Erba Chem Service Manual

Service Manual
For
Semi-Automated Clinical Chemistry Analyzer
and
Document Version: 2017.01
Last Updated: February 16, 2017

Service Manual CHEM 5V3 / CHEM 5X
Foreword
This manual is organized in a progressive sequence for easy study and reference. It is an
instructional aide to provide a reference for easy servicing and maintenance of the
analyzer. It contains detailed description of the analyzer features, specifications, PCB
layouts, wiring diagrams, trouble shooting and replacement procedures.
Use of this manual along with proper training will ensure better serviceability,
maintenance and trouble free analyzer operation with optimum performance.
Before servicing the analyzer, service engineer should:
1. Read and understand this manual.
2. Be trained by authorized person.
3. Be familiar with the operation of the analyzer.
NOTE: Keep this manual in an easily accessible place.
II
Legal Information
All rights are reserved by manufacturer of this product.
Manufacturer is the copyright owner of this document.
The contents of this document are subject to change without prior notice and without legal
obligation.
This document and the information herein are provided for the sole use of the intended
recipient(s) and for information purposes only.
This document contains contents which are the confidential and proprietary information of
the manufacturer.
This document cannot be modified, reproduced, translated or transmitted in any form or

by any means for any purpose, without prior written permission from the manufacturer.
No part of this document can be copied or reprinted, in whole or in part, without prior
written permission from the manufacturer.
III
CONTENTS
1. OVERVIEW OF ANALYZER........................................................................................... 1-1

1.1. INTRODUCTION ................................................................................................. 1-1
1.2. ANALYZER VIEW ................................................................................................ 1-2
2. SAFETY .......................................................................................................................... 2-1
3. ANALYZER FEATURES ................................................................................................ 3-1
3.1. HARDWARE SPECIFICATIONS ......................................................................... 3-1
3.2. SOFTWARE SPECIFICATIONS .......................................................................... 3-2
3.3. KEYBOARD DESCRIPTION ............................................................................... 3-3
3.4. ASPIRATION SWITCH ........................................................................................ 3-4
4. INSTALLATION .............................................................................................................. 4-1
4.1. INSPECTION ....................................................................................................... 4-1
4.2. UNPACKING ....................................................................................................... 4-1
4.3. INSTALLATION REQUIREMENTS ..................................................................... 4-2
4.4. ELECTRICAL REQUIREMENTS ......................................................................... 4-2
4.5. INSTALLATION PROCEDURE ........................................................................... 4-2
4.6. PRINTER HOUSING AND PRINTER PAPER INSTALLATION........................... 4-3
4.6.1. INTERNAL PRINTER ................................................................................................. 4-3
4.6.2. EXTERNAL PRINTER................................................................................................ 4-3
4.6.3. PC COMMUNICATION .............................................................................................. 4-4
4.7. EXTERNAL KEYBOARD INSTALLATION........................................................... 4-4
5. BLOCK DIAGRAM ......................................................................................................... 5-1
6. FUNCTIONAL DESCRIPTION OF PCB ......................................................................... 6-1
6.1. POWER SUPPLY SECTION (ELLC2004R4 / EL20203R3)................................. 6-7
6.2. CONTROL LOGIC SECTION ............................................................................ 6-11
6.3. MOTOR CONTROL AND MEMORY ................................................................. 6-13
6.4. PHOTOMETRIC UNIT (ELLC2002R2 / ELLC2002R4) ...................................... 6-14
6.5. USB PCB ELLC2003R5 (Not used with Cortex) ................................................ 6-18
6.6. PRINTER ........................................................................................................... 6-20
6.7. KEYPAD AND DISPLAY SECTION ................................................................... 6-20
7. WIRING DIAGRAM ......................................................................................................... 7-1
8. TESTING AND PARAMETERS ...................................................................................... 8-1
8.1. TESTING OF SMPS ............................................................................................ 8-1
8.2. TESTING OF CPU PCB ...................................................................................... 8-1
8.3. POWER ON HARDWARE TEST ......................................................................... 8-2
8.3.1. HARDWARE TEST .................................................................................................... 8-2
8.4. SETTING PARAMETERS.................................................................................... 8-5
8.4.1. SYSTEM SETUP........................................................................................................ 8-5
8.4.2. SETTING THE DATE ................................................................................................. 8-6
8.4.3. SETTING THE TIME .................................................................................................. 8-6
8.4.4. SETTING THE DATA OUTPUT MODE ..................................................................... 8-7
8.4.5. LAB INFORMATION .................................................................................................. 8-7
8.4.6. BLANK DEDUCTION ................................................................................................. 8-8
8.4.7. AIR PURGE................................................................................................................ 8-8
IV
8.5. ADJUSTMENT AND CALIBRATION ................................................................... 8-9

8.5.1. OFFSET AND GAIN CALIBRATION OF PHOTOMETER ......................................... 8-9
8.5.2. ENTERING OFFSET ADJUSTMENT DATA MANUALLY ......................................... 8-9
8.5.3. ADJUSTING LCD DISPLAY BRIGHTNESS ............................................................ 8-10
8.5.4. TEMP CALIBRATION (IN NORMAL CONDITION) .................................................. 8-10
8.5.5. PUMP CALIBRATION .............................................................................................. 8-11
9. PROGRAMMING PROCEDURES .................................................................................. 9-1
9.1. Cortex CPU Board (ELLC2008R0/EL20205R1) Programming ............................ 9-1
9.1.1. Pre-requisite ............................................................................................................... 9-1
9.1.2. Programming Procedure ............................................................................................ 9-1
9.2. Software Upgrading for Cortex CPU Board ....................................................... 9-11
9.2.1. Pre-requisite ............................................................................................................. 9-11
9.2.2. Programming Procedure .......................................................................................... 9-12
10. MAINTENANCE .......................................................................................................... 10-1
10.1. DAILY MAINTENANCE ................................................................................... 10-1
10.2. QUATERLY MAINTENANCE .......................................................................... 10-1
10.3. REPLACEMENT OF TUBING ......................................................................... 10-2
10.3.1. ASPIRATION TUBE REPLACEMENT ................................................................... 10-2
10.3.2. REPLACEMENT OF PERISTALTIC PUMP TUBINGS .......................................... 10-4
10.4. REPLACEMENT OF LAMP ASSEMBLY ......................................................... 10-5
10.5. REPLACEMENT OF PRINTER PAPER .......................................................... 10-7
10.6. PROCEDURE FOR REFITTING THE ROLLER IN WINSPU MECHANISM ... 10-9
11. TROUBLESHOOTING GUIDE.................................................................................... 11-1
11.1. TROUBLESHOOTING SECTION .................................................................... 11-6
12. SPARE PARTS ........................................................................................................... 12-1
12.1. SPARES DETAILS AND ORDERING INFORMATION.................................... 12-1
12.2. LIST OF CONSUMABLES ............................................................................... 12-4
13. APPENDIX .................................................................................................................. 13-1
13.1. REVISION HISTORY ....................................................................................... 13-1
V
1. OVERVIEW OF ANALYZER
1.1. INTRODUCTION
The CHEM5X (hereafter referred as an analyzer) is a low power consuming,
compact and high performance 32-bit micro controller based Biochemistry
analyzer, which is used for Routine Chemistries, Electrolytes, Hormones and Drug
tests.
There are 11 modes of operation. Programming, Reading and Reporting
operations are user friendly.
The analyzer is provided with memory for storage of Quality Control Data, Reagent
Blank Absorbance, Factor, and Non-linear Calibration Data and up to last 5000
results with Patient ID. Operation is through a non-tactile Keyboard with quick shift
from one function to another without going through complex sequential operations.
The analyzer is provided with a 240 X 64 dots LED backlight with liquid crystal
display having alphanumeric and graphic capabilities.
A Patient ID wise or Date wise or Patient ID with Date wise collated report can be
generated upon request. Exhaustive Quality Control Data at 2 levels, for any of the
tests can be stored and printed.
The software is complete with the device diagnostic self-test function capable of
providing timely flag / error messages related to Test results or analyzer
malfunctioning.
The State-of-the-Art features, advanced optics, versatile analytical capabilities and
economy of 33μl flow cell make it the analyzer of choice for all laboratories..
This analyzer is intended to be used:
 For In-vitro quantitative and qualitative determination of wide range of
analytes in body fluids as mentioned above.
 By the trained personnel in controlled environment and continuously
monitored operation.
1-1
1.2. ANALYZER VIEW
PHOTOMETER COVER PRINTER COVER
DISPLAY KEYPAD
ASPIRATION TUBE ASPIRATION SWITCH
1-2
ON/OFF SWITCH INCUBATOR CONNECTOR
PERISTALTIC PUMP COVER PC INTERFACE PORT
EXTERNAL USB PRINTER EXTERNAL PC/AT KEYBOARD

PORT PORT
DC INPUT SUPPLY SERIAL NUMBER PLATE
FUSE
1-3
2. SAFETY
This section provides safety information about analyzer. Use this product properly
and safely to prevent injuries and or damage to property. User must read these
safety precautions before installation/use and follow the directions.
 Only qualified personnel should use the analyzer.
 While operating, maintaining, servicing or repairing the analyzer, follow all the
procedures described in this manual.
 Always ensure that mains switch is OFF while connecting or removing or
servicing the analyzer.
 Observe all WARNINGS and CAUTIONS posted on the system or described in
this manual.
 Avoid contact with all electrical circuits of analyzer; observe CAUTIONS posted
on the analyzer.
 Never use substitute parts on the analyzer or modify it in any way.
 Keep the analyzer out of the rain and any other water splash. Pay attention to
inclination, vibration, shock etc.
 During the operation photometric lamp becomes extremely hot. DO NOT look
directly into the light path of the lamp when it is ON. DO NOT touch the lamp
when it is ON.
 If the lamp needs to be changed, always switch off the lamp by switching off
the analyzer and then wait for minimum 10-min/until lamp has cooled down.
 Avoid using dangerous flammable material around the analyzer. Fire or
explosion may be caused by ignition.
 Avoid areas that are adversely affected by atmospheric pressure, temperature,
humidity, ventilation, sunlight, dust and air containing salt, sulfur, etc.
 Take necessary precautions against hazards associated with the use of clinical
laboratory chemicals. Specific recommendations for each reagent used with the
analyzer are normally found on the manufacturer’s package inserts or on
product information sheets for each chemical. Wipe up any reagent spillage on
the analyzer immediately.
 Pay attention not to exceed time and volume necessary for diagnosis. Keep
monitoring the behavior of whole system in order to detect any malfunction.
 Take immediate corrective measures including shutdown of operation when
any malfunction is detected in the analyzer.
 In the event of trouble, do not play with the analyzer and leave any repair work
to an authorized expert.
Caution: NEVER OPERATE ON A WET OR DAMP SURFACE.
2-1
3. ANALYZER FEATURES
3.1. HARDWARE SPECIFICATIONS
1 SYSTEM TYPE Open, Flow cell.
2 MEASUREMENT Colorimetry (Rate/End Point)
PRINCIPLE
3 APPLICABLE ANALYTES Photometric assays – Substrates, Enzymes, Lipid,
Protein, Sugar, Inorganic Substances
4 SETUP Benchtop.
5 LIGHTSOURCE Quartz Halogen Lamp, 12V, 20 Watts.
6 PHOTOMETRIC RANGE 0 ~ 3 O.D. (Range 340~630nm)
7 RESOLUTION 0.0001.
8 OPTICS 6 wavelength static photometric group with following
interference filters: 340, 405, 505, 546, 578, 630 nm.
9 DETECTORS 6 UV / VIS Silicon photodiodes.
10 CUVETTE Unique triple cuvette system:
 33 µl flow cell
 10 mm rectangular polystyrene cuvette
 6 mm round Glass Tube with adapter for Coagulation
and Elisa tests.
11 THERMOSTAT Peltier temperature control
Range 20°C to 40° C with 1°C steps.
12 FLOWCELL VOLUME 33 µl
13 SAMPLE ASPIRATION By means of a peristaltic pump, Aspiration Volume
programmable from 100µl to 2997µl.
14 PRECISION Better than 1% CV.
15 KEYBOARD Rugged water proof, non-tactile legend membrane panel
25 keys
16 SMPS EXTERNAL 18VDC – 24.5VDC @ 3.6A
17 PRINTER  Thermal Printer 2-inch ( 384 dots per line, thermal type
with full graphics facility).
 External USB printer (optional).
18 DISPLAY: High-resolution Graphics LCD 240x64 dots display with
LED backlight and a view area of 134mm x 40 mm.
19 INTERFACES USB B type port for host computer and USB A type port
for External USB DeskJet Printer.
External PC/AT keyboard.
20 PROCESSOR 32-bit Cortex M4 Microcontroller.
21 MEMORY Built-in1MB Flash, 136KB SRAM, 16KB EEPROM and 64
KB ROM.
22 REAL TIME CLOCK Built in.
23 REPLACEABLE BATTERY Lithium Battery CR2032 (3V)
3-1
ON PCB
24 WASTE COLLECTION Waste collected in closed container.
25 INCUBATOR Optional external incubator.
26 OPERATING 20 – 40 Degree Celsius
TEMPERATURE
27 STORAGE TEMPERATURE -10 to +50 Degree Celsius.
28 HUMIDITY Max.80% RH, non-condensing.
29 MAINS SUPPLY 115/230V AC (±10%), 50/60 Hz (input for power adapter).
30 SIZE 446 (W) x 312 (D) x 175 (H) mm.
31 WEIGHT Approximately 5 kg.
NOTE: Above specifications subject to change without prior notice.
3.2. SOFTWARE SPECIFICATIONS

 11 analytical modes of operation:
 1-point Linear
 2-point Linear
 Rate A Linear
 1-point Non-Linear (Cubic Spline / Point to point / Logit Log)
 2-point Non-Linear (Cubic Spline / Point to point / Logit Log)
 Rate A Non-Linear (Cubic Spline / Point to point / Logit Log)
 1-point Sample Blank Linear
 1-point Sample Blank Non-linear (Cubic Spline / point to point / Logit
Log)
 Absorbance
 Coagulation
 Index Mode
 150 totally “OPEN” test programs selectable through keypad
 Parameters can be viewed, edited, and printed
 Facility to memorize Reagent Blank ABS., Sample Blank ABS., Standard
ABS., Factor, Non-linear curve.
 Patient report for last 5000 results stored in memory are obtained by
 Date
 I.D
 Both by Date and I.D
3-2
 Graphic presentation of Non Linear calibration curves

 QC (QC Data available for two controls per test)
 Daily QC
 Monthly QC
 Rate calculation by least square regression method.
 Automatic zeroing of Water OD during Run Test.
 Total reaction time: Delay time and Read time both are programmable
between 1 second to 999 seconds.
 Non-linear calibration (6 standards).
 On-line reagent stability check.
 Substrate depletion / Non-linearity check.
 In built reaction non-linearity check.
 Monochromatic as well as bichromatic measurements possible.
 Calibration of peristaltic pump.
 On-line display of cuvette temperature.
 On-line help.
 Self-diagnostics.
 Help messages on erroneous entry.
 Reports can be printed on USB Printer or Thermal Printer by either using
PRINT key or Automatic.
3.3. KEYBOARD DESCRIPTION

KEY DESCRIPTION
These are multi-function keys. Each key is used for
entering a number seen on the key, and upto three
alphabets in upper and lowercase. E.g. The numeric key ‘1’
is used to select or enter an alphabet or the number ‘1’ in
the sequence: ‘A’, ‘B’, ‘C’, ’a’, ’b’, ’c’, ‘1’ following every
press. Note: Sequence can change from menu to menu.
This is a dual function Key.
It is used as <YES>key to save changes in parameters and
as <DECIMAL>key when entering numerical parameters.
This is a dual function Key.
It is used as <NO>key to reject changes in parameters
value or to skip aspiration of analytes. It is used as <0>key
while entering numerical parameters.
3-3
It is used to advance the thermal printer paper roll by few

lines and is operational in most of the menus.
This key is a multi-purpose key used for different functions

and different screens.
For Linear test, CALIB key is used when factor is to be

calculated by running sample as standard.
For non-linear test it is used to calibrate curve.
This key is used to enter the negative sign. This key is also
used as READ key to take reading from Rectangular
Polystyrene in place of flow cell, avoiding use of ASP
switch.
This key is used to return to the previous screen.
This key is used as key to cancel a typed character.
This key is used to display help menu.
This key is used to reset the instrument without resetting

the memory. When this key is pressed the instrument stops
any test that it is performing and goes back to the starting
mode.
This key is used to print data on selected Printer (USB

Printer or Thermal Printer or Both).
These four keys with arrows are used to bring the cursor to
the required position on the screen.
Enter:-This key is used to select a chemistry, to display test
parameters, to run the test or for QC reports.
3.4. ASPIRATION SWITCH

The Switch Actuator is located at right hand side below the aspiration tube which is
provided for aspiration of liquid into the flow cell and for washing flow cell.
3-4
4. INSTALLATION
4.1. INSPECTION
The analyzer is tested before shipment and is packed carefully to prevent any
shipping damage. It is user’s responsibility to inspect all cartons upon arrival and
notify the carrier of any apparent damage. Follow the steps described in the
paragraphs below to install the analyzer.
4.2. UNPACKING
The main unit and accessories are packed in single carton. Other additional
accessories such as power cord may be packed in another carton. The
representative is responsible for unpacking, installing and initial setting up of the
analyzer.
Serial Item Code Description Quantity
Number
1 110036 SET OF STANDARD ACCESSORIES 1 SET
2 110348 DUST COVER 1 NOS
3 110347 RECTANGULAR POLYSTYRENE MICRO CUVETTE 5 NOS
POWER CORD WITH TYPE D / M TYPE PLUG & C5
4 116117 TYPE CONNECTOR. LENGTH 1.5 METERS 1 NO.
(ONLY FOR DOMESTIC)
POWER CORD WITH TYPE E / F TYPE PLUG & C5
5 116118 TYPE CONNECTOR. LENGTH 1.5 METERS 1 NO.
(ONLY FOR EXPORT)
5 110309 THERMAL PRINTER PAPER ROLL (57MM X 30M) 3 NOS
6 115981 POWER ADAPTER AC (O/P : 19.5 VDC ; 90 W) 1 NO
7 110326 ALLEN KEY SIZE: 2.5 MM 1 NO
8 110035 ASSEMBLY WASTE BOTTLE 1 NO
9 -- OPERATOR MANUAL for CHEM5X / CHEM5V3 1 NO
10 110046 P.M. KIT FOR CHEM5X / CHEM5V3 1 NO
11 110018 ASSEMBLY LAMP 1 NO
12 110353 SYRINGE 5 ML (CAT NO 300850 MAKE B-D) 1 NO
13 110354 TUBING PVC (ID 2.8 MM, OD 4.3 MM) 0.55 M
14 111213 TUBE TEFLON 0.75MM X 1.5 MM (442-5409-4) 0.21 M
15 110194 TUBE TEFLON (ID 1 MM, OD 2 MM, PTFE - M0004) 0.027 M
16 110021 PERISTALTIC TUBE ASSEMBLY 2 NOS
17 110356 SILICON TUBING (ID 2 MM, OD 4 MM) (IMPORTED) 0.36 M
18 110355 TUBE SILICON (ID-0.8 MM, OD-2.4 MM) 0.012 M
NOTE: Please refer to dispatch note for detailed checklist.
4-1
4.3. INSTALLATION REQUIREMENTS

The proper location is an important consideration; an improper location can lead to
malfunction of the analyzer. Please follow our environmental and electrical
suggestions to ensure the accuracy and precision of analyzer and to maintain high
level of safety for your personnel.
Since the analyzer is comparatively smaller, it can be comfortably accommodated
on any standard sized table.
Remember that minimum 30 cm. space is maintained between the rear panel and
the wall to allow for heat dissipation. The waste bottle should be placed on the
same level or below the level of analyzer.
Please ensure while taking any electrical measurement, the multimeter used must
have been calibrated and should possess valid calibration identification traceable
to National/International standard.
Also ensure that the power supply should be placed near to the analyzer in such a
way that ON/OFF switch is easily accessible to the user. This will help the user to
switch OFF the instrument immediately in case malfunctioning is detected.
PROBLEM resulting from the relocation of the analyzer done by
unauthorized service representative are not covered under warranty.
4.4. ELECTRICAL REQUIREMENTS

Single phase continuous stabilized AC 115/230 volts ± 10%, 50 / 60
Voltage and Frequency
Hz.
Perfect earthing must be provided at power source with all
applicable local requirement (A grounded, power plug only should be
Grounding
used). The Voltage between earth and neutral should not exceed
more than 5 V.
3 No. of 5 Amps outlet and 2 No. of 5 Amp sockets should be
available near the mounting desks. (Normally only one socket is
required per analyzer and 2 extra sockets are recommended for
using any measuring equipment and engineering tool if required
while servicing). Failure to properly ground the analyzer bypasses
Plug Points
important safety features and may result in an electrical hazard.
Heavy duty electrical devices like Air-conditioners, Refrigerators,
Oven, Centrifuge etc., should not be operated on the same electrical
lines as the analyzer. The mains connection should be easily
accessible, for emergency switch off.
4.5. INSTALLATION PROCEDURE

1. Unpack the accessory box.
2. Remove the waste bottle and place it on the table.
3. The Analyzer comes equipped with an external AC power adapter and one
three/two pin power cord (with earth terminal) for external AC power
adapter.
4-2
4. Proper use of the appropriate power cord assures adequate grounding for
the system. Failure to properly ground the analyzer bypasses important
safety features and may result in an electrical hazard.
5. Connect the 3/2 pin cord (with earth terminal) of the external SMPS to the
mains socket and check the output of the SMPS, it should be ± 0.5V range.
6. Connect the Peristaltic Pump tubing correctly and place the end of the
peristaltic pump tubing coming out of the analyzer into the waste bottle
provided for collecting the Waste.
4.6. PRINTER HOUSING AND PRINTER PAPER

INSTALLATION
4.6.1. INTERNAL PRINTER
There is a Thermal printer mounted inside the cabinet. It is extremely low noise
printer. The non-presence/improper installation (printer lever is not pressed
downward) of the thermal paper is detected and it is alarmed by 4 continuous
beeps.
Refer below Figure 1 for proper routing of Thermal Printer Paper roll.
NOTE: The thermal paper used must match the specification of the original one,
since the calibration of the working temperature is optimized for that kind of paper.
Failure to use proper quality of paper may permanently damage the printer.
4.6.2. EXTERNAL PRINTER

1. Switch off the analyzer before connecting printer.
2. HP DeskJet Printer (USB) 56XX,57XX,12XX and Dot matrix Printer(USB)
EPSON LQ-300-II, HP Officejet 6000 and K7108 series, can be attached to
the analyzer.
3. USB A Type connector is provided at the rear of the analyzer. Connect the
printer cable to this port before switching ON the analyzer.
4-3
NOTE: In case of error at external printer get the error corrected, restart the printer
and reissue PRINT command.
4.6.3. PC COMMUNICATION
NOTE: USB Connectivity to PC requires operating system 2000/XP or above.
4.7. EXTERNAL KEYBOARD INSTALLATION

Switch off the analyzer before connecting PS2 keyboard. Then connect to the port
provided at the rear of the analyzer.
External Keyboard can be used to enter Lab Information data.
4-4
5. BLOCK DIAGRAM
The major blocks of the Chem 5V3 / Chem 5X consists of CPU PCB, thermal
printer, external DeskJet printer (external printer can also be connected)
Photometer, Keypad and liquid crystal display (LCD), Peltier Assembly, Peristaltic
Pump and External keyboard which can be connected to the analyzer.
Soft key functions are designed in such a way that it operates with single touch
with quick shift from one function to another without going through complex
sequential operations.
The LCD is a 240x64 dots, LED backlight display with alphanumeric and graphic
capabilities with backlit feature which enables the user to read in case of less
ambient light. This is most sensitive device to get damaged, which require careful
handling, which is interfaced with keypad using a interface card. External keyboard
can be connected to the analyzer using PS/2 connector provided on the rear of the
analyzer.
5-1
Photometer is a device to measure the intensity of the light. Where the absorbance
of the radiation from the colored substances are measured by means of
photodiode. It can serve 8 different wavelengths. The filter defines the
wavelengths.
CPU PCB as the name suggests is the heart of the analyzer, which controls all the
hardware & software functions of the analyzer. Refer the details of main board in
the operation section.
5-2
6. FUNCTIONAL DESCRIPTION OF PCB

As shown in block diagram analyzer CPU PCB is the heart of this analyzer. This
CPU PCB gives necessary commands and controls the operation of other
peripheral such as Keyboard, LCD, Printer and Photometer. Major blocks are
explained below.
Block Diagram of CHEM 5X
6-1
CPU PCB COMPONENT LAYOUT FOR ELLC2001R5
6-2
OR
6-3
CPU PCB COMPONENT LAYOUT FOR ELLC2008R0
6-4
ELLC2008R0 - SSB
OR
6-5
CPU PCB COMPONENT LAYOUT FOR EL20205R1
6-6
EL20205R1 - SSB
6.1. POWER SUPPLY SECTION (ELLC2004R4 /

EL20203R3)
Instrument is operated at 115-230 V AC +/- 10% 50/60Hz power supply which,
acts as input for the internal devices.
This instrument uses three power supply sections designed to provide power to
electronic circuit, lamp & photometer and the thermal printer.
Power Supply  External SMPS provides +18/24 V DC, then the following
Voltages are generated by the Power distribution Board, +5V, +12 V DC & +5V, -5
V for analog section.
6-7
+5 V DC, +12 V DC is given as input to the main board (which generates + 3.3 V
DC for microprocessor and other logic ICs.)
+ 5 V & -5 V DC isolated supply for photometer and ADC.
+12 V DC to motor and Incubator.
Any defect in the section will lead to any of the following problem(s):
1. Lamp/Fan voltage fluctuation.
2. Lamp/Fan not working.
3. Printer not working.
4. Backlight of LCD is OFF.
5. Analyzer is not getting switched ON.
Action to be taken
 Check ON/OFF switch; any loose connection of cable assy.
 Check 18V DC ±1V DC; if NOT OK then replace power adaptor.
 Check 5V, 12V & ±5V supply (±5%); if not OK then replace DC-DC Power
Supply PCB assembly.
POWER SUPPLY COMPONENT LAYOUT (ELLC2004R4)
6-8
OR
Component Layout (EL20203R3)
6-9
POWER SUPPLY SCHEMATIC DIAGRAM
6-10
6.2. CONTROL LOGIC SECTION

The operations for controlling the instrument are performed by the CPU PCB. This
section is provided with MB90F334A microcontroller, 2MB of EEPROMs, a serial
interface RS 232C for interfacing Thermal Printer. The logic is all in CMOS
technology to guarantee low consumption and high reliability. The RTC is provided
with 3V coin battery.
1. Communication is not taking place between processor and peripheral
devices.
2. External printer is not working.
3. Calibration data is not getting stored.
Action to be taken:
 Replace CPU PCB.
.
6-11
SCHEMATIC – CONTROL LOGIC SECTION
6-12
6.3. MOTOR CONTROL AND MEMORY

This section controls the motion of motor using IC A3979. It is a DMOS Fully
Integrated Stepper Motor driver features a non-dissipative over current protection
on the high side Power MOSFETs and thermal realized in Multi-power-BCD
technology. It includes a constant off time PWM current controller. When the
voltage drop across the sense resistor becomes greater than the voltage at the
reference input (VREFA or VREFB) the sense comparator triggers the mono stable
switching the motor off. When, the mono stable times out the motor will again turn
on.
To store different types of data three 1024K bits IC 24c1024 are used to store.IC
U4 is used for chemistry parameters, patient reports, values of standards and
blank for non-linear chemistry, for quality control data and U6 is used for default
parameter.
IC 1338Z is a Real Time Clock plus RAM. The function includes a nonvolatile time
of day, calendar. The time of day and memory are maintained even in the absence
of power.
Any defect in the section will lead to any of the following problem(s)
1. Water, standard, solution is not getting aspirated after pressing ASP switch.
2. Motor is not running or not stopping.
3. Chemistry parameters are not stored.
4. Patient report or quality control data is not stored.
5. Date and time is not correct.
6. Default parameters are incorrect
7. Quality Control Data is not stored
Action to be taken
 For defect number 1 and 2, replace CPU PCB.
 For defect number 3 and 4, replace U4.
 For defect number 5, replace U16.
 For defect number 6, replace U6.
 For defect number 7, replace U6
6-13
MOTOR CONTROL AND MEMORY SCHEMATIC DIAGRAM
6.4. PHOTOMETRIC UNIT (ELLC2002R2 / ELLC2002R4)

It is one of the major blocks of the instrument & it contains 8 different narrowband
optical interference filters of wavelengths 340, 405, 450, 505, 546, 578, 600, and
670 nm for specific chemistry tests. When ray of light is passed through the
reaction cell part of it gets absorbed by the reaction solution and then passes
through the filter. This filtered light is detected by photodiodes, which is amplified,
and send to the multiplexer CD 4051which selects the one signal and
communicates to processor for further processing.
1. Absorbance values not displayed.
Action to be taken:
 Check that the flowcell is clean and scratch free.
 Replace Photometer PCB.
6-14
Photometer Component Layout for ELLC2002R2
OR
Photometer Component Layout for ELLC2002R4
6-15
SCHEMATIC – PHOTOMETRIC UNIT (ELLC2002R2)
OR
6-16
SCHEMATIC – PHOTOMETRIC UNIT (ELLC2002R4)
6-17
6.5. USB PCB ELLC2003R5 (Not used with Cortex)

USB PCB having USB ‘A’ type connection for external USB printer (selected
models only). USB ‘B’ type connection for PC communication. IC CP2102 is used
to convert the serial data (Result) being dumped by the microcontroller to the PC in
USB format.
1. USB printer not printing instrument chemistry test results.
2. Communication between PC and USB not established.
Action to be taken:
 Check USB A-B cable and if found faulty, replace with new.
 Check CP2102 driver in PC.
 Check software communication settings in PC.
 Replace USB PCB assembly.
USB PCB COMPONENT LAYOUT
6-18
USB PCB SCHEMATIC DIAGRAM
6-19
6.6. PRINTER
The printer is 40 column graphic printers, able to give a very high printing quality,
high speed and a considerable noiselessness on thermal paper without having to
move the printing head.
6.7. KEYPAD AND DISPLAY SECTION

The liquid crystal graphic with 240x64 dots, with alphanumeric and graphic
capability.
A 25 key membrane tactile keyboard is provided.
6-20
7. WIRING DIAGRAM
7-1
8. TESTING AND PARAMETERS

The instrument assemblies are factory adjusted and does not require any field-
testing, adjustment or settings. It is advisable not to change setting unless
necessary.
If it is necessary, the testing, adjustment or setting must be carried out by trained
and authorized personnel only.
8.1. TESTING OF SMPS

1. Check the mains power supply. It should be within 115/230V AC, 50/60Hz,
±10%.
2. .Connect one end of 2/3-pin power cord to the External SMPS and the
output of SMPS to the DC input of the Analyzer.
Check the input/outputs of the Power Distribution Board using a calibrated Multi-
meter, it should be as follows:
a. Input:
J5-Pin No Normal Condition Description Test Point.
1 +18/24V(±1.0V) Input DC Supply TP2
2 GND Ground TP1
b. Output: connector details:
1. Adjust the Lamp voltage to 11.70V with preset P1 on the Power Supply
PCB.
2. Measure all voltage with respect to GND pin TP1.
Normal Condition Description Test Point.

+5.0V ( ±0.25V) VCC TP6
GND GND TP1
+12V (±0.5V ) Motor Supply TP4
+5.0V (±0.25V) Printer Supply TP5
+11.70V (adjustable by POT P1) LAMP Voltage TP3
8.2. TESTING OF CPU PCB

Give supply at J1 connector from Power Supply PCB and measure voltages at
various test points with respect to common ground point using a calibrated Multi-
meter.
Test Point Normal Condition TP details
TP5 with respect TP6 +3.3VDC; +/-0.15V
TP4 with respect TP3 -5.0VDC; +/-0.25V -Vcc
TP2 with respect TP3 +5.0VDC; +/-0.25V Vcc
TP3 AGND GND analog
TP5 DGND GND digital
8-1
8.3. POWER ON HARDWARE TEST

1. Switch ON the analyzer by pressing the ON/OFF switch provided on the
SMPS adaptor.
2. After switching ‘ON’ the analyzer, ERBA MANNHEIM logo is displayed and
analyzer will do self-diagnostic it will automatically check all the important
devices and will show the status on display.
3. If all the hardware tests are OK then the following display appears during
the self-diagnostic test.
4. This is routine test that will be performed every time the analyzer is
switched ON.
5. If any of the parameter is not ok, then the following message will be
displayed;
Press <YES> key if you want to proceed.

6. If all the hardware tests are OK then the Home Screen will be displayed.
8.3.1. HARDWARE TEST

Press numeric key < 4 > and go to maintenance in the Home screen and the
following screen is displayed.
8-2
To set the temperature of the flowcell press any of the numeric keys <0-9> in the
range of 20 – 40C and press <ENTER>, the corresponding temperature is
attained in the flowcell. Press <0> to switch OFF.
Press < > > key to display the next page.
PUMP CALIBRATION: Aspirate 1000µL of water by pressing aspirate switch to

start and stop. The calibrated count is displayed on the screen. Now the peristaltic
pump is calibrated to aspirate any volume from 100 μl up to 2997 μl.
Note: Perform WASH with 3-5ml DI Water to fill the tube up to Peristaltic pump
before proceeding for Pump Calibration.
Press < > > key on the Pump Calibration screen to display the next page.
LOAD DEFAULT PARAMETERS: Press <fn> to download default Test
parameters from the memory.
Press <>> key to go to the next page or <<> to go back to the previous page.
Press numeric keys <1> to<6> get PRE CHANNEL and LOG CHANNEL readings
for 6 filters.
Press <>> key to display the next page or <<> to go back to the previous page.
8-3
PRINTER CHECK: Press <PRINT> key to obtain Test printout from Thermal
printer.
Press < > > key to display the next page or <<> to go back to the previous page.
TRANSMISSION CHECK: Press <fn> to check the transmission.
8-4
LAMP SAVE: By selecting this option, user can select the time in minutes to
switch OFF the lamp. The range selectable is between 0 to 99 minutes. 0 means
lamp save is disabled.
KEYPAD CHECK: Test all the 25 keys in this menu by pressing each key on the
keypad. The key legend should disappear from the LCD on successful press of the
particular key.
8.4. SETTING PARAMETERS

8.4.1. SYSTEM SETUP
The system setup option allows the user to view, edit and print the system date,
time and the data output mode.
The “System Setup” screen is as follows:
The numeric keys 1, 2, 3, 4, 5 and 6 are used to set the date, time, data output
mode, laboratory information, Blank Deduction and Air Purge option respectively.
8-5
8.4.2. SETTING THE DATE

The analyzer incorporates a built-in calendar function, which is maintained by a
battery, and once set, the Date and Time will be printed every time the analyzer
prints result data on the printer.
Press numeric key '1' and the following screen appears:
The cursor is positioned on the DATE field on the SYSTEM SETUP: DATE
screen. Enter an appropriate data in the following format:
DAY : Enter a day from 01 to 31
MONTH : Enter a month from 01 to 12
YEAR : The last 2 digits of any year from 00 to 99
After appropriate entry is made, press the <fn> key to save date and return to the
System Setup screen or press < PREV. > to quit without saving and return to the
System Setup screen.
NOTE: If the date is entered wrong, the user will be prompted with the message,
"INVALID DATE. PLEASE ENTER AGAIN".
8.4.3. SETTING THE TIME

Choose the option '2' from the SYSTEM SETUP menu and SET TIME. The display
appears.
The cursor is positioned on the TIME field on the SYSTEM SETUP: TIME screen.
Enter an appropriate time in the format as stated below.
8-6
HOUR: Enter an hour from 00 to 23.

MINUTE: Enter minutes from 00 to 59.
SECONDS: Enter seconds from 00 to 59.
Each entry is separated by a ‘:’ sign, which appears automatically after the entry of
the 2nd digit.
After appropriate entry is made, press the <fn> key to save and return to the
System Setup screen or press <PREV.> to quit without saving and go back to the
System Setup screen.
NOTE: If the Time is entered wrong, the user will be prompted with the message,
“INVALID TIME. PLEASE ENTER AGAIN”.
8.4.4. SETTING THE DATA OUTPUT MODE

Choose numeric key 3 on the SYSTEM SETUP screen to select the data output
mode.
Press <YES> or <NO> to select or deselect Thermal printer or USB Printer for
auto print options or printout on Thermal printer/USB Printer after pressing
<PRINT> key.
Tick mark <√> will be displayed in front of selected option & it will disappear if any
option deselected.
8.4.5. LAB INFORMATION

Choose the option 4 <LAB INFORMATION> from the SYSTEM SETUP screen
and the following screen appears:
8-7
The user can enter laboratory information (25 characters each on 5 lines) with
external PC/AT keyboard or the analyzer keypad. This is stored in the memory.
Example of Using analyzer Keypad to Enter Lab information:
Item Description
Each key can be used for entering three alphabets in upper
and lowercase. And followed by the number seen on the key,
e.g. ‘A’, ‘B’, ‘C’, ’a’, ’b’, ’c’, ‘1’
to
‘Y’, ’Z’, ’y’, ’z’, ’-‘, ’9’
‘*’, ', '(', ')', '.', '0'
The laboratory information is printed as header in Thermal and External Printouts.
8.4.6. BLANK DEDUCTION

If 1-POINT/SMP-BK option is selected then Reagent Blank O. D. will be subtracted
from all the test O. D. for 1 point and sample Blank modes, all modes of kinetic
and 2 – point assays as well as for One point mode. If 2-POINT/RATE A option is
selected then Blank O. D. will be subtracted for all modes of kinetic and 2 – point
assays. The options can be selected or de-selected by pressing <YES> or <NO>
respectively.
8.4.7. AIR PURGE

Choose the option ‘6’ < AIR PURGE> from the SYSTEM SETUP screen and the
following screen appears:
8-8
The user can select or deselect Air Purge option from this menu. For Rate A and
Two Point mode, Air Purge must be enabled if aspiration volume is less than
450μl.
However, Air Purge is optional if the aspiration volume value is between 450 – 999
µl.
If Air Purge is enabled extra 150 μl air is aspirated after displaying the result.
If Air Purge is disabled, extra 150 μl air will not be aspirated
8.5. ADJUSTMENT AND CALIBRATION

8.5.1. OFFSET AND GAIN CALIBRATION OF PHOTOMETER
1. Go to the ‘Maintenance’ menu.
2. Go to the screen where pre-channel and log channel readings of every filter
is displayed (Filter Check Screen).
3. Block the light by keeping the flowcell reverse way.
4. Press < fn > key three times. Photometer Offset Storage screen appears.
5. Message to Press<YES> to do offset adjustment.
6. If <YES > key pressed the offset for the 6 filters will be displayed (and
stored in the memory) and Message for Gain Calibration will appear.
7. Put the Flow cell in its original position with DI Water aspirated in it and
press <YES> key.
8. The Gain will be displayed on the LCD and printed on Thermal Printer.
9. Press <RESET> key or Switch off the instrument & restart again to store the
new offset and Gain values.
8.5.2. ENTERING OFFSET ADJUSTMENT DATA MANUALLY

1. Go to the ‘Maintenance’ menu.
8-9
2. Go to the screen where pre-channel and log channel readings of every filter
is displayed.
3. Press ‘< CALIB >’ key three times.
4. Offset adjustment screen will appear. Use UP/DOWN arrow keys to go to
different offsets. Enter the offset always in 6 digits. E.g. if offset to be
entered is 300, enter it as 000300.
5. Press ‘< fn >’ key to save the offsets.
6. Press ‘< PRINT >’ key to print these newly entered offsets.
7. Press <RESET> key to exit this menu.
8.5.3. ADJUSTING LCD DISPLAY BRIGHTNESS

Open the front cover and rotate preset R12 provided on the main board as per
required brightness. Brightness will increase if rotated clockwise and brightness
will be reduced if rotated anticlockwise.
8.5.4. TEMP CALIBRATION (IN NORMAL CONDITION)

The Temperature Calibration procedure is as follows.
Actual Temperature Calibration
1. Go to the first screen of the ‘Maintenance’ menu.
2. Select a temperature which is to be calibrated.
3. Press the <READ> key three times.
4. Allow the machine to attain the temperature. Read it with the help of
temperature jig till it settles down.
5. Read the flow cell temperature at that time.
6. Enter this actual temperature in 3 digits including one decimal point.
7. Press <ENTER> to confirm. This temperature will be stored in memory and
when temperature 37C is selected, actual temperature will be 37 C. (This
may take 5-7 min.)
8-10
RESISTANCE VERSUS TEMPERATURE -40˚C to +150˚C

Temp RES Temp RES Temp RES Temp˚ RES Tem RES Temp RES Temp RES
˚C in Ω ˚C in Ω ˚C in Ω C in Ω p˚C in Ω ˚C in Ω ˚C in Ω
-40 3356k -10 565.5k 20 125.5k 50 34.70k 80 11.54k 110 4427 140 1914
-39 3147k -9 535.6k 21 119.0k 51 33.44k 81 11.15k 111 4297 141 1865
-38 2951k -8 507.5k 22 114.5k 52 32.15k 82 10.70k 112 4172 142 1817
-37 2769k -7 481.0k 23 109.4k 53 30.82k 83 10.42k 113 4051 143 1770
-36 2599k -6 456.0k 24 104.5k 54 29.74k 84 10.08k 114 3933 144 1725
-35 2440k -5 432.4k 25 100.0k 55 28.61k 85 9744 115 3820 145 1681
-34 2292k -4 410.0k 26 95.51k 56 27.53k 86 9424 116 3711 146 1639
-33 2154k -3 389.2k 27 91.34k 57 26.50k 87 9117 117 3605 147 1598
-32 2025k -2 369.4k 28 87.38k 58 25.50k 88 8821 118 3502 148 1558
-31 1904k -1 350.7k 29 83.60k 59 24.58k 89 8536 119 3403 149 1519
-30 1791k 0 333.1k 30 80.00k 60 23.65k 90 8281 120 3307 150 1481
-29 1685k 1 316.4k 31 76.58k 61 22.77k 91 7996 121 3214
-28 1588k 2 300.6k 32 73.32k 62 21.94k 92 7741 122 3124
-27 1494k 3 285.7k 33 70.22k 63 21.14k 93 7496 123 3038
-26 1407k 4 271.6k 34 67.26k 64 20.37k 94 7259 124 2953
-25 1326k 5 258.3k 35 64.44k 65 19.63k 95 7030 125 2872
-24 1250k 6 245.7k 36 61.75k 66 18.93k 96 6810 126 2793
-23 1178k 7 233.8k 37 59.19k 67 18.25k 97 6598 127 2717
-22 1111k 8 222.5k 38 56.75k 68 17.60k 98 6393 128 2643
-21 1049k 9 211.9k 39 54.42k 69 16.97k 99 6195 129 2571
-20 989.8k 10 201.7k 40 52.19k 70 16.37k 100 6005 130 2501
-19 934.6k 11 192.2k 41 50.07k 71 15.80k 101 5821 131 2434
-18 882.7k 12 183.1k 42 48.04k 72 15.25k 102 5643 132 2369
-17 834.0k 13 174.5k 43 46.11k 73 14.72k 103 5472 133 2306
-16 788.2k 14 166.3k 44 44.26k 74 14.21k 104 5307 134 2244
-15 745.2k 15 158.6k 45 42.50k 75 13.72k 105 5147 135 2185
-14 704.7k 16 151.3k 46 40.81k 76 13.25k 106 4993 136 2128
-13 666.7k 17 144.3k 47 38.20k 77 12.79k 107 4844 137 2072
-12 630.9k 18 137.7k 48 37.66k 78 12.36k 108 4700 138 2018
-11 597.2k 19 131.4k 49 36.19k 79 11.94k 109 4561 139 1965
8.5.5. PUMP CALIBRATION

Go to Maintenance mode.
8.5.5.
Press < > > right arrow key display will show pump calibration.
8.5.5.Note: Perform WASH with 3-5ml DI Water to fill the tube up to peristaltic pump
before proceeding for Pump Calibration.
8.5.5.
a. Take 1000 micro liters of distilled water in test tube.
8.5.5. b. Press ASP switch & aspirate distilled water. Aspirate till the last drop of
water is aspirated and again press ASP switch to stop aspiration.
8.5.5.
c. The count will be displayed on the screen. Now the peristaltic pump is
8.5.5. calibrated to aspirate any volume from 100 µl up to 2997 µl.
8.5.5.
8.5.5.
8-11
8.5.5.
8.5.5.1. Hidden Menus

 Setting of Default Parameters for Dry Powder/Liquid stable Reagents
and Product Name for Local or Export order.
a. Go to System Setup menu.
b. Press key sequence <7> <8> <9> <0>
c. The screen will display <Dry powder params/Liquid Stable params>
and
d. <Local/Export>
e. Select the desired parameter option by using <fn>, Message appears.
f. <Please Wait> while the parameters are being downloaded.
g. The selected Default parameters are set for 30 pre defined chemistries
on page 1.
h. To select the desired heading, press <READ>. A tick mark will be
displayed in front of the selected option. The selected heading ‘Erba
CHEM5X’ will be displayed in home screen.
i. The option of <Dry powder Params/Liquid Stable Params> is
activated by the service engineer based on the requirement.
 Selecting Multi Lingual Option Menu
b. Press key sequence <7> <8> <9> <6>
c. The screen will display 5 languages to choose from.
d. Scroll through the language options using <UP> and <DOWN> arrow
keys.
e. Select the desired Language using <YES> key (A tick mark will be
displayed in front of the selected language).
f. The selected Default parameters are set for 30 predefined chemistries
on page 1.
g. To select the desired heading, press <READ>. A tick mark will be
displayed in front of the selected option. The selected heading ‘Erba
CHEM 5X’ will be displayed in home screen.
h. The option of <Dry powder params/Liquid Stable Params> is
activated by the service engineer based on the requirement.
 Selecting Thermal Printer

8-12
b. Press key sequence <fn> <CALIB> <fn> <CALIB>.

c. The screen will display three options to choose from.
d. Scroll through the options using <UP> and <DOWN> arrow keys.
e. Select the desired printer option using <YES> key (A tick mark will be
displayed in front of the selected printer).
 Selecting External USB Printer
b. Press key sequence <fn> <READ> <fn> <READ>.
c. The screen will display three options to choose from;
TYPE 1 – Epson Dot Matrix
TYPE 2 – HP DeskJet Printer (USB) 56XX,57XX,12XX, HP Officejet
6000 and K7108 series
TYPE 3 – For future use
d. Scroll through the options using <UP> and <DOWN> arrow keys.
e. Select the desired printer type using <YES> key (A tick mark will be
displayed in front of the selected printer).
 Setting Lamp Voltage Calibration
a. Go to Maintenance menu from main screen.
b. Press key sequence <fn> <fn> <fn>
c. Use numeric keys <0> to <9> and < . > key for decimal point. A
maximum of four digits only can be entered.
d. Press <ENTER> to confirm and set the new lamp voltage.
 System Configuration Backup/Restore
For Backup:
b. Press right arrow < > > key twice to go on the <fn> - LOAD DEFAULT
PARAMETERS screen.
c. Then press key sequence <CALIB> <CALIB> <CALIB>.
d. The screen will display the factory backup menu.
e. Press <YES> to take backup of the system configuration or <NO> to
skip and cancel backup procedure.
NOTE: Once the backup is taken, it will overwrite the previous System
Configuration Data saved in the memory.
8-13
For Restore:
b. Press right arrow < > > key twice to go on the <fn> - LOAD DEFAULT
PARAMETERS screen.
c. Then press key sequence <READ> <READ> < READ>.
d. The screen will display the factory restore menu.
e. Presses <YES> to restore the system configuration or <NO> to skip and
cancel restore procedure.
NOTE: Once the data is restored it is not possible to recover the
previous data. This will only restore the System Configuration Data, QC
data will be wiped off (depending on the date setting) however Test
Parameters and Patient Report will be preserved as it is.
8-14
9. PROGRAMMING PROCEDURES
9.1. Cortex CPU Board (ELLC2008R0/EL20205R1)
Programming
9.1.1. Pre-requisite
The following aids are required for programming procedure
 PC with in-built serial and/or USB port facility
 Flash Magic utility latest version
 2 Pin Shorting Jumper caps
 A-B USB cable as shown in the figure below
Type A
To Computer
Type B
To Analyzer
9.1.2. Programming Procedure

1. Power OFF the Analyzer.
2. Open the analyzer to make CPU board (ELLC2008R0/EL20205R1)
accessible for programming.
3. Short pins 3 to 4 and 5 to 6 of JP 31 using 2 pin shorting jumper cap.
See the following image for reference;
9-1
4. Connect the serial cable to J6 (ELLC2008R0) with 3 pin molex connector

and other end to PC serial cable.
NOTE:
 If using a USB cable note that the JP1 on the USB PCB must be shorted
to enable the programming.
 Serial cable coming from USB PCB must be connected to J6.
OR
Connect the serial cable to J49 (EL20205R1) with 3 pin molex connector
and other end to PC serial cable.
NOTE:
 If using a USB cable note that the JP1 on the USB PCB must be shorted
to enable the programming.
 Serial cable coming from USB PCB must be connected to J49.
5. Now, power ON the Analyzer.

Open Flash Magic folder and Run ‘MCU Programmer’ Flash Magic.exe on
the connected PC.
6. Click Select… button in flash magic window as shown in the following
image to open Device Database.
9-2
7. Select LPC4357 controller from the device database (Do not select
LPC4357 Ethernet)
9-3
8. Configure Flash Magic as per the following image.
9-4
9. Select the appropriate serial port number which is getting connected (Either
direct serial port or serial port assigned to USB connected) to the board
from the COM Port drop-down.
9-5
10. Click ISP on the file menu of flash magic to select Erase Flash…
11. Select Erase all Flash as shown below;
9-6
12. After successfully erasing Flash Bank A, select Flash Bank B from the
drop-down box.
9-7
13. Once selected, the screen appears as shown below;
14. Now erase Flash Bank B as well. Repeat Steps 10 and 11 for the same.
9-8
15. Verify that both the banks are blank using Blank Check… command as
marked in the following image;
16. Now again select Bank A.

17. Click Browse… to open the latest version of Hex File to be programmed in
the Cortex Board.
18. The configuration after re-selecting Bank A, COM port and Hex File is
shown in the following image.
NOTE: Com Port and file location will be different for different computers.
9-9
19. Now click Start button to program the board with the latest versioned
software.
NOTE: If an error message like “Communication Error” appears after
clicking on Start, then follow the procedure mentioned in Step 20, else skip
to Step 21.
20. If an error occurs after clicking on Start button then do not close the Flash
Magic Soft ware. Simply follow these steps;
a) Power OFF the analyzer
b) Disconnect the power cable
c) Disconnect the USB cable
d) Wait for 30 seconds
e) Reconnect power cable
f) Reconnect USB cable
g) Power On the analyzer and then
h) Go to Flash Magic and again click on Start button
9-10
21. After the successful completion, the word FINISHED appears in green color
in the bottom left corner of the screen and the progress bar will reach to the
extreme right.
22. Power OFF the instrument.

23. Remove both Jumper caps from Berg Strip.
24. Remove the serial cable connected.
25. Power On the analyzer and verify the software number in corresponding
screen to confirm the software download.
9.2. Software Upgrading for Cortex CPU Board

9.2.1. Pre-requisite
The following aids are required for programming procedure
 PC with in-built serial and/or USB port facility
 Flash Magic utility latest version
 A-B USB cable as shown in the figure below
9-11
9.2.2. Programming Procedure

1. Go to System Setup menu from Main screen.
2. Press <1> to enter the Set Date menu.
3. Now press the key sequence <CALIB> <CALIB> <CALIB>. This will
display the programming screen.
4. There are 2 types of system upgrades;
Option 1: ERASE ALL AND UPGRADE SYSTEM SOFTWARE
In this option the entire memory will get erased including Test Parameters,
Patient reports, QC Data and System Setup values. Once this option is
selected it will not be possible to recover any data from the memory.
Option 2: UPGRADE SYSTEM SOFTWARE

In this option the memory is kept as it is and only the software is upgraded.
All the data like Test Parameters, Patient Reports, QC Data and System
Setup values will preserved as it is.
5. If you have selected,
Option 1: On pressing<1>, a Warning/Confirmation message is displayed on
the screen stating, THIS WILL ERASE THE ENTIRE MEMORY. Press
<YES> to proceed, however once user confirms this the entire memory will
get erased as mentioned in point 4. The analyzer then enters the
Programming Mode. Press <NO> to cancel the procedure. This will bring the
analyzer back into the main menu.
NOTE: On entering the programming mode screen through Option 1, if the

analyzer is switched OFF while this screen is displayed and again turned
ON, it will load the default parameters (System Setup and Test
Parameters), however Patient Reports and QC Data are deleted and
analyzer will work with the Firmware that is programmed into it.
Option 2: On pressing <2>, no confirmation message appears and the

analyzer will directly enter in the Programming Mode.
NOTE: On entering the programming mode screen through Option 2, if the

analyzer is switched OFF while this screen is displayed and again turned ON,
it will not have any loss of memory and data. Analyzer will work with the
Firmware that is programmed into it.
6. Once the analyzer has entered the programming mode connect the
analyzer to PC using the A-B USB cable.
7. On the connected PC, go to Device Manager from Control Panel and click
on Ports. Note-down the Communication Port number (e.g. COM1).
8. Open Flash Magic utility by double-clicking on the icon present on the
desktop as shown below or by selecting the FlashMagic.exe from folder.
9-12
9. Click Select… button in flash magic window to open Device Database.
10. Select LPC4357 controller from the device database (Do not select
LPC4357 Ethernet)
9-13
11. Configure Flash Magic as per the following image. Ensure that Bank A is
selected as indicated in the image.
9-14
12. Select the appropriate serial number which is getting connected to the
board (Communication Port assigned to USB– CP2102 which was noted in
step 7) from the COM Port drop-down.
13. Click Browse… to open the latest version of Hex File to be programmed in
the Cortex Board.
14. The configuration after re-selecting Bank A, COM port and Hex File is
shown in the following image.
NOTE: Com Port and file location will be different for different computers.
9-15
15. Now click Start button to program the board with the latest versioned
software.
NOTE: If an error message like “Communication Error” appears after
clicking on Start, then follow the procedure mentioned in Step 16, else skip
to Step 17.
16. If an error occurs after clicking on Start button then do not close the Flash
Magic Soft ware. Simply follow these steps;
i) Power OFF the analyzer
j) Disconnect the power cable
k) Disconnect the USB cable
l) Wait for 30 seconds
m) Reconnect power cable
n) Reconnect USB cable
o) Power On the analyzer and then,
p) Go to Flash Magic and again click on Start button
17. After the successful completion, the word FINISHED appears in green color
in the bottom left corner of the screen and the progress bar will reach to the
extreme right.
9-16
9-17
10. MAINTENANCE
The analyzer is designed for trouble free operation and requires minimum
maintenance. For good functioning of the analyzer it is advisable to follow the
instructions given below
1. Handle the analyzer with care and keep it clean.
2. When not in use, cover the analyzer with the dust cover to avoid
accumulation of dust.
3. Though air conditioning is not a must, it is advisable to keep the analyzer in
a dust free, cool atmosphere, away from direct sunlight.
10.1. DAILY MAINTENANCE

1. Wipe off any reagent spills on the analyzer immediately.
2. After every chemistry run, wash the flowcell thoroughly with good quality
distilled water using the "fn" key.
3. Always leave the flowcell filled with distilled water. Never leave any reaction
mixture in it.
4. At the end of each day, aspirate Erba cleaning solution into the flowcell and
leave it filled overnight. Every morning aspirate distilled water 5-6 ml to
thoroughly rinse the flowcell.
5. Empty the waste solution bottle every evening.
Caution: DO NOT USE STRONG ACIDIC OR ALKALINE
SOLUTIONS WHICH CAN CAUSE IRREPAIRABLE DAMAGE TO
THE ANALYZER.
Caution: DO NOT LEAVE THE FLOWCELL DRY. ALWAYS LEAVE

IT FILLED WITH DISTILLED WATER DURING THE DAY AND
WITH CLEANING SOLUTION AT NIGHT.
NOTE: It is advisable to carry out the peristaltic pump calibration every week in
order to compensate for the change in elasticity of the tubing.
10.2. QUATERLY MAINTENANCE

Replace the aspiration tubing and peristaltic pump tubing once every THREE
months (as explained below) or earlier if it shows signs of wear and tear.
NOTE: Failure to change the peristaltic pump tubing in time can cause serious
errors of aspiration volumes and can also damage the analyzer due to the leakage
of corrosive reagents through torn tubing. Also, the change in peristaltic pump
tubing should be followed by Pump Calibration procedure.
10-1
Besides the above, certain other simple maintenance operations have to be

performed as and when required.
These are:
 Replacement of the paper roll
 Replacement of tubing’s
10.3. REPLACEMENT OF TUBING

Warning: THE REPLACEMENT OF ASPIRATION AND
PERISTALTIC TUBINGS SHOULD BE PERFORMED BY THE
TRAINED PERSON ONLY.
The replacement has to be carried out once in THREE months, or whenever an
alteration in the aspiration volume occurs. Disconnect the tubing from the
peristaltic pump if the analyzer is not going to be operated for a few days or longer.
10.3.1. ASPIRATION TUBE REPLACEMENT

1. Open the Photometer Cover.
2. Gently remove the flow cell from cuvette holder assembly.
10-2
3. Unscrew the aspiration tubing from the flow cell.
4. Slide out the washer and ‘O’ ring of the old aspiration tubing.
5. Discard the old aspiration tubing onto an appropriate location, as it is bio-

hazardous.
6. Slide the washer and ‘O’ ring into the new aspiration tubing.
7. Lock it to the flow cell with the plastic screw available.
8. Place the flow cell back into the cuvette holder assembly.
9. Pass the end of the aspiration tube through the holder and pull it out so that
the length is adequate.
10. Aspirate the DI water.
11. Close the Photometer Cover.
NOTE: Take care to see the side of the flowcell with the arrow mark is in light path
and to your left. Also, whenever the flowcell is not in use, fill the flowcell with DI
water.
10-3
10.3.2. REPLACEMENT OF PERISTALTIC PUMP TUBINGS

1. Remove the Cover of the peristaltic pump housing.
2. Before the old tube is removed, note the exact manner in which it is
positioned around the pump.
3. Release the peristaltic pump tubing.
4. Detach both the ends of the tubing from Aspiration tubing and Waste tubing
respectively.
5. Insert the one end of new peristaltic tubing assembly into the tubing coming
from the flow cell.
6. Position the new tubing around the rotor.
10-4
7. Insert the other end of peristaltic tubing into the waste tube and direct the
waste tube towards waste bottle.
8. Perform pump calibration with 1 ml DI water.
NOTE: Perform WASH with 3 ml DI Water to fill the tube up to Peristaltic
pump before proceeding for Pump Calibration
9. Put the cover of the peristaltic pump housing.
10.4. REPLACEMENT OF LAMP ASSEMBLY

Warning: THE REPLACEMENT OF LAMP ASSEMBLY SHOULD
BE PERFORMED BY THE TRAINED PERSON ONLY.
10. Open the Photometer Cover.

11. Unscrew the thumbscrew and remove lamp cover.
12. Before the old lamp is removed, note the exact manner in which it is
positioned.
13. Unscrew the two lamp terminals using (--) screw driver.
10-5
14. Unscrew the thumbscrew provided on the lamp holder.
15. Pull out the lamp.
16. Place a new lamp and connect the lamp terminals and fix thumbscrews.
17. Refit the lamp cover.
18. Close Photometer Cover.
NOTE: Due to the aging effect the lamp intensity may get reduced and results may
be improper, it is advisable to replace the lamp after every six month.
Warning: SWITCH OFF THE POWER SUPPLY BEFORE
REMOVING THE COVER.
10-6
10.5. REPLACEMENT OF PRINTER PAPER

Warning: THE REPLACEMENT OF PRINTER PAPER SHOULD
BE PERFORMED BY THE TRAINED PERSON ONLY.
Before starting the instrument, make sure that enough printer paper is on the roll.
The paper roll is located under the printer cover. To check and / or replace the
paper roll lift off the printer cover. For inserting a new paper roll do as follows.
1. Lift off the printer cover and take the roll out of the paper roll housing.
2. Then take a new paper roll and lay down into the paper roll housing.
FOR FUJITSU PRINTER
3. Release the printer lever by pulling it upward.
4. Cut the paper in ‘V’ shape and feed this paper tongue into the slot of the
paper feeder. Smoother side should face up.
5. Close the printer lever by pressing it down and close the printer cover.
10-7
FOR WINSPU PRINTER

NOTE: - Unlike FUJITSU Mechanism the WINSPU Mechanism does not have a
leaver to release the roller grip from paper and has a capability to completely come
out of the assembly (Currently only one side is allowed in the mounting
arrangement) to allow the user to insert the paper
FUJITSU Mechanism
WINSPU Mechanism
6. Keep the paper (Smoother side face up) touching the roller.
7. Press PAPER FEED key provided on the keypad to advance the paper
Warning: BE CAREFUL - SHARP PAPER CUTTER.
Warning: SWITCH OFF THE POWER SUPPLY BEFORE

REMOVING THE COVER.
10-8
10.6. PROCEDURE FOR REFITTING THE ROLLER IN

WINSPU MECHANISM
In WINSPU mechanism the rubber roller which holds and moves the paper ahead
has a capability to completely come out of the assembly (Currently only one side is
allowed in the mounting arrangement) & allows the user to insert the paper.
1. This roller can be easily replaced in its original position by pressing it
downwards in the correct position. Refer below figure
Rubber roller for

guide and hold the
paper.
Roller with possibility

of getting detached
from the assembly.
2. Slide the paper below the roller and can easily fit the roller by pressing it in
correct position
10-9
11. TROUBLESHOOTING GUIDE

The following list is an extension of the troubleshooting section outlined in the
operator’s manual. The reader should familiarize with the setup, operation and
troubleshooting section of the operators manual before attempting to service the
unit.
In all cases of problem that are not described in this chapter and that cannot be
solved by you according to the given remedies, it is strongly recommended to
contact your technical product specialist.
NOTE: It is very important while diagnosing problem to look at the non-
instrumental aspects of troubleshooting. This will save time and efforts for reaching
to the correct solution.
 Please ensure the following before opening the instrument.
 The Quality of reagents and samples used is good.
 There are no voltage fluctuations or stabilization problems in mains voltage.
 There are no pipetting errors.
 While re-programming new/old tests for instrument, ensure the parameters
entered are as per the reagents brands used.
 There are no environmental problems.
FIXING A PROBLEM:
1. Analyzer is not turning ON.
Probable Cause Corrective Action
No supply voltage. Check supply voltage.
Defective SMPS. Replace SMPS.
Test point voltages are not OK. Replace CPU PCB.
Loose connection. Firmly connect the loose connector.
2. Blank or Black Display.
1. Loose Connection. Remove all connectors on CPU PCB and
Power Distribution PCB. Tighten all the
connections.
2. Defective Display assembly. Replace display assembly.
3. Intensity control for display not set. Adjust display intensity Pot R12 on the
CPU PCB.
3. No Back Light Effect.
1. +5 V DC at LCD for LED backlight not Possible loose connection of the connector
present. on CPU PCB assembly and LCD
11-1
2. Defective CPU PCB. Replace main board.

4. Liquid is not aspirated when the “ASP” switch is pressed.
1. Peristaltic tube elongated. Replace peristaltic tube with new one.
2. Loosely fitted tubing. Tighten the tube joints and flowcell
connector.
3. Loosely fitted flowcell connector. Tighten the flowcell connectors.
4. Blockage in tubing’s flow cell. Check and remove blockage. Replace
tubing if blockage is not removed.
5. “ASP” switch is stuck Open the top cover and check if “ASP”
switch is working. If yes then refit the top
cover such that the “ASP” switch is
properly released.
6. “ASP” switch is defective. Replace “ASP” switch.
7. Defective motor assembly. Replace defective motor assembly.
8. Defective keyboard assembly. Replace keyboard PCB assembly.
9. Defective main board. Replace main board assembly.
5. Liquid is not aspirated when the Dynamic key “WASH” switch is
pressed.
1. Check all the above-mentioned points Check the all above mentioned points
6. Liquid is aspirated continuously.
1. Peristaltic pump not calibrated. Carry out pump calibration.
2. SMPS output is not OK Replace SMPS unit.
3. Defective keyboard assembly Replace keyboard PCB assembly
7. Air bubbles in flowcell.
1. Peristaltic pump wrongly calibrated. Carry out pump calibration.
2. Leakage/cut/pinched flowcell Replace aspiration tube.
connectors.
3. Loosely fitted flowcell connectors. Tighten the flowcell connectors.
4. Flowcell damaged. Replace flowcell.
8. Dripping or Leakage from Aspiration tube.
1. Peristaltic tube reversed. Fix the peristaltic tube in the correct
position.
2. Hole in tubing before peristaltic pump. Replace tubing.
3. Flowcell damaged. Replace flowcell.
9. Erratic results/poorly reproducible results/peaks in graphs.
11-2
1. Inconsistence aspiration of solution. Replace peristaltic tube assembly and

recalibrate peristaltic pump.
2. Dripping or leakage from aspiration Refer point 8 as mentioned above.
tube.
3. Dirty flow cell. Aspirate ERBA wash and clean flowcell.
4. Air bubbles in flow cell. Refer point no.7 as mentioned above.
5. Brownish/Defective lamp assembly. Replace with new lamp assembly.
6. Peristaltic tube elongated. Replace peristaltic tube assembly.
7. Lamp voltage fluctuation. Check and replace power supply PCB
assembly.
8. Loosely fitted Photometer Box. Fix the photometer box properly.
9. Defective photometer assembly. If the gain is abnormal replace photometer.
10. NO Paper Feed.
1. Printer lever is open (release position). Push the printer lever down to lock paper.
2. Loose or poor contact Check for any loose connections to printer
cables and connectors
3. Defective keypad assembly Replace keypad
4. Defective printer assembly Replace printer PCB assembly
11. NO Printout.
1. Printer is not selected. Select printer option in system setup.
2. Printer lever is open (released) Press lever down and lock paper.
position.
3. Paper roll is installed reverse way. Install paper in right way.
4. Cable between CPU (J27) & Power Remove and refit the cable.
Supply PCB (J4) is lose (On every print issue the LED 3 on power
supply PCB turns OFF and turns ON again
with 2 second interval)
5. Defective Printer PCB assembly. Replace printer PCB assembly.
12. Faint printout/some characters missing.
1. Dirty printer head. Clean the printer head with alcohol.
2. Defective printer PCB head Replace with new printer PCB head.
Note: - WINSPU and FUJITSU Thermal Printer Heads are interchangeable.
i.e.112578 & 110191 are interchangeable & can be used with 110184 & 112579
13. Continuous Buzzer.
1. Aspiration switch stuck. Release the aspiration switch.
2. Printer lever is open. Close printer lever by pressing it down.
11-3
14. Beep Sound

1. Probable Cause 2. Corrective Action
3. Paper is not present. 4. Insert paper in properly.
5. Printer lever open (released). 6. Close printer lever by pressing it down.
15. External Printer not working
1. Printer is not selected in output mode. Select external printer in output mode.
2. USB cable is loose. Tighten USB cable.
16. The result printout is accompanied by the warning “RX ABS LIM
OVER” in all Chemistries.
1. The initial reaction of mixture is more Check the RX ABSLIM value has been
than ABS MIN value in test correctly entered. Prepare fresh reagent
parameters. and check the values.
17. The result printout is accompanied by the warning “RX ABS LIM
UNDER” in all Chemistries.
1. The initial reaction of mixture is more Check the RX ABSLIM value has been
than ABS MIN value in test correctly entered. Prepare fresh reagent
parameters. and check the values.
18. The result printout is accompanied by a warning message
“HYPERACTIVE SAMPLE!!”
1. The change in the absorbance per set. Verify the limit.
minute (∆A/min) pf the sample is
greater than the value fed as “LIN,
LIM”.
2. Kinetic reaction is still in lag phase. Amount of enzyme in the measurement
solution is very low, dilute the sample and
perform the test again.
3. Check if the initial absorbance is OK. Lamp intensity is low /flow cell is not
blocked.
19. All the readings are zero.
1. The lamp is not ON If lamp is fused replace lamp assembly
2. Flowcell is not inserted properly Place the flowcell properly in light path
20. Keypad is locked or not working.
1. Aspiration Switch is pressed. Release ASP switch.
Reset the analyzer using ON/OFF switch.
S/W Ver 2012.01.08 onwards we get a
warning message at power on if the “ASP”
switch is stuck or kept pressed.
11-4
21. Date and time is not OK.

1. Analyzer is not switched ON for more Set date and time by going through the
than 3 to 4 weeks. system setup option.
2. 3V battery may be drained out. Replace 3V battery.
22. Memory/Data storage error.

1. Chemistry parameters not stored. Replace CPU PCB.
2. Patient report and values for non linear Replace CPU PCB.
chemistry not stored.
3. Linear chemistry not stored Quality Replace CPU PCB.
Control Data not stored.
23. Hardware Check shows Temperature Sensor NOK.
1. Loosely connected Temperature Tighten Temperature sensor connectors
sensor connectors. and check for continuity with a multimeter.
2. Temperature Sensor faulty. Go to Temperature Check Menu and if
temperature displayed is junk and LED D4
turns ON for 1.5 sec. (approx.) Then
replace temperature sensor.
If problem still persists, replace CPU
board.
24. Hardware Check shows Photometer NOK.
1. Light path is blocked. Remove obstacle if any in light path.
2. Flowcell is empty. Aspirate distilled water.
3. Bubbles in flow cell. Remove bubbles by aspirating water.
4. Loose connection of mains Properly insert the mains cord/DC jack
socket/cord/DC jack connector. connector.
5. DC jack PCB faulty. Replace DC jack PCB.
25. The temperature attained in the flow cell is not within ± 0.1º C of the
selected temperature.
1. Flowcell is not completely inserted Insert flowcell completely in proper way
2. Refrigerated reagent is used. Bring the temp. of reagent to room
temperature and then use it. Replace
thermister still persists, replace peltier
11-5
11.1. TROUBLESHOOTING SECTION

SERIAL SYMPTOM LIKELY CAUSE/CORRECTIVE ACTION
NUMBER
1 Liquid is not aspirated when the 1. Check if peristaltic pump tubing is connected
Dynamic key <WASH> switch is properly, if not reconnects correctly.
pressed 2. Perform pump calibration again.
3. ASP switch may be defective.
4. Call Service Engineer
2 Peristaltic Pump operates but 1. Ensure that tubing and aspiration tubing are
liquid is not aspirated. properly connected.
2. Check tubing for blockage, crimps or leaks.
3. Perform pump calibration again.
4. Replace the tubing.
5. Call Service Engineer.
3 The graph of a Kinetic chemistry 1. The graph of a Kinetic chemistry is never
is not printed along with the printed along with the result automatically.
result. 2. A printout of the graph can be obtained by
using the 'PRINT' key after getting the graph
on display.
4 The temperature attained in the 1. Call Service Engineer.

flowcell is not within ± 0.1º C of
the set Temperature
5 Poorly reproducible & erratic 1. Check if the aspiration volume that is

readings programmed and then check whether the
same amount of liquid aspirated is as
programmed.
2. If it is found that the aspiration is not proper
then performs pump calibration.
3. Check expiry date of the reagents and control
material used.
4. Check if all the necessary precautions have
been taken. Always use clean glassware.
6 Control values not within range 1. Ensure that the procedures specified by the
reagent manufacturer are followed.
2. Check the wavelength, temperature, sample
and reagent volumes, and factor and std.
concentration. In case of Kinetic chemistries
make sure that the Delay time Read time, and
Read number are correctly programmed.
3. Check reagents, controls and standards for
expiry.
4. Ensure that water used for the reconstitution of
dry powder reagents is of reagent grade
quality i.e. De-ionized water or Double Distilled
water.
7 The result printout is 1. The initial absorbance of reagent is less than
accompanied by the warning the RG. ABS Lim. value test parameters.
11-6

NUMBER
“CRITICAL REAGENT 2. Check if the "RG. ABS LIM." value has been
ABSORBANCE" in All correctly entered.
chemistries.
3. Prepare fresh reagent and repeat the test.
Additional Troubleshooting Points

NUMBER
1. Check I/P supply at customer end AC
230V±10%.
2. Proper earthing voltage which should be 0-5V
between N&E.
3. Check power cord continuity. (If NOK then
replace it).
4. Check 18 V ±10% at SMPS dc jack pin.
5. If output is not ok (18V ±10% dc) then replace
the SMPS (AC Adaptor).
1. Machine Dead/Not switching on 6. Switch ON the instrument by ON/OFF switch.
Change the switch in case it is not working.
7. If switch is OK then check the supply on dc
jack Pcb in instrument, if there is no supply
then change the dc jack Pcb.
8. If DC jack PCB is ok, check the input voltage at
power supply PCB TP5 w.r.t. TP6 (gnd), if
voltage 18 V not coming, replaced the power
supply PCB.
Please follow all the above mentioned steps
before changing any Pcb.
1. Remove the lamp cover from instrument.
2. Check the lamp voltage on terminal strip
(11.70v).
3. If the voltage is OK, check the lamp visually if it
is fused then replace it.
2. Lamp not glowing 4. If lamp is ok, then check the same voltage on
P/S Pcb (TP2 & TP6).
5. If voltage is not coming then change the P/S
PCB.
1. Open the instrument & check the FRC cable
connection at J12 on CPU Pcb. Refix it
(especially in case of display flickering).
2. Adjust display intensity from pot R12 at CPU
Display blank /Flickering/Intensity Pcb.(specially in case of low intensity display)
3.
low
3. Check display visually by removing from
instrument (soldering of FRC cable &
components).
4. Check another display, if it is ok then replaced
11-7

NUMBER
with faulty display.
5. If not ok with new display then change the CPU
Pcb.
1. Check the ASP switch, if stuck then release it
by proper fitment of cabinet.
2. Check the keypad cable visually & refix the
same on J3 & J3A connector.
3. Check another keypad without fixing on
cabinet. If new keypad is ok, then replace
4. Keypad not working
faulty keypad with new one.
4. In case if new keypad also not working, then
change the CPU Pcb without changing the
keypad.
1. Do the offset calibration and observe that
channel at which the error is showing.
2. Now open the instrument & detector box. Then
remove the photometer Pcb from detector box.
3. Check the power supply & signal cable of PH.
Pcb for proper connection either on PH. Pcb
or on CPU Pcb.
5. Offset error 4. Check the RTV application on photometer Pcb.
Every single point should be cover with RTV
glue. If found such point then apply the RTV
glue on it.
5. If RTV is OK but no effect on problem then
change the PH. Pcb.
1. Check thermal paper roll is present or not.
2. If lever is open then close it towards down
wards.
3. Reconnect the printer Pcb cables (both supply
& signal).
4. Check the printer Pcb visually, if found any
component damage, and then change the
6. Printer lever error printer Pcb.
5. Check the thermal printer tail which should be
properly connects with printer Pcb.
6. If software version is 2010.03 instead of
2011.01(at present) or older ver. Then replace
the CPU Pcb.
7. No Print Out & Faint Print Out 1. Check if paper roll is installed in reverse way; if
11-8

NUMBER
so then install it correctly.
2. Check the settings in output mode (system
setup), if thermal printer not selected then
select it.
3. In case of faint print out, check for any dust
particle on printer head.
4. Check the printer Pcb visually, if found any
component damage, and then change the
printer Pcb.
5. Check the thermal printer tail which should be
properly connects with printer Pcb.
1. Clean the flowcell by aspirate with ERBA wash
then with DI water. (Especially in case of any
bubble in working area).
2. Check the complete peristaltic tube assy.
visually for any cut mark, pinched, fitment of
tubing, loose fitment of straight through
connector & loose fitment of rotor base assy.
8. Improper aspiration/No aspiration
3. In case of slow aspiration check the peristaltic
tube (9cm) for elongation, if found elongated
then change the same.
4. In case of "No" aspiration check the motor
assembly, if found defective then replace the
motor assy.
Perform pump calibration again.
1. Check the complete peristaltic tube assy.
visually for any cut mark, pinched, fitment of
Leakage from peristaltic tubing, loose fitment of straight through
9. connector & loose fitment of rotor base assy.
pump/Aspiration tube
Check any loose connector on flowcell & any cut
on flowcell tubing.
1. Check at rear side of instrument the ext.
keyboard/ printer connectors should be
centrally aligned.
2. Check for any fault in printer & keyboard of
customer itself by confirming it on any PC.
3. Check the connector visually from rear side for
any bend or broken of any pin if yes then
External Keyboard/printer not change the USB Pcb.
10.
working 4. Check for any particle dropped on USB Pcb.
5. Check for any loose connection of cables either
on USB Pcb (J2 & J4) or on CPU Pcb (J13 &
J39).
6. If not ok with above steps then change the
CPU Pcb.
Please follow all above mentioned steps before
changing any Pcb.
11-9

NUMBER
1. Check lamp voltage on terminal strip (11.7 V).
2. Change the lamp & confirm the lamp image.
11. Gain saturation 3. Do the offset calibration & gain calibration, if
not ok then change the PH Pcb.
1. Check the flowcell visually any finger prints,
any impression, dust particle in working area.
2. Check for any cuvette chip or foreign particle in
flowcell housing.
3. Check for any bubble in working area. If there
is bubble then aspirate with DI water.
4. Check the lamp image. It should be clear in
round form. If not then make its proper
12. Filter gain not ok/low gain alignment or change the lamp.
5. Check the alignment of detector box. Also
check the screw tightening on detector box &
clamp.
6. Clean the 9.5 mm condensing lens with optical
grade tissue cloth.
7. If not ok then change the PH. Pcb.
1. Check if aspiration switch get stuck with
cabinet. Release it firmly.
2. Check the loose connection of ASP key/LED
cable at J5 connector on CPU Pcb.
3. Check the CPU Pcb visually for any drop age
of any foreign particle, chips etc.
13. Filter gain not ok/low gain
4. If not ok with above steps then change CPU
Pcb.
5. Clean the photodiode with acetone or alcohol
with optical grade cloth.
1. Check if switch is tightly pressed while
functioning, if so then change it.
2. Check for any loose & improper crimping of
ON/OFF switch not wire.
14.
working/Intermittent operation 3. Check if switch connector is not having contact
with power supply cable connector.
If NOK with above steps then change the
ON/OFF switch.
1. Do the offset & gain calibration.
Erratic result/Improper 2. Check the reagents (expiry) & contamination.
15.
result/Negative result 3. Check the flowcell housing area for any foreign
particle or cuvette chip (to avoid zero result).
11-10

NUMBER
4. Properly clean the flowcell with ERBA wash &
then with DI water mandatory (to avoid
negative result).
5. In case of slow aspiration check the peristaltic
tube (9cm) elongation, if found elongated then
change the same. Then recalibrate the
peristaltic pump.
6. Check pump calibration & test parameters
thoroughly.
7. If the graph is erratic then change the lamp. Be
sure that the lamp image is clear. Also check
the Lamp voltage fluctuation. In such case
change the P/S Pcb.
8. If graph still not ok then change the 9.5 mm
condensing lens.
9. If all above case not resolved then change the
CPU Pcb.
Recalibrate the pump with 1 ml DI water (pump
16. Pump calibration not ok
count should be 1800 to 2100)
11-11
12. SPARE PARTS

12.1. SPARES DETAILS AND ORDERING
INFORMATION
Sr.
Component Description Item UOM Qty/M
No.
1 104809 Assembly Photometer with Square Filter For Chem 5x NOS 1
2 110042 ASSEMBLY LENS HOLDER FOR CHEM6 NOS 1
3 110049 ASSEMBLY CUVETTE HOUSING FOR EC5V3 NOS 1
4 110038 ASSEMBLY DETECTOR BOX FOR CHEM6 NOS 1
5 110040 ASSEMBLY PHOTOMETER METAL BLOCK TOP EP NOS 1
6 110018 ASSEMBLY LAMP NOS 1
7 104810 Assembly Mirror & Square Filter For Chem 5x NOS 1
8 115901 ASSEMBLY PCB PHOTOMETER ELLC2002R4 NOS 1
9 110021 ASSEMBLY PERISTALTIC TUBE NOS 1
10 107722 ASSEMBLY PCB DC JACK ELP62004R5 RA NOS 1
11 107925 ASSEMBLY PCB USB CONNECTOR ELLC2003R5 NOS 1
12 115069 ASSEMBLY PCB CPU EL20205R1 NOS 1
ELECTRICAL ASSEMBLY FOR TEMP SENSOR &
13 111097 NOS 1
PELTIERS EACHEM5V302 R2
14 111451 ELECTRICAL ASSEMBLY MOTOR EACHEM5V301 R5 NOS 1
15 110037 ELECTRICAL ASSEMBLY FAN - EACHEM5V303 NOS 1
16 110032 ASSEMBLY DISPLAY NOS 1
17 116793 ASSEMBLY PCB POWER SUPPLY EL20203R3 NOS 1
18 110197 FLOWCELL 30 UL (CLOSED BODY) NOS 1
19 110355 TUBE SILICON ID 0.8 MM X OD 2.4 MM M 0.006
20 110194 TUBE TEFLON ID 1 MM OD 2 MM M 0.027
21 110356 TUBING SILICON ID 2 MM OD 4 MM (IMPORTED) M 0.3
Dia 9.5mm ,BK7 Lens, R1-22.3mm,R2-22.3mm, Biconvex
22 111127 NOS 1
lens FL:22mm , Tol +/-0.1
SILICA GEL BAG; SIZE - 55 MM LENGTH & 30 MM
23 104855 NOS 2
WIDTH WEIGHT 2.5 GMS
24 105946 GASKET FOR FILTER HOLDER NOS 1
25 107256 THUMB NUT (M3x7L) NOS 2
26 107229 HEAT SINK NOS 1
CABLE ASSEMBLY OF ON/OFF SWITCH FOR DC JACK
27 106669 NOS 1
CWCHEM5V320 R0
28 110148 FOOT REST FOR CHEM5 V3 NOS 4
29 110377 TUBE HOLDER BRACKET - PLASTIC NOS 1
30 110380 SWITCH ACTUATOR_EP NOS 1
31 110163 SPRING SWITCH CHEM 5X NOS 1
32 110389 MOUNT FOR EP SWITCH NOS 1
33 110396 SWITCH DISPLAY NOS 1
12-1
34 110384 HOLDER FOR CARD FOR CHEM5X OLD NOS 1

35 110168 SPACER HEX HSG PLATE NOS 2
36 110370 PPC LOCKING NUT NOS 2
37 110349 SPACER NYLON DIA.1/4" ( FOR KEYBOARD) NOS 4
38 110146 CAP FOR INCUBATOR CONNECTION NOS 1
ROTOR BASE (V2) WITH CYLINDRICAL PIN DIA 5.0 X
39 110394 SET 1
16.5 L
40 110393 BUSH FOR EC5V2 NOS 4
41 111507 SWITCH SHAFT NOS 1
42 111074 END SUPPORT NOS 1
CIRCLIP FOR SHAFT "C" TYPE; BN 679 FOR SHAFT
43 101527 NOS 1
DIA 3.2
44 110354 TUBING PVC ID 2.8 MM OD 4.3 MM M 0.55
45 110350 STUD AND NUT FOR D CONNECTOR NOS 2
46 104779 CLAMP FOR PHOTOMETER BOX NOS 1
47 105809 FAN DUCT (PLASTIC) NOS 1
48 105920 SPACER FOR MOTOR NOS 1
49 106285 SPACER FOR ASP SWITCH EP NOS 1
50 104700 MOUNT FOR USB & ROCKER SWITCH NOS 1
51 107027 Grommet NOS 1
52 103571 SWITCH PUSH BUTTON PRT, BLUE NOS 1
53 107864 PLATE BASE CHEM5V3-5X NS NOS 1
54 107867 SIDE PLATE (PLASTIC) NOS 1
55 107868 STUD FOR LAMP MOUNT ASSY. NOS 1
56 108083 COVER FOR PERISTALTIC PUMP NOS 1
57 110379 PHOTOMETER COVER_EP NOS 1
58 110181 DISPLAY LEGEND EP NOS 1
59 110406 PIN PAPER ROLLER NOS 1
FUJITSU Printer Spares
60 110191 PRINTER FTP-628MCL054 FOR V2 / 5X / CH7 / V3 NOS 1
PCB BARE PRINTER INTERFACE (FTP-
61 110184 NOS 1
628DSL308)(V270190 003AB)
CABLE ASSEMBLY JUNCTION PCB J8 TO 8PIN ZH
62 107761 NOS 1
CONN (PRINTER INTER. PCB) ASSY, CWEC5V206 R3
105806 PRINTER MOUNT EP NOS 1
105807 PRINTER PCB MOUNT EP NOS 1
62 110381 COVER FOR PRINTER EP NOS 1
WINSPU Printer Spares
63 112578 WINSPU THERMAL PRINTER HEAD: TP27FP6RZEA NOS 1
WINSPU THERMAL PRINTER CONTROL BOARD:
64 112579
TP27FX
NOS 1
65 112878 PRINTER MOUNT NOS 1
66 112880 PRINTER PCB MOUNT EP NOS 1
CABLE ASSY. CPU PCB J2 TO Winspu PRINTER
67 113044
INTERFACE & PRINTER SIGNAL CW10K020
NOS 1
Refer 63 to 67 only for WINSPU printer assembly
12-2
Note: - WINSPU and FUJITSU Thermal Printer Heads are interchangeable. i.e.
112578 & 110191 are interchangeable & can be used with 110184 & 112579
68 110403 PLATE LCD FOR CHEM5X OLD NOS 1
69 103866 MOUNT FOR DISPLAY-RH NOS 1
70 103867 MOUNT FOR DISPLAY-LH NOS 1
71 103868 CABLE GUIDE NOS 1
72 106688 CABINET EP NOS 1
PCB BASE KEYBOARD LEGEND,MEMBRANE SWITCH
73 106690 NOS 1
NON TACTILE TYPE CHEM 5X NS
74 105599 SERIAL NO. PLATE-TRANSASIA+ERBA FOR CHEM5X NOS 1
CABLE ASSEMBLY CPU PCB J38 TO PELTIER &
75 110107 NOS 1
SENSOR CWCHEM5V301
CABLE ASSEMBLY PHOTOMETER PCB POWER TO
76 110310 NOS 1
CPU PCB J8 CONN CWCHEM5V304
CABLE ASSEMBLY EXTERNAL KEYBOARD
77 110108 NOS 1
CWCHEM5V305 R2
CABLE ASSEMBLY J5 CPU PCB TO ASP. SW. & ASP
78 110314 NOS 1
LED CWCHEM5V307
CABLE ASSEMBLY CPU PCB J18 TO PHOTOMETER
79 110311 NOS 1
PCB J1 CWCHEM5V312
CABLE ASSEMBLY CPU PCB J39 TO SERIAL -USB
80 110315 NOS 1
CONVERTER CWCHEM5V316
CABLE ASSEMBLY USB PCB J2 TO CPU PCB J13 -
81 111524 NOS 1
CWCHEM5V303 R-4
82 107280 Cable Assembly for Earthing CWCHEM5V314R5 NOS 1
CABLE ASSEMBLY DC JACK J2 TO POWER SUPPLY
83 107479 NOS 1
J1 & INCUBATOR CONN. CWCHEM5V315 R9
CABLE ASSEMBLY POWER SUPPLY PCB J2 CONN
84 107441 NOS 1
CWCHEM5V302 R8
85 110257 LED LEADED ROUND 5mm RED NOS 1
HOLDER LED 3 PIN 5 MM PANEL MOUNTING
86 110304 NOS 1
CUTOUT DIA 8 MM
87 110082 SET OF STANDARD ACCESSORIES FOR CHEM-5X NOS 1
ASSEMBLY WASTE BOTTLE FOR
1 110035 NOS 1
CHEM7/EC5V2/CHEM5X/CHEM5V3
THERMAL PAPER ROLL (57 MM X 30 M) FOR
2 110309 ROL 1
PRINTER
3 110348 COVER FOR DUST FOR EP NOS 1
4 110347 MICRO CUVETTE RECTANGULAR POLYSTYRENE NOS 5
5 110326 ALLEN KEY SIZE: 2.5 MM NOS 1
6 110943 PIPETTE TIPS SERIES 200UL YELLOW T200Y NOS 50
7 110944 PIPETTE TIPS SERIES 1000UL BLUE T1000B NOS 50
8 110978 PIPETTE STAND (PLASTIC) NOS 1
9 115981 POWER ADAPTER AC (O/P : 19.5 VDC ; 90 W) NOS 1
10 111654 TopPette Adjustable Volume Pipette 5 - 50 Ul (720020) NOS 1
TopPette Adjustable Volume Pipette 100 - 1000 Ul
11 111655 NOS 1
(720060)
Power cord with TYPE D / M type Plug & C5 type
12 116117 NOS 1
Connector. Length 1.5 Meters (Domestic)
12-3
Power cord with TYPE E / F type Plug & C5 type

13 116118 NOS 1
Connector. Length 1.5 Meters (Export)
14 103936 P.M.KIT – CHEM 5X / CHEM5V3 NOS 1
1 110018 ASSEMBLY LAMP NOS 1
2 110353 SYRINGE 5 ML (CAT NO 300850 MAKE B-D) NOS 1
3 110354 TUBING PVC ID 2.8 MM OD 4.3 MM M 0.55
4 111213 TUBE TEFLON 0.75MM X 1.5MM M 0.42
5 110194 TUBE TEFLON ID 1 MM OD 2 MM M 0.027
6 112546 ASSEMBLY PERISTALTIC TUBE NOS 1
7 110356 TUBING SILICON ID 2 MM OD 4 MM (IMPORTED) M 0.36
8 110355 TUBE SILICON ID 0.8 MM X OD 2.4 MM M 0.012
12.2. LIST OF CONSUMABLES

For continuous and trouble free working of analyzer, it is a recommended to keep
certain spare consumables handy.
One set of the items mentioned below is also supplied along with the instrument as
standard accessories. It is recommended to store the consumables/spare in the
OEM packing until the actual use.
SR. NO. ITEM CODE DESCRIPTION QUANTITY
1 110021 PERISTALTIC TUBE ASSEMBLY 2 NOS.
2 111213 TUBE TEFLON 0.75MM X 1.5MM 1 NO.
3 110018 LAMP ASSEMBLY 1 NO.
4 110309 PRINTER PAPER ROLL 57 MM X 30 M (SET OF 3 ) 1 NOS.
5 110347 RECTANGULAR POLYSTYRENE MICRO-CUVETTE 5 NOS.
7 120232 ERBA wash kit (4 x 50 ml) 1 NO.
12-4
13. APPENDIX
13.1. REVISION HISTORY
Revision Date Revision Description Author
2011.00.01 3-Sept-2011 First Release SD
14-March-2012 Updated section Self-Test & Trouble PP
2012. 01
shooting points
2012.01.01 20-February 2013  Added Air Purge feature PS
 Introduced Section wise page
numbering style ,Standardized
forward & legal information
2013.01 23-August-2013  Trouble shooting guide updated PS
for ASP Switch error
 Spare part list updated
2013.02 31-December-2013 Following changes are updated: PS

 Functional Description of pcb &
Wiring diagram
 Added WINSPU mechanism
related paper loading tips & roller
refitting procedure
 Spare parts list.
2014.01 -- Not used SD
2015.01 -- Not used SD
2017.01 16-February-2017 Following changes are updated: MB
 Hardware specification table
updated.
 Software Programming and
upgrade steps added for Cortex.
 Spares list updated.
 Lamp Save Added
 Index Mode Added
 Hidden Keys Updated
13-1

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Service Manual

Semi-Automated Clinical Chemistry Analyzer

Document Version: 2017.01

Last Updated: February 16, 2017

Before servicing the analyzer, service engineer should:

1. Read and understand this manual.

2. Be trained by authorized person.

3. Be familiar with the operation of the analyzer.

NOTE: Keep this manual in an easily accessible place.

Manufacturer is the copyright owner of this document.

This document cannot be modified, reproduced, translated or transmitted in any form or

1. OVERVIEW OF ANALYZER........................................................................................... 1-1

8.5. ADJUSTMENT AND CALIBRATION ................................................................... 8-9

1.2. ANALYZER VIEW

PHOTOMETER COVER PRINTER COVER

ASPIRATION TUBE ASPIRATION SWITCH

ON/OFF SWITCH INCUBATOR CONNECTOR

PERISTALTIC PUMP COVER PC INTERFACE PORT

EXTERNAL USB PRINTER EXTERNAL PC/AT KEYBOARD

DC INPUT SUPPLY SERIAL NUMBER PLATE

Caution: NEVER OPERATE ON A WET OR DAMP SURFACE.

3.2. SOFTWARE SPECIFICATIONS

 Graphic presentation of Non Linear calibration curves

3.3. KEYBOARD DESCRIPTION

It is used to advance the thermal printer paper roll by few

This key is a multi-purpose key used for different functions

For Linear test, CALIB key is used when factor is to be

This key is used to return to the previous screen.

This key is used as key to cancel a typed character.

This key is used to display help menu.

This key is used to reset the instrument without resetting

This key is used to print data on selected Printer (USB

3.4. ASPIRATION SWITCH

4.3. INSTALLATION REQUIREMENTS

4.4. ELECTRICAL REQUIREMENTS

4.5. INSTALLATION PROCEDURE

4.6. PRINTER HOUSING AND PRINTER PAPER

4.6.2. EXTERNAL PRINTER

4.7. EXTERNAL KEYBOARD INSTALLATION

6. FUNCTIONAL DESCRIPTION OF PCB

Block Diagram of CHEM 5X

CPU PCB COMPONENT LAYOUT FOR ELLC2001R5

CPU PCB COMPONENT LAYOUT FOR ELLC2008R0

CPU PCB COMPONENT LAYOUT FOR EL20205R1

6.1. POWER SUPPLY SECTION (ELLC2004R4 /

Component Layout (EL20203R3)

POWER SUPPLY SCHEMATIC DIAGRAM

6.2. CONTROL LOGIC SECTION

SCHEMATIC – CONTROL LOGIC SECTION

6.3. MOTOR CONTROL AND MEMORY

MOTOR CONTROL AND MEMORY SCHEMATIC DIAGRAM

6.4. PHOTOMETRIC UNIT (ELLC2002R2 / ELLC2002R4)

Photometer Component Layout for ELLC2002R2

SCHEMATIC – PHOTOMETRIC UNIT (ELLC2002R2)

SCHEMATIC – PHOTOMETRIC UNIT (ELLC2002R4)

6.5. USB PCB ELLC2003R5 (Not used with Cortex)

USB PCB COMPONENT LAYOUT

USB PCB SCHEMATIC DIAGRAM

6.7. KEYPAD AND DISPLAY SECTION

8. TESTING AND PARAMETERS