ABBOTT
CELL-DYN 1800
Automated Hematology Analyzer
Service & Support Manual
ABBOTT CD1800 SM
Theory of Operation ... 4
System Overview... 4
Major Subsystem Descriptions... 6
Circuit Descriptions ... 15
Signal Processor Module (SPM)... 18
Cell Count Module (CCM) ... 21
Troubleshooting... 31
Troubleshooting Charts... 33
Raw Data Description... 40
CCM On-Board Diagnostic LEDs... 41
CPU Hardware/Software Configuration ... 44
Service Special Commands... 45
Sample Probe Description ... 49
CELL-DYN 1800 Error Messages... 60
Software Commands and Sequence ... 72
Engineering Drawings and Schematics ... 76
CELL-DYN 1800 PCB Reference ... 77
Removal & Replacement ... 96
Service Equipment Required... 96
Covers (CD18-A1) ... 97
Flow Panel (CD18-B1)... 105
Fluid Power Supply (CD18-C1)... 115
Syringe Assembly (CD18-E1)... 119
RR-E1.04 Sample Syringe Driver Assembly ... 125
RR-E1.06 Lyse Syringe Driver Assembly... 127
Electronics / Card Cage (CD18-F1) ... 129
RR-F1.01 PAM (Pre-Amplifier Module) ... 129
RR-F1.02 MPM (Motor Processor Module) Board ... 131
RR-F1.03 CDM (Cable Distribution Module) Board ... 133
RR-F1.04 Hard Disk Drive... 135
RR-F1.05 Floppy Disk Drive ... 138
RR-F1.06 Signal Processor Module (SPM)... 140
RR-F1.07 Cell Count Module (CCM) ... 142
RR-F1.08 Data Link Adapter (DLA) ... 143
RR-F1.09 Single Board Computer (SBC) ... 145
RR-F1.10 Card Cage Backplane PCB ... 147
LCD/Keyboard (CD18-G1)... 149
Power Supply (CD18-H1) ... 151
Verification Procedures ... 154
VP-01 Preparation for Alignment and Verification ... 154
VP-01 Preparation for Alignment and Verification... 154
Test Equipment and Supplies Required... 154
Order of Alignment/Verification... 156
VP-02 Decontamination ... 157
VP-03 Vacuum and Pressure Adjustments... 158
Regulator Alignment... 159
Pressure Adjustment (0.5 psi)... 160
Pressure Verification (High) ... 161
Vacuum Adjustment (8 inch) ... 161
VP-04 Metering System Timing Adjustments - RBC and WBC ... 162
Metering Timing Fault Report... 163
RBC Metering System Timing Adjustment ... 165
WBC Metering System Timing Adjustment ... 166
VP-05 CMOS Setup Verification/Adjustment... 167
VP-06 Card Cage Backplane Test Points ... 171
VP-07 Cable Distribution Module Test Points... 172
VP-08 Pre-Amplifier Module (PAM) Adjustment ... 173
VP-09 Signal Processor Module (SPM) Verification/Adjustment ... 176
RBC Gain ... 178
RER Adjustment ... 179
WBC Gain ... 182
PLT Gain ... 184
VP-10 Diluent and Sample Verification/Adjustment ... 187
Diluent Volume Verification ... 188
Sample Volume Verification ... 188
VP-11 Stepper Motor Power Test and Verification ... 189
VP-12 Sample Probe Alignment Check ... 190
VP-13 Serial Transmit to LIS Verification ... 191
VP-14 Hard Disk Drive Setup and Verification... 194
Theory of Operation
System Overview
The CELL-DYN 1800 Automated Hematology Analyzer is a complex system. Analyzer performance depends on several components that together make up the complete hematology system. The system is comprised of the following components and subsystems:
• Flow Panel System [3] • Fluid Power Supply [2] • Reagent Inlet Panel [6] • Syringe Drive Assemblies [7] • Electronics Card Cage [8] • LCD Display System [4]
• Touchpad (Membrane) Keyboard [5] • Power Supply Assembly [1]
The Flow Panel consists of tubing, solenoid valves, and other hardware components used for sample aspiration, dilution, measurement and waste removal.
Fluid Power Supply
The Fluid Power Supply contains the vacuum and pressure pumps, accumulators, waste bottles, and associated solenoids and hardware.
Reagent Inlet Panel
The Reagent Inlet Panel provides connections for incoming reagents and outgoing waste. The Lyse solenoid is also mounted on this panel.
Syringe Drive Assembies
The Syringe Drive Assemblies include the Sample Syringe for aspirating samples, the Diluent Syringe for supplying Diluent throughout the Flow Panel, and the Lyse Syringe for dispensing Lyse to the WBC transducer for the HGB measurement process.
Electronics Card Cage
The electronics card cage, with associated PCBs, provides command and control signals for the various electronic components of the instrument. This assembly contains the Backplane PCB, Cell Count Module, Signal Processor Module, Data Link Adaptor and Single Board Computer.
LCD Display Screen and Keyboard
The LCD Display Screen provides a visual data display and the keyboard provides data input by the operator.
The Power Supply Assembly provides an AC and DC voltage source to various components on the CELL-DYN 1800 System. The DC Regulator PCB provides power to the Backplane PCB for use with the digital circuitry on various PCBs. It also provides power to the Cable Distribution Module and fans.
The AC Regulator PCB provides power to the Backplane PCB (for use with the analog circuitry on various PCBs). It also provides power to the Pump Relay Module.
The +28VDC Switching Power Supply provides power for the stepper motors via the Motor Processor Module. It also provides power to initially energize solenoids.
Major Subsystem Descriptions
To aid in understanding the overall system, the electronic modules are divided into the following major functional subsystems:
• Data Interface and Control Subsystem • Measurement Subsystem
• Solenoid Motor and Pump Subsystem • Single Board Computer Subsystem
• AC and DC Power Distribution Subsystem
Data Interface and Control Subsystem
The purpose of this subsystem is to interface the user data, control data, measurement data, and system status data in the system. This data is connected via four independent data busses:
• DLA/CCM (Data Link Adapter/Cell Count Module)
• CCM/SPM (Cell Count Module/Sample Processor Module) • CCM/CDM (Cell Count Module/Cable Distribution Module) • CCM/MPM (Cell Count Module/Motor Processor Module)
See the figure below for a diagram showing the data connections. Data Interface and Control Block Diagram
When power to the instrument is turned ON, the system is operating software is loaded from the hard disk into RAM on the SBC (Single Board Computer). The SBC then uses various handshaking signals and data bytes to communicate with the CCM (Cell Count Module) via the DLA (Data Link Adapter).
The CCM functions as the master controller with all system functional commands residing in firmware (PROM). The CCM sends control data and receives status data from the CDM (Cable Distribution Module).
The CCM provides current control to the von Behrens RBC and WBC Transducers and the two metering PCBs and serves as the system's analog voltmeter for use in converting the HGB signal. Data is written and read via the CCM/CDM and
CCM/MPM data buses.
The CDM (Cable Distribution Module) acts as a controller for the solenoids and also interfaces data from various system sensors.
The MPM (Motor Processor Module) acts as a controller for all Stepper Motor Drive PCBs.
The measurement subsystem provides detection, amplification, and processing of the signals from the von Behrens RBC/PLT Transducer, von Behrens WBC Transducer, and HGB Flow Cell. RBC/PLT and WBC metering is also included in this subsystem.
See the figure below for a diagram of the measurement process. Measurement Block Diagram
The PAM (Pre-Amplifier Module) supplies constant current for the von Behrens RBC/PLT and WBC Transducers and HGB LED voltage.
The RBC/PLT and WBC cell pulses are input to the PAM where they are amplified and routed to the SPM (Signal Processor Module).
When the SPM receives signals from the RBC/PLT and WBC, the following occurs:
• The WBC signal is amplified (gain).
• The RBC signal is routed to the cell editing circuitry.
• Cell editing is performed on the RBC signal to eliminate invalid RBC pulses.
The SPM discriminates cell size by converting pulse height to a proportional digital value. The amplitude of each valid pulse is measured by a fast A/D converter then sent across the data bus to the CCM.
The A/D data for RBC, PLT, and WBC are individually divided by the CCM into 256 discrete size channels. The cell count in each channel is accumulated in discrete memory locations and is used to generate count data, percentage data, and histogram data for RBC, PLT, WBC, and other derived parameters.
Signals from the upper and lower detectors on the RBC/PLT and WBC metering PCBs are converted to TTL levels by comparators on the CDM. The signals are then routed to the CCM where they are used to control RBC/PLT and WBC sample timing.
The HGB analog signal from the HGB Flow Cell is captured by the PAM where it is amplified and routed to the CCM. The HGB signal is then measured and converted to a digital format by a voltmeter-A/D converter.
Solenoid, Motor Drive, and Pump Subsystem
Solenoid control commands reside in firmware on the CCM. These commands are sent to the CDM where they are multiplexed to the appropriate SDM (Solenoid Drive Module). The SDM then provides the current to open and close individual drive solenoids.
Stepper Motor commands are handled in much the same manner as described above. However, the final multiplexing of the Stepper Drive PCBs is controlled by the MPM.
There are two pressure pumps and one vacuum pump in the CELL-DYN 1800 System. These pumps are described as follows:
• A pressure pump provides air to bubble-mix samples in the Pre-Mixing Cup and the mixing chambers of the von Behrens RBC/PLT and WBC Transducers. A pressure regulator regulates the 0.5 psi in the pressure accumulator for this process.
• An unregulated pressure pump provides air to push waste from the waste bottles inside the instrument to the waste container attached to the instrument and to apply back pressure to clear the apertures in the von Behrens RBC/PLT and WBC Transducers.
• An 8" Hg vacuum accumulator, vacuum sensor, and vacuum pump supply a constant vacuum to the entire system to transport Diluent, Detergent, and Lyse throughout the flow system and to maintain a constant vacuum to the
RBC/PLT and WBC metering tubes. A vacuum regulator maintains a constant vacuum source to both metering tubes.
See Solenoid, Motor Drive and Pump Block Diagram for a diagram of the solenoid and motor drive connections. Solenoid, Motor Drive and Pump Block Diagram
The Single Board Computer subsystem consists of the following components: • Single Board Computer PCB
• Data Link Adapter
• Input/Output Ports (serial/parallel) • Keyboards (PC and membrane) • LCD Display Screen
• Disk Drives (hard and floppy)
The figure below illustrates the major components of the User Interface Computer. User Interface Computer
SBC (Single Board Computer) PCB
The Single Board Computer (SBC) PCB is a complete Celeron 850 Megahertz PC computer system with 128 Megabytes of RAM that is self-contained on one board. It utilizes a PC compatible BIOS with DOS capability that directly interfaces with the LCD Display Screen, Hard Disk Drive, Floppy Disk Drive, PS/2 Keyboard, one (1) Parallel Port and two (2) Serial Ports. It connects directly into the Backplane PCB along with the Data Link Adapter (DLA) and utilizes the ISA bus and Backplane PCB to communicate with one another.
The DLA PCB connects directly into the Backplane PCB. It provides a program-controlled data channel from the SBC to the CCM. The DLA performs the following three functions:
• Receives measurement and analyzer status data from the CCM • Transfers commands from the SBC to the CCM
• Sends control data from the UIC to the CCM.
Serial I/O Ports
The CELL-DYN 1800 contains two (2) Serial I/O Ports for transferring data to other computer systems:
COM1 RS-232 Data Output COM2 Spare
Parallel I/O Port
The CELL-DYN 1800 contains one parallel I/O port for transferring data to a printer.
PC/2 Keyboard
The external 101 key PC keyboard is used to enter alphanumeric data, such as demographic information, into the instrument.
Touch Pad (Membrane) Keyboard
The touch pad (membrane) keyboard is located below the LCD Display Screen. The keyboard includes a row of eight (8) unmarked rectangular-shaped keys corresponding to labels displayed at the bottom of the screen. These keys activate the indicated function or display the indicated submenu.
LCD Display Screen (Color)
The LCD Display Screen has the following characteristics: • Size: 8.5 x 6.4 inches (10.4 inches measured diagonally) • Number of colors: 16
• Pixels: 640 width x 480 height (or 800 x 600)
• Backlight on/off control (software controlled screen saver)
An LCD Adapter, connected directly on the SBC PCB, drives the LCD Display Screen. The adapter supports SVGA 640 x 480 and 800 x 600 graphics modes.
Hard Disk Drive
Floppy Disk Drive
The 1.44MB 3.5" floppy disk drive is used for program installation and provides the QC (Quality Control) data upload/download capability.
Printer
The User Interface Software supports Epson ESC-P or PCL-3 languages. The printer has its own buffer and is capable of printing on 8.5" x 11" (letter size) or A4 paper size. The printer supports alphanumeric and graphics reports from stored data and screen displays.
Speaker
The PC speaker or buzzer is controlled by software and is mounted on the SBC PCB. AC and DC Power Distribution Subsystem
The Power Supply Assembly is comprised of three components: AC Regulator PCB, DC Regulator PCB and +28VDC Switching Power Supply. These components are mounted together as an assembly and are located at the right/rear side of the instrument.
When the system is turned on, the AC line is routed into the AC Regulator PCB and +28VDC Switching Power Supply. The AC Regulator PCB automatically accommodates line voltages of 90 - 130VAC and 200 - 260VAC by sensing the input voltage and utilizing an internal comparator bank and power transformer to produce the 120VAC necessary for the
subsystem's function. The Power Supply Assembly then provides an AC and DC voltage source to various components on the CELL-DYN 1800 System.
+28VDC Switching Power Supply
The +28VDC Switching Power Supply provides the voltage source to the DC Regulator PCB, which the board then uses to produce other voltages. The power supply cooling fan is thermistor controlled, which means that when the internal
temperature rises above 70°C, the fan operates at full speed. The fan is then turned off at 50°C and kept off until the temperature rises above 70°C.
AC Regulator PCB
The AC Regulator PCB provides the 120VAC used by the Pump Relay Module (PRM) for vacuum and pressure pump operation.
The ±12VDC (analog) is provided to the Backplane PCB, which is used by the Cell Count Module (CCM) and Signal Processor Module (SPM). The ±12VDC is also provided to the Cable Distribution Module (CDM), Motor Processor Module (MPM) and Pre-Amplifier Module (PAM) (for its circuitry).
The +100VDC is provided to the PAM for use in its constant current circuitry. In between the AC Regulator PCB and the PAM is the Pre Amp Filter that is used to filter out noise.
DC Regulator PCB
The DC Regulator PCB provides +5VDC, ±12VDC (digital), +14VDC and +28VDC. The +5VDC is provided to the Backplane PCB, which is used by the SPM, CCM, Data Link Adapter (DLA) and Single Board Computer (SBC). This voltage is also used by the CDM, MPM, Hard and Floppy Disk Drives.
The ±12VDC (digital) is provided to the Backplane PCB for use on the CPU fan. The Hard and Floppy Disk Drives receive +12VDC for their operation.
The +14VDC is provided through the CDM to the Solenoid Driver Modules (SDM) and is used to hold the solenoids closed or open for normally closed solenoids.
The +28VDC is provided to the MPM for operating stepper motors and through the CDM to the SDMs to initially close solenoids or open for normally closed solenoids. This voltage is also used for the system's internal cooling fans. The cooling fans are thermistor controlled, which means that when the ambient temperature inside the instrument drops below 25°C, the fans operate at half speed. Once the temperature rises above 25°C, the speed is increased linearly until it reaches 35°C, when the fans operate at full speed.
The DC Regulator PCB also provides +5VDC and +14VDC to the AC Regulator PCB.
Circuit Descriptions
• Pre-Amplifier Module (PAM) • Signal Processor Module (SPM) • Cell Count Module (CCM) • Cable Distribution Module (CDM) • Solenoid Driver Module (SDM) • Motor Processor Module (MPM)
• Stepper Drive Printed Circuit Board (SDP) • Pressure/Vacuum Regulator Module (PVRM) • Power Supply Assembly
• Pump Relay Module (PRM) • Single Board Computer (SBC) • Data Link Adapter (DLA)
Pre-amplifier Module (PAM) Note
Refer to PAM PCB Diagram. PAM PCB Diagram
The PAM performs the following functions:
• Provides constant current control to the von Behrens RBC/PLT and WBC Transducers. • Amplifies the initial RBC/PLT, WBC and HGB signals.
The constant current bias (+100VDC) is switched by U6, then routed to Q2 and Q3, which supplies constant current to the von Behrens RBC/PLT transducers. The RBC/PLT current is adjusted with R72. Once received, the RBC/PLT signals are initially amplified by U7, then routed to U5, where they are re-inverted and further amplified. The combined RBC/PLT signal is then routed to the SPM PCB.
Transistors Q4, Q5 and associated circuitry provide constant current for the von Behrens WBC Transducer. The WBC current is adjusted via R66. Once received, the WBC signal is initially amplified by U12, then routed to U11 where it is re-inverted and further amplified. The WBC signal is then routed to the SPM PCB.
The output of the HGB Flow Cell is amplified by U1 and U2 prior to being routed to the SPM PCB. The HGB self test and gain voltages are adjusted with R14 and R4 respectively.
Signal Processor Module (SPM)
Note
Refer to SPM Architecture. SPM Architecture
EPLD (SPM)
The EPLD is an enhanced programmable logic device. The SPM EPLD is used to control data acquisition.
There are three state machines that run in the EPLD. One each is used for controlling data acquisition elements such as Multiplexers and Peak/Hold Amplifiers. The inputs to the EPLD state machines are the outputs of the various Threshold and Slope Detectors as well as Bubble and Area Comparators.
There is a data transfer state machine which controls data flow to the CCM.
Signal Processing
There are two signals from the RBC and WBC transducers that are processed through two basic data acquisition circuits. The Platelet signal is derived from the RBC signal. There are three gain adjustments associated with each of these signals. In addition to the three gain adjustments there is a integration adjustment for detecting pulses that are too long.
WBC Signal
• The WBC signal is received through a differential amplifier to reduce noise. There is a gain adjustment after the differential amplifier but before the Test Signal injection point.
• The WBC signal is then "Baseline Restored" to remove DC components and Baseline fluctuations due to varying duty cycle of the blood cells.
• A threshold detector signals to the EPLD the presence of valid pulses.
• Simultaneously the Bubble detector signals if the pulse is determined to be a bubble. The bubbles are much larger than pulses from blood cells. The EPLD discards the information from the pulse if it is determined to be a bubble. • The data from the pulse is processed on the falling edge of the Threshold Detector unless the Slope Detector senses
another rising edge before the falling edge of the Threshold Detector. The data is processed immediately if there is another rising edge before the falling edge of the Threshold Detector.
• The WBC Held Peak is converted and sent to the CCM on a 15µS cycle. Average pulses from the impedance transducers are 35µS.
RBC and PLT Signals
There are two modes for RBC/PLT data acquisition: • RBC MCV
• RBC Count/PLT
RBC MCV
RBC MCV is for RBC MCV data only. In this mode, an integrator is enabled to determine if the cell is moving through the middle of the aperture. If the cell is not moving through the center of the aperture, the data is falsely high and the pulse is abnormally long. The integrated signal is compared to a proportion of its height. If the pulse is too long for its height, it is discarded.
RBC Count/PLT
RBC Count mode is for count information. During this run, Platelets are counted simultaneous with RBCs and no integration is used. The Platelet signal is derived from the RBC signal by an adjustable gain.
• The RBC signal is received through a differential amplifier to reduce noise. There is a gain adjustment after the differential amplifier but before the Test Signal injection point.
• The RBC signal is then "Baseline Restored" to remove DC components and Baseline fluctuations due to varying duty cycle of the blood cells. At this point an additional gain stage is added to create the Platelet signal.
• A threshold detector(s) signals to the EPLD the presence of valid pulses. The Platelet Threshold Detector is used if in RBC Count mode.
• If in Count mode, the Platelet Lower and Upper Threshold detectors are used. If the Upper Threshold Detector is triggered, the pulse is a RBC and the RBC pulse is accumulated into the RBC Count histogram. If only the Lower Detector is triggered, the PLT pulse is accumulated into the PLT histogram.
• The data from the pulse is processed on the falling edge of the Threshold Detector unless the Slope Detector(s) senses another rising edge before the falling edge of the Threshold Detector. If this occurs, the data is processed immediately.
• The RBC Held Peak or the PLT Held Peak is converted and sent to the CCM on a 15µs cycle.
Cell Count Module (CCM)
Note
Refer to PAM PCB Diagram. CCM Architecture
System Clock and Microprocessor Description
The CCM uses a 16 MHz crystal as a time base. The fundamental cycle time for the MC68HC11KW1 processor is 4 MHz. The processor has many built in functions such as:
• 16 bit address bus • 8 bit data bus
• Small amounts of Internal RAM and Internal EEPROM (analyzer serial number) • Internal Timers (system timer)
• Internal UART (debug port)
EPLD (CCM)
The EPLD is an enhanced programmable logic device and is used for address decode and histogram building functions. Its program is used in coordination with the processor software.
LEDs Note
Refer to CCM On-Board Diagnostic LEDs.
Scratch Pad RAM
This RAM is used for general purpose programming.
Histogram Memory
This RAM is used for histogram building.
Histogram Building (cell counting)
The following sequence is executed to build histograms: 1. Histogram Memory is cleared.
2.
Counting is enabled.This disconnects Histogram Memory from the processor buss. 3. Wait for an End of Conversion (EOC) signal from SPM. 4. At the EOC, data is read from the SPM ADC
5. The data then becomes the address for the histogram memory.
6.
The data from the histogram memory is read.This data is the count information for the respective pulse height. 7. The count is incremented and stored back into histogram memory.
8.
Counting is disabled. And the histogram can be read by the processor.HGB Measurement
A 12 bit ADC with an input multiplexer is used to measure the HGB signal from the PAM. This data is read by the processor. Along with the HGB measurement, various DC voltages are read by the 12 bit ADC as a diagnostic.
CDM Port
The CDM port is connected directly to microprocessor ports E, G and K.
SBC Port
The SBC port is connected directly to microprocessor ports J and part of port A.
Cable Distribution Module Note
Refer to Solenoid, Motor Drive and Pump Block Diagram. Solenoid, Motor Drive and Pump Block Diagram
• Status Sensor Interface
• Control of Solenoid Driver Module • Pump Relay Module interface and control • Start Board (Touch Plate) Interface
The CDM communicates with the CCM via the CCM/CDM data bus at J2. Analog outputs of the Metering Modules are converted to TTL levels by comparators (U12) and placed directly on the CCM/CDM data bus. Signals from the Pump Relay board, Probe Position Switches, and Start Board (Touch Plate) are interfaced by Data Drivers (U5, U10).
Data is interfaced to the Solenoid Driver Modules via J32. This data is then multiplexed by One-of-Eight Decoders (U1, U2) via J3, J4, J6, J7, and J9.
Vacuum and pressure control data is latched by U14 and routed to the Pump Relay Module via J11. Pump status signals (Vac On, Pres On) are converted to TTL levels by U3 and placed on the data bus by U5.
LED drive signals are routed to the Start Board (Touch Plate) via J17. The start signal enters at J17 and is placed on the data bus by U5.
Solenoid Driver Module (SDM) Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
The purpose of the SDM is to provide drive current to the solenoids. Each SDM has eight Darlington drivers (Q1-Q8) which are individually controlled by data bits (D0-D7) and data latch (U3).
There are two power modes available for each solenoid - activate (+28V) and hold (+14V). This is controlled by the Hi CLK signal in conjunction with data bits (D0-D7) and the current control latch (U1).
Motor Processor Module (MPM) Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
The MPM controls drive data to the Stepper Drive printed circuit boards and also provides self-test capability for motor winding current. The MPM is comprised of the following major circuits:
• Microprocessor
• Program Control EPROM
• I/O Peripheral Interface Adapter (PIA) • Direct Memory Access (DMA) Control • Motor Phase Latches
• Motor Current Latches • Motor Winding Self Test
The operating program for the microprocessor is stored in Program Control EPROM (U3).
Data communications between the CCM and MPM are controlled by I/O PIA (U6) and serial data is interfaced via ACIA (U2) and Data Bus Connector (J1).
Phase data, motor direction, and step rate are stored in RAM (U7). This data is sent to the Motor Phase Latches under control of the DMA Control circuitry, which consists of U11, U12, U15, U16, U18, U21 and associated circuitry. The data is strobed into the appropriate Motor Phase Latch by ALG0 through ALG2.
The Motor Phase Latches U23, U26, and U29 provide phase data to the Stepper Drive printed circuit boards. Each is an 8-Bit Addressable Latch which can control up to four Stepper Drive printed circuit boards and subsequently four Stepper Motors. Four levels of motor current for each motor is controlled by the Motor Current Latches (U22, U25, and U28). Each latch can control up to four stepper drive printed circuit boards. Data is strobed into the appropriate latch by WR0 through WR2. The Feedback- and Feedback+ inputs at J3 through J14 are connected, via resistors on the Stepper Drive printed circuit board, to the stepper motor windings. This allows the circuitry consisting of U30, U31, and U32 to monitor the winding current during an internal self-test. These values can be read by the CCM to isolate a defective Stepper Drive or Stepper Motor.
Stepper Drive Printed Circuit Board Note
Refer to MPM section, blocks 20, 23, and 24 of Solenoid, Motor Drive and Pump Block Diagram.
The Stepper Drive printed circuit board consists of two PBL 3717 motor drive chips. Each chip drives a winding of the Stepper Motor. Bits I0 and I1 are used to control four motor current levels:
• P0 - High Current • P1 - Medium Current • P2 - Low Current • P3 - Current Off
Bits PH0 and PH1 control motor phase and, therefore, direction and step-rate (velocity). Feedback+ and Feedback- are used to generate a motor self-test.
Pressure/Vacuum Regulator Module Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
Pressure (or vacuum) is sensed by a transducer that is internally configured as a Wheatstone Bridge. Transistor Q1and resistors R4 and R5 are used to generate a stable reference voltage for the Wheatstone Bridge. The output of the Wheatstone Bridge is partially amplified (U1-7), stabilized against long term drift (voltage follower U1-1) and made offset-adjustable by R18 and associated resistors.
Maximum transducer sensitivity can only be achieved when the output is zero volts at TP-1 and when there is no pressure differential across the transducer. To accomplish this, R18 is adjusted for zero volts when both transducer inlet ports (P1 and P2) are open to atmospheric pressure.
In order to maintain the operating point of comparator U2-14 at the fixed 2-volt trip level, it is necessary to maintain the output of U2-8 within a relatively narrow range. This is accomplished by making the differential amplifier (whose inputs are U1-10 and U2-10) adjustable by selecting 1 of 4 possible jumper positions. A stable reference point for the DC operating level of U1-8 and U2-8 is established by U1-14 in conjunction with R6 and resistor network RP1.
Measurement of pressure in the range of approximately 0.5 lbs/sq. inch is accomplished by using transducer inlet port P1 in conjunction with jumper setting A/B.
Vacuum pressure in the range of 8 inch Hg is accomplished by using inlet port P2 in conjunction with jumper setting C/D. The regulation point for either vacuum or pressure is established by the setting of potentiometer R16.
When the output of comparator U2-14 goes positive, the collector of Darlington transistor Q2 is pulled to ground, thereby turning on either the pressure or vacuum pump. When the pumps are running, LED DS1 is lit and stays lit until either the pressure or vacuum increases past the hysteresis point established by R8 of U2-14.
The output of the pressure/vacuum regulator can be inhibited by a logic low at J1-1. This completes the circuit description.
Power Supply Assembly Note
Refer to major subsystem descriptions of AC and DC Power Distribution Subsystem.
Pump Relay Module (PRM)
Refer to Solenoid, Motor Drive and Pump Block Diagram.
The PRM provides drive to the vacuum and pressure pumps, via three Solid State Relays: K1, K2, and K3.
Single Board Computer (SBC)
The Single Board Computer (SBC) is designed around a Celeron 850MHz microprocessor and connects directly into the Backplane PCB. The SBC receives power from the Power Supply Assembly via the Backplane PCB and receives status and measurement data from the CCM through the DLA. The board contains EPROM, CMOS, RAM, input/output circuitry for the interface ports, disk drives (hard and floppy) circuitry, LCD Display Screen Interface, and PS/2 Keyboard connectivity.
Data Link Adapter (DLA)
The Data Link Adapter provides interfaces from the SBC to both the CCM (Cell Count Module) and the Touch Pad
(membrane) keyboard. These two interfaces function independently under user interface software control. However, some of the circuits on the DLA board are shared. The DLA uses an 82C55 PPI (Parallel Peripheral Interface) IC. Refer to the figure below for an illustration of the DLA board.
DLA (Data Link Adapter) Block Diagram
Interface to CCM
A 20-pin ribbon cable connects the DLA to the CCM. This interface is a bi-directional, parallel interface that is
software-controlled at both ends. Data is transferred in 8-bit bytes on 8 data lines (D0 - D7) in one direction at a time. The SBC (Single Board Computer) initiates an inquiry message handshake on a periodic basis or when it has a command to send. The CCM responds by sending data or replying to the command sent.
The interface is controlled cooperatively by the UIC and CCM according to the state of the handshake signals. Refer to Cell Count Module (CCM). The UIC always sends data first. The CCM responds by sending data back (if any is available). Thus, the 82C55 switches its A-port from input to output and back to input during every message transaction.
The key handshake signals are REQ1 and REQ2. REQ2 going low initiates the communication protocol. The CCM responds by bringing REQ1 low. After the DLA has sent its data, it brings REQ2 high. Then the CCM sends its data.
Each byte received by the DLA generates an IRQ. The application software responds to the IRQ by putting the byte into a buffer. When the CCM brings REQ1 high, the communication is complete; the DLA returns to an idle state, and port A is set to input. Both REQ1 and REQ2 remains high until the next message/data transfer.
The two LEDs on the printed circuit board, DS1 and DS2, indicate the active state of REQ2 and REQ1, respectively. They should always be flickering when the application software is running because the User Interface Software program is
constantly polling the CCM to check its state. (There are some exceptions to this during power up and certain diagnostics/test modes.)
The I-O address of the DLA board is assigned by four jumpers. The default I-O address (pins 3 - 6 on S1 hard-wired) is: [off
off on off], 340 hexadecimal. The DLA interrupt level is assigned by a jumper.
Jumpers W1 - W6 assign the DLA interrupt to one of the following:
W # IRQ # W1 IRQ 5 * W2 IRQ 10 W3 IRQ 10 W4 IRQ 11 W5 IRQ 12 W6 IRQ 15
* Since IRQ 5 is used by the DLA, W1 is hard-wired (this is the default).
Interface to Touch Pad (membrane) Keyboard
A 14-pin ribbon cable connects the DLA to the key panel. The key panel is also polled by the User Interface Software program. This interface is not interrupt-controlled.
The keyboard is interfaced as a parallel switch matrix circuit with 4 lines out and 8 lines in. Four scan rows are driven active one at a time via an LS175 latch. Then the columns of the key panel matrix are read from port B of the 82C55. The software interprets a low active signal as a key is pressed.
Troubleshooting
Diagnostics Menu Usage
Utilization of the DIAGNOSTICS Menu enables the operator and/or service representative to identify and correct both operator-correctable and service-correctable faults. When the computer senses a fault, the message <NOT READY: SEE
DIAGNOSTICS> displays in the System Status Box. The following keys are available in the DIAGNOSTICS Menu.
Level One
• INITIALIZATION: Used to perform an Initialization cycle: returns movable components to home position and performs internal self-tests.
• RAW DATA: Used to display raw measurement data for the last specimen.
• COUNT TEST: Used to run specimens without returning to RUN Menu and display Raw Data. • MORE: Used to display additional functions (levels).
• PRINTER OUTPUT: Used to toggle printer output ON and OFF.
• HELP/ERROR: Used to display help information regarding the diagnostics menu screens. The fault log can also be accessed through this key function.
• MAIN: Used to return to Main Menu.
Level Two
• WBC HISTOGRAM: Used to display WBC count and histogram data accumulated in each of 256 size channels. • RBC HISTOGRAM: Used to display RBC histogram data accumulated in each of 256 size channels.
• PLT HISTOGRAM: Used to display PLT count and histogram data accumulated in each of 256 size channels. • SMOOTHING ON/OFF: Used to toggle histogram display status. With Smoothing Off, only raw counts are displayed.
With Smoothing On, channels are numbered, data is normalized and the number of the peak channel displays.
Smoothing On/Off (example) gives an example of Smoothing On/Off. • MORE: See Level One description.
• PRINTER OUTPUT: See Level One description. • HELP/ERROR: See Level One description. • MAIN: Used to return to Main Menu.
Level Three
• PROBE HOME: Moves Sample Probe up and above RBC Cup. Displays probe assembly sensor status. • PROBE UP: Moves Sample Probe up. Displays probe assembly sensor status.
• MORE: See Level One description.
• PRINTER OUTPUT: See Level One description. • HELP/ERROR: See Level One description. • MAIN: Used to return to Main Menu.
• SYSTEM STATUS: Used to display all pending alarms.
• FAULT REPORT: Used to display all pending faults or warnings.
• SERVICE HEX CODES: Hex system codes. Not used for operator or service troubleshooting.
• SERVICE DEC CODE: Used to initiate individual actions in the CELL-DYN 1800 hardware and software. • MORE: See Level One description.
• PRINTER OUTPUT: See Level One description. • HELP/ERROR: See Level One description. • MAIN: Used to return to Main Menu.
Smoothing On/Off (example)
Fault Report Description
A detailed list of all faults generated by the CELL-DYN 1800 System software and hardware is contained in CELL-DYN 1800 Error Messages. The fault classifications reported in the Fault Report primarily contains data pertaining to the last CCM fault.
If a fault occurs, pressing the [HELP/ERROR] key immediately displays the [FAULT LOG] in the DIAGNOSTICS Menu. This log may contain up to 16 faults, with the most current fault at the top of the list. An alternative procedure is to go to the MAIN
MENU and press [DIAGNOSTICS]. In this case, the [FAULT REPORT], not the Fault Log, is immediately displayed.
The Fault Log can be viewed from any of the menus, except SETUP. To view the Fault Log, enter the desired menu, followed by [HELP/ERROR] and [FAULT LOG]. The system displays up to 16 past faults. From the MAIN MENU, press
[DIAGNOSTICS] followed by [MORE] three (3) times and [FAULT REPORT] to display the FAULT REPORT screen. A
display of <NO FAULTS OR WARNINGS PENDING> indicates that all faults have been cleared.
CELL-DYN 1800 Troubleshooting Guide
A list of symptoms, probable causes, and corrective actions for the most common problems encountered on the CELL-DYN 1800 System is given in the Troubleshooting Chart. The probable causes and corrective actions for each symptom are arranged in descending order from most likely to least likely. When troubleshooting a problem, start with the most likely cause first.
If possible, thoroughly verify that a component is defective before replacement. Some problems can be verified visually, but other problems may require a measurement tool such as a DVM (Digital Volt Meter).
When troubleshooting DATA PROBLEMS, only the measured parameters RBC, PLT, WBC, HGB, and MCV should be used for reference. Using the calculated parameters can become confusing when trying to isolate a problem.
When troubleshooting CLOG AND FLOW ERROR PROBLEMS, refer to VP-04 Metering System Timing Adjustments - RBC and WBC for the MIN and MAX specifications for the RBC and WBC Upper (T1) and Lower (T2) times.
Troubleshooting Charts
Nonfunctional Instrument Problems
Symptom Probable Cause Corrective Action
Power Cord Check Power Cord No Functions. No Fans
Power Source Check Power Source
No 5VDC Check that 5VDC LED on Card Cage Backplane is On
Note
If off replace Power Supply Assembly. Defective CCM Replace CCM
No Functions. Fans Run
Defective SBC Replace SBC
Symptom Probable Cause Corrective Action
Loose Connection Check all LCD Display Screen Connections Flash BIOS or
CMOS settings reset to Default
Connect a computer monitor to the top of the SBC PCB. Power ON instrument and open CMOS setup screen. Check that Advanced Chipset Setup is configured correctly. Refer to VP-05 CMOS Setup Verification/Adjustment.
Defective Backlight Interconnect PCB
Replace Backlight Interconnect PCB
Defective LCD Interconnect PCB Replace LCD Interconnect PCB LCD Display Screen Blank/Solenoids OK Note
Do not measure voltage on backlight inverter PCB. Measuring voltage can damage PCB.
Defective LCD Display Screen
Replace LCD Display Screen
Characters Out Of Focus Defective LCD Display Screen
Replace LCD Display Screen
Defective SBC PCB
Replace SBC PCB Characters OK But Garbled
Defective LCD Display Screen
Replace LCD Display Screen
Defective SBC PCB Replace SBC PCB Missing Characters Defective LCD Display Screen
Replace LCD Display Screen
Displayed Error and Fault Problems
Symptom Probable Cause Corrective Action
Restriction Check Lines
Check In-Line Sensor Defective In-Line Sensor
Replace Sensor PCB Detergent Empty
Defective CDM Replace CDM
Restriction Check Lines
Check In-Line Sensor Defective In-Line Sensor
Replace Sensor PCB Diluent Empty Defective CDM Replace CDM Check Solenoid 3-3 Solenoid 3-3 Replace Solenoid 3-3 Check Solenoid 3-4 Solenoid 3-4 Replace Solenoid 3-4 Check Solenoid 3-1 Solenoid 3-1 Replace Solenoid 3-1 Check Pressure Switch Defective Pressure Switch
Replace Switch Pressure Overlimit
Defective CDM Replace CDM
Leak 8" Hg Check for air leaks in Fluid Power Supply and Flow Panel
Defective Pump Replace Pump Vacuum Low Error
Defective Vac Regulator Replace Vacuum Regulator
Leak 0.5 Psi Check for air leaks in Fluid Power Supply and Flow Panel
Defective Pump Replace Pump Pressure Low Error
Defective Pres Reg Replace Pressure Regulator Check Unreg Pressure Replace Unreg Pump No Air Pressure Replace CDM Check Solenoid 5-3 Solenoid 5-3 Replace Solenoid 5-3 Check Solenoid 5-7 Solenoid 5-7 Replace Solenoid 5-7 Check Solenoid 1-6 Waste Overflow Into
Accumulators
Solenoid 1-6
Check Accumulator Sensor Connections Flush Accumulator with DI Water
Accumulator Sensor Falsely Detecting Liquid
Replace CDM
Check Internal Waste Sensor Connections Defective Internal Waste Sensor
Replace Sensor Check Unreg Pressure Unreg Air Pressure Low
Replace Pump
Restriction Check tubing at Fluid Power Supply, Waste Bottles, A and B
Waste Empty Timeout
Defective CDM Replace CDM
DLA/CCM Cable connection Check DLA/CCM Cable connection Defective DLA/CCM Cable Replace DLA/CCM Cable
Defective CCM Board Replace CCM Board Defective DLA Board Replace DLA Board CCM/DLA Communication Error
Defective SBC PCB Replace SBC PCB
Power Source Check 5VDC and +12VDC (Digital) at Card Cage Backplane PCB
Check CMOS Setup Defective SBC PCB
Replace SBC PCB Disk Errors (Hard Disk or Floppy
Drives)
Defective Disk Drive (Hard Disk or Floppy Drives)
Replace Disk Drive
Defective Switch Replace Switch and Perform Alignment
Defective CDM Replace CDM
Run Motor Power test Defective Stepper Drive Printed
Circuit Board Replace Chopper Drive PCB
Exercise Probe (Diagnostic Menu, Probe Home) Defective Sample Probe Assembly
Replace Sample Probe Assembly Run Motor Power Test
Position Faults
Defective Motor
Data Problems
Symptom Probable Cause Corrective Action
Check ±12VDC (Analog) LEDs on Card Cage Backplane PCB
Replace Power Supply Module All Results Are "0" No ±12VDC (Analog)
Replace CCM
Check that PAM 100VDC LED is On No 100VDC
Replace Power Supply Assembly Defective SPM Replace SPM
HGB OK All Others "0"
Defective PAM Replace PAM Reference lower than
sample reading
Check for bubbles in Detergent line and Solenoid 2-6
No sample aspiration Check associated tubing, solenoids and sample syringe Perform VP-08 Pre-Amplifier Module (PAM) Adjustment
Defective PAM
Replace PAM Defective CCM Replace CCM HGB "0" all others OK
Defective HGB Flow Cell Replace HGB Flow Cell
Check 0.5 psi (Bubble Mix) pressure Check associated tubing and hardware 0.5 psi (Bubble Mix)
pressure
Perform Pressure Adjustment (0.5 psi)
Inadequate Probe Cleaning Check associated wash block tubing and hardware Perform Sample Volume Verification
Imprecise Sample Aspiration
Check associated sample aspiration tubing and hardware Imprecise Diluent Dispense Perform Diluent Volume Verification
Imprecision on all Parameters
Carryover Check for correct draining of Pre Mix Cup Defective SPM Replace SPM
Imprecision on all Parameters,
HGB OK Defective PAM Replace PAM
Check 0.5 psi (Bubble Mix) Pressure Check associated tubing and hardware Incorrect 0.5 psi (Bubble
Mix) Pressure
Perform Pressure Adjustment (0.5 psi)
Defective SPM Replace SPM Imprecision on RBC and PLT,
WBC/HGB OK
Carryover Check for correct draining of RBC/PLT Transducer Dirty WBC Transducer Clean WBC Transducer
Check 0.5 psi (Bubble Mix) Pressure Check associated tubing and hardware Incorrect 0.5 psi (Bubble
Mix) Pressure
Perform Pressure Adjustment (0.5 psi)
Defective SPM Replace SPM Imprecision on WBC/HGB,
RBC and PLT OK
Carryover Check for correct draining of WBC Transducer Dirty Flow Cell Clean Flow Cell
Check reference reading (Diagnostics Menu, Raw Data) Reference reading out of
specification
Perform HGB Ref Adjustment on PAM VP-08 Pre-Amplifier Module (PAM) Adjustment
Defective Flow Cell Replace Flow Cell Imprecision on HGB, Others OK
Solenoid operation Check Solenoid 3-6, 2-6 and 2-7
Dirty Aperture. Clean RBC/PLT Transducer and Aperture Plate RBC RER Perform VP-09 Signal Processor Module (SPM)
Verification/Adjustment
Imprecision on MCV
Defective SPM Replace SPM
Dirty Transducer Clean WBC Transducer and Aperture Plate Replace Lyse Syringe
Incorrect Lyse Volume
Replace Lyse Syringe Drive Assembly
WBC Gain Perform VP-09 Signal Processor Module (SPM) Verification/Adjustment Replace SPM WBC "R" Codes, Reagents OK Defective PCBs Replace CCM Check power
Check overhead lighting High Electrical Backgrounds Environmental
Install filter (line conditioner) Isolate line (dedicated line)
Check grounding cable on Front Cover Replace grounding cable
Poor instrument cover grounding
Check EMI Shielding on Card Cage Backplane PCB Check correct routing of WBC and RBC/PLT Transducer cables to PAM
Defective PAM
Replace PAM
Check Power Supply Module "Noisy" Power Supply
Module Replace Power Supply Module
Check Connections on Pre-Amplifier Filter PCB Defective Pre-Amplifier Filter
PCB Replace Pre-Amplifier Filter PCB Defective Transducer(s) Replace Transducer(s)
Clog and Flow Error Problems
Symptom Probable Cause Corrective Action
Perform VP-03 Vacuum and Pressure Adjustments
Incorrect vacuum
Check Solenoid 1-4 and 1-5 (closed during metering) Diluent and Detergent lines
reversed
Check Reagent lines "CLOG" both sides constant
Metering Tube position Top of Metering Tube (tapered edge) should be visible on top of upper DET sensor
Check Vent Tubing "CLOG" T1 = Max T2 = 0, No Vent Restriction
Check Vent Solenoid 3-6, 2-1 and 1-3 Dirty Transducer Clean Transducer and Aperture Plate
Check plumbing
Check Count Solenoid 1-2 and 4-3 "CLOG" T1 = Max T2 = 0, No
Meniscus
Restriction
Check for bubbles on right side of Transducers Dirty Transducer Clean Transducer and Aperture Plate
Check associated tubing Restriction
Check Vent Solenoid 3-6
Perform VP-03 Vacuum and Pressure Adjustments
"CLOG" T1 = Max T2 = 0, Slow Meniscus
Incorrect Vacuum
Check Solenoid 1-4 and 1-5 (closed during metering) Defective Upper Detector Replace Metering Printed Circuit Board
"CLOG" T1 = Max Meniscus
speed OK Defective CDM Replace CDM
Defective Lower Detector Replace Metering Printed Circuit Board "CLOG" T1 =OK T2 = Max
Meniscus speed OK Defective CDM Replace CDM
Defective Upper Detector Replace Metering Printed Circuit Board "FLOW ERR" T1 = Min T2 = Max
Defective CDM Replace CDM
Defective Lower Detector Replace Metering Printed Circuit Board "FLOW ERR" T1 = OK T2 = Min
Defective CDM Replace CDM
Miscellaneous Problems
Symptom Probable Cause Corrective Action
Defective SPM Replace SPM Garbled Histograms
Defective CCM Replace CCM
Raw Data Description
From the MAIN MENU, press [DIAGNOSTICS] followed by [RAW DATA]. The [RAW DATA] key displays raw data obtained from the last count cycle.
When a single count is done, all data is contained in the first column. When a PLT recount occurs, data from the first cycle displays in column #2 and data from the recount displays in column #1.
• RBC, WBC and PLT counts are RAW, uncorrected total counts. • HGB Error is not used.
• HGB Reference is the output of the A/D Converter when reading reference (2000 = 5 volts). • HGB Sample is the output of the A/D Converter when reading sample (2000 = 5 volts). • WBC and RBC Up Times are the upper times in milliseconds for the last sample. • WBC and RBC Count Times are the times in milliseconds for the last sample. • Flow Error is coded Clog or Flow Error data.
• RBC RER is RBC Cell Editing percentage.
• WBC and RBC Upper max and Upper min are the maximum and minimum Upper Times, respectively.
• WBC and RBC Avg. Time are the averages of the previous count times. The WBC and RBC Avg. time is reset when the [Clear Orifice] key is pressed.
• WBC and RBC Time-Outs are the floating Upper Clog Alarm Limits calculated by the "Running Average Program".
Note
An example of a raw data report displays in Raw Data (example).
Raw Data (example)
CCM On-Board Diagnostic LEDs
The seven LEDs on the CELL-DYN 1800 CCM can reveal much about the fundamental CCM and overall machine state. In general, the LEDs indicate whether the CCM is in a normal functioning mode or in a fault state, and in either case, help to characterize the CCM state. Also, LED2 gives some information about the state of the SBC.
The CCM tests itself on power-up. These fundamental tests include MC68HC11KW1, RAM, and SPM interfaces. If any test fails, the CCM attempts to execute an endless loop routine which flashes the green LED on the board. Also, it places a 4-bit fault code into the adjacent yellow LEDs (see Power-on LED Patterns - Fault States on Startup).
The LEDs on the CCM (labeled LED1 through LED7) are entirely under program control. Their use is as follows:
Note
Refer to CELL-DYN 1800 CCM for location of LEDs on PCB.
• LED7, a green LED, should not be not flashing after the CCM has successfully completed its internal power-on self-check diagnostics, otherwise if it is flashing slowly (~1Hz.), there is a fundamental CCM fault.
• LED5 and LED6, for CER and CEW, indicate the state of the CCM firmware generated signals CER (Count Enable Red) and CEW (Count Enable White). These signals enable cell counting. When the associated LED is on, the DMA cell counting circuitry is active.
• LED3 and LED4, for WCP and RCP, are on during the metered count time intervals, LED3 for the white count time interval and LED4 for the red count time interval.
• LED2 is driven by the signal NREQ1, and indicates the UIC/CCM communication activity. This LED state directly relates to the hi/lo state of NREQ1. When LED2 is flickering, which should always be the case during normal system operation, it indicates that the UIC/CCM communications link is active. (There is a corresponding LED on the DLA (UIC comm. board) that will also be flickering in sync with LED2; it is controlled by the DLA output signal NREQ2.) • LED1 is used to indicate that a self-test is in progress. This indicates that the tests for the pulse processing A to D
circuitry on the SPM with the pulse counting circuitry on the CCM are active.
Power-on LED Patterns - Normal Setup
Step LED2 NREQ1 LED3 WCP LED4 RCP LED5 CEW LED6 CER LED7 READY State 0 ON ON ON ON Power on 1 RAM testing 2 Flashing RBC/PLT testing 3 Flashing WBC testing
4 ON ON CCM tests done; Homing flowscript running
5 Flashing ON ON UIC program comm. started
6 Flashing Initialized (running/idle)
Power-on LED Patterns - Fault States on Startup
NREQ1 WCP RCP CEW CER READY Fault
ON ON Flashing MC68HC11KW1 CONFIG reg ON Flashing MC68HC11KW1 RAM test ON Flashing 8K RAM bit test
Flashing 8K RAM clear test ON ON ON Flashing Histogram RAM test ON ON Flashing MC68HC11KW1 timer test
ON Flashing CDM init. test
1 Cell Count Monitor (CCM) PCB 8 J6 - NOT USED 2 S1 RESET 9 LEDs 2-7 3 S3 BUFFALLO 10 E2 DGND 4 J2 MPM 11 J8 - NOT USED 5 J1 CDM 12 E3 DGND 6 J3 SPM 13 E1 DGND 7 J5 DLA 14 LED 1
CPU Hardware/Software Configuration
RS-232 Communications Test Procedure
CMOS Setup
The CMOS Setup contains all the information needed by the Basic Input/Output System (BIOS) to establish proper
communications between the single board computer (SBC) and the various computer system devices. Refer to VP-05 CMOS Setup Verification/Adjustment:
Special Function
Probe Check
There are two probe check functions activated by softkeys in the DIAGNOSTICS menu.
• The [PROBE UP] softkey moves the probe up and maintains position without rotational motion. (The [PROBE DOWN] softkey then displays to restore the probe to the down position.)
• The [PROBE HOME] softkey places the probe over the RBC/PLT transducer. (The [PROBE DOWN] softkey then
displays to restore the probe to the down position.)
Note
Neither procedure puts the probe in the STANDBY position (on the left).
Service Special Commands
Discussion
Several commands are available to initiate individual actions in the CELL-DYN 1800 System hardware and software. These commands are used for troubleshooting and/or alignment when a single action is desired or required to be repeated several times.
The special command mode resides in the DIAGNOSTICS Menu. From the MAIN Menu, press [DIAGNOSTICS] followed by
[MORE] three (3) times, then [SERVICE DEC CODE]. When this softkey is pressed, the message Test Select --- FOR SERVICE USE ONLY --- displays.
A command can now be entered. Pressing the Enter key on the keyboard initiates the action. Only one command can be entered at a time and [SERVICE DEC CODE] must be pressed before a command is entered.
All commands available by direct softkey can be accessed by pressing [MORE].
Note
Use only the commands listed in DEC Service Commands and always verify that the correct number has been
entered before initiating the action. Use only those numbers listed in DEC Service Commands. Other numbers may refer to engineering commands which are not used in the field and which may cause damage if used improperly. Be fully aware of the purpose of any of the DEC Service Commands before using them. This is a direct-activation method which should be used with caution because the physical state of the CELL-DYN 1800 System may not be in agreement with the function to be performed. After using service commands, always re-initialize the system by turning the power OFF then ON again or by pressing the [INITIALIZATION] key in the DIAGNOSTICS Menu to ensure the instrument is in the proper configuration for normal operation.
DIAGNOSTICS Menu Service Code Function List
When the [SERVICE DEC CODE] key is pressed, the (Enter number (currently, 102):____ prompt displays. The number above corresponds to the decimal code for the last code entered.
DEC Service Commands lists the decimal-coded (DEC) service commands that can be invoked by pressing the [SERVICE
DEC CODE] key in the DIAGNOSTICS Menu and entering the appropriate number.
DEC Service Commands
UIC DEC Codes Function
07 NOT USED
08 NOT USED
09 NOT USED
11 NOT USED
15 fill lyse into system
16 NOT USED
17 NOT USED
18 NOT USED
19 fill Diluent & detergent
20 mini-wash 22 NOT USED 23 NOT USED 24 NOT USED 25 NOT USED 26 NOT USED 33 NOT USED 34 NOT USED 36 NOT USED
37 pre-dilute sample run setup 38 pre-dilute sample run exit
39 aperture current off (uses whole blood script) 40 open all valves
41 NOT USED
47 platelet recount 48 initialization (homing) 49 open sample run
50 clean orifice (back-flushing) 51 pre-dilute sample run 52 background count run
53 prime system with all reagents 54 daily shutdown
55 empty transducers and cups
56 gain adjust
57 unpinching normally closed valves 59 fill transducers and cups after empty 60 gain adjustment setup
61 dispense 10 ml saline 62 open sample wash 63 clean-for-shipping
64 clean sample syringe setup
65 aspirate 40 µl sample for 1/250 dilution 66 dispense 10 ml saline for 1/250 dilution 67 aspirate 100 µl sample for 1/50 dilution 68 dispense 5 ml for 1/50 dilution
69 NOT USED
71 lyse syringe down
72 NOT USED
73 NOT USED
74 lyse syringe up and home 75 lyse syringe down restore
76 pre-dilute sample wash
77 NOT USED
78 NOT USED
81 NOT USED
83 diluent syringe down 84 enzyme clean setup
85 probe up and rotate and home
86 back to ready position from probe home 87 probe up for probe adjustment
88 probe down (when finished, operator should initialize the instrument to place the probe in the home position)
89 sample syringe up and restore 90 sample syringe down and home 91 enzyme clean the system 92 diluent syringe up and home 93 diluent syringe down and restore
117 NOT USED
118 NOT USED
119 NOT USED
120 NOT USED
121 cycle solenoids on waste assy 122 cycle solenoids on flow panel assy 123 sample syringe aspirate
124 sample syringe dispense 125 vacuum test
126 check mixing pressure 127 check backflush pump
128 motor power test (see Service DEC Code 128) 129 motor power level test (see Service DEC Code 129) 130 exercise motors (see Service DEC Code 130)
999 auto-cycle (see Auto-Cycling (Code 999))
Note
Certain commands are not sent to the CCM when the system is in an interlock state, such as STANDBY or UNINITIALIZED.
Auto-Cycling (Code 999)
The CELL-DYN 1800 can be pre-set to do a specified number of RUN cycles without user intervention. This capability applies only to normal RUN Count Test, Pre-Dilute RUN, (PRE-DIL TEST), Gain Adjust (GAIN ADJ), and Electrical Background (ELEC BKGD). This capability helps reduce test time for the instrument. The following entry screen displays after entering code 999:
Auto Cycle Test Set Up
--Use Spacebar to accept current number
Use "<--" key to delete a digit
Use "ESC" key to cancel
Enter Number of Times to Repeat Test (currently, 10):
Sample Probe Description
The motors that enable the Sample Probe to move up/down and to rotate are stepper motors which are under direct
computer control. Since there is no direct positional feedback sent to the computer, position switches are employed to verify critical positions during normal operation. It is important to understand that these switches only verify and do not control the movement of the Sample Probe.
In the DIAGNOSTICS Menu, Service DEC Codes 128, 129, and 130 allow the service representative to control and exercise all stepper motors in the CELL-DYN 1800 System. This description focuses on the Probe Up/Down Motor (B/2) and the Probe Rotate Motor (C/3) which control the movement of the Sample Probe.
Service DEC Codes 128, 129, and 130 Descriptions
These commands reside in the SERVICE DEC CODE screen of the DIAGNOSTICS Menu and are used to test, control, and exercise CELL-DYN 1800 stepper motors. A description of each of these three commands is given.
This code runs a computer generated test (Motor Power Test) of all stepper motors, motor driver boards, and associated circuitry.
The Motor Power Test should be run whenever a problem is suspected with any assembly that is driven by a stepper motor. The following entry screen displays after entering code 128:
Motor Power Test Started.
To MPM: {I }
To MPM: {pD32}
To MPM: {mC1!2} AC}
To MPM: {C1}
inp: 0415
A report (Motor Power Test (example)) automatically displays and can be printed. Refer to VP-11 Stepper Motor Power Test and Verification.
Note
Press the [INITIALIZE] key before leaving the DIAGNOSTICS Menu. Motor Power Test (example)
This code allows the Run and Idle power levels to be set when exercising a stepper motor. The four levels are: 0) Full Power
1) Medium Power 2) Low Power 3) Off
This code tests mechanical assemblies at various power levels or to remove idle power so the mechanism can be more easily moved or checked manually. The Motor Power Level Test (example) screen displays after entering code 129 (press the ENTER key after each entry):
Motor Power Level Test (example)
Note
After the entries are made, a message, such as Motor "A" set to running power of 1 and idle power of 3, displays.
Service DEC Code 130
This code allows the direction, speed, and number of steps to be set when exercising a stepper motor. The Motor Check (example) screen displays after entering code 130:
Note
After the entries are made, a message, such as Motor "B": motion in direction "0" at speed "&" for 100 steps, displays.
Motor Direction Commands
The table below contains information on the motor designation, command and direction of the motor to be tested. Motor Speed Commands lists the motor speed commands to determine the speed of the motor being tested. Both tables are needed to properly test the motor.
Motor Direction Commands
Motor Designations Function Command Direction
0 Down/Aspirate A/1 Sample Syringe
1 Up/Dispense 0 Up B/2 Probe Up/Down 1 Down 0 CCW/To RBC cup C/3 Probe Rotation
1 CW/To Pre-Mixing Cup 0 Down/Aspirate
D/4 Diluent Syringe
1 Up/Dispense 0 CCW/Dispense
E/5 Directional Valve 1 CW/Aspirate F/6 Spare G/7 Spare 0 Down/Aspirate H/8 Lyse Syringe 1 Up/Dispense
Motor Speed Commands
Command Speed in Steps per Second
1 50 2 75 3 283 4 300 5 166 6 200 7 250 8 10 9 151 10 222 11 25 12 182 13 100 14 125 15 91 16 67 17 111
Probe Up/Down INITILIZE and RUN Modes illustrates the Sample Probe's up/down sequence during the INITIALIZE and RUN cycles. Probe Rotate "INITALIZE" Mode shows the probe's rotation movement during the INITIALIZE cycle.
Probe Up/Down INITILIZE and RUN Modes
Probe Rotate "INITALIZE" Mode
The Initialization cycle places mechanical and electrical components in the "home" position, drains any liquid in the tubing, Pre-Mix Cup, and the Mixing Chamber of the von Behrens RBC Transducer to the Waste System, then places the instrument in the INITIALIZED state.
Stepper Motor Homing
Homing a stepper motor is the process of setting up the initial position from which all future movement is referenced. In the CELL-DYN 1800 System, this is accomplished by forcing the motor to move against a physical stop (Hard Stop). When the mechanical assembly, driven by the motor, reaches the Hard Stop, the stepper motor electrically slips until it is forced to stop. This mechanical position then becomes the zero reference position for the motor.
Operation:
1. The Sample Probe moves up at a fast speed until the Upper Switch (#2) is activated. It is then changed to a slow speed, and homed against the Upper Hard Stop, which is the metal plate at the top of the Sample Probe Assembly. 2. The probe moves down six steps and the Upper Switch (#2) is checked.
3. The probe moves CCW at a fast speed until the Right Switch (#4) is activated. It is then changed to a slow speed, and homed against the Right Hard Stop, which is the mounting bracket for Right Switch (#4).
4. The probe moves CW to the Pre-Mix Cup and Left Switch (#3) is checked. The probe then moves into the Pre-Mixing Cup.
5. The probe moves up and Upper Switch (#2) is checked.
6. The probe moves CCW to center and down positions; and the Lower Switch (#1) is checked.
7.
This completes the Initialization cycle.Run Mode
The figure below illustrates the probe's movements during the RUN cycle.
Operation:
1. When the Start Switch is pressed, 30 µL of sample is aspirated and Lower Switch (#1) is checked.
2. The Sample Probe then moves up to a position six steps from Upper Hard Stop, and Upper Switch (#2) is checked. 3. The probe moves CW to Pre-Mix Cup and Left Switch (#3) is checked.
4. The probe moves down eight steps and into the Pre-Mix Cup, where dispense, probe shake, and aspiration of RBC sample takes place.
5. The probe then moves up to a position six steps from Upper Hard Stop, and Upper Switch (#2) is checked. 6. The probe moves CCW to the Mixing Chamber of the von Behrens RBC/PLT Transducer, stops three steps from
Right Hard Stop, and Right Switch (#4) is checked.
7. The probe moves down into the RBC/PLT Mixing Chamber and RBC sample is dispensed.
8. The probe moves up to a position six steps from Upper Hard Stop, and Upper Switch (#2) is checked. 9. After completion of the count cycle, the probe moves CW to center position.
10. The probe moves down and Lower Switch (#1) is checked.
11.
This completes the RUN cycle.Switch Failure Descriptions
Example of fault reports are shown in the following figures:
Lower Switch (#1) Fault Report Upper Switch (#2) Fault Report Left Switch (#3) Fault Report Right Switch (#4) Fault Report
When a switch is checked by the computer and found to be deactivated (open) in normal operation, the message "Not Ready:
SEE DIAGNOSTICS" displays on the RUN Menu.
From the MAIN MENU, press [DIAGNOSTICS]. The screen immediately displays one of the Fault Reports shown in Lower Switch (#1) Fault Report, Upper Switch (#2) Fault Report, Left Switch (#3) Fault Report, and Right Switch (#4) Fault Report. The message <SWITCH: 1 CHECK> indicates that Lower Switch (#1) failed when checked. The message <* NOT ON ANY
SWITCH *> indicates that none of the switches were activated when the failure occurred. Refer to Lower Switch (#1) Fault Report.
Lower Switch (#1) Fault Report
The message <SWITCH: 2 CHECK> indicates that Upper Switch (#2) failed when checked. The message <* NOT ON ANY
SWITCH *> indicates that none of the switches were activated when the failure occurred. Refer to Upper Switch (#2) Fault Report.
Upper Switch (#2) Fault Report
The message <SWITCH: 3 CHECK> indicates that Left Switch (#3) failed when checked. The message <ON SWITCH(ES):
