Professional Documents
Culture Documents
Service Manual
Chapter 1........................................................................................................................................................1
Chapter 2......................................................................................................................................................11
Troubleshooting......................................................................................................................................11
2.a Troubleshooting Overview.................................................................................................................11
2.b Troubleshooting Guide ......................................................................................................................12
2.c DC Power Verification .......................................................................................................................13
2.d Display Verification ............................................................................................................................13
2.e Probe Motor Verification ....................................................................................................................14
2.f Printer Verification .............................................................................................................................15
2.g Sample Detector Verification .............................................................................................................16
2.h Serial Communication Verification.....................................................................................................17
Chapter 3......................................................................................................................................................18
Repair .........................................................................................................................................................18
3.a Repair Overview ................................................................................................................................18
3.b Recommended Tools ........................................................................................................................18
3.c Rear Housing Removal .....................................................................................................................19
3.d Rear Housing Installation ..................................................................................................................19
3.e Power Supply Removal .....................................................................................................................21
3.f Power Supply Installation ..................................................................................................................21
3.g Printer Removal .................................................................................................................................22
3.h Printer Installation..............................................................................................................................22
3.i CPU Board Removal .........................................................................................................................25
3.j CPU Board Installation ......................................................................................................................25
3.k Display Removal................................................................................................................................27
3.l Display Installation.............................................................................................................................27
3.m Pump Motor Removal........................................................................................................................30
3.n Pump Motor Installation.....................................................................................................................30
3.o Probe Motor Assembly Removal .......................................................................................................32
3.p Probe Motor Assembly Installation ....................................................................................................32
3.q Guide Rod Removal ..........................................................................................................................35
3.r Guide Rod Installation .......................................................................................................................35
3.s Electrode Jack Removal....................................................................................................................37
3.t Electrode Jack Installation.................................................................................................................37
1
Chapter
P R O L Y T E A N A L Y Z E R
Product Description
1.a System Overview
The proLYTE analyzer is designed to make service and repair quick and easy. Modular construction is used
throughout the design. The basic operating system consists of a motor which drives the peristaltic pump.
The peristaltic pump draws the desired fluid through the system. A second motor drives the sample probe
through the solutions valve to aspirate the appropriate fluid for pumping: sample; standards; or air. The
sample detector in the fluid path communicates the position of the fluid in the line.
Please note that mechanical and electrical assemblies can be replaced. Follow the instructions in the
TROUBLESHOOTING SECTION to determine if assembly replacement is necessary. Refer to the
Replacement List in this section which lists replaceable assemblies, components, and appropriate part
numbers.
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P R O L Y T E A N A L Y Z E R
RUN CALIBRT’N
YES NO
ANALYZE BLOOD?
DAILY CLEANER?
STANDBY MODE?
*SECOND MENU?*
YES NO
*ANALYZE URINE?*
*SEE RESULTS?*
*PACK USAGE?*
*QUAL
CONTROL?*
Run Controls, See Last Control, See/Print Statistics,
Delete Results YES NO
*OPER FUNCTS?*
*DIAGNOSTICS?*
*DATE/RANGES?*
st
Change Date/Time, Cal Frequency, 1 Cal, Set Na/K/Cl Ranges YES NO
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P R O L Y T E A N A L Y Z E R
Table of Symbols
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P R O L Y T E A N A L Y Z E R
CPU Board contains the CPU board with digital components and analog
sensor inputs:
Auto-Sampler Port port for Auto-Sampler device
Serial Port port for RS-232 for serial device
Peristaltic Pump Assembly peristaltic pump to move fluids through the analyzer
Peristaltic Pump Motor powers pump
Peristaltic Pump Head Assembly contains pump rotor and rollers
Peristaltic Pump Connection connects the pump to the CPU assembly
Probe Arm holds and moves the probe to aspirate samples and calibrants
Printer
Front Housing
Rear
Housing
Probe
Arm
Sample
Probe
Display
Screen
Electrode
Jacks
Yes/No
Touchpad
Solutions
Valve
Peristaltic
Pump
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P R O L Y T E A N A L Y Z E R
Probe
Position Display
Locator Cable
CPU
Board
Serial
Port
Linear
Actuator Auto-Sampler
Port
Optical Power
Switch Supply
Connection Cable
Printer
Cable
Linear
Actuator Voltage
Connection Selector
Peristaltic Entry
Pump Module
Connection
AC/AC Step
Down
Transformer
Fuse
Power Bay
Supply
Figure P2 Rear Assembly
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P R O L Y T E A N A L Y Z E R
Electrode
Jacks
CPU
Mounts
Probe
Motor
Support
Optical
Switch
Peristaltic
Peristaltic Pump
Pump Motor Assembly
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P R O L Y T E A N A L Y Z E R
Sample Detector detects presence of air/liquid, sets sample position inside electrodes
Internal Filling Solution 2 molar KCL solution, acts as a “salt bridge” for the reference
electrode
Membrane Assembly creates the connection between the reference electrode and the other
electrodes
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P R O L Y T E A N A L Y Z E R
Membrane Assembly
Fill Plug
Fill Solution
Electrode Housing
Sample Detector
Potassium Electrode
Sodium Electrode
Chloride Electrode
Locating
Pins
Reference
Electrode
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P R O L Y T E A N A L Y Z E R
The CPU Board is supplied with the software installed to operate the proLYTE.
2
Chapter
Troubleshooting
2.a Troubleshooting Overview
This section describes troubleshooting of the mechanical and electrical functions of the proLYTE analyzer.
This section is based on the principle of replacing suspected faulty assemblies with new assemblies.
Diamond Diagnostics recommends keeping an inventory of functioning test assemblies for
troubleshooting the proLYTE. Refer to the Troubleshooting Guide in this section to determine the cause and
corrective action that must be taken to properly service the proLYTE analyzer.
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P R O L Y T E A N A L Y Z E R
Refer to the chart below to help determine the problem and corrective action needed.
1. Remove the rear housing. See Rear Housing Removal in the REPAIR SECTION for
details.
2. Connect the power cord first to an outlet, then to the entry module.
3. Connect the reference side of the voltage meter to TP12 on the CPU board.
5. If any of the voltage values in STEP 4 are not within specification, AND the AC
power verification is successful, replace the CPU board.
1. Disconnect the display cable from the CPU board. See Display Assembly Removal in the
REPAIR SECTION for details.
2. Connect a known good display assembly to the CPU board and connect the main
power cord. Verify that the test display is operative. Based on the test results, take the
appropriate corrective action.
1. Disconnect the power cord, wait ten seconds, then reinstall the power. The probe
arm should move down and back up. If there are no error messages, resume normal
operation. If a “PRB” error occurs, proceed to STEP 2.
2. Remove the sample probe from the probe arm. For details refer to proLYTE
Operator’s Manual. Remove and reinstall the power cord. The probe arm should move
down and back up. If there are no error messages examine and if necessary replace
the sample probe, solutions valve and/or probe wiper. If a “PRB” error occurs,
proceed to STEP 3.
3. If the probe arm does not move at all perform the following operations.
A. Visually inspect that the actuator and retaining ring are correctly installed on the
probe motor lead screw. If the installation is incorrect, refer to CPU Board
Removal and Probe Motor Installation in the REPAIR SECTION for details.
B. Check that the probe motor wires are completely seated inside the 4-pin
connector as follows:
4. If the probe arm moves and stops anywhere except the top position, or if the probe
arm vibrates against the top of the proLYTE housing, replace the probe position
sensor. To replace the sensor, first remove the CPU Board and the probe position
locator. Refer to Probe Motor Assembly Removal in the REPAIR SECTION for details.
5. If the probe does not move at all, check for a short circuit on the CPU Board
between TP12 and TP2. If there is a short circuit, replace the Stepper driver daughter
board at positions U35 and U36. See Front and Rear Assembly Components in the Product
Description Section.
6. If no short circuit is found, replace the probe motor assembly. Refer to the Probe
Motor Assembly in the REPAIR SECTION for details.
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P R O L Y T E A N A L Y Z E R
1. Press the printer paper advance button. If the printer head moves proceed to
STEP 2. If the printer head does not move, proceed to STEP 3.
2. Verify that the printer is on. Turn the printer on by pressing “NO” to the
PRINTER OFF? question in the USER OPTIONS section.
3. If the printer is still not working, remove the power cord from the analyzer and
wait for ten seconds, then install the power cord back into the entry module. The
printer head should move across the paper and the paper should advance forward
printing “proLYTE”.
4. If the printer is still not working, remove the printer cover and check for any
paper obstruction in the printer head area. Remove any obstructions if possible,
without damaging the printer assembly or printer window. If an obstruction is
present and cannot be removed, replace the Printer Assembly. Refer to Printer
Removal and Installation in the REPAIR SECTION for details.
5. If there are no obstructions, but the printer does not work, perform the following
steps.
6. If the printer still does not print, connect a test printer assembly to the CPU
Board. If the test printer works, install a new printer assembly. If the test printer
does not work, replace the CPU board. Refer to CPU Board Installation in the
REPAIR SECTION for details.
1. Remove the electrode housing from the analyzer. See the proLYTE Operator’s Manual
for further details.
-With the sample detector installed, the value on the display screen should be less
than 200.
-With the test in progress, remove the sample detector. The display should rapidly
change to 255.
If the sample detector test meets these specifications, resume normal operation.
A value of 255 with the sample detector installed indicates a bad connection. Proceed
to STEP5 to check the sample detector circuit.
5. Reinstall the sample detector. Look at the left side of the sample detector. A red light
must shine from the LED hole. If there is no red light, install a known good sample
detector. If there is still no red light, replace the Display Assembly. Refer to the
REPAIR SECTION for information.
6. If the TEST sample detector red light is on, check the four connecting pins on the
ORIGINAL sample detector. The pins must face straight out forming a rectangle. If
the pins are bent against the black plastic body, straighten the pins using a small flat
head screwdriver.
-If the red light comes ON: Reassemble the proLYTE and perform a SOLUTIONS
PRIME and a SAMPLE DET. TEST. Resume normal operation.
-If the red light remains OFF: Install a new sample detector.
1. Connect the proLYTE analyzer to a device with a known working serial port. Use
a known good proLYTE serial cable, part no. ME-1334D. Make cross
connections as required (e.g. 2 to 3; 4 to 5).
3. When correctly linked the proLYTE will transmit to the external device all of the
data that is printed by the proLYTE printer, in the same format.
3
Chapter
Repair
3.a Repair Overview
Always consult the TROUBLESHOOTING SECTION first to determine the problem before
attempting to repair the analyzer.
Always remove the solutions pack and the electrode housing from the
analyzer before beginning any repair work. Refer to the proLYTE
Operator’s Manual for detailed instructions.
Follow the assembly and removal instructions in the order outlined in this section unless otherwise
noted. Always unplug the power cord from the analyzer before beginning any repair work.
Note that only complete mechanical and electronic assemblies can be replaced. Refer to the Replacement
List in the PRODUCT DESCRIPTION SECTION which lists replaceable assemblies as well as
consumable items. Consult the list to determine the appropriate replacement item and part number.
The following is a list of the tools required to perform repairs on the proLYTE analyzer.
Please refer to this list to determine the appropriate tool and size needed.
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P R O L Y T E A N A L Y Z E R
2. Detach the four screws from the rear housing using a Phillips head screw driver, as
shown below.
1. Align and attach the front and back housing. See figure below. Verify that all cable
connectors are attached properly. Refer to figures in the PRODUCT DESCRIPTION
SECTION for detail. Verify that all wires are contained within the front housing
before proceeding.
Figure P5 –
Rear Housing
Removal
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P R O L Y T E A N A L Y Z E R
1. Disconnect the power supply cable from the CPU board, see Figure P6.
2. Detach the four screws from front housing, using a Phillips head screw driver.
4. Lift and remove the power supply assembly from under the CPU board.
1. Slide the power supply assembly under the CPU board, as shown in figure below. Fit
into the alignment holes in the bottom of the front housing.
2. Perform steps 1,2 and 3 from Power Supply Removal in reverse.
4. Detach the printer cable from the retaining clamps located along the right side of the
CPU board.
5. Detach the two screws using a Phillips head screw driver. Remove the printer body, as shown in
Figure P7.
6. Pull the printer cable up from behind the CPU board, while holding the printer body as shown in
Figure P8.
3. Attach the two screws using a Phillips head screw driver. See Figure P7.
5. Using scissors, cut the beginning of the paper roll into a “V” shape. Insert the paper into the feeder
slot inside the printer bay, and press the paper feed button.
8. Attach the printer cable to the retaining clamps located along the right side of the CPU board.
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P R O L Y T E A N A L Y Z E R
Printer Bay
Printer
Connection
Figure P8 – Printer Removal/Installation
1. Remove the display cable from the top of the CPU board shown in Figure P9.
2. Disconnect the electrode jacks from behind the CPU board. See figure below for the location of
the electrode jacks. To disconnect, gently pull electrode jack straight away from the connector pin
of the CPU board.
▲ The connector pins are extremely delicate. Avoid pin breakage when removing the electrode jacks,
gently pull the electrode jacks straight away from the pins. If a pin breaks the entire CPU board will
require replacement.
3. Disengage the CPU board from the four plastic mounting posts as shown.
4. Slide the CPU board off the mounting posts. See Figure P9.
1. Align the CPU board with the plastic mounting posts. Snap the right side mounting posts of the
CPU board into place.
2. Connect the electrode jacks to the back of the CPU board. To connect, gently push the electrode
jack straight into the connector pin. See figure below to determine the proper connector pin
position on the CPU board and the recommended installation order.
▲ Do not bend the connector pin when installing the electrode jack. If a pin breaks the
entire CPU board will require replacement.
3. Snap the left and center mounting posts of the CPU board into place.
4. Attach the display cable to the CPU board. Push the display cable tabs to the front to secure cable
in place. See Figure P9.
5. Connect the probe motor, sensor, pump motor, power supply and printer cables to the CPU
board, see Figure P9.
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P R O L Y T E A N A L Y Z E R
1. Detach the two screws from the sample detector board using a Phillips head screw driver.
2. Move and hold the display cable to expose the three display assembly screws. Detach the three
screws from the display assembly using a Phillips head screw driver. See Figure P10.
3. Carefully remove the display cable from the LCD screen, holding both items together. See Figure
P11.
▲ Notice the orientation of the LCD screen which is extremely important when installing the display
assembly. The display has soldered leads located on the bottom of the LCD screen.
▲ There is an orientation notch on the display adapter. The display mounts on the two posts below
the window. When installing the display adapter, the orientation notch is located on the top inside
edge of the adapter.
1. Place the foam pad on the display board between the screen and mounting plate.
2. Place the LCD screen on top of the foam pad. The orientation of the LCD screen is extremely
important, see Figure P11. The display has soldered leads located on the bottom of the LCD
screen.
3. Position the front housing so that the front of the analyzer is facing down. Align the display
assembly and insert into place, as shown in Figure P11. Use mounting holds as a guide.
4. Hold the display in place and attach the three screws using a Phillips head Screw driver. See Figure
P10.
5. Align the sample detector board so the sample detector cable is positioned on the right side. Attach
the two screws lightly, using a Phillips head screw driver, see Figure P10.
6. Install the sample detector in the front of the analyzer to verify the sample detector board
alignment. When properly aligned fully tighten the sample detector screws.
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P R O L Y T E A N A L Y Z E R
2. Detach the four screws from the front of the analyzer, using a Phillips head screw driver or 1.5
Hex as applicable. See Figure P12.
1. Install the pump motor assembly through the front housing, as shown in Figure P13. The pump
motor wires are positioned below the pump when properly aligned.
2. Attach the four screws into the front of the analyzer, using a Phillips head screw driver. See Figure
P12.
3. Using a tie wrap cable, secure the loose wires under the pump motor to the lead screw/probe
motor wires and the sensor wires.
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P R O L Y T E A N A L Y Z E R
1. Detach the screw at the top of the probe position locator, using a Phillips head screw driver, as
shown in figure below. Remove the washer.
3. Remove the retaining ring from the actuator, using the retaining ring pliers. The retaining ring must
be replaced once removed. DO NOT stretch out the retaining ring with the pliers. Disengage the
actuator from the top of the lead screw assembly.
4. Detach the three screws from the probe motor bracket, using a Phillips head screw driver, as
shown in Figure P14.
1. Place the probe motor assembly into place. See Figure P14.
2. Attach the three washers and screws to the probe motor assembly bracket, using a Phillips head
screw driver. See Figure P14.
▲ The other two screws are located on the bottom edge of the bracket.
3. Insert the actuator through the top of the lead screw assembly. Install the retaining ring onto the
actuator using the retaining ring pliers. DO NOT stretch out the retaining ring with the pliers.
4. Place the probe motor cable wires into the retaining clamp. Secure the wires to the sensor cable
wires with a tie wrap cable.
The optimum location for the tie wrap cable is slightly to the left of the retaining clamp.
6. Remove the black thumb grip from the solutions valve. Install the sample probe as normal. Refer
to Figure P14 for details.
A. With the probe hole facing to the left, toward the inside body of the proLYTE,
align the probe collar with the notch on the top of the probe arm. When
aligned, snap the probe into the probe arm.
B. Manually move the probe arm until the sample probe hole is aligned with the
top chamber on the solutions valve.
▲ When the sample probe is aligned, DO NOT move the probe arm until the
probe motor installation is complete.
7 Place the locator into position. The locator should be seated inside the probe position sensor and
inside the mounting bracket slot.
8. Attach and slightly tighten the washer and screw at the top of the position locator. Do not fully
tighten the screw.
9. Align the probe position locator slot within the center of the optical switch. Gently move the
locator to the left and visually confirm the alignment. Refer to Figure P2 for correct alignment.
▲ Confirm that the sample probe hole is aligned with the top chamber on the solutions valve
before continuing.
10. When alignment is complete, fully tighten the probe position screw into place using a Phillips head
screw driver.
1. Remove the sample probe from the probe arm and the solutions valve. Remove the solutions
valve.
2. Detach the screw from the bottom of the guide rod, using a Phillips head screw driver. Remove the
washer.
3. Remove the guide rod and probe arm assembly, down and away from the housing.
1. Install the guide rod. To install, first insert the guide rod into the alignment hole located in the top
wall of the front assembly.
2. Attach the washer and screw to the bottom of the guide rod, using a Phillips head screw driver.
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P R O L Y T E A N A L Y Z E R
1. Insert the electrode jack wires into the supplied 11/32 inch nut driver.
3. Pull the electrode jacks from the front housing of the analyzer, as shown in Figure P16.
1. Push the electrode jacks through the holes in the front of the analyzer, see Figure P16.
2. Insert the electrode jack wires into the 11/32 inch nut driver.
3. Attach the hex nut using the nut driver and tighten.