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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)


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


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


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


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.


Note

Refer to major subsystem descriptions ofAC and DC Power Distribution Subsystem.

Pump Relay Module (PRM)


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.


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.





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.





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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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


Defective SBC

PCB

Replace SBC PCB

Characters OK But GarbledDefective LCD

Display Screen


Defective SBC

PCB

Replace SBC PCB

Missing CharactersDefective 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


Check Solenoid 3-3

Solenoid 3-3Replace Solenoid 3-3

Check Solenoid 3-4


Check Solenoid 3-1

Solenoid 3-1

Replace Solenoid 3-1

Check Pressure Switch

Defective Pressure SwitchReplace Switch

Pressure Overlimit


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


Check Solenoid 5-7


Check Solenoid 1-6

Waste Overflow Into

Accumulators


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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


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


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)


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


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


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 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



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

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