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ABBOTT
CELL-DYN 1800
Automated Hematology Analyzer
Service & Support Manual
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ABBOTTCD1800 SM
Theory of Operation............................................................................................................................................................................ 4
System Overview .................................................................................................................................................................... 4
Major Subsystem Descriptions ........................................................................................................................................... 6
Circuit Descriptions ............................................................................................................................................................. 15
Signal Processor Module (SPM)....................................................................................................................................... 18
Cell Count Module (CCM) ................................................................................................................................................... 21
Troubleshooting.................................................................................................................................................................................31
Troubleshooting Charts ...................................................................................................................................................... 33
Raw Data Description .......................................................................................................................................................... 40
CCM On-Board Diagnostic LEDs ...................................................................................................................................... 41
CPU Hardware/Software Configuration .......................................................................................................................... 44
Service Special Commands ............................................................................................................................................... 45
Sample Probe Description................................................................................................................................................. 49
CELL-DYN 1800 Error Messages ...................................................................................................................................... 60
Software Commands and Sequence ............................................................................................................................... 72
Engineering Drawings and Schematics............................................................................................................................................. 76
CELL-DYN 1800 PCB Reference .................................................................................................................................................... 77
Removal & Replacement .................................................................................................................................................................. 96
Service Equipment Required ............................................................................................................................................. 96
Covers (CD18-A1) .................................................................................................................................................................... 97
Flow Panel (CD18-B1)............................................................................................................................................................ 105
Fluid Power Supply (CD18-C1).............................................................................................................................................. 115
Syringe Assembly (CD18-E1)................................................................................................................................................. 119
RR-E1.04 Sample Syringe Driver Assembly .................................................................................................................... 125
RR-E1.06 Lyse Syringe Driver Assembly ..................................................................................................................... 127
Electronics / Card Cage (CD18-F1) ........................................................................................................................................ 129
RR-F1.01 PAM (Pre-Amplifier Module) ............................................................................................................................. 129
RR-F1.02 MPM (Motor Processor Module) Board .......................................................................................................... 131
RR-F1.03 CDM (Cable Distribution Module) Board ........................................................................................................ 133
RR-F1.04 Hard Disk Drive................................................................................................................................................... 135
RR-F1.05 Floppy Disk Drive ............................................................................................................................................... 138
RR-F1.06 Signal Processor Module (SPM)...................................................................................................................... 140
RR-F1.07 Cell Count Module (CCM)................................................................................................................................. 142RR-F1.08 Data Link Adapter (DLA) ................................................................................................................................... 143
RR-F1.09 Single Board Computer (SBC) ......................................................................................................................... 145
RR-F1.10 Card Cage Backplane PCB .............................................................................................................................. 147
LCD/Keyboard (CD18-G1)..................................................................................................................................................... 149
Power Supply (CD18-H1).................................................................................................................................................... 151
Verification Procedures ................................................................................................................................................................... 154
VP-01 Preparation for Alignment and Verification ................................................................................................................. 154
VP-01 Preparation for Al ignment and Verification ..................................................................................................... 154
Test Equipment and Supplies Required ....................................................................................................................... 154
Preparation for Alignment/Verification ......................................................................................................................... 155
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Order of Alignment/Verification ...................................................................................................................................... 156
VP-02 Decontamination.................................................................................................................................................... 157
VP-03 Vacuum and Pressure Adjustments .................................................................................................................. 158
Regulator Alignment.......................................................................................................................................................... 159
Pressure Adjustment (0.5 psi)......................................................................................................................................... 160
Pressure Verification (High) ............................................................................................................................................ 161
Vacuum Adjustment (8 inch) ........................................................................................................................................... 161
VP-04 Metering System Timing Adjustments - RBC and WBC.............................................................................. 162
Metering Timing Fault Report .......................................................................................................................................... 163
RBC Metering System Timing Adjustment .................................................................................................................. 165
WBC Metering System Timing Adjustment ................................................................................................................. 166
VP-05 CMOS Setup Verification/Adjustment ............................................................................................................... 167
VP-06 Card Cage Backplane Test Points ..................................................................................................................... 171
VP-07 Cable Distribution Module Test Points ............................................................................................................. 172
VP-08 Pre-Amplifier Module (PAM) Adjustment ......................................................................................................... 173
VP-09 Signal Processor Module (SPM) Verification/Adjustment ........................................................................... 176
RBC Gain.............................................................................................................................................................................. 178
RER Adjustment................................................................................................................................................................. 179
WBC Gain............................................................................................................................................................................. 182
PLT Gain............................................................................................................................................................................... 184
VP-10 Diluent and Sample Verification/Adjustment ........................................................................................................ 187
Diluent Volume Verification ............................................................................................................................................. 188
Sample Volume Verification............................................................................................................................................ 188
VP-11 Stepper Motor Power Test and Verification.................................................................................................... 189
VP-12 Sample Probe Alignment Check........................................................................................................................ 190
VP-13 Serial Transmit to LIS Verification ..................................................................................................................... 191
VP-14 Hard Disk Drive Setup and Verification ............................................................................................................ 194
VP-15 Software Installation/Upgrades.......................................................................................................................... 197
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Theory of Operation
System Overview
The CELL-DYN 1800 Automated Hematology Analyzer is a complex system. Analyzer performance depends on several
components that together make up the complete hematology system. The system is comprised of the following components
and subsystems:
Flow Panel System [3]
Fluid Power Supply [2]
Reagent Inlet Panel [6]
Syringe Drive Assemblies [7]
Electronics Card Cage [8]
LCD Display System [4]
Touchpad (Membrane) Keyboard [5]
Power Supply Assembly [1]
Flow Panel
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The Flow Panel consists of tubing, solenoid valves, and other hardware components used for sample aspiration, dilution,
measurement and waste removal.
Fluid Power Supply
The Fluid Power Supply contains the vacuum and pressure pumps, accumulators, waste bottles, and associated solenoids
and hardware.
Reagent Inlet Panel
The Reagent Inlet Panel provides connections for incoming reagents and outgoing waste. The Lyse solenoid is also mounted
on this panel.
Syringe Drive Assembies
The Syringe Drive Assemblies include the Sample Syringe for aspirating samples, the Diluent Syringe for supplying Diluent
throughout the Flow Panel, and the Lyse Syringe for dispensing Lyse to the WBC transducer for the HGB measurement
process.
Electronics Card Cage
The electronics card cage, with associated PCBs, provides command and control signals for the various electronic
components of the instrument. This assembly contains the Backplane PCB, Cell Count Module, Signal Processor Module,
Data Link Adaptor and Single Board Computer.
LCD Disp lay Screen and Keyboard
The LCD Display Screen provides a visual data display and the keyboard provides data input by the operator.
Power Supply Assembly
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The Power Supply Assembly provides an AC and DC voltage source to various components on the CELL-DYN 1800 System.
The DC Regulator PCB provides power to the Backplane PCB for use with the digital circuitry on various PCBs. It also
provides power to the Cable Distribution Module and fans.
The AC Regulator PCB provides power to the Backplane PCB (for use with the analog circuitry on various PCBs). It also
provides power to the Pump Relay Module.
The +28VDC Switching Power Supply provides power for the stepper motors via the Motor Processor Module. It also
provides power to initially energize solenoids.
Major Subsystem Descriptions
To aid in understanding the overall system, the electronic modules are divided into the following major functional
subsystems:
Data Interface and Control Subsystem
Measurement Subsystem
Solenoid Motor and Pump Subsystem
Single Board Computer Subsystem
AC and DC Power Distribution Subsystem
Data Interface and Control Subsystem
The purpose of this subsystem is to interface the user data, control data, measurement data, and system status data in the
system. This data is connected via four independent data busses:
DLA/CCM (Data Link Adapter/Cell Count Module)
CCM/SPM (Cell Count Module/Sample Processor Module)
CCM/CDM (Cell Count Module/Cable Distribution Module)
CCM/MPM (Cell Count Module/Motor Processor Module)
See the figure below for a diagram showing the data connections.
Data Interface and Control Block Diagram
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When power to the instrument is turned ON, the system is operating software is loaded from the hard disk into RAM on the
SBC (Single Board Computer). The SBC then uses various handshaking signals and data bytes to communicate with the
CCM (Cell Count Module) via the DLA (Data Link Adapter).
The CCM functions as the master controller with all system functional commands residing in firmware (PROM). The CCM
sends control data and receives status data from the CDM (Cable Distribution Module).
The CCM provides current control to the von Behrens RBC and WBC Transducers and the two metering PCBs and serves as
the system's analog voltmeter for use in converting the HGB signal. Data is written and read via the CCM/CDM and
CCM/MPM data buses.
The CDM (Cable Distribution Module) acts as a controller for the solenoids and also interfaces data from various system
sensors.
The MPM (Motor Processor Module) acts as a controller for all Stepper Motor Drive PCBs.
Measurement Subsystem
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The measurement subsystem provides detection, amplification, and processing of the signals from the von Behrens
RBC/PLT Transducer, von Behrens WBC Transducer, and HGB Flow Cell. RBC/PLT and WBC metering is also included in
this subsystem.
See the figure below for a diagram of the measurement process.
Measurement Block Diagram
The PAM (Pre-Amplifier Module) supplies constant current for the von Behrens RBC/PLT and WBC Transducers and HGB
LED voltage.
The RBC/PLT and WBC cell pulses are input to the PAM where they are amplified and routed to the SPM (Signal Processor
Module).
When the SPM receives signals from the RBC/PLT and WBC, the following occurs:
The RBC/PLT signal is amplified (gain) and split into independent RBC and PLT signals.
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The WBC signal is amplified (gain).
The RBC signal is routed to the cell editing circuitry.
Cell editing is performed on the RBC signal to eliminate invalid RBC pulses.
The SPM discriminates cell size by converting pulse height to a proportional digital value. The amplitude of each valid pulse
is measured by a fast A/D converter then sent across the data bus to the CCM.
The A/D data for RBC, PLT, and WBC are individually divided by the CCM into 256 discrete size channels. The cell count in
each channel is accumulated in discrete memory locations and is used to generate count data, percentage data, and
histogram data for RBC, PLT, WBC, and other derived parameters.
Signals from the upper and lower detectors on the RBC/PLT and WBC metering PCBs are converted to TTL levels by
comparators on the CDM. The signals are then routed to the CCM where they are used to control RBC/PLT and WBC
sample timing.
The HGB analog signal from the HGB Flow Cell is captured by the PAM where it is amplified and routed to the CCM. The
HGB signal is then measured and converted to a digital format by a voltmeter-A/D converter.
Solenoid, Motor Drive, and Pump Subsystem
Solenoid control commands reside in firmware on the CCM. These commands are sent to the CDM where they are
multiplexed to the appropriate SDM (Solenoid Drive Module). The SDM then provides the current to open and close
individual drive solenoids.
Stepper Motor commands are handled in much the same manner as described above. However, the final multiplexing of theStepper Drive PCBs is controlled by the MPM.
There are two pressure pumps and one vacuum pump in the CELL-DYN 1800 System. These pumps are described as
follows:
A pressure pump provides air to bubble-mix samples in the Pre-Mixing Cup and the mixing chambers of the von
Behrens RBC/PLT and WBC Transducers. A pressure regulator regulates the 0.5 psi in the pressure accumulator for
this process.
An unregulated pressure pump provides air to push waste from the waste bottles inside the instrument to the waste
container attached to the instrument and to apply back pressure to clear the apertures in the von Behrens RBC/PLT
and WBC Transducers.
An 8" Hg vacuum accumulator, vacuum sensor, and vacuum pump supply a constant vacuum to the entire system to
transport Diluent, Detergent, and Lyse throughout the flow system and to maintain a constant vacuum to the
RBC/PLT and WBC metering tubes. A vacuum regulator maintains a constant vacuum source to both metering
tubes.
See Solenoid, Motor Drive and Pump Block Diagramfor a diagram of the solenoid and motor drive connections.
Solenoid, Motor Drive and Pump Block Diagram
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Single Board Computer Subsystem
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The Single Board Computer subsystem consists of the following components:
Single Board Computer PCB
Data Link Adapter
Input/Output Ports (serial/parallel)
Keyboards (PC and membrane)
LCD Display Screen
Disk Drives (hard and floppy)
The figure below illustrates the major components of the User Interface Computer.
User Interface Computer
SBC (Single Board Computer) PCB
The Single Board Computer (SBC) PCB is a complete Celeron 850 Megahertz PC computer system with 128 Megabytes of
RAM that is self-contained on one board. It utilizes a PC compatible BIOS with DOS capability that directly interfaces with the
LCD Display Screen, Hard Disk Drive, Floppy Disk Drive, PS/2 Keyboard, one (1) Parallel Port and two (2) Serial Ports. It
connects directly into the Backplane PCB along with the Data Link Adapter (DLA) and utilizes the ISA bus and Backplane
PCB to communicate with one another.
DLA (Data Link Adapter)
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The DLA PCB connects directly into the Backplane PCB. It provides a program-controlled data channel from the SBC to the
CCM. The DLA performs the following three functions:
Receives measurement and analyzer status data from the CCM
Transfers commands from the SBC to the CCM
Sends control data from the UIC to the CCM.
Serial I/O Ports
The CELL-DYN 1800 contains two (2) Serial I/O Ports for transferring data to other computer systems:
COM1RS-232 Data Output
COM2Spare
Parallel I/O Port
The CELL-DYN 1800 contains one parallel I/O port for transferring data to a printer.
PC/2 Keyboard
The external 101 key PC keyboard is used to enter alphanumeric data, such as demographic information, into the instrument.
Touch Pad (Membrane) Keyboard
The touch pad (membrane) keyboard is located below the LCD Display Screen. The keyboard includes a row of eight (8)
unmarked rectangular-shaped keys corresponding to labels displayed at the bottom of the screen. These keys activate the
indicated function or display the indicated submenu.
LCD Display Screen (Color)
The LCD Display Screen has the following characteristics:
Size: 8.5 x 6.4 inches (10.4 inches measured diagonally)
Number of colors: 16
Pixels: 640 width x 480 height (or 800 x 600)
Backlight on/off control (software controlled screen saver)
An LCD Adapter, connected directly on the SBC PCB, drives the LCD Display Screen. The adapter supports SVGA 640 x
480 and 800 x 600 graphics modes.
Hard Disk Drive
The hard disk drive stores the User Interface Software program and the Patient Data Log.
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Floppy Disk Drive
The 1.44MB 3.5" floppy disk drive is used for program installation and provides the QC (Quality Control) data
upload/download capability.
Printer
The User Interface Software supports Epson ESC-P or PCL-3 languages. The printer has its own buffer and is capable of
printing on 8.5" x 11" (letter size) or A4 paper size. The printer supports alphanumeric and graphics reports from stored data
and screen displays.
Speaker
The PC speaker or buzzer is controlled by software and is mounted on the SBC PCB.
AC and DC Power Distribution Subsystem
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The Power Supply Assembly is comprised of three components: AC Regulator PCB, DC Regulator PCB and +28VDC
Switching Power Supply. These components are mounted together as an assembly and are located at the right/rear side of
the instrument.
When the system is turned on, the AC line is routed into the AC Regulator PCB and +28VDC Switching Power Supply. The
AC Regulator PCB automatically accommodates line voltages of 90 - 130VAC and 200 - 260VAC by sensing the input
voltage and utilizing an internal comparator bank and power transformer to produce the 120VAC necessary for the
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subsystem's function. The Power Supply Assembly then provides an AC and DC voltage source to various components on
the CELL-DYN 1800 System.
+28VDC Switching Power Supply
The +28VDC Switching Power Supply provides the voltage source to the DC Regulator PCB, which the board then uses to
produce other voltages. The power supply cooling fan is thermistor controlled, which means that when the internal
temperature rises above 70C, the fan operates at full speed. The fan is then turned off at 50C and kept off until the
temperature rises above 70C.
AC Regulator PCB
The AC Regulator PCB provides the 120VAC used by the Pump Relay Module (PRM) for vacuum and pressure pump
operation.
The 12VDC (analog) is provided to the Backplane PCB, which is used by the Cell Count Module (CCM) and Signal
Processor Module (SPM). The 12VDC is also provided to the Cable Distribution Module (CDM), Motor Processor Module
(MPM) and Pre-Amplifier Module (PAM) (for its circuitry).
The +100VDC is provided to the PAM for use in its constant current circuitry. In between the AC Regulator PCB and the PAM
is the Pre Amp Filter that is used to filter out noise.
DC Regulator PCB
The DC Regulator PCB provides +5VDC, 12VDC (digital), +14VDC and +28VDC. The +5VDC is provided to the BackplanePCB, which is used by the SPM, CCM, Data Link Adapter (DLA) and Single Board Computer (SBC). This voltage is also used
by the CDM, MPM, Hard and Floppy Disk Drives.
The 12VDC (digital) is provided to the Backplane PCB for use on the CPU fan. The Hard and Floppy Disk Drives receive
+12VDC for their operation.
The +14VDC is provided through the CDM to the Solenoid Driver Modules (SDM) and is used to hold the solenoids closed or
open for normally closed solenoids.
The +28VDC is provided to the MPM for operating stepper motors and through the CDM to the SDMs to initially closesolenoids or open for normally closed solenoids. This voltage is also used for the system's internal cooling fans. The cooling
fans are thermistor controlled, which means that when the ambient temperature inside the instrument drops below 25C, the
fans operate at half speed. Once the temperature rises above 25C, the speed is increased linearly until it reaches 35C,
when the fans operate at full speed.
The DC Regulator PCB also provides +5VDC and +14VDC to the AC Regulator PCB.
Circuit Descriptions
This section contains a description of the circuitry for the following printed circuit boards:
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Pre-Amplifier Module (PAM)
Signal Processor Module (SPM)
Cell Count Module (CCM)
Cable Distribution Module (CDM)
Solenoid Driver Module (SDM)
Motor Processor Module (MPM)
Stepper Drive Printed Circuit Board (SDP)
Pressure/Vacuum Regulator Module (PVRM)
Power Supply Assembly
Pump Relay Module (PRM)
Single Board Computer (SBC)
Data Link Adapter (DLA)
Pre-amplif ier Module (PAM)
Note
Refer to PAM PCB Diagram.
PAM PCB Diagram
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The PAM performs the following functions:
Provides constant current control to the von Behrens RBC/PLT and WBC Transducers. Amplifies the initial RBC/PLT, WBC and HGB signals.
The constant current bias (+100VDC) is switched by U6, then routed to Q2 and Q3, which supplies constant current to the
von Behrens RBC/PLT transducers. The RBC/PLT current is adjusted with R72. Once received, the RBC/PLT signals are
initially amplified by U7, then routed to U5, where they are re-inverted and further amplified. The combined RBC/PLT signal is
then routed to the SPM PCB.
Transistors Q4, Q5 and associated circuitry provide constant current for the von Behrens WBC Transducer. The WBC
current is adjusted via R66. Once received, the WBC signal is initially amplified by U12, then routed to U11 where it is
re-inverted and further amplified. The WBC signal is then routed to the SPM PCB.
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The output of the HGB Flow Cell is amplified by U1 and U2 prior to being routed to the SPM PCB. The HGB self test and gain
voltages are adjusted with R14 and R4 respectively.
Signal Processor Module (SPM)
Note
Refer to SPM Architecture.
SPM Architecture
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EPLD (SPM)
The EPLD is an enhanced programmable logic device. The SPM EPLD is used to control data acquisition.
There are three state machines that run in the EPLD. One each is used for controlling data acquisition elements such as
Multiplexers and Peak/Hold Amplifiers. The inputs to the EPLD state machines are the outputs of the various Threshold and
Slope Detectors as well as Bubble and Area Comparators.
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There is a data transfer state machine which controls data flow to the CCM.
Signal Processing
There are two signals from the RBC and WBC transducers that are processed through two basic data acquisition circuits.
The Platelet signal is derived from the RBC signal. There are three gain adjustments associated with each of these signals.
In addition to the three gain adjustments there is a integration adjustment for detecting pulses that are too long.
WBC Signal
The WBC signal is received through a differential amplifier to reduce noise. There is a gain adjustment after the
differential amplifier but before the Test Signal injection point.
The WBC signal is then "Baseline Restored" to remove DC components and Baseline fluctuations due to varying
duty cycle of the blood cells.
A threshold detector signals to the EPLD the presence of valid pulses.
Simultaneously the Bubble detector signals if the pulse is determined to be a bubble. The bubbles are much larger
than pulses from blood cells. The EPLD discards the information from the pulse if it is determined to be a bubble.
The data from the pulse is processed on the falling edge of the Threshold Detector unless the Slope Detector senses
another rising edge before the falling edge of the Threshold Detector. The data is processed immediately if there is
another rising edge before the falling edge of the Threshold Detector.
The WBC Held Peak is converted and sent to the CCM on a 15S cycle. Average pulses from the impedance
transducers are 35S.
RBC and PLT Signals
There are two modes for RBC/PLT data acquisition:
RBC MCV
RBC Count/PLT
RBC MCV
RBC MCV is for RBC MCV data only. In this mode, an integrator is enabled to determine if the cell is moving through the
middle of the aperture. If the cell is not moving through the center of the aperture, the data is falsely high and the pulse is
abnormally long. The integrated signal is compared to a proportion of its height. If the pulse is too long for its height, it is
discarded.
RBC Count/PLT
RBC Count mode is for count information. During this run, Platelets are counted simultaneous with RBCs and no integration
is used. The Platelet signal is derived from the RBC signal by an adjustable gain.
The RBC signal is received through a differential amplifier to reduce noise. There is a gain adjustment after the
differential amplifier but before the Test Signal injection point.
The RBC signal is then "Baseline Restored" to remove DC components and Baseline fluctuations due to varying duty
cycle of the blood cells. At this point an additional gain stage is added to create the Platelet signal.
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A threshold detector(s) signals to the EPLD the presence of valid pulses. The Platelet Threshold Detector is used if in
RBC Count mode.
If in Count mode, the Platelet Lower and Upper Threshold detectors are used. If the Upper Threshold Detector is
triggered, the pulse is a RBC and the RBC pulse is accumulated into the RBC Count histogram. If only the Lower
Detector is triggered, the PLT pulse is accumulated into the PLT histogram.
The data from the pulse is processed on the falling edge of the Threshold Detector unless the Slope Detector(s)
senses another rising edge before the falling edge of the Threshold Detector. If this occurs, the data is processed
immediately.
The RBC Held Peak or the PLT Held Peak is converted and sent to the CCM on a 15s cycle.
Cell Count Module (CCM)
Note
Refer to PAM PCB Diagram.
CCM Architecture
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System Clock and Microprocessor Description
The CCM uses a 16 MHz crystal as a time base. The fundamental cycle time for the MC68HC11KW1 processor is 4 MHz.
The processor has many built in functions such as:
16 bit address bus
8 bit data bus 7 - 8 bit multi-purpose I/O ports (CCM and SBC ports)
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Small amounts of Internal RAM and Internal EEPROM (analyzer serial number)
Internal Timers (system timer)
Internal UART (debug port)
EPLD (CCM)
The EPLD is an enhanced programmable logic device and is used for address decode and histogram building functions. Its
program is used in coordination with the processor software.
LEDs
Note
Refer to CCM On-Board Diagnostic LEDs.
Scratch Pad RAM
This RAM is used for general purpose programming.
Histogram Memory
This RAM is used for histogram building.
Histogram Building (cell counting)
The following sequence is executed to build histograms:
1. Histogram Memory is cleared.
2. Counting is enabled.
This disconnects Histogram Memory from the processor buss.
3. Wait for an End of Conversion (EOC) signal from SPM.
4. At the EOC, data is read from the SPM ADC
5. The data then becomes the address for the histogram memory.
6. The data from the histogram memory is read.
This data is the count information for the respective pulse height.
7. The count is incremented and stored back into histogram memory.
8. Counting is disabled. And the histogram can be read by the processor.
HGB Measurement
A 12 bit ADC with an input multiplexer is used to measure the HGB signal from the PAM. This data is read by the processor.
Along with the HGB measurement, various DC voltages are read by the 12 bit ADC as a diagnostic.
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CDM Port
The CDM port is connected directly to microprocessor ports E, G and K.
SBC Port
The SBC port is connected directly to microprocessor ports J and part of port A.
Cable Distribution Module
Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
Solenoid, Motor Drive and Pump Block Diagram
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The CDM performs the following functions:
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Status Sensor Interface
Control of Solenoid Driver Module
Pump Relay Module interface and control
Start Board (Touch Plate) Interface
The CDM communicates with the CCM via the CCM/CDM data bus at J2. Analog outputs of the Metering Modules are
converted to TTL levels by comparators (U12) and placed directly on the CCM/CDM data bus. Signals from the Pump Relay
board, Probe Position Switches, and Start Board (Touch Plate) are interfaced by Data Drivers (U5, U10).
Data is interfaced to the Solenoid Driver Modules via J32. This data is then multiplexed by One-of-Eight Decoders (U1, U2)
via J3, J4, J6, J7, and J9.
Vacuum and pressure control data is latched by U14 and routed to the Pump Relay Module via J11. Pump status signals
(Vac On, Pres On) are converted to TTL levels by U3 and placed on the data bus by U5.
LED drive signals are routed to the Start Board (Touch Plate) via J17. The start signal enters at J17 and is placed on the data
bus by U5.
Solenoid Driver Module (SDM)
Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
The purpose of the SDM is to provide drive current to the solenoids. Each SDM has eight Darlington drivers (Q1-Q8) which
are individually controlled by data bits (D0-D7) and data latch (U3).
There are two power modes available for each solenoid - activate (+28V) and hold (+14V). This is controlled by the Hi CLK
signal in conjunction with data bits (D0-D7) and the current control latch (U1).
Motor Processor Modu le (MPM)
Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
The MPM controls drive data to the Stepper Drive printed circuit boards and also provides self-test capability for motorwinding current. The MPM is comprised of the following major circuits:
Microprocessor
Program Control EPROM
I/O Peripheral Interface Adapter (PIA)
Direct Memory Access (DMA) Control
Motor Phase Latches
Motor Current Latches
Motor Winding Self Test
Control functions of the MPM are performed by microprocessor (U5).
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The operating program for the microprocessor is stored in Program Control EPROM (U3).
Data communications between the CCM and MPM are controlled by I/O PIA (U6) and serial data is interfaced via ACIA (U2)
and Data Bus Connector (J1).
Phase data, motor direction, and step rate are stored in RAM (U7). This data is sent to the Motor Phase Latches under
control of the DMA Control circuitry, which consists of U11, U12, U15, U16, U18, U21 and associated circuitry. The data is
strobed into the appropriate Motor Phase Latch by ALG0 through ALG2.
The Motor Phase Latches U23, U26, and U29 provide phase data to the Stepper Drive printed circuit boards. Each is an 8-Bit
Addressable Latch which can control up to four Stepper Drive printed circuit boards and subsequently four Stepper Motors.
Four levels of motor current for each motor is controlled by the Motor Current Latches (U22, U25, and U28). Each latch can
control up to four stepper drive printed circuit boards. Data is strobed into the appropriate latch by WR0 through WR2.
The Feedback- and Feedback+ inputs at J3 through J14 are connected, via resistors on the Stepper Drive printed circuit
board, to the stepper motor windings. This allows the circuitry consisting of U30, U31, and U32 to monitor the winding current
during an internal self-test. These values can be read by the CCM to isolate a defective Stepper Drive or Stepper Motor.
Stepper Drive Printed Circuit Board
Note
Refer to MPM section, blocks 20, 23, and 24 of Solenoid, Motor Drive and Pump Block Diagram.
The Stepper Drive printed circuit board consists of two PBL 3717 motor drive chips. Each chip drives a winding of theStepper Motor. Bits I0 and I1 are used to control four motor current levels:
P0 - High Current
P1 - Medium Current
P2 - Low Current
P3 - Current Off
Bits PH0 and PH1 control motor phase and, therefore, direction and step-rate (velocity). Feedback+ and Feedback- are used
to generate a motor self-test.
Pressure/Vacuum Regulator Module
Note
Refer to Solenoid, Motor Drive and Pump Block Diagram.
Pressure (or vacuum) is sensed by a transducer that is internally configured as a Wheatstone Bridge. Transistor Q1and
resistors R4 and R5 are used to generate a stable reference voltage for the Wheatstone Bridge. The output of the
Wheatstone Bridge is partially amplified (U1-7), stabilized against long term drift (voltage follower U1-1) and made
offset-adjustable by R18 and associated resistors.
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Maximum transducer sensitivity can only be achieved when the output is zero volts at TP-1 and when there is no pressure
differential across the transducer. To accomplish this, R18 is adjusted for zero volts when both transducer inlet ports (P1 and
P2) are open to atmospheric pressure.
In order to maintain the operating point of comparator U2-14 at the fixed 2-volt trip level, it is necessary to maintain the output
of U2-8 within a relatively narrow range. This is accomplished by making the differential amplifier (whose inputs are U1-10
and U2-10) adjustable by selecting 1 of 4 possible jumper positions. A stable reference point for the DC operating level of
U1-8 and U2-8 is established by U1-14 in conjunction with R6 and resistor network RP1.
Measurement of pressure in the range of approximately 0.5 lbs/sq. inch is accomplished by using transducer inlet port P1 in
conjunction with jumper setting A/B.
Vacuum pressure in the range of 8 inch Hg is accomplished by using inlet port P2 in conjunction with jumper setting C/D. The
regulation point for either vacuum or pressure is established by the setting of potentiometer R16.
When the output of comparator U2-14 goes positive, the collector of Darlington transistor Q2 is pulled to ground, thereby
turning on either the pressure or vacuum pump. When the pumps are running, LED DS1 is lit and stays lit until either the
pressure or vacuum increases past the hysteresis point established by R8 of U2-14.
The output of the pressure/vacuum regulator can be inhibited by a logic low at J1-1. This completes the circuit description.
Power Supply Assembly
Note
Refer to major subsystem descriptions ofAC and DC Power Distribution Subsystem.
Pump Relay Module (PRM)
Refer to Solenoid, Motor Drive and Pump Block Diagram.
The PRM provides drive to the vacuum and pressure pumps, via three Solid State Relays: K1, K2, and K3.
Single Board Computer (SBC)
The Single Board Computer (SBC) is designed around a Celeron 850MHz microprocessor and connects directly into theBackplane PCB. The SBC receives power from the Power Supply Assembly via the Backplane PCB and receives status and
measurement data from the CCM through the DLA. The board contains EPROM, CMOS, RAM, input/output circuitry for the
interface ports, disk drives (hard and floppy) circuitry, LCD Display Screen Interface, and PS/2 Keyboard connectivity.
Data Link Adapter (DLA)
The Data Link Adapter provides interfaces from the SBC to both the CCM (Cell Count Module) and the Touch Pad
(membrane) keyboard. These two interfaces function independently under user interface software control. However, some of
the circuits on the DLA board are shared. The DLA uses an 82C55 PPI (Parallel Peripheral Interface) IC. Refer to the figure
below for an illustration of the DLA board.
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DLA (Data Link Adapter) Block Diagram
Interface to CCM
A 20-pin ribbon cable connects the DLA to the CCM. This interface is a bi-directional, parallel interface that is
software-controlled at both ends. Data is transferred in 8-bit bytes on 8 data lines (D0 - D7) in one direction at a time. TheSBC (Single Board Computer) initiates an inquiry message handshake on a periodic basis or when it has a command to send.
The CCM responds by sending data or replying to the command sent.
The interface is controlled cooperatively by the UIC and CCM according to the state of the handshake signals. Refer to Cell
Count Module (CCM). The UIC always sends data first. The CCM responds by sending data back (if any is available). Thus,
the 82C55 switches its A-port from input to output and back to input during every message transaction.
The key handshake signals are REQ1 and REQ2. REQ2 going low initiates the communication protocol. The CCM responds
by bringing REQ1 low. After the DLA has sent its data, it brings REQ2 high. Then the CCM sends its data.
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Each byte received by the DLA generates an IRQ. The application software responds to the IRQ by putting the byte into a
buffer. When the CCM brings REQ1 high, the communication is complete; the DLA returns to an idle state, and port A is set
to input. Both REQ1 and REQ2 remains high until the next message/data transfer.
The two LEDs on the printed circuit board, DS1 and DS2, indicate the active state of REQ2 and REQ1, respectively. They
should always be flickering when the application software is running because the User Interface Software program is
constantly polling the CCM to check its state. (There are some exceptions to this during power up and certain diagnostics/test
modes.)
The I-O address of the DLA board is assigned by four jumpers. The default I-O address (pins 3 - 6 on S1 hard-wired) is: [off
off on off], 340 hexadecimal. The DLA interrupt level is assigned by a jumper.
Jumpers W1 - W6 assign the DLA interrupt to one of the following:
W # IRQ #
W1 IRQ 5 *
W2 IRQ 10
W3 IRQ 10
W4 IRQ 11
W5 IRQ 12
W6 IRQ 15
* Since IRQ 5 is used by the DLA, W1 is hard-wired (this is the default).
Interface to Touch Pad (membrane) Keyboard
A 14-pin ribbon cable connects the DLA to the key panel. The key panel is also polled by the User Interface Softwareprogram. This interface is not interrupt-controlled.
The keyboard is interfaced as a parallel switch matrix circuit with 4 lines out and 8 lines in. Four scan rows are driven active
one at a time via an LS175 latch. Then the columns of the key panel matrix are read from port B of the 82C55. The software
interprets a low active signal as a key is pressed.
The DLA board must be plugged into a 16-bit slot. There are no adjustments on the DLA board.
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Troubleshooting
Diagnostics Menu Usage
Utilization of the DIAGNOSTICSMenu enables the operator and/or service representative to identify and correct both
operator-correctable and service-correctable faults. When the computer senses a fault, the message displays in the System Status Box. The following keys are available in the DIAGNOSTICSMenu.
Level One
INITIALIZATION: Used to perform an Initialization cycle: returns movable components to home position and
performs internal self-tests.
RAW DATA: Used to display raw measurement data for the last specimen.
COUNT TEST: Used to run specimens without returning to RUN Menu and display Raw Data. MORE: Used to display additional functions (levels).
PRINTER OUTPUT: Used to toggle printer output ON and OFF.
HELP/ERROR: Used to display help information regarding the diagnostics menu screens. The fault log can also be
accessed through this key function.
MAIN: Used to return to Main Menu.
Level Two
WBC HISTOGRAM: Used to display WBC count and histogram data accumulated in each of 256 size channels.
RBC HISTOGRAM: Used to display RBC histogram data accumulated in each of 256 size channels.
PLT HISTOGRAM: Used to display PLT count and histogram data accumulated in each of 256 size channels.
SMOOTHING ON/OFF: Used to toggle histogram display status. With Smoothing Off, only raw counts are displayed.
With Smoothing On, channels are numbered, data is normalized and the number of the peak channel displays.
Smoothing On/Off (example)gives an example of Smoothing On/Off.
MORE: See Level Onedescription.
PRINTER OUTPUT: See Level Onedescription.
HELP/ERROR: See Level Onedescription.
MAIN: Used to return to Main Menu.
Level Three
PROBE HOME: Moves Sample Probe up and above RBC Cup. Displays probe assembly sensor status.
PROBE UP: Moves Sample Probe up. Displays probe assembly sensor status.
MORE: See Level Onedescription.
PRINTER OUTPUT: See Level Onedescription.
HELP/ERROR: See Level Onedescription.
MAIN: Used to return to Main Menu.
Level Four
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SYSTEM STATUS: Used to display all pending alarms.
FAULT REPORT: Used to display all pending faults or warnings.
SERVICE HEX CODES: Hex system codes. Not used for operator or service troubleshooting.
SERVICE DEC CODE: Used to initiate individual actions in the CELL-DYN 1800 hardware and software.
MORE: See Level Onedescription.
PRINTER OUTPUT: See Level Onedescription.
HELP/ERROR: See Level Onedescription.
MAIN: Used to return to Main Menu.
Smoothing On/Off (example)
Fault Report Description
A detailed list of all faults generated by the CELL-DYN 1800 System software and hardware is contained in CELL-DYN 1800
Error Messages. The fault classifications reported in the Fault Report primarily contains data pertaining to the last CCM fault.
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If a fault occurs, pressing the [HELP/ERROR] key immediately displays the [FAULT LOG]in the DIAGNOSTICSMenu. This
log may contain up to 16 faults, with the most current fault at the top of the list. An alternative procedure is to go to the MAIN
MENUand press [DIAGNOSTICS] . In this case, the [FAULT REPORT], not the Fault Log, is immediately displayed.
The Fault Log can be viewed from any of the menus, except SETUP. To view the Fault Log, enter the desired menu, followed
by [HELP/ERROR] and [FAULT LOG]. The system displays up to 16 past faults. From the MAIN MENU, press
[DIAGNOSTICS] followed by [MORE] three (3) times and [FAULT REPORT]to display the FAULT REPORT screen. A
display of indicates that all faults have been cleared.
CELL-DYN 1800 Troubleshoot ing Guide
A list of symptoms, probable causes, and corrective actions for the most common problems encountered on the
CELL-DYN 1800 System is given in the Troubleshooting Chart. The probable causes and corrective actions for each
symptom are arranged in descending order from most likely to least likely. When troubleshooting a problem, start with the
most likely cause first.
If possible, thoroughly verify that a component is defective before replacement. Some problems can be verified visually, but
other problems may require a measurement tool such as a DVM (Digital Volt Meter).
When troubleshooting DATA PROBLEMS, only the measured parameters RBC, PLT, WBC, HGB, and MCV should be used
for reference. Using the calculated parameters can become confusing when trying to isolate a problem.
When troubleshooting CLOG AND FLOW ERROR PROBLEMS, refer to VP-04 Metering System Timing Adjustments - RBC
and WBCfor the MIN and MAX specifications for the RBC and WBC Upper (T1) and Lower (T2) times.
Troubleshooting Charts
Nonfunctional Instrument Problems
Symptom Probable Cause Corrective Act ion
Power Cord Check Power Cord
No Functions. No Fans Power Source Check Power Source
No 5VDC Check that 5VDC LED on Card Cage Backplane is On
Note
If off replace Power Supply Assembly.
Defective CCM Replace CCMNo Functions. Fans Run
Defective SBC Replace SBC
Video Display Problems
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Symptom Probable Cause Corrective Act ion
Loose Connection Check all LCD Display Screen Connections
Flash BIOS or
CMOS settings
reset to Default
Connect a computer monitor to the top of the SBC PCB. Power ON
instrument and open CMOS setup screen. Check that Advanced
Chipset Setup is configured correctly. Refer to VP-05 CMOS Setup
Verification/Adjustment.
Defective Backlight
Interconnect PCB
Replace Backlight Interconnect PCB
Defective LCD
Interconnect PCB
Replace LCD Interconnect PCB
LCD Display Screen
Blank/Solenoids OK
Note
Do not measure voltage
on backlight inverter
PCB. Measuring voltage
can damage PCB.
Defective LCD
Display Screen
Replace LCD Display Screen
Characters Out Of Focus Defective LCD
Display Screen
Replace LCD Display Screen
Defective SBC
PCB
Replace SBC PCB
Characters OK But GarbledDefective LCD
Display Screen
Replace LCD Display Screen
Defective SBC
PCB
Replace SBC PCB
Missing CharactersDefective LCD
Display Screen
Replace LCD Display Screen
Displayed Error and Fault Problems
Symptom Probable Cause Corrective Action
Restriction Check Lines
Check In-Line Sensor
Defective In-Line SensorReplace Sensor PCB
Detergent Empty
Defective CDM Replace CDM
Solenoid 3-1, 3-3, 3-4 Tubing Check Solenoid 3-1, 3-3, 3-4
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Restriction Check Lines
Check In-Line Sensor
Defective In-Line SensorReplace Sensor PCB
Diluent Empty
Defective CDM Replace CDM
Check Solenoid 3-3
Solenoid 3-3Replace Solenoid 3-3
Check Solenoid 3-4
Solenoid 3-4Replace Solenoid 3-4
Check Solenoid 3-1
Solenoid 3-1
Replace Solenoid 3-1
Check Pressure Switch
Defective Pressure SwitchReplace Switch
Pressure Overlimit
Defective CDM Replace CDM
Leak 8" Hg Check for air leaks in Fluid Power Supply and
Flow Panel
Defective Pump Replace PumpVacuum Low Error
Defective Vac Regulator Replace Vacuum Regulator
Leak 0.5 Psi Check for air leaks in Fluid Power Supply and
Flow Panel
Defective Pump Replace PumpPressure Low Error
Defective Pres Reg Replace Pressure Regulator
Check Unreg Pressure
Replace Unreg PumpNo Air Pressure
Replace CDM
Check Solenoid 5-3
Solenoid 5-3Replace Solenoid 5-3
Check Solenoid 5-7
Solenoid 5-7Replace Solenoid 5-7
Check Solenoid 1-6
Waste Overflow Into
Accumulators
Solenoid 1-6Replace Solenoid 1-6
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Check Accumulator Sensor Connections
Flush Accumulator with DI WaterAccumulator Sensor Falsely Detecting
LiquidReplace CDM
Check Internal Waste Sensor Connections
Defective Internal Waste SensorReplace Sensor
Check Unreg Pressure
Unreg Air Pressure LowReplace Pump
Restriction Check tubing at Fluid Power Supply, Waste
Bottles, A and B
Waste Empty Timeout
Defective CDM Replace CDM
DLA/CCM Cable connection Check DLA/CCM Cable connection
Defective DLA/CCM Cable Replace DLA/CCM Cable
Defective CCM Board Replace CCM Board
Defective DLA Board Replace DLA Board
CCM/DLA Communication Error
Defective SBC PCB Replace SBC PCB
Power Source Check 5VDC and +12VDC (Digital) at Card Cage
Backplane PCB
Check CMOS Setup
Defective SBC PCBReplace SBC PCB
Disk Errors (Hard Disk or Floppy
Drives)
Defective Disk Drive (Hard Disk or
Floppy Drives)
Replace Disk Drive
Defective Switch Replace Switch and Perform Alignment
Defective CDM Replace CDM
Run Motor Power testDefective Stepper Drive Printed
Circuit BoardReplace Chopper Drive PCB
Exercise Probe (Diagnostic Menu, Probe Home)
Defective Sample Probe AssemblyReplace Sample Probe Assembly
Run Motor Power Test
Position Faults
Defective MotorReplace Motor
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Data Problems
Symptom Probable Cause Corrective Action
Check 12VDC (Analog) LEDs on Card Cage Backplane
PCB
Replace Power Supply ModuleAll Results Are "0" No 12VDC (Analog)
Replace CCM
Check that PAM 100VDC LED is On
No 100VDCReplace Power Supply Assembly
Defective SPM Replace SPMHGB OK All Others "0"
Defective PAM Replace PAM
Reference lower than
sample reading
Check for bubbles in Detergent line and Solenoid 2-6
No sample aspiration Check associated tubing, solenoids and sample syringe
Perform VP-08 Pre-Amplifier Module (PAM) Adjustment
Defective PAMReplace PAM
Defective CCM Replace CCM
HGB "0" all others OK
Defective HGB Flow Cell Replace HGB Flow Cell
Check 0.5 psi (Bubble Mix) pressure
Check associated tubing and hardware0.5 psi (Bubble Mix)
pressurePerform Pressure Adjustment (0.5 psi)
Inadequate Probe Cleaning Check associated wash block tubing and hardware
Perform Sample Volume VerificationImprecise Sample Aspiration
Check associated sample aspiration tubing and hardware
Imprecise Diluent Dispense Perform Diluent Volume Verification
Imprecision on all Parameters
Carryover Check for correct draining of Pre Mix Cup
Defective SPM Replace SPM
Imprecision on all Parameters,
HGB OKDefective PAM Replace PAM
Dirty RBC/PLT Transducer Clean RBC/PLT Transducer
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Check 0.5 psi (Bubble Mix) Pressure
Check associated tubing and hardwareIncorrect 0.5 psi (Bubble
Mix) PressurePerform Pressure Adjustment (0.5 psi)
Defective SPM Replace SPM
Imprecision on RBC and PLT,
WBC/HGB OK
Carryover Check for correct draining of RBC/PLT Transducer
Dirty WBC Transducer Clean WBC Transducer
Check 0.5 psi (Bubble Mix) Pressure
Check associated tubing and hardwareIncorrect 0.5 psi (Bubble
Mix) PressurePerform Pressure Adjustment (0.5 psi)
Defective SPM
Replace SPM
Imprecision on WBC/HGB,
RBC and PLT OK
Carryover Check for correct draining of WBC Transducer
Dirty Flow Cell Clean Flow Cell
Check reference reading (Diagnostics Menu, Raw Data)
Reference reading out of
specificationPerform HGB Ref Adjustment on PAM VP-08 Pre-Amplifier
Module (PAM) Adjustment
Defective Flow Cell Replace Flow Cell
Imprecision on HGB, Others OK
Solenoid operation Check Solenoid 3-6, 2-6 and 2-7
Dirty Aperture. Clean RBC/PLT Transducer and Aperture Plate
RBC RER Perform VP-09 Signal Processor Module (SPM)
Verification/AdjustmentImprecision on MCV
Defective SPM Replace SPM
Dirty Transducer Clean WBC Transducer and Aperture Plate
Replace Lyse Syringe
Incorrect Lyse Volume Replace Lyse Syringe Drive Assembly
WBC Gain Perform VP-09 Signal Processor Module (SPM)
Verification/Adjustment
Replace SPM
WBC "R" Codes, Reagents OK
Defective PCBsReplace CCM
Check power
Check overhead lightingHigh Electrical Backgrounds Environmental
Check for other items on same power line
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Install filter (line conditioner)
Isolate line (dedicated line)
Check grounding cable on Front Cover
Replace grounding cablePoor instrument cover
groundingCheck EMI Shielding on Card Cage Backplane PCB
Check correct routing of WBC and RBC/PLT Transducer
cables to PAMDefective PAM
Replace PAM
Check Power Supply Module
"Noisy" Power Supply
Module
Replace Power Supply Module
Check Connections on Pre-Amplifier Filter PCB
Defective Pre-Amplifier Filter
PCBReplace Pre-Amplifier Filter PCB
Defective Transducer(s) Replace Transducer(s)
Clog and Flow Error Problems
Symptom Probable Cause Corrective Act ion
Perform VP-03 Vacuum and Pressure Adjustments
Incorrect vacuumCheck Solenoid 1-4 and 1-5 (closed during metering)
Diluent and Detergent lines
reversed
Check Reagent lines"CLOG" both sides constant
Metering Tube position Top of Metering Tube (tapered edge) should be visible on
top of upper DET sensor
Check Vent Tubing
"CLOG" T1 = Max T2 = 0, No VentRestrictionCheck Vent Solenoid 3-6, 2-1 and 1-3
Dirty Transducer Clean Transducer and Aperture Plate
Check plumbing
Check Count Solenoid 1-2 and 4-3
"CLOG" T1 = Max T2 = 0, No
MeniscusRestriction
Check Vent Solenoid 1-3 and 2-1
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Check for bubbles on right side of Transducers
Dirty Transducer Clean Transducer and Aperture Plate
Check associated tubing
Restriction Check Vent Solenoid 3-6
Perform VP-03 Vacuum and Pressure Adjustments
"CLOG" T1 = Max T2 = 0, Slow
Meniscus
Incorrect VacuumCheck Solenoid 1-4 and 1-5 (closed during metering)
Defective Upper Detector Replace Metering Printed Circuit Board
"CLOG" T1 = Max Meniscus
speed OKDefective CDM Replace CDM
Defective Lower Detector Replace Metering Printed Circuit Board
"CLOG" T1 =OK T2 = MaxMeniscus speed OK
Defective CDM Replace CDM
Defective Upper Detector Replace Metering Printed Circuit Board
"FLOW ERR" T1 = Min T2 = MaxDefective CDM Replace CDM
Defective Lower Detector Replace Metering Printed Circuit Board
"FLOW ERR" T1 = OK T2 = MinDefective CDM Replace CDM
Miscellaneous Problems
Symptom Probable Cause Corrective Act ion
Defective SPM Replace SPM
Garbled HistogramsDefective CCM Replace CCM
Raw Data Descr ipt ion
From the MAIN MENU, press [DIAGNOSTICS] followed by [RAW DATA]. The [RAW DATA]key displays raw data obtained
from the last count cycle.
When a single count is done, all data is contained in the first column. When a PLT recount occurs, data from the first cycle
displays in column #2 and data from the recount displays in column #1.
Raw Data Display Description
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RBC, WBC and PLT counts are RAW, uncorrected total counts.
HGB Error is not used.
HGB Reference is the output of the A/D Converter when reading reference (2000 = 5 volts).
HGB Sample is the output of the A/D Converter when reading sample (2000 = 5 volts).
WBC and RBC Up Times are the upper times in milliseconds for the last sample.
WBC and RBC Count Times are the times in milliseconds for the last sample.
Flow Error is coded Clog or Flow Error data.
RBC RER is RBC Cell Editing percentage.
WBC and RBC Upper max and Upper min are the maximum and minimum Upper Times, respectively.
WBC and RBC Avg. Time are the averages of the previous count times. The WBC and RBC Avg. time is reset when
the [Clear Orifice]key is pressed.
WBC and RBC Time-Outs are the floating Upper Clog Alarm Limits calculated by the "Running Average Program".
Note
An example of a raw data report displays in Raw Data (example).
Raw Data (example)
CCM On-Board Diagnostic LEDs
The seven LEDs on the CELL-DYN 1800 CCM can reveal much about the fundamental CCM and overall machine state. In
general, the LEDs indicate whether the CCM is in a normal functioning mode or in a fault state, and in either case, help to
characterize the CCM state. Also, LED2 gives some information about the state of the SBC.
The CCM tests itself on power-up. These fundamental tests include MC68HC11KW1, RAM, and SPM interfaces. If any test
fails, the CCM attempts to execute an endless loop routine which flashes the green LED on the board. Also, it places a 4-bit
fault code into the adjacent yellow LEDs (see Power-on LED Patterns - Fault States on Startup).
LED Function & Counting Control
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The LEDs on the CCM (labeled LED1 through LED7) are entirely under program control. Their use is as follows:
Note
Refer to CELL-DYN 1800 CCMfor location of LEDs on PCB.
LED7, a green LED, should not be not flashing after the CCM has successfully completed its internal power-on
self-check diagnostics, otherwise if it is flashing slowly (~1Hz.), there is a fundamental CCM fault.
LED5and LED6, for CER and CEW, indicate the state of the CCM firmware generated signals CER (Count Enable
Red) and CEW (Count Enable White). These signals enable cell counting. When the associated LED is on, the DMA
cell counting circuitry is active.
LED3and LED4, for WCP and RCP, are on during the metered count time intervals, LED3for the white count time
interval and LED4for the red count time interval.
LED2is driven by the signal NREQ1, and indicates the UIC/CCM communication activity. This LED state directly
relates to the hi/lo state of NREQ1. When LED2is flickering, which should always be the case during normal system
operation, it indicates that the UIC/CCM communications link is active. (There is a corresponding LED on the DLA(UIC comm. board) that will also be flickering in sync with LED2; it is controlled by the DLA output signal NREQ2.)
LED1is used to indicate that a self-test is in progress. This indicates that the tests for the pulse processing A to D
circuitry on the SPM with the pulse counting circuitry on the CCM are active.
Power-on LED Patterns - Normal Setup
Step
LED2
NREQ1
LED3
WCP
LED4
RCP
LED5
CEW
LED6
CER
LED7
READY
State
0 ON ON ON ON Power on
1 RAM testing
2 Flashing RBC/PLT testing
3 Flashing WBC testing
4 ON ON CCM tests done; Homing flowscript running
5 Flashing ON ON UIC program comm. started
6 Flashing Initialized (running/idle)
Power-on LED Patterns - Fault States on Startup
LED2 LED3 LED4 LED5 LED6 LED7 CCM
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NREQ1 WCP RCP CEW CER
READY Fault
ON ON FlashingMC68HC11KW1 CONFIG reg
ON FlashingMC68HC11KW1 RAM test
ON Flashing8K RAM bit test
Flashing8K RAM clear test
ON ON ON FlashingHistogram RAM test
ON ON FlashingMC68HC11KW1 timer test
ON FlashingCDM init. test
CELL-DYN 1800 CCM
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1 Cell Count Monitor (CCM) PCB 8 J6 - NOT USED
2 S1 RESET 9 LEDs 2-7
3 S3 BUFFALLO 10 E2 DGND
4 J2 MPM 11 J8 - NOT USED
5 J1 CDM 12 E3 DGND
6 J3 SPM 13 E1 DGND
7 J5 DLA 14 LED 1
CPU Hardware/Software Configuration
RS-232 Communications Test Procedure
Detailed information on the CELL-DYN 1800 System Interface Specifications is available on the WWCS Intranet website.
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CMOS Setup
The CMOS Setup contains all the information needed by the Basic Input/Output System (BIOS) to establish proper
communications between the single board computer (SBC) and the various computer system devices. Refer to VP-05 CMOS
Setup Verification/Adjustment:
Special Function
Probe Check
There are two probe check functions activated by softkeys in the DIAGNOSTICSmenu.
The [PROBE UP]softkey moves the probe up and maintains position without rotational motion. (The [PROBE
DOWN]softkey then displays to restore the probe to the down position.)
The [PROBE HOME]softkey places the probe over the RBC/PLT transducer. (The [PROBE DOWN]softkey then
displays to restore the probe to the down position.)
Note
Neither procedure puts the probe in the STANDBY position (on the left).
Service Special Commands
Discussion
Several commands are available to initiate individual actions in the CELL-DYN 1800 System hardware and software. These
commands are used for troubleshooting and/or alignment when a single action is desired or required to be repeated several
times.
The special command mode resides in the DIAGNOSTICSMenu. From the MAINMenu, press [DIAGNOSTICS] followed by
[MORE] three (3) times, then [SERVICE DEC CODE]. When this softkey is pressed, the message Test Select --- FOR
SERVICE USE ONLY --- displays.
A command can now be entered. Pressing the Enterkey on the keyboard initiates the action. Only one command can be
entered at a time and [SERVICE DEC CODE]must be pressed before a command is entered.
All commands available by direct softkey can be accessed by pressing [MORE].
Note
Use only the commands listed in DEC Service Commandsand always verify that the correct number has been
entered before initiating the action. Use only those numbers listed in DEC Service Commands. Other numbers may
refer to engineering commands which are not used in the field and which may cause damage if used improperly. Be
fully aware of the purpose of any of the DEC Service Commandsbefore using them. This is a direct-activation
method which should be used with caution because the physical state of the CELL-DYN 1800 System may not be in
agreement with the function to be performed. After using service commands, always re-initialize the system by
turning the power OFF then ON again or by pressing the [INITIALIZATION]key in the DIAGNOSTICSMenu to
ensure the instrument is in the proper configuration for normal operation.
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DIAGNOSTICS Menu Service Code Funct ion List
When the [SERVICE DEC CODE]key is pressed, the (Enter number (currently, 102):____prompt displays.
The number above corresponds to the decimal code for the last code entered.
DEC Service Commandslists the decimal-coded (DEC) service commands that can be invoked by pressing the [SERVICE
DEC CODE]key in the DIAGNOSTICSMenu and entering the appropriate number.
DEC Service Commands
UIC DEC Codes Function
07 NOT USED
08 NOT USED
09 NOT USED
11 NOT USED
15 fill lyse into system
16 NOT USED
17 NOT USED18 NOT USED
19 fill Diluent & detergent
20 mini-wash
22 NOT USED
23 NOT USED
24 NOT USED
25 NOT USED
26 NOT USED
33 NOT USED
34 NOT USED
36 NOT USED
37 pre-dilute sample run setup
38 pre-dilute sample run exit
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39 aperture current off (uses whole blood script)
40 open all valves
41 NOT USED
47 platelet recount
48 initialization (homing)
49 open sample run
50 clean orifice (back-flushing)
51 pre-dilute sample run
52 background count run
53
prime system with all reagents
54 daily shutdown
55 empty transducers and cups
56 gain adjust
57 unpinching normally closed valves
59 fill transducers and cups after empty
60 gain adjustment setup
61 dispense 10 ml saline
62 open sample wash
63 clean-for-shipping
64 clean sample syringe setup
65 aspirate 40 l sample for 1/250 dilution
66 dispense 10 ml saline for 1/250 dilution
67 aspirate 100 l sample for 1/50 dilution
68 dispense 5 ml for 1/50 dilution
69 NOT USED
71 lyse syringe down
72 NOT USED
73 NOT USED
74 lyse syringe up and home
75 lyse syringe down restore
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76 pre-dilute sample wash
77 NOT USED
78 NOT USED
81 NOT USED
83 diluent syringe down
84 enzyme clean setup
85 probe up and rotate and home
86 back to ready position from probe home
87 probe up for probe adjustment
88
probe down (when finished, operator should initialize the instrument to place the probe in the homeposition)
89 sample syringe up and restore
90 sample syringe down and home
91 enzyme clean the system
92 diluent syringe up and home
93 diluent syringe down and restore
117 NOT USED
118 NOT USED
119 NOT USED
120 NOT USED
121 cycle solenoids on waste assy
122 cycle solenoids on flow panel assy
123 sample syringe aspirate
124 sample syringe dispense
125 vacuum test
126 check mixing pressure
127 check backflush pump
128 motor power test (see Service DEC Code 128)
129 motor power level test (see Service DEC Code 129)
130 exercise motors (see Service DEC Code 130)
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999 auto-cycle (seeAuto-Cycling (Code 999))
NoteCertain commands are not sent to the CCM when the system is in an interlock state, such as STANDBY or
UNINITIALIZED.
Auto-Cycling (Code 999)
The CELL-DYN 1800 can be pre-set to do a specified number of RUN cycles without user intervention. This capability
applies only to normal RUN Count Test, Pre-Dilute RUN, (PRE-DIL TEST), Gain Adjust (GAIN ADJ), and Electrical
Background (ELEC BKGD). This capability helps reduce test time for the instrument. The following entry screen displaysafter entering code 999:
-- Auto Cycle Test Set Up --
Use Spacebar to accept current number
Use "
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This code runs a computer generated test (Motor Power Test) of all stepper motors, motor driver boards, and associated
circuitry.
The Motor Power Test should be run whenever a problem is suspected with any assembly that is driven by a stepper motor.
The following entry screen displays after entering code 128:
Motor Power Test Started.
To MPM: {I }
To MPM: {pD32}
To MPM: {mC1!2} AC}
To MPM: {C1}
inp: 0415
A report (Motor Power Test (example)) automatically displays and can be printed. Refer to VP-11 Stepper Motor Power Test
and Verification.
Note
Press the [INITIALIZE]key before leaving the DIAGNOSTICSMenu.
Motor Power Test (example)
Service DEC Code 129
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This code allows the Run and Idle power levels to be set when exercising a stepper motor. The four levels are:
0) Full Power
1) Medium Power
2) Low Power
3) Off
This code tests mechanical assemblies at various power levels or to remove idle power so the mechanism can be more
easily moved or checked manually. The Motor Power Level Test (example)screen displays after entering code 129(press
the ENTERkey after each entry):
Motor Power Level Test (example)
Note
After the entries are made, a message, such as Motor "A" set to running power of 1 and idle power of 3,
displays.
Service DEC Code 130
This code allows the direction, speed, and number of steps to be set when exercising a stepper motor.
The Motor Check (example)screen displays after entering code 130:
Motor Check (example)
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Note
After the entries are made, a message, such as Motor "B" : motion in direction " 0" at speed "&" for 100 steps,
displays.
Motor Direction Commands
The table below contains information on the motor designation, command and direction of the motor to be tested. Motor
Speed Commandslists the motor speed commands to determine the speed of the motor being tested. Both tables are
needed to properly test the motor.
Motor Direction Commands
Motor Designations Function Command
Direction
0 Down/Aspirate
A/1 Sample Syringe1 Up/Dispense
0 Up
B/2 Probe Up/Down1 Down
0 CCW/To RBC cup
C/3 Probe Rotation1 CW/To Pre-Mixing Cup
0 Down/Aspirate
D/4 Diluent Syringe1 Up/Dispense
0 CCW/Dispense
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E/5 Directional Valve 1 CW/Aspirate
F/6 Spare
G/7 Spare
0 Down/Aspirate
H/8 Lyse Syringe1 Up/Dispense
Motor Speed Commands
Command Speed in Steps per Second
1 50
2 75
3 283
4 300
5 166
6 200
7 250
8 10
9 151
10 222
11 25
12 182
13 100
14 125
15 91
16 67
17 111
Sample Probe Normal Operation
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Probe Up/Down INITILIZE and RUN Modesillustrates the Sample Probe's up/down sequence during the INITIALIZE and
RUN cycles. Probe Rotate "INITALIZE" Modeshows the probe's rotation movement during the INITIALIZE cycle.
Probe Up/Down INITILIZE and RUN Modes
Probe Rotate " INITALIZE" Mode
Initialization Mode
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The Initialization cycle places mechanical and electrical components in the "home" position, drains any liquid in the tubing,
Pre-Mix Cup, and the Mixing Chamber of the von Behrens RBC Transducer to the Waste System, then places the instrument
in the INITIALIZED state.
Stepper Motor Homing
Homing a stepper motor is the process of setting up the initial position from which all future movement is referenced. In the
CELL-DYN 1800 System, this is accomplished by forcing the motor to move against a physical stop (Hard Stop). When the
mechanical assembly, driven by the motor, reaches the Hard Stop, the stepper motor electrically slips until it is forced to stop.
This mechanical position then becomes the zero reference position for the motor.
Operation:
1. The Sample Probe moves up at a fast speed until the Upper Switch (#2) is activated. It is then changed to a slow
speed, and homed against the Upper Hard Stop, which is the metal plate at the top of the Sample Probe Assembly.
2. The probe moves down six steps and the Upper Switch (#2) is checked.
3. The probe moves CCW at a fast speed until the Right Switch (#4) is activated. It is then changed to a slow speed,
and homed against the Right Hard Stop, which is the mounting bracket for Right Switch (#4).
4. The probe moves CW to the Pre-Mix Cup and Left Switch (#3) is checked. The probe then moves into the Pre-Mixing
Cup.
5. The probe moves up and Upper Switch (#2) is checked.
6. The probe moves CCW to center and down positions; and the Lower Switch (#1) is checked.
7. This completes the Initialization cycle.
Run Mode
The figure below illustrates the probe's movements during the RUN cycle.
Probe Rotate "RUN" Mode
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Operation:
1. When the Start Switch is pressed, 30 L of sample is aspirated and Lower Switch (#1) is checked.
2. The Sample Probe then moves up to a position six steps from Upper Hard Stop, and Upper Switch (#2) is checked.
3. The probe moves CW to Pre-Mix Cup and Left Switch (#3) is checked.
4. The probe moves down eight steps and into the Pre-Mix Cup, where dispense, probe shake, and aspiration of RBC
sample takes place.
5. The probe then moves up to a position six steps from Upper Hard Stop, and Upper Switch (#2) is checked.
6. The probe moves CCW to the Mixing Chamber of the von Behrens RBC/PLT Transducer, stops three steps from
Right Hard Stop, and Right Switch (#4) is checked.
7. The probe moves down into the RBC/PLT Mixing Chamber and RBC sample is dispensed.
8. The probe moves up to a position six steps from Upper Hard Stop, and Upper Switch (#2) is checked.
9. After completion of the count cycle, the probe moves CW to center position.
10. The probe moves down and Lower Switch (#1) is checked.
11.This completes the RUN cycle.
Switch Failure Descript ions
Example of fault reports are shown in the following figures:
Lower Switch (#1) Fault Report
Upper Switch (#2) Fault Report
Left Switch (#3) Fault Report
Right Switch (#4) Fault Report
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When a switch is checked by the computer and found to be deactivated (open) in normal operation, the message "Not Ready:
SEE DIAGNOSTICS" displays on the RUN Menu.
From the MAINMENU, press [DIAGNOSTICS] . The screen immediately displays one of the Fault Reports shown in Lower
Switch (#1) Fault Report, Upper Switch (#2) Fault Report, Left Switch (#3) Fault Report, and Right Switch (#4) Fault Report.
The message indicates that Lower Switch (#1) failed when checked. The message indicates that none of the switches were activated when the failure occurred. Refer to Lower Switch (#1) Fault
Report.
Lower Switch (#1) Fault Report
The message indicates that Upper Switch (#2) failed when checked. The message indicates that none of the switches were activated when the failure occurred. Refer to Upper Switch (#2) Fault
Report.
Upper Switch (#2) Fault Report
The message indicates that Left Switch (#3) failed when checked. The message indicates that Left Switch (#3) was activated when the failure occurred. Refer to Left Switch (#3) Fault Report.
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Left Swi tch (#3) Fault Report
The message indicates that Right Switch (#4) failed when checked. The message indicates Right Switch (#4) was activated when the failure occurred. Refer to Right Switch (#4) Fault Report.
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Right Switch (#4) Fault Report
The above conditions do not necessarily indicate that a switch has actually failed. They only indicate that the switch was not
read as activated when checked by the computer. A failure could also be caused by improper switch alignment, an electronic
hardware failure, or a mechanical hardware failure.
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CELL-DYN 1800 Error Messages
The table below lists error messages on the CELL-DYN 1800 System.
Error Message
(Status box)
Description
Time-out at N seconds A CCM process initiated by the user took longer to complete than allowed (usually indicating
a failure of the CCM). The process ran approximately N seconds before the time-out
occurred.
Process Aborted A count test was stopped either by the user or because of a fault detected by the CCM.
Fix then press [CLEAR
ALARM]
A user-correctable fault condition was detected.
Process Monitoring Aborted A process was stopped by the user (using the asterisk (*) key.
Error Message
(Display Area II)
Description of the error.
Printer Time-out The Printer Output option was ON and the printer did not print the requested report in the
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expected time.
Code N is Invalid The user has entered a command for the CCM whose numeric value exceeds 127. The
value entered was N.
Cannot do this Function The user has attempted to issue a command to the CCM that cannot be executed becauseof a pending fault condition.
WBC Meniscus Detection,
RBC Meniscus Detection
During the most recent count, a meniscus was not detected or was detected at an
unexpected time.
WBC Count Time-out (clog),
RBC Count Time-out (clog)
During the most recent count, a Clog occurred.
CCM Pulse Height Memory
Saturation Warning
During the most recent count, there was an overflow in one of the pulse-height arrays
(histograms).
External Waste Full The external waste bottle has been filled.
Lyse Empty, Detergent
Empty, Diluent Empty
The indicated reagent has run out.
Invalid Alarm Set A bit was set in the fault message from the CCM that has no valid interpretation.
*NOT ON ANY SWITCH* After some mechanical motion, a reading of all the position sensors indicates that none are
activated. (This message does not necessarily mean that a mechanical fault has occurred.)
Waste Overflow Into
Accumulators
A reading of the sensor in the Waste Accumulator suggests that there is liquid in the
accumulator.
Error Message (Status box) Description
Vacuum There was a vacuum failure during power-up or the instrument is unable to maintain vacuum
level while in the READY state.
Pressure There was a pressure failure during power-up.
Position Fault A mechanical assembly is not in the correct position for the most recent function to be
performed, as indicated by position sensors.
Sensor Fault - Internal Waste
Empty
A Time-Out fault occurred in draining one of the waste bottles. This error is also associated
with positive pressure.
Canceling Auto-Cycling This message displays when the user cancels Auto-Count Testing.
Invalid UIC Command Sent to
CCM
The UIC sent a command to the CCM that it cannot interpret.
Error in Flow System Timing An error in the timing of a flow script has occurred. This occurs during instrument
initialization when the flow script takes more than three minutes to complete.
Histogram Memory Clear The CCM was unable to clear the pulse-height memory.
CCM Program, RAM Memory The CCM detected a failure in its RAM.
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CCM/MPM Message Fault
Other error-related messages
MPM to CCM, Message
Transmit Error
Command to be Sent to MPM
is Incorrect
Abnormal Time-out/No MPM
Response
Fault Response from MPM
Incorrect Command to be
Sent to MPM
Attempt to Send MPM a New
Command while Busy
An error in CCM/MPM interprocessor communications occurred. A fault was generated in an
attempt to send or receive motor or other command to or from MPM, or the MPM was unable
to perform the function.
No Such Script in ROM or
RAM
Error in loading a flow script.
CCM/UIC Message Fault An error in UIC/CCM interprocessor communications occurred.
No Response from CCM The CCM is not functioning or the signal cable connecting the CCM and UIC is faulty or
disconnected. Turn the instrument OFF, check the CCM/UIC cable, then turn the instrument
ON.
CCM is Initializing The CCM is in the middle of its Initialization process.
Undefined Event An undefined event or process occurred.
Count Test
The [COUNT TEST] key in the DIAGNOSTICSMenu is used to run specimens and display Count Check data without
returning to the RUN Menu. Coded data relating to specific cycle functions, raw measurement, and flow count time are
displayed for use in troubleshooting or service.
Event Messages During Diagnostic Menu Count Testlists the event messages that are displayed during the Diagnostic Menu
Count Test.
Event Messages During Diagnostic Menu Count Test
Event Messages Descript ion
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SampSw. pressed Touch Plate was pressed.
Remove specimen Specimen should be removed.
Count valve open The counting valve is open.
RBC histogram availRBC histogram is available.
WBC upper det WBC upper meniscus detection.
WBC lower det WBC lower meniscus detection.
RBC upper det RBC upper meniscus detection.
RBC lower det RBC lower meniscus detection.
Plt recount strt Platelet recount starts.
CCM initing
CCM initializing.
Data invalid Data entered is invalid.
WBC histo avail WBC histogram is available.
Proc complete Process is completed.
Data avail Data is available.
CCM init done CCM initialization is completed.
Canceled Canceled operation.
Operator-Correctable Alarm or Fault Messages
This table lists operator-correctable alarm or fault messages.
Event Messages Descript ion
External Waste FullWaste full sensor is activated.
Detergent Low Detergent is low as dete