BM480V2

Users Guide Vol.
AU480
Chemistry Analyzer
For In Vitro Diagnostic Use
BM480V2AB
AUG 2010
Beckman Coulter, Inc.
250 S. Kraemer Blvd.
Brea, CA 92821
Copyright 2009 Beckman Coulter Inc. All rights reserved. Printed in the United States of America.
AU480 is a registered trademark of Beckman Coulter Corporation, Beckman Coulter Inc., or their
affiliated entities.
No part of this publication may be reproduced in any form or by any means without prior written
permission of Beckman Coulter Inc. While every precaution has been taken during document
preparation, Beckman Coulter Inc. assumes no responsibility for errors or omissions. Neither is any
liability assumed for damages resulting from the use of the information contained herein.
BECKMAN COULTER INC.
250 S. Kraemer Blvd.
Brea, CA 92821
This guide was written to comply with Clinical and Laboratory Standards Institute Protocols (CLSI)
guidelines for Clinical Laboratory Procedure Manuals; however, each laboratory may need to modify
and/or add procedures to meet the laboratory requirements of CLSI.
The AU480 is ISO13485 certified. Design and production adheres to ISO13485 international quality
standards.
The AU480 has been tested and found to comply with the limits for a Class A digital device, pursuant
to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy. If the instrument is not installed and used
in accordance with the instruction manual, harmful interference to radio communications may result.
Operation of this equipment in a residential area is likely to cause harmful interference in which case
the users will be required to correct the interference at their own expense.
FCC Warning: Changes or modifications not expressly approved by the party responsible for
compliance could void the users authority to operate the equipment.
Table of Contents
AU480 Users Guide Volume 2
Maintenance, ISE Maintenance, Error Flags, Error Messages,
Troubleshooting, Menu Tree, Terminology, Index Parameters
Table of Contents
Maintenance 8-1
8.1 Daily Maintenance...................................................................................................... 8-3
8.1.1
Inspect the Syringes for Leaks and Proper Installation........................... 8-3
8.1.2
Inspect the Wash Solution Roller Pump Unit for Leaks .......................... 8-5
8.1.3
Inspect and Replenish the Concentrated Wash Solution ........................ 8-6
8.1.4
Inspect the Stability of the Upper Cover.................................................. 8-7a
8.1.4
Inspect, Clean and Prime the Sample and Reagent Probes................... 8-8
8.1.5
Inspect and Clean the Mix Bars .............................................................. 8-10
8.1.6
Inspect the Printer and Paper.................................................................. 8-10
8.1.7
Replace the DI Water in the Pre-dilution Bottle....................................... 8-10
8.1.8
Prepare for a Sample Probe Wash.......................................................... 8-10
8.2 Weekly Maintenance.................................................................................................. 8-11
8.2.1
Perform a W2 .......................................................................................... 8-11
8.2.2
Perform a Photocal.................................................................................. 8-13
8.2.3
Clean the Sample Pre-diluent Bottle........................................................ 8-16
8.3 Monthly Maintenance................................................................................................. 8-17
8.3.1
Clean the Sample Probe and Reagent Probe Wash Wells ..................... 8-18
8.3.2
Clean the Mix Bar Wash Wells................................................................ 8-19
8.3.3
Clean the Wash Nozzle Unit and Check the Tube Mounting Joints......... 8-21
8.3.4
Clean the Deionized Water Tank, DI Filter, and Sample Probe Filter...... 8-25
8.4 Quarterly Maintenance.............................................................................................. 8-29
8.4.1
Clean the Air Filters................................................................................. 8-30
8.4.2
Replace the Wash Solution Roller Pump Tubing..................................... 8-31
8.5 As Needed Maintenance............................................................................................ 8-33
8.5.1
Replace O-rings in the Wash Nozzle Tube Mounting Joints ................... 8-34
8.5.2
Replace the Cuvettes ............................................................................. 8-35
8.5.3
Replace Sample Probe and Reagent Probe............................................ 8-36
8.5.4
Replace Mix Bars..................................................................................... 8-38
8.5.5
Replace the Wash Nozzle Joint .............................................................. 8-39
8.5.6
Replace Syringes..................................................................................... 8-42
8.5.7
Clean the Inside of the STAT Table Compartment and
Reagent Compartments........................................................................... 8-46
8.5.8
Clean or Replace the Antistatic Brushes................................................. 8-47
8.5.9
Replace the Sample and Reagent Probe Tubing ................................... 8-48
8.5.10 Replace the Photometer Lamp ............................................................... 8-48
8.5.11 Clean Cuvettes and the Cuvette Wheel .................................................. 8-51
8.5.12 Clean the Probes and Mix Bars............................................................... 8-55
8.5.13 Replace the Deionized Water Filter and Sample Probe Filter................. 8-58
8.5.14 Perform a W1 Procedure......................................................................... 8-60
8.6 AU480 Maintenance Schedule.................................................................................... 8-61
ISE Maintenance
ISE-1
ISE Errors
ISE-3
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April 14, 2010
Table of Contents
ISE Maintenance
ISE-4
1 List of Parts Used for ISE Maintenance ...................................................................... ISE-5

2 Tubing Block Diagram for ISE Maintenance ................................................................ ISE-7
3 Daily Maintenance ......................................................................................................... ISE-8
3.1 Inspect the ISE Buffer Syringe for Leaks ......................................................... ISE-8
3.2 ISE Cleaning..................................................................................................... ISE-10
4 Weekly Maintenance ...................................................................................................... ISE-12
4.1 Enhanced Cleaning of Electrode Line .............................................................. ISE-12
5. Maintenance Every Other Week .................................................................................. ISE-14
5.1 Manually Clean the Mix Bar, Liquid Level Sensors,
Sample Pot and Sample Pot Tubing ....................................................... ISE-14
6 Quarterly Maintenance................................................................................................... ISE-18
6.1 Replace the Mixture Aspiration and Mid Standard Roller Pump Tubing........... ISE-18
6.2 Replace the Pinch Valve Tubing....................................................................... ISE-20
7 As-Needed Maintenance ............................................................................................... ISE-22
7.1 Replacing the Sample Pot ................................................................................ ISE-22
7.2 Manually Clean the K Electrode ....................................................................... ISE-25
7.3 Replacing Reagents ......................................................................................... ISE-29
7.4 Replacing the ISE Buffer Syringe...................................................................... ISE-31
7.5 Enhanced ISE Cleaning (Manual)..................................................................... ISE-34
7.6 Replacing the Na, K, or Cl Electrode ............................................................... ISE-36
7.7 Replacing the Tubing between Sample Pot and
Electrode Unit, and T-Connector.............................................................. ISE-39
7.8 Replacing the Drain Tube and Manually
Washing the Drain Tank .......................................................................... ISE-42
9 ISE Maintenance Schedule ........................................................................................... ISE-45
Error Flags
9-1
9.1 Summary of Error Flags............................................................................................ 9-3

9.2 Error Flag Details ...................................................................................................... 9-5
d (Excluded from QC by user)................................................................................. 9-5
e (Data edited by user) ........................................................................................... 9-5
( (Shortage of wash solution for contamination parameters) ................................. 9-5
Wa (Result has been analyzed with an erroneous cuvette) ................................... 9-5
R (Insufficient reagent) ........................................................................................... 9-6
# (Insufficient sample) ............................................................................................ 9-6
% (Clot detected) ................................................................................................... 9-7
? (Unable to calculate a result) .............................................................................. 9-7
?a (Sample/reagent detection abnormal)................................................................ 9-7
n (LIH test not performed) ...................................................................................... 9-8
l (Result may be affected by lipemia) ..................................................................... 9-8
i (Result may be affected by icterus) ...................................................................... 9-8
h (Result may be affected by hemolysis) ............................................................... 9-8
Y (Reagent blank OD at last photometric point high) ............................................. 9-8
U (Reagent blank OD at last photometric point low) .............................................. 9-9
y (Reagent blank/routine OD at first photometric point high) ................................. 9-9
u (Reagent blank/routine OD at first photometric point low) .................................. 9-9
@ (OD is higher than 3.0) ...................................................................................... 9-10
$ (Not enough data to determine linearity of reaction) ........................................... 9-10
D (OD of reaction is higher than the maximum OD range) .................................... 9-11
B (OD of reaction is lower than the minimum OD range) ....................................... 9-12
* (Linearity error in rate methods) .......................................................................... 9-12
& (Prozone test data abnormal) ............................................................................. 9-13
Z (Prozone error) .................................................................................................... 9-13
E (Overreaction in a rate assay detected) .............................................................. 9-13
Fx (Result (OD) is higher than dynamic range) ...................................................... 9-13
Gx (Result (OD) is lower than dynamic range) ...................................................... 9-14
! (Unable to calculate concentration) ...................................................................... 9-14
) ( Reagent lot no. used at sample analysis is different from
that used at calibration analysis) ............................................................ 9-14
a (Reagent expired) ............................................................................................... 9-15
ba (No calibration data or expired) ......................................................................... 9-15
bh (Invalid calibration data or expired) ................................................................... 9-15
bn (Mastercurve used) ........................................................................................... 9-15
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November 1, 2009
bz (Calibration curve for Prozone data used) ......................................................... 9-15

F (Result is higher than the dynamic range) .......................................................... 9-16
G (Result is lower than the dynamic range) ........................................................... 9-16
ph (Result is higher than the upper panic value) .................................................... 9-16
pl (Result is lower than the low panic value) .......................................................... 9-16
T (Abnormality found in inter-chemistry check.) ..................................................... 9-17
P (Positive) ............................................................................................................. 9-17
N (Negative) ........................................................................................................... 9-17
H (Result is higher than reference range) .............................................................. 9-17
L (Result is lower than reference range) ................................................................ 9-17
J (Result is higher than the repeat decision range) ................................................ 9-18
K (Result is lower than the repeat decision range) ................................................ 9-18
fh (Result is higher than the repeat run reflex range) ............................................. 9-18
fl (Result is lower than the repeat run reflex range) ............................................... 9-18
Va (The result of multiple measurement alienation check is NG)........................... 9-19
xQ (Failure of one control used in a multirule QC) ................................................. 9-19
1Q (QC data exceeds the range entered in Single Check Level field) ................... 9-20
2Q (QC data exceeds 13SD control range) ........................................................... 9-20
3Q (QC data continuously exceeds the 2 SD control limit ..................................... 9-21
4Q (QC Data exceeds R4S control range) ............................................................. 9-21
5Q (QC Data exceeds 41S control range) ............................................................. 9-22
6Q (A preset number of consecutive QC results fall on one side of the mean) ..... 9-22
7Q (Consecutive QC results show steadily increasing or decreasing values) ....... 9-23
S (Sample repeated and original results replaced by repeat result)....................... 9-23
/ (Test pending) ...................................................................................................... 9-23
r (Data transmitted to host) .................................................................................... 9-23
c (Data corrected by user) ...................................................................................... 9-24
Error Messages
10-1
Error Messages In the Comment column.................................................................... 10-14

Error Messages using the HOME menu....................................................................... 10-16
Error Messages Using the Start menu or Shifting to Another mode............................ 10-19
Messages Starting STAT................................................................................................... 10-26
STAT Table Tab Comments............................................................................................... 10-28
Troubleshooting 11-1
11.1 Troubleshooting and Maintenance .......................................................................... 11-3
11.2 Troubleshooting the System Data Problems .......................................................... 11-3
11.2.1 Data Problem Checklist .......................................................................... 11-3
11.2.2 Checking Abnormal Data ........................................................................ 11-4
11.2.3 Troubleshooting Software ....................................................................... 11-5
11.3 Troubleshooting the System - Reagents and Samples ......................................... 11-7
11.3.1 Sample Related Issues ........................................................................... 11-7
11.3.2 Reagent Related Issues ......................................................................... 11-8
11.3.3 QC and Calibrator Related Issues .......................................................... 11-8
11.3.4 Wash Solution Related Issues ................................................................ 11-9
11.3.5 Deionized Water Related Issues ............................................................. 11-9
11.3.6 Other Causes of Abnormal Data ............................................................. 11-9
11.4 Troubleshooting the System - Mechanical Problems ............................................ 11-10
11.4.1 Syringe Problems ................................................................................... 11-10
11.4.2 Probe Problems ...................................................................................... 11-11
11.4.3 Abnormal Data Caused by Cuvette Wheel or Wash Nozzles ................. 11-12
11.4.4 Abnormal Data Caused by Photometer Lamp or Photometer Unit ......... 11-13
11.4.5 Mixing Problems ..................................................................................... 11-13
11.4.6 Deionized Water Tank Problems ............................................................. 11-13
11.4.7 Deionized Water or Filter Problems ........................................................ 11-14
11.4.8 Incubation Temperature Problems .......................................................... 11-14
11.4.9 Piping and Pump Problems .................................................................... 11-14
11.4.10 Reagent Refrigerator Problems .............................................................. 11-15
11.4.11 STAT Table Problems .............................................................................. 11-15
11.4.12 Rack Problems ....................................................................................... 11-15
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Table of Contents
iii
11.5 Troubleshooting the System - System Problems .................................................. 11-16

11.5.1 TEMP REF HIGH Alarm for the Cooling Unit .......................................... 11-16
11.5.2 Abnormal Sound from Inside the System................................................ 11-16
11.5.3 Empty Alarm for the Water Supply Tank.................................................. 11-17
11.5.4 Leaks from the Wash Solution Roller Pump............................................ 11-17
11.5.5 Barcode Errors ........................................................................................ 11-18
11.5.6 Leaks from the Bottom of the System ..................................................... 11-18
11.5.7 No Wash Solution to Mix bars ................................................................. 11-18
11.5.8 Reagent Alarm when Sufficient Reagent Remains in Bottles ................. 11-18
11.5.9 Sample Alarm when Sufficient Sample Remains .................................... 11-18
11.5.10 No Sample Cup Alarm when Sample Cup is Present ............................. 11-19
11.5.11 No Sample Cup on the STAT Table ........................................................ 11-19
11.5.12 Printer Not Printing or Printer Light Not On ............................................ 11-19
11.5.13 Liquid Leaking from the Reagent Probe and Sample Probe .................. 11-19
11.5.14 Reagent Probe and Sample Probe not Aligned over the Cuvette ........... 11-19
11.5.15 Error Flag # (Sample Level Detection Error) Displayed in the
Second Half of the Sample Dispense Operation .................................... 11-20
11.5.16 Sample Rack Jammed ............................................................................ 11-20
11.5.17 Printer Problems ..................................................................................... 11-20
11.6 Troubleshooting the System - Data Processor Problems ..................................... 11-21
11.6.1 Menu Cannot be Selected ...................................................................... 11-21
11.6.2 Number Key Pad on Keyboard Does Not Work ...................................... 11-21
11.6.3 Keyboard Not Responding ...................................................................... 11-21
11.6.4 Inaccessible Floppy Disc ........................................................................ 11-22
11.6.5 Results Do Not Print Automatically ......................................................... 11-22
11.6.6 Online Auto-Output by Host Computer Not Executed ............................. 11-22
11.6.7 Unsuccessful Movement of Data between the System and the
Host Computer......................................................................................... 11-22
11.7 Recovering from an Emergency Stop or Power Loss ........................................... 11-23
11.7.1 Performing an Emergency Stop .............................................................. 11-23
11.7.2 Resetting the System after a Power Failure or an Emergency Stop....... 11-23
11.8 Recovering from a Cuvette Wheel Overflow........................................................... 11-24
11.8.1 What causes an overflow?....................................................................... 11-24
11.8.2 Recognizing a Overflow........................................................................... 11-24
11.8.3 Recovering from an overflow................................................................... 11-25
11.8.4 After the overflow problem is fixed........................................................... 11-26
Menu Tree
12-1
12.1 Home Menu................................................................................................................. 12-2

12.2 Permanently Displayed Button Configuration and Function ................................ 12-3
Group of Function Selection Buttons ..................................................................... 12-3
Group of System Control Buttons .......................................................................... 12-3
Group of Alarm Related Buttons ............................................................................ 12-3
Group of Other Buttons .......................................................................................... 12-3
12.3 Menu Buttons Overview ........................................................................................... 12-4
12.4 Routine Menu............................................................................................................. 12-5
12.5 Calibration Menu........................................................................................................ 12-6
12.6 QC Menu..................................................................................................................... 12-7
12.7 Parameter Menu ........................................................................................................ 12-8
12.8 Maintenance Menu .................................................................................................... 12-9
12.9 System Menu ............................................................................................................. 12-10
AU480 Terminology
13-1
Index 14-1
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Table of Contents
AU480 User Guide

November 1, 2009
8 Maintenance
The maintenance frequency described in this chapter is based on
analysis of 2,000 or less tests per day. Laboratories may have to
increase the amount of maintenance required depending upon the
number of tests and local environmental conditions.
This chapter illustrates how to keep the system operating in good
condition through periodic maintenance procedures.
Contents
8.1
8.2
8.3
8.4
8.5
Daily Maintenance..........................................................................................................8-3
8.1.1
Inspect the Syringes for Leaks and Proper Installation....................................8-3
8.1.2
Inspect the Wash Solution Roller Pump Unit for Leaks ...................................8-5
8.1.3
Inspect and Replenish the Concentrated Wash Solution ................................8-6
8.1.4
Inspect the Stability of the Upper Cover.........................................................8-7a
8.1.4
Inspect, Clean and Prime the Sample and Reagent Probes............................8-8
8.1.5
Inspect and Clean the Mix Bars .....................................................................8-10
8.1.6
Inspect the Printer and Paper.........................................................................8-10
8.1.7
Replace the DI Water in the Pre-dilution Bottle..............................................8-10
8.1.8
Prepare for a Sample Probe Wash.................................................................8-10
Weekly Maintenance....................................................................................................8-11
8.2.1
Perform a W2 ................................................................................................ 8-11
8.2.2
Perform a Photocal.........................................................................................8-13
8.2.3
Clean the Sample Pre-diluent Bottle..............................................................8-16
Monthly Maintenance..................................................................................................8-17
8.3.1
Clean the Sample Probe and Reagent Probe Wash Wells ...........................8-18
8.3.2
Clean the Mix Bar Wash Wells.......................................................................8-19
8.3.3
Clean the Wash Nozzle Unit and Check the Tube Mounting Joints...............8-21
8.3.4
Clean the Deionized Water Tank, DI Filter, and Sample Probe Filter.............8-25
Quarterly Maintenance................................................................................................8-29
8.4.1
Clean the Air Filters........................................................................................8-30
8.4.2
Replace the Wash Solution Roller Pump Tubing............................................8-31
As Needed Maintenance..............................................................................................8-33
8.5.1
Replace O-rings in the Wash Nozzle Tube Mounting Joints ..........................8-34
8.5.2
Replace the Cuvettes ....................................................................................8-35
8.5.3
Replace Sample Probe and Reagent Probe..................................................8-36
8.5.4
Replace Mix Bars...........................................................................................8-38
8.5.5
Replace the Wash Nozzle Joint .....................................................................8-39
8.5.6
Replace Syringes...........................................................................................8-42
8.5.7
Clean the Inside of the STAT Table Compartment and Reagent

Compartments................................................................................................8-46
8.5.8
Clean or Replace the Antistatic Brushes........................................................8-47
8.5.9
Replace the Sample and Reagent Probe Tubing ..........................................8-48
8.5.10 Replace the Photometer Lamp ......................................................................8-48

8.5.11 Clean Cuvettes and the Cuvette Wheel ........................................................8-51
8.5.12 Clean the Probes and Mix Bars......................................................................8-55
8.5.13 Replace the Deionized Water Filter and Sample Probe Filter........................8-58
8.5.14 Perform a W1 Procedure................................................................................8-60
8.6 AU480 Maintenance Schedule........................................................................................8-61
AU480 User Guide

April 14, 2010
Maintenance
8-1
CAUTION
8-2
Failure to perform user maintenance according to the instructions within this User
Guide can adversely affect system performance and might invalidate the service
agreement.
Maintenance
AU480 User Guide

July 24, 2009
8.1 Daily Maintenance

To obtain the highest performance from the system and to use the analyzer safely, be sure to perform
the following daily maintenance.
8.1.1
Inspect the Syringes for Leaks and Proper Installation....................................8-3
8.1.2
Inspect the Wash Solution Roller Pump Unit for Leaks ...................................8-5
8.1.3
Inspect and Replenish the Concentrated Wash Solution ................................8-6
8.1.4
Inspect the Stability of the Upper Cover.........................................................8-7a
8.1.4
Inspect, Clean and Prime the Sample and Reagent Probes............................8-8
8.1.5
Inspect and Clean the Mix Bars .....................................................................8-10
8.1.6
Inspect the Printer and Paper.........................................................................8-10
8.1.7
Replace the DI Water in the Pre-dilution Bottle..............................................8-10
8.1.8
Prepare for a Sample Probe Wash.................................................................8-10
Always wear personal protective equipment when performing any maintenance

procedure. To avoid injury and infection, observe the WARNING and CAUTION
notations described in this Users Guide.
CAUTION
8.1.1
Inspect the Syringes for Leaks and Proper Installation
The system utilizes a sample syringe, a reagent syringe, and an optional ISE syringe. The sample and
reagent syringes are responsible for accurately measuring the volume of sample or reagent to be used
in a reaction. The ISE syringe is responsible for measuring the correct volume of buffer for the ISE.
Although the syringes may be different sizes and serve different functions, the proper performance can
be gauged in the same way for each.
Inspect all components of the syringes, including the syringe case head, the syringe case, the fixing
nut and the piston fixing screw for leaks and proper installation.
Materials:
Clean dry cloth or paper towel
1.
Ensure the system is in Warm up, Standby , or Stop mode.
2.
Open the right door.
3.
Using the cloth or paper towel, search the top and bottom connetions of the syringe case head,
the syringe case and the bottom fixing screw for leaks.
Sample Syringe
ISE reagent Syringe
Reagent Syringe
Fixing nut
Fixing screws
Case head
Syringe case
Piston fixing screw
Possible leakage locations
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July 24, 2009
Maintenance
8-3
3.
Using a cloth or paper towel, search the top and bottom connections of the syringe case head,
the syringe case, and the bottom fixing screw for leaks.
CAUTION
CAUTION
Make sure that the syringe case is not contaminated with any strong alkali such as
wash solution. If the syringe case is contaminated with a strong alkali, it may be
broken.
If the case comes in contact with the strong alkali, remove the syringe case and flush
the contamination.
If the users hands or fingers come in contact with any liquid, wash them thoroughly
with water immediately.
4.
Ensure the case is tightened to the head by attempting to hand turn the case.
5.
If a leak or crack is encountered, refer to 8.5.6 Replace Syringes, in the As Needed

Maintenance section.
6.
Close the right front door of the analyzer.
If any leak persists even after tightening,the syringe must be replaced.

CAUTION
8-4
Maintenance
AU480 User Guide

July 24, 2009
8.1.2
Inspect the Wash Solution Roller Pump Unit for Leaks
The wash solution roller pump draws concentrated wash solution from the bottle and supplies it to the
diluted wash solution bottle where it is diluted to a 1% solution. If the pump leaks, concentrated wash
solution may be diluted improperly. Always check the wash solution roller pump unit for leaks prior to
starting analysis.
Materials :
Clean dry cloth
1.
Ensure the system is in Warm up , Standby , or Stop mode.
2.
Open the left door.

Roller tube
Wash solution
roller pump
Connectors
CAUTION
If the operators hands or fingers come in contact with any liquid, wash them
thoroughly with water immediately.
3.
Visually inspect the wash solution roller pump tube for any cracks.
4.
Blot the peripheral part of the wash solution roller tube at its connections with a clean dry cloth to
detect any leaks.
5.
Verify the tube connections are tight.
6.
Close the left door.
CAUTION
If any leak persists even after being re-tightened, replace the wash solution roller
pump tubing with a new one.
For details on replacement of the wash solution roller pump tubing, refer to section
8.4.2 Replace the Wash Solution Roller Tube.
AU480 User Guide

July 24, 2009
Maintenance
8-5
8.1.3
Inspect and Replenish the Concentrated Wash Solution
If the concentrated wash solution level is low, system operation will be interrupted. To avoid
transferring the system into Pause mode, always observe the level of concentrated wash solution. If
it is low, replenish the concentrated wash solution.
Materials:
Concentrated wash solution
Clean dry cloth
Inspect the concentrated wash solution level

1.
Ensure the system is in Warm up , Standby , or Stop mode.
2.
Open the left door.
Wash solution tank
8-6
3.
Find the small mark etched on the concentrated wash solution tank (approximately 200 mL).
At that level, the volume of concentrated wash solution is insufficient.
Verify that the level is sufficient for the days workload. As a reference, for a laboratory that runs
2,000 tests per day, consumption of concentrated wash solution is generally 0.5 L/day.
4.
Maintenance
AU480 User Guide

July 24, 2009
Replenishing the Concentrated Wash Solution
WARNING
When removing the concentrated wash solution cap, wear gloves to prevent
hands from coming in contact with the concentrated wash solution. If hands or
clothes come in contact with concentrated wash solution, wash them immediatley
with water. If the concentrated wash solution comes into contact with the eyes or
mouth, flush with water and consult a doctor immediately.
If the concentrated wash solution is splashed or accidentally spills, wear gloves
and wipe the area with a dry cloth or paper towel. If any spill is left untreated, it
may generate toxic gas and may cause parts of the analyzer to corrode.
1.
Pull the wash solution tank forward to access the wash solution tank cap.
2.
Unscrew the wash solution tank cap, and remove the cap and connector from the wash solution
tank.
3.
Place the wash solution tank cap and connector in a new bottle of wash solution. Tighten the cap.
4.
Place the new bottle of wash solution back on the analyzer.
CAUTION
Dripping may occur when the level sensor is removed from the tank. If dripping
occurs, wipe the area with a dry cloth or paper towel wearing protective gloves.
Wash solution tank
TIP
5.
The remaining concentrated wash solution in the tank being replaced can be added to
the new wash solution tank.
AU480 User Guide

July 24, 2009
Maintenance
8-7
8.1.4
Inspect the Stability of the Upper Cover
Before starting daily analysis, check the stability of the upper cover of the analyzer to verify that it is stable
and remains in the upright position when raised. If the upper cover starts to descend when opened, have
the cover supports inspected and replaced by Beckman Coulter authorized personnel.
Upper Cover
8-7a
Maintenance
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Maintenance
8-7b
8.1.4
Inspect, Clean and Prime the Sample and Reagent Probes
The probes are responsible for delivering precise quantities of either reagent or sample to the
cuvettes. If they are clogged, bent, or otherwise damaged, proper analysis may not be achieved.
Prior to starting analysis inspect the sample and reagent probes, for damage or deterioration as well
as verify proper operation of each.
Materials:
Alcohol prep
Inspect the Sample and Reagent Probes for Damage or Deterioration

1.
Ensure the system is in Warm up, Standby, or Stop mode.
2.
Open the main cover.
3.
Visually inspect that each probe is not bent or damaged.

If a probe is bent or damaged, replace the probe. Refer to 8.5.3 Replacing the Sample and
Reagent Probes.
4.
Verify each probe is free of debris.

If any contaminants or crystallization adhere to the probes, wipe the outside surface with an
alcohol prep pad.
Verify Proper Operation of the Probes

1.
From the AU480 Home screen, select A n a l y z e r M a i n t e n a n c e .
2.
Place a check mark in the box next to the A n a l y z e r M a i n t e n a n c e option. The

m a i n t e n a n c e o p e ra t i o n buttons become functional.
3. Select P r i m e Wa s h i n g - l i n e .
4.
8-8
In the S t a r t dialog box, select O K .
Maintenance
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July 24, 2009
5.
Press the green TA B L E R OTAT I O N / D I A G button to start the operation.
TABLE ROTATION/DIAG button
ON, EM STOP,
RESET buttons
6.
Verify a thin straight stream of water is dispensed from the sample followed by the reagent
probe. The stream should be dispensed through the small hole in the metal plate in the wash
well. Also, note that the wash wells are filling with water during the dispense. Watch the wash
nozzle and mix unit perform a sequence to verify proper operation. It may be necessary to press
the TA B L E R OTAT
I OSpray
N / D I8-14
A G button again to verify the components operate without
Probe
errors.
Correct
CAUTION
After the probes have been primed, if the dispense is incorrect, replace the probes.
For details on replacing the sample and reagent probes, refer to Replace the
Sample and Reagent Probes in section 8.5.3.
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July 24, 2009
Incorrect
Maintenance
8-9
8.1.5
Inspect and Clean the Mix Bars
The mix bars mix the contents of the cuvettes after each addition. Prior to starting analysis inspect the
mix bars for damage or deterioration.
Materials:
Alcohol prep
1.
Visually inspect each mix bar. If any contaminants or crystallization adhere to the mix bar, wipe
the outside surface with an alcohol prep pad.
2.
Inspect each mix bar for deformities. If a mix bar is bent, scratched, or chips are found in the
Teflon coating, the mix bar must be replaced.
CAUTION
8.1.6
Verify that the sample probe, reagent probe and mix bars are not bent during
cleaning.
Inspect the Printer and Paper
Before starting daily analysis, verify the printer is turned on and that there is a sufficient amount of
paper in the printer.
1.
Verify the printer is on. A Ready message will appear on the printer display.
2.
Open tray 2 and verify a sufficient amount of paper remains.
For additional information on printer usage, refer to the Printer User Guide supplied with the printer.
8.1.7
1.
Discard the water in the pre-dilution bottle.
2.
Rinse the bottle twice with DI water.
3.
Fill the bottle with DI water and replace it on the instrument.
8.1.8
1.
8-10
Replace the DI Water in the Pre-dilution Bottle
Prepare for a Sample Probe Wash
Verify there is a sufficient amount of 2% wash solution in the Sample Probe Detergent tube,
located in the W1 position of the STAT Table. If there is insufficient detergent, add 2% wash
solution.
Maintenance
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July 24, 2009
8.2 Weekly Maintenance

To obtain the highest level of performance from the system perform these tasks on a weekly basis.
8.2.1
Perform a W2 ................................................................................................ 8-11
8.2.2
Perform a Photocal.........................................................................................8-13
8.2.3
Clean the Sample Pre-diluent Bottle..............................................................8-16
8.2.1
Perform a W2
If the sample probe, reagent probe, mix bars, and cuvettes become contaminated, appropriate
analysis results may not be obtained. The W2 prepares the cuvettes for the photocal by thoroughly
cleaning them. Perform a photocal to check the integrity of the cuvettes. The photocal can be
performed after the W2 automatically by selecting this option when executing the W2.
The W2 can be performed in conjunction with an End Process. Start the W2, wait until W2 displays
in the mode area and begins its countdown. Return to the Home screen and select the End Process
key. The system can be programmed to automatically start up and perform the photocal the following
morning.
TIP
The W2 procedure must be followed by the photocal, which checks the integrity
of the cuvettes. Patient samples should not be run between these two procedures.
For more information on performing the Photocal, refer to 8.2.2 Perform a
Photocal Each of these procedures requires approximately 22 minutes to complete.
Performing a W2
The W2 is accomplished by running 1N HCL or 10% bleach through the system. Each week the
chemical used will be alternated. The acidic detergent removes stains that are formed by protein
deposits left in the cuvettes. The bleach removes a very small quantity of inorganic substances such
as metallic ions as well as any bacterial contamination.
WARNING
Avoid mixing bleach and acid; all detergent containers onboard the instrument
should contain the same chemical. The mixing of HCl and bleach results in the
formation of chlorine gas, which is highly toxic. To avoid such risk, clearly label
containers designated for bleach and HCl and ensure that all positions requiring W2
cleaning chemicals contain the same chemical.
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July 24, 2009
Maintenance
8-11
Materials:
60 mL plastic reagent bottle1
1 glass tube (part number ZM0062)
Cleaning Chemical
65 mLs of 1N HCL
or
65 mLs of 10% Bleach
1.
Ensure the system is in Standby or Stop Mode.
2.
3.
4.
Fill the glass tube with at least 3 mLs of the cleaning chemical chosen for this weeks procedure.
(If bleach was used previously for the W2, use HCL for the current procedure.)
5.
Place the tube in the W2 position of the STAT Table.
6.
Fill the 60 mL bottle with approxmately 60 mLs of the same chemical (bleach or HCI) being
careful not to fill into the neck of the bottle.
7.
8.
Place the bottle in the position normally occupied by the predilution bottle.
W2 Wash dialog 8-22
9. Select W 2 ( F 6 ) from the bottom right corner of the screen. The W2 dialog box displays.
10. Decide whether the photocal will start immediately when the W2 completes, without operator
input. Also, the weekly ISE cleaning procedure may be run in conjunction with the W2 without
adding any time to the procedure.
a. If the photocal should start after the W2 completes, place a check mark next to the After W2
ends, perform the photocal prompt.
b. If the ISE cleaning procedure should start during the W2, place a check mark next to the ISE
Cleaning prompt and refer to the ISE maintenance chapter in the ISE section for instructions
on how to clean the ISE.
8-12
Maintenance
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July 24, 2009
11. In the software, select S t a r t . The W2 will start and will require 22 minutes to complete. A
countdown may be viewed in the mode display window.
12. When the W2 is complete, the photocal will automatically start if it was selected in step 4. If it
was not selected, at completion of W2, the instrument enters the Standby mode. At this point,
immediately remove the plastic bottles containing cleaning chemicals. For information on how to
execute a Photocal, refer to 8.2.2 Perform a Photocal.
The system can perform the Enhanced ISEISE Clean and the W2 simultaneously..
For details on preparation, refer to ISE Maintenance chapter.
TIP
8.2.2
Perform a Photocal
When the W2 is finished cleaning, a photocal should be performed. The photocal is a check on the
integrity of the cuvettes. It will detect dirt, stains, or scratches and identifies cuvettes that require
cleaning or replacing.
The photocal may be started from the W2 Start window. If it was not selected there, it may be started
in the following way.
CAUTION
To obtain optimal results, always perform photocal measurement only when the
photometer lamp has been stabilized after system startup. The photometer lamp
needs approximately 20 minutes to stabilize after system start up.
1.
Ensure the system is in Standby mode.
2.
From the AU480 Home screen select A n a l y z e r M a i n t e n a n c e .
3. Select P h o t o c a l ( F 7 ) .
This brings up the P h o t o c a l S t a r t dialog
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July 24, 2009
Maintenance
8-13
4. Select A L L C u v e t t e s to perform the check entirely and select S t a r t . (If individual

cuvettes fail, they may be cleaned or replaced and checked again by selecting their specific
number.) Refer to section 8.5.2 Replace Cuvettes in this chapter.
5.
The photocal measurement takes 23 minutes to complete. The system will automatically move to
Standby mode after the photocal measurement is complete.
TIP
The first photocal value after lamp replacement date is updated is saved automatically
as a reference value.
View the Photocal Results
8-14
1.
An audible alarm will sound if a cuvette fails the photocal.

Example: 5202 Cuvette Mean Check Error
2.
From the AU480 Home screen select A n a l y z e r M a i n t e n a n c e , and then the Photocal
Monitor tab. Look for failed cuvettes.
a.
Cuvettes failing the Mean Check appear in red.
b.
Cuvettes failing the Cuvette Check appear in green.
c.
Cuvettes failing the Photometer Check appear in orange.
Maintenance
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July 24, 2009
Correct Photocal Failures

Cuvette numbers displayed in color failed the photocal check.
TIP
If a cuvette displays in red, it failed the Mean Cuvette Check. It is most likely
contaminated or stained and could possibly be cleaned and reused.
If a cuvette displays in green, it failed the Internal Cuvette Check (Cuvette
Check). It is most likely scratched and will need to be replaced.
If cuvettes display in orange, the photometer lamp is deteriorating and

needs to be replaced. Refer to Section 8.5.10 Replace the Photometer
Lamp.
3.
Remove the cuvettes where an error was indicated. If a cuvette failed the Mean Check, inspect
the surface for stains, wipe the outside surfaces with a kimwipe, and replace the cuvette in its
original position. If the cuvette failed the Internal Cuvette Check and a scratch is apparent,
replace the cuvette with a new one and continue.
4.
Select the Maintenance Tab.
5. Select P h o t o c a l ( F 7 ) . The P h o t o c a l S t a r t dialog box displays.

6. Select C u v e t t e s N o . and then enter the cuvette number to be checked. This will require 4
minutes to complete.
7.
Repeat steps under the View Photocal Results heading.
8.
If the same error occurs even after the surface is wiped, replace the cuvette with a new one and
repeat the photocal check beginning with step 3 in this procedure.
For details on removal and replacement of cuvettes, refer to 8.5.2. Replacing Cuvettes.
TIP
In order to print photocal results, go to the Photocal Monitor tab. Select

P r i n t ( F 8 ) and then O K .
Perform W2 and Photocal in Conjunction with an End Process
TIP
The W2 and photocal may be completed over night as part of a shut down/
start up procedure.
1.
Start the W2 as specified above.
2.
Return to the Home menu, and perform an E n d P r o c e s s . Press the E n d P r o c e s s

key.
3.
Program the instrument to automatically start up. Press the S e t t i n g button.
4.
At Auto Start up, select Ye s .
5.
Enter the date and time for the instrument to start up. Allow for the 20 minute warm up to
complete before the 23 minute photocal starts. (43 minutes total before the instrument is needed
for daily operation.)
6.
At with Auto Preparation, select Ye s .
7.
Press the C o n f i r m button.
8.
At the Power Off prompt, select Ye s . The instrument will power itself down.
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July 24, 2009
Maintenance
8-15
8.2.3
Clean the Sample Pre-diluent Bottle
Bacterial contamination could result from an exposed bottle of pre-dilution solution (DI Water) sitting
on the analyzer without being periodically cleaned.
Materials Needed:
60 mL reagent bottle (optional)
10% Bleach
8-16
1.
2.
Ensure the system is in Standby Mode.
3.
Remove the pre dilution bottle from the analyzer and dispose of its contents.
4.
Wash the sample pre dilution bottle by filling it with 10% bleach.
5.
Rinse well using DI water.
6.
If an extra 60 mL bottle was obtained, fill it with DI water and place it on the analyzer while the
original bottle is more thoroughly rinsed and allowed to dry. Alternate the weekly use of each
bottle. If an extra bottle was not obtained, the original may be replaced so long as the scent of
bleach has been rinsed away.
Maintenance
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July 24, 2009
8.3 Monthly Maintenance

To obtain the highest level of performance from the system perform the following maintenance
procedures on a montly basis.
Maintenance routines
Perform the following tasks monthly:
8.3.1
Clean the Sample Probe and Reagent Probe Wash Wells ...........................8-18
8.3.2
Clean the Mix Bar Wash Wells.......................................................................8-19
8.3.3
Clean the Wash Nozzle Unit and Check the Tube Mounting Joints...............8-21
8.3.4
Clean the Deionized Water Tank, DI Filter, and Sample Probe Filter.............8-25
CAUTION

procedure. To avoid injury and infection, observe and follow all the WARNINGS and
CAUTIONS throughout this Users Guide.
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July 24, 2009
Maintenance
8-17
8.3.1
Clean the Sample Probe and Reagent Probe Wash Wells
Probe wash wells clean the outside surface of the probe by rinsing each probe tip in DI water. Dirty
wash wells could result in improperly cleaned probes, which could contaminate reagents or samples.
To maintain the reliability of the instrument and prevent contamination, clean the wash wells once each
month.
Materials Needed:
Squirt bottle with freshly prepared 10% bleach
Cotton swab
1.
2.
3.
4.

5. Select C l e a n i n g Wa s h Ta n k , and then select O K .
8-18
6.
Press the green, TA B L E R OTAT I O N / D I A G button. All probes move from their home
positions over the wash wells to hover over the cuvettes.
7.
Dispense 10% bleach into the sample probe and reagent probe wash wells.
8.
Use a cotton swab to clean each well. Use a different cotton swab for each wash well to avoid
spreading any contamination.
9.
Press the green, TA B L E R OTAT I O N / D I A G button. The probes re-position

themselves over the wash wells.
Maintenance
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July 24, 2009
Reagent probe
Reagent probe
wash station
TABLE ROTATION
/DIAG button
Sample probe
Sample probe wash station
10. Select P r i m e Wa s h i n g - l i n e from the M a i n t e n a n c e O p e ra t i o n buttons,

then O K , and then press the TA B L E R OTAT I O N / D I A G button. This primes water
through the wash wells to rinse the bleach out.
Avoid spilling the bleach outside the wash station. If spilled, wipe it off
immediately.
CAUTION
While cleaning the inside of the wash well, avoid touching the sample and
reagent probe.
11. Deselect the A n a l y z e r M a i n t e n a n c e check box when the cycle is complete.
8.3.2
Clean the Mix Bar Wash Wells
Mix bar wash wells clean the outside surface by washing each mix bar in 1% wash solution, then
rinsing each one in DI water. Dirty wash wells could result in improperly cleaned mix bars, which could
lead to carryover problems. To maintain the reliability of the instrument and prevent contamination,
clean the wash wells once each month.
Materials:
Squirt bottle with freshly prepared 10% Bleach
Cotton swabs
1.
2.
3.
From the AU480 Home screen, select Analyzer Maintenance.
4.

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July 24, 2009
Maintenance
8-19
5.
Turn the mix unit so the mix bars are not over the wash wells.
6.
Dispense 10% bleach into each of the two wash wells while cleaning them with a cotton swab.
Use a different cotton swab for each wash well to avoid spreading any contamination.
Mix bar
Mixing unit
Mix bar wash station
TABLE ROTATION
/DIAG button
CAUTION
7.
Avoid spilling the sodium hypochlorite solution outside the mix bar wash station. If it is
spilled, wipe it up immediately.
Turn the mix bar units so the mix bars are over the wash wells.
8. Select Re p l a c i n g M i x i n g B a r , specify the number of cycles and then O K . Press the

TA B L E R OTAT I O N / D I A G button.
The mix bar wash wells rinse themselves by dispensing DI water into the wells.
9.
8-20
Close the main cover.
Maintenance
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July 24, 2009
The shapes of the mix bars differ between mix types/times. Note the placement of
each mix bar shape in the following diagram.
R1 and S positions: spiral shaped mix bar (MU9599)
CAUTION
R2 positions: L shaped mix bar (MU8267)

mix bar for R1 and S
R1
mix bar for R2
S
R2
R2
4
R1
mix bar for R2
mix bar for R1 and S
8.3.3
Clean the Wash Nozzle Unit and Check the Tube Mounting
Joints
The wash nozzle unit consists of eight nozzles, responsible for aspirating liquid out of the cuvettes,
and dispensing liquid into the cuvettes. If any of the nozzles become clogged, their functionality may
suffer, resulting in inefficient cleaning of the cuvettes.
The tube mounting joints should be inspected for cracks or leaks. If any damage exists, the aspiration
and dispense by nozzles could be affected.
Materials:
Dry, clean cloth or paper towel
Sonicator filled with deionized water
Removing the wash nozzle station and checking the tube mounting joints
1.
2.
Ensure the system is in Standby or Warm up mode.
3.
From the AU480 Home screen select A n a l y z e r M a i n t e n a n c e .
4.

5. Select Re p l a c i n g Wa s h N o z z l e , and then O K .

6.
Press the TA B L E R OTAT I O N / D I A G button. The liquid in the tubes is drained.
CAUTION
Always drain the water remaining in the wash nozzles before cleaning or replacing
the tube mounting joints. If any tube mounting joint is loosened without draining the
remaining water, the water will spill out of the nozzle.
7.
Open the rear cover.
8.
Loosen the four grey manifolds and remove them from their mounting positions.
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July 24, 2009
Maintenance
8-21
CAUTION
A total of six O-rings are used inside the water supply tube mounting joint of the
wash nozzle station. When the joints have been removed, make sure that there
are six O-rings inside the joint. If an O-ring is missing, check the back of the joint
to ensure the O-ring is not stuck, or the area around the tube mounting joint. If it
cannot be found, install a new O-ring (MU9638) in the place concerned.
When loosening the knob on the wash nozzle station, do not loosen the
positioning screws on either side of the knob. These screws are used for
positioning the wash nozzle station.
For detailed information about cleaning or replacing an O-ring of the tube mounting joint, refer to
section 8.8.1 Replace O-rings in the Wash Nozzle Supply Tube Mounting Joints in this chapter.
Tube mounting joint
(A total of six O-rings are
used inside the tubes)
Wash nozzle
station
Knob
Positioning screws
Rear cover
9.
Loosen the silver knob holding the wash nozzle unit in place. Loosen the knob until it stops
turning. Lift the was nozzle up over the fitting screws. Be careful not to bump or bend the
nozzles.
10. Remove the wash nozzle unit along with the tubing and inspect the joints for cracks. If a crack is
found the joint should be replaced. For details refer to 8.5.5 Replace the Wash Nozzle Joint.
wash nozzle joint
Tubes
Wash nozzle station
8-22
Maintenance
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July 24, 2009
When cleaning the wash nozzle station using an ultrasonic cleaner, avoid
damaging the wash nozzles.
CAUTION
When mounting the wash nozzle station do not bring the nozzle tips into contact
with the cuvette wheel cover.
11. Sonicate the wash nozzle unit in deionized water for 15 minutes. Only the nozzle portion needs
to be submerged. Take care not to get the springs above the nozzles wet. If water does get into
the springs, dry them well using a towel or canned air.
12. Remove the wash nozzle unit from the sonicator and dry the nozzles thoroughly.
TIP
The ultrasonic cleaner is recommended for cleaning the wash nozzles. If an

ultrasonic cleaner is not available, use tap water. While pouring water into the wash
nozzles, clean each nozzle hole using the supplied mandolin string.
After washing in water, wipe up water drops using a absorbent paper.
13. Inspect the O-rings of the manifolds. Check that all six O-rings are properly inserted in individual
grooves. Verify that they are not ripped or overstretched. Look for dust or detergent crystals
around each O-ring. If faults are found with O-rings they should be replaced. For detailed
procedures on cleaning or replacing an O-ring of the tube mounting, refer to 8.5.1 Replacing
O-rings in the wash nozzle tube mounting joints.
Verify that the following precautions are followed to ensure tests are performed
correctly and avoid unexpected system damage.
CAUTION
When installing the tube mounting joints, verify that the joints are in the right
position.
When attaching a wash nozzle to the tube mounting joint tighten the wash
nozzle station firmly. If the wash nozzle station is securely tightened, water leaks
will result.
Make sure any tubes that run from the nozzles or tube mounting joint are not
missing.
Do not damage any of the joints and tubes. Damaged parts may cause leaks
and contaminate or flood the cuvette.
14. Replace each of the manifolds into its original position. Match the colored dot on the manifold
with the one next to its position. Tighten the manifolds without cross threading them. Also take
care not to over tighten them.
15. Close the rear cover.
16. Select P r i m e Wa s h i n g - l i n e from the M a i n t e n a n c e O p e ra t i o n buttons,
and select O K . Then press the green TA B L E R OTAT I O N / D I A G button to start the
function. The air in the tubing is purged as the wash nozzle unit moves up and down. Verify this
movement is completed without interference.
17. Close the Main Cover.
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July 24, 2009
Maintenance
8-23
Tubing Diagram
Follow the diagram to reconnect any broken or disconnected tube mounting joints.
Tube mounting joint
Wash nozzle station
6
1
3
Wash
nozzles
4
5
6
Knob
7
8
2
4
6
1
3
4
6
1
7
8
8-24
Maintenance
4
6
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July 24, 2009
8.3.4
Clean the Deionized Water Tank, DI Filter, and Sample

Probe Filter
The deionized water filter and sample probe filter are used to prevent particles from entering the
internal deionized water system.
The deionized water tank must be cleaned to avoid bacterial contamination of the system.
Materials Needed:
Dry, clean cloth
Basin
Sonicator filled with Deionized water
Extra deionized water tank, filled with 5 L of DI water
Remove the Deionized Water Tank

1.
Perform an E n d P r o c e s s .
2.
Open the left door.
3.
Position a basin on the floor under the DI water tank to catch spilled water.
4.
Unplug the black float sensor cable.
5.
Press the grey button of the quick disconnect on the front of the tank and remove the tube.
6.
Pull the DI water tank out of the analyzer. Make sure the four tubes clear the top of the tank and
wrap them in a clean cloth.
7.
Unscrew the cap of the tank and remove the float sensor.
8.
Place it into the new DI water tank filled with 5L of DI Water and tighten the cap.
9.
Remove the filter case over the basin by unscrewing it. Water will drip from it.
10. Remove the DI water filter from its case and place it into the sonicator.
Water supply tube
Filter case
Deionized water filter
Drainage pan
Cap of filter case
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July 24, 2009
Maintenance
8-25
Cleaning and attaching the sample probe filter 8-39

11. Locate the sample probe filter case directly to the left of the DI water tank and remove it from the
bracket.
12. Press the grey button of the quick disconnects and pull to remove the tubes from the top and
bottom of the filter case.
13. Unscrew the filter case over the basin and remove the sample probe filter.
O-ring
Sample probe filter

Filter case
14. Place the sample probe filter in the sonicator.

15. Sonicate the DI water filter and the sample probe filter in DI water for 10 minutes.
When working with the sample probe filter, do not lose the O-ring.
CAUTION
16. Reinsert the DI water filter into its case and tighten.
17. Reinsert the sample probe filter into the filter case.
Filter Positioning
Insert
Filter
O-Ring
Case
Top
18. Tighten the filter case firmly.
CAUTION
Do not connect the filter case to the joints upside down.

If the filter case is connected upside down, debris, will cause a data error.
19. Reconnect the quick disconnects by forcing the tubes into their connections until a distinct click is
heard.
20. Fit the filter case into its retainer.
8-26
Maintenance
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July 24, 2009
Replace the Deionized Water Tank

1.
Place the new DI water tank filled with 5 L of deionized water into its position. Reinsert all water
supply tubes into the top of the tank and push it back into place.
2.
Reconnect the quick disconnect by forcing the tube into its connection until a distinct click is
heard.
3.
Plug the float sensor connector into its outlet.
4.
Wipe any spilled water from the analyzer surface and remove the basin.
5.
Press the O N button. The system powers up and initializes.
6.
From the AU480 home screen, select A n a l y z e r M a i n t e n a n c e .
7.

8. Select P r i m e Wa s h i n g - l i n e , and then O K .

9.
Press the Ta b l e Ro t a t i o n / D a i g b u t t o n . Watch as the prime is performed. Repeat

the prime if necessary by pressing the green TA B L E R OTAT I O N / D I A G button again
until all bubbles are removed from the line.
10. Deselect the check box next to A n a l y z e r M a i n t e n a n c e to exit the menu.

11. Close the door.
Cleaning the Deionized Water Tank

Materials Needed:
Dry, clean cloth
Basin
Deionized water
Deionized water tank postion 8-50
1.
Discard the DI water in the used tank.
2.
Clean that tank with 20% bleach.
3.
Rinse the bleach thoroughly using DI water and set aside to allow the tank to dry.
Deionized water tank
Connector
Joint
Deionized water drainage hose
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July 24, 2009
Vessel
Maintenance
8-27
Removing the deionized water tank 8-50
Cap
Float switch
Deionized water tank
Tube
CAUTION
8-28
Be sure to fill the deionized water tank with 5 L of deionized water before turning the
system power to on. If the pump is idled when the tank is empty, a malfunction may
result.
Maintenance
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July 24, 2009
8.4 Quarterly Maintenance

To obtain the highest level of performance from the system perform the following maintenance tasks
on a quarterly basis (every three months).
Maintenance routines
Perform the following tasks every three months:
8.4.1
Clean the Air Filters........................................................................................8-30
8.4.2
Replace the Wash Solution Roller Tube.........................................................8-31
CAUTION

procedure. To avoid injury and infection, observe and follow all the WARNINGS and
CAUTIONS throughout this Users Guide.
AU480 User Guide

July 24, 2009
Maintenance
8-29
8.4.1
Clean the Air Filters
The four air filters prohibit dust and other contaminates from entering the system.
Do not run the instrument without filters in place.

CAUTION
1.
Remove the air filters from the lower left side and rear of the instrument, according to the
diagram below.
Air Filters
8-30
2.
Vacuum the dust from the filters.
3.
Replace them in their original positions.
Maintenance
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July 24, 2009
8.4.2
Replace the Wash Solution Roller Pump Tubing
The roller pump tubing will stretch and deteriorate over time. It should be replaced every three
months.
CAUTION
When attaching or detaching the roller pump tubing, wear gloves to prevent hands
from coming in contact with concentrated wash solution detergent. Avoid splashing
the liquid in the tube over the peripheral area. If hands or clothing come in contact
with the liquid, wash with water immediately. If the concentrated wash solution
comes into contact with the eyes or mouth, wash with water and consult a doctor
immediately.
Materials:
Roller pump tubing MU9623
1.
Open the left door.
2.
Ensure the system is in Standby Mode
3.
4.

5. Select Re p l a c i n g Ro l l e r p u m p t u b i n g from the m a i n t e n a n c e

o p e ra t i o n buttons and then select O K .
6.
Press the TA B L E R OTAT I O N / D I A G button.

The pump reverses its direction, clearing the line of detergent.
AU480 User Guide

July 24, 2009
Maintenance
8-31
Rounding direction of roller pump

(Normal)
roller tube
Wash solution
roller pump
7.
Remove the tube from the pump by gripping the connection at the bottom and gently pulling
down and out of the bracket. Disconnect the rolling tube from the detergent tube by twisting the
connectors in the counter clockwise direction.
Roller tube
Wash solution
roller pump
ID No.
ID No.
TABLE ROTATION
/DIAG button
Roller tube connectors
Relay tubes
8.
Replace the used rolling pump tubing with a new one by twisting the connectors together in the
clockwise direction.
9.
Match the numbers on the detergent tubes with the numbers on the bracket of the pump. Insert
one end of the rolling pump tube under the bracket, and stretch it over the top of the pump, until
the other end fits under the other side of the bracket.
10. With the Re p l a c e Ro l l e r P u m p t u b i n g function still highlighted, press the

TA B L E R OTAT I O N / D I A G button. The roller pump rotates to refill the line with wash
solution.
11. Close the door.
8-32
Maintenance
AU480 User Guide

July 24, 2009
8.5 As Needed Maintenance

This section describes the procedures used to perform as needed maintenance.
As Needed Maintenance
8.5.1
Replace O-rings in the Wash Nozzle Tube Mounting Joints ..........................8-34
8.5.2
Replace the Cuvettes ....................................................................................8-35
8.5.3
Replace Sample Probe and Reagent Probe..................................................8-36
8.5.4
Replace Mix bars............................................................................................8-38
8.5.5
Replace the Wash Nozzle Joint .....................................................................8-39
8.5.6
Replace Syringes...........................................................................................8-42
8.5.7
Clean the Inside of the STAT Table Compartment and Reagent

Compartments................................................................................................8-46
8.5.8
Clean or Replace the Antistatic Brushes........................................................8-47
8.5.9
Replace the Sample and Reagent Probe Tubing ..........................................8-48
8.5.10 Replace the Photometer Lamp ......................................................................8-48

8.5.11 Clean Cuvettes and the Cuvette Wheel ........................................................8-51
8.5.12 Clean the Probes and Mix Bars......................................................................8-55
8.5.13 Replace the Deionized Water Filter and Sample Probe Filter........................8-58
8.5.14 Perform a W1 Procedure................................................................................8-59
CAUTION

procedure. For precautions against other than infection, observe the descriptions of
WARNING and CAUTION given in this User Guide.
AU480 User Guide

July 24, 2009
Maintenance
8-33
8.5.1
Replace O-rings in the Wash Nozzle Tube Mounting Joints
The wash nozzle tube mounting joint supplies water and wash solution to the wash nozzles to clean
and rinse the cuvettes. The O-rings provide a seal to this connection. O-rings must be replaced as
needed, if any leaks are observed.
Materials Needed:
O-rings MU9638
Dry, clean cloth or absorbent paper
Replacing O Rings 8-64
Pair of tweezers
O-ring
1.
Remove the wash nozzle unit. For details refer to section 8.3.3 Clean the Wash Nozzle Unit and
Check the Tube Mounting Jpints.
2.
Using the pair of tweezers, remove each O-ring from its position.
3.
Wipe away any crystallization or foreign matter found around O-ring receptacles.
4.
Set new O-rings into their receptacles.
5.
Replace the wash nozzle unit. For details refer to 8.3.3 Clean the Wash Nozzle Unit and Tube
Mounting Joints.
6.

7. Select P r i m e Wa s h N o z z l e and then O K .

8.
Push the green TA B L E R OTAT I O N / D I A G button. Watch the tube mounting joints for
leaks. If a leak is encountered, open the joint cover and reseat every O-ring.
9.
CAUTION
8-34
If the O-rings are used for an extended period of time without being cleaned or if
the joint cover has been closed without the O-rings set properly in each groove,
detergent crystals will generate, causing scratches on cuvettes. Be sure to check
the O-rings along with the monthly maintenance of the wash nozzle station.
Maintenance
AU480 User Guide

July 24, 2009
8.5.2
Replace the Cuvettes
Stained or scratched cuvettes cause errors in photometric analysis. Upon completion of the photocal
procedure, replace cuvettes that have been flagged as failing.
WARNING
Avoid mixing cuvettes when replacing or cleaning them in laboratories with

multiple Beckman Coulter analyzers other than the AU480. The AU480 utilizes a
cuvette (Part No. MU8465) with a smaller interior sample size (5X5mm) than other
Beckman Coulter analyzers (5X6mm). Use of a Non AU480 cuvette on the AU480
analyzer will result in erronous results.
Materials Needed:
MU8465
Other
Cuvettte MU8465
Neutrad part # Fisher 0435510
Cotton tip applicators
CAUTION
Verify that all the removed cuvettes are replaced without any omission. If one of
the cuvettes is missing, the mixture, reagent, or detergent will spill into the cuvette
wheel causing a flood, hampering the analysis to be successfully performed.
When replacing cuvettes on the cuvette wheel, be careful not to scratch the
cuvettes. To ensure correct photometric analysis, avoid getting fingerprints on the
photometric surface of the cuvettes.
1.
Ensure the system is in Warm up, Standby , or Stop Mode.
2.
Open the main cover and the rear cover.
3.
Loosen the knob of the wash nozzle station. Without disconnecting the tubing, remove the
nozzle portion from its stand and hang it on the nearby hook.
4.
Manually rotate the mix bar units approximately 60 degrees so they are not over the cuvette
cover.
5.
Lift the cuvette wheel cover, carefully remove it from the instrument, and set aside.
6.
Locate the failed cuvette. Every 10th cuvette is numbered.
7.
Gently insert a cotton tipped applicator into the cuvette to be removed and lift out of the wheel.
8.
Determine if the cuvette needs to be replaced or cleaned.

To replace individual cuvettes: Insert the new cuvette into the wheel. Gently push the
cuvette completely into the wheel.
To clean individual cuvettes: Sonicate cuvettes in a 2% Neutrad solution for 15 minutes.
AU480 User Guide

July 24, 2009
Maintenance
8-35
If a sonicator is not available, soak them in a 5% Neutrad solution overnight. Rinse the
cuvette in DI water. Allow the cuvettes to dry completely.
9.
Replace the new or cleaned cuvette into its position.
10. Replace the cuvette wheel cover.

11. Manually turn the mix bar unit back to its original position.
12. Replace the wash nozzle unit.
13. From the AU480 Home screen, select A n a l y z e r M a i n t e n a n c e .
14. Place a check mark in the box next to the A n a l y z e r M a i n t e n a n c e option. The
15. Select P r i m e Wa s h N o z z l e , and then O K . Press the green TA B L E
R OTAT I O N / D I A G button. Watch as the wash nozzle moves, and verify the downward
motion is not inhibited.
16. Perform a Photocal on the individual cuvette. Refer to 8.2.2 Perform a Photocal.
8.5.3
Replace Sample Probe and Reagent Probe
The probes deliver precise quantities of either reagent or sample to the cuvettes. If they are clogged,
bent, or damaged, correct analysis could be affected. If the probes are still contaminated after
cleaning, replace them.
Materials Needed:
Sample probe, MU9934
Reagent probe, MU9958
1.
Ensure the system is in Warm up, Standby , or Stop Mode.
2.
3.
Unscrew the silver connector above the probe.
4.
Allow water to drip from the probe, then lift the probe from the arm.
Reagent probe connectors

Reagent probe
Probe connector
Sample probe
Sample probe wash station
5.
8-36
Place the new probe into its position and tighten the silver connector over the top.
Maintenance
AU480 User Guide

July 24, 2009
Ensure that the proper probe type is chosen. The sample probe has a
smaller diameter than the reagent probe.
TIP
6.
Tighten the probe connector to attach it to the sample probe or reagent probe. Be sure to tighten
the connector firmly so that no liquid will leak from the joint.
7.
8.

9.
In order to replace the sample probe, select Re p l a c i n g S a m p l e P r o b e . In the start

dialog box specify the desired number of cycles and then select O k . (One cycle should be
sufficient).
10. Start operation by pressing the green TA B L E R OTAT I O N / D I A G button. DI water will
be dispensed from the probe tip. Verify that the DI water is dispensed in a thin straight stream. It
should not spray or dispense at an angle.
11. Deselect the check in the box next to A n a l y z e r M a i n t e n a n c e .
12. Close the main cover.
TIP
Analyze quality control material, and check the data.
AU480 User Guide

July 24, 2009
Maintenance
8-37
8.5.4
Replace Mix Bars
Replace the mix bars if they are stained, damaged, or if the teflon coating is chipped.
Materials Needed:
4 R1/S: spiral shape mix bar, part #MU9599
2 R2: L shape mix bar, part # MU8267
1.
Check that the system has entered the Warm up mode or Standby mode.
2.
3.
Pull out the mix bar to be replaced.
Mix bar
Mixing unit
Do not scratch the mix bar when inserting the mix bar into the mix unit.
CAUTION
4.
Insert a new mix bar into the mix unit. After inserting the mix bar, rotate it slightly to engage the
notch on the mix bar with the gear in the hole of the mix unit.
TIP
5.
8-38
Insert the spiral shaped mix bars into the positions marked R1 and S. Insert the L
shaped mix bars into the positions marked R2.
Maintenance
AU480 User Guide

July 24, 2009
8.5.5
Replace the Wash Nozzle Joint
If a wash nozzle joint is damaged or cracked, leaks or insufficient aspiration of a cuvette may occur.
To avoid errors, immediately replace the damaged wash nozzle joint.
Materials Needed:
Wash nozzle joint, ZM1131 (3 pieces per set)
1.
2.
3.
4.

Removing the wash nozzles 8-71
m a i n t e n a n c e o p e ra t i o n buttons become functional
5. Select Re p l a c i n g Wa s h N o z z l e , and then O K .

6.
Press the TA B L E R OTAT I O N / D I A G button. The liquid in the tubes is drained.
7.
Loosen the four grey manifolds and remove them from their mounting positions.
Tubes
Wash nozzle station
Knob
Rear cover
AU480 User Guide

July 24, 2009
Tube mounting joint
Maintenance
8-39
CAUTION
8.
When loosening the knob on the wash nozzle station, do not loosen the positioning
screws on both sides of the knob. These screws are used to position the wash
nozzle station.
Loosen the silver knob holding the wash nozzle unit in place. The knob should be loosened to
the extent it allows the wash nozzle unit to be lifted up and over the fitting
screws. Take care not to bump or bend the nozzles.
Tubes
Knob
Tube mounting joint
Tube mounting
joint
A total of six
pieces of
O-rings are
used inside
the tubes
Positioning pin
Wash nozzle
station
FFRR
OONT
T
Wash nozzle joint

Tube
Wash nozzle joint

ZM1131
Wash nozzle
station
9.
Remove the wash nozzle unit along with the tubing and place it on an appropriate surface such
as a table.
10. Remove the wash nozzle joint to be replaced.
8-40
Maintenance
AU480 User Guide

July 24, 2009
Cross-sectional View
Wash nozzle station
Position both
ends of the tube
and nozzle in the
center of the wash
nozzle joint
Tube
Wash nozzle
joint
Approx. 1mm
Nozzle
11. Insert the new wash nozzle joint onto the open end of the tube, and then insert the nozzle
into the other end of the wash nozzle joint. Center the tube and nozzle in the joint, allowing
approximately 1 mm between them.
12. While holding tubing and manifolds clear, replace the nozzle portion of the wash nozzle unit. Fit it
over the fitting screws and hold it in place while tightening the silver knob.
13. Replace each of the manifolds into its original position. Match the colored dot on the manifold
with the one next to its position. Tighten the manifolds without mis-threading the grooves. Also,
take care not to over tighten them.
15. In the software, select P r i m e Wa s h N o z z l e , and then O K .
16. Press the green TA B L E R OTAT I O N / D I A G button. The air in the tubing is purged
as the wash nozzle unit moves up and down. Verify this movement is completed without
interference.
AU480 User Guide

July 24, 2009
Maintenance
8-41
8.5.6
Replace Syringes
If a leak, crack, or any other damage is found when the syringes are inspected, the syringe must be
replaced. If syringe performance is questionable because of abnormal data, remove and check the
syringe.
Replace a syringe when:
Pulling on the piston, the syringe is hard to loosen and the movement is no longer smooth
with a little resistance.
The Teflon tip is worn or damaged.
There are leaks around the syringe even after proper installation.
The head of the syringe is cracked.
Materials Needed:
Sample syringe, ZM0111
Reagent syringe, ZM0112
Kimwipe or lint free paper
Remove the Syringe
8-42
1.
Ensure the system is in Warm up, Standby, or Stop Mode.
2.
Open the right door.
3.
Loosen the bottom fixing screw.
4.
Loosen the top fixing screw.
Maintenance
AU480 User Guide

July 24, 2009
5.
Pull the syringe case forward to remove it from the mounting grooves. Invert the syringe unit.
Fixing nut
Mounting groove
Fixing screws
Syringe case
Mounting groove
Piston fixing screw
Case head
O-ring
Syringe
ZM0111/ZM0112
Syringe case
When removing the syringe case do not apply excessive force to the fixing
screws, the syringe case may be damaged.
CAUTION
6.
Be careful not to bend the tube when removing the syringe case.
Remove the syringe case by holding the case head and twisting the syringe case counter
clockwise. Slide the case off the syringe.
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July 24, 2009
Maintenance
8-43
Removing a syringe 8-76
7.
Pull the syringe from the case head. If the O-ring remains in the case head, carefully remove it
with tweezers.
Case head
O-ring
Syringe
Syringe
case
Installing a New Syringe

Replacing a syringe 8-77
1.
Insert the new syringe into the case head.
2.
Dry excess water from the syringe and case head to prevent condensation form forming in the
case.
3.
Replace the syringe case by twisting clockwise on to the case head. Do not over tighten.
Fixing screw
Case head
Syringe case
Mounting groove
4.
8-44
Re-install the syringe and secure the top fixing screw first and then tighten the bottom fixing nut.
Maintenance
AU480 User Guide

July 24, 2009
Priming New Syringes

New syringes must be primed :
1.
From the AU480 home screen, select A n a l y z e r M a i n t e n a n c e .
2.

3.
After replacing the sample syringe select Re p l a c i n g S a m p l e S y r i n g e . In the start

dialog box verify Times displays with 260 cycles and then select O k . The sample syringe
prime could take up to 32 minutes to complete.
In order to replace the reagent syringe, select Re p l a c i n g Re a g e n t P r o b e /

S y r i n g e . In the start dialog box specify the desired number of cycles and then select O k .
Repeat the prime until all bubbles are cleared from the syringe.
4.
Press the TA B L E R OTAT I O N / D I A G button. DI water will prime the lines.
5.
Close the right door.
TIP
Analyze quality control material, check the data, re-calibrate if necessary.
AU480 User Guide

July 24, 2009
Maintenance
8-45
8.5.7
Clean the Inside of the STAT Table Compartment and

Reagent Compartments
Due to exposure to outside air, condensation will form inside the STAT table and reagent
compartments. Be sure to keep the STAT table and reagent compartment covers in place to diminish
the amount of condensation formed.
Clean the inside of compartments when a reagent or sample is spilled, or as needed after inspection.
Materials Needed:
TIP
If bacterial contamination is suspected, or mold is observed, call Beckman Coulter

Technical Services for the proper decontamination procedure.
Dry, clean cloth
Clean the Inside of the STAT Table Compartment

1.
Remove the STAT Table cover.
2.
By hand, loosen the two fixing screws near the center of the STAT Table. Remove the STAT Table
while lifting up the central column. Place the STAT Table gently on a safe place.
3.
Wipe off the condensation and stains on the wall, bottom, and central area inside the STAT Table
unit with a dry clean cloth.
4.
Replace the STAT Table to its original position, tighten the two fixing screws near the center with
fingers.
5.
Replace the STAT Table cover.
Clean the Inside of the Reagent Compartments
8-46
1.
Remove the reagent refrigerator lid.
2.
Remove the reagents along with the reagent tray by lifting the white securing pins until they
unclip from the base, and gently place the tray in a safe place.
3.
Wipe off the condensation and stains on the wall, bottom, and central area inside the reagent
compartments with a dry clean cloth.
4.
Return reagents and reagent tray to its original position.
5.
Replace the reagent refrigerator lid.
Maintenance
AU480 User Guide

July 24, 2009
8.5.8
Clean or Replace the Antistatic Brushes
Static discharge brushes reduce the chance of static electricity affecting a sample reading by allowing
static electricity to discharge before sampling takes place.
CAUTION
To avoid infection always wear latex gloves to clean or replace the static discharge
brushes. If your hands come in contact with the static discharge brushes, wash the
affected area thoroughly.
Materials Needed:
2 Antistatic brushes MU8525
1.
Select the S t o p key or icon to place the analyzer in a STOP mode.
2.
Remove the dark acrylic cover from the rack transport area over the cup detector and barcode
reader
area. the Antistatic brush 8-81
Replacing
3.
Loosen the static discharge brush screws by turning them gently counter clockwise until they stop
turning. The screws will not come off the analyzer.
4.
Lift the brush assembly out of the instrument by tilting the bottom of the static discharge brush
away from the static brush housing, then, lift it up and out clearing the mounting hole for the flat
mounting pin located on the side of the static discharge screw.
Antistatic brush
5.
Follow the same procedure with the brush assembly on the other side of the rack transport.
6.
Clean any stains on the brushes with an alcohol prep from the base to the end of the bristle tips.
7.
If the static discharge brushes are still stained after cleaning or show signs of wear, replace them.
8.
Dispose of the old brushes in a receptacle for biohazard waste.
9.
Reinstall the clean or replaced brushes, making sure the flat mounting pins on the static
discharge housing fit into the mounting holes on the brush assembly.
10. Tighten the brush screws on each assembly.

11. Replace the dark acrylic cover from the rack transport above the cup detector and barcode
reader area.
12. Select the Stop key or icon to place the analyzer in warm up or standby mode.
AU480 User Guide

July 24, 2009
Maintenance
8-47
8.5.9
Replace the Sample and Reagent Probe Tubing
Replace the sample or reagent probe tubing if the tubing leaks or breaks.
To replace the tubing of the sample probe and reagent probes:
Materials:
Sample Probe Tube MU0262,
Reagent Probe Tube MU0261,
Before disconnecting the tube, verify the probe is positioned over the wash well. Dripping will occur.
1.
Verify that the system is in Warm up or Standby mode.
2.
3.
Loosen the connectors on both sides of the probe tubing to remove it.
4.
Tighten the new tubing connectors to secure each probe and joints. Tighten the connectors firmly
to ensure that no liquid leaks from the joints.
5.

Reagent
Probe Tube
Sample
Probe Tube
8.5.10 Replace the Photometer Lamp

Over time the intensity of the photometer lamp will diminish and results will be affected. The lamp is
under warranty for 1,000 hours.
After replacing the lamp, a photocal is required to evaluate the quality and intensity of the new lamp.
Replace the lamp when a cuvette(s) displays in orange for Lamp Check Error in the Photocal Monitor
menu, or when troubleshooting indicates the lamp.
8-48
Maintenance
AU480 User Guide

August, 2010
Procedure for Replacing the Photometer Lamp

Materials:
Photometer lamp MU9888
1.
Perform an E n d P r o c e s s . Allow the lamp to cool for a minimum of five minutes.
2.
When removing
the lamp unit
cover, avoid bumping the cover against the reagent
Photometer
lamp location
8-56
probe.
CAUTION
3.
Remove the lamp unit cover.
4.
Loosen the two terminals by turning the knobs counterclockwise. The lead wires should easily
separate from the terminal.
Knobs
Lamp holder
Lamp cords
Removing the photometer lamp 8-56

5.
Remove the lamp by turning the silver collar counterclockwise , then pull the lamp from its
mounting.
Photometer lamp
Lamp holder
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July 24, 2009
Maintenance
8-49
Photometer Detail 8-57
6.
Remove the black and silver collars from the lamp and keep them for future use.
7.
Discard the old lamp.
Protrusion
Lamp receptacle
Notch
Guide key
Collar notch
8.
Obtain a new lamp. Take care to handle it by the wires only. The bulb may be damaged if
touched.
9.
Slide the black, notched collar along the lead wires with the opening of the notch toward the rear
of the lamp. Align the notched collar with the notch of the lamps guide key.
10. Insert the lamp into the receptacle with the notches lined up on the top. They should slide into
the keyed protrusion of the receptacle.
11. Slide the silver collar along the wires behind the lamp and tighten to hold it in place.
12. Connect the two lead wires by sliding the end connection under the knob of the terminal. The
wires are interchangeable. Tighten the knobs.
13. Replace the lamp unit cover.
16. Press the O N button. The system powers up and initializes.
17. Allow the lamp 20 minutes to warm up and come to the proper intensity before completing the
procedure.
18. Perform a photocal. For details on starting a photocal refer to 8.2.2 Perform a Photocal.
TIP
8-50
Analyze quality control material, check the data, re-calibrate if necessary.
Maintenance
AU480 User Guide

July 24, 2009
8.5.11
Clean Cuvettes and the Cuvette Wheel
To ensure proper operation of the photometry system the cuvettes and the wheel must be clean. The
cuvettes are checked weekly during the Photocal procedure. This procedure is performed every 6
months by your Field Service Engineer as part of the Preventive Maintenance Service to keep the
cuvettes in optimal condition. Perform this procedure as needed if a wheel overflow occurs.
WARNING
MU8465
Materials:
Other
Cotton tip applicator

2% Neutrad
Sonicator
Paper Towel
Kimwipe or lint free cloth
Removing the Cuvette Wheel and Cuvettes

Remove
Wash
8-59 or Stop Mode.
1. Ensure
the system
is inNozzle
Warm station
up, Standby,
2.
Open the main and rear covers.

When handling a wash nozzle be careful not to damage the nozzle.
CAUTION
3.
When removing the wash nozzle station be careful not to bring the nozzle tips
into contact with the cuvette wheel cover.
Loosen the knob of the wash nozzle station. Without disconnecting the tubing, remove the
nozzle portion from its stand and hang it on the nearby hook.
Hook
Knob
Rear cover
4.
Wash nozzle station
Manually rotate the mix bar unit so it is not over the cuvette cover.
AU480 User Guide

July 24, 2009
Maintenance
8-51
Mixing unit
Cuvette wheel cover
The green positioning marks
N
FRO
CAUTION
5.
When removing the cuvette wheel cover, do not damage the sample probe, reagent
probe, and mix bars.
Lift the cuvette cover, carefully remove it from the instrument, and set aside.
When removing the cuvette wheel, avoid contact with peripheral devices.
CAUTION
Removing cuvettes 8-60
6.
Locate the two black knobs in the center portion of the cuvette wheel. Remove them from their
current positions and screw into holes located near the securing knobs but on the next level
down. Tighten the knobs into the holes to use as handles.
7.
Using the black knobs as handles, lift the cuvette wheel out of its compartment.
8.
Place the cuvette wheel on a protected surface to remove the cuvettes.

Cuvette
When removing cuvettes, do not scratch them.
CAUTION
To ensure correct photometric analysis, avoid getting fingerprints on the

photometric surface of the cuvettes.
Cotton Tip
Applicator
Cuvette
Photometric
face
Frosted
glass face
8-52
Maintenance
AU480 User Guide

July 24, 2009
WARNING

MU8465
9.
Other
Using the end of a cotton tip applicator, push each cuvette from the bottom to remove it from the
wheel. All 88 cuvettes must be removed. Exercise caution during this procedure! The cuvettes
may be scratched when they are removed from the cuvette wheel and subsequently will not pass
the photocal.
Cleaning the Cuvettes and Cuvette Wheel
CAUTION
1.
When cleaning cuvettes do not scratch them. If a cuvette is scratched, the

photometric data will be inaccurate.
Submerge all cuvettes in a beaker containing a 2% solution of Neutrad.
CAUTION
To wash the cuvette wheel, do not use any detergent. Otherwise, the metallic plating
on the cuvette wheel may be removed.
2.
Sonicate for 15 minutes.
3.
Thoroughly rinse the cuvettes in deionoized water, or sonicate them in deionized water for 10
minutes to remove any residual detergent.
4.
Allow the cuvettes to dry completely. Use one of the following methods:
5.
a. Allow cuvettes to dry naturally.

b. Use an oven with the heat set under 50 degrees Celsius (122 Fahrenheit). (A hair dryer
works well).
c. Use a Kimwipe or other lint free cloth.
Rinse the cuvette wheel with DI water and dry thoroughly with a clean cloth.
6.
Insert the cuvettes back into the wheel. Ensure the cuvette is gently pushed down completely
into the wheel.
AU480 User Guide

July 24, 2009
Maintenance
8-53
7.
Replace the cuvette wheel in its original position on the instrument. Align the numbers on the
wheel with the numbers on the instrument. Secure the wheel with the black knobs.
8.
Remove the knobs used as handles and return them to their holders in the center of the wheel.
9.
Replace the wheel cover. It will align over two pins.
10. Turn the mix bar unit back to its original position.
11. Remove the wash nozzle unit from the hook and screw it back into position.
8-54
Maintenance
AU480 User Guide

July 24, 2009
Check the System

1.
From the 480 home screen, select A n a l y z e r M a i n t e n a n c e .
2.
Place a check mark in the box next to A n a l y z e r M a i n t e n a n c e . The

3. Select P r i m e Wa s h N o z z l e and then O K .

4.
Push the green TA B L E R OTAT I O N / D I A G button. The wash nozzle tubing is primed
with DI water.
5.
Deselect the check next to A n a l y z e r M a i n t e n a n c e .
6.
7.
Perform a photocal. For details on how to execute a photocal measurement, refer to 8.2.2
Perform a photocal.
8.5.12 Clean the Probes and Mix Bars

If probe or mix bars become contaminated or stained, carryover between reagents or samples may
result. If there are stains or crystallization on the outside of the sample probe, reagent probes, or mix
bars, clean the part with an alcohol prep as needed.
CAUTION
To prevent contamination and ensure proper analysis and results, clean the sample
probe, reagent probe, and mix bars as needed.
The cleaning procedure for each probe is identical.

Materials Needed:
Alcohol Prep (70% Isopropyl alcohol)
1.
Ensure the system is in the Warm up , Standby or Stop Mode .
2.
AU480 User Guide

July 24, 2009
Maintenance
8-55
3.
Unscrew the silver connector above the probe.
4.
After all liquid drips from the probe, lift the probe from the arm.
5.
Wipe the tip of each probe with an alcohol prep.
TIP
If there is blockage in the probe, a stylet may be used. Carefully insert the
stylet into the probe tip to remove the blockage.
6.
Return the probe to its arm and tighten the silver connector over the top.
7.
Remove mix bars individually and wipe each with an alcohol prep.
Return each to its original position.
Mix bar
Mixing unit
Mix bar wash station
TABLE ROTATION
/DIAG button
TIP
CAUTION
8-56
Insert the two spiral-shape mix bars in the positions labeled R1/S and the four
L-shape mix bars in the positions labeled R2..
When replacing the sample probe, reagent probes, or mix bars, make sure the
probes or mix bars are not bent or damaged.
When inserting the mix bars into the mix unit, be careful not to scratch the bars.
8.
From the AU480 H o m e screen, select A n a l y z e r M a i n t e n a n c e .
9.
Place a checkmark in the box next to A n a l y z e r M a i n t e n a n c e the

Maintenance
AU480 User Guide

July 24, 2009
10. Select the P r i m e Wa s h i n g L i n e function.

11. Select O K and then start operation by pressing the green TA B L E R OTAT I O N / D I A G
button.
12. Watch each dispense to ensure the probes were reinstalled properly.
13. Deselect the check box next to A n a l y z e r M a i n t e n a n c e in order to exit the menu.
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July 24, 2009
Maintenance
8-57
8.5.13 Replace the Deionized Water Filter and Sample Probe Filter
The deoinized water and sample probe filters are used to collect various materials and debris from the
external water system and should be replaced.
Materials Needed:
Sample Probe Filter or Deionized Water Filter ZM3079
Basinand Mounting the deionized water filter 8-37
Cleaning
1.
Perform an E n d P r o c e s s .
2.
Open the left door.
3.
Position a basin on the floor under the DI water tank to catch spilled water.
4.
Pull the DI water tank out far enough to allow the tubes to be accessed.
5.
Remove the water supply tube.
6.
Remove the the filter case over the basin by unscrewing it. Water will drip from it.
Water supply
tube
Filter case
Deionized
water filter
Basin
Connector of rolling pump
8-58
7.
Remove the DI water filter from its case and replace it with the new one.
8.
Replace the filter case.
9.
Locate the sample probe filter case directly to the left of the DI water tank and remove it from the
bracket.
Maintenance
AU480 User Guide

August, 2010
O-ring
Sample probe filter

Filter case
10. Press the grey buttons of the quick disconnects and pull to remove the tubes from the top and
bottom of the filter case.
11. Unscrew the filter case over the basin and remove the sample probe filter and replace it with a
new one.
Filter Positioning
Insert
Filter
O-Ring
Case
Top
12. Tighten the filter case firmly.

13. Reconnect the quick disconnects by forcing the tubes into their connections until a distinct click is
heard.
14. Fit the filter case into its retainer.
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July 24, 2009
Maintenance
8-59
8.5.14 Perform a W1 Procedure

Perform a W1 (Cuvette Wash) on an as needed basis. The W1 cleans all cuvettes with 1% wash
solution using the wash nozzle unit. The sample probe, reagent probe, and mix bar unit are cleaned in
the wash wells.
As Needed
This procedure takes 9 minutes. View the upper left corner of the screen for procedure progress.The
system counts down the remaining time.
Perform this procedure when either of the following is true:

a. Stop is selected in the middle of a run, and analysis is not started again immediately.
b. Power was lost to the system during analysis, and not recovered in a short period of
time.
1.
From Standby, select the A n a l y z e r M a i n t e n a n c e jump button at the bottom of the

screen.
2.
Select function key F 5 : ( W 1 ) .
3. Select S t a r t .
8-60
Maintenance
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July 24, 2009
AU480 User Guide
April 14, 2010
Maintenance
8-61
Clean the Deionized

Water Tank, DI and
Sample probe Filters
Clean the Wash Nozzle

unit , and Check the tube
mounting joints
Clean the Mix bar Wash

Wells
Clean the sample and

reagent probe wash wells
Monthly
Maintenance
Perform a Photocal
Perform a W2
Clean Sample PreDilution Bottle
Weekly
Maintenance
Inspect and Replenish

the Wash bottles
Replace the DI Water in

the Pre-dilution Bottle
Check the printer and

paper
Inspect and clean the

mix bars
Inspect, Clean, prime

the Sample and Reagent
probes
Check the ISE Reagent

Syringe (Optional) for
leaks
Inspect the stability of the

upper cover
Inspect and Replenish

the Concentrated Wash
Solution
Inspect the Wash

Solution Roller pump Unit
for leaks
Inspect the Syringes for

leaks and proper
installation
Daily
4
5
6
7
8
9
10
11
12
8.6 AU480 Maintenance Schedule

13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
8-62
Maintenance
AU480 User Guide
July 24, 2009
Perform a W1 Procedure
Replace the Deionized

Water and the Sample
Probe Filters.
Clean the Probes and

mix bars
Wash the Cuvette and

Cuvette wheel
Replace the Photometer

lamp
Replace the Sample and

Reagent probe tubing
Replace the anti-static

brush
Clean the STAT TABLE

interior and the Reagent
Refrigerator
Replace Syringes
Replace the Wash

Nozzle Joint
Replace the Mix bars
Replace the Sample and

Reagent Probes
Replace Cuvettes
Replace the O rings in

the Wash Nozzle Tube
Mounting Joint
As Needed
Replace the Detergent

Rolling Tube
Clean the Air Filters
Quarterly
Maintenance
10 11 12 13 14 15 16 17
19 20 21 22 23 24 25 26 27 28 29 30 31
ISE Maintenance
This section of the Maintenance Chapter is for our clients who use the
Electrolyte Measuring Unit (ISE) of AU480 and are interested in
maintaining the original performance of this unit and keep it in good running
condition.
Contents
ISE Maintenance
ISE-1
ISE Errors
ISE-3
ISE Maintenance
ISE-4
1 List of Parts Used for ISE Maintenance ...................................................................... ISE-5

2 Tubing Block Diagram for ISE Maintenance ................................................................ ISE-7
3 Daily Maintenance ......................................................................................................... ISE-8
3.1 Inspect the ISE Buffer Syringe for Leaks ......................................................... ISE-8
3.2 ISE Cleaning..................................................................................................... ISE-10
4 Weekly Maintenance ...................................................................................................... ISE-12
4.1 Enhanced Cleaning of Electrode Line .............................................................. ISE-12
5. Maintenance Every Other Week .................................................................................. ISE-14
5.1 Manually Clean the Mix Bar, Liquid Level Sensors, Sample Pot and
Sample Pot Tubing ........................................................................................... ISE-14
6 Quarterly Maintenance................................................................................................... ISE-18
6.1 Replace the Mixture Aspiration and Mid Standard Roller Pump Tubing........... ISE-18
6.2 Replace the Pinch Valve Tubing....................................................................... ISE-20
7 As-Needed Maintenance ............................................................................................... ISE-22
7.1 Replacing the Sample Pot ................................................................................ ISE-22
7.2 Manually Clean the K Electrode ....................................................................... ISE-25
7.3 Replacing Reagents ......................................................................................... ISE-29
7.4 Replacing the ISE Buffer Syringe...................................................................... ISE-31
7.5 Enhanced ISE Cleaning (Manual)..................................................................... ISE-34
7.6 Replacing the Na, K, or Cl Electrode ............................................................... ISE-36
7.7 Replacing the Tubing between Sample Pot and Electrode Unit,
and T-Connector............................................................................................... ISE-39
7.8 Replacing the Drain Tube and Manually Washing the Drain Tank ................... ISE-42
9 ISE Maintenance Schedule ........................................................................................... ISE-45
AU480 User Guide

July 24, 2009
ISE Maintenance
ISE-1
ISE-2
ISE Maintenance
AU480 User Guide

July 24, 2009
ISE Errors
If any of the following errors are encountered, contact Beckman Coulter Technical Services.
These errors indicate the unit that is malfunctioning.
Alarm No.
AU480 Display
3182
ISE Buffer Dispenser (SA-ISE) Error
3183
ISE Mixture Rolling Pump (IB-S) Error
3184
ISE MID Rolling Pump (IB-M) Error
3185
ISE Mixture Unit (ISE-MIX) Error
3186
ISE Analog Power Supply Error
These errors indicate abnormal communication conditions.

Alarm No.
AU480 Display
3032
ISE Control Error 1
3033
ISE Control Error 2
3180
ISE sequence error
3181
ISE A/D error
If any of the following errors are encountered, check for the level of relevant auxiliary solution.
These errors indicate the liquid levels of the reagents are insufficient.
Alarm No.
AU480 User Guide

July 24, 2009
AU480 Display
3251
ISE Buffer Solution Short
3252
ISE MID Solution Short
3253
ISE REF Solution Short
3254
ISE Detergent Short
3255
ISE Serum Standard Solution H Short
3256
ISE Serum Standard Solution L Short
3257
ISE Urine Standard Solution H Short
3258
ISE Urine Standard Solution L Short
3259
ISE Electrode Check Liquid (Na) Short
3260
ISE Electrode Check Liquid (K) Short
3261
ISE CRS Standard Solution H Short
3262
ISE CRS Standard Solution M Short
3263
ISE CRS Standard Solution L Short
ISE Maintenance
ISE-3
ISE Maintenance
This section of ISE MAINTENANCE describes periodic maintenance procedures and how to
perform them, to maintain the performance of the unit and avoid problems and errors that may occur
during analysis. Each series of maintenance procedures is based on the conventional maintenance
procedures used in the regular Maintenance Chapter of this Users Guide.
CAUTION
When performing maintenance procedures on the ISE unit,

wear gloves and other personal protective equipment to avoid
infection and other injury. For other precautions observe all
the WARNING and CAUTION notations in this User Guide.
The ISE maintenance schedule for biweekly or longer periodic maintenance, should be managed
either periodically or by the number of samples analyzed.
The number of ISE samples processed per day on the AU480 is based on 200 samples/day.
ISE-4
ISE Maintenance
AU480 User Guide

July 24, 2009
1 List of Parts Used for ISE Maintenance

The following table lists the names and numbers of the parts used for ISE maintenance routine. These
parts are described in detail in the maintenance procedures given in chapter 5 and later. Use this
parts list along with 2. TUBING BLOCK DIAGRAM FOR ISE MAINTENANCE on the next page at the
time of maintenance routine and ordering any part.
Maintenance
Interval
Daily
Maintenance
Item
Parts to be
Used
Part Number
Target
Location
(In Diagram)
3.1 Inspect the ISE

Buffer Syringe for
Leaks
(0)
3.2 Auto-washing
the Sample Pot
and Electrode line
ISE Cleaning solution
AUH1019
(1) to (11)
Weekly
4.1 Enhanced
Cleaning of
Electrode line
ISE Cleaning solution
AUH1019
(1) to (11)
Every Two
Weeks or
3,000 Samples
5.1 Manually
clean Mix Bar,
Liquid Level
Sensors, Sample
Pot, Sample Pot
Tubing
Alcohol Prep
Commercial
Item
(1) and (2)
Every three
months
or 20,000
samples.
6.1 Replace the

Mixture Aspiration
and Mid standard
roller pump
tubing.
Rolling Tube
MU9623
(9)
On an As
Needed basis
7.1 Replacing the

Sample Pot
Sample Pot
MU9627
(3)
Electrodes
Buffer Solution
AUH1011
MID Solution
AUH1012
REF Solution
AUH1013
7.4 Replacing the

ISE Buffer Syringe
R Syringe
ZM0112
(0)
7.5 Procedure
for Enhanced
Cleaning of the
Electrode Line
(Manual)
ISE Cleaning Solution
AUH1019
(1) to (11)
Pipette
Commercial
Item
7.3 Replacing
Reagents
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July 24, 2009
ISE Maintenance
ISE-5
Maintenance
Interval
On an as
Needed basis
(Continued)
Maintenance
Item
7.6 Replacing
the Na K or Cl
Electrode
ISE Maintenance
Part Number
Na electrode
MU9194
K electrode
MU9195
Cl electrode
MU9196
O ring
MU9900
7.7 Replacing the

Tubes between
Sample Pot and
Electrode Unit and
T-Connector
Tube set
MU5386
7.8 Replacing
the REF Block
Side Drain Tube
and Pinch Valve
Tubing
Tube set 2
MU8247
Pinch valve tubes
ZM2970
Drain Tube 2
MU8303
Sodium hypochlorite
solution
Commercial
Item
7.9 Replace the

Drain Tube and
Manually Washing
the Drain Tank
ISE-6
Parts to be
Used
Target
Location
(In Diagram)
(7) and (8)
(10) and (11)
AU480 User Guide

July 24, 2009
AU480 User Guide
July 24, 2009
(inlet)
REF solution
electrode block
(6) REF
REF solution tube
(5) Electrode block
(4) Tubes between the

sample pot and
electrode unit (tube set)
(2) Mixing bar
(1) Liquid level sensor
Electrode
REF
(7) REF block-side

drain tube (tube set)
Na
Cl
T-connector
(3) Sample pot
Nozzle
Level sensor connector

Mixer connector
(9) Rolling tube
(8) Pinch valve tubing
Buffer solution
dispenser
(0)
Buffer solution
Rolling pump
(for mixture
aspiration)
(10) Drain tube
Waste solution
(11) Drain tank
Description of Tubing Block Diagram Symbols

(0) to (11): The numbers of tubing, etc.,
for which maintenance is performed
A to H:
The symbols of detaching locations, etc.,
that are shown in the detail description of maintenance routine
(10) Rolling tube
(for MID solution dispense)
Rolling pump
MID solution
ING BLOCK DIAGRAM FOR ISE

NTENANCE
2 Tubing Block Diagram for ISE Maintenance
ISE Maintenance
ISE-7
3 Daily
Maintenance
ISE tubing
block diagram
3.1 Inspect the ISE Buffer Syringe for Leaks
The ISE buffer syringe dispenses a small amount of buffer into the sample pot. If liquid leaks from
the syringe, incorrect amounts of buffer will be dispensed and a problem with ISE analysis may result.
Before starting daily analysis, check the ISE buffer syringe for leaks or condensation in the syringe
case.
Maintenance location: No. 0 in the ISE tubing block diagram
Maintenance location: No. 0 in the ISE tubing block diagram
Fixing screws
Case head
(0)
Syringe case
Syringe
Buffer solution
dispenser
Materials:
1. Open the right front door of the analyzer.
2. Confirm that the system is in Warm up , Standby , or Stop mode.
3. Using the cloth or paper towel, blot the top and bottom connections of the syringe case head, the
syringe case, and the bottom fixing screw for leaks.
Sample Syringe
ISE reagent Syringe
Reagent Syringe
Fixing nut
Fixing screws
Case head
Syringe case
Piston fixing screw
Possible leakage locations
ISE-8
ISE Maintenance
AU480 User Guide

July 24, 2009
4.
Visually inspect the inside of the syringe case for condensation, which would reflect an internal
leak of the syringe. If a leak is recognized, advance to 7.4 Replacing the ISE Buffer Syringe.
5.
Visually inspect the syringe case head and the syringe case for cracks. If cracks are found, the
case head must be replaced.
6.
Ensure the case is tightened to the head by attempting to manually turn the case.
7. Check the fixing nut (top) and piston fixing screw (bottom). Tighten them if necessary. Verify that
the bottom screw is placed securely against the syringe, firmly tighten the fixing screws, fixing
nut, and piston fixing screw.
8. Close the right front door of the analyzer.
CAUTION
AU480 User Guide

July 24, 2009
If a leak persists after tightening a loose part, the syringe may need to be
replaced.
ISE Maintenance
ISE-9
3.2 ISE Cleaning

CAUTION
Always wear gloves when handling ISE solution. If skin or clothing come in
contact with ISE solution, rinse with large amounts of water. If solution gets
in eyes or mouth, immediately rinse with water and consult a physician.
After completing daily analysis, clean the sample pot and electrode lines. Contamination or inaccurate
results may occur if the cleaning cycle is not performed. This procedure requires approximately 4
minutes to complete.
Calibrate the ISE before analyzing samples.
Materials:
Sample cup MU8532
1.
Ensure the system is in the Warm up mode or Standby mode.
2.
Fill the sample cup with approximately 1 mL of ISE Cleaning Solution.
3.
Remove the cover of the Stat table.
4.
Set the sample cup filled with the ISE Cleaning Solution in the CLEAN position on the Stat
Table, and close the lid.
Wipe up spills of ISE cleaning solution immediately.

CAUTION
ISE-10
ISE Maintenance
AU480 User Guide

July 24, 2009
5.
From the AU480 H o m e screen select A n a l y z e r M a i n t e n a n c e , then select the

I S E M a i n t e n a n c e button.
6. Select F 5 : C l e a n i n g , and then O K .

7.
After completing a cleaning operation, remove the sample cup from the system.
TIP
AU480 User Guide

July 24, 2009
Press the green TABLE ROTATION/DIAG button to stop the cleaning procedure
before completion.
ISE Maintenance
ISE-11
4 Weekly Maintenance
4.1 Enhanced Cleaning of Electrode Line
Contamination or inaccurate results may occur if the ISE enhanced cleaning cycle is not performed.
Refer to Nos. (1) to (11) in the 2 TUBING BLOCK DIAGRAM FOR ISE MAINTENANCE.
TIP
This cleaning procedure requires 30 minutes to complete. It may be run in

conjunction with the W2 procedure, without adding any time to that 30 minute task.
Materials:
1 ISE sample cup
CAUTION
ISE-12
When handling the detergent, wear gloves to avoid contact. If hands or clothing
come into contact with the detergent, immediately wash the detergent off with water.
Should any detergent come in contact with the eyes or mouth, rinse with water
immediately and consult a doctor.
1.
2.
Fill the sample cup with approximately 1.5 mL of ISE Cleaning Solution.
3.
Place the sample cup filled with ISE Cleaning Solution in the CLEAN position of the Stat Table.
ISE Maintenance
AU480 User Guide

July 24, 2009
4.

5. Select F 6 : C l e a n i n g ( E n h a n c e d ) , and then O K .

The enhanced cleaning operation will start. This process requires 32 minutes to complete.
6.
After performing the enhanced cleaning remove the ISE cleaning solution
TIP
AU480 User Guide

July 24, 2009
The enhanced cleaning of the electrode line can be implemented in W2 operation.
ISE Maintenance
ISE-13
5. Maintenance Every Other Week

ISE Maintenace loactions 1 and 2
5.1 Manually Clean the Mix Bar, Liquid Level Sensors,

Sample Pot and Sample Pot Tubing
To obtain accurate results and optimum system performance, perform the following ISE
maintenance procedure every two weeks or every 3,000 samples, whichever comes first.
Maintenance locations: Nos. (1) and (2) in the ISE tubing block diagram.
Maintenance locations: Nos. (1) and (2) in the ISE tubing block diagram
Mixing unit

Mixing motor connector
Mixing unit clamp knob
Buffer solution and
MID solution connecting tubes
Nozzle
(2) Mixing bar
(3) Sample pot
Getting the System Ready for Maintenance
ISE-14
1.
2.
3.
Open the ISE cover.
ISE Maintenance
AU480 User Guide

July 24, 2009
4.

5.
Place a check mark in the box next to ISE Maintenance. The m a i n t e n a n c e

o p e ra t i o n buttons become functional.
6. Select D ra i n - F l o w c e l l , and then O K .

7.
Press the green TA B L E R OTAT I O N / D I A G button once.

The buffer solution in the sample pot is drained.
Clean the Nozzles, Mixing Bar and Liquid Level Sensors

Materials
Alcohol Prep Pad
1.
Disconnect the connectors of the liquid-level sensor (714) and mixing motor (706) from the mixing
unit.
2.
Loosen the knob securing the mixing unit. Gently lift the mixing unit to unseat it.
Be careful not to bend or break the liquid level sensors when washing.
CAUTION
AU480 User Guide

July 24, 2009
ISE Maintenance
ISE-15
3.
Use an alcohol prep to wipe the two nozzles, two liquid-level sensors, and the mix bar.
Mixing bar
Nozzles
Connecting tubes
Liquid level sensors
Mixing unit
CAUTION
Do not change the orientation or the position of the two nozzles attached to
the mixing unit. Do not apply excess pressure to the tubes.
Clean the Sample Pot and Tubing

Materials:
1% Wash solution Part No.: OSR0001
Deionized water
Ultrasonic cleaner
ISE-16
1.
Loosen the retaining knob securing the sample pot, and lift the pot from the peg.
2.
Hold the sample pot with one hand while removing the sample pot tubing from the inlet of the
flowcell. Follow the bypass tubing and remove it from the pinch valve. Disconnect the bypass
tubing #5 at the Y-connector near the mixture aspiration pump.
3.
Fill the sample pot tubing and bypass tubing with 1% wash solution. This is best accomplished
by using a disposable pipette tip attached to a squeeze bottle or a syringe. Place the pipette tip
or syringe inside the bottom of the sample pot. Force the wash solution through the sample pot
tubing. Next, place the pipette tip or syringe in the end of the bypass tubing. Force the wash
solution through it.
4.
Submerge the sample pot and all attached tubing into a beaker filled with 1% wash solution.
5.
Place the beaker in the sonicator filled with DI water and sonicate for 10 minutes.
6.
Rinse the sample pot and tubing with DI water. Place the pipette tip or syringe at the bottom
of the sample pot. Force DI water through the sample pot tubing. Next, place the pipette tip
or syringe in the bypass tubing. Force DI water through it. Verify the lines have been flushed
thoroughly.
7.
Use a cloth or towel to dry the sample pot and tubing before returning it to the instrument.
ISE Maintenance
AU480 User Guide

July 24, 2009
Re-install the Sample Pot, Tubing, and Mix Bars

8.
While holding the sample pot, connect the sample pot tubing to the inlet of the flowcell.
9.
Re-install the sample pot. Align the hole on the top of the sample pot with the peg and slide the
screw post into the groove on the opposite side. Tighten the screw.
(3) Sample pot
(4)Tubes between
the sample pot and
T-connector
B
Electrode unit
10. Connect the pinch valve tubing onto the Y-connector located near the mixture aspiration rolling
pump.
11. Slide the pinch valve tubing into the top slot of the pinch valve.
12. Mount the mix unit on the two positioning pins. Tighten the knob to secure the unit. Connect the
mix motor connector 706 and the liquid level sensor connector 714.
TIP
CAUTION
The connectors are specifically keyed to fit each plug. To avoid damage to the pins,
do not force a connector into its plug. If the pins are damaged, the mix bar will not
rotate or the level sensors will not function.
When remounting the mix unit, ensure the tubing is not pinched between the mix
unit and its stand.
13. Press the TA B L E R OTAT I O N / D I A G button to re-prime the lines with MID standard
solution. Confirm that liquid is properly dispensed from the sample pot to the electrode unit by
verifying that no bubbles are present in the #6 tubing coming from the bottom of the flowcell. If
necessary, repeat the prime, by pressing the TA B L E R OTAT I O N / D I A G button again.
Repeat until all bubbles are cleared from the line.
14. Close the ISE cover.
16. Deselect the check box next to ISE Maintenance to exit the menu.
AU480 User Guide

July 24, 2009
ISE Maintenance
ISE-17
6 Quarterly Maintenance
Replace the Rolling Tubes for Mid Sol Dispense and Mix Aspiration
To obtain accurate results and optimum system performance, perform the following ISE maintenance
procedures every three months or every 20,000 samples.
6.1 Replace the Mixture Aspiration and Mid Standard Roller

Pump Tubing
The roller pump tubes will deteriorate due to the friction of each rolling pump and vibrations. If the
roller tubing is not replaced for an extended period of time, it may become flat or worn and leaks may
occur. Replace the roller pump tubes with new ones every three months or every 20,000 samples.
Maintenance locations: No. (9) in the ISE tubing block diagram
Maintenance locations: No. (9) in the ISE tubing block diagram
Tube connectors
Tube number
Pump-side tube number
Tube number
Pump-side tube number
Rolling pump
(9) Rolling tube
Replacing the Rolling Tubes

Materials:
Roller Pump Tubing MU9623
ISE-18
ISE Maintenance
AU480 User Guide

July 24, 2009
1.
Ensure the system has entered the Warm up mode or Standby mode.
2.

3.


5.
Press the green TA B L E R OTAT I O N / D I A G button.
6.
7.
Open the ISE cover.
8.
Remove the MID solution roller tube and the mixture aspiration roller tube by twisting the
connectors at each end apart.
9.
Connect a new rolling tube. Turn the connectors at both ends of the tube to secure it.
10. Place the roller tubes on the correct rolling pump, then match the connectors to their
corresponding numbers on the pump bracket. Hook one end of the tube in the bracket, stretch
the tube around the pump, and hook the other end in the bracket.
11. Select P r i m e B y p a s s button, and then O K .
12. Press the TA B L E R OTAT I O N / D I A G button. The two rolling pumps are activated to
prime liquid through the lines. The rolling pumps rotate for approximately one minute to bleed the
air from the tubes.
AU480 User Guide

July 24, 2009
ISE Maintenance
ISE-19
6.2 Replace
the Pinch Valve Tubing
ISE Tubing block diagram
If the pinch valve tubing is used for an extended period of time, the section pinched by the valve will
deteriorate. Replace the pinch valve tubing with a new one every three months.
Maintenance
location:locations:
No (8) in Nos.
the ISE
Maintenance
(7) tubing
and (8)block
in thediagram
ISE tubing block diagram
Tubes between
the sample pot and
E
CI
(8) Pinch valve tube
Na
Electrodes
K
C
REF
(6)REF electrode
block
(7) REF block-side

drain tube
(tube set 2)
Pinch valve
A
Procedure for Replacing Pinch Valve Tubing

Materials:
Pinch valve tubing: ZM2970
CAUTION
Prepare the system for maintenance before starting the replacing operation. If the
operation is performed in other state, liquid may be dispensed from nozzles, tubes,
etc. during maintenance.
1.
2.
3.
Open the ISE cover.
4.

5.

ISE-20
ISE Maintenance
AU480 User Guide

July 24, 2009
7. Press the green TA B L E R OTAT I O N / D I A G The liquid is drained from the electrodes.
TIP
Select D ra i n - F l o w c e l l and then press the TA B L E R OTAT I O N /

D I A G button. The first time this button is pressed, liquid is drained from the
tubing.
Each additional time the button is pressed, MID solution is injected into the tubing.
Performing the Maintenance Procedure

8.
Remove the pinch valve tubing from the pinch valve grooves by pulling upward.
9.
Follow the diagram on page ISE-21 to disconnect the pinch valve tubes at their three
connections, labeled A, B, and C.
10. Replace the pinch valve tube by connecting the short end to position C in the diagram above, the
shorter of the two remaining legs to position A, and the longest leg to position B.
11. Floss the two legs of the pinch valve tube into the grooves of the pinch valve. Ensure the tubes
sits all the way into the groove. According to the diagram below, tube #6 fits into position A,
while tube #5 fits into position B.
CAUTION
Mount the shorter tube in the bottom groove of the pinch valve (between A and C in
the tubing block diagram). Mount the longer tube in the top groove of the pinch valve
(between B and C in the tubing block diagram).
Groove
To position B
To position A
Pinch valve
Pass the tube through

the middle of the groove
12. Confirm that D ra i n - F l o w c e l l has been selected on the ISE Maintenance: Maintenance
tab screen.
13. Press the TA B L E R OTAT I O N / D I A G button. The two rolling pumps are activated to
prime liquid through the ISE.
Repeat this prime until all air bubbles are cleared from the #6 tube. This may require as many as
five repetitions.
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July 24, 2009
ISE Maintenance
ISE-21
7 As-Needed Maintenance
ISE Maintenace loactions 1 and 2
7.1 Replacing the Sample Pot
Replace the sample pot if contaminants accumulate and cannot be removed with the bi-weekly
Manual Cleaning of the Sample Pot procedure. Also replace the pot if any cracks or flaws are found
in the pot.
Maintenance location: No. (3) in the ISE tubing block diagram
Maintenance locations: Nos. (1) and (2) in the ISE tubing block diagram
Mixing unit

Mixing motor connector
Mixing unit clamp knob
Buffer solution and
MID solution connecting tubes
Nozzle
(2) Mixing bar
(3) Sample pot
Replacing the Sample Pot

Materials:
Sample pot: MU9627
ISE-22
ISE Maintenance
AU480 User Guide

July 24, 2009

1.
2.
3.
Open the ISE cover.
4.

5.


7.
Press the green TA B L E R OTAT I O N / D I A G button. The liquid is drained from the
electrodes.
TIP
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July 24, 2009

flowcell.
Each additional time the button is pressed, mid standard is dispensed into the
sample pot and through the flowcell.
ISE Maintenance
ISE-23

1.
Disconnect the connectors of the liquid-level sensor (714) and mixing motor (706) from the
mixing unit.
2.
Loosen the knob holding the mixing unit. Gently lift the mixing unit to dismount it and place it
aside.
3.
4.
Disconnect the sample pot from the tubing by twisting the silver connector from the bottom of the
sample pot.
5.
Reatatch the tubing to the new sample pot. Re-install the sample pot.
6.
Align the hole on the top of the sample pot with the peg and slide the screw post into the groove
on the opposite side. Tighten the screw.
7.
Re-install the mixing unit in place, and then secure the unit by tightening the knob.
8. Reconnect the connectors of the liquid-level sensor (714) and mixing motor (706) of the mixing
unit in place.
9. Press the TA B L E R OTAT I O N / D I A G button. Confirm that liquid is properly aspirated
from the sample pot to the electrode unit, by verifying that no bubbles are present in the #6 tubing
coming from the bottom of the flow cell. This step may need to be repeated as many as five
times.
12. Deselect the check box next to ISE Maintenance.
ISE-24
ISE Maintenance
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July 24, 2009
Maintenance location Electrodes

7.2 Manually
Clean the K Electrode
If calibration errors, such as slope readings of 0, occur frequently for the K electrode only, the
Reference reagent may have contaminated the K electrode. In this situation, perform the manual
cleaning of the K electrode.
Maintenance location: Electrodes in the ISE tubing block diagram
Sample pot
E (O-ring)
Electrodes
Cl
Cl electrode cord (blue)
Na
Na electrode cord (yellow)
K electrode cord (red)

REF
Lock lever
Procedure for Cleaning the K Electrode

Materials:

1.
2.
3.
Open the ISE cover.
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July 24, 2009
ISE Maintenance
ISE-25
4.

5.


7.
electrodes.
TIP
ISE-26

flowcell.
Each additional time the button is pressed, mid standard is dispensed into the
sample pot and through the flowcell.
ISE Maintenance
AU480 User Guide

July 24, 2009

1.
Move the lock lever to release the electrodes.
2.
Remove the K electrode from the electrode unit.
3.
Disconnect the lead wire of the K electrode
4.
Detach the O-ring of the K electrode.
5.
Use a squeeze bottle to dispense DI water to clean the O-ring and O-ring groove of the electrode.
Deionized water that gets into the electrode flow path will not cause a problem.
6.
Wipe the side face (location F in the tubing block diagram) of the REF electrode block in contact
with the K electrode using a clean cloth dampened with deionized water.
7.
Using a clean, dry cloth, sufficiently dry the K electrode, O-ring, and Ref electrode block side
faces.
8.
Connect the red lead wire to the K electrode.
9.
Remount all electrodes in order.
CAUTION
Four O-rings are included, one for each of the electrodes and one for the top of the
flow cell.
Be careful not to lose the O-rings when mounting the electrodes.
10. Move the lock lever to secure the electrodes.

11. Confirm that D ra i n - F l o w c e l l has been selected in I S E M a i n t e n a n c e :.
12. Press the TA B L E R OTAT I O N / D I A G button. Visually check each tube to determine
that the solution passing through the electrodes does not include air bubbles.
16. Allow at least 5 minutes before performing calibration analysis.
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July 24, 2009
ISE Maintenance
ISE-27
To obtain the best possible analysis data, perform two successive

calibration measurements to confirm the electrode stability.
CAUTION
If the difference in factor value between the first and second calibrations is within the
following values, the electrodes are stable. The MID solution concentrations in the
following table are those that have been set from Specific Test Parameters: ISE
menus.
Na
Cl
MID Solution Concentration
140
4.0
100
Difference between 1st and 2nd factors
0.020
0.045
0.025
If the difference between those factor values is not within each

value shown above, or if slope 0 is outputted at the first calibration:
There is a possibility that air remains inside the electrode block.
First, open the main cover and ISE cover. From the AU480 H o m e
screen select Menu>Maintenance>User Maintenance>ISE
Maintenance>Maintenance to display the ISE Maintenance:
Maintenance tab screen. After selecting the I S E M a i n t e n a n c e
check box, Select M I D / R E F P r i m e , and then repeat steps 9 to 12
in the above maintenance procedure.
If slope 0 is outputted in both calibrations: The electrodes might not be set
correctly. Remove the electrodes once, then repeat steps 1 to 16 in the above
maintenance procedure
ISE-28
ISE Maintenance
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July 24, 2009
7.3 Replacing Reagents
The ISE reagent on board stability is specified below for each reagent. Replace expired reagent
bottles with new ones. When the quantity of reagent becomes insufficient, an alarm message will
appear. The number of samples the system is capable of alarming after the alarm occurs is listed
below for each reagent. Replace the reagent before the bottle empties.
Mid
180 samples
Buffer
240 samples
Ref
600 samples
On Board Stability of Reagents for the ISE Unit

The on board stability for the buffer solution, MID solution, and REF solution used for the ISE unit are
specified. If an expired reagent is used, data will be incorrect. Replace the corresponding reagent
before the on board stability expires.
On Board Stability: Check your package insert for on board stability claims.
On board stability
Remark
Buffer Solution
90 days after breaking seal
Refer to the package insert
MID Solution
REF Solution
Procedure for Replacing ISE Reagents

Materials:
Buffer solution bottle
MID solution bottle
REF solution bottle
CAUTION
Reference solution is highly concentrated. Do not contaminate other bottles with

Reference solution.
1.
Open the right front door of the analyzer.
2.
Pull out the reagent bottle to be replaced.
3.
Loosen the cap of the reagent bottle, then remove the aspiration tube.
4.
Place the aspiration tube in a new bottle, tighten the cap, and place it on the instrument. Dispose
of the old solution as liquid waste is handled.
5.
Push the reagent bottle to the back of its position.
6.

7.
Place a check mark in the box next to I S E M a i n t e n a n c e . The maintenance operation

buttons become functional.
8.
Select one of following buttons from the Maintenace Operation buttons.

For replacing Buffer solution: B u f f e r P r i m e
For replacing MID solution: M I D / R E F P r i m e
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July 24, 2009
ISE Maintenance
ISE-29
For replacing REF solution: M I D / R E F P r i m e

9. Select O K .
10. Press the TA B L E R OTAT I O N / D I A G button. The reagent is primed for approximately
90 seconds.
ISE-30
ISE Maintenance
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July 24, 2009
Replacing the Buffer Dispenser Syringe
7.4 Replacing the ISE Buffer Syringe

Fixing nut
Mounting groove
Fixing screws
Syringe case
Mounting groove
Piston fixing screw
Materials:
R Syringe: ZM0112
1.
Open the right front door of the analyzer.
2.
3.
Loosen the piston fixing screw located at the bottom of the syringe.
4.
Loosen the fixing nut located at the top of the syringe.
5.
Pull the syringe case forward to remove the syringe from the mounting grooves.
CAUTION
6.
When removing the fixing screws from the syringe case do not use excessive force,
or the syringe case may be damaged
While holding the case head and syringe case, turn the syringe case counterclockwise to remove
it.
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July 24, 2009
ISE Maintenance
ISE-31
7.
Pull out the syringe from the case head.

Case head
Buffer Dispense Syringe CautionO-ring

Graphic
Syringe
ZM0112
Syringe case
If the O-ring remains in the case head, carefully take out the O-ring with tweezers so as not to
scratch the case head.
Set the R syringe in place. The S syringe and R syringe are identified with the piston shaft
Set the R syringe in place. The S syringe and R syringe are identified with a
diameter.
piston Shaft.
Piston shaft diameter: D
CAUTION
D = 5mm: R syringe
D = 2mm: S syringe
Do not
outpiston
from afrom
newa syringe.
If the Once
pistonthe
is removed,
Dopull
notthe
pullpiston
out the
new syringe.
piston hasthe
been pulled out, the
syringe
cannot
maintain
accurate
dispensing accuracy
even if theeven
piston
is reinserted
to its in the
Buffer Dispense
Syringe
Remounting
syringe
cannot
maintain
the dispensing
if the
piston is inserted
original
position.
original
position.
8.
Insert the new R syringe into the case head.
9.
Mount the syringe case on the case head.
10. Insert the syringe into the mounting grooves by holding the case head. Tighten the fixing nut
while holding the case head.
Mounting groove
Lock nut
Fixing screws
Case head
Syringe case
Piston fixing screw
11. Tighten the piston fixing screw.
ISE-32
ISE Maintenance
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July 24, 2009
12. From the AU480 H o m e screen select A n a l y z e r M a i n t e n a n c e , then select the

13. Place a check mark in the box next to ISE Maintenance. The M a i n t e n a n c e
O p e ra t i o n buttons become functional.
14. Select B u f f e r P r i m e , and then O K .
15. Press the green TA B L E R OTAT I O N / D I A G button.
CAUTION
All air bubbles should be removed from the syringe after installation and prime is
complete. If air bubbles remain, perform the Buffer Prime until bubles are cleared
from the syringe.

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July 24, 2009
ISE Maintenance
ISE-33
7.5 Enhanced ISE Cleaning (Manual)
To help eliminate sample buildup and residue from high volume sample testing, this ISE cleaning may
be necessary on an as-needed basis. This method should be used when the ISE calibration slopes
are in the mid-to-low forties, or if a build-up/residue is present upon inspection of the sample pot or
T-tubing. This is the ONLY ISE cleaning procedure recommended by Beckman Coulter.
Materials:
10% Bleach Solution
Pipette (that is commercially available and can collect more than 1 mL of liquid)
CAUTION
When handling the detergent, wear protective gloves so that your hands do not
come into contact with the detergent. If your hands or clothing come into contact
with the detergent, immediately wash the detergent off with water. Should a
detergent get in your eyes or mouth, immediately rinse with water and consult a
doctor.
1.
From the AU480 H o m e screen, select A n a l y z e r M a i n t e n a n c e .
2.
Select the I S E M a i n t e n a n c e tab.
3.
Place a check mark in the box next to the IS E M a i n t e n a n c e option. The

4. Select D ra i n - F l o w c e l l and then O K .
ISE-34
ISE Maintenance
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July 24, 2009
5.
Press the green TA B L E R OTAT I O N / D I A G button.
TIP

tube.
Each additional time the button is pressed MID solution is injected into the tube.
6.
Remove the mix assembly from its mount.
7.
Remove both pinch valve tubes (#5 and #6) from the pinch valve.
8.
For the first 2 minutes, pipette the 10% bleach solution into the ISE sample pot and manually
turn the roller pump assembly located on the right assembly clockwise until most of the bleach
Manual
electrode
line
empties
fromwashing
the sample
pot into the
ISE tubing. Continue filling the sample pot with the bleach
solution while turning the right roller pump assembly.
TIP
Do not completely empty the sample pot before adding more bleach solution.
Ensure the tubing is filled with the bleach solution.
Pipette
Mixing bar
9.
Sample pot
Let the bleach solution remain in the line for 5 minutes.
10. Manually turn the roller pump to clear the bleach from the lines.
11. Pipette 10 mL of ISE Mid-Standard Solution into the sample pot and manually turn the roller
pump to clear the Mid-Standard Solution. Repeat 3-5 times.
12. Replace the mix assembly and the pinch valve tubes.
13. Press the TA B L E R OTAT I O N / D I A G button to re-prime the lines.
14. Perform three to four MID/REF primes.
15. Perform a To t a l p r i m e .
16. Deselect the check mark at ISE Maintenance.
17. Calibrate the ISE.
18. Run QC material.
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July 24, 2009
ISE Maintenance
ISE-35
Replacing the Na K or Cl Electrode
7.6 Replacing the Na, K, or Cl Electrode
If the electrodes have deteriorated, appropriate analysis results will not be obtained. Replace
electrodes when calibration results are out of range, and troubleshooting has been performed.
Electrodes are under warranty for 40,000 samples or 6 months. Replace them based on calibration
and QC results.
Maintenance location:
Electrodes
in the ISE
tubing block
Maintenance
location:
Electrodes
in thediagram.
Sample pot
E (O-ring)
Electrodes
Cl
Cl electrode cord (blue)
Na
Na electrode cord (yellow)
K electrode cord (red)

REF
Lock lever
Replacing the Na, K, or Cl Electrode

Materials:
Na electrode: MU9194
K electrode: MU9195
Cl electrode: MU9196
O-ring: MU9900
ISE-36
1.
Ensure the system has entered the Warm up mode or Standby mode.
2.
3.
Open the ISE cover.
ISE Maintenance
AU480 User Guide

July 24, 2009
4.
From the AU480 H o m e screen select A n a l y z e r M a i n t e n a n c e , then select the I S E

M a i n t e n a n c e button.
5.


7.
Press the TA B L E R OTAT I O N / D I A G button once.

The liquid remaining in the electrodes is drained.
TIP

tube. Each additional time button is pressed, MID standard solution is pumped into
the lines.
8.
Move the lock lever to the left, if viewed from the front, to unlock the electrodes.
9.
Remove the three electrodes.
10. Disconnect the lead wires from each of the electrodes.
CAUTION
Each electrode has an O-ring seated on its back side. Be careful not to lose the
O-rings when mounting the electrodes. There is a separate O-ring seated in the top
of the flowcell, next to the Cl electrode. Insert the separately sold
O-ring between the right side of the Cl electrode and the metal plate.
11. Replace the failed electrode with a new one.
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July 24, 2009
ISE Maintenance
ISE-37
12. Connect the blue wire to the Cl electrode, yellow wire to the Na electrode, and red wire to the K
electrode.
13. Mount the three electrodes on the electrode block. Mount the electrodes in order of Cl, Na, and K
from the sample pot side to the front side.
14. Push the lock lever to the right to secure the electrodes.
15. Press the TA B L E R OTAT I O N / D I A G button to re-prime the lines with MID standard
solution. After the cycle is complete, press the button a minimum of 4 more times (5 primes
total).
Confirm that liquid is properly aspirated from the sample pot to the electrode unit by verifying that
no bubbles are present in the #6 tubing coming from the bottom of the flowcell.
19. Allows at least 5 minutes after closing the main cover, and then perform calibration.
To obtain the best possible analysis data, perform two calibration measurements to
confirm the electrode stability.
CAUTION
If the difference in factor value between the first and second calibrations is within the
following values, the electrodes are stable. The MID solution concentrations in the
following table are those that have been set from Specific Test Parameters: ISE
menus.
Na
Cl
MID Solution Concentration
140
4.0
100
Difference between 1st and 2nd factors
0.020
0.045
0.025
If the difference between those factor values is not within each value shown
above, of if slope 0 is outputted at the first calibration:
There is a possibility that air remains inside the electrode block. First, open the
main cover and ISE cover.
From the AU480 H o m e screen select Analyzer Maintenance > ISE
Maintenance to display the ISE Maintenance: Maintenance tab screen.
Select the ISE Maintenance check box. Select the M I D / R E F P r i m e ,
press the TA B L E R OTAT I O N / D I A G button.
If slope 0 is outputted in both calibrations:
The electrodes might not be set correctly. Remove the electrodes once, then
repeat steps 9 to 15 in the above maintenance procedure.
ISE-38
ISE Maintenance
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July 24, 2009
7.7 Replacing the Tubing between Sample Pot and

Electrode Unit, and T-Connector
Maintenance Locations 3 and 4
If the system analyzes certain samples (such as dialysis samples) that contain large amounts of fibrin
and protein, it may accumulate near the T-connector between the sample pot and electrode unit,
possibly causing errors.
If the accumulated contaminates are not removed during the sample pot washing that occurs every
two weeks, replace the tubes and the T-connector.
For details on how to clean the sample pot, tubes, and T-connector, refer to 5.1 Manually Clean the
Mix Bar, Liquid Level Sensors, Sample Pot and Sample Pot Tubing .
Maintenance
location: No.
(4) in the
ISE(3)
tubing
block
diagram
Maintenance
locations:
Nos.
and (4)
in the
(3) Sample pot
(4) Tubes between

the sample pot and
T-connector
B
Electrode unit
Replacing the Tubing between Sample Pot and Electrode Unit, and
T-connector
Materials:
Tube set: MU5386
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July 24, 2009
ISE Maintenance
ISE-39
TIP
Always prepare the system for maintenance procedures which require the ISE to
be taken apart. The software will keep liquid from being dispensed while tubing is
disconnected.
1.
2.
3.
Open the ISE cover.
4.

I S E M a i n t e n a n c e button
5.


7.
electrodes.
TIP
ISE-40

D I A G button. The first time this button is pressed liquid is drained from the tube.
Each additional time the button is pressed MID solution is injected into the tube.
ISE Maintenance
AU480 User Guide

July 24, 2009

1.
Disconnect the connectors of the liquid-level sensor (714) and mixing motor (706) from the mixing
unit.
2.
Loosen the knob securing the mixing unit. Gently lift the mixing unit to dismount it and set it aside.
3.
4.
Follow the tube from the bottom of the sample pot to its connection at the top of the flow cell.
Disconnect the tube from the flow cell.
5.
Follow the bypass tubing from the T-connector to its junction with the pinch valve tube.
Disconnect the bypass tube from the pinch valve tube.
6.
Unscrew the tube connected to the bottom of the sample pot, and discard the tubes.
7.
Connect a new set of tubing by reconnecting the tube to the top of the flowcell, and then to the
pinch valve tube. Reconnect the pot by screwing it into the silver connector.
CAUTION
8.
Re-install the sample pot. Align the hole on the top of the sample pot with the peg and slide the
screw post into the groove on the opposite side. Tighten the screw.
CAUTION
9.
To connect the T-connector and tubes, push them all the way so each
joint will not leak. To attach the tube to the bottom of the sample pot, tighten the tube
knob firmly with fingers.
When remounting the mixing unit in place, avoid splashing the buffer solution and
MID solution on the ISE.
Reconnect the connectors of the liquid-level sensor (714) and mixing motor (706) of the mixing
unit.
10. Confirm that D ra i n - F l o w c e l l has been selected on the I S E M a i n t e n a n c e :

Maintenance tab screen.
11. Press the TA B L E R OTAT I O N / D I A G button. Confirm that liquid is properly aspired
from the sample pot to the electrode unit, by verifying that no bubbles are in the #6 tubing coming
from the bottom of the flowcell. Repeat the prime by pressing the TA B L E R OTAT I O N /
D I A G button again if necessary.
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July 24, 2009
ISE Maintenance
ISE-41
7.8 Replacing the Drain Tube and Manually

Washing the Drain Tank
If the system analyzes samples that contain large amounts of fibrin and protein, it may accumulate
near the drain tube outlet and drain tank, possibly causing errors.
Replace the drain tube and manually wash the drain tank as needed.
Maintenance
locations:
Nos. (10)
theinISE
blockblock
diagram
Maintenance
locations:
Nos.and
(10)(11)
andin(11)
thetubing
ISE tubing
diagram
Pinch valve tubing
Waste solution
D
H
(10) Drain tube
Rolling pump
(for mixture aspiration)
G (Joint No.3)
(11)
Drain tank
Procedure for Replacing the Drain Tubing and Manually Washing the Drain
Tank
Materials:
Drain tube: MU8303
10% bleach, prepared within the last 24 hours
ISE-42
ISE Maintenance
AU480 User Guide

July 24, 2009

1.
2.
3.
Open the ISE cover.
4.

5.

6. Select D ra i n - F l o w c e l l , and then OK.

7.
electrodes.
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July 24, 2009
ISE Maintenance
ISE-43

1.
Remove the drain tube end from the tube joint (No.3) of the mixture aspiration rolling pump by
twisting it from its connector. According to the diagram, the drain tube is disconnected from the
rolling pump in block G.
2.
Remove the waste station from the hook on the drain tank, and then dismount the whole drain
tube. According to the diagram, the drain tube in block D is removed.
CAUTION
When handling the sodium hypochlorite solution, wear gloves to avoid contact with
the sodium hypochlorite solution.
If hands or clothing come into contact with the sodium hypochlorite solution,
immediately wash the solution off with water. Should any sodium hypochlorite
solution get in the eyes or mouth, immediately rinse with water and consult a doctor.
3.
Prepare approximately 50 mL of the 10% bleach solution.
4.
Pour the diluted bleach solution into the drain tank directly from the top (position H in the tubing
block diagram).
5.
Allow the bleach solution to sit for approximately 10 minutes, and then pour a sufficient amount of
water into the drain tank (position H in the tubing block diagram) to rinse out the bleach solution.
6.
Connect a new drain tube to the mixture aspiration rolling tube and the drain tank side, and then
remount it.
To connect the tubing, push it all the way so each joint will not leak.
CAUTION
7. Press the TA B L E R OTAT I O N / D I A G button.

Ensure that the solution is aspirated from the sample pot into the electrode, and
drained from the electrode, and that no bubbles are in the drain tank.
CAUTION
If liquid remains in the sample pot check the tube connections.

ISE-44
ISE Maintenance
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July 24, 2009
AU480 User Guide
July 24, 2009
ISE Maintenance
ISE-45
6.2 Replacethe
Pinch Valve
Tubing
6.1 Replace the

Roller Tubes for
MID Solution
Dispense and
Mixture Aspiration
Every three
months
5.1 Manually
Wash the Mix
Bars ,Liquid Level
Sensors, Sample
Pot and Sample
Pot Tubes
Every other
Week
4.1 Enhanced
Cleaning of
Electrode Line
Weekly
3.2 ISE Cleaning
3.1 Check the

Buffer Syringe for
Leaks
Daily
Maintenance
10
11
12
13
14
15
16
17
18
Date (below)
Month:
Year:
If the client uses multiple ISE units, use an individual copy taken for each ISE unit.
19
Make a copy of the following maintenance schedule every month and use it for daily management
of the ISE unit by applying checkmarks into checkboxes on each day when ISE maintenance is
performed.
9 ISE Maintenance Schedule
20
21
22
23
24
25
26
27
28
29
30
31
ISE-46
ISE Maintenance
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July 24, 2009
7.9 Replace the

Drain Tube and
Manually Wash
the Drain Tank
7.8 Procedure for

Electrode Line
(Manual)
7.7 Replace the

tubes between the
sample pot and
Electrode Unit and
the T connector/
7.6 Replace
the Na, K, or Cl
Electrode
7.5 Enhanced
Cleaning of the
ISE (Manual)
7.4 Replace the

Buffer Syringe
Replace the
REF solution
Replace the
MID solution
Replace the
Buffer Solution
7.3 Replace
Reagents
7.2 Manually
Clean the K
Electrode
7.1 Replace the

Sample Pot
As Needed
Maintenance
10
11
12
13
14
15
16
17
18
Date (below)
Month:
Year:
19
20
21
22
23
24
25
26
27
28
29
30
31
Error Flags
Error flags are generated by the system when it encounters a condition

that can affect the result. This condition can range from minor warnings
to severe errors that require immediate attention. It is important that
the operator reviews each flag as it is generated and identifies the root
cause, and takes appropriate action.
No result should be reported with an unresolved, unexpected flag.
When in doubt, always consider repeating the sample analysis, and
diluting it if necessary.
This chapter contains a list of all error flags in order priority,
suggestions of their cause, and action to take.
Contents
9.1
Summary of Error Flags................................................................................................9-3
9.2
Error Flag Details ..........................................................................................................9-5

d (Excluded from QC by user).......................................................................................9-5
e (Data edited by user) .................................................................................................9-5
( (Shortage of wash solution for contamination parameters) ........................................9-5
Wa (Result has been analyzed with an erroneous cuvette) .........................................9-5
R (Insufficient reagent) .................................................................................................9-6
# (Insufficient sample) ..................................................................................................9-6
% (Clot detected) ..........................................................................................................9-7
? (Unable to calculate a result) .....................................................................................9-7
?a (Sample/reagent detection abnormal)......................................................................9-7
n (LIH test not performed) ............................................................................................9-8
l (Result may be affected by lipemia) ...........................................................................9-8
i (Result may be affected by icterus) ............................................................................9-8
h (Result may be affected by hemolysis) .....................................................................9-8
Y (Reagent blank OD at last photometric point high) ...................................................9-8
U (Reagent blank OD at last photometric point low) ....................................................9-9
y (Reagent blank/routine OD at first photometric point high) .......................................9-9
u (Reagent blank/routine OD at first photometric point low) .........................................9-9
@ (OD is higher than 3.0) ..........................................................................................9-10
$ (Not enough data to determine linearity of reaction) ...............................................9-10
D (OD of reaction is higher than the maximum OD range) ........................................ 9-11
B (OD of reaction is lower than the minimum OD range) ...........................................9-12
* (Linearity error in rate methods) ...............................................................................9-12
& (Prozone test data abnormal) .................................................................................9-13
Z (Prozone error) ........................................................................................................9-13
E (Overreaction in a rate assay detected) ..................................................................9-13
Fx (Result (OD) is higher than dynamic range) ..........................................................9-13
Gx (Result (OD) is lower than dynamic range) ...........................................................9-14
! (Unable to calculate concentration) ..........................................................................9-14
) ( Reagent lot no. used at sample analysis is different from that used
at calibration analysis) ...................................................................................9-14
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November 1, 2009
Error Flags
9-1
a (Reagent expired) ....................................................................................................9-15

ba (No calibration data or expired) .............................................................................9-15
bh (Invalid calibration data or expired) .......................................................................9-15
bn (Mastercurve used) ...............................................................................................9-15
bz (Calibration curve for Prozone data used) .............................................................9-15
F (Result is higher than the dynamic range) ..............................................................9-16
G (Result is lower than the dynamic range) ...............................................................9-16
ph (Result is higher than the upper panic value) ........................................................9-16
pl (Result is lower than the low panic value) ..............................................................9-16
T (Abnormality found in inter-chemistry check.) .........................................................9-17
P (Positive) .................................................................................................................9-17
N (Negative) ...............................................................................................................9-17
H (Result is higher than reference range) ..................................................................9-17
L (Result is lower than reference range) ....................................................................9-17
J (Result is higher than the repeat decision range) ....................................................9-18
K (Result is lower than the repeat decision range) .....................................................9-18
fh (Result is higher than the repeat run reflex range) .................................................9-18
fl (Result is lower than the repeat run reflex range) ...................................................9-18
Va (The result of multiple measurement alienation check is NG)................................9-19
xQ (Failure of one control used in a multirule QC) .....................................................9-19
1Q (QC data exceeds the range entered in Single Check Level field) .......................9-20
2Q (QC data exceeds 13SD control range) ...............................................................9-20
3Q (QC data continuously exceeds the 2 SD control limit .........................................9-21
4Q (QC Data exceeds R4S control range) .................................................................9-21
5Q (QC Data exceeds 41S control range) .................................................................9-22
6Q (A preset number of consecutive QC results fall on one side of the mean) ..........9-22
7Q (Consecutive QC results show steadily increasing or decreasing values) ...........9-23
S (Sample repeated and original results replaced by repeat result)...........................9-23
/ (Test pending) ...........................................................................................................9-23
r (Data transmitted to host) .........................................................................................9-23
c (Data corrected by user) ..........................................................................................9-24
9-2
Error Flags
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November 1, 2009
9.1 Summary of Error Flags

The following table summarizes the error flags in order of priority:
Flag
Cause
Excluded from QC by user
Data edited by user.
Shortage of wash solution for contamination parameters.
Wa
Result has been analyzed with an erroneous cuvette.
Insufficient reagent.
Insufficient sample.
Clot detected.
Unable to calculate a result.
?a
Sample/Reagent detection abnormal
LIH test not performed.
Result may be affected by lipemia.
Result may be affected by icterus.
Result may be affected by hemolysis.
Reagent blank OD at last photometric point high.
Reagent blank OD at last photometric point low.
Reagent blank/routine OD at first photometric point high.
Reagent blank/routine OD at first photometric point low.
OD is higher than 3.0.
Not enough data to determine linearity of reaction.
OD of reaction is higher than maximum OD range.
OD of reaction is lower than minimum OD range.
Linearity error in rate method.
&
Prozone test data is abnormal.
Prozone error.
Overreaction in a rate assay detected.
Fx
Result (OD) is higher than the dynamic range.
Gx
Result (OD) is lower than the dynamic range.
Unable to calculate concentration.
Reagent lot no. used at sample analysis is different from that used at calibration analysis.
Reagent expired.
ba
Calibration expired.
bh
No valid calibration used.
bn
Mastercurve used.
bz
Calibration curve for Prozone data used.
Result is higher than the dynamic range.
Result is lower than the dynamic range.
ph
Result is higher than the upper panic value.
pl
Result is lower than the low panic value.
Abnormality found in inter-chemistry check.
Positive
Negative
Result is higher than reference range.
Result is lower than reference range.
Result is higher than the repeat decision range.
Result is lower than the repeat decision range.
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Error Flags
9-3
Flag
9-4
Cause
fh
Result is higher than the repeat run reflex range.
fl
Result is lower than the repeat run reflex range.
Va
The result of multiple measurement alienation check is NG.
xQ
Failure of one control used in a multirule QC.
1Q
QC data exceeds the range entered in the Single Check Level field.
2Q
QC data exceeds 13SD control range.
3Q
QC data continuously exceeds the 2 SD control limit.
4Q
QC data exceeds R4S control range.
5Q
QC data exceeds 41S control range.
6Q
A preset number of consecutive QC results fall on one side of the mean.
7Q
Consecutive QC results show steadily increasing or decreasing values.
Sample repeated and original results replaced by repeat result.
Test pending or not analyzed.
Data transmitted to host.
Data corrected by user.
Error Flags
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July 24, 2009
9.2 Error Flag Details

d (Excluded from QC by user)
QC data has been manually excluded from calculation by the user. This flag is applied
in Menu List>QC>QC Data Review. For details on excluding QC data, refer to section
7.5.1 Entering Material Parameters in chapter 7.
Action:
No action is specifically required. Prior to excluding any QC data, investigate and
record the cause of the anomalous value, as dictated by laboratory standard Operating
Procedures.
e (Data edited by user)

Data has been edited.
For details on editing results, refer to section 6.14 Editing Analysis Data in
chapter 6.
For details on viewing analysis results, refer to section 6.4.2 Displaying Reaction
Monitor in chapter 6.
Action:
No action is specifically required. Review any edited or changed data carefully prior to
reporting results.
( (Shortage of wash solution for contamination parameters)

One or more wash solutions set in contamination parameters in the reagent refrigerator
are empty. Contamination parameters are suspended for the related cleaning solution.
Carry-over might have occurred on tests that have this flag.
Action:
1. Fill the wash solution bottles.
2. Analyze the flagged tests again.
Wa (Result has been analyzed with an erroneous cuvette)

The result has been analyzed with an erroneous cuvette.
Action:
1. Wash the erroneous cuvette and perform a photocal.
2. If the error still occurs, replace the cuvette.
3. Repeat analysis.
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July 24, 2009
Error Flags
9-5
R (Insufficient reagent)
Level detectors cannot detect reagent.
Action:
1. Review all results generated immediately prior to this flag for consistency and
validity (especially low or high results), and repeat if necessary.
2. Place new reagent onto the system and repeat analysis.
3. If the error occurs in spite of sufficient reagent, the reagent bottle may contain
bubbles. If so remove the bubbles and perform another reagent check.
4. Wipe the reagent bottle opening if it is wet and inspect the reagent probe, clean
or replace as necessary. For details on inspecting, cleaning and priming reagent
probe and wash stations, refer to sections 8.3.4 Inspect, Clean and Prime the
Sample, Reagent Probes, and Mix bars on and 8.5.1 Clean the Sample Probe
and Reagent Probe Wash Stations in chapter 8.
5. Ensure the reagent probe is correctly installed and connected.
# (Insufficient sample)
The sample probe cannot detect liquid. This is caused by one of the following:
Insufficient sample volume.
Malfunction of the sample level detection system.
Action:
1. Review all other results that were generated on the same sample prior to
generating the # flag to verify validity and consistency-no extremely low or high
values.
2. Add more sample to the sample cup, and repeat the test.
3. Wipe the probe with an alcohol swab and check the probe is attached correctly.
4. Replace the sample probe. For details on replace a sample probe, refer to section
8.8.4 Replace Sample Probe and Reagent Probe in chapter 8.
Error Flags
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July 24, 2009
% (Clot detected)
The sample probe has become blocked or partially blocked during sample aspiration.
Action:
1. Review all other results that were generated on the same sample prior to
generating the # flag to verify validity and consistency-no extremely low or high
values.
2. Verify that the sample is free of clots, and remove any present. If necessary,
centrifuge the sample and repeat analysis.
3. If the error still occurs, wash the sample probe.
For details on replacing the sample probe, refer to section 8.8.4 Replace Sample
Probe and Reagent Probe in chapter 8.
? (Unable to calculate a result)

Data for this sample cannot be calculated due to one of the following:

A. The absorbance of the sample exceeds 2.5.

B. Less than three photometric readings, for a rate reaction, satisfy the
assay criteria specified in the individual test parameters.
C. The Photometric data was defective.
D. The analyzer had a mechanical or electrical malfunction. The samples
in progress, that cannot be completed, will have the ? flag attached.

Action:
1. The sample may be severely lipemic, icteric, hemolytic or may contain

excessively large amounts of the analyte being tested. Dilute the sample and run
it again.
2. Verify the reagent. For more information see Troubleshooting Reagents and
Samples located in the Troubleshooting Chapter.
3. The analyzer will generate error codes and/or other mechanical alarms to specify
the malfunction. Once the problem is rectified, run the samples again. For
detailed procedures on checking syringes, probes and calibrator material, refer to
the section in this chapter called, Troubleshooting for Data Flags ?, @, $, D, F,
G, !.
4. If there is no other error flag, repeat analysis after checking the photometer lamp
and the corresponding cuvette. If the system still does not recover from the error
contact Beckman Coulter Technical services.
5. Check the reaction data including those processed immediately before and
after the flagged data result. If any abnormality is found, check the cuvettes and
cuvette wash station for an overflow, then recheck the results processed before
and after the flagged data results. If the issue persists contact Beckman Coulter
Technical services.
6. Check the syringes.
7. Check the probes.
8. Verify the calibrator material. Refer to Troubleshooting for Data Flags in this
chapter for procedures.
?a (Sample/reagent detection abnormal)

AU480 User Guide

November 1, 2009
The sample/reagent level monitor has detected an abnormal sample or reagent

level.
Error Flags
9-7
Action:
1. Check the quantity of sample or reagent and replenish as nescessary.,
2. Perform analysis again.
If the issue persists contact Beckman Coulter Technical Services.
n (LIH test not performed)

The LIH test has not been performed.
Action:
1. Examine the sample and repeat if necessary.
2. Check the LIH reagent.
l (Result may be affected by lipemia)

The result may be affected by lipemia.
Action:
Follow laboratory procedure for lipemic samples.
i (Result may be affected by icterus)

The result may be affected by bilirubin.
Action:
Follow laboratory procedure for icteric samples.
h (Result may be affected by hemolysis)

The result may be affected by hemolysis.
Action:
Follow laboratory procedure for hemolytic samples.
Y (Reagent blank OD at last photometric point high)

Reagent blank OD is higher than the reagent OD limit range defined for the
last photometric point. This is set in Menu List>Parameters>Specific Test
Parameters>General. This could be caused by:
Reagent expired.
Reagent contamination.
Improperly prepared reagents.
9-8
Error Flags
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July 24, 2009
Action:
1. Check the reagent expiration date.
2. Check the reagent condition.
3. Replace the reagent and repeat analysis.
U (Reagent blank OD at last photometric point low)

Reagent blank OD is lower than the reagent OD limit range defined for the
last photometric point. This is set in Menu List>Parameters>Specific Test
Parameters>General. This could be caused by:
Reagent expired.
Action:
y (Reagent blank/routine OD at first photometric point high)

Reagent OD at P0 in reagent blank or normal analysis is higher than the
reagent OD limit range defined for the first photometric point. This is set in Menu
List>Parameters>Specific Test Parameters>General. This could be caused by:
Reagent expired.
Action:
u (Reagent blank/routine OD at first photometric point low)

Reagent OD at P0 in reagent blank or normal analysis is lower than the reagent
OD limit range defined for the first photometric point. This is set in Menu
List>Parameters>Specific Test Parameters>General. This could be caused by:
Reagent expired.
AU480 User Guide
July 24, 2009
Error Flags
9-9

Action:
3 Replace the reagent and repeat analysis.
@ (OD is higher than 3.0)

In dual wavelength measurement, an error occurs if either of the two wavelengths

exceeds 2.5 OD. The probable causes are:

Action:
Specimen quality
Incorrect placement of reagents within the reagent compartment
Photometer lamp deterioration
excessively large amounts of the analyte being tested. Dilute, then run the sample
again or perform a dilution rerun. If the sample is severely lipemic, perform
ultracentrifugal processing on it and then dilute it.
2. Verify all the reagent positions. An incompatible R1 reagent combination often
will cause absorbancies which exceed the measurable limits.
3. Perform a Photometer Check to verify lamp integrity. If the results are out-ofrange, install a new lamp.
Important: After lamp installation, allow the lamp to stabilize, then a photocal must
be performed. Repeat the Photometer Check with the new lamp installed to verify
integrity. Recalibrate all tests before starting specimen analysis.
4. Verify that the correct settings were programmed in [Parameters], [Specific Test
Parameters].
5. Check the reaction data including those processed immediately before and after
the flagged data result. If any abnormality is found, check the cuvettes and
Technical services.
6. Check syringes.
7. Check probes.
8. Verify calibrator material.
9. Verify reagent integrity and position.
$ (Not enough data to determine linearity of reaction)

Less than three read points of a rate reaction fall within the acceptable OD range
specified. In order to properly calculate a rate reaction, at least three readings must
be taken prior to reaching the maximum or minimum OD limits. If the OD limits are
9-10
Error Flags
AU480 User Guide

November 1, 2009
exceeded, the reaction may have gone into substrate depletion due to either a high
result, or a problem with the integrity of the reagent. The nonlinearity calculations are
not made.
Action:
it again.
2. Check syringes.
3. Check probes.
5. Verify reagent integrity and position.
Technical services.
D (OD of reaction is higher than the maximum OD range)

This flag is generated during a positive reaction or a negative reaction rate method
when the OD of the photometry point FST+2 (first photometry point plus two) exceeds
the OD Value Range Maximum. It is more likely that this flag will occur during a positive
reaction.
OR
In addition, this flag is generated during a fixed method when the OD of a specified
read point (first photometry point or last photometry point) has exceeded the OD
Value Range Maximum.
Action:
1. Verify that the correct settings were programmed in [Parameters], [Specific Test
Parameters].
it again or perform a dilution rerun. If the sample is severely hemolytic, collect
the blood again, then repeat analysis. If the sample indicates an absorbance
decrease reaction, it is assumed to be severly lipemic. If possible perform
ultracentrifugal processing on it.
3. Verify reagent integrity and position. Refer to Troubleshooting for Data Flags in
this chapter for procedures.
4. If the flag is generated for multiple assays, the lamp may need to be replaced.
The integrity of the lamp can be verified by performing a photometer check. For
procedures, refer to the Maintenance Chapter.
Technical services.
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November 1, 2009
Error Flags
9-11
B (OD of reaction is lower than the minimum OD range)

In one or more values among photometric values below, the optical density of a
specified read point has gone under the minimum optical density value range.
The optical density of a specified read point FST+2, first photometry point plus
two, (a negative reaction rate method)
The optical density of a specified read point LST+2, (a positive reaction rate
method)
The optical density of a specified point(first photometry point, a fixed method)
Action:
excessively large volumes of the analyte being tested. Dilute the sample and run
the test again.
2. Ensure the reagent has not expired.
3. If this flag is generated for several assays, the lamp might need to be replaced.
Perform a photometer check, to assess the condition of the photometer lamp. For
details on how to check perform a photometer, refer to section 8.4.3 Perform a
Photocal in chapter 8.
the flagged result. In the presence of any abnormality, check the cuvette and the
cuvette washing station for possible overflows, then re-check the cuvette and the
cuvette washing nozzles.
* (Linearity error in rate methods)

This flag is generated when the rate of a reaction varies by more than the defined %
variance, as defined in Menu List>Parameters>Specific Test Parameters>General and
is therefore deemed non-linear. Possible causes are:
Contaminated reagent.
Unusually high result.
Defective cuvettes.
Light source lamp deteriorated.
Dirty or defective mix bars.
Reagent syringe or probe alignment problem.
Sample probe misalignment.
Outer cuvette walls or the cuvette wheel is wet.
Action:
1. Verify that the correct settings were programmed in [Parameters] [Specific Test
Parameters].
2. Replace reagent if contaminated or expired.
9-12
Error Flags
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November 1, 2009
3. Perform troubleshooting or maintenance procedures listed in the bullet points

above.
5. If the sample is assumed to be abnormally high, dilute the sample and repeat
analysis.
and after the flagged data results. If the issue persists contact
Beckman Coulter Technical services.
& (Prozone test data abnormal)

The data for prozone judgement is abnormal.
Action:
Dilute the sample and repeat analysis.
If the issue persists contact Beckman Coulter Technical Services.
Z (Prozone error)
The data check equation for any one of logic check 1, 2 or 3 is satisfied. This is often
caused by an abnormally high concentration of analyte in a sample.
Action:
E (Overreaction in a rate assay detected)

In the rate assay, the result is judged as an error by checking an overreaction in which
the reaction was finished in an excessively short time. This is often caused by an
abnormally high concentration of analyte in a sample.
Action:
Fx (Result (OD) is higher than dynamic range)

No concentration could be calculated. The OD of the sample exceeded the OD of the
upper limit of the dynamic range.
Action:
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November 1, 2009
Error Flags
9-13
Gx (Result (OD) is lower than dynamic range)

No concentration could be calculated. The OD of the sample is lower than the OD of the
low limit of the dynamic range.
Action:
1. Review the result in the clinical context of the patient and repeat if necessary.
2. Check the reagent probe and vials for proper position.
3. Check the reagents for bubbles.
! (Unable to calculate concentration)

The absorbance exceeds the limit of the calibration curve.
Action:
it again. Refer to the package insert for information on dilutions.
2. Verify reagent positions of the two reagent assays. An incompatible R1/R2
reagent combination often will cause absorbencies which exceed the measurable
limits.
3. Check syringes.
4. Check probes.
Technical services.

If Generated During ISE Measurement

Cause: An unstable reading has been generated, or the A/D conversion is over range.
Action:
Repeat the sample(s), if the problem persist, contact Beckman Coulter Technical
Services.
) ( Reagent lot no. used at sample analysis is different from that

used at calibration analysis)
The reagent lot number does not match the calibrated reagent lot number.
Action:
1. Calibrate the reagent used in the test that generated the flag.
2. Calculate the results manually by selecting Menu List>Routine>Sample
Manager>Main and use Recalculating function.
9-14
Error Flags
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November 1, 2009
a (Reagent expired)
The reagent has either expired or has been onboard beyond the period defined in the
Specific Test parameters.
Action:
Replace the reagents as soon as possible, perform a reagent check and perform a
calibration if necessary.
ba (No calibration data or expired)

There is no reagent blank or calibration data, or the data is expired.
Action:
1. Perform calibration. For details on calibrating tests, refer to section 5.5
Calibrating Tests in chapter 5.
2 Review calibration in Menu>Calibration>Calibration Monitor.
3. Repeat analysis for any sample that generated this flag.
bh (Invalid calibration data or expired)

The most recent reagent blank or calibration failed or is expired. Results can be
erroneous and should not be reported.
Action:
1. Perform calibration. For details on calibrating tests, refer to section 5.5
Calibrating Tests in chapter 5.
2. Review calibration in Menu>Calibration>Calibration Monitor.
3. Repeat analysis for any sample that generated this flag.
bn (Mastercurve used)
Calibration has either not been performed, or was not successful. The system has
used the lot-specific master curve to generate the result. Review calibration in
Menu>Calibration>Calibration Monitor.
Action:
Results can be erroneous and should not be reported.
1. Perform lot-specific user calibration.
2. Repeat analysis samples using a valid calibration.
For details on calibrating tests, refer to section 6.7 Performing a Repeat Run in
chapter 6.
bz (Calibration curve for Prozone data used)

The system has used the calibration curve for prozone data to generate the result. It is
similar to real result and should be used to estimate the dilution rate for repeat run.
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November 1, 2009
Error Flags
9-15
Action:
Carefully review any results generated with this flag and repeat the analysis in diluted
mode.
F (Result is higher than the dynamic range)

The concentration of the sample is above the dynamic range high limit. Set in Menu
List>Parameters>Specific Test Parameters>General.
Action:
Dilute the sample with the appropriate sample diluent and re-analyze.
Samples should be diluted so that they yield a value in the middle of the measuring
range.
G (Result is lower than the dynamic range)

The concentration of the sample is below the dynamic range low limit, set in Menu
List>Parameters>Specific Test Parameters>General. Or the reagent was not pipetted
properly.
Action:
1. Review the result in the clinical context of the patient and repeat if necessary.
2. Check the reagent probe and reagent bottle for proper position.
3. Check the reagents for bubbles.
ph (Result is higher than the upper panic value)

The result higher than the upper panic value. This is set in Menu
List>Parameters>Specific Test Parameters>Range.
Action:
This denotes that the result is outside user-defined panic ranges. Take immediate
action on behalf of the laboratory in accordance with local operating procedures.
pl (Result is lower than the low panic value)

The result lower than the low panic value. This is set in Menu List>Parameters>Specific
Test Parameters>Range.
Action:
This denotes that the result is outside user-defined panic ranges. Take immediate
action on behalf of the laboratory in accordance with local operating procedures.
9-16
Error Flags
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July 24, 2009
T (Abnormality found in inter-chemistry check.)

An abnormality has been detected by the checked tests i.e. result exceeds the check
range specified in Menu List>Parameters>Misc.>Checked Tests.
Action:
1. Repeat analysis.
2. Follow laboratory protocol for abnormal test results.
P (Positive)
Qualitative result: Sample result exceeds the upper value. This is set in Menu
Action:
No action required.
N (Negative)
Qualitative result: Sample result is lower than the low value. This is set in Menu
Action:
No action required.
H (Result is higher than reference range)

Result value is higher than value entered for level High in Specific Ranges in Menu
For details on setting reference intervals, refer to section 4.5.5 Set the Range in
chapter 4.
Action:
Follow laboratory protocol for abnormal test results.
L (Result is lower than reference range)

Result value is lower than value entered for level Low in Specific Ranges in Menu
For details on setting reference intervals, refer to section 4.5.5 Set the Range in
chapter 4.
Action:
Follow laboratory protocol for abnormal test results.
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July 24, 2009
Error Flags
9-17
J (Result is higher than the repeat decision range)

The result exceeds the repeat decision range. This is set in Menu
List>Parameters>Repeat Parameters>Repeat Specific.
Action:
Execute user defined action.
K (Result is lower than the repeat decision range)

The result is lower than the repeat decision range. This is set in Menu
Action:
fh (Result is higher than the repeat run reflex range)

The generated result is higher than a user specified reflex range, set in Menu
Action:
fl (Result is lower than the repeat run reflex range)

The generated result is lower than a user specified reflex range, set in Menu
Action:
9-18
Error Flags
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July 24, 2009
Va (The result of multiple measurement alienation check is NG)

The precision of replicates exceeds allowable range (set as analysis parameters).
Action:
Perform the appropriate maintenance:
Check syringes.
For details on inspecting syringes and tubes for air bubbles and leaks, refer to
sections 8.3.1 Inspect the Syringes for Leaks and Proper Installation and 8.3.2
Inspect the Wash Solution Roller Pump Unit for Leaks, in chapter 8
Check sample probe.
For details on how to check sample probe, refer to section 8.3.4 Inspect, Clean
and Prime the Sample, Reagent Probes, and Mix bars on in chapter 8.
Check for signs of system contamination.
xQ (Failure of one control used in a multirule QC)

If one of the two pairs of data, in multirule QC, is out of range, the other piece of data is
flagged. This is set in Menu List>Parameter>QC Parameters>QC Specific.
For details on setting single or multi-check QC rules (all samples), refer to section 4.8.2
Set the Specific Quality Control Parameters in chapter 4.
Action:
If QC results fall outside the acceptable range, investigate the cause before deciding
whether to report patient results. If any trends or sudden shifts in values are detected,
review all operating parameters.
Follow standard laboratory procedure for out-of-range QC results such as:
Repeat with fresh QC material.
Perform calibration as required.
Undertake maintenance as appropriate.
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July 24, 2009
Error Flags
9-19
1Q (QC data exceeds the range entered in Single Check Level field)
One point of QC data exceeds the limit defined in the Single Check Level on the check
tab in Menu List>Parameters>QC Parameters>QC Specific.
Action:
2Q (QC data exceeds 13SD control range)

One point of QC data exceeds the 3SD limit defined in the Multi Check Level on the
Check tab in Menu List>Parameters>QC Parameters>QC Specific.
Action:
9-20
Error Flags
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July 24, 2009
3Q (QC data continuously exceeds the 2 SD control limit

Two contiguous QC data points exceed the control limit of 2SD in the same direction.
This is set in Multi Check Level on the Check tab in Menu List>Parameters>QC
Parameters>QC Specific.
Action:
4Q (QC Data exceeds R4S control range)

One of the two consecutive high and low concentration QC data points exceeds the
control limit of +2SD and the other exceeds the control limit of -2SD. This is set in Multi
Check Level on the Check tab in Menu List>Parameters>QC Parameters>QC Specific.
The difference between two controls exceeds 4SD. This is set in Multi Check Level on
the Check tab in Menu List>Parameters>QC Parameters>QC Specific.
Action:
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July 24, 2009
Error Flags
9-21
5Q (QC Data exceeds 41S control range)

Four consecutive QC data point results have exceeded the 1SD limit. This is set in Multi
Check Level on the Check tab in Menu List>Parameters>QC Parameters>QC Specific.
Action:

6Q (A preset number of consecutive QC results fall on one side of

the mean)
Results for a preset number (7-10) of consecutive data points falls either above
or below the mean. This is set in Multi Check Level on the Check tab in Menu
List>Parameters>QC Parameters>QC Specific.
Action:
9-22
Error Flags
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July 24, 2009
7Q (Consecutive QC results show steadily increasing or decreasing

values)
Results for a preset number (4-10) of consecutive data points tends to increase
or decrease. This is set in Multi Check Level on the Check tab in Menu
List>Parameters>QC Parameters>QC Specific.
Action:
S (Sample repeated and original results replaced by repeat result)

A sample test has been repeated and this repeat result has replaced the previous result
to become the final result.
Action:
No action required.
/ (Test pending)
The test was not performed, even though it was requested (usually because of a
reagent shortage), or the result has not been reacted yet.
Action:
Review all results generated immediately prior to this flag for consistency and validity
(especially low or high results) and repeat if necessary.
1. Place new reagent onto the system and repeat analysis.
2. Inspect the reagent probe, clean or replace as necessary.
3. Ensure the reagent probe is correctly installed and connected.
r (Data transmitted to host)

Action:
No action required.
AU480 User Guide

July 24, 2009
Error Flags
9-23
c (Data corrected by user)

Data has been corrected in the Data Correction window.
For details on correcting results, refer to section 6.14 Editing Analysis Data in chapter
6.
Action:
No action specifically required. Review any edited or changed data carefully prior to
reporting results.
9-24
Error Flags
AU480 User Guide

July 24, 2009
10 Error Messages
This chapter describes the error messages that operators can
encounter.
Contents
After checking cups on STAT table, please perform STAT check
in STAT status menu. .....................................................................................10-3
After checking printer, please resume printer in XXXX menu.
XXXX: window name. ....................................................................................10-3
After closing the reagent refrigerator lid, please perform reagent check. ...................10-3
Calibration requisition is renewed. Please set new calibrator on STAT table. ............10-3
Calibration stability is expired.
Please open Calibration requisition menu and requisition the item. ..............10-3
Calibration stability will be expired soon. ....................................................................10-4
Concentrated waste tank full ......................................................................................10-4
Cuvette Error found. Please check it at User Maintenance. .......................................10-4
Diluted Wash Solution short. ......................................................................................10-4
Dispensed STAT sample exists. .................................................................................10-4
Error sample(s) exists. Please check sample(s) in STAT Status menu. .....................10-5
Host communication in progress ................................................................................10-5
Incorrect Parameter is found. Please open [MM...MM] menu
and check the parameters. MM...MM: Menu name........................................10-5
Liquid remains in Vacuum tank. .................................................................................10-5
No Cup to be processed on STAT table. ....................................................................10-6
No deionized water. Please check water outlet valve. ...............................................10-6
No Master Curve is scanned. Please check it at Reagent Management. ..................10-6
No Photocal Data. Please perform photocal at User Maintenance. ...........................10-6
No Reagent volume. Please check it at Reagent Management. ................................10-7
Please check STAT Status and set calibrators as needed. ........................................10-7
Please check STAT Status and set controls to be needed. ........................................10-7
Please check STAT Status and set RB cup as needed. .............................................10-7
Please perform Reagent Check. ................................................................................10-8
Printing in Progress. ...................................................................................................10-8
QC requisition is renewed. Please set new control on STAT table. ............................10-8
QC requisition is renewed. Please set new control. ...................................................10-8
Rack collection area full .............................................................................................10-8
RB stability is expired. Please open Calibration requisition menu
and requisition the item. ................................................................................10-9
RB stability will be expired soon. ................................................................................10-9
Reagent error found. Please check it at Reagent Management. ...............................10-9
Reagent is expired. Please check Reagent Management
and set new reagent in the refrigerator. .........................................................10-9
Reagent with the new reagent lot is added. ...............................................................10-9
R Probe wash solution is not set. .............................................................................10-10
S Probe diluent is not set. ........................................................................................10-10
AU480 User Guide

July 24, 2009
Error Messages
10-1
S Probe wash solution is not set. .............................................................................10-10

Temperature of the Incubator is outside or exceeds the normal range. ...................10-10
Temperature of the refrigerator is over (under) the normal range. ...........................10-10
Test has no Calibration Data. Please open Calibration requisition menu
and requisition the item. ..............................................................................10-10
Test has no RB Data. Please open Calibration requisition menu
and requisition the item. .............................................................................. 10-11
Test items are set as Disabled at Start Condition. .................................................... 10-11
The cover of Dispensing Position is open. ............................................................... 10-11
The cover of Rack Supply Unit is open. ................................................................... 10-11
The cover of reagent refrigerator is open. ................................................................ 10-11
The large cover of STAT table is open. ....................................................................10-12
The sample on STAT table is incorrect. Please check it on STAT status menu. ......10-12
The small cover of STAT table is open. ....................................................................10-12
The volume is reached to Alarm volume. Please check it
at Reagent Management. ............................................................................10-12
Wash Solution short. ................................................................................................10-12
Waste Tank full..........................................................................................................10-13
Error Messages In the Comment column.......................................................................10-14
Error Messages using the HOME menu.........................................................................10-16
Error Messages Using the Start menu or Shifting to Another mode..............................10-19
Messages Starting STAT.....................................................................................................10-26
STAT Table Tab Comments.................................................................................................10-28
10-2
Error Messages
AU480 User Guide

July 24, 2009
After checking cups on STAT table, please perform STAT check in STAT status
menu.
Cause:
The STAT table cover is open or parameter has been changed.
Action:
1. Check that the sample cups have been set in place on the STAT table.
2. Perform STAT check operation on the STAT Status window.
After checking printer, please resume printer in XXXX menu. XXXX: window
name.
Cause:
The printer status is abnormal.
Action:
Resume printing on the Analyzer Status window.
After closing the reagent refrigerator lid, please perform reagent check.
Cause:
After opening the reagent refrigerator lid, reagent check has not been performed.
Action:
Perform reagent check on the Reagent Management window.
Calibration requisition is renewed. Please set new calibrator on STAT table.

Action:
1. Check the STAT Status window to set the calibrators again.
2. If the STAT Operation has been set to Manual on the Analysis Mode window,
perform STAT check.
Calibration stability is expired. Please open Calibration requisition menu and

requisition the item.
Cause:
Calibration data has expired.
Action:
1. Implement a calibration requisition on the Calibration window.
2. Perform calibration analysis.
AU480 User Guide

July 24, 2009
Error Messages
10-3
Calibration stability will be expired soon.

Cause:
Calibration data is just close to expiration.
Action:
Concentrated waste tank full

Cause:
The tank is full of concentrated waste liquid.
Action:
Contact Beckman Coulter Technical Services.
Cuvette Error found. Please check it at User Maintenance.

Cause:
An anomaly has been found in the cuvette.
Action:
Check the cuvette on the User Maintenance window.
Diluted Wash Solution short.

Action:
There is insufficient diluted wash solution. Check and replenish if necessary.
Dispensed STAT sample exists.

Cause:
The sample has been dispensed at the sample position where the STAT Table
attribution was set to First Run or Repeat Run.
Action:
1. Check the sample on the STAT Status window, and remove the sample cup.
perform STAT check.
10-4
Error Messages
AU480 User Guide

July 24, 2009
Error sample(s) exists. Please check sample(s) in STAT Status menu.

Cause:
An anomaly has been found in a sample that has been set on the STAT table.
Action:
1. Check the error information on the STAT Status window.
2. Take an appropriate action for the error.
perform STAT check.
Host communication in progress

Cause:
The analyzer is under communication with the host computer.
Action:
Check the analyzer for the status of communication with the host computer on the
Analyzer Status window.
Incorrect Parameter is found. Please open [MM...MM] menu and check the
parameters. MM...MM: Menu name.
Cause:
An error occurs in parameter check on either of parameter-related windows.
Action:
Check the parameters according to the indication.
Liquid remains in Vacuum tank.

Cause:
Waste liquid exists in the vacuum tank.
Action:
AU480 User Guide

July 24, 2009
Error Messages
10-5
No Cup to be processed on STAT table.

Cause:
No sample has been set on the STAT table.
Action:
Set the samples to be analyzed.
No deionized water. Please check water outlet valve.

Cause:
Displayed when deionized water tank is empty.
Unless the deionized water replenished in 20 minute after alarmed, the system will
change to STOP mode for safety and will need to be restarted.
Action:
1. Check the water outlet valve.
2. If no abnormality is found in the water outlet system, contact Beckman Coulter
Technical Services.
No Master Curve is scanned. Please check it at Reagent Management.

Cause:
Reagent bottles with new lots of reagents have been set.
Action:
1. Check them in detail on the Reagent Management window.
2. Read the data of master curves for the required tests with a hand-held scanner.
No Photocal Data. Please perform photocal at User Maintenance.

Cause:
No Photocal data exists.
Action:
Perform Photocal measurement on the User Maintenance window.
10-6
Error Messages
AU480 User Guide

July 24, 2009
No Reagent volume. Please check it at Reagent Management.

Cause:
A test cannot be performed due to insufficient reagent required for analysis.
Action:
1. Check it in detail on the Reagent Management window.
2. Replenish reagent as needed.
Please check STAT Status and set calibrators as needed.

Cause:
The calibrators required for the calibration analysis are not set on the STAT table.
Action:
1. Check the calibrators required on the STAT Status window.
2. Set the calibrators on the STAT table.
perform STAT check.
Please check STAT Status and set controls to be needed.

Cause:
The controls required for the QC analysis are not set to the STAT table.
Action:
1. Check the controls required on the STAT Status window
2. Set the controls in the STAT table.
perform STAT check.
Please check STAT Status and set RB cup as needed.

Cause:
The RB cup required for the reagent blank analysis is not set on the STAT table.
Action:
1. Check the RB cup required on the STAT Status window.
2. Set the RB cup in the STAT table.
perform STAT check.
AU480 User Guide

July 24, 2009
Error Messages
10-7
Please perform Reagent Check.

Cause:
The reagent refrigerator lid is opened or a parameter is changed.
Action:
Perform reagent check on the Reagent Management window.
Printing in Progress.
Cause:
Batch print or real-time print is being performed in standby mode.
Action:
Check the printer status on the Analyzer Status window.
QC requisition is renewed. Please set new control on STAT table.

Action:
1. Check the STAT Status window to set the control sample again.
perform a STAT check.
QC requisition is renewed. Please set new control.

Action:
1. Check the control setting positions on the STAT Status window to set the control
again.
perform a STAT check.
Rack collection area full

Cause:
The rack storage unit is full of racks.
Action:
Remove the rack from the rack storage.
10-8
Error Messages
AU480 User Guide

July 24, 2009
RB stability is expired. Please open Calibration requisition menu and

Cause:
Reagent blank data has expired.
Action:
1. Implement a reagent blank requisition on the Calibration window.
2. Perform reagent blank analysis.
RB stability will be expired soon.

Cause:
Reagent blank data is just close to expiration.
Action:
Reagent error found. Please check it at Reagent Management.

Cause:
An error has been found in setting reagent bottles.
Action:
Check reagent bottle location on the Reagent Management window.
Reagent is expired. Please check Reagent Management and set new reagent in
the refrigerator.
Cause:
An expired reagent bottle has been found.
Action:
1. Check reagents in detail on the Reagent Management window.
2. Replace the expired reagent bottles with a new reagent bottle.
3. After adding a new reagent bottle, check the reagent.
Reagent with the new reagent lot is added.

Reagent bottles with new lots of reagents have been added.
AU480 User Guide

July 24, 2009
Error Messages
10-9
R Probe wash solution is not set.

Action:
Add the reagent probe wash solution.
S Probe diluent is not set.

Action:
Add the sample diluent.
S Probe wash solution is not set.

Action:
Add the sample probe wash solution.
Temperature of the Incubator is outside or exceeds the normal range.

Cause:
When analysis is started, no correct analysis data can be output due to abnormal
temperature in the cuvette.
Action:
Check the incubator cover.
Temperature of the refrigerator is over (under) the normal range.

Cause:
The reagent refrigerator temperature is abnormal.
Action:
Check the refrigerator cover.
Test has no Calibration Data. Please open Calibration requisition menu and
Cause:
No calibration data exists. Calibration analysis failed.
Action:
10-10
Error Messages
AU480 User Guide

July 24, 2009
Test has no RB Data. Please open Calibration requisition menu and requisition
the item.
Cause:
No reagent blank data exists. Otherwise, a reagent blank analysis failed to be made.
Action:
Test items are set as Disabled at Start Condition.

Cause:
There exist tests for which masking has been set on the Start Condition window. The
disabled test items will not be analyzed.
The cover of Dispensing Position is open.

Cause:
The rack unit cover is open.
Action:
Close the cover.
The cover of Rack Supply Unit is open.

Cause:
The rack supply unit cover is open.
Action:
Close the cover.
The cover of reagent refrigerator is open.

Cause:
The reagent 1 refrigerator lid is open.
Action:
Close the cover.
AU480 User Guide

July 24, 2009
Error Messages
10-11
The large cover of STAT table is open.

Cause:
The large STAT table cover (L) is open.
Action:
Close the STAT table cover (L).
The sample on STAT table is incorrect. Please check it on STAT status menu.
Cause:
Error sample(s) exists on the STAT table.
Action:
1. Check the error information on the STAT Status window.
2. Take an appropriate action for the error.
perform STAT check.
The small cover of STAT table is open.

Cause:
The STAT table cover (S) is open.
Action:
Close the STAT table cover (S).
The volume is reached to Alarm volume. Please check it at Reagent

Management.
Cause:
The remaining number of reagent shots has been reduced under the specified number.
Action:
1. Check reagents in detail on the Reagent Management window.
2. Add a new reagent bottle.
3. After adding a new reagent bottle, check the reagent.
Wash Solution short.

Action:
There is insufficient wash solution. Check and replenish if necessary.
10-12
Error Messages
AU480 User Guide

July 24, 2009
Waste Tank full

Cause:
The tank is full of waste liquid.
Action:
AU480 User Guide

July 24, 2009
Error Messages
10-13
Error Messages In the Comment column

To verify an error message in the comment column:
Select Menu List>Routine>Reagent>Detail
Reagent Related Errors
Descriptions
Reagent ID Error
A reagent error occurred.
Undefined Reagent
The reagent is not programmed in the group.
Incorrect reagent ID
The edited reagent ID is incorrect.
Incorrect Bottle Size
The edited bottle size is incorrect.
Overlapped Reagent Position
The position is occupied by multiple bottles.
Bottle Set Miss
The reagent bottle is placed on a different position while in

Pause mode.
No Reagent
No bottle is detected on fixed position during the reagent check.
Same Reagent Bottle
The same lot # and bottle # are present within the same item.
However, when the lot # and the bottle # are not defined, it will not
be an error.
No Lot No. / Bottle No.
No lot # and bottle # are defined on the item that is set to the
Advance Cal and Auto Cal.
Expired
The reagent date has expired.
Onboard Expired
The reagent on-board stability has expired.
Unpaired Reagent
No pair bottles are present in the REF comportment.
R1(R1-1) Unset
The R1 of the R1/R2 pair is missing.
R2(R2-1) Unset
The R2 of the R1/R2 pair is missing.
No Reagent (XXXXXX,YY)
No common reagent is present. The display is as follows.

XXXXXX,YY
XXXXXX : Common reagent
YY
: Position
Dilution Unset
Pre-Dilution is not defined.
No Color Reagent (XXXXXX)
The color reagent (TBIL of DBIL) is missing.
No Blank Reagent (XXXXXX)
The blank reagent (TBIL of DBIL) is missing.
No T-Hb Reagent
No Pretreatment
Over Max Bottle
(1) When there is no setting on the [ Lot to Lot calibration ], there

are more than 6 series of bottle switching
(2) When there is a setting on the [ Lot to Lot calibration ], there
are more than 3 series of switching.
No Master Curve
No master curve is present on the lot.
No Volume to Process
No reagent left for analysis while in Measure
No Volume in the Bottle
No reagent left in the bottle.
Lack of Volume
Reagent shots is less than the specific shots on the item.
No Calibration Data
No calibration data for a lot or bottle
No CAL Data for Reference
When in use of Lot to Lot calibration, no calibration data on the lot.
CAL. Failed
Calibration failed.
CAL. Stability Expired
Calibration stability expired.
CAL. Expired soon
Calibration expires in a few (pre-programmed) hours.
No RB Data
No RB data for a lot bottle.
RB Failed
Reagent blank failed.
RB stability expired
Reagent blank expired.
RB Expired soon
RB expires in a few (pre-programmed) hours.
mode.
The following messages are statements, not errors.
10-14
Errors related to the reagents
Descriptions
ID Edit
The position that has failed ID reading is edited.
Error Messages
AU480 User Guide

July 24, 2009
Reagent Related Errors

[ Position occupied ] *1
Descriptions
The reagent position is occupied by a large bottle.
This message is not fixed, may change to another message later.
AU480 User Guide

July 24, 2009
Error Messages
10-15
10-16
Error Messages
AU480 User Guide
July 24, 2009
Level
No.
10
11
12
No R-Probe Wash
Solution.
No Diluted Solution.
No Reagent(s).
The other abnormalities

in Analyzer.
Incorrect Cuvette(s))
Photocal not performed.
No S-Probe Wash
Solution.
Under Printing.
Under Online
communication.
Incorrect Parameter(s).
STAT Check not

performed.
Reagent Check not

performed.
Main Message (Big

Letters)
Measurement of the following test(s)

cannot be performed.


Measurement cannot be started.

(Note: This is within Standby mode.)

(Note: This is within Standby mode.)
Sub Message (Small Letters)
Item No. / Name
Item No. / Name
Item No. / Name
None
None
None
None
None
Menu names
None
None
Refer to Menu
Check Reagent Management menu and set a

required wash solution.

required diluted solution.
Check Reagent Management menu and set

required reagent(s).
Check Analyzer Status menu.
Check User Maintenance menu and

exchange incorrect cuvette(s)).
Perform Photocal with User Maintenance

menu.

required wash solution.
Wait for a while till printing is finished.
Wait for a while till online communication is

closed.
Check the setting of the parameter menus.
Check STAT Status menu and perform STAT

Check.
Check Reagent Management menu and

perform Reagent Check.
Actions to be taken
No. indicates that the newer numbers are higher priority than the older numbers.
Level = 0 or 1 indicates that the analysis can/may not be performed. Level = 2 or 3 indicates a Notification (Information).
Actions to be taken in the popup display after the message is selected.
This table details the error message, menu to refer to, and the actions to be taken when an error message appears when the Home button is selected.
Error Messages using the HOME menu
AU480 User Guide
July 24, 2009
Error Messages
10-17
Level
No.
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Calibration Expires
Soon.
RB Data Expires Soon.
Reagent Expires Soon.
Reagent Short.
Masking Item exist.
Consumption needs to
be exchanged.
ISE selectivity check

error.
ISE slope range over.
ISE selectivity check not

performed.
Daily Calibration not

performed.
ISE STOP
Reagent Expired.
No Calibration.
No RB Data.
No Master Curve.
Maintenance not
performed.
Main Message (Big

Letters)

becomes impossible soon.




Measurement may not be performed

correctly.
ISE may not be measured correctly.
ISE measurement cannot be

performed.
Measurement is performed by the

reagent of expiration.



Measurement may not be performed

correctly.
Item No. / Name
Item No. / Name
Item No. / Name
Item No. / Name
Item No. / Name
None
None
None
None
None
None
Item No. / Name
Item No. / Name
Item No. / Name
Item No. / Name
None
Refer to Menu

measure Calibration about the test.

measure RB about the test.

required bottle(s).

required bottle(s).
Cancel Masking with Start Condition menu to

perform measurement.
Check User Maintenance menu and perform

required maintenance.
Perform Selectivity check.
Perform Daily Calibration.
Perform Selectivity check.
Perform Daily Calibration.
Shift ISE to Ready mode.

perform Reagent Check.
Measure Calibration about the test(s)

selected by the Reagent Check.
Measure RB about the test(s) selected by the

Reagent Check.

required Master Curve.
Check User Maintenance menu and perform

required maintenance.
Actions to be taken
10-18
Error Messages
AU480 User Guide
July 24, 2009
Level
No.
29
30
31
32
33
34
35
36
37
38
39
Empty Bottle(s).
Incorrect Bottle(s).
Under Printing.
Under Online
communication.
ISE REF Solution Short.
ISE BUF Solution Short.
ISE MID Solution Short.
The other abnormalities

in Analyzer.
S-Probe Wash Solution

Short.
R-Probe Wash Solution

Short.
Diluted Solution Short.
Main Message (Big

Letters)
Measurement can be started.
Measurement can be re-started.

(Note: This is within Measure mode.)
Measurement can be re-started.

(Note: This is within Measure mode.)
S-Probe Wash Solution becomes

empty soon. Measurement may not be
performed correctly.
R-Probe Wash Solution becomes

empty soon. The following items may
not be measured correctly.

R1/R2
None
None
None
None
None
None
None
None
Item No. / Name
Item No. / Name
Refer to Menu

remove empty bottle(s).

remove incorrect bottle(s).
System Status can be confirmed with

Analyzer Status menu.
System Status can be confirmed with

Analyzer Status menu.
Exchange REF Solution bottle.
Exchange BUF Solution bottle.
Exchange MID Solution bottle.
Check Analyzer Status menu.
Check Reagent Management menu and refill

a required wash solution.

a required wash solution.

a required diluted solution.
Actions to be taken
AU480 User Guide
July 24, 2009
Error Messages
10-19
The printer is busy in batch printing

when in sta ndb y mode.
The HOST communication is busy in
batch import or export when starting
from sta n dby mode.
No Reagent check has been made.
STAT check is required on the STAT
status.
Under printing to printer.
Under communicating with HOST.
Please perform Reagent Check.
After checking cups on STAT table,

please perform STAT check in STAT
status menu.
1
1
The sub cover of STAT table is

open.
The main cover of STAT table is

open.
1. Starting measure from rack
When items that are defined Auto
Cal or Auto QC are in the round,
the small cover on the STAT table is
open.
2. Starting measure from STAT
When the small cover on the STAT
table is open.
When unexpected state in present,

refer to the users guide, section
7.1.7.2.2.
After checking printer, please

resume printer in Analyzer Status
menu.
1
Explanations
Incorrect parameter is found. Please MMM.MM indicates the second

open [MM....MM/NN....NN] menu
level menu.
and check the parameters.
NNN.NN indicates the third level
menu.
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
The table below details any error messages and their explanation when the Start button is selected.
Standby M1
M2 M1
M1PAUSE
M2PAUSE
Check timing (When is it checked?)

indicates as Check.
indicates as No Check
Error Messages Using the Start menu or Shifting to Another mode
Start by
ANL
10-20
Error Messages
AU480 User Guide
July 24, 2009
1
1
1
1
Full of Waste tank.
Full of Conc Waste tank
Liquid is remained in Vacuum tank.
Full of rack at Rack Collection.
The Scratch check / Cuv check /

Lamp check / Dispersion check will
be checked when Fatal error is set
on the maker setting in the system
maintenance menu.
Diluted Wash Solution short
Cuvette Error found. Please check it

at User Maintenance.
Wash Solution short
The photocal will be checked when

1
Fatal error is set on the maker setting
in the system maintenance menu.
No deionized water. Please check

water supply valve.
No Photocal Data. Please perform

photocal at User Maintenance.
The cover of repeat position is open.
The temperature will be checked when 1

Fatal error is set on the maker setting
in the system maintenance menu.
The cover of Dispensing Position is

open.
Temperature of the refrigerator is

over(under) the normal range.
The cover of Rack Feeder is open.
1
1
The cover is open on the R1 REF.
Explanations
ISE cover is open.
The cover of reagent refrigerator is

open.
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
Standby M1
M2 M1
M1PAUSE
M2PAUSE

indicates as Check.
Start by
ANL
AU480 User Guide
July 24, 2009
Error Messages
10-21
The temperature will be checked when 2

No fatal error is set on the maker
setting in the system maintenance
menu.
Temperature of the incubator bath is

ISE Status is stop.
The small cover of STAT table is

open.
When either case is met, the small

cover will not be checked.
1. Items that are defined Auto QC
or Auto QC is in the round.
2. The main cover already is open.

2
QC is in the round, there will be cups
to be required for the renew by the QC
requisition.
QC requisition is renewed. Please

set new control on STAT table.
Temperature of the refrigerator is


Cal is in the round, there will be cups
to be required for the renew by the
calibration requisition.
Calibration requisition is renewed.

Please set new calibrator on STAT
table.

Cal or Auto QC are in the round, the
samples on the STAT will be located
wrong positions or not in present.
The sample on STAT table is

incorrect. Please check it on STAT
status menu.
The reagent rest volume will be

checked when STOP is set on the
analysis mode parameter on the
system condition menu.
Explanations
No S Probe Wash Solution.
No Reagent. Please check it at

Reagent Management.
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
Standby M1
M2 M1
M1PAUSE
M2PAUSE

indicates as Check.
Start by
ANL
10-22
Error Messages
AU480 User Guide
July 24, 2009
The reagent rest volume will be

checked when CONTINUE is set on
the analysis mode parameter on the
system condition menu.
There will be bottles in present that
have not the master curve.
In the R1 REF.
In the R1 REF.
No Reagent volume to analyze

anymore. Please check it at
Reagent Management.
Master Curve is not scanned.

Please check it at Reagent
Management.
Reagent is expired. Please check

Reagent Management and set new
reagent in the refrigerator.
Onboard Stability is expired. Please

check Reagent Management and
set new reagent in the refrigerator.
Test has no RB Data. Please open

Calibration Requisition menu and
requisition the test.
Refer to the below table for more

details regarding the Reagent Error.
Reagent error found. Please check

it at Reagent Management.
ISE select error(K)
MMM.MM indicates the item

name.
NNN.NN indicates the sample
kind.
ISE slope is over(under) the range

[MMMMMM, NN....NN]
ISE select error(Na)
MMM.MM indicates the item

name.
NNN.NN indicates the sample
kind.
Explanations
ISE slope is zero [MMM....MM,

NN....NN]
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
Standby M1
M2 M1
M1PAUSE
M2PAUSE

indicates as Check.
Start by
ANL
AU480 User Guide
July 24, 2009
Error Messages
10-23
2
2
2
This is the same with the message

No. 1022.
However, the Cuv check will be
checked when No fatal error is set
maintenance menu.
This is the same with the message
No. 1022.
However, the Cuv check will be
checked when No fatal error is set
maintenance menu.
Calibration stability is expired.

Please open Calibration Requisition
menu and requisition the test.
RB stability is expired. Please open

Calibration Requisition and
No R Probe wash solution at

Reagent Management menu.
No Diluent. Please check it at

Reagent Management menu.
No Photocal Data. Please perform

photocal at User Maintenance.
Cuvette Error found. Please check it

at User Maintenance.
2
3
Maintenance item is expired. Please

perform maintenance.
Please check STAT Status and set

RB cup to be needed.
Explanations
Test has no Calibration Data. Please

open Calibration Requisition and
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
Standby M1
M2 M1
M1PAUSE
M2PAUSE

indicates as Check.
Start by
ANL
10-24
Error Messages
AU480 User Guide
July 24, 2009
3
3
3
3
3
3
3
3
Overflow of Diluted wash solution.

Please check the tank.
Overflow of Deionized water. Please

check the tank.
ISE MID Solution short
ISE BUF Solution short
ISE BUF Solution short
Calibration stability will be expired

soon.
RB stability will be expired soon.
The volume is reached to Alarm

volume. Please check it at Reagent
Management.
Lack of S Probe Wash Solution.

Management.
Lack of R Probe Wash Solution.

Management.
Test item(s) is set as Disabled at

Start Condition.

controls to be needed.
Lack of Diluent. Please check it at

Reagent Management.
Explanations

calibrators to be needed.
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
Standby M1
M2 M1
M1PAUSE
M2PAUSE

indicates as Check.
Start by
ANL
AU480 User Guide
July 24, 2009
Error Messages
10-25
1
1
1
1
1
1
1
1
No rack at Rack Set Pos.
Incorrect rack at Rack Set. Please

remove it.
Incorrect rack at Normal Lane.

Please remove it.
Incorrect rack at buffer. Please

remove it.
Incorrect rack at Rack Return.

Please remove it.
Incorrect rack at Repeat Run Lane.

Please remove it.
Please check the alarm.
Unable to start. Please wait.
R2(R2-1) Unset
No common reagent
Dilution Unset
No Color Reagent
No T-Hb Reagent
No Pretreatment
Over Max Bottle
Reagent ID Error
Incorrect reagent ID
Incorrect Bottle Size
Overlapped Reagent Position
Bottle Set Miss
No Reagent
Same Reagent Bottle
Error descriptions of the Message

No. 1161
Explanations
Maintenance item will be expired

soon. Please check it.
Messages
Level
1 Fatal Error
2 No Fatal Error
3 Notification
(Information)
Standby M1
M2 M1
M1PAUSE
M2PAUSE

indicates as Check.
Start by
ANL
10-26
Error Messages
AU480 User Guide
July 24, 2009
When either case is met, the message will come up.

1. No cups on the STAT table.
2. No samples on the STAT table that will be able to
measure.
There are cups to be required for the renew by the
calibration requisition.
There are cups to be required for the renew by the QC
requisition.
No Cup to be processed on STAT

table.
Calibration requisition is renewed.

Please set new calibrator on STAT
table.
QC requisition is renewed. Please

set new control on STAT table.
These are the same descriptions

with the Messages (M Start).
When either case is met, the message will come up.

1. Sample(s) that are attached on the level 1 are in
present.
2. Other IDs are in present.
The sample on STAT table is

incorrect. Please check it on STAT
status menu.

Check
No.2
(Start by
ANL)
Check
No.3
(Not in
use)
Auto Analysis mode

Check
No.1
(Start
STAT
analysis)
Explanations
Error Level
1 Fatal Error
2 No Fatal Error
3 Notification (Information)

Messages
To verify Error Messages when starting STAT:

Select Menu List>STAT Requisition>STAT Status>Start STAT (F1)
Messages Starting STAT
Check
No.1
(Start
STAT
analysis)
Check
No.2
(Start by
ANL)
Normal mode
AU480 User Guide
July 24, 2009
Error Messages
10-27

There are samples in present that have already been

analyzed.
Dispensed STAT sample exists.
The error message will be displayed on the Comment 3

tab in the STAT status menu. For more information
refer to STAT Table Tab Comments table in this
chapter.

controls to be needed.
Error sample(s) exists. Please

check sample(s) in STAT Status
menu.

calibrators to be needed.
When one of the RB cup positions has no cup, the

message will come up.

RB cup to be needed.
Check
No.2
(Start by
ANL)
Check
No.3
(Not in
use)
Auto Analysis mode

Check
No.1
(Start
STAT
analysis)
Explanations

Messages
Error Level
1 Fatal Error
2 No Fatal Error
3 Notification (Information)
Check
No.2
(Start by
ANL)
Normal mode
Check
No.1
(Start
STAT
analysis)
10-28
Error Messages
AU480 User Guide
July 24, 2009
Not in use of
bar code label
Routine
sample
ACAL Sample Not in use of

bar code label
In use of bar
code label
Bar code Label
Sample Kinds
Edited ID
Cup exists
Dispense
failed
No cup
No cup
ID Read Error 2
Different ID
Same ID
Dispense
failed
Broken ID
No cup
*2
Level
No
assignment
Error
Messages
*1
Priority
Explanations
Unexpected cup exists.
Sample has been removed while it is being analyzed.
ID has been edited after failed ID reading.
Sample has not been dispensed.

(This is not available as of 12/14, this may be changed later.)
ID reading is failed with the STAT check.
Sample has been replaced with another while it is being analyzed.
Same ID exists on the STAT table.

(This will apply both original run and repeat run.)
Same ID is read consecutively.

Cup that is already assigned has been removed.
Sample has not been assigned.

(This message will not be displayed under the Auto analysis mode.)
*1 The Priority column lower numbers are higher priority than the older numbers
*2 Level 1 Fatal Error
Level 2 No Fatal Error
Level 3 Notification (Information)
If the following error is received when starting STAT,

Error sample(s) exists. Please check sample(s) in STAT Status menu.
To verify the cause of the error Select Menu List>Routine>STAT Requisition>STAT Status
STAT Table Tab Comments
AU480 User Guide
July 24, 2009
Error Messages
10-29
QC Sample
Sample Kinds
Sample Kinds
Not in use of
bar code label
Bar code
In use of bar
code label
Bar code Label
ID Read Error 2
Undefined ID
Cal Set Miss
No cup
Unnecessary
cup
Dispense
failed
Edited ID
10
No cup
Cup exists
Cup to be
changed
Dispense
failed
Priority Error
Messages
Different ID
Explanations

Unnecessary calibrator has on the STAT table against the CAL test requisitions.
Calibrator is placed in a wrong position.
Calibrator ID exists that has not been assigned.
Calibrator has been replaced with another while it is being analyzed.
Same calibrator ID is assigned on the STAT table.

When Cal test requisition has been changed from the previous cal setting (Cal # ,
position), the message will generate for reminding the change.

When QC test requisition has been changed from the previous QC setting (QC # ,
position), the message will generate for reminding the change.
Unexpected cup exists.
Level Explanations
Duplicated ID
Broken ID
Dispense
failed
*2
Level
Cup to be
changed
Error
Messages
*1
Priority
10-30
Error Messages
AU480 User Guide
July 24, 2009
RB Sample
Sample Kinds
Not in use of
bar code label
In use of bar
code label
Bar code Label
No cup
Unnecessary
cup
Dispense
failed
Edited ID
10
Unnecessary
cup
QC Set Miss
Undefined ID
No cup
ID Read Error 2
Different ID
Duplicated ID
*2
Level
Broken ID
Error
Messages
*1
Priority
Explanations
Unnecessary cup is placed on the STAT table.

Unnecessary QC control has on the STAT table against the QC test requisitions.
QC control is placed in a wrong position.
QC control ID exists that has not been assigned.
QC control has been replaced with another while it is being analyzed.
Same QC control ID is assigned on the STAT table.
11 Troubleshooting
This chapter can assist in locating and solving any problems that may
occur when operating the AU480.
Contents
11.1 Troubleshooting and Maintenance ............................................................................11-3
11.2 Troubleshooting the System Data Problems ...........................................................11-3
11.2.1 Data Problem Checklist ................................................................................. 11-3
11.2.2 Checking Abnormal Data ............................................................................... 11-4
11.2.3 Troubleshooting Software .............................................................................. 11-5
11.3 Troubleshooting the System - Reagents and Samples ...........................................11-7
11.3.1 Sample Related Issues .................................................................................. 11-7
11.3.2 Reagent Related Issues ................................................................................ 11-8
11.3.3 QC and Calibrator Related Issues ................................................................. 11-8
11.3.4 Wash Solution Related Issues ....................................................................... 11-9
11.3.5 Deionized Water Related Issues ................................................................... 11-9
11.3.6 Other Causes of Abnormal Data .................................................................... 11-9
11.4 Troubleshooting the System - Mechanical Problems ............................................11-10
11.4.1 Syringe Problems ........................................................................................ 11-10
11.4.2 Probe Problems ........................................................................................... 11-11
11.4.3 Abnormal Data Caused by Cuvette Wheel or Wash Nozzles ...................... 11-12
11.4.4 Abnormal Data Caused by Photometer Lamp or Photometer Unit .............. 11-13
11.4.5 Mixing Problems .......................................................................................... 11-13
11.4.6 Deionized Water Tank Problems ................................................................. 11-13
11.4.7 Deionized Water or Filter Problems ............................................................. 11-14
11.4.8 Incubation Temperature Problems ............................................................... 11-14
11.4.9 Piping and Pump Problems ......................................................................... 11-14
11.4.10 Reagent Refrigerator Problems ................................................................... 11-15
11.4.11 STAT Table Problems .................................................................................. 11-15
11.4.12 Rack Problems ............................................................................................ 11-15
11.5 Troubleshooting the System - System Problems ..................................................11-16
11.5.1 TEMP REF HIGH Alarm for the Cooling Unit .............................................. 11-16
11.5.2 Abnormal Sound from Inside the System..................................................... 11-16
11.5.3 Empty Alarm for the Water Supply Tank....................................................... 11-17
11.5.4 Leaks from the Wash Solution Roller Pump................................................. 11-17
11.5.5 Barcode Errors ............................................................................................ 11-18
11.5.6 Leaks from the Bottom of the System ......................................................... 11-18
11.5.7 No Wash Solution to Mix bars ..................................................................... 11-18
11.5.8 Reagent Alarm when Sufficient Reagent Remains in Bottles ...................... 11-18
11.5.9 Sample Alarm when Sufficient Sample Remains ........................................ 11-18
11.5.10 No Sample Cup Alarm when Sample Cup is Present .................................. 11-19
11.5.11 No Sample Cup on the STAT Table ............................................................. 11-19
11.5.12 Printer Not Printing or Printer Light Not On ................................................. 11-19
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July 24, 2009
Troubleshooting
11-1
11.5.13 Liquid Leaking from the Reagent Probe and Sample Probe ....................... 11-19
11.5.14 Reagent Probe and Sample Probe not Aligned over the Cuvette ............... 11-19
11.5.15 Error Flag # (Sample Level Detection Error) Displayed in
the Second Half of the Sample Dispense Operation .................................. 11-20
11.5.16 Sample Rack Jammed ................................................................................ 11-20
11.5.17 Printer Problems .......................................................................................... 11-20
11.6 Troubleshooting the System - Data Processor Problems .....................................11-21
11.6.1 Menu Cannot be Selected ........................................................................... 11-21
11.6.2 Number Key Pad on Keyboard Does Not Work .......................................... 11-21
11.6.3 Keyboard Not Responding .......................................................................... 11-21
11.6.4 Inaccessible Floppy Disc ............................................................................. 11-22
11.6.5 Results Do Not Print Automatically .............................................................. 11-22
11.6.6 Online Auto-Output by Host Computer Not Executed ................................. 11-22
11.6.7 Unsuccessful Movement of Data between the System
and the Host Computer................................................................................ 11-22
11.7 Recovering from an Emergency Stop or Power Loss ...........................................11-23
11.7.1 Performing an Emergency Stop .................................................................. 11-23
11.7.2 Resetting the System after a Power Failure or an Emergency Stop............ 11-23
11.8 Recovering from a Cuvette Wheel Overflow...........................................................11-24
11.8.1 What causes an overflow?........................................................................... 11-24
11.8.2 Recognizing a Overflow................................................................................ 11-24
11.8.3 Recovering from an overflow........................................................................ 11-25
11.8.4 After the overflow problem is fixed............................................................... 11-26
11-2
Troubleshooting
AU480 User Guide

November 1, 2009
11.1 Troubleshooting and Maintenance

Regular preventative maintenance is essential for optimum system performance. A significant number
of problems outlined in this chapter are caused by neglecting to perform preventative maintenance
and required care.
For each aspect of troubleshooting, useful information can be found by referring to the corresponding
section of the maintenance chapter.
For details on maintenance, refer to chapter 8 Maintenance.
11.2 Troubleshooting the System Data Problems

The following can identify data problems:
11.2.1 Data Problem Checklist ................................................................................. 11-3
11.2.2 Checking Abnormal Data ............................................................................... 11-4
11.2.3 Troubleshooting Software .............................................................................. 11-5
11.2.1
Data Problem Checklist
Before troubleshooting, answer the following questions:

Has the data printout been interpreted correctly?
For details on performing analysis, refer to chapter 6 Performing Analysis.
Is the data flagged?
For details on error flags, refer to chapter 9 Error Flags.
Is the calibration out of range?
For details on checking calibration, refer to section 7.5 Calibration Verification in chapter 7.
Is QC out of range?
For details on checking QC, refer to section 6.4 Check Results in chapter 6.
Is data inconsistent?
This might be caused by maintenance tasks that are overdue. For details on maintenance, refer
to chapter 8 Maintenance.
Abnormal Data Analysis Using Routine Menu

Compare the reaction processes of samples showing normal data and of samples showing abnormal
data with the Reaction Monitor of the Routine menu and identify the difference between them.
After performing a precision run for data confirmation, use Data Statistics of the Routine menu to
obtain the results for mean value, SD, CV, range, etc.
For details on operating procedure for the Reaction Monitor menu, refer to section 6.4.2
Displaying Reaction Monitor in chapter 6.
For details on operating procedure for the Data Statistics menu, refer to section 7.4
Calculating Statistics in chapter 7.
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July 24, 2009
Troubleshooting
11-3
Abnormal Data Analysis Using the Calibration Monitor Menu

Compare the calibration data for which normal data is obtained with the calibration data for which
abnormal data is generated, using the Calibration Monitor menu, then identify the difference between
them.
For details on operating procedure for the Calibration Monitor menu, refer to section 6.4.3 Check the
Calibration and Reagent Blank in chapter 6.
Abnormal Data Analysis Using QC Monitor Menu

Compare the test with data that seems to be abnormal with the control reference designated in the
parameters using the QC Monitor menu. Judge the data reliability for that test. If the test may include
abnormal data due to low data reliability, identify the cause of abnormal data: a systematic error or a
random error (accidental error).
Confirm the meaning of the error flags of the multi-rule check. After confirmation, check the data again
from the point of view of the meaning of the error flags.
For details on operating procedure for the Quality Control menu, refer to section 5.6
Performing Quality Control (QC) in chapter 5.
For details on meaning of error flags and countermeasures, refer to chapter 9 Error Flags and
section 6.4 Check Results in chapter 6.
Abnormal Data Analysis Using Photocal Monitor Menu

Check for an abnormal cuvette using the Photocal Monitor menu.
Check that the cuvette where abnormal data is generated is identical to that recognized to be
abnormal by the Photocal Monitor menu.
If no abnormal cuvette is recognized by the Photocal Monitor menu, or if the cuvette where abnormal
data is generated and that recognized to be abnormal by the Photocal Monitor menu are not
identical, perform the photocal measurement again. After the measurement, check the measurement
result in the same described above, using the Photocal Monitor menu.
For details on how to use the Photocal Monitor menu, refer to section 8.4.3 Perform a Photocal in
chapter 8.
11.2.2
Checking Abnormal Data
Check the following:

QC Monitor: Compare the test with the normal QC data and identify the differences. Check QC
parameters by selecting Menu List>Parameters>QC Parameters>QC Specific. For details on
entering quality control (QC) parameters, refer to section 4.5 Setting Specific Test Parameters
in chapter 4.
Error Flags: Check the error flag definition. For details on error flags, refer to chapter 9 Error
Flags.
Calibration Monitor: Use the calibration monitor to check the differences in measured counts
and factor readings between the normal and abnormal calibration data. For details on calibrating
tests, refer to section 5.5 Calibrating Tests in chapter 5.
11-4
Troubleshooting
AU480 User Guide

July 24, 2009
11.2.3
Troubleshooting Software
Troubleshoot abnormal data by checking the following:

Check Patient Data.
Verify Parameters (Checking the relationship between the analysis condition and symptom).
Re-check the Measurement Data.
Check the Calibration and the Reagent Blank.
Check Monitor Progress.
Check Photocal Measurement Data.
Check Patient Data

If abnormal data is recognized:
In a single test: If abnormal data is found, check the QC and calibrator material for expiration
date. Check reagent stability also.
In all tests: If abnormal data is found, check wash solution quality and deionized water purity.
If the cause of abnormal data cannot be determined after checking patient data, try to determine if the
problem occurs at certain intervals during testing.
Does the problem occur after a specific sequence of reagent bottles is used?
This can indicate the deterioration of reagents.
Do the patient samples have something in common? Was a certain anticoagulant used?
Verify Parameters (Checking the relationship between the analysis condition

and symptom)
Verify the parameters if abnormal data is found in a single test or some tests.
If abnormal data is found in some tests, compare the analysis conditions (parameters) of the tests that
have abnormal data with each other to identify a common parameter(s). There is a high possibility that
the common parameters may result in abnormal data.
If a data error affects all the samples for a specific analysis test, check if the analysis parameters for
the specific analysis test that includes the error have been correctly set.
Recheck the Measurement Data

If the cause of abnormal data cannot be determined after checking the parameters, recheck the
measurement data to identify the frequency of abnormal data, common analysis sequence, common
items of samples, etc.
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July 24, 2009
Troubleshooting
11-5
Check the Calibration and the Reagent Blank

Check whether the calibration and the reagent blank is causing the abnormal data to occur:
In a single test: Compare normal calibration data with abnormal calibration data to identify the
difference between them, using the Calibration Monitor window. For details on the calibration
monitor, refer to section 6.4.3 Check the Calibration and Reagent Blank in chapter 6.
Check the reagent blank the same way it was checked for calibration data.
TIP
In some tests: Identify the commonalities between calibrators. If all abnormalities are derived
from the same calibrator, the calibrator may be the cause of the abnormal data.
If there are no commonalities, perform abnormal data analysis in the same way that it was
performed in the above case using the Calibration Monitor menu. Check the reagent blank in
the same way that it was checked for the calibration data.
In all tests: There is a strong possibility that the calibration analysis itself is causing the
abnormal data. Check the reagent probe or syringes, deionized water, calibration material and
common hardware. For details on how to check error flags, refer to chapter 9 Error Flags.
Check Reaction Progress

Identify which reaction progress causes abnormal data using the Reaction Monitor menu.
For details on how to check reaction progress, refer to section 6.4.2 Displaying Reaction Monitor in
chapter 6.
Check Photocal Measurement Data

Check the photocal measurement data to identify an abnormality with cuvettes or a photometer using
the Photocal Monitor menu.
For details on how to check reaction progress, refer to section 8.4.3 Perform a Photocal in chapter 8.
11-6
Troubleshooting
AU480 User Guide

July 24, 2009
11.3 Troubleshooting the System - Reagents and

Samples
The following section outlines specific system issues that can lead to erroneous results.
11.3.1 Sample Related Issues .................................................................................. 11-7
11.3.2 Reagent Related Issues ................................................................................ 11-8
11.3.3 QC and Calibrator Related Issues ................................................................. 11-8
11.3.4 Wash Solution Related Issues ....................................................................... 11-9
11.3.5 Deionized Water Related Issues ................................................................... 11-9
11.3.6 Other Causes of Abnormal Data .................................................................... 11-9
11.3.1
Sample Related Issues
The following two items cause most data problems:

Sample evaporation: This can cause unusually high results. Store samples properly, and keep
sample caps closed tightly if they need to be stored for a short period before analysis.
Incorrect sample handling: Refer to the relevant Instructions for use (IFU) supplied with
reagents to find the correct procedures for sample collection, handling and storage.
Please note the following sample requirements:
This system is designed to analyze serum, plasma and urine. If problems are encountered when
analyzing a specific test, or when using a specific reagent, refer to the relevant reagent IFU or
contact Beckman Coulter Technical Services.
Use serum or plasma that is adequately separated from cells, and urine that is free of
suspended matter, to prevent the sample probe from becoming blocked and adversely affecting
analysis.
Check that blood samples are sufficiently coagulated before serum separation. Remove any
suspended fibrin before placing serum on the system.
If there is any suspended matter present in urine to be tested, perform centrifugal separation to
precipitate the suspended matter before testing the specimens.
If a sample requires pretreatment depending on the analysis test, refer to the relevant reagent
IFU.
A minimum quantity of sample is required for analysis. Ensure that an appropriate quantity of
sample is available for analysis. For details on entering specific test parameters, refer to section
5.4.5 Sample Preparation in chapter 5.
To prevent sample evaporation, do not leave samples uncovered for an extended period of time.
Evaporation can lead to biased results being observed.
Bubbles on the surface of samples, QC and calibrator material, may result in level sensing
problems. Ensure all bubbles are removed from the surface of the sample before placing onto
the system.
Ensure that the sample cups and racks are set properly. For details on preparing samples for
analysis, refer to section 5.4.6 Placing the Sample Cups/Tubes in the Rack in chapter 5.
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July 24, 2009
Troubleshooting
11-7
Check the serum for the extent of hemolysis, lipemia, bilirubin, etc.
When the serum was concentrated or deteriorated, or the QC sample was incorrectly
reconstituted, replace the serum or dissolve the new QC sample, then repeat analysis.
11.3.2
Reagent Related Issues
Check the following if reagents cause data problems:

Correct reagent was not used: Use the correct reagent to analyze serum, urine, or other
samples using this system.
Reagent not stored properly: The correct methods for storing reagents, calibrators, and
controls are provided in each reagent IFU. Follow these instructions. If reagents, calibrators and
reagents are not stored properly, results will be incorrect even if used within effective periods.
Reagent on board stability expired: Consult the relevant reagent IFU, or Beckman Coulter
Technical Services for the stability of the opened product. If the reagent has expired, replace it.
For details on replacing reagents, refer to section 5.2.1 Confirm the Analyzer Status and the
Reagent in chapter 5.
Reagents not placed into the system correctly: Place reagents in the system. Unless the
reagents are placed in the system properly, accurate results may not be obtained and the
system can be damaged. For details on preparing for analysis, refer to section 5.2.1 Confirm
the Analyzer Status and the Reagent in chapter 5 and the relevant reagent IFU.
Reagent interference between analysis tests: If a reagent has become contaminated by
another reagent during analysis, results can be affected. The degree of interference depends
on the reagent. For detailed information, consult the relevant reagent IFU or contact Beckman
Coulter Technical Services.
Reagent has expired: Never use expired reagents.
Liquid level sensor does not function properly during reagent aspiration:
Bubbles in the reagent bottle can cause problems with liquid level detection. Remove bubbles in
the reagent bottle. See the reagent IFU for instructions.
11.3.3
QC and Calibrator Related Issues
Check the following items for general QC and calibrator issues:

Ensure that the material was stored and prepared correctly.
Check the open-bottle date and expiration date.
Ensure that the material has not been exposed to the air for an extended period of time, or
shows any visible evidence of deterioration.
Ensure that the correct material is in the correct position in the rack. For details on performing
daily startup checks, refer to section 5.4 Preparing Samples for Analysis in chapter 5.
11-8
Troubleshooting
AU480 User Guide

July 24, 2009
11.3.4
Wash Solution Related Issues
The correct wash solution was not used: Contact Beckman Coulter Technical Services.
Correct wash solution not used: Use only the Beckman Coulter Wash Solution specific to this
system.
Diluted wash solution tank has been contaminated: For details on how to clean the diluted
wash solution tank, refer to section 8.6.4 Clean the Deionized Water Tank in chapter 8.
Wash solution was changed: Contact Beckman Coulter Technical Services.
11.3.5
Deionized Water Related Issues
Check the following if the deionized water causes data problems:

Check water quality by checking if the facilities deionized water supply system needs to be
serviced.
If the deionized water tank is contaminated. For details on Replace the Deionized Water Filter,
refer to section 8.6.4 Clean the Deionized Water Tank in chapter 8.
If the deionized water filter is dirty. For details on Clean the Deionized Water Filter and the
Sample Probe Filter, refer to section 8.5.4 Clean the Deionized Water Filter and the Sample
Probe Filter in chapter 8.
11.3.6
Other Causes of Abnormal Data
Abnormal data can arise if periodic maintenance is not performed or is overdue. Be sure to perform all
maintenance routines along with regular preventative maintenance.
For details on maintenance, refer to chapter 8 Maintenance.
Water purity, conductivity and environmental specifications are incorrect for this system.
For details on precautions, installation and specifications, refer to section 2.2.1 Installation
Environment in chapter 2 or contact Beckman Coulter Technical Services.
This system is designed to use specific sample probe, reagent probe and cuvettes supplied by
Beckman Coulter. Use only genuine Beckman Coulter parts.
A mosquito coil or insecticides were used in the vicinity of the system: It may markedly affect
the cholinesterase (CHE). If an abnormality is experienced, replace the sample cups, reagents,
and reagent bottles with new ones. Also wash the sample probe, reagent probe, Mix bars, and
cuvettes.
For details on how to wash the sample probe, reagent probe, and Mix bars, refer to
sections 8.3.4 Inspect, Clean and Prime the Sample, Reagent Probes, and Mix bars and
8.8.3 Manually Wash the Reagent Probe in chapter 8
For details on how to wash the cuvettes, refer to section 8.7.2 Washing Cuvettes and the
Cuvette Wheel in chapter 8.
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11-9
11.4 Troubleshooting the System - Mechanical

Problems
Erroneous results can also be caused by hardware malfunctions.
For details on cleaning and replacing system parts, refer to chapter 8 Maintenance .
11.4.1 Syringe Problems ........................................................................................ 11-10
11.4.2 Probe Problems ........................................................................................... 11-11
11.4.3 Abnormal Data Caused by Cuvette Wheel or Wash Nozzles ...................... 11-12
11.4.4 Abnormal Data Caused by Photometer Lamp or Photometer Unit .............. 11-13
11.4.5 Mixing Problems .......................................................................................... 11-13
11.4.6 Deionized Water Tank Problems ................................................................. 11-13
11.4.7 Deionized Water or Filter Problems ............................................................. 11-14
11.4.8 Incubation Temperature Problems ............................................................... 11-14
11.4.9 Piping and Pump Problems ......................................................................... 11-14
11.4.10 Reagent Refrigerator Problems ................................................................... 11-15
11.4.11 STAT Table Problems .................................................................................. 11-15
11.4.12 Rack Problems ............................................................................................ 11-15
11.4.1
Syringe Problems
Check for:
Water leaking at syringes: Tighten the syringe cases and case heads of the sample and
reagent syringes by hand. For details on replace syringes, refer to section 8.8.7 Replace
Syringes in chapter 8.
Bubbles in the tubing connected to the syringe: Select Menu List>Maintenance>User
Maintenance>Analyzer Maintenance>Maintenance. Then select P r i m e Wa s h i n g - l i n e
and press TA B L E R OTAT I O N / D I A G button to start removing air from the tubing. For
details on replace syringes, refer to section 8.8.7 Replace Syringes in chapter 8.
General Syringe Troubleshooting:
a. Ensure the top and bottom screws are tightened.
b. Ensure the probes are not blocked.
c. Ensure the bottom screw is tight up against the piston.
d. Ensure there is a smooth resistant pull.
e. Ensure the correct syringe is used.
f. Ensure one O-ring is being used, and that it is not damaged.
g. Ensure the syringe is fitted to the system properly.
h. Check the tubing connected to the syringe head for scratches, folds or leaks.
i. Check the teflon tip of the syringe for wear.
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July 24, 2009
11.4.2
Probe Problems
Check for:
Reagent probe leaking from loose probe connectors: Tighten the probe connectors. Verify
that the tubing is firmly connected.
Reagent probe blocked: Drain deionized water from the blocked probe and ensure that it
drains properly.
Reagent probe bent or damaged: Replace the probe. For details on replacing reagent probe,
refer to section 8.8.4 Replace Sample Probe and Reagent Probe in chapter 8.
Sample aspiration position of the sample probe incorrect: The sample probe moves down
to aspirate sample. The maximum distance the probe can move downward is defined in the
system software, but can be changed by a service engineer. If it is set incorrectly, the probe
might hit the bottom. Contact Beckman Coulter Technical Services.
Reagent probe not aligned over refrigerator: If the reagent probe is hitting the reagent bottle
or refrigerator cover, examine the reagent probe for abnormalities. If it is bent, replace it. If it is
not bent and the reagent aspiration position is still not right, contact Beckman Coulter Technical
Services. For details on replacing reagent probe, refer to section 8.8.4 Replace Sample Probe
and Reagent Probe in chapter 8.
Sample probe or reagent probe not aligned over the cuvette: If the sample probe or reagent
probe are coming into contact with the cuvettes, examine the sample probe or reagent probe for
abnormalities. If a probe is bent, replace it. If it is not bent but still not aligned properly, contact
Beckman Coulter Technical Services. For details on replacing reagent probe, refer to section
8.8.4 Replace Sample Probe and Reagent Probe in chapter 8.
Abnormal wash position of reagent probe and sample probe: If the reagent probe is hitting
the wash stations, examine it for bends. If a probe is bent, replace it. If it is not bent but the
probe wash position is still abnormal, contact Beckman Coulter Technical Services.
General trouble shooting on reagent probe and sample probe:
a. Ensure water is dispensed in a straight stream.
b. Ensure the metal cap screws for the probe connections are tight.
c. Verify that the probe tubing is free of air bubbles.
General trouble shooting on reagent transfer unit and sample transfer unit: Verify no drops
remain on the path of the transfer.
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Troubleshooting
11-11
11.4.3
Abnormal Data Caused by Cuvette Wheel or Wash Nozzles
Scratches, fingerprints, stains, or foreign matter on the cuvettes: Wash the cuvettes. If
abnormal data is not corrected after washing, replace the cuvettes.
For details on washing cuvettes, refer to section 8.7.2 Washing Cuvettes and the Cuvette
Wheel in chapter 8.
For details on Replace Cuvettes, refer to section 8.8.2 Replace Cuvettes in chapter 8.
Some cuvettes were damaged: Replace the related cuvettes.
For details on Replace Cuvettes, refer to section 8.8.2 Replace Cuvettes in chapter 8.
The outside of the cuvette and/or the cuvette wheel was wet or flooded: Check the tube
joints for looseness. Tighten the loosened tube joints. The wash nozzles may be clogged. Clean
the wash nozzles.
For details on how to clean the wash nozzles, refer to section 8.5.3 Clean the Wash Nozzle
Unit and Check the Tube Mounting Joints in chapter 8.
The wash water and wash solution dripping from the washing nozzles: Check the tube
joints on the wash nozzles for looseness. Tighten the loose tube joints. The wash nozzles may
be clogged. Clean the wash nozzles.
After washing the cuvettes, a large amount of water remained in the cuvettes: Check
the tube joints on the wash nozzles for looseness. Tighten the loosened tube joints. The wash
nozzles may be clogged. Clean the wash nozzles.
The tube in the master wash solution tank floats: Straighten the tube, then insert it toward
the tank bottom so that it does not come into contact with the tank opening.
The system has trouble with the level sensor in master wash solution tank or the wash
solution tank: Connect the level sensor connector firmly, and bring the tube in the tank out of
contact with the level sensor. If the trouble is not corrected after conforming the above state, the
level sensor needs to be replaced. Contact the nearest Beckman Coulter Service Network.
Some cuvettes are contaminated with foreign matter: Clean the cuvettes. If abnormal data is
not corrected after washing the cuvettes or if any cuvettes are broken, replace those cuvettes.
For details on washing cuvettes, refer to section 8.7.2 Washing Cuvettes and the Cuvette
Wheel in chapter 8.
For details on cuvettes replacement, refer to section 8.8.2 Replace Cuvettes in chapter 8.
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July 24, 2009
11.4.4
Abnormal Data Caused by Photometer Lamp or Photometer

Unit
The quality of the photometer lamp has deteriorated: Check the record of photocal
measurement results for abnormal data. If an abnormal data is encountered, replace the
photometer lamp.
For details on the photocal measurement result record, refer to section 8.4.3 Perform a
Photocal in chapter 8.
For details on Replace the Photometer Lamp, refer to section 8.7.1 Replace the
Photometer Lamp in chapter 8.
The photometer lamp does not stay constantly lit: Perform the photocal measurement 2
times to check the difference between 2 sets of measurement data. If there is a great difference
between them, the photometer lamp may be defective. Replace the lamp. For details on
Replace the Photometer Lamp, refer to section 8.7.1 Replace the Photometer Lamp in chapter
8.
11.4.5
Mixing Problems
The mix bars are contaminated: Wash the mix bars.

For details on washing the mix bars, refer to section 8.3.4 Inspect, Clean and Prime the
Sample, Reagent Probes, and Mix bars in chapter 8.
The teflon coating on the mix bars are chipped: Replace the mix bars.
For details on how to replace mix bars, refer to section 8.8.5 Replace Mix bars in chapter 8.
The mixing unit malfunctions, there is abnormal noise from the system during the mixing
motion: If there is an audible abnormal noise coming from the system, check for bent mix bars,
if none are found contact Beckman Coulter Technical Services.
The wash water and wash solution are not properly drained from the mix bar wash
station: Contact Beckman Coulter Technical Services.
The mix bars are not properly installed on the mixing unit, the mixing of the sample and
reagents was insufficient: install the mix bars properly again.
For details on mounting mix bars, refer to section 8.8.5 Replace Mix bars in chapter 8.
11.4.6
Deionized Water Tank Problems
Check for:
The Deionized water tank is contaminated or dirty: If there are signs of particulate
contamination on the inside of the tank, clean the tank thoroughly.
For details on Replace the Deionized Water Filter, refer to section 8.6.4 Clean the Deionized
Water Tank in chapter 8.
Residual wash solution remains in the Deionized Water Tank after cleaning: Clean the tank
again and rinse thoroughly with deionized water.
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Troubleshooting
11-13
11.4.7
Deionized Water or Filter Problems
Check water quality by performing a water quality check. Check for:

Water conductivity too high: Check water quality by performing a water quality check. Always
ensure that the deionized water conductivity is within specifications.
Tap water below 5 C used: Always ensure that water supply to the deionizer is above 5 C.
For detailed information, contact Beckman Coulter Technical Services.
Dirty, stained or blocked filters: Clean the deionized water filter and the reagent probe filter.
Replace filters if data continues to be abnormal after cleaning. For details on Replace the
Deionized Water Filter, refer to section 8.6.2 Replace the Deionized Water Filter in chapter 8.
11.4.8
Incubation Temperature Problems
Check the following:

Check that there is adequate space surrounding the system for air to circulate effectively.
Ensure this space is in accordance with Beckman Coulter recommendations outlined. For
details on installation environment, refer to section 2.2.4 System Connections in chapter 2.
Ensure the room temperature is between 18 C and 32 C. Contact Beckman Coulter Technical
Services.
The cuvette wheel was left detached for an extended period of time after detaching from the
system. Analysis was started immediately after the cuvette wheel was replaced on the system: If
the cuvette wheel is left detached for an extended period, allow one hour or more after replacing
it before starting analysis.
11.4.9
Piping and Pump Problems
The filters in each part were dirty or clogged: Clean the deionized water filter and the sample probe
filter. If abnormal data is not corrected after cleaning filters, replace the filters.
For details on how to clean the deionized water filter, refer to section 8.5.4 Clean the Deionized
Water Filter and the Sample Probe Filter in chapter 8.
For details on how to clean the sample probe filter, refer to section 8.5.5 Clean the Sample
Probe Filter in chapter 8.
For details on how to replace the deionized water filter, refer to section 8.6.2 Replace the
Deionized Water Filter in chapter 8.
For details on how to replace the sample probe filter, refer to section 8.6.3 Replace the Sample
Probe Filter and O-Ring in chapter 8.
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July 24, 2009
11.4.10 Reagent Refrigerator Problems

If the reagent refrigerator temperature is out of range:
1. Select A n a l y z e r S t a t u s and check the reagent refrigerator temperature.
2.
Open the reagent refrigerator and ensure the reagent bottles are cool.
11.4.11 STAT Table Problems

If the STAT table temperature is out of range:
1. Select A n a l y z e r S t a t u s and check the STAT table temperature.
2.
Check that the two STAT table covers (large and small) are mounted properly. If STAT analysis
samples are set and removed frequently, the temperature in the STAT table will be increased.
11.4.12 Rack Problems

Check for the following general problems:
Ensure the rack is clean and no surface is sticky.
Check barcode positioning.
Ensure the correct number of magnets are in the bottom of the rack. Compare the configuration
of magnets on the underside of the rack with that of another rack of the same color. The
configuration should be identical. If a magnet is missing, do not use that rack until it is replaced.
Ensure the rack was loaded correctly.
For details on attaching the barcode label to the sample rack, refer to section 5.4.1
Attaching Barcode Labels to Sample Racks on page 5-3.
For details on placing the sample cups/tubes in the rack, refer to section 5.4.6 Placing the
Sample Cups/Tubes in the Rack in chapter 5.
Rack advance direction
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Troubleshooting
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11.5 Troubleshooting the System - System Problems

11.5.1 TEMP REF HIGH Alarm for the Cooling Unit .............................................. 11-16
11.5.2 Abnormal Sound from Inside the System..................................................... 11-16
11.5.3 Empty Alarm for the Water Supply Tank....................................................... 11-17
11.5.4 Leaks from the Wash Solution Roller Pump................................................. 11-17
11.5.5 Barcode Errors ............................................................................................ 11-18
11.5.6 Leaks from the Bottom of the System ......................................................... 11-18
11.5.7 No Wash Solution to Mix bars ..................................................................... 11-18
11.5.8 Reagent Alarm when Sufficient Reagent Remains in Bottles ...................... 11-18
11.5.9 Sample Alarm when Sufficient Sample Remains ........................................ 11-18
11.5.10 No Sample Cup Alarm when Sample Cup is Present .................................. 11-19
11.5.11 No Sample Cup on the STAT Table ............................................................. 11-19
11.5.12 Printer Not Printing or Printer Light Not On ................................................. 11-19
11.5.13 Liquid Leaking from the Reagent Probe and Sample Probe ....................... 11-19
11.5.14 Reagent Probe and Sample Probe not Aligned over the Cuvette ............... 11-19
11.5.15 Error Flag # (Sample Level Detection Error) Displayed
in the Second Half of the Sample Dispense Operation ............................... 11-20
11.5.16 Sample Rack Jammed ................................................................................ 11-20
11.5.17 Printer Problems .......................................................................................... 11-20
11.5.1
TEMP REF HIGH Alarm for the Cooling Unit
If there is a problem with the reagent storage refrigerator unit, check that there is adequate
space surrounding the system for air to circulate effectively. Ensure this space is in accordance
with Beckman Coulter recommendations outlined. For details on installation environment
precautions, refer to section 2.2.4 System Connections in chapter 2.
Ensure the room temperature is from 15C to 32 C. If the problem persists, contact Beckman
11.5.2
Abnormal Sound from Inside the System
Check for:
Air bubbles trapped in tubing: Check the deionized water filter. If it is stuck, replace it.
Deionized Water Tank Empty alarm: The ion-exchange capability of the deionizer can be
insufficient. Replace the deionizer if it is not up to standard. Check the deionized water filters. If
they have become dirty or blocked, clean or replace them.
For details on Clean the Deionized Water Filter and the Sample Probe Filter, refer to
section 8.5.4 Clean the Deionized Water Filter and the Sample Probe Filter in chapter 8.
For details on Replace the Deionized Water Filter, refer to section 8.6.2 Replace the
Deionized Water Filter in chapter 8.
If the cock at the bottom of wash solution tank is OFF: the wash solution will not be
generated. For this situation, open the cock.
For all other sources of noise such as a faulty circulation pump, radiator fan, air pump, 24V
power supply fan or pump, contact Beckman Coulter Technical Services.
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July 24, 2009
11.5.3
Empty Alarm for the Water Supply Tank
The ion exchange capability of the deionizer is insufficient: Check if the deionizer meets the
specification. If the deionizer does not meet the specification, replace it.
For detailed information, consult the deionizer maker.
The deionized water filter is clogged: Check the deionized water filters with a finger to check
for sliminess. If the filter surface is slimy, the filter may be clogged. Clean the deionized water
filter.
For details on how to clean the deionized water filter, refer to section 8.5.4 Clean the Deionized
Water Filter and the Sample Probe Filter in chapter 8.
11.5.4
Leaks from the Wash Solution Roller Pump

Roller tube
Wash solution
roller pump
Connector
Relay tubes
The roller tubes may be deteriorated: Check the roller tubes for cracks due to deterioration. If
deteriorated, replace the roller tubes.
For details on replacing the roller tube, refer to section 8.6.5 Replace the Wash Solution Roller
Tube in chapter 8.
The connector connecting tubes may be loose: Make sure the connectors that connect tubes
are not lose, tighten the connectors firmly if loose.
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Troubleshooting
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11.5.5
Barcode Errors
Check for:
Barcode reader dirty: Wipe the window of refrigerator for reagents and STAT using absorbent,
lint-free paper and 70% Isopropanol.
Barcode labels on sample cups, racks or reagent bottles discolored: Wipe barcode labels
clean. Replace any sample or rack barcodes that are worn or damaged.
Barcode labels seriously damaged:
On sample cups or racks: Replace any barcodes that are worn or damaged.
On reagents: Discard the reagent or contact Beckman Coulter Technical Services.
Barcode labels are falling off the sample cups or are not affixed properly:
For details on how to put barcodes on properly, refer to sections 5.4.4 Applying Barcode Labels
to Sample Cups and 5.4.1 Attaching Barcode Labels to Sample Racks in chapter 5.
CAUTION
11.5.6
While the system is turned on, avoid looking directly into the laser beam emitted from
the barcode reader. Looking directly into the laser beam can cause eye damage.
Leaks from the Bottom of the System
Check for:
Wash line obstructed: Check for obstructions in the wash stations for sample probe and
reagent probe. Clean them if any blockages are found. For details on maintenance, refer to
chapter 8 Maintenance .
Waste line not installed properly: If the waste line is leaking or if the tube itself is too long,
contact Beckman Coulter Technical Services.
11.5.7
No Wash Solution to Mix bars
The deionized water filters may be clogged: Check the deionized water filters using a finger to check
for sliminess. If the filter surface is slimy, the filter may be clogged. Clean the deionized water filter.
For details on how to clean the deionized water filter, refer to section 8.5.4 Clean the Deionized Water
Filter and the Sample Probe Filter in chapter 8.
11.5.8
Reagent Alarm when Sufficient Reagent Remains in Bottles
The liquid level sensor could be faulty. See the alarm online help, and contact Beckman Coulter
Technical Services.
11.5.9
Sample Alarm when Sufficient Sample Remains
There is a possibility that sample probe doesn't more down to the liquid level of the reagent due to
incorrect detection of the height of the cup. Make sure an inappropriate cup is not used or the cup is
appropriately set.
If an error still occurs, contact Beckman Coulter Technical Services.
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July 24, 2009
11.5.10 No Sample Cup Alarm when Sample Cup is Present

Unspecified cup used: Check that the appropriately specified sample cups were used in each rack.
Also, check that the adapter for the blood collection tube is used.
11.5.11 No Sample Cup on the STAT Table

The related test was not selected during the requisition operation, or the requisition setup
information did not meet the sample cup position on the STAT table: Repeat the requisition
operation.
The sample cup set on the STAT table did not use the appropriate adaptor: Check if the sample
cup is set properly for the STAT table. If it is not, set the sample cup again using an adaptor
appropriate for the sample cup diameter.
An unspecified sample cup was used: Check if the sample cups specified by the STAT table are
used. If they are not, use the specified sample cups.
11.5.12 Printer Not Printing or Printer Light Not On

See the printer manual for assistance with all printer troubleshooting.
Printer is disconnected. Check the plug and socket and connecting lead.
Printer toner empty and needs to be replaced.
Ensure the online button is on.
Ensure paper is loaded properly.
11.5.13 Liquid Leaking from the Reagent Probe and Sample Probe
Verify that the Reagent probe and Sample probe is installed correctly:
1. Select Menu List>Maintenance>User Maintenance>Analyzer Maintenance.
2. Select P r i m e Wa s h - L i n e to check the reagent probe and sample probe.
3. Select O K to dispense water from the reagent probe and sample probe. If the deionized water
does not dispense normally, the reagent probe and sample probe might improperly installed.
Check the reagent probe and sample probe installation.
11.5.14 Reagent Probe and Sample Probe not Aligned over the
Cuvette
Check if the Reagent probe or Sample probe is bent: Examine the probe and replace it if it is bent.
For details on replacing reagent probe, refer to section 8.8.4 Replace Sample Probe and Reagent
Probe in chapter 8.
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Troubleshooting
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11.5.15 Error Flag # (Sample Level Detection Error) Displayed in

the Second Half of the Sample Dispense Operation
Check if the sample volume is too low: Ensure there is sufficient sample for the requested tests.
The dead volume for the different tests has to be considered. For details on sample preparation, refer
to section 5.4.5 Sample Preparation in chapter 5.
1. Select Menu List>Maintenance>User Maintenance>Analyzer Maintenance>Maintenance.
2. Select S y s t e m 2 tab and verify that the appropriate setting for the type of sample tube being
used is displayed for each rack type.

Check if the sample volume is sufficient for the following cups:

HITACHI cup: Required volume + 50 L or more
12.3 mm tube: Required volume + 200 L or more
15.4 mm tube: Required volume + 250 L or more
HITACHI-micro cup (STAT only): Required volume + 30 L or more
Nested cup* (Rack only): Required volume + 180 L or more
*Nested cup use only HITACHI cup.
The above necessary sample amount includes remainder (5 L) for each test item in addition
to the sample amount necessary for analysis. When analyzing 20 tests/sample or more, set the
required sample amount + 200 L (provisional) to suppress dilution by sample probe wash water.
11.5.16 Sample Rack Jammed

Check for:
Contamination on the rack: Verify that nothing has fallen onto the rack and that the rack ID
label, or sample ID labels have not peeled off, causing the rack jam.
Rack feeder unit sticky or dusty: Clean surfaces with deionized water using a lint free
dampened cloth.
11.5.17 Printer Problems

Check for:
Analysis started while printer was offline.
Printer turned off while analysis was in progress.
Printer is out of paper.
a. Turn on the printer and ensure it is online.
b. Load paper if needed.
c. To printout results use Sample Manager.
d. Select P r i n t e r C o n t r o l ( F 5 ) .
e. Select Re s u m e to begin printing data from analysis. When printing is finished, the
system moves to Standby mode.
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July 24, 2009
11.6 Troubleshooting the System - Data Processor

Problems
The following lists potential data processor problems:
11.6.1 Menu Cannot be Selected ........................................................................... 11-21
11.6.2 Number Key Pad on Keyboard Does Not Work .......................................... 11-21
11.6.3 Keyboard Not Responding .......................................................................... 11-21
11.6.4 Inaccessible Floppy Disc ............................................................................. 11-22
11.6.5 Results Do Not Print Automatically .............................................................. 11-22
11.6.6 Online Auto-Output by Host Computer Not Executed ................................. 11-22
11.6.7 Unsuccessful Movement of Data between the System
and the Host Computer................................................................................ 11-22
11.6.1
Menu Cannot be Selected
Function is inaccessible: Menu items which are greyed out are inaccessible. Contact the
facilities system administrator to increase the level of access to the system.
System software crashes: To reset the system:
a. Press C T R L + A l t + D e l e t e together.
b. Select S h u t d o w n .
c. Once the PC shuts down, press E M S TO P , then R E S E T , then Po w e r O n
to resume operation.
Contact Beckman Coulter Technical Services if crashes become frequent.
11.6.2
Number Key Pad on Keyboard Does Not Work
Num Lock is not selected: Press the Num Lock key and then check that the LED light over Num
Lock on the keyboard is on.
11.6.3
Keyboard Not Responding
Possible causes:
Keyboard cable: Verify that the cable connector is in the right socket in the back of the
computer (color coded).
System crash: For details on system crash, refer to section 11.6.1 Menu Cannot be Selected
in this chapter.
System busy: The system might be saving data or performing a series of tasks simultaneously.
Wait for a few minutes until the system is ready. If this happens frequently, contact Beckman
Data processing, such as data saving, is being executed: Wait until data processing has
been completed.
Electrical Noise: If a buzz is audible from the socket, take out the plug and replace it firmly.
Consult the Internal Systems Department.
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Troubleshooting
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11.6.4
Inaccessible Floppy Disc
Check for:
The floppy disc is not formatted properly: Format the floppy disc by selecting Menu
List>System>External Data Management>External Data management. Select the way desired
to initialize the diskette: For parameters or data, select M e d i a I n i t i a l i z e ( F 2 ) .
For details on saving information to disc, refer to section 7.7.1 External Data Management in
chapter 7. Formatted, 2HD 1.44 MB of disc should be used:
Floppy disc is write-protected: Slide the tab on the disc cover. If the diskette is punched, put
in a new blank unpunched diskette. Consult internal systems department for the facility.
Floppy disc is damaged: If writing is continuously unsuccessful, the floppy disc is probably
damaged. Use a new disc.
Floppy disc drive damaged: If the floppy disc is new and properly formatted and data cannot
successfully saved, the floppy disc drive might be broken. Contact Beckman Coulter Technical
Services.
11.6.5
Results Do Not Print Automatically
Check for:
Realtime output is not set: Set the realtime output of reports from System>Format>List
Format.
For details on how to set the realtime output, refer to section 4.11.1 Set the Basic Condition for
Print in chapter 4.
Printer is not available during analysis (out of paper, printer is turned off, printer is offline.): Turn on the printer to make sure it is on -line (set papers as necessary).
a. Select Home>Analyzer Status.
b. Select P r i n t e r C o n t r o l ( F 5 ) .
c. Select Re s u m e to start printing the analyzed data.
11.6.6
Online Auto-Output by Host Computer Not Executed
Check for:
I/F cable to the host computer disconnected: Connect the cable.
Host I/O parameters incorrectly modified: Set the appropriate I/O parameters by selecting
the Online window.
For details on how to set host I/O parameters, refer to section 4.3 Entering Online Settings in
chapter 4 and Specification of Host Online.
11.6.7
Unsuccessful Movement of Data between the System and

the Host Computer
Check if:
I/F cable to a clinical laboratory system (host computer system) disconnected: Connect
the cable correctly.
I/F cable defective: Take an appropriate action such as replacement or repair.
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July 24, 2009
11.7 Recovering from an Emergency Stop or Power

Loss
In the event of power failure or an emergency stop, the main power is cut off immediately. Power to
the incubator and reagent refrigerator is also cut off.
11.7.1 Performing an Emergency Stop .................................................................. 11-23
11.7.2 Resetting the System after a Power Failure or an Emergency Stop............ 11-23
CAUTION
11.7.1
If an emergency stop or power failure occurs during a measure mode, the data
generated is unusable. Sample analysis must be performed again. If the system
is without power for a lengthy period of time after a power loss or emergency stop,
check reagent integrity before restoring analysis.
Performing an Emergency Stop
To perform an emergency stop:

1.
Press the E M S TO P button on the front of the system to turn off all power to the system.
2. Press C T R L + A l t + D e l e t e to access the Windows Security window, select the Task

Manager button
3.
In the Task Manger window Select S h u t d o w n to close all running software and shutdown
the PC.
11.7.2
Resetting the System after a Power Failure or an

Emergency Stop
After power failure or emergency stop follow the steps below to reset the system
Resetting the System

Print the repeat run work list, then check the samples required to perform repeat run.
1.
Press the R E S E T button on the front of the system.
2.
Wait 10 seconds and press the O N button to load the software.

Program down load to analyzer is displayed.
End process was not completed at previous shut down. Database retrieval is required. is then
displayed as an alarm (Select O K to remove it).
RESET button
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Troubleshooting
11-23
Checking Samples
1. Select S a m p l e S t a t u s on the Home window to display the Sample Status window.
2. Select S t a t u s .
Displays a list of test conditions of samples on the Analyzer.
Confirm the sample number which is finished data output.
Checking Reagents
1.
From the AU480 Home window select Menu List>Routine>Reagent>Reagent

Management>Main to display the Reagent Management: Main tab window.
2. Select Re a g e n t C h e c k ( F 5 ) .
The Reagent Check window appears.
3.
Select Check all positions.
4.
Select Read reagent ID.
5. Select S t a r t . Reagent check starts and Checking is displayed on the window. After check
completion, Reagent check completed is displayed.
11.8 Recovering from a Cuvette Wheel Overflow

The following procedure explains what can cause an overflow, and how to recognize and recover.
Performing scheduled maintenance greatly reduces the chances of a cuvette wheel overflow. For
more information about maintenance for each system component, refer to the Maintenance Chapter.
11.8.1 What causes an overflow?........................................................................... 11-24
11.8.2 Recognizing a Overflow................................................................................ 11-24
11.8.3 Recovering from an overflow........................................................................ 11-25
11.8.4 After the overflow problem is fixed............................................................... 11-26
11.8.1
What causes an overflow?
A wash nozzle is clogged or partially clogged. When this happens, liquid is not aspirated from
the cuvette completely and eventually liquid spills over the side. This can occur when the wash
nozzles are not cleaned properly, or when particles such as glass are aspirated into the nozzle.
The wash nozzle is bent or damaged.
Damaged or missing O-rings on tube mounting joint manifold.
The reagent probe is bent. A bent probe could be dispensing outside of the cuvette.
The sample probe is bent. A bent probe could be dispensing outside of the cuvette.
Cuvettes are chipped or cracked due to alignment problems with the reagent probes or wash
nozzles.
The wash nozzle tubing is not connected to the nozzle
11.8.2
Recognizing a Overflow
If the error flags *, ?, @, $, D, B, ! occur with greater than normal frequency, this may indicate a
11-24
Troubleshooting
AU480 User Guide

November 1, 2009
cuvette wheel overflow. The data, alarms and/or flags will vary depending on the severity of the
overflow. One or all tests could be affected by a overflow. Here are some problems to look for:
QC on tests are out-of-range. QC alarms have occurred.
Reagent blank flags and alarms have occurred on one or more tests.
Is the entire data printout incorrect?
The analyzer is not performing as usual.
Numerous cuvette failures after photocal.
Lift the cuvette wheel cover.

The cuvettes should appear frosty or white, if they are dark, black, or wet when removed, the cuvette
wheel has overflowed.
11.8.3
Recovering from an overflow
CAUTION
Immediate attention should be given to an overflow. If nothing is done to fix the

problem, the wheel will continue to overflow.
Check the following list:

The wash nozzle station should be aligned over the cuvettes. Visually inspect and ensure
nozzles are centered over cuvettes then check the alignment. If you require assistance
performing these procedures, please contact Beckman Coulter Technical Services.
The wash nozzles should be straight. Sonicate and clean the nozzles with a stylus to remove
any debris.
Check reagent and sample probes to be sure they are properly aligned. Rotate the sample and
reagent probes over the cuvette wheel. If you require assistance performing these procedures,
please contact Beckman Coulter Technical Services.
It is very important that the probes are centered over the cuvettes.
CAUTION
Instruction
Check for chipped or cracked cuvettes. Replace them if necessary.
TIP
For information about replacing cuvettes, refer to the Maintenance Chapter.
Verify the wash nozzle tubing connections are secure

Verify the O-rings on the manifolds are in place and not damaged.
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November 1, 2009
Troubleshooting
11-25
11.8.4
CAUTION
After the overflow problem is fixed

Do not start cleaning cuvettes unless the cause of the overflow is
determined.
Please refer to Cleaning Cuvettes and the Cuvette Wheel located in the As Needed Section of the
Maintenance chapter.
11-26
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November 1, 2009
12 Menu Tree
This chapter provides a reference to the menu options available on the
AU480.
Contents
12.1 Home Menu...................................................................................................................12-2
12.2 Permanently Displayed Button Configuration and Function ..................................12-3
Group of Function Selection Buttons ..........................................................................12-3
Group of System Control Buttons ...............................................................................12-3
Group of Alarm Related Buttons .................................................................................12-3
Group of Other Buttons ..............................................................................................12-3
12.3 Menu Buttons Overview .............................................................................................12-4
12.4 Routine Menu...............................................................................................................12-5
12.5 Calibration Menu..........................................................................................................12-6
12.6 QC Menu.......................................................................................................................12-7
12.7 Parameter Menu ..........................................................................................................12-8
12.8 Maintenance Menu ......................................................................................................12-9
12.9 System Menu .............................................................................................................12-10
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July 24, 2009
Menu Tree
12-1
12.1 Home Menu

The Home window appears when the system starts up. The menus displayed on the Home
window are referred to as Home menus. Users can advance to various menus from this window.
The list of menus included in the Home menu is indicated below. Also, individual menu functions are
summarized.
Home Menus
Menu
Home Menu
Submenu
Option
Sample Status
A real-time display used to monitor
the status of samples during analysis
as well as their print status.
Analyzer Status
Used to display the analyzer status.
Simple STAT mode
Allows an untrained operator to run a
sample using the STAT table.
12-2
Menu Tree
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July 24, 2009
12.2 Permanently Displayed Button Configuration

and Function
The multiple function buttons located at the upper and lower outside of the Home menus are always
displayed whatever menu is selected.
Group of Function Selection Buttons

Button
Button name
Function
Home
Displays the Home window.
Menu List
Displays the menu list.
User Menu
Displays the user menu list.
Group of System Control Buttons

Button
Button name
Function
Start
Starts or restarts analysis.
Pause
Temporarily stops sampling.
Feeder Stop
Temporary stops the rack feeder

during analysis.
Stop/Standby
Transfers the system to the Stop

mode and transfers from Stop back to
Standby.
Group of Alarm Related Buttons

Button
Button name
Function
Alarm List
Displays the alarm list.
Alarm Clear
Button for silencing an alarm and

clearing the alarm display field.
Group of Other Buttons

Button
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July 24, 2009
Button name
Function
Help
Displays the Help window.
Logout
Facilitates operator login and logout.
End
Shuts down the system.
Menu Tree
12-3
12.3 Menu Buttons Overview

To perform parameter setup necessary for analysis, requisition concerning analysis, and check for
analysis results after operation, select a menu from various menu buttons at the left side of the Menu
List window.
The display contents of submenus displayed to the right vary depending on the selected menu.
12-4
Menu Tree
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July 24, 2009
12.4 Routine Menu

The Routine menu is a group of basic operation menus for performing test. Unless the basic setup is
performed beforehand with the [Parameters] menu, some submenus cannot be used.
Menu
Routine
Submenu
Option
Start Condition
Used to set the index date and

time, start sample number,
etc., before starting analysis.
Reagent
Reagent Management
Used to check the quantity of reagent and the

number of tests available in a bottle.
Reagent Inventory
Sets up the reference value for each day of the

week to perform a daily check.
Reagent Consumption
Displays the number of shots consumed each

day for each reagent.
Rack Requisition
Sample
Used to set the sample numbers and analysis

items required for rack analysis.
Calibration
Used to set the requisitions for calibration for

rack analysis.
QC
Used to set the requisitions for quality control

analysis for rack analysis.
STAT Requisition
STAT Status
Use to view the status of the STAT table and

start STAT sample analysis.
Sample
Performs requisition of patient samples to be

analyzed on the STAT table.
Calibration
Performs requisition of calibrators to be

QC
Performs requisition of QC samples to be

Repeat Run
Repeat Order
Used to requisition repeat samples.
Repeat Data Verification
Used to view repeat results and perform

overwriting of the data.
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July 24, 2009
Menu Tree
12-5
Menu
Routine
Submenu
Sample Manger
Option
Sample
Used to display analysis results, perform data

correction, print data list and batch transfer data
online.
RB/CAL/QC
Used to print and batch transfer RB/ CAL/QC

results online.
Data Monitor
Reaction Monitor
Displays information about reaction processes of

analysis results.
Data Statistics
Displays key statistics of patient sample results

and the results of a test within one index as bar
charts.
Correlation Chart
Displays a correlation chart.
12.5 Calibration Menu

The Calibration menu is a group of menus for displaying and managing calibration results and
histories.
Menu
Calibration
Submenu
Option
Calibration Monitor
Displays calibration results as

a graph or a data list.
Calibration Verification Calibration Verification
Verifies the calibration performance.
Material Parameter
Set Parameters for calibration verification.
12-6
Menu Tree
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July 24, 2009
12.6 QC Menu
The QC menu is a group of menus for displaying and editing quality control (QC) results and
histories.
Menu
QC
Submenu
QC Monitor
Option
Daily Chart
Display the QC data variation within the same

or between index dates as a daily chart.
Day to Day Chart
Display the QC data variation within the same

or between index dates as a day to day chart.
Twin Plot Chart
Display the QC data variation of two QC

samples as a twin plot chart.
QC Data Review
Used to edit QC result.
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Menu Tree
12-7
12.7 Parameter Menu

The Parameters menu is a group of menus for setting various parameters such as the analysis
method. Be sure to set those parameters before using this system for the first time. To set the system
own conditions, use the System menu.
Menu
Parameters
Submenu
Common Test
Parameters
Options
Test Name
Used for basic parameters such as test name

and reagent ID.
Profile
Used to select specified test items for one

profile. Multiple profile setting for samples, RB/
Calibration and QC is possible.
Group of Tests
Used to set the round name and test items for

each round.
Specific Test
Parameters
General
Used to set detailed parameters for general test

items.
LIH
Used to set detailed parameters for the Lipemia/

Icterus/Hemolysis test.
ISE
Used to set detailed parameters for the ISE test.
Calculated Tests
Used to set detailed parameters for calculated

tests.
Range
Used to set parameters for the reference range

of each test.
Repeat Parameters
Repeat Common
Used to set the common parameters for a repeat

run analysis.
Repeat Specific
Used to set the repeat and reflex decision ranges

and the repeat dilution rate of repeat run analysis
for individual test items.
Calibration Parameters Calibrators
Used to set common calibrator parameters such

as name, ID and Lot number.
Calibration Specific
Used to set specific calibration parameters for

individual test items.
STAT Table Calibration
Used to set parameters for calibration analysis

using the STAT Table.
12-8
Menu Tree
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July 24, 2009
Menu
Parameters
Submenu
QC Parameters
Options
Controls
Used to set the common parameters for a quality

control analysis.
QC Specific
Used to set the average value and standard

deviation of the control sample for quality control
of individual items.
STAT Table QC
Used to set parameters for QC analysis using

the STAT Table.
Misc.
Checked Tests
Used to set parameters for logic checked tests.
Contamination Parameters
Used to set parameters for contamination of tests
Data Check Parameters
Used to set parameters for data check such as

diagnosis of prozone. For detailed information,
contact Beckman Coulter Sales or Technical
Services.
12.8 Maintenance Menu

The Maintenance menu is a group of menus that are used for daily maintenance of the system. It
allows the user to plan a maintenance schedule and check for a generated alarm.
Menu
Maintenance
Submenu
User Maintenance
Options
ANL Maintenance
Used to display the maintenance schedule and

provide instruction on maintenance procedures.
ISE Maintenance
Used to display the maintenance schedule

of the ISE unit and provide instruction on ISE
maintenance procedures.
OSV
Displays the connection status of the Beckman

Coulter Support Vision (OSV) and transmits the
AU480s various files.
Alarm Log
Chronologically lists the alarm

that have accrued.
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July 24, 2009
Menu Tree
12-9
12.9 System Menu

The System menu is a group of menus used for setting the print format, use/nonuse of barcode,
optional conditions, etc.
Menu
System
Submenu
Options
Online
Used to set the parameters for

online communication between
a host computer and the
system.
Format
Requisition Format
Used to enter the sample requisition

parameters.
List Format
Used to set the common format parameters for

printing the pending list, work list, repeat list and
the data list.
Comment Masters
Used to customize the

comments appended to the
analysis results.
System Condition
Analysis mode
Used to set the analysis mode, barcode

definition, auto/standard repeat and so on.
Set Date and Time
Used to set the system date and time.
Auto Power On
Used to set the auto power on time for each day

of the week.
Password
Used to set and change passwords
Login Condition
Used to set login information.
User Menu
Used to set a menu as a user

menu.
External Data
Management
External Data Management
Saves the analysis data on an external storage

device or media.
File Management
Used to save and up load parameter files on an

external storage device or media.
Offline Format
Used to set the output format of results and

save data in a delimited format for use in
external applications (spreadsheets, etc).
12-10
Menu Tree
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July 24, 2009
13 AU480 Terminology
ACAL
Abbreviation for auto-calibration. It represents the automatic creation of calibration curves.

A calibration curve is automatically created using the yellow rack. It is mainly used for the analysis
tests in the end point assay method.
Advanced Calibration
Calibration of multiple bottles of the same reagent set in the reagent refrigerator can be performed
together in advance.
Alarm Shots
The Alarm Shots function enables the operator to set the number of remaining reagent shots which
when reached, prompts a system alarm.
Auto Power On
Allows the operator to set a time when the analyzer will automatically power on.
Calibration Curve
The calibration curve is calculated from calibrator. A curve that is generated, before measurement, to
calculate the unknown analyte concentration in a sample.
Calibration Trace
The calibration trace is a graph that displays a record of calibration of each analyte.
Calibrator
Material with a known value which is used to establish the measurement relationship.
Consumable
Consumable are materials required by the system such as photometer lamps, etc.
Cuvette
A transparent glass vessel with one side face frosted, which is used as a reaction vessel between a
sample and a reagent.
Dead volume
Sample volume that cannot be aspirated by the system but remains in the tube/cup. The dead volume
depends on the type of cup/tube that is used.
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July 24, 2009
Terminology
13-1
Disabling (a Test)
To select tests to be left out of an analysis run during analysis. This feature is used if calibration or QC
fails but samples are already on the rack feeder and the system is running.
END (End Point Assay)
There are three types of end-point assay:

One-point assay is a general end-point assay that determines the optical density of the
reaction mixture from the optical density measured at a specified photometric measuring
point.
Two Point (Self-blank method) assay provides sample blank adjustment. The optical
density values before dispensing reagent are eliminated as the sample blank. This optical
density value is then subtracted from those calculated after dispensing the second reagent.
Any contribution to the final reaction OD from the sample (turbidity, icterus etc.) is removed
to improve measurement reliability.
Blanked End Assay measures the blank channel and then subtracts this from the
measured optical density, to calculate the actual optical density of the reaction. This
requires an additional blank. END1 does not use reagent blank absorbance as the
reference for measurement data at each photometric point.
Error Flag
Symbols that appear beside analysis results, indicating that a problem or an error has occurred during
analysis. The generated result must be reviewed.
FIXED (Fixed Point Assay)
Fixed-Point Assay is a method of calculation that determines the difference between the optical
densities at two specific time points within a reaction.
FIXED1 does not use reagent blank absorbance as the reference for measurement data at each
photometric point.
Group
Group is a category in which a combination of arbitrary analysis tests has been set up. Set
a desired group using the Common Test Parameters: Group of Tests window. Select Menu
List>Parameters>Common Test Parameters>Group of Tests to display the Common Test Parameters:
Group of Tests window.
For example, designate the analysis tests frequently used for the routine analysis to Group 1, and the
analysis tests used for the specific analysis to Group 2. Perform routine analysis under Group 1 and
switch to Group 2 for specific analysis as required. Then, the specific analysis tests can be accessed
quickly.
LAG_TIME Check
If a reaction is terminated too quickly, effective data at two points or more may not be acquired. In such
case, the system can be set up to calculate the analysis result using the data in the lag phase.
Used for the analysis tests in the rate assay method.
LIH Testing
Performs test of lipemia (L), icterus (I), and hemolysis(H) in serum. LIH is the symbol used for testing
Lipemia (L), Icterus (I), and Hemolysis (H).
13-2
Terminology
AU480 User Guide

July 24, 2009
Linearity
Ability of a measuring method to generate test results that are proportional to the analyte
concentration in a sample.
MCAL
Abbreviation for manual calibration. It defines manual creation of calibration curves. A calibration curve
is created by manually entering the individual data. It is mainly used for the analysis tests in the rate
assay method.
Photocal Measurement
This measurement checks the stain, scratches, etc. on the cuvettes to obtain appropriate analysis
results. Confirm the photocal data obtained from a photocal measurement on the Analyzer
Maintenance Photocal Monitor tab window.
For details on performing photocal measurement, refer to section 8.4.3 Perform a Photocal in
chapter 8.
QC Monitor
The QC Monitor gives an instant visual summary of QC analysis results.
QC Sample
Material used to verify the performance characteristics of an in vitro diagnostic medical device.
Quality Control (QC) Analysis
The process of analyzing samples with known concentrations of analytes in order to test the quality of
reagents, calibrators, equipment and procedures.
RATE (Rate Assay)

Normal rate assay measures the variation in the rate of absorbance per minute by calculating
the average change in absorbance between each two photometric points, using the least
squares method.
Double rate assay determines the rate of absorbance variation per minute by calculating the
average of the absorbance variations between each two measuring points, using the least
squares method. The rate of absorbance before dispensing reagent 2 is subtracted from those
calculated after dispensing the second reagent.
RATE1 does not use reagent blank absorbance as the reference for measurement data at each
photometric point.
RB
Abbreviation for reagent blank.

In routine analysis the reagent blank serves as the reference value for the reagents at each
photometric point of individual analysis tests. It also becomes the Y-segment data of calibration curves
created by ACAL.
Reagent
A reagent is a combination of chemicals that react with the target analyte in the AU480, which uses
two reagents, R1 and R2.
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July 24, 2009
Terminology
13-3
Reagent ID
The system identifies reagents placed on board the system using the barcode.
Reflex Testing
Reflex testing enables a test to be automatically run by linking it to a repeat flag generated by another
test. Up to 10 sets of tests can be programmed as Reflex tests. Therefore, if a test generates a value
outside of a given range, another complementary test is automatically performed.
Repeat Run
A repeat run is a process whereby samples are tested again, either manually or automatically by the
system.
Sample Diluent
Solution used for manual or automatic diluent of samples.
Standard Deviation
Most commonly used measure of statistical dispersion. Simply put, in multiple measurements of the
same sample, it measures how spread out the values are.
Test Requisitions
An instruction to perform tests on a sample. When a sample is placed into the system, the test
requisition information is used to link the sample to the required tests.
Twin Plot
Twin Plot is used to determine whether a problematic variation in QC is caused by the system or just a
random error. QC analysis is usually performed using two controls: normal, and pathological. The twin
plot function displays the first control on the x-axis of a 2-dimensional plot and the second control on
the y-axis.
W1
Abbreviation for automatic wash of cuvettes.

Usually, W1 is used for cuvette washing before and after daily analysis.
If analysis operation was forcibly stopped, W1 is used to remove the sample remaining in the cuvette
and to wash the cuvettes.
W2
Abbreviation of automatic wash of cuvettes, sample probe, and reagent probe.

Perform W2 operation weekly. After performing W2, be sure to perform Photocal measurement.
This alternates between the usage of either 10% sodium hypochlorite or 1N HCI.
For details on W2, refer to section 8.4.2 Perform a W2 (Automatic Washing of each Probe, Mix bar
and Cuvettes, etc.) in chapter 8.
13-4
Terminology
AU480 User Guide

July 24, 2009
14 Index
Symbols
1-point Assay 3-4
2-point Assay 3-5
A
ACAL 13-1
Adapters 5-29
Adobe Acrobat Reader 1-10
alarm description 1-9
Alarm Help 1-9
Alarm Shots 4-16, 13-1
Alarm Sound 4-4
Analysis
1-point Assay 3-4
2-point Assay 3-5
Double Rate Assay 3-6
end assay 3-5
End Point Assay 3-4
Fixed Point Assay 3-6
Quality Control (QC) Analysis 13-3
Rate Assay 3-6
sample blank correction 3-5
self-blank method 3-5
Analysis Mode
Analysis Mode 3-12, 4-2
Barcode (Sample ID) analysis mode 3-12
Rack No. analysis mode 3-12
Sequential mode 3-12
Analyzer Front Unit 6-7
Applying Barcode Labels 5-25
AU480
Assumptions 1-7
Auto Power ON 7-2, 13-1
Shutdown the system 6-51
System Specifications 2-17
Automatic Startup Function 7-2
automatic window lock function 7-8
Auto Repeat 4-3
Auto STAT Operation 4-6
B
Backup of Condition File 7-27
Backup of data 7-24
Barcode analysis 4-3
AU480 User Guide
July 24, 2009
Barcode (Sample ID) analysis mode 3-12

Bath status 6-5
Between Items 4-70
Between Sample Types 4-72
Breakers 3-30
by Analysis Items 4-73
C
Calculated Tests 4-18, 4-35
calibration
Advance Calibration 13-1
Calibration Analysis 4-44
Calibration editing for advanced calibration
6-18
Calibration Trace 13-1
Calibration Verification 7-19
Check the Calibration 6-15
Material Parameters 7-19
Reference to calibration data 6-19
Reference to Factor 6-20
Reference to present calibration 6-15
Verification Chart 7-20
Calibrator 4-52, 13-1
Calibrator Registration 4-45
Change of the calibrator concentration 4-47
Handling Calibrators 2-8
Cancellation of pause status 6-49
Change of the calibrator concentration 4-47
Checked Tests 4-67
check range 4-37
Check the Analyzer Status 6-4
Check the Printer 5-7
Check the Sample Status 6-3
Check the Test Results 6-11
Clean the Air Filters 8-30
Clean the Deionized Water Filter 8-25
Clean the Mix Bar Wash Station 8-19
Clean the Sample Pre-diluent Bottle 8-16
Clean the Wash Nozzle 8-21
Clean the Wash Station 8-18
Comment Master 7-22
Consumable 13-1
contamination prevention 4-69
Index
14-1
Correlation 4-30, 7-16

Cuvette 13-1
Cuvette overflow 11-24
D
Daily Maintenance 8-3
Daily Variation Chart 6-23
Data Lists 4-74
Data Statistics 7-12
Data Transmission Method 4-10
Date and Time 4-8
Day-to-Day Variation Chart 6-25
Dead volume 13-1
Default type 4-3
Deionized Water Tank 3-29
Diluent bottle 6-5
Diluted Wash Solution Tank 3-29
Disabling (a Test) 13-2
Displaying Reaction Monitor 6-11
display online operational help 3-33
Displays 2-27
Double Rate Assay 3-6
Drainage and Exhaust 2-16
Dynamic Range 4-30
E
Electrical and Noise Conditions 2-12
Electromagnetic Wave and Noise Precautions
2-10
emergency stop
emergency stop 6-52, 11-23
Reset operation after emergency stop 6-52
EM STOP (Emergency Stop) button 3-17
end assay 3-5
End Point Assay 3-4, 13-2
Ensuring Optimal Analytical Performance 2-7
Error Flag 9-1, 13-2
Error Messages 10-1
External storage device 7-24
F
Factor for Maker 4-30
FIXED 13-2
Fixed Point Assay 3-6, 13-2
for the STAT table 4-54
G
General Tests 4-29
Graphical User Interface (GUI) 3-32
Group 5-43, 13-2
Group Editing 4-26
Guarantee 1-7
14-2
Index
H
Handling Samples 2-9
Handling the Keyboard, Monitor and Mouse 2-6
Help
Alarm Help 1-9
Operation Help 1-9
Tip Help 1-9
I
Important Checks at Analysis 2-7
Incubation Bath Unit 3-23
Index 5-4
Inspect the Printer 8-10
Inspect the Probes 8-8
Inspect the Syringe 8-3
Inspect the upper cover 8-7a
Inspect the Wash Solution Roller Pump 8-5
Installation
Installation Environment 2-12
Space 2-24
ISE
Check slope chart 6-65
Correction Factor 4-34
CRS Calibration 5-14, 6-64
Dynamic Range 4-34
ISE Calibration 5-10
ISE Test 4-34
Performing or Check selectivity check 6-66
ISE Unit (optional) 3-30
K
Keyboard 3-35
L
Labels 2-27
Lag Time Check 4-30, 13-2
Layout editing 4-77
LIH
LIH Influence Check 4-30
LIH Judgment level 4-33
LIH Test 4-32, 13-2
Reagent Volume 4-33
Sample Volume 4-33
Linearity 13-3
Linearity limit 4-30
Log in 5-3
M
Maintenance
Daily Maintenance 5-8, 8-3
Maintenance Every Three Months 8-29
Maintenance Performed Yearly or As Necessary
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July 24, 2009
8-33
Monthly Maintenance 8-17
Routine Maintenance 2-11
Weekly Maintenance 8-11
Managing Liquid Waste 2-10
Managing Solid Waste 2-10
Manual STAT Operation 4-6
MCAL 13-3
Measure Mode
Measure 1 3-34
Measure 2 3-34
Pause 3-34
Standby 3-34
Stop 3-34
Warm up 3-34
Measuring Point-1 4-30
Measuring Point-2 4-30
Menu Access Level 7-7
Method 4-30
Multi Reagent Switch 4-16
N
No Reagent Operation 4-3
Normal repeat 4-39
O
OD Limit 4-30
Offline conditions 7-29
Olympus Guarantee 1-7
Onboard Stability 4-30
Online Help 1-9
Online Item Number 4-14
Online Protocol 4-12
Online transfer 6-41
ON (sub power) button 3-17
Overwriting the data 6-46
P
parameters
calibration parameters 4-48
Quality Control Parameters 4-59
Test Parameters 4-28
Password Expiration Date 7-8
Pause analysis 3-34
Pausing Analysis 6-49
Pausing Analysis Operation 6-49
Perform a W2 8-11
Performing STAT Table Analysis 6-31
Photocal Measurement 13-3
Photometry Unit 3-23
pictograms 2-27
power switches 5-2
Precautions for Operating the System 2-6
Pre-Dilution Rate 4-30
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July 24, 2009
Preventing Damage to Other Equipment 2-4

Preventing Electric Shocks 2-4
Preventing Fire and Damage 2-4
Preventing Infection 2-6
Preventing Personal and Serious Injury 2-5
Preventing Water Leaks 2-10
print format 4-74
Printing Other Sample Data 6-40
Processing Time 3-33
Profile 4-20
Q
QC Analysis 4-57
QC Monitor 13-3
QC sample
Handling QC Samples 2-8
QC Sample 13-3
quality control (QC)
Editing Quality Control Data 6-53
Quality Control Profile 4-23
Quality Control Using the STAT Table 4-64
Requesting QC Analysis 5-38
R
Rack Feeder Top Unit 6-6
Rack Feeder Unit 3-18
rack ID labels 5-19
Rack No. analysis mode 3-12
Rack Number 4-5
Racks 3-20
rack setting order 5-33
RATE 13-3
Rate Assay 3-6
RB 13-3
RB/Calibration Profile 4-22
Reaction Slope 4-30
Reagent 5-17
Handling Reagents 2-8
Reagent 13-3
reagent bottles 5-17
Reagent ID 13-4
Reagent OD Limit 4-30
Reagent Refrigeration Unit 3-25
Reagent refrigerator status 6-5
Setting reagents 5-16
Reagent Blank
Reagent Blank 3-3
Reference to Factor 6-20
Reference to reagent blank data 6-19
reference to reagent blanks 6-15
Reagent confirmation 5-15
real-time printing 4-76
Reference value (cumulative value) 4-62
Reference value (preset) 4-61
Reflex Range 4-43
Index
14-3
Reflex Testing 13-4

Registration of controls to be used with the STAT
table 4-65
repeat run
Repeat Run 13-4
Repeat run Group Setting 4-41
Repeat run parameters 4-42
Repeat run with condense 4-39
Repeat run with dilution 4-39
Repeat Tests 4-39
Repeat Run Work List 6-44
Replace Mix bars 8-38
Replace Sample Probe and Reagent Probe 8-36
Replace Syringes 8-42
Replacing Parts 2-11
Replenishing the Concentrated Wash Solution
8-7
requisition
Batch Requisitions 5-46
Manual Requisitions 5-45
requisition for advance calibration 5-35
requisition for calibration 5-34
Requisition for Calibration Analysis with STAT
table 5-37
Requisition for QC analysis with STAT table
5-41
Requisition for Repeat Run 6-43
Requisitions for Emergency Samples 5-49
Test Requisitions 13-4
Requisition Information Receiving Method 4-9
RESET button 3-18
restart after feeder stop 6-50
Routine Maintenance 2-11
S
Sample
Precautions in handling and storing samples
2-9
Pretreating samples 2-9
Samples available for analysis 2-9
Sample Barcode 5-20
sample blank 3-5
sample blank correction 3-5
Sample Cup 5-23
Sample Cups and Tubes 3-19
sample data
Correcting Patient Sample Data 6-59
Recalculating Analysis Data 6-62
Rewriting Patient Sample Data 6-57
Transferring the Edited Data 6-63
sample diluent 3-14, 13-4
Sample Order 5-30
Sample Transfer Unit 3-21
sample volume 4-30, 5-26
see if an alarm occurred 6-22
self-blank method 3-5
14-4
Index
Sequential analysis 4-3

Sequential mode 3-12
Set the analysis parameters 4-3
Setting Password 7-4
Setting User Name 7-4
shut down system operation 3-33
Shutdown the system 6-51
S. ID Barcode 4-3
Simple STAT Mode 6-36
Standard Deviation 13-4
Start Condition 5-4
STAT Operation 4-3
STAT table
automatic analysis mode 6-31
ID editing 6-34
Sample Confirmation Mode 6-32
STAT analysis pause 6-34
STAT table 6-6
STAT table sample placement positions 4-6
STAT Table Unit 3-26
STAT table adaptor 6-30
stop the analysis 3-34
stop the rack feeder 3-34
Syringe Unit 3-28
System Installation 1-8
System Switches and Buttons 3-17
T
TABLE ROTATION/DIAG button 3-18
Tank Storage 3-29
Temperature and Humidity Conditions 2-14
Test Name 4-15
Transfer of Overwritten Data 6-47
troubleshooting
Abnormal Sound 11-16
Barcode Errors 11-18
Bubbles in the syringe 11-10
Check for an abnormal cuvette 11-4
Checking Abnormal Data 11-4
Check Patient Data 11-5
Check the Calibration 11-6
Check the Calibrator 11-8
Check the Deionized Water 11-9
Check the photocal measurement data 11-6
Check the QC 11-8
Check the reagents 11-8
Compare the calibration data 11-4
Compare the reaction processes 11-3
Data Problem Checklist 11-3
Emergency Stop 11-23
hardware malfunctions 11-10
identify data problems 11-3
Incubation Temperature 11-14
Keyboard Not Responding 11-21
Leaking from a probe 11-19
leaking from syringes 11-10
AU480 User Guide

July 24, 2009
Leaks from the System 11-18

Leaks from the wash solution roller pump 11-17
Menu Cannot be Selected 11-21
Mix bars 11-13
mixing unit malfunctions 11-13
No Sample Cup on the STAT Table 11-19
No wash solution to Mix bars 11-18
Online Auto-Output Not Executed 11-22
Photometer Lamp 11-13
position of the probe 11-11
Power Failure 11-23
probes leaking 11-11
Processor Problems 11-21
Reagent Refrigerator Problems 11-15
Results Do Not Print 11-22
room temperature 11-14
Sample Rack Jammed 11-20
sample requirements 11-7
STAT table temperature 11-15
Syringe Problems 11-10
Verify Parameters 11-5
Water Tank Dirty 11-13
Tubing Diagram 8-23
Twin Plot 13-4
Typographical Conventions 1-12
U
Unit Status Descriptions 6-8
Updating Index 5-4
User Guide
Printing this User Guide 1-11
user level 7-4
User Menu 7-10
using the analyzer independently 2-11
W
W1 13-4
W2 13-4
Warning Labels 2-3
Wash Nozzle Unit 3-24
Wash Solution
Handling Wash Solutions 2-8
Wash Solution Roller Pump Unit 3-28
Wash Solution Tank 3-29
Water Supply 2-14
Wave length 4-30
ways to perform a repeat 6-42
Weekly Maintenance 8-11
Work List Printing 6-41
AU480 User Guide

July 24, 2009
Index
14-5

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Users Guide Vol.

AU480 User Guide

1 List of Parts Used for ISE Maintenance ...................................................................... ISE-5

9.1 Summary of Error Flags............................................................................................ 9-3

AU480 User Guide

bz (Calibration curve for Prozone data used) ......................................................... 9-15

Error Messages In the Comment column.................................................................... 10-14

AU480 User Guide

11.5 Troubleshooting the System - System Problems .................................................. 11-16

12.1 Home Menu................................................................................................................. 12-2

AU480 User Guide

Inspect the Syringes for Leaks and Proper Installation....................................8-3

Inspect and Replenish the Concentrated Wash Solution ................................8-6

Inspect the Stability of the Upper Cover.........................................................8-7a

Inspect, Clean and Prime the Sample and Reagent Probes............................8-8

Inspect and Clean the Mix Bars .....................................................................8-10

Inspect the Printer and Paper.........................................................................8-10

Replace the DI Water in the Pre-dilution Bottle..............................................8-10

Prepare for a Sample Probe Wash.................................................................8-10

Perform a W2 ................................................................................................ 8-11

Clean the Sample Pre-diluent Bottle..............................................................8-16

Clean the Mix Bar Wash Wells.......................................................................8-19

Clean the Air Filters........................................................................................8-30

Replace the Wash Solution Roller Pump Tubing............................................8-31

Replace O-rings in the Wash Nozzle Tube Mounting Joints ..........................8-34

Replace the Cuvettes ....................................................................................8-35

Replace Sample Probe and Reagent Probe..................................................8-36

Replace Mix Bars...........................................................................................8-38

Replace the Wash Nozzle Joint .....................................................................8-39

Clean the Inside of the STAT Table Compartment and Reagent

Clean or Replace the Antistatic Brushes........................................................8-47

Replace the Sample and Reagent Probe Tubing ..........................................8-48

8.5.10 Replace the Photometer Lamp ......................................................................8-48

AU480 User Guide

AU480 User Guide

8.1 Daily Maintenance

Inspect the Syringes for Leaks and Proper Installation....................................8-3

Inspect and Replenish the Concentrated Wash Solution ................................8-6

Inspect the Stability of the Upper Cover.........................................................8-7a

Inspect, Clean and Prime the Sample and Reagent Probes............................8-8

Inspect and Clean the Mix Bars .....................................................................8-10

Inspect the Printer and Paper.........................................................................8-10

Replace the DI Water in the Pre-dilution Bottle..............................................8-10

Prepare for a Sample Probe Wash.................................................................8-10

Always wear personal protective equipment when performing any maintenance

Inspect the Syringes for Leaks and Proper Installation

Ensure the system is in Warm up, Standby , or Stop mode.

Open the right door.

Piston fixing screw

Possible leakage locations

AU480 User Guide

If a leak or crack is encountered, refer to 8.5.6 Replace Syringes, in the As Needed

Close the right front door of the analyzer.

If any leak persists even after tightening,the syringe must be replaced.

AU480 User Guide

Inspect the Wash Solution Roller Pump Unit for Leaks

Ensure the system is in Warm up , Standby , or Stop mode.

Open the left door.

Verify the tube connections are tight.

Close the left door.

AU480 User Guide

Inspect and Replenish the Concentrated Wash Solution

Inspect the concentrated wash solution level

Ensure the system is in Warm up , Standby , or Stop mode.