sampling needle.
9.5 Startup (F4)

To execute the start-up procedure. Useful for remote access to the instrument.
9.6 Special pump tests (F5)
FIGURE 92
Special pump tests
Special tests:
1. Pumps test.
2. Fill tubes + pumps self test.
3. Empty tubes.
4. Check residue.
5. Adjust pumps.
76
9.6.1 PUMPS TEST (F5-1)
FIGURE 93
Pump test
For the pumps test a primary tube filled with 5 ml of water is required in sample
position or in the diluent bottle. If it is missing, the procedure is halted.
The pumps test performs a precise measure of the flow of the six dispensing
pumps of the wash station and the needle wash dispensing pump. It checks also
the wash station vacuum pump.
The results of the test can be verified in the monitoring section of the HI soft-
ware Maintenance panel.
The test is performed in four steps:

1. It calibrates the level sensor in the reaction cuvettes.
2. Test the wash station needles aspiration evaluating the vacuum pump flow.
If the reaction cuvettes are not empty at the second step, the test fails.
3. Test the water dispensation from the needle.
4. Test the dispensation of the six pumps of the wash station.
According to the new calibration of the level sensor in the reaction cells, (para-
meters 278 OPL150 and 279 OPL450), the analyzer asks (if it is necessary) if you
The parameter 278 OPL150 is want to adjust the SN1 dispensing quote 053 SN1DS2.
a reference value for mixing
and must be fixed. It corresponds Type Y to adjust, else to keep the old value.
to 100 l mixing volume. Therefo- If Y was selected, repeat F5-1 Pumps test. The parameter 278 OPL150 should
re the samle needle goes 21 steps be 150.
into the liquid in the cuvette.

WASHINGS (F5) 77
9.6.2 FILL HYDRAULIC TUBES + PUMPS SELF TEST (F5-2)

This procedure is used to fill all the hydraulic tubes after tank replacement or for
the initial fill-up.
In the HI software, MAINTENANCE panel, there are three options:

- Fill water tubes after water tank replacement.
- Fill wash tubes after wash tank replacement.
- Fill all hydraulic system.
In the SERVICE/WASHINGS menu only the Fill ALL option is possible.
To avoid dangerous water overflow caused by aspiration pumps malfunctioning

or unpredictable results caused by wash dispensing failure, during the fill hy-
draulics procedure a self-test of the pumps is performed.
The self-test is performed mainly to check if the aspiration and vacuum pumps
are performing. It also checks the flow rate of the needle wash dispensation,
both internally and externally.
The self-test is based on the use of the level sensor. So the first step of the self-
test is to check the level sensor in the diluent bottle. If the diluent bottle is em-
pty, the procedure is halted.
The fill hydraulics procedure then performs the following steps:

- Well tubes filling using the external needle wash flow, stop when water is
flowing.
- Well tubes filling using the internal needle wash flow, stop when water is
flowing.
- Check and measure the flow of the well pumps (external needle, internal
needle, aspiration).
- Fill seven reaction cells with 350 l.
- Check the wash station vacuum pump with a double-step aspiration, evalu-
ate the vacuum flow-rate and a final test result PASS/FAIL.
- Wash solution tubes filling, using the pump 2 and needle 2 of the wash stati-
on. Every 5 cycles, check with the level sensor if the wash solution is flowing.
- Internal tubes filling. Repeat several cuvette washes to complete the filling
of the wash station tubes with the system solution (needles 1, 3, 4, 5, 6).
Every 5 cycles, check if water is flowing from needle 6. When the water is
flowing regularly from needle 6, the procedure stops.
78
FIGURE 94
Fill hydraulic tubes pumps
self-test
Fill the tubes of the needle wash.

Measure the flow rate of the needle wash (internal, external, aspiration).
Fill reaction tubes with 350 l.
Test vacuum pump for wash station aspiration (PASS / FAIL).
Fill wash solution tubes through wash station needle 2.
Fill system solution tubes.
9.6.3 EMPTY TUBES (F5-3)

To perform the same procedure as fill hydraulic tubes, except that its duration is
fixed and it doesnt check when the tubes are filled.
Extract the floats from the tanks before executing the empty tubes procedure.
Do not unplug the external tubes from the analyzer until the procedure is com-
pleted.
9.6.4 CHECK RESIDUES (F5-4)

This procedure can be performed to verify the liquid residues left by the wash
station inside the reaction cells.

WASHINGS (F5) 79
9.6.5 ADJUST PUMPS (F5-5)

This test measures precisely the volume dispensed by the six wash station peri-
staltic pumps and allows eventually adjusting the pump timer values to obtain
the specified dispensation volume.
FIGURE 95
Adjust pumps 1
The measuring is repeated six times, and then a report is displayed:

- Minimum volume dispensed.
- Difference between minimum and maximum volume dispensed. The volume of pump 1 is lo-
- Average volume dispensed. wer then the volumes of all
- Old pumps timers. other pumps. This avoids the as-
- Suggested adjusted pumps timers, to correct the dispensed volumes to cent of dirt at the inner walls of
reach the 177 WSHVOL parameter value (default: 400 l). the cuvettes.
Values of the parameters 165 DIWSH6 to 160 DIWSH1 (from left to right).
FIGURE 96
Adjust pumps 2
80
The pumps timers range from a minimum of 45 to a maximum of 80. Values

outside this range will be clipped to the minimum and maximum values.
Press Y to adjust the pumps timers, else to keep the old values.
The analyzer processes the six pumps. If the new value is accepted, ok is displa-
yed, else if the volume is too low, low is displayed.
9.7 Wash needle (F6)

To execute a needle wash cycle in the well.
9.8 Wash station test (F7)

To execute a single cycle of the wash station and move the wash position to the
next cell.
9.9 Clear errors (F8)
FIGURE 97
Washings error message
A system error is eventually displayed in reverse blue.

It can be acknowledged and cleared with F8.
9.10 Rinse cuvettes (F9)

To execute the Rinse cuvettes procedure.

SYSTEM PARAMETERS 81
10 SYSTEM PARAMETERS
10.1 Edit parameters (F7)
FIGURE 98
Edit system parameters
Parameters shown in red are

The system parameters edit function is called from Terminal by the OP com- critical to the instrument and
mand, from the service menu with F7 Edit Parameters or from the Hardware therefore protected by a pass-
test, Reading test and Washings menus by pressing three times the dot "." key. word. For password handling, re-
fer to the appropriate Human Ser-
Exit the Edit Parameters menu by pressing the Esc key. vice Bulletin (HSB).
F1 SELECT PARAM. Locate a parameter by its number.

F2/PG UP NEXT PAGE Next page.
F3/PG DN PREVIOUS PAGE Previous page.
F4 LOCK / UNLOCK Lock/unlock parameters for editing.
F5 FIND PARAMETER Locate a parameter by its name.
F6 BACKUP PARAMETERS Backup all the parameters.
F7 RESTORE BACKUP Restore all the parameters from the last
backup.
82
10.2 Parameters pages

In the upper right corner the name of one of the 9 parameter pages is displayed:
1. IP, OP, FS
2. SN Needle, DS
3. REAG, WASH STATION
4. SPEEDS
5. WASH PUMPS
6. MISCELLANEOUS
7. LEVELS, FLOATS
8. TEMP., DILs, PIPETTING
9. READINGS
Parameters table description:

1st column Parameter number.
2 column
nd
Parameter name.
3rd column Parameter type (P, U, I, O, R, S, A, V, C, F, D, c, m, s).
P = Integer (-32000 to +32000)
U = Unsigned integer 0 to 65535)
I = Inner plate
O = Outer plate
R = Needle rotation
S = Sampling needle
A = Wash station
V = Speed
C = Check sum
F = Filters selection
D = Diluter syringe
c = 10th of milimeters
m = Milimeters
s = Seconds
4th column Parameter value.
5th column Default parameter value in parenthesis.
If the parameter value in the 4th column equals to the default
value, this column is empty.
Trying to input a value outside the parameter range causes a beep, the new va-
lue is rejected and the old value is kept.

SYSTEM PARAMETERS 83
10.3 Find parameter (F5)
FIGURE 99
Find system parameter
Type the name of the parameter to be found.

The cursor will move on the selected parameter.
10.4 Backup parameters (F6)

Press F6 to backup all the current values of the system parameters.
A confirmation (Y/N) will be requested:
Backup all parameters (Y/N)?
10.5 Restore parameters (F7)
FIGURE 100
Restore system parameter
84
Press F7 to restore the parameters values recorded during the last backup.
A confirmation (Y/N) will be requested:
Restore parameters from backup (Y/N)?
10.6 Save the parameters list as a text file

To create a parameters list file:
- Go to the Service Terminal.

- Select the LOG tab and tick the LOGS check box.
- Select the TERMINAL tab.
- Enter the PL command.
- Wait for the end of the parameters list (last parameter: CODCHK).
- Select again the LOG tab. The list of all the parameters must be there.
- Save the parameters list file as .TXT file by a right mouse click.
- CLOSE the Service Terminal.
- Open the created parameters list file with WORDPAD or with WORD.

ADJUSTMENTS 85
11 ADJUSTMENTS
11.1 A/D voltage references adjustment
FIGURE 101
A/D voltage adjustment
The voltage reference of the A/D converter for the photometer signal is adjusted
on the CPU board with trimmer P1 and must be 1.000 Vcc on pin 2 of U26.
The voltage reference for temperature A/D converter is adjusted on the CPU
board with trimmer P2 and must be 2.731 Vcc on pin 6 of U30.
Check the two reference voltages VREF1 and VREF2 on the CPU board as follows:
VREF1 Connect the negative probe of the voltmeter on the analog ground (e. g.
the board fixing screw in the lower left corner) and the positive probe on
the pin 2 of the U26 and then adjust the trimmer P1 to obtain a value of
voltage equal to 1.000 Vcc 0.005 Vcc. Trimmers P1 and P2 are fixed
by screw securing lacquer to
VREF2 Connect the negative probe of the voltmeter on the analog ground and the factory settings. Under nor-
the positive probe on the pin 6 of the U30 and then adjust the trimmer mal circumstances they never
P2 to obtain a value of voltage equal to 2.731 Vcc 0.005 Vcc. must be changed.
86
11.2 Reaction plate temperature adjustment

The procedure is to calibrate the temperature sensors so to match an external
thermometer.
FIGURE 102
Reaction plate temperature
adjustment
The reaction outer plate temperature is calibrated with trimmer P3 on CPU board
(see FIGURE 101). The calibration requires a thermometer with a 3 mm probe to
measure the temperature inside a reaction cuvette of the outer plate.
Fill the reaction cuvette at the center of the access hole to the reaction cuvettes
with 0.5 ml of water. Insert then the thermometer probe in this reaction cuvette.
There are two variants of temperature adjustment available:
A) TERMINAL OS SERVICE MENU F1 HARDWARE TEST F5 DISPLAY

INPUTS
In the upper right corner a window is displayed with the values of all the
inputs. The row OP temp indicates the outer plate temperature in tens
of degrees Celsius in continuous reading.
B) TERMINAL OS SERVICE MENU F5 WASHINGS

The reaction plate temperature is displayed in degrees Celsius in the up-
per right corner.

ADJUSTMENTS 87
The sensor is in a feed-back loop for temperature control, so the system will al-
ways slowly drive the temperature to the same (apparent) reference.
If the measured temperature is higher than the set-point, turn the trimmer up
(so that the displayed temperature goes close to the measured temperature)
and wait for stabilization.
If the measured temperature is lower than the set-point, turn the trimmer down
(so that the displayed temperature goes close to the measured temperature)
and wait for stabilization.
The procedure must be repeated some times until the displayed value is identical
to the measured value.
Adjust the P3 trimmer on the CPU board until getting the same indication on the
displayed temperature in variant A) or B) and an external thermometer placed
in the outer plate.
To achieve a temperature of 37 C in the cuvettes the displayed temperature

should be approx. 38 C.
11.3 Optical offset and gain adjustment
FIGURE 103
Optical offset and gain adjust-
ment
88
The optical preamplifier board is located in the inner side of the reaction plate.
The left hole (seen from the front) is to adjust the gain trimmer.
The right hole (seen from the front) is to adjust the offset trimmer.
The two trimmers GAIN and OFFSET are accessible in two ways:
A) TERMINAL OS SERVICE MENU F4 READING TEST F2 SELECT

CUVETTE 32.
B) TERMINAL OS SERVICE MENU F4 READING TEST G.
OFFSET and GAIN adjustment must be made after the thermal stabilization of
the optical group, the reaction plate and the optical preamplifier.
11.3.1 NECESSARY TOOLS

Flat screwsriver (1.5 mm) for the trimmers with minimum 22 mm length.
11.3.2 OFFSET ADJUSTMENT

Select filter 0 (black) by pressing the 0 (zero) key.
Check the reading and adjust the offset with trimmer (right) so that the value is
approximately 15.
11.3.3 GAIN ADJUSTMENT

During the reading test you can select all the filters with the keys 0-9 and get the
corresponding reading.
Check on the AUTOZERO readings list which is the filter with the highest
reading and select this filter pressing the numeric key corresponding to the fil-
ter number.
Adjust the GAIN with the trimmer (left) so that the maximum reading of the
highest (most transparent) filter is close to 16,000 and the lowest one (less
transparent) is higher than 12,500 (note that the maximum reading of the A/D
converter is 19,999).

ADJUSTMENTS 89
Since cuvette 32 is selected, the current reading is obtained with the light beam
through it. Depending on the absorbance of this cuvette, the A/D reading during
the adjustment of the trimmers is 10 % lower (or even less) than the real AUTO-
ZERO value. To check the true A/D reading, take the screwdriver off the holes and
select cuvette 0 with F2 SELECT CUVETTE. Press F4 READ ALL FILT. to get a quick
reading of all the wavelengths.
In the A/D reading of the bare beam (cuvette 0 selected) it is preferable not to go
beyond 18000, because it is needed some margin of tolerance to avoid reading
overflow when changing the lamp. Lamps can have an emission tolerance, main-
ly in the low wavelength range (340-400 nm).
When all A/D reading values are satisfactory, press F5 AUTOZERO and then 1 for
a single AUTOZERO.
Wait for the end of the procedure and eventually confirm (1) or reject (0) the
values.
11.3.4 CUVETTES SELECTION SHORTCUT

In the F4 Reading Test menu:
- Press the G key to select cuvette 32 for the trimmers adjustment with the
screwdriver.
- Press the Z key to select cuvette 0 to check the reading at the true range.
11.3.5 INTERFERENCE FILTERS

The interference filters are factory equalized, so that the maximum difference in
the A/D readings is typically lower than 20 %.
Anyway, to reduce the difference between the final transmittances, it is possible
that a light quartz grey filter has been mounted on some interference filters for
finer matching. Interference filters have a very high stability and are mechani-
cally protected. It is very unlikely that they must be replaced. But it is eventually
possible that a quartz grey filter has cracked if it has been locked too tight.
11.3.6 READINGS OUT OF RANGE

If a filter has an AUTOZERO reading out of range, all the methods employing
this filter will be marked with "AUTOZERO ERROR" and these methods cannot
be executed.
90
The filter 1 (340 nm) is used also for the check of the cuvettes washing. An AU-
TOZERO error on this filter will give an "AUTOZERO ERROR" during the washings.
11.4 Filter wheel adjustment

Allen key #2, #3 and #4 screwdrivers for M3, M4 and M5 Allen screws.
11.4.2 OPTICAL HOME SWITCH ADJUSTMENT
Attention
The optical switch must never be touched. Only if it is broken it will be necessary
to replace it. Else all the adjustments will be done without touching the optical
switch.
To check if the filter wheel is operating properly there are two basic tests to be
executed:
- F4 READING TEST F7 1: TEST FS HOME REPEATABILITY (see 8.7.1.).
- F3 MECHANICAL CHECK F4: OP-FS HOME CHECK (see 7.4.).
F4 READING TEST F7 1: TEST FS HOME REPEATABILITY

The first test checks if the mechanics are working properly and if the stepper mo-
tor is well phased on the limit switch. If all the results are not OK (excluding
the first row with two numbers), once a big problem in the mechanics has been
excluded, it is possible that the home positioning is not repeatable because the
optical switch position is phased in the middle of two mechanical steps.
In this case the cogwheel of the FS motor must be shifted a bit. This is a blind
operation, because you can check the result only later, repeating the FS HOME
REPEATABILITY test.
Procedure:
1. Open the filter wheel cover (one Allen screw M5 placed over the FS motor).
2. Release with a #2 Allen key screwdriver the two M3 Allen screws on the cog-
wheel of the FS motor.

ADJUSTMENTS 91
3. Rotate the cogwheel just a bit on the motor axle.

4. Tighten the two Allen screws of the motor's cogwheel.
5. Repeat the FS HOME REPEATABILITY test. If it fails, repeat from step 2.
6. At the end, close the filter wheel cover (one M5 Allen screw).
11.4.3 FS BELT ADJUSTMENT

The second test, F4 OP-FS HOME CHECK, will check the home search from all the
filter positions. When the filter wheel is operating perfectly, it must give all null
values.
If it gives non-null values higher than 2, the filter wheel belt must be tightened.
To tighten the belt, release the four M4 Allen screws of the motor, pull with one
hand the motor, sliding outward, to tighten the belt and then tighten the four
motor screws with the other hand.
11.4.4 OFFSET ADJUSTMENT

Once the FS positioning is accurate and repeatable, the offsets of the single fil-
ters must be detected. This operation is done automatically by the analyzer run-
ning the F4 READING TEST F7 2: ADJUST FS OFFSETS (see 8.7.2.).
11.5 Reaction plate belt adjustment

Allen key #3 screwdriver for M4 Allen screws.
11.5.2 OP BELT TIGHTENING

To tighten the OP belt, follow the procedure:
1. Take off the sample tray and the upper cover of the analyzer.
2. Move the reaction rotor by hand to identify the OP motor.
3. Using the 3 mm Allen key screwdriver, loosen the four M4 Allen screws that
hold the OP motor.
4. While keeping the belt well tightened, pulling the OP motor, tighten the four
motor's screws.
92
11.5.3 ACCESS TO THE OP MOTOR SCREWS

The four screws are placed on a square of approx. 50 mm.
FIGURE 104
First screw
FIGURE 105
Second screw
The two outer screws are accessible by rotating the reaction rotor in such a way
that the hole placed on the bottom of the rotor will be, in sequence, over the two
screw's head.
FIGURE 106
Third screw

ADJUSTMENTS 93
FIGURE 107
Fourth screw
The two inner screws are accessible by rotating first the sample rotor in such a
way that the hole on the IP plate will be overlying on the vertical of a second hole
of the reaction rotor (the IP hole and the OP hole must be then on the same radi-
us).
Move then the IP and OP rotors over the heads of the inner screws of the OP
motor.
11.6 Needle vertical adjustment in the wash well

Go to SERVICE F2 MECHANICAL CALIBRATION, select row 09: WASH / SN L.
The needle goes down in the wash needle position.
Press F6 SPECIAL FUNCTION to enter the special check function and then press
the space bar to step through the check:
- The water springs out the needle and washes the needle internally and exter-
nally. Check if the water flows well (INWELV = pump speed).
- The flow stops and the needle moves up to the drip position. The needle must
stay about 1 mm inside the water drop (the bottom of the needle must be at
the same level of the top of the white well nipple (adjust SN1WSH).
- The water flows from the lateral nozzle and washes the needle externally.
The water jet must hit the needle gently with a downward parabola and not
hit horizontally. In this way the drops will not remain attached on the needle
side (adjust EXWELV).
When completed, you can adjust with the "+" / "-" keys the vertical position of
the needle inside the well so that, when it goes up to the drip position, the need-
le remains 1 mm inside the water drop.
94
11.7 Wash station down adjustment
11.7.1 ROUGH AUTOMATIC CALIBRATION

To be used only by operators not able to execute the FINE CALIBRATION proce-
dure.
Go to SERVICE F2 MECHANICAL CALIBRATION, select row 18 and press
See "6.2. Calibration rows", row 18.
11.7.2 FINE CALIBRATION

Go to SERVICE F2 MECHANICAL CALIBRATION, select row 18 and press
See "6.2. Calibration rows", row 18.
Use the "+" / "-" keys to move the wash station up and down one step.
Go down until the wash station white swab touches the bottom of the reaction
cuvettes.
Then go up two steps and press F2 SAVE POSITION to store the new calibration.
11.8 Adjustment of the cover detection switch

Use the two screws (A) to adjust the position of the cover detection switch.
FIGURE 108
Cover detection switch adjust-
ment
When the instrument is open, pull the button of the detector (B) up, to simulate
the cover closed and enable the sampling operations

SERVICING 95
12 SERVICING
12.1 Lamp replacement

FIGURE 109
Lamp replacement
To execute when the lamp is burnt off. Lamp life has a wide distribution, can
range from 500 to 2000 hours, with a typical life of 1000 hours.
1. Switch the instrument off.

2. Open the lamp window in the back side of the instrument.
3. Unplug the lamp connector (A).
4. Unscrew the lamp knob (B).
5. Remove the old lamp.
6. Insert the knob in the new lamp holder.
7. Insert the new lamp and fasten the knob (A).
8. Plug in the connector.
9. Close the lamp window.
10. Switch on the instrument.
11. Wait 20 minutes for warm-up.
If you are not in TERMINAL > OS:
12. Put the instrument in RUN to execute an autozero and then go to

MAINTENANCE / OPTICAL GROUP to check the lamp emission.
13. If lamp has a correct emission (all the wavelengths readings are bet-
ween 11,000 and 19,000), execute the instrument start-up. Else go to the
TERMINAL > OS.
96
If you are in TERMINAL > OS (the procedure is more strictive to allow the opera-
tor to have a longer autonomy):
12. Go to F4 READING TEST and execute the F5 AUTOZERO procedure to check

the lamp emission.
13. If the lamp is not having a correct emission (all the wavelengths readings
between 13,000 and 18,000), you have to adjust these values within this ran-
ge trimming the optical preamplifier gain. See "11.3. Optical offset and gain
Do not touch the glass part of adjustment".
the lamp with your fingers. 14. In F4 READING TEST, verify the filters offset with the F7-2 function and even-
Fat, dust and humidity shorten tually adjust the filters offset. See "8. OPTICAL READING TEST".
the life of the lamp and limit the 15. In F4 READING TEST, verify the reaction plate offset with the F6-1 function
lamp emission. and eventually adjust the reaction plate reading offset. See "8. OPTICAL REA-
The AUTOZERO procedure is DING TEST".
used to store in memory the 16. Execute the instrument START-UP.
AUTOZERO values, which are the
optical reading values of the lamp
for all the filters.
12.2 Sample tray replacement
There are two versions of the sample tray:
FIGURE 110
Sample tray 30+30
The first (default) sample tray holds 60 samples:

60 primary tubes, diameter 12-13 mm, height 55-100 mm.

SERVICING 97
FIGURE 111
Sample tray 20+20
The second (to be extra ordered) holds 40 samples:

20 primary tubes, diameter 12-16 mm, height 55-100 mm,
20 "Hitachi" cups.
When installing a sample tray, the operator must configure the following sy-
stem parameters, using the F7 EDIT PARAMETERS function:
System parameters for sample tray with 60 samples:

IPNPS0: 30 N. POSITIONS ON EXTERNAL RING
IPNPS1: 30 N. POSITIONS ON INNER RING
IPTYPE: 2
System parameters for sample tray with 40 samples:

IPNPS0: 20 N. POSITIONS ON EXTERNAL RING
IPNPS1: 20 N. POSITIONS ON INNER RING
IPTYPE: 1
Then the operator must go to F2 MECHANICAL CALIBRATION and calibrate the

high and low position of the first tube of the internal and the external tubes
rows:
- PTU is the low position of primary tubes.
- CUP is the low position of the cups mounted on the adapter. The adapter is
necessary to allow level detection with the cups.
- CU2 is the low position of the Hitachi cups of the inner row of the 40 posi-
tions tray. The inner row of this tray can hold only these cups, without ad-
apter.
98
Sampling needle high, 5 mm over sample primary tube 1 (follow the affected
parameters):
11 IP01/SN H IPOFF0 RN_IP0 SN1MID
Sampling needle low, at the bottom of the sample primary tube 1:

12 IP01/SN PTU IPOFF0 RN_IP0 SN1PTU
Sampling needle high, 5 mm over sample primary tube 21 or 31 (first tube of

inner circle, depending on tray):
13 IPx1/SN H IPOFF1 RN_IP1 SN1MID
Sampling needle low, at the bottom of sample cup 1 (cup placed on the adapter):
14 IP01/SN CUP IPOFF0 RN_IP0 SN1CUP
Sampling needle low, at the bottom of the cup 21 (only for the 40 samples tray):
11 IPx1/SN CU2 IPOFF1 RN_IP1 SN1CU2
On exit from the mechanical calibration, the instrument automatically evalu-

ates the IPPHOM parameter that is the IP tube for fast pre-positioning during
the home procedure.
12.3 Single reaction cell replacement
See also the HumaStar 100/200 User Manual.
- With the analyzer switched on and connected, from the HI software press
the lower-left MAINTENANCE button.
- Press the REACTION CUVETTES button.
The excluded cuvettes are displayed in RED color.
- Press on the cuvette to be replaced. The rotor will move and bring the se-
lected cuvette to the center of the opening. Verify that the engraved number
corresponds to the selected one.

SERVICING 99
FIGURE 112
Cuvette position number
- With the specific cell extraction pliers ES07017A (from the HumaStar100/200
accessories) extract the cuvette placed at the center of the opening.
- Insert the new cuvette. The cuvette has a rectangular foot. It must be in-
serted, oriented so that the marks (one or two) on the bottom face are situa-
ted on the external side of the rotor ring.
- Confirm on the screen that the cuvette has been changed. This will reset
all the cuvette references and AUTOZEROs and mark the cuvette as dirty, to
enable its washing before it can be used in a reaction.
12.4 Reaction rotor replacement
FIGURE 113
HumaStar 200 wash station cover
HumaStar 100:
Loosen the 3 screws of the black wash station cover to extract it.
HumaStar 200 (see picture):

Extract the wash station cover (A). Lift upwards.
100
'
FIGURE 114
Needles group
Disassemble the needles group of the wash station (two screws (B) and (C)).
FIGURE 115
Reaction plate cover
Disassemble the reaction plate cover:

- Unscrew the screws (D), (E) and (F).
- Extract the reaction plate cover (G).
FIGURE 116
Reaction plate

SERVICING 101
- Unscrew the six screws (A), (B), (C), etc., holding the reaction carousel.
- Insert the new carousel taking care to keep the orientation (six screws and
one pin).
- Tighten the six screws progressively, taking care the rotor is in the correct
flat position.
- Reassemble the reaction plate cover, the wash station and its cover.
12.5 Needle replacement
FIGURE 117
Needle holder cap
Take off the needle cover.

Unscrew the needle holder cap.
FIGURE 118
Level sensor connector
Disconnect the level sensor connector (A).

Unscrew the four screws that hold the level sensor board.
102
FIGURE 119
Needle guide
Unscrew the needle guide (B).
FIGURE 120
Needle detachment
Detach the Teflon tube from the needle (C).

Take off the needle group (D):
Needle + brass needle contact + needle screw.
FIGURE 121
Needle group components
The needle screw (E), the needle (F), the brass needle contact (G).

SERVICING 103
After re-assembling, check that the needle slides correctly in the needle guide
without friction, so that the spring holds the needle in the lower position and
the shock sensor is correctly activated in the upper position (the red LED goes
on).
If the needle doesnt slide freely, try to loosen the white needle holder cap.
12.6 Interference filters replacement and equalization

Eight or nine interference filters are mounted in the instrument. Their wave-
length is defined in the system parameters FILTR1 to FILTR9.
The wavelength defined in the system parameters is detected by the software
when the instrument is connected.
The filters rotor has ten positions. Position zero is for the dark offset reading.
Every interference filter is marked, with the corresponding number engraved,
on the filters rotor.
The filters are equalized (matched) so that the reading of each filter is within a
20 % difference to the reference 340 nm filter. Typical final adjustment of the
autozero of the filters is a minimum of 13,000 and a maximum of 18,000.
The filters supplied belong to a set of 8 or 9 factory matched filters. This means,
the filters dont need a strong equalization with dark gray filters or pinhole disks.
It can happen that a light gray quartz filter of 38 mAbs or 100 mAbs is added
to the filters with a higher transmittance to reduce the emission and to have a
better equalization.
1. Remove the instrument cover.

2. Open the filters cover.
3. Rotate the wheel to reach the filter with the requested number.
4. To extract the old filter, unscrew the filter locking ring with the special tool.
5. Replace the filter without mounting any gray quartz filter and the rubber
O-ring.
6. Screw the locking ring with the special tool.
7. Close the filter cover.
8. In F4 READING TEST check the filter equalization.
9. If the A/D reading of the new filter is higher than the others, you must open
again the filter and add a gray quartz filter.
104
10. If the A/D reading of the new filter is lower than the others, you must check
if you can increase the gain of the optical preamplifier (if no readings reach
18,000). If not, you can leave it at its low level if its reading is higher than
13,000. Else you must add a gray filter to the readings with the highest levels
and then increase the preamplifier gain.
Cuvette 0: Position to get filter reading value.

Cuvette 32: Position for screwdriver holes alignment to adjust GAIN and
OFFSET.
- Select the DARK position on the filter wheel with the 0 key and cuvette 32
with the F2 key. Adjust the optical preamplifier OFFSET in the range 15 to 30.
- Select cuvette 0 with the F2 command. One by one, adjust all the mounted
filters (select filters with the 19 keys).
- Adjust the readings with gray filters (38 mAbs or 100 mAbs) assembled toge-
ther with the interference filters.
- Adjust the optical preamplifier GAIN selecting cuvette 32 with the F2 key,
then go back to cuvette 0 with the F2 key.
The order of the pack must be:
- gray filter,
- O-ring,
- interference filter,
- locking ring.
The reading of all the filters must be in the range 14,000 to 17,000.
- Execute the AUTOZERO (F5-1) to verify the final readings (they can be slight-
ly different from those obtained from the immediate reading) and eventual-
ly repeat the matching.

SERVICING 105
12.7 Vacuum pump replacement
FIGURE 122
Vacuum pumps
Seen from rear, on the left is the vacuum pump (A) aspirating from the wash
station cleaning nozzle.
On the right is the vacuum pump (B) aspirating from the 6 wash station aspira-
tion needles.
FIGURE 123
Vacuum tubing Y nipple
The two outputs of the vacuum pumps are connected together through a Y
nipple (E) and the hydraulics panel manifold (C) to the waste output (D).
For (C) and (D) see FIGURE 122 above.
To remove the vacuum pump from the base plate, unscrew the four ALLEN
screws underneath the motor (F).
106
12.8 Vacuum pump wearing parts replacement
12.8.1 HUMASTAR 100
FIGURE 124
Vacuum pump
Unscrew the pump head's four corner screws.
FIGURE 125
Vacuum pump head opened
Open the upper part of the pump head.

Replace the two O-rings if they are worn.
Also replace any solid particles eventually assembled inside the unit.
FIGURE 126
Vacuum pump rubber
membranes level
After removing the part with the two O-rings there's access to the two rubber
membranes.

SERVICING 107
Replace them if they are worn.

Also replace any solid particles eventually assembled inside the unit.
12.8.2 HUMASTAR 200
Unscrew the pump head's four corner FIGURE 127

screws. Vacuum pump
Open the upper part of the pump head. FIGURE 128

Vacuum pump head opened
The two membrane valves are inserted FIGURE 129

in two pins. Membrane valves
Take off the two disks. FIGURE 130

Center the two new membrane valves Membrane valves opened
on the two pins and carefully position
them. Close the pump head and screw it
back.
108
12.9 Peristaltic pump head replacement
FIGURE 131
Peristaltic pumps D1 to D6,
AW and DW
Open the wicket of the hydraulic unit placed on the left side of the instrument.
Find the pump that has to be replaced.
Extract the two tubes of the pump head from the barbed fitting.
Extract the pump head clenching the two clips placed on the opposit sides of
the pump head.
12.10 Diluter replacement
FIGURE 132
Diluter
To replace the diluter the following three parts are needed:
(A) EE0101A Diluter.

(B) ES05111B Teflon tube with two fittings (diluter to panel).
(C) ES05114B Teflon tube with one fitting and silicone adapter (diluter to
pinch valve).
The fitting size is -28 UNF.

SERVICING 109
FIGURE 133
Tubing connectors
Unconnect the motor connector (MDS) and the limit switch connector (SDS) and
take them off the hydraulic panel frame.
Unconnect the hydraulic fittings (B) and (C).
Unscrew the four screws at the base of the diluter head to remove the diluter
from the hydraulic panel.
Place the new diluter and fix it with the four screws.
Connect the new (B) and (C) fittings.
Insert the new (MDS) and (SDS) connectors on the hydraulic panel frame and
connect them to the wiring.
FIGURE 134
Electrical connectors
FIGURE 135
Power board connectors
110
Check in F1 Hardware Test if the diluter executes the home sequence correctly.
If it moves in the opposite direction, it is necessary to swap two wires on the
motors diluter wiring to exchange the movements direction of the new diluter.
Unconnect the DS-AN connector. On the left are the four DS wires (diluter syrin-
ge), on the right the four AN wires (wash station).
FIGURE 136
Power board connector DS-AN
Extract the WHITE and the BLUE wires of the DS diluter motor (3rd and 4th from
the left) and swap them to exchange the motors directions.
Go to the EDIT PARAMETERS procedure.
It is possible to set two options:

- Set DSTYPE to 3 to run the diluter at the maximum speed,
- Set DSTYPE to 4 to run the diluter at a bit slower speed (1,400 steps/sec).
The DSTYPE is normally set to 3. If, due to hydraulic narrowings, the diluter is
not working properly, set DSTYPE to 4 and the DSVELD to 1,500 or 1,400 to have
higher torque margins.
The system parameters whose values are constrained are:

DSTROK = 368
DSTEPS = 2,600
DSOFFS = 0
DSGAPH = -2
DSVELD = 1,400 to 1,700
DSVELA = 1,400
DSVELZ = 1,200

SERVICING 111
These values are automatically updated on exit of the EDIT PARAMETERS proce-
dure, after having changed the DSTYPE parameter.
On exit, press the F2 key to accept the modifications.
12.11 Diluter sealing gasket replacement

This procedure applies to diluter type 3 or 4 (EE0101A) to replace the sealing
gasket (orange O-ring inside the diluter head).
The gasket must be replaced when it doesnt seal any more and there is a water
leakage from the back of the head or from the optical switch opening.
- Remove the water hydraulic connector to avoid completely emptying the
tubes.
- Unscrew the diluter head with an Allen key and extract the head.
- Remove the orange sealing gasket.
- Place the new sealing gasket, oriented with the engraved letters on the outer
side.
- Insert gently the head on the piston, avoiding to damage the new gasket.
- Tighten gently the two screws.
- Reconnect the water hydraulic connector.
- Execute a filling of the water tubes in MAINTENANCE of the HI software.
12.12 Sampling arm replacement
FIGURE 137
Sampling arm replacement
- Disconnect the wiring connectors and the needle tube blue fitting.
- Unscrew the two screws on the two lower spacers.
112
- Unscrew the two screws on the two upper spacers. One of the two screws
will remain trapped under the reaction plate incubator, but the sampling
arm can be anyway disengaged. This screw is the last to be unscrewed.
- Replace the sampling arm, tighten first the two screws of the upper spacers,
then the two screws of the lower spacers, re-connect the electrical connec-
tors and the needle tube fitting.
- Go to SERVICE F2 MECHANICAL CALIBRATION and adjust all the quotes
related to the needle position.
12.13 Level sensor wiring replacement
FIGURE 138
Level sensor wiring replacement
(1 and 2)
Refer to the sampling arm replacement procedure for the disassembly and re-
assembly of the arm.
The level sensor wiring ES02006A is routed and fastened to reduce the stress of
the wires, with a larger size of the white plastic holder.
FIGURE 139
Level sensor connector

SERVICING 113
The wiring is composed of six ultra-flexible wires. They are supplied, on the le-
vel sensor board side, already crimped but not yet inserted in the Molex 8 pins
connector case.
The wires must be passed through the rectangular duct without the connector
case. They must be routed carefully and inserted into the MOLEX connector.
Molex MX254 8 pins F Minifit 8 pins 4x2 M Swapping the wires can da-
(top) (bottom)
mage the CPU board. Short-
1 Black 1 GND
circuiting the red wire with the
2 Yellow 2 Level out
yellow wire will damage the CPU
3 Red 3 12 Vcc
4 4 - board.
5 5 -
6 Red 6 12 Vcc
7 Yellow 7 Shock out
8 Black 8 GND
FIGURE 140
Connector pin layout
Pin 1 of the Molex MX254 8 pins, on the drawing, is on the upper side.
On the 8 pins 4x2 minifit connectors, pin numbers are printed on the back of
the connectors.
5 6 7 8
1 2 3 4
12.14 External tanks floats replacement

To check if the float of an external tank is out of work, go to SERVICE F5
WASHINGS.
In the upper right corner of the screen the status of the floats is displayed.
Extract the float from the tank and rotate it upside down and up slowly
(5 seconds).
You must see the displayed status of the float toggle on the screen.
114
If it is not toggling, it must be replaced.
The contact of each float is closed in the normal status. This means that the
water and wash tanks are closed in the up position (FULL) and the waste tank is
closed in the lower position (EMPTY).
To replace the wiring, it is necessary to employ the specific TRIM-TRIO extractor

Each float contains a toroidal to extract the two pins of its cable from the connector:
magnet in one side. The ma- Trim-Trio/Mate-n-lok pins extraction tool, P/N: CON-TRIO-ESTR.
gnet must be mounted in the op-
posite position when it belongs to Open the connector shield, insert the extractor into the pin to close its harpoons
a water/wash tank (normally and pull gently the wire out.
open) or to a waste tank (normal-
ly closed). Then insert the replacement pin from the back of the connector and push it until
the harpoons click. Pull gently the wire to verify that it doesnt come out.
The single float with the wiring is P/N ES02013A.
ES02013A W Tanks float with cable (for floats replacement)

ES01009A PW
(HumaStar 200)
ES01009AV1 PW
(HumaStar 100)
CON-TRIO-ESTR Trim-Trio/Mate-n-lok pins extraction tool
12.15 Optical preamplifier replacement
FIGURE 141
Replacement step 1
Remove the sample tray.

SERVICING 115
FIGURE 142
Replacement step 2
Unscrew the wash station needles holder (2 screws).
FIGURE 143
Replacement step 3
Take off the wash station needles holder.
FIGURE 144
Replacement step 4
Unscrew the reaction rotor cover (2 + 1 screws).

116
FIGURE 145
Replacement step 5
Unscrew the reaction rotor (6 screws).
FIGURE 146
Replacement step 6
Extract the reaction rotor.
FIGURE 147
Replacement step 7
Rotate the reaction rotor support until the notch is positioned over the pream-
plifier cover, then unscrew the preamplifier cover (2 screws) from the incubator.

SERVICING 117
FIGURE 148
Replacement step 8
Push up the preamplifer cable (red wires with black sleeve) by hand in such a
way that the preamplifier board is lifted up out of the incubator.
FIGURE 149
Replacement step 9
Unscrew the preamplifier board.
FIGURE 150
Replacement step 10
Replace the preamplifier board.

118
FIGURE 151
Replacement step 11
Reassemble everything. Adjust eventually GAIN and OFFSET (see "11.3. Optical
offset and gain adjustment").
12.16 CPU board replacement

If the CPU board has to be replaced, take the two firmware EPROMs (U2 and U3)
and the parameters EPROM (U4) from the old CPU board and place them on the
new one.

FIRMWARE UPDATING EPROMS REPLACEMENT 119
13 FIRMWARE UPDATING EPROMS REPLACEMENT

The operators interface is programmed in the PC. The software is a .NET pro-
gram written in C# and running under .NET Framework.
All the instruments operations are programmed in the two EPROMs, moun-
ted on the CPU board. This part of the software is called the firmware. The two
EPROMs must always be changed together.
The EPROMs are labeled with the firmware version, e. g. 1.34B.

If the reason for updating is a change of the compilation (indicated by the trai-
ling character), e. g. 1.34B to 1.34F, the EPROMs must be simply exchanged (see The HI software works best
"13.1 EPROMs replacement compilation change"). with the most recent firm-
If the version changes, e. g. 1.22 to 1.34, it has to be done by the help of the TER- ware version available but it also
MINAL program (see "13.2 EPROMs replacement version change"). works with all older firmware ver-
sion. It detects the firmware ver-
sion of the installed EPROMs and
does not activate the HI features
13.1 EPROMs replacement compilation change which require newer firmware
To replace the two EPROMs: versions.
- Shut the instrument off.
- Remove the cover of the instrument.
- Open the boards cover (3 plastic nails to extract).
- Extract the two EPROMs.
- Insert EPROM 1 in the upper position, with the notch on the right.
- Insert EPROM 2 in the lower position, with the notch on the right.
FIGURE 152
EPROM positions on CPU board
- Switch the analyzer on.

120
13.2 EPROMs replacement version change

To replace the two EPROMs:
- Enter the TERMINAL program and verifiy that the instrument is answering to
the commands, e. g. OS.
- Shut the instrument off.
- Remove the cover of the instrument.
- Open the boards cover (3 plastic nails to extract).
- Extract the two EPROMs.
- Insert EPROM 1 in the upper position, with the notch on the right.
- Insert EPROM 2 in the lower position, with the notch on the right. (See
FIGURE 152 above.)
- Switch the analyzer on.
- The @ symbol appears on the screen.
- Press ENTER twice.
- The following message is displayed on the screen:
FIGURE 153
EPROM menu
- While it is waiting for the keyboard confirmation, the analyzer shakes con-
tinuously the sample plate with two short moves forwards and one longer
backwards. This is to remind the service operator that he has to confirm the
EPROM change on the TERMINAL, else the software will not connect to the
analyzer.
- Press 1 (Load new parameters defaults + check). A list of new or moved para-
meters will be displayed, e. g.:
FIGURE 154
New or moved parameters
- Confirm with 1 (Load = yes) to all the parameters to initialize to the new va-
lue introduced with this release, e. g.:

FIRMWARE UPDATING EPROMS REPLACEMENT 121
FIGURE 155
New parameter
FIGURE 156
Changed parameter
- After the final parameter confirmation <NAK> will be displayed, e. g.:

FIGURE 157
Final parameter
- Exit the terminal function (press the X button in the upper right corner of the If you are using the HumaStar
TERMINAL window). 100/200 TERMINAL software,
do not exit from it because the
HumaStar 100/200 HI software
13.3 Replacement of very old EPROMs data synchronization cannot connect when the instru-
If the software doesnt connect after the EPROMs update procedure, it is possi- ment is in the "Load+Check" con-
ble that there is an incompatibility between the old data structures inside the firm status. In this case you need
instrument and those in the PC. to use a special program to con-
In this case it is simply necessary to delete the old data inside the instrument. firm the EPROMs update.
When you are in TERMINAL,
From the Service TERMINAL, type the following commands: you can shut off and on the
MK<enter> to delete the old methods, instrument without any connec-
SK<enter> to delete the old samples, tion problem.
WK<enter> to delete the old worklists.
Then exit the Service TERMINAL, return to the HI software and run the Methods
upload procedure to reload the methods into the instrument.
122

TROUBLESHOOTING 123
14 TROUBLESHOOTING
14.1 Analyzer doesn't connect

Press CONNECT.
If it doesnt connect:
1. Check if power is ON (red lamp on the main switch and orange lamp on the
reagents cooling switch).
2. Switch the instrument OFF, wait five seconds, and switch ON again. At power-
on, the instrument must shake the sample plate three times to show it is wor-
king. In addition to the 3rd shake the wash well aspiration pump (peristaltic
pump 7) has to turn for a short time. If it doesnt shake or shake only twice,
contact the service. No shake means that the CPU or EPROM 1 or the power sup-
ply bord are not working. Only two shakes means that EPROM 2 is not working.
Try again to connect. If it doesnt connect, continue with step 3.
3. Verify if the USB cable between the computer and the instrument is correctly
inserted. Try again to connect. If it doesnt connect, continue with step 4.
4. Verify the USB port. Exit from the software. Enter the Windows CONTROL
PANEL SYSTEM HARDWARE PERIPHERALS DEVICE MANAGER.
Unplug and plug-in again the USB cable from/at the instrument. Ve-
rify that the computer detects correctly the COM port (Ports COM &
LPT section, USB serial port COMx). If not, check the USB cable and
the USB port on the computer. Replace the analyzers USB-to-RS232
converter to check if the problem is in the internal converter board.
If the USB port is detected correctly by the PC, note which is the detected
COM port and continue with step 5.
5. Check the internal serial port. Start the EdifTerminalX86.exe program. Select
in the upper left corner the COM port detected in the previous step. Click at
the center of the window to focus on it. Shut the instrument OFF and then
ON. Wait for the three shakings of the sample plate. The instrument mo-
tors are OFF and a @ character is displayed on the screen. Press ENTER three
times. The instrument motors go ON (hold) and a <NAK> must appear on
the screen. If the @ doesnt appear, the instrument is not transmitting on its
internal RS232 output .
124
If it doesnt answer to the ENTER (the motors remain OFF), the instrument
is not receiving on its internal RS232 input. It is then necessary to check
the internal USB-to-RS232 adapter ES03004A, the internal serial cable
ES02008B and the serial port in the CPU board EI0302B1V1 (ICL232 driver IC).
Continue with step 6.
6. Check the CPU on-board serial port. Remove the cover of the instrument and
the CPU board carter. Unplug the CPU serial port cable (16 pins connector on
the left side of the board). Short-circuit on the CPU connector pin 3 to pin 5
and pin 9 to pin 14. Switch the instrument OFF, wait five seconds and then
ON. The sample tray must begin to shake continuously once a second. When
you open the short-circuit, the sample tray will shake three more times.
If not, the problem is on the CPU board, otherwise continue with step 7.
7. Check the internal serial cable and the serial port on the USB-to-RS232 con-
verter. Short-circuit on the 16 pins female flat-cable connector pin 3 to pin 5
and on the CPU serial port connector pin 9 to pin 14. Go to TERMINAL opera-
tion. Press the terminal window to focus on the terminal. Type some letters
Notes on the USB-to-RS232 on the keyboard. The letters must be displayed on the terminal screen. If the
adapter: Every USB controller check fails, the problem is on the internal USB-to-RS232 internal adapter
has its own internal serial ES03004A or on the internal serial cable ES02008B.
number. This means that every
USB controller corresponds for EdifTerminalX86 lists on the upper left corner all the detected COM ports and
the PC to a different COM serial allows to check the correct detection of the USB adapter.
port. Once it has been detected Do not unplug the USB cable when the software or the EdifTerminal are running
for the first time, the same COM it will not reconnect. The software will not find the USB port anymore and it
port number is assigned to that could crash.
USB controller.
For this reason, if you connect
two instruments to the same 14.2 Bad precision of optical readings
PC, every instrument will have its There can be several reasons causing bad precision in readings:
own COM port assigned. - Noise on the optical signal,
- Imprecision in the reaction plate positioning,
- Imprecision in the filter wheel positioning,
- Dispensation problems,
- Incorrect vertical positioning of the needle dispensation in the outer plate.

TROUBLESHOOTING 125
14.2.1 NOISE ON THE OPTICAL SIGNAL

It can be checked in the reading test. Selecting filter 0 (dark), the signal must be
stable and the maximum oscillation range is 1 unit.
Selecting filter 1 and cuvette 0, the signal must be in the range of 15,000 to
18,500 and the maximum oscillation range must be lower than 10 units.
If not, check in this order:
1. Spray a contact cleaner on all the lamp contacts, in the front and in the back.
2. Possible defective or close to end-of-life lamp.
3. The optical signal cable from the preamplifier to the CPU.
4. The optical preamplifier.
5. The reading section of the CPU board.
See next chapter 14.3. for more detailed troubleshooting.
14.2.2 IMPRECISION OF THE REACTION PLATE POSITIONING

It can be checked with the mechanical check F4. If the positioning is unstable,
the belt must be tightened correctly.
14.2.3 IMPRECISION OF THE FILTER WHEEL POSITIONING

It can be checked with the mechanical check F4. If the positioning is unstable,
the belt must be tightened correctly.
The imprecision in a single filter can be caused by a loose filter locking ring.
14.2.4 DISPENSATION PROBLEMS

Check if the silicone tube is well inserted in the pinch valve and that it is not
worn.
Check that all the pipetting Teflon fittings are well tight.
Check the diluter gasket (white+orange). Eventually replace it.
Check the diluter mechanics (Mechanical Check, F7 DILUTER TEST).
Check if the needle is clogged.
14.2.5 INCORRECT VERTICAL POSITIONING OF THE NEEDLE

Incorrect vertical positioning of the needle during dispensation and mixing in
the reaction plate (SN1DS2 quote). Execute in the WASHINGS MENU the PUMPS
TEST F5-1. At the end of the test the program will suggest eventually to update
the SN1DS2 quote.
126
14.3 Bad repeatability of autozero, unstable optical signal

Go to READING TEST, wait that the instrument is warmed-up and do the follow-
ing tests:
1. Select filter 0 (dark), unconnect the optical cable from the CPU
board. The A/D signal on the screen must be close to 0 and stable.
If not, there is a problem on the CPU A/D converter or the CPU analog pre-
amplifier/multiplexer.
2. Re-connect the optical cable on the CPU and disconnect the optical pream-
plifier. The A/D signal must be close to 0 and stable. If not, there is a problem
on the optical cable. There is a second optical cable in the wiring, used only
for double-cuvette analyzers. Swap the defective optical cable with the se-
cond one.
3. Re-connect the optical preamplifier. The A/D signal must be in the range 1.5
mV to 5.0 mV (15-50 A/D units) and stable 0.2 mV ( 2 A/D units). If not,
there is a problem in the optical preamplifier.
4. In READING TEST, select filter 1 (340 nm). The A/D signal must not oscillate
more than 1.0 mV (10 A/D units). If not, there could be a problem of the lamp
or the lamp contacts. Clean the lamp contacts with a contact cleaner. If the
contacts are old tinned contacts, replace the lamp contacts (lamp and power
board), if possible, with the new golden contacts.
5. Select filter 2 and then again filter 1. Then filter 3 and again filter 1, etc. Wait
for 10 seconds. The A/D signal on filter 1 must come back to the original va-
lue within 2 mV (20 A/D units). If not, there is a problem in the filters wheel
positioning. Check the filter wheel offset (F7-2), if the filter wheel belt is well
tightened and it is not damaged (Test in MECHANICAL CHECK F4-1). It can
happen that the belt doesn't look damaged but it doesn't work well anyway.
If you are in doubt, replace the filter wheel belt.
14.4 Reaction plate temperature out of control

Involved devices:
- 5 Vcc analog power supply.
- Reaction plate temperature sensor and wiring.
- AD844 temperature A/D converter on CPU board.
- 2.731 Vcc voltage reference on CPU board.
- Reaction plate etched coil heating resistance and wiring.
- Reaction plate thermostat.
- Heating resistance driver MOSFET transistor on power board.

TROUBLESHOOTING 127
Go to HARDWARE TEST.
Press F5 for continuous inputs display.
Observe the inputs window in the upper right corner:
1. The displayed temperature is higher than 500 (tenths of C) and PWM R = 0.

- The reaction plate is at room temperature: The temperature sensor is broken
or unconnected or the 2.731 Vcc voltage reference is broken.
- The reaction plate is really at 50 C: The driver MOSFET transistor is short-
circuited.
2. The displayed temperature is correctly 38.0 C 0.2 C, but the reaction plate
temperature is wrong.
- The temperature measurement is unadjusted.
3. The displayed temperature and the reaction plate are at room temperature
and PWM R = 70.
- The heating is not working. Check the voltage on the resistance connector:
- The voltage on the resistance is close to 24 Vcc: The resistance is broken.
- The voltage on the resistance is close to zero: Check the voltage on the power
board connector J4, pin 3 - pin 4:
- The voltage on the board connector is close to 24 Vcc: Check the wiring and
the thermostat.
- The voltage on the board connector is close to zero: The driver MOSFET tran-
sistor is broken.
4. The displayed temperature is close to zero and the reaction plate tempera-
ture is high:
- The AD844 A/D converter is not working or the temperature sensor is short-
circuited.
FIGURE 158
Temperature display
128
14.5 Dirty and quickly excluded reaction cuvettes
14.5.1 FIRST CHECKS

Check if the specified systemic solution is used.
It is possible that some reagents can create problems in the washing. Verify that
all the employed reagents are well tested for the wash purposes.
Check if all the reaction volumes are limited to 310 l.
Verify that the user never shuts the instrument off before the washings have
been completed (in run or in shut-down).
14.5.2 CHECK THE REACTION CUVETTES

It is important to check and find out in which way the cuvettes are dirty, because
it is very important to understand the cause.
The absorbance threshold for the cuvette to be considered clean is 120.0 mAbs
at 340 nm. Typical absorbance for a new cuvette at 340 nm is lower than 60.0
mAbs, and for the other wavelengths is lower than 35.0 mAbs.
In MAINTENANCE Reaction Cuvettes, check the spectrum of the excluded cu-

vettes.
The deposits that absorb at 340 nm cannot be seen by the human eye, so the
cuvette seems clean. If the spectrum is very high at 340 nm and low at the other
wavelengths, the cuvette looks clean to the eye, but it is anyway excluded.
High absorbances on all the wavelengths, are typical for scratches or uncoloured
(white/grey) deposits.
14.5.3 CHECK THE CAUSE OF THE HIGH ABSORBANCES

There are internal deposits, i. e. the washing is poor. If the deposit is coloured,
you can try to understand which reagents cannot be washed.
There are internal vertical scratches, i. e. the stub touches the inner side of the
reaction cuvette.

TROUBLESHOOTING 129
There are external horizontal scratches, i.e. the reaction cuvette touches some-
where and is scratched during the rotation.
There are external "clouds", i.e. the vacuum pump is not working well or the
operator made some mistake and water poured outside. The "cloud" is the solid
deposit that remained on the outer side of the cuvettes after the water was
evaporated. In this case the two external sides of the cuvettes can be cleaned
with a soft glass cloth.
If the area is highly humid, the two external optical faces of the cuvettes can
become dirty after some months. Take off the cuvettes rotor (see "12.4. Reaction
rotor replacement") and pass a soft optical cloth on the two optical faces of the
80 cuvettes mounted on the rotor.
14.5.4 EXECUTE THE PUMP TEST

Put a 5 ml tube filled with tap water in sample position 1.
Go to SERVICE MENU F5 WASHINGS F5 TEST PUMPS DISP 1 TEST PUMPS.
Verify that the aspiration flow in the aspiration test is higher than 1,500 l and
that the final result is Asp. PASS (not Asp. FAIL).
The wash station dispensation must have the values higher than 350 l.
If the Aspiration test failed, the membrane valves of the vacuum pump or the
entire pump must be replaced.
If the Wash station dispensation is low, the peristaltic pumps timers must be
increased. This can be done manually, increasing the DIWSH1 to DIWSH6 para-
meters in the following way:
The DIWSHx parameters ran-

ge is between 45 and 80. If
Example: Pump dispensation = 300. the parameter has to be set high-
Old value of DIWSH1 = 50. er than 80, the pumps head must
New value of DIWSH1 = 50 x 400 / 300 = 67. be replaced.
130
The pumps timer correction can also be made automatically executing the AD-
JUST PUMPS procedure:
SERVICE MENU F5 WASHINGS F5 TEST PUMPS DISP 1 ADJUST PUMPS.
14.5.5 EXECUTE THE CUVETTES SPECIAL WASH

To eliminate protein and lipid deposits in the reaction cuvettes, put a reagent
bottle with 26 ml of NaOH solution at 4 % in reagent position 1 and start the
Special Wash Procedure. At the end, a Startup procedure is executed.
To eliminate salt deposits in the reaction cuvettes, put a reagent bottle with 26
ml of HCl solution at 5 % in reagent position 1 and start the Special Wash Proce-
dure. At the end, a Startup procedure is executed.
14.6 Droplet forms on needle tip
14.6.1 DROPLET FORMES AT THE END OF THE NEEDLE TIP

If the drop is formed at the end of the needle tip, there can be several causes.
The most common causes are:
- The silicone tube inside the pinch valve is damaged, not correctly inserted
or too long out of the pinch valve toward the diluter (max. 1 cm). Check the
silicone tube and eventually replace it.
- For the 368 l diluter (DSTYPE 3 or 4), the parameter DSGAPH (l of gap after
diluter home) must be at -2. If necessary, increase it to -3.
- There are air bubbles in the diluter or the needle tubing.
- There can be a leakage in the fitting under the level sensor board or between
the Teflon tube and the sampling needle.
- There can be a narrowing somewhere in the needle tubing so that the tubes
blow up and the water flow is delayed.
- The needle vertical position SN1WSH in the wash well is not well calibrated
and the needle tip does not pause on the white nipple 1 mm inside the water
drop to let the droplets be captured.

TROUBLESHOOTING 131
14.6.2 DROPLET HANGS AT THE SIDE OF THE NEEDLE

If the drop is hung in a higher position, on the side of the needle, it has probably
been left there by the jet of the external wash nozzle. Clean the needle with
alcohol to ease the drop fall.
The water jet speed can be reduced with the parameter EXWELD, so that the jet
hits the needle in a descending parabola, allowing a better leaching of the dro-
plet. Try to reduce the EXWELD parameter by 5 or 10 units.
If the external wash nozzle splashes the needle at the end of the internal needle
wash, it means that the delay for the valve commutation ASWELD is too low
(increase it by 10 to 30 units) or the Y tubing connected to the well dispensa-
tion pump, placed on the back side of the hydraulic panel, is too resilient and
balloons. Actually it is used a silicone tube 1 x 3 mm to eliminate this problem.
14.7 Aberrant/null results, reagent bottles wrongly detected full

It happens more or less frequently that some reagent bottles are detected as
completely full (green color) even if they are not. At the same time it happens,
that the needle sometimes fails to pipet the sample or reagent 2 (the results are
null) or fails to pipet the reagent 1 (the results are aberrant).
The cause most probably is the wiring of the sampling arm that is broken.
Open the sampling arm cover and check the red level sensor LED during the
execution.
If the red LED blinks when the arm is still in a higher position, before having
detected the liquid level, the level sensor board wiring is broken and must be
replaced.
See "12.12. Sampling arm replacement".
14.8 Error "Needle shock detector is stuck"

The "Needle shock detector is stuck" message is issued when the needle is in an
upper position and begins to move down. If a shock signal is detected before
starting the movement, it means that the shock sensor is not working properly
and the error message is issued.
132
There can be three causes:

- The needle is bent or the white cap over the needle is too tight.
In this case the needle doesn't slide well and it can remain in the upper
"shock" position.
- The optical sensor of the needle shock is broken: Replace the level sensor
board or replace the opto-coupler on the level sensor board.
- If the level sensor wiring is broken and the yellow wire of the shock signal is
open, the system detects this as a shock situation and the alarm is issued:
Replace the level sensor board wiring.

PERIODICAL CHECK-UP, SERVICE PROCEDURE 133
15 PERIODICAL CHECK-UP, SERVICE PROCEDURE
15.1 Twelve months programmed maintenance
15.1.1 UPDATE FIRMWARE AND SOFTWARE

If the firmware or the software of the analyser is significantly old, proceed to
update the EPROMs and the PC software (check the release on the info button
on the lower left corner of the software screen).
15.1.2 COVER
Check if the instrument is correctly levelled.
Check if the top cover shuts correctly the cover switch.
15.1.3 LAMP
Check the lamp life. Lamp life ranges between 1,000 and 2,000 hours.
If the lamp has more than 1,000 hours of work and a new maintenance check-
up is not scheduled, you can consider the lamp to change (remember to reset
the lamp timer).
15.1.4 SAMPLING NEEDLE

Check the sampling needle (coating, shape).
Check if the needle slides correctly in the needle holder, otherwise take off the
holder and clean it from eventual deposits.
Check if the needle holder is not broken or worn.
Check the shock sensor (in Mechanical calibration menu).
Check if the sampling needle is clogged. Clean it in the special wash solution.
15.1.5 WASH STATION NEEDLES

Check if the wash station needles are clogged, especially the first needle on the
right. Eventually unclog them with a probe or a copper wire. The deposit on the
needles depends on the type of reagents employed. Clean them with the special
wash solution (basic) to remove protein or lipids deposits. Use an acid solution
to remove salt deposits.
134
Check if all the needles are not bent and are well centered in the cuvettes (ME-
CHANICAL CALIBRATION procedure).
Check if the dryer needle tip is not worn or broken or rotated.
Replace all the damaged needles.
15.1.6 WIRING, CONNECTORS

Check the lamp connectors (in the back and on the power board) and spray the
contacts with a contact cleaner. In READING TEST, filter 1 selected, move the
lamp wires and connectors. The reading value must not change for more than a
few A/D units. Otherwise, check the lamp wires.
Check the arm wiring: Wires can be stressed or, inside the isolation, the copper
could be broken. The continuity of the signal is then precarious.
Press, on the CPU board, all the connectors and the integrated circuits mounted
on sockets.
15.1.7 HYDRAULIC TUBES, FLOATS

Replace old tubes, dirty or with algae.
Check if there is air leakage from the hydraulic connectors of the tanks. Check
the tubes collars.
Check if the three floats work correctly (check the floats in the WASHINGS
MENU).
15.1.8 DILUTER
Replace the sealing gasket (orange O-ring inside the diluter head).
15.1.9 PUMPS
Run the pumps test (WASHINGS F5-1) and print the report.
Adjust the SN1DS2 quote if requested by the pumps test.
Check the peristaltic pumps life and flow-rate.
If the flow-rate of any pump is lower than 500 l/s or if the pump head work-ti-
me is higher than 30-50 hours, replace the pumps head, reset the pumps work
timer and then execute the pumps adjustment procedure (WASHINGS F5-5).
On the pumps test report (WASHINGS F5-1), check the vacuum pump flow rate.
If lower than 2,000 l/s for analyzers with 7 aspiration needles or else if lower
than 1,100 l/s for analyzers with 5 aspiration needles, then:

PERIODICAL CHECK-UP, SERVICE PROCEDURE 135
- First check if any aspiration needle (the longer ones) is clogged and eventu-
ally unclog them.
- Else replace the pumps membrane valves or the vacuum pumps (see "12.8.
Vacuum pump wearing parts replacement").
15.1.10 REAGENTS COOLING

Check the power supply voltage (14.1 Vcc to 14.2 Vcc).
Check if the cold plate is correctly cooled (3 Peltiers positions).
If not, check the supply current. It must be in the range 2.3 A to 2.6 A.
Clean the cold plate, remove eventual mildew.
Check if there is mildew between the warm and the cold plate.
15.1.11 SAMPLE PLATE

If necessary, clean it with a sterilising solution and then rinse abundantly, wipe
and dry.
If it is a 20+20 sample plate, check if the external tubes clips are well inserted
and not damaged.
15.1.12 REACTION PLATE CUVETTES

Check the cuvettes absorbances on the reaction plate. If absorbances are typi-
cally higher than 800, take the reaction rotor off and clean gently the two exter-
nal faces of the cuvettes, wiping them with a lens cleaning cloth. Pay attention
to avoid dust deposits on the two faces. After the cleaning, execute a wash of all
the cuvettes (WASHINGS, F2, 80 cuvettes).
Replace cuvettes which show an OD higher than 1,000 units (= 100 mAbs).
Follow software MAINTENANCE Reaction cuvettes Cuvettes replacement
procedure.
After these two operations it is necessary to execute the start-up. There is a fast
version of the start-up in the Washings menu.
15.1.13 TEST AND ADJUSTMENT PROCEDURES IN THE SERVICE MENU

The following menus must be called from the service menu to execute the test
procedures.
136
F2 Mechanical calibration Check all the mechanical calibrations, especially

the sampling needle dispensation quote (SN1DS2),
the wash station down quote (ANWASP), the
sampling needle wash in the well drop (SN1WSH),
the sampling needle in the reagent bottles and in
the sample tubes and cups.
F3 Mechanical check To verify the belts and the mechanics. Execute the
mechanical check tests, especially the F4.
If FS or OP fails, eventually tighten the belt.
F5 Washings menu F5-2 Fill the hydraulics if the tubes are empty,
otherwise the following tests will be faulty:
- F5-1 Pumps test: Adjustment of the reaction
cuvettes level check and of the needle dispen-
sation quote.
- F5-5 Adjust pumps.
F4 Reading test menu F6-1 OP Reading Offset check.
F7-2 FS Filter wheel check.
F5-2 AUTOZERO test: The CV% must be lower
than 0.1500 for filters 1 and 2 and lower than
0.1000 for the other filters. In the first column
FSOP, there must be only zero values (It is a si-
gnal of good FS and OP positioning). If the CV%
are anyway high with zero FSOP values, check the
lamp, its connectors and its wiring.
15.1.14 DILUTER AND PIPETTING

Run the 2 l pipetting test procedure with E124 (OD at 505 nm: 30 - 50 abs, 1 ml
in sample tube 1).
Commands to start the run:

OK1,1
XM6
Commands to report:
WS1
XM0
The CV% must be lower than 2.5 - 3 %. Factory value is lower than 2 %.

SYSTEM PARAMETERS LIST 137
16 SYSTEM PARAMETERS LIST
16.1 EPROM parameters table

There are 361 parameters, consecutively numbered.
Parameters, named "Qnnn", are unassigned.
Parameters printed in red are critical to the instrument and therefore protected
by a password. For password handling refer to the appropriate Human Service
Bulletin (HSB).
Do not change the parame-
Table columns: ters described in this chapter,
1st column Parameter name as long as it is not expressively re-
2nd column Parameter ID commended by Human.
3rd column Parameter description
16.1.1 INNER PLATE (IP) MOTOR
IPNPS0 000 IP N. positions on external ring.

IPNPS1 001 IP N. positions on inner ring.
IPOFF0 002 IP/SN needle offset for external ring.
IPOFF1 003 IP/SN needle offset for inner ring.
IPDDIL 004 IP Rotation for tube-side dilution dispensation.
IPMODE 005 1: Enable reverse rotation for small movements of IP.
IPPHOM 006 IP Pre-position for fast home.
IPOPER 007 IP Delta steps for tube in front of operator.
IPTYPE 008 IP Type: 0: Free, PTU; 1: 20 ext=PTU, int=CUP2; 2: 30+30
PTU.
IPHOME 009 Enable IP home after every sample.
IPOFBC 010 Samples barcode IP offset.
IPSHFT 011 Numbering shift between inner and external ring.
(0=Inner follows with half step) For barcode use.
Q12 012
Q13 013
Q14 014
Q15 015
Q16 016
Q17 017
Q18 018
Q19 019
138
16.1.2 OUTER PLATE (OP) MOTOR
OPOFAN 020 OP Offset AN side.

Q21 021
OPOFRD 022 OP Offset reading side.
OPPHOM 023 OP Pre-positioning for home speed-up.
OPMODE 024 3: No home during run.
OPCHTU 025 OP Offset between AN and tube change (in tube positions).
OPANSN 026 OP Offset between AN and SN (in tube positions).
OPR1R2 027 N. of R1/R2 incubation cycles = OP offset between R1 and
R2.
OPR2R3 028 N. of R2/R3 incubation cycles = OP offset between R2 and
R3.
Q29 029
OPOFGO 030 OP tube for reading gain + offset.
16.1.3 FILTERS SELECTION (FS) MOTOR
FSOFFS 031 Filter wheel offset.

Q32 032
Q33 033
Q34 034
Q35 035
Q36 036
Q37 037
Q38 038
Q39 039
16.1.4 SAMPLING NEEDLE (SN) MOTOR
SNOFFS 040 SN Offset.

SN1HOM 041 SN1 High out of FC for fast home search.
SN1LOW 042 SN1 Low position over the reaction tubes.
SN1MID 043 SN1 Mid position over the sample tubes.
SN1HIG 044 SN1 High, for rotation over reagent bottles.
SN1WSH 045 SN1 For wash needle 1 in wash well.
SN1WEL 046 SN1 Low position over the wash well.
SNDWEL 047 Delta to SN1WEL for dispensation in wash well.
SN1DWU 048 SN1 Delta SN1 up for drop.
SN1REA 049 SN1 At the bottom of reagent bottles.
SN1CUP 050 SN1 For sampling on IP: Cups.

SN1PTU 051 SN1 For sampling on IP: Primary tubes.

SN1DDS 052 SN1 Upside delta/SN1DS2 for 1st dispensation on OP.
SN1DS2 053 SN1 For 2nd dispensation in OP, with mixing, correspondi-
ng to 100 l in OP.
SN1CU2 054 SN1 For internal row cups for IP 20 + 20.
SN1RET 055 SN1 At the bottom of reagent bottle type: Tube.
SN1REC 056 SN1 At the bottom of reagent bottle type: Cup.
SN1DLC 057 SN1 At the bottom of diluent bottle.
SNDLWE 058 Delta to SN1WSH for level sensing in needle wash well
test.
SNDXWN 059 Delta to SN1WSH-SN1DWU for external needle wash.
Q60 060
SNDMOD 061 Enable dispensation from SN1DDS and then down to
SN1DS2 with level check.
Q62 062
Q63 063
Q64 064
Q65 065
16.1.5 DILUTER SYRINGE (DS) MOTOR
DSKADD 066 DS Steps correction.

MIXVO1 067 DS Reaction mixing volume 1st dispensation.
DSTYPE 068 0: Free parameters, 1=Sanwa 530 l, 2=Sanwa 354 l,
3=Edif 368 l.
DSOFFS 069 Syringe home offset.
DSTROK 070 Diluter syringe volume (full stroke).
DSTEPS 071 DS Steps/stroke.
MIXVO2 072 DS Reaction mixing volume 2nd dispensation.
MIXRP1 073 DS Reaction mixing repetitions DISP.1.
MIXRP2 074 DS Reaction mixing repetitions DISP.2.
DLYMIX 075 Delay in needle mixing in csec.
DSGAP1 076 Diluter syringe first GAP.
DSGAP3 077 Diluter syringe third GAP.
DSGAPH 078 Diluter GAP after home: Diluter type 3-4: -2, else 0.
MIXRPD 079 DS Predilution in OP mixing repetitions.
140
16.1.6 NEEDLE ROTATION (RN) MOTOR
NREAG 080 N. of reagents on RN plate (last position is for diluent).

Q81 081
RNREA1 082 RN Position of 1st reagent bottle.
RNREAN 083 RN Position of last reagent bottle.
Q84 084
RNWRAP 085 RN Wrap position.
RNWASH 086 RN On wash well.
RN1DWN 087 RN Delta for wash on well SN1 side.
RNDWEL 088 RN Delta for check WN pumps.
Q89 089
RN_IP0 090 RN Needle 1 on IP external ring.
RN_IP1 091 RN Needle 1 on IP inner ring.
RN1_OP 092 RN Needle 1 on outer plate tubes.
Q93 093
Q94 094
RNDILC 095 RN On clinical chemistry diluent bottle.
Q96 096
Q97 097
Q98 098
Q99 099
Q100 100
Q101 101
Q102 102
Q103 103
Q104 104
Q105 105
Q106 106
Q107 107
Q108 108
Q109 109
16.1.7 WASH STATION (AN) MOTOR
ANOFFS 110 AN Offset.

ANHOME 111 AN Home position.
ANHIGH 112 AN High position under home.
ANWA1D 113 AN 1st pause during wash aspiration / Rising start vacu-
um aspiration.
ANWA2D 114 AN 2nd pause during wash aspiration.
ANWASP 115 AN Bottom wash aspiration.
ANZMOD 116 AN Home search mode.

ANTUBE 117 AN Low immediately over the OP reaction tubes.

Q118 118
Q119 119
16.1.8 MOTOR SPEEDS, HOME TOLERANCES
IPVEL 120 IP Normal speed.

IPVELZ 121 IP Home speed.
IPDYBC 122 IP Delay in barcode scanning.
Q123 123
Q124 124
OPVEL 125 OP Normal speed.
OPVELZ 126 OP Home speed.
OPVELR 127 OP Reading speed.
Q128 128
Q129 129
FSVEL 130 FS Speed.
FSVELZ 131 FS Home speed.
DLYFLT 132 Delay for filter rotation in reading.
DSVELD 133 DS Dispensation speed.
DSVELA 134 DS Aspiration speed.
DSVLOW 135 DS Speed low (GAP + sample aspiration).
Q136 136
DSVELZ 137 DS Home speed.
RNVEL 138 RN Speed.
RNVELZ 139 RN Home speed.
Q140 140
Q141 141
Q142 142
Q143 143
SNVELU 144 SN Up speed.
SNVELD 145 SN Down speed.
SNVELZ 146 SN Home speed.
Q147 147
Q148 148
ANVELH 149 AN Speed high.
ANVELL 150 AN Speed low.
ANVELZ 151 AN Home speed.
Q152 152
IPZERR 153 Steps limit for IP home step error.
RNZERR 154 Steps limit for RN home step error.
OPZERR 155 Steps limit for OP home step error.
142
SNZERR 156 Steps limit for SN home step error.

FSZERR 157 Steps limit for FS home step error.
ANZERR 158 Steps limit for AN home step error.
DSZERR 159 Steps limit for DS home step error.
16.1.9 PUMPS
DIWSH1 160 Water dispensation 1 time (csec).

DIWSH2 161 Wash dispensation 2 time (csec).
ASVAC4 166 Fourth vacuum aspiration (csec).
ASVAC1 167 First Vacuum aspiration (csec).
ASVAC2 168 Second vacuum aspiration (csec).
ASVAC3 169 Third vacuum aspiration (csec).
DLYPMP 170 Delay after pump stop, before VAC2
FILLWS 171 2 low digits=repetition for wash (wash prime on 2nd
needle),
2 high digits=repetition for water prime.
NRIPWS 172 N. repetitions of filling/aspiration cycles in wash station.
ENANDN 173 Enable check AN down limit switch.
EPM6ER 174 Enable PUMP 6 WASH DISPENSATION ERROR in test wash
station dispensation.
FILCHK 175 Enable pumps check in fill hydraulics,
1: Dispensation well, 2: Aspiration well, 4: Test well,
8: Wash station aspiration.
EPMDER 176 Enable PUMPS WASH DISPENSATION ERROR in test wash
station dispensation.
WSHVOL 177 Target volume (l) for wash station.
Q178 178
Q179 179
THMCNV 180 THOMAS peristaltic pump dispensation l per second
conv. factor, over evaluated, to calculate water and waste
variations (measured range: 700 to 1,050).
NDWMOD 181 Wash needle in well mode 0=center / 1=side+center.
NDWSHO 182 Wash dispensation, SN in OP tube (csec for 400 l)
SN_Wash().
NDWSHS 183 Wash dispensation, SN in well / samples 1st + 2nd dispen-
sation (csec).

NDWSHR 184 Wash dispensation, SN in well / reagents check level, R3,

R4 (csec).
NDWSHX 185 Wash dispensation, SN in well / external wash (csec).
ASWELD 186 Well aspiration extension after well dispensation.
DIWELD 187 Well Dispensation delay after pump stop, to avoid drop.
EXWELD 188 Well external wash delay after pump stop, to avoid drop.
Q189 189
Q190 190
Q191 191
ASVAV1 192
ASVAV2 193
ASVAV3 194
EXWELV 195
INWELV 196
PERILF 197 Peristaltic pump expected life (hours).
VAC1LF 198 Vacuum pump 1 expected life (hours).
VAC2LF 199 Vacuum pump 2 expected life (hours).
16.1.10 VARIOUS PARAMETERS
RELEAS 200 Current software release for automatic parameter update.

Q201 201
ENASIC 202 Enable door security limit-switch.
Q203 203
ENALOG 204 Enable LOG prints.
SVSCRN 205 Enable automatic Save Screen with Terminal 2.2.
SPAUSE 206 1=Sstep, >1: breakpoint at SStatus=SPAUSE - RESERVED.
DISPLV 207 Local printer test mode reserved.
EXECOD 208 Enable full execution status codes (SW >= 0.38).
ENVACS 209 Enable Vacuum ERROR:
1=needles aspiration test with SN, 2=swap aspiration test
with SN, 4=vacuum sensor.
ENAWY 210 Enable WY command.
EEXCHK 211 Enable execution flag check.
ESWR12 212 Enable reagents swap in R1+R2 dispensation.
Q213 213
Q214 214
RDSTEP 215 Optical reading step (1 or 2 cycles).
NDISP 216 N. of dispensations per cycle.
PHASD3 217 Beginning of 2nd dispensation (sec), 0: No second dispen-
sation.
144
MCYCLE 218 Machine cycle (sec) clinical chemistry.

PHASD2 219 Beginning of 2nd dispensation (sec), 0: No second dispen-
sation.
EWNREA 220 Enable needle external wash after REAG.
EWNSMP 221 Enable needle external wash after SMP if volume <=
EWNSMP.
ENWSHS 222 Enable wash station in run (0 for diagnostics only).
NWPRIM 223 N. of wash prime at run start (0=disable).
NSPWSH 224 N. of special cuvettes special washes (1/2).
Q225 225
Q226 226
Q227 227
LMPSAV 228 Lamp saver - delay after switch on (sec).
LMPLIF 229 Optical lamp expected life (hours).
16.1.11 BARCODE
BARCOD 230 Barcode installed 0 or 1.

Q231 231
Q232 232
Q233 233
Q234 234
Q235 235
Q235 236
Q237 237
Q238 238
Q239 239
16.1.12 LEVEL SENSOR, FLOATS
LEVPTU 240 Primary tube sample level check: -1=no, else steps before
needle stops.
LEVCUP 241 Cups sample level check: -1=no, else steps before needle
stops.
LEVREA 242 Reagent level check: -1=no, else steps before needle stops.
LEVDIL 243 Sample dilution level check: -1=no, else steps before
needle stops.
LEVCUV 244 Sample dilution in OP level check: -1=no, else steps before
needle stops.
SN: 0.151 mm/step.
KLVPTU 245 Coefficient: Primary tubes, L/10 per SN needle step.

KLVCUP 246 Coefficient: Cups, L/10 per SN needle step.

KLVREL 247 Coefficient: Reagent bottles, large, L/10 per SN needle
step.
KLVRES 248 Coefficient: Reagent bottles, small, L/10 per SN needle
step.
KLVDLC 249 Coefficient: Diluent bottles, L/10 per SN needle step.
LMXPTU 250 Primary tube sample maximum level (steps) above which
detection is disabled.
LMXCUP 251 Cup sample maximum level (steps) above which detec-
tion is disabled.
LMXREA 252 Reagent maximum level (steps) above which detection is
disabled.
LMXDLC 253 Diluent maximum level (steps) above which detection is
disabled.
Q254 254
RELVOL 255 Reagent large bottle maximum level (ml) to which mea-
sured level is clipped.
RESVOL 256 Reagent small bottle maximum level (ml) to which mea-
LVERWN 257 Reagent tube bottle maximum level (ml) to which mea-
LEVWEL 258 Reagent cup bottle maximum level (ml) to which mea-
Q259 259
WSTFUL 260 Full volume of waste (ml) = fatal alarm.
WSTRES 261 Reserve volume of waste full (ml). Float commutation.
WATFUL 262 Full volume of water (ml).
WATRES 263 Reserve volume of Water (ml). Float commutation.
WATRS2 264 Reserve alarm volume of water (ml).
WSHFUL 265 Full volume of wash (ml).
WSHRES 266 Reserve volume of wash (ml). Float commutation.
WSHRS2 267 Reserve alarm volume of wash (ml).
Q268 268
Q269 269
DELREA 270 1=Delete reagents at power-on, 0=Don't delete, -1=Keep
also levels.
Q271 271
DSMPLV 272 Maximum difference error in sample level double check
(l).
EFLOAT 273 Enable waste and wash floats alarm.
ESHOCK 274 Enable shock sensor.
Q275 275
Q276 276
REF150 277
OPL150 278 OP level calibration 150 l.
146
OPL450 279 OP level calibration 450 l.
16.1.13 TEMPERATURES
OP1TMP 280 Normal OP temperature (0.1 C).

MAXRS1 281 Maximum PWM for RS1 OP heating.
PR1PWM 282 Fixed reagent pre-heating % PWM.
OPTMPO 283 OP Temperature offset (0.1 C).
OPTSBY 284 Standby OP temperature (0.1 C).
Q285 285
Q286 286
Q287 287
TMPERR 288 Temperature error for alarm (0.1 C).
TMPTOU 289 Temperature timeout for alarm (sec).
Q290 290
Q291 291
Q292 292
Q293 293
Q294 294
Q295 295
Q296 296
Q297 297
Q298 298
Q299 299
16.1.14 DILUTIONS, PIPETTING
DLYASR 300 CC: Delay aspiration reagent.

DLYASS 301 CC: Delay aspiration sample.
DLYDSP 302 CC: Delay dispensation diluent / reagent / sample.
Q303 303
VOLDIL 304 Pre-dilutions base (dead) volume (l).
DILSHK 305 Pre-dilutions shake time (sec).
MIXDIL 306 Pre-dilution needle mixing repetitions.
Q307 307
MXDIL2 308 Maximum in-needle dilution rate.
MINSMP 309 Minimum sample volume.
Q310 310
Q311 311
Q312 312

16.1.15 READING
Q313 313
Q314 314
SLFMOD 315 Self blank mode: 1 check bubble.
NRSLFB 316 N. of readings employed in the self blank.
Q317 317
INISTU 318 Initial sampling tube in run (for diagnostics), 0=Auto.
Q319 319
FILTR1 320 Filter 1 wavelength (nm).
FILTR9 328 Filter 9 wavelength (nm), optional.
FILAUX 329 Auxiliary filter for colorimetric tests.
ZIF0 330 F0 Factory initial autozero value.
Q331 331
Q332 332
Q333 333
Q334 334
Q335 335
Q336 336
Q337 337
Q338 338
Q339 339
FITMIN 340 Minimum fit for kinetics (/1000).
OPGAIN 341 Current optical gain.
OPRDER 342 Enable CancelLastReading() in OP home != 0.
CLCMOD 343 Internal use: 0=No calculations.
ENALIN 344 Enable linearity in WF: 0=No, 1=Abs. value, 2=Alg. Value.
SHRTRD 345 Enable short reading.
ENTUBZ 346 &1: Enable sub. tube zero in KINE/FIXT.
&2: Enable sub. tube zero in BICR+COLOR.
ADJKIN 347 Enable kinetic adjustment of the number of readings.
Q348 348
RDGDOD 349 Threshold Dod1 x Dod2 for reading elimination.
DIFAUZ 350 Maximum autozero difference in 1/1000 / previous auto-
zero (50 = 21 mAbs).
DIFAZ2 351 Maximum autozero difference /1000 in 2nd repetition
(12 = 5 mAbs).
148
MINAUZ 352 Minimum A/D value for autozero.

MAXZER 353 Maximum zero value at FILTER1 (UV) for a reaction cuvet-
te (0.1 mAbs).
MAXDZE 354 Maximum zero absolute difference between Startup 340
nm and current 340 nm (0.1 mAbs).
MAXZE2 355 Maximum zero value at visible filters for a reaction cuvet-
te (0.1 mAbs).
Q356 356
MXDIRT 357 Maximum number of excluded tubes for error cuvette ro-
tor dirty.
ELSNGP 358 Enable singular points elimination.
CODCHK 359 Weighted parameters checksum.
NPARAM 360 N. of elements in the parameter table.

ERROR CODES 149
17 ERROR CODES
17.1 HI software error codes
Table columns:
1st column Error code
2nd column Error mnemonics (first 15 characters)
3rd column Error description
e0001 INSTR_CLOSE You are not connected to an instrument!

The program will be closed now.
e0002 UNABLE_TO_READ_ Unable to read firmware version from in-
strument.
e0003 CONN_BF_PROC Connect the instrument before proceeding.
e0004 ERROR_REMOVING_ Error removing the selected method.
e0005 METHOD_UPLOAD_P Method upload procedure cannot be exe-
cuted when instrument is running or during
check of reagent levels.
e0006 PROBLEM_UPLOADI Problem uploading methods.
e0007 Internal system error (error during test sta-
tus update).
e0008 AN_ERROR_OCCURE An error occurred while saving the settings.
e0009 SAMP_POS_NV Not valid sample position.
e0010 PATIENT_LINKERROR A linked patient should be defined to conti-
nue with the creation of the sample.
e0011 INV_FIELD_BLANK Invalid field value for blank validity.
e0012 INV_FIELD_OD1 Invalid field value for blank OD 1.
e0013 INV_FIELD_STD Invalid field value for standards number.
e0014 INV_FIELD_CALVA Invalid field value for calibration validity.
e0015 INV_FIELD_FACT Invalid field value for calibration factor.
e0016 INVALID_CORRELATION Invalid value for correlation factor.
e0017 SU_FIN_INT Start-up procedure has been interrupted. It
is recommended to repeat the procedure.
e0018 NR_FIN_INT Needle rinse procedure has been inter-
rupted. It is recommended to repeat the
procedure.
e0019 ET_FIN_INT Empty tubes procedure has been inter-
procedure.
e0020 PH_FIN_INT Prime hydraulics procedure has been in-
terrupted. It is recommended to repeat the
procedure.
150
e0021 WC_FIN_INT Wash cuvettes procedure has been inter-

procedure.
e0022 SD_FIN_INT Shut-down procedure has been interrupted.
It is recommended to repeat the procedure.
e0023 MET_UP_PARTIAL Only the first 40 methods have been loaded
on the instrument. Please check the number
of methods and try again.
e0024 ACCOUNT_LOG Internal system error (error in account login).
e0025 METH_MAX_EXCEED The maximum number of methods has been
reached.
e0026 METH_ALR_EXIST The current method already exists in the
method list. Operation aborted.
e0027 METH_ERR_LOAD Error loading a method.
e0028 SAMP_POS_ALR_EX This sample position is already used.
e0029 SAMP_POS_INV Invalid position for current sample.
e0030 SAMP_POS_NT_CHANG Sample position can be changed only if the
sample doesnt have executing or scheduled
tests.
e0031 SAMP_POS_VAL_INV Invalid sample position value.
e0032 TO_REMOVE_AN_EX To remove an executing test the instrument
must be connected.
e0033 THE_INSTRUMENT_ The instrument is not responding. Check the
cable connection.
If the problem persists contact the assi-
stance.
e0034 ERR_MAIN_LOGS Error saving maintenance log.
e0035 EXECUTION_STOPP Execution stopped.
e0036 NON-VOLATILE_RA Non-volatile RAM error.
e0037 LAMP_OUT-OF-WOR Lamp out-of-work.
e0038 NO_CLEAN_REACTI No clean reaction tubes.
e0039 REACTION_HIGH_T Reaction high temperature error.
e0040 ERROR_ON_SAMPLI Error on sampling needle HOME search.
e0041 ERROR_ON_WASH_S Error on wash station HOME search.
e0042 ERROR_ON_NEEDLE Error on needle rotation HOME search.
e0043 ERROR_ON_SAMPLE Error on sample plate HOME search.
e0044 ERROR_ON_REACTI Error on reaction plate HOME search.
e0045 ERROR_ON_DILUTE Error on diluter syringe HOME search.
e0046 ERROR_ON_FILTER Error on filter wheel HOME search.
e0047 REACTION_LOW_TE Reaction low temperature error.
e0048 BARCODE_READER_ Barcode reader not ready.
e0049 WELL_WASH_DISP. Well wash dispension pump error.
e0050 WELL_WASH_ASP._ Well wash aspiration pump error.
e0051 VACUUM_PUMP_1_E Vacuum pump 1 error.

ERROR CODES 151
e0052 VACUUM_PUMP_2_E Vacuum pump 2 error.

e0053 WASH_DISP._1_PU Wash dispension 1 pump error.
e0058 WASH_DISP._6_PU2 Wash dispension 6 pump error. (Bubbles
may be in the system. If problem persists af-
ter prime, the cause may be the malfunction
of dispension pump 6.)
e0059 DOOR_OPEN:_WAIT Door open (waiting).
e0060 WASTE_FULL Waste full.
e0061 WATER_TANK_EMPT Water tank empty.
e0062 WASH_TANK_EMPTY Wash tank empty.
e0063 SAMPLE_TUBE_EMP Sample tube empty during predilutions.
e0064 DILUENT_BOTTLE_ Diluent bottle empty during predilutions.
e0065 NEEDLE_SHOCK_ER Needle shock error.
e0066 REAGENT_POSITIO Reagent position request out-of-range.
e0067 FILTER_POSITION Filter position request out-of-range.
e0068 FIRMWARE_ERROR Internal firmware error.
e0069 READING_A/D_OVE Optical reading A/D overflow.
e0070 READING_A/D_TIM Optical reading A/D time-out (A/D malfunc-
tion).
e0071 INVALID_AUTOZER Invalid autozero.
e0072 REACTION_ROTOR_ Reaction rotor dirty (too many dirty tubes).
e0073 WASH_STATION_DO Wash station down error.
e0074 ERROR_ON_REAGEN Error on reagent plate HOME search.
e0075 ERROR_IN_OUTER_ Error in reaction plate OFFSET calibration.
It is recommended to execute the optical
calibration.
e0076 LOW_LIQUID_LEVE Low liquid level in sample tube 1.
e0077 RINSE_BOTTLE_MI Rinse bottle missing in reagent position 1.
e0078 NEEDLE_SHOCK_DE Needle shock detector is stuck (shock is de-
tected in high needle position).
e0079 COMPOSED_ERROR Composed method error (formula of a com-
posed method must not contain a cyclic re-
ference).
e0080 Internal system error (retrieving readings).
e0081 Internal system error (RefreshTests).
e0082 Internal system error (ElaborateTests
Queue).
e0083 Internal system error (UpdateMethods
AvailableTests).
152
e0084 Internal system error (UpdateInstrument-

Status).
e0085 Internal system error (RefreshTimeLeftFor
Execution).
e0086 Internal system error (UpdateWarmUp).
e0087 Internal system error (not assigned).
e0088 Internal system error (Core.TimerPolling-
CallBack).
e0089 Internal system error (not assigned).
e0090 Internal system error (loading calibrators
and controls).
e0091 Internal system error (saving calibrators and
controls).
e0092 Internal system error (saving quality con-
trol).
e0093 Internal system error (SerializeQC).
e0094 Internal system error (SerializeQC).
e0095 Internal system error (loading QC log file).
e0096 Internal system error.
e0108 Internal system error (assigned).

ERROR CODES 153

e0133 Internal system error (MainInterface.
PrintSampleReportDirectly).
e0134 Internal system error (SheetTabPage.In-
sertTests).
e0144 Internal system error (PlaySound).
e0151 Internal system error (PlaySound).
e0152 Internal system error (AddTestToScheduler).
e0153 Internal system error (RemoveTestFrom-
Scheduler).
e0154 Internal system error (TestReportButton_
Click).
e0155 Internal system error (unable to refresh
sample).
e0156 Internal system error (finding patient on
RefreshSample).
e0157 Internal system error (unable to clear
fields).
e0158 Internal system error (check test on a null
test).
154
e0159 Internal system error (managing optical

error).
e0160 Internal system error (during autodilution
process).
e0161 Internal system error (during QC registra-
tion).
e0162 Internal system error (trying to serialize
method).
e0163 Internal system error (trying to archive test).
e0164 Internal system error (trying to remove test
from instrument).
e0165 Internal system error (color test).
e0166 Internal system error (composed test).
e0167 Internal system error (removing test from
instrument).
e0168 Internal system error (refreshing values for
test and sample).
e0169 Internal system error (InitSQC).
e0170 Internal system error (loading xx QC item).
e0171 ERR_LOAD_BKP_WORK Worklist backup was corrupted too. HI will
make a copy of the file CurrentWorklist.
sdw_corruptedBkp.
e0172 Internal system error (CheckIfPrintAreNee-
ded).
e0173 ERR_CREA_MET A method code must not contain spaces,
commas and must not be longer than 6
characters.
e0176 Internal system error (during sample sync).
e0177 Internal system error (during sample crea-
tion).
e0178 Internal system error (during sample selec-
tion on grid).
e0180 Internal system error (QC print).
17.2 Firmware execution error codes
Table columns:
1st column Error code
2nd column Error description

ERROR CODES 155
17.2.1 EXECUTION ERRORS
1 Execution stopped.
2 Non-volatile RAM error.
3 Lamp out-of-work.
4 No clean reaction tubes.
5 Reaction high temperature error.
6 ERROR ON SAMPLING NEEDLE.
7 ERROR ON WASH STATION.
8 ERROR ON NEEDLE ROTATION.
9 ERROR ON SAMPLE PLATE.
10 ERROR ON REACTION PLATE.
11 ERROR ON DILUTER SYRINGE.
12 ERROR ON FILTER WHEEL.
13 Reaction low temperature error.
14 Barcode reader not ready.
15 Well wash disp. pump error.
16 Well wash asp. pump error.
17 Vacuum pump 1 error.
18 Vacuum pump 2 error.
19 Wash disp. 1 pump error.
17.2.2 RESOURCES ERRORS
26 Waste full - Empty tank before start.

27 Water bottle empty.
28 Wash bottle empty.
17.2.3 OFF-LINE PREDILUTIONS ERRORS
29 Sample tube empty in predilutions.

30 Diluent bottle empty in predilutions.
156
17.2.4 ERRORS CAUSED BY FIRMWARE/SOFTWARE MISTAKES
32 Reagent position request out of range.

33 Filter position request out of range.
34 Firmware error.
35 Reading A/D Overflow.
36 Reading A/D time-out.
37 Invalid autozero.
38 Reaction rotor dirty, more than MXDIRT excluded tubes.
39 Wash station down error.
40 ERROR ON REAGENT PLATE (LITHIA ONLY).
41 OP Calibration error.
42 Low level in sample tube IP-01.
43 Low level Rinse bottle R1.
44 SN needle shock detector is stuck.

HI SOFTWARE INSTALLATION/UPDATE 157
18 HI SOFTWARE INSTALLATION/UPDATE
FIGURE 159
Human Interface icon
18.1 Settings
The HI software is a Windows .Net application and runs under Microsoft Frame-
work 4.0. It also requires some more Microsoft applications (Microsoft SQL
Server Compact and Microsoft Report Viewer). All these Microsoft tools are al-
ready included in the installation CD and are installed automatically before the
HI software will be installed.
The program runs with almost any last generation CPUs. For slow cheap CPUs,
like the Atom N270, it will be necessary to disable the fading effects in the HI
software settings to reduce the graphics CPU load.
The software auto-scales on the computer screen. It is anyway suggested to use

the 1280 x 1024 screen resolution to get the best results. Minimum vertical re-
solution required is 900 dots.
18.2 HI software updating release 0.4X
18.2.1 LOGGING ON
To install the software you need to log-on to your computer as Windows Admi-
nistrator.
158
18.2.2 CREATION OF A BACKUP COPY OF THE DATA FOLDER

It is recommended to back-up the "Human" data folder. If you want to return to
the old release, you have to replace the newly modified "Human" folder by the
old backup data folder. See "18.3. HI data folder" to locate the "Human" data
folder.
18.2.3 INSTALLATION OF THE NEW SOFTWARE

If the new software has been downloaded:
- Unzip the installation software file (if it is compressed).

- Execute the SETUP.EXE program.
If the new software is on an installation disk, just insert the CD and the installa-
tion will start automatically (assuming the AUTORUN.INF feature is enabled). If
AUTORUN.INF is disabled, execute the SETUP.EXE program.
18.2.4 INSTALLATION STEPS

A: Only if the old installation has not been correctly uninstalled, a new win-
dow will ask you to remove the old installation. In this case confirm that
the old installation must be removed, then press the CLOSE button and
restart the installation.
B: FTDI CDM - USB-RS232 driver installation: Press INSTALL a DOS black
window will open during this installation.
C: MICROSOFT LICENSE AGREEMENT window (if the Microsoft Framework
4.0 tools are already present in your computer, this step can be skipped
by the installer): Select the "I agree" option 3 times, first for Microsoft
Framework, second for Microsoft Report Viewer and third for Microsoft
SQL Server. In this case, the system will ask you to reboot the computer.
Accept and wait while the computer restarts and enters again the instal-
ler.
D: HI (HUMAN INTERFACE) LICENSE AGREEMENT window: Select the "I agree"
option and press the NEXT button.
E: Select the COMPLETE INSTALLATION option.
F: CONFIRM INSTALLATION window: Press the NEXT button. The software is
installed in a few seconds.
G: INSTALLATION COMPLETE window: Press the CLOSE button.

HI SOFTWARE INSTALLATION/UPDATE 159
H: The installer creates a data folder named "Human" with only void files. If
you want to keep your old data, you have to copy the old "Human" data
folder. Follow the steps described in the next chapter. Otherwise contact
your distributor for your default data folder. A reference default data fol-
der is supplied in the Settings CD.
I: A "HI" icon is now available on the desktop to start the program.
J: When you start the program the first time, you must select the COM port
that will be used for the communication with the instrument.
K: Since the internal method structure could have been changed, log-on as
ADMINISTRATOR or INSTALLER and execute the METHODS UPLOAD to
synchronize the analyzer with the PC.
18.3 HI data folder

The software installer initializes a void data folder.
You can copy your own data folder or a default data folder, replacing the void
folder created by the installer.
The data folder path is:

- For Windows XP:
C:\Documents and Settings\All Users\Application Data\HI\Human.
- For Windows Vista / Windows 7:
C:\ProgramData\HI\Human
The "Program Data" folder
To maintain the application data from an old installation, copy the old "Human" may be hidden. To show it, go
folder and paste it into the following folder: to "Windows Control Panel Fol-
- For Windows XP: der Options View" and set the
C:\Documents and Settings\All Users\Application Data\HI "View Hidden Files" option.
- For Windows Vista / Windows 7:
C:\ProgramData\HI
Once copied, rename your new data folder to "Human".
To avoid the risk of data loss, it is anyway safe to back-up periodically the com-
plete "Human" data folder.
DEFAULT METHODS: There is a data folder in the Settings CD that can be used by
beginners, replacing the void data folder that is created by the installation CD.
160
18.4 Compatibility with Windows 7

There is full compatibility with Windows 7 when the Microsoft Framework 4.0
is installed.
18.5 Device drivers

Make sure that the following drivers have been loaded (normally installed by
the HI Software Installation CD):
- Microsoft .Net Framework 4.0.
- Microsoft SQL Server Compact 3.5 SP2 ENU.
- Microsoft Report Viewer 2010 re-distributable.
- FTDI CDM Driver package 17/02/2009 24.16 (this driver reinstalls at every
installation).
Optionally to be installed if using the recommended HUMAN touch screen

monitor:
- Device driver for RS-232 or USB controlled touch screen (comes on the CD
with the monitor).

LIS ASTM INTERFACE SOFTWARE 161
19 LIS ASTM INTERFACE SOFTWARE

Please refer to the most current version of the external documentation "LIS
ASTM interface software for the HumaStar 100/200".
162

SERVICE SCHEMATICS 163
20 SERVICE SCHEMATICS
20.1 Instrument block diagram
FIGURE 160
Instrument block diagram
164
20.2 CPU board layout
FIGURE 161
CPU board layout

20.3 Power board layout
FIGURE 162
Power board layout
166
20.4 Sampling arm board layout
FIGURE 163
Sampling arm board
layout

20.5 High voltage wiring
FIGURE 164
High voltage wiring
168
20.6 Low voltage wiring
FIGURE 165
Low voltage wiring 1
Legend of colors
BK = black OG = orange
BR = brown RD = red
BU = blue SH = shielding
GN = green WH = white
GY = gray YE = yellow

FIGURE 166
Low voltage wiring 2
Legend of colors
BK = black OG = orange
BR = brown RD = red
BU = blue SH = shielding
GN = green WH = white
GY = gray YE = yellow
170
Wiring plan 1
FIGURE 167
Wiring plan 1

Wiring plan 2
FIGURE 168
Wiring plan 2
172
Wiring plan 3
FIGURE 169
Wiring plan 3

Wiring plan 4
FIGURE 170
Wiring plan 4
174
20.7 Internal RS232 serial cable
FIGURE 171
Internal RS232 serial cable
20.8 Optical preamplifier cable
FIGURE 172
Optical preamplifier cable
20.9 Sampling arm cable
FIGURE 173
Sampling arm cable

20.10 Sampling arm cable constructive schema
FIGURE 174
Sampling arm cable constructive
schema
176
20.11 Hydraulics diagram HumaStar 100
FIGURE 175
Hydraulics diagram
HumaStar 100

20.12 Hydraulics diagram HumaStar 200
FIGURE 176
Hydraulics diagram
HumaStar 200
178
20.13 Hydraulics panel layout (front side)
FIGURE 177
Hydraulics panel layout (front
side)

20.14 Hydraulics panel layout (rear side)
FIGURE 178
Hydraulics panel layout (rear side)
180
20.15 Pumps plate hydraulics manifold
FIGURE 179
Pumps plate hydraulics manifold

20.16 Wash station
FIGURE 180
Wash station
182
20.17 Wash station hydraulics manifold HumaStar 100
FIGURE 181
Wash station hydraulics manifold
HumaStar 100

20.18 Wash station hydraulics manifold HumaStar 200
FIGURE 182
Wash station hydraulics manifold
HumaStar 200
184
20.19 Floats and tubes connection assembly
FIGURE 183
Floats and tubes connection
assembly

20.20 Floats and tubes electrical connections
FIGURE 184
Floats and tubes electrical con-
nections
186
20.21 Refrigeration plate
Electrical drawing
FIGURE 185
Electrical drawing
Electrical cabling
FIGURE 186
Electrical cabling

20.22 Main power input panel
FIGURE 187
Main power input panel
188
20.23 Central mechanical assembly
View 1
FIGURE 188
Central mechanical assembly -
view 1

View 2
FIGURE 189
view 2
190
View 3
FIGURE 190
view 3

20.24 Mechanical design internal view
FIGURE 191
Mechanical design internal view
192
20.25 Frame base
FIGURE 192
Frame base

HUMAN
Gesellschaft fr Biochemica und Diagnostica mbH
Max-Planck-Ring 21 65205 Wiesbaden Germany
Tel.: +49 6122/9988 0 Fax: +49 6122/9988 100
eMail: [email protected] www.human.de

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HumaStar 100/200

Cat. No. 168902

Copyright 2013, Human Gesellschaft fr Biochemica und Diagnostica mbH, Wiesbaden,

SERVICE UND SUPPORT

2 THE ANALYZER HUMASTAR 100/200 13

5 HARDWARE TEST MENU (F1) 43

6 MECHANICAL CALIBRATIONS MENU (F2) 49

7 MECHANICAL CHECKS MENU (F3) 55

8 OPTICAL READING TEST MENU (F4) 59

8.6.2 Adjust cuvette rough offset (F6-2) 66

13 FIRMWARE UPDATING EPROMS REPLACEMENT 119

13.2 EPROMS REPLACEMENT VERSION CHANGE 120

15 PERIODICAL CHECK-UP, SERVICE PROCEDURE 133

16 SYSTEM PARAMETERS LIST 137

17 ERROR CODES 149

18 HI SOFTWARE INSTALLATION/UPDATE 157

19 LIS ASTM INTERFACE SOFTWARE 161

20 SERVICE SCHEMATICS 163

1.2 User Warranty

1.3 Intended Use of the Instrument

1.4 General Safety Warnings

1.5 Disposal Management Concept

HumaStar 100/200 | Service manual

1.6 Biohazard Warning

1.7 Instrument Disinfection

HumaStar 100/200 | Service manual

2 THE ANALYZER HUMASTAR 100/200

2.1 General description

HumaStar 100/200 performs both clinical chemistry and turbidimetric immu-

2.2 Main characteristics

2.3.1 SHIPPING AND DELIVERY

If the shipment arrives by private or commercial carrier, immediately inspect the

2.3.4 PRIOR TO SETTING-UP

HumaStar 100/200 | Service manual

If sufficient space is available a surface 90 cm deep by 200 cm in working width

However, the cardboard carton of miscellaneous items and accessories may be

HumaStar 100/200 | Service manual

2.3.5.1 Left side

2.3.5.2 Right side

USB port type B; power cord fitting (incuding fuses compartment).

Connect the USB mouse to a PC port (1).

Connect the monitor to PC with a VGA cable (2).

HumaStar 100/200 | Service manual

Adaptors may be required for

2.3.5.4 Instrument connections

2.3.5.5 Hydraulic connections

FIGURE 14 Place the three tanks below the work

Position connecting tubes as straight as

FIGURE 16 Insert and rotate the BLACK connector

HumaStar 100/200 | Service manual

2.4 Analyzer Components

2.4.1 FUNCTION GROUP IDENTIFICATION

1. Sampling arm. FIGURE 17

FIGURE 18 8. Diluter syringe.

2.4.2 MECHANICAL FUNCTIONS

2.4.3 SAMPLING ARM

HumaStar 100/200 | Service manual

High-precision coated sampling needle.

A single arm is positioned to serve all sampling functions (reagents, samples