Service Manual

™
Part Number 270-2251
VARIANT II
Hemoglobin
Testing
System

March 2003
702:038
702:038
 Variant II Hemoglobin Testing System

Bio-Rad Laboratories
Diagnostic Group
4000 Alfred Nobel Drive
Hercules, California
94547
USA

Technical Assistance Contact Information:

[email protected]

CAUTION

Please read through and familiarize yourself with the contents of the service manual.

All personnel using the Variant II should wear standard laboratory safety apparatus.

(e.g. safety glasses, laboratory coat and gloves)

All reference material (i.e. standards and controls) and patient samples should be
considered as biohazardous material and must be handled with caution.

Waste material contains sample waste plus reagents: treat and dispose of as directed by
your laboratory safety guidelines or by local ordinance.

TRADEMARKS AND REFERENCES

Variant™ II is a trademark of Bio-Rad Laboratories, Inc.

All other trademarks are the property of their respective companies.

ii Service Manual 702:038

VARIANT II Hemoglobin Testing System

Table of Contents
1.0 Introduction

1.1. Introduction 1-1

1.2. Theory of Operation 1-2
1.3. System Overview 1-3
1.4. Safety Precautions 1-6

Table of Contents
2.0 Specifications

2.1. Sampling Station Physical and Electrical Specifications 2-1

2.2. Sampling Station Component Specifications 2-1
2.2.1. Regulatory Compliance 2-5
2.3. Chromatographic Station Physical and Electrical Specifications 2-5
2.4. Chromatographic Station Component Specifications 2-6
2.4.1. Regulatory Compliance 2-11
2.5. Minimum Computer Specifications 2-11

3.0 Installation and De-Installation

3.1. Installation Requirements 3-1

3.2. Unpacking and Inspection 3-1
3.3. VARIANT II System Setup 3-3
3.4. De-Installation 3-12

4.0 VARIANT II Service Software

4.1. Introduction 4-1

4.2. VCS Service Software 4-2
4.3. VSS Service Software 4-11

5.0 VCS Adjustment Procedures

5.1. Introduction 5-1

5.2. Column Heater 5-1
5.3. Degasser 5-2
5.4. Pump System 5-5
5.4.1. Zero Pressure Adjustment 5-6
5.4.2. High Pressure Calibration 5-7
5.4.3. Pump Drive Current Adjustment 5-7
5.4.4. Pump Flow Rate Adjustment 5-8

702:038 Service Manual iii

 VARIANT II Hemoglobin Testing System

5.5. Dynamic Mixer 5-13

5.6. 6 Port and 7 Port Valve Check 5-14
5.7. Syringe Check 5-15
5.8. Reservoir Unit 5-16
5.9. Detector 5-18

6.0 VSS Adjustment Procedures

6.1. Alignment Tools 6-1

6.2. Alignment Order 6-2
Table of Contents

6.3. Interlock Key 6-2

6.4. Rear Rack Guide Rail and Vertical Guide Plate 6-4
6.5. Front Rack Vertical Guide Plate 6-6
6.6. Rack Carrier Fingers 6-7
6.7. Side Rack Guides (Conveyor Width) 6-9
6.8. Checking the Sample Rack Movement 6-10
6.9. Spin Head Vertical Alignment 6-11
6.10. Spin Head Lowest Position 6-14
6.11. Spin Head Limit (Hold) Position 6-15
6.12. Tube Holder Unit Adjustment (Y-axis) 6-16
6.13. Sample Needle Vertical Alignment 6-20
6.14. Wash Tower X-axis (Needle at Wash Port) 6-22
6.15. Tube Holder Head Adjustment (Needle Guide, X-axis) 6-23
6.16. Sample Needle Y-axis at Wash Port 6-25
6.17. Needle Y-axis at Sampling Position 6-26
6.18. Needle Z-axis at the Dilution Well 6-28
6.19. Needle Z-axis at the Sampling Adjust Position 6-29
6.20. Sample Tube Z Positions 6-31
6.21. Rear Rack Carrier Home and Limit 6-33
6.22. Front Rack Carrier Home and Limit Positions 6-35
6.23. Tube Sensor 6-37
6.24. Rear Rack Carrier Spinning Position 6-38
6.25. Barcode Reader Unit Adjustment (Barcode Tube Position) 6-41
6.26. Spin Head X and Y Position Adjustment 6-44
6.27. Rear Rack Carrier Sampling Position 6-46
6.28. Rear Rack Carrier Barcode Reading Position Adjustment 6-48
6.29. Syringe Home Position Flag 6-50
6.30. Syringe Home Position 6-52
6.31. Pull Air Adjustment 6-54

7.0 Replacement Procedures

7.1. VCS Parts Replacement

7.1.1. Main CPU Board (No. 242) 7-1
7.1.2. Pump Board (No. 244C) 7-2

iv Service Manual 702:038

VARIANT II Hemoglobin Testing System

7.1.3. Power Supply Board (No. 245B) 7-3

7.1.4. Degasser Board (No. 246) 7-5
7.1.5. Pump Unit 7-5
7.1.6. Column Heater 7-22
7.1.7. Detector 7-27
7.1.8. Mixer Stir Bar and Gasket 7-32
7.1.9. Vacuum Pump 7-33
7.1.10. Syringe Lead Screw and Flange Nut 7-37
7.1.11. 6 and 7 Port Valves 7-39

7.2. VSS Parts Replacement

Table of Contents
7.2.1. Syringe Plungers 5 mL ITO and 1 mL ITO 7-42
7.2.2. Syringe Tubing Replacement 7-43
7.2.3. Pinch Valves 1 and 2 7-44
7.2.4. Syringe Home Sensor PCB 7-45
7.2.5. Syringe Pump Lead Screw and Flange Nut 7-45
7.2.6. Complete Sampling Head Unit 7-46
7.2.7. Sampling Head Unit Z-axis Belt 7-48
7.2.8. Sampling Head Unit Z-axis Motor 7-49
7.2.9. Sampling Head Unit Z Lead Screw Set 7-50
7.2.10. Sampling Head Y-axis Belt 7-51
7.2.11. Sampling Head Y-axis Motor 7-52
7.2.12. Needle Arm 7-53
7.2.13. Sampling Head Y-axis Sensor Assembly 7-54
7.2.14. Sampling Head Z-axis Sensor Assembly 7-55
7.2.15. Complete Mixing Head Unit 7-55
7.2.16. Spinning Head 7-56
7.2.17. Spinning Assembly 7-56
7.2.18. Spinning Drive Head Assembly 7-57
7.2.19. Complete Tube Holder 7-58
7.2.20. Conveyor Assembly Units Right and Left 7-60
7.2.21. Conveyor Belt 7-61

7.3. References 7-62

8.0 Maintenance

8.1. Materials 8-1

8.2. VCS 8-2
8.3. VSS 8-5
8.4. Performance Verification 8-8
8.5. VARIANT II Maintenance Report 8-8

9.0 Troubleshooting

9.1. Chromatography Review 9-1

702:038 Service Manual v

 VARIANT II Hemoglobin Testing System

9.1.1. Early Retention Times 9-3

9.1.2. Late Retention Times 9-5
9.1.3. Total Area Counts 9-8
9.1.4. Detector 9-10
9.1.5. Spikes 9-13
9.1.6. Pressure 9-13

9.2. Error Codes 9-14

9.3. VSS Self Diagnostics Flow 9-20
9.4. VARIANT II Timing Charts 9-22
Table of Contents

10.0 Spare Parts

10.1. VCS Parts 10-1

10.2. VSS Parts 10-25
10.3. Computer and Components 10-53

Appendix A

Barcode Label Specifications A-1

VCS Test Points A-3
Pressure Voltage Table (Degasser) A-7
Pump Board Modification Procedure A-9

Appendix B

Universal LIMS Adapter Configuration Chart B-1

LIMS Connection on VARIANT II B-2
Troubleshooting LIMS Transmission B-6
Examples of Transmissions B-7

Appendix C

VCS Tubing Diagram C-1

VSS Tubing Diagram C-2

Appendix D

VCS Mechanical Drawings D-1

VSS Mechanical Drawings D-12

vi Service Manual 702:038

VARIANT II Hemoglobin Testing System

Appendix E

VCS Electronic Diagrams and Layer Drawings

Appendix F

VSS Electronic Diagrams and Layer Drawings

Table of Contents

702:038 Service Manual vii

 VARIANT II Hemoglobin Testing System
Table of Contents

viii Service Manual 702:038

VARIANT II Hemoglobin Testing System

List of Figures
Number Title Page

Section 1
Figure 1-1: VARIANT II Hemoglobin Testing System 1-1

List of Figures
Figure 1-2: VSS Sample Tube Processing Components 1-3
Figure 1-3: VSS Syringes 1-4
Figure 1-4: VSS Ports 1-4
Figure 1-5: VCS Hardware Components 1-5
Figure 1-6: VCS Pump Assembly 1-5
Figure 1-7: VCS Ports 1-6

Section 3

Figure 3-1: Unpacking the VSS 3-2

Figure 3-2: Unpacking the VCS 3-2
Figure 3-3: Compaq Slimline DeskPro EN Ports 3-4
Figure 3-4: Waste Tank Level Sensor 3-4
Figure 3-5: Cartridge and Prefilter Holders 3-6
Figure 3-6: Pump Settings 3-8
Figure 3-7: Configuration Screen 3-11

Section 4

Figure 4-1: VCS Service Software Main Menu Options 4-2

Figure 4-2: Communication Port Settings 4-2
Figure 4-3: Status Window 4-3
Figure 4-4: Syringe Window 4-4
Figure 4-5: Valve Window 4-5
Figure 4-6: Pump Window 4-6
Figure 4-7: Detector Window 4-7
Figure 4-8: Gradient Window 4-8
Figure 4-9: LED/Buzzer Window 4-9
Figure 4-10: Reservoir Window 4-9
Figure 4-11: Reset Hardware Window 4-10
Figure 4-12: VSS Service Software Main Menu Options 4-11
Figure 4-13: Manual Window 4-12
Figure 4-14: Adjustment Window 4-16

702:038 Service Manual ix

 VARIANT II Hemoglobin Testing System

Figure 4-15: Expanded Needle Height Adjustment Window 4-19

Figure 4-16: Sampling Head Control Window 4-20
Figure 4-17: Spinning Head Control Window 4-20
Figure 4-18: Barcode Terminal Window 4-21
Figure 4-19: Sensor Status Window 4-22
Figure 4-20: Barcode Window 4-23

Section 5
List of Figures

Figure 5-1: Column Heater Adjustment 5-2

Figure 5-2: Degasser Vent Port 5-3
Figure 5-3: T Fitting at Pressure Sensor 5-5
Figure 5-4: Pump Current Test Points 5-8
Figure 5-5: Pump Board Switch Array 5-8
Figure 5-6: Tubing Setup for Flow Rate Measurement 5-9
Figure 5-7: Tubing in Flask 5-10
Figure 5-8: Meniscus of Liquid in Flask 5-10
Figure 5-9: Switch Settings 5-13
Figure 5-10: Detector Board Location 5-18
Figure 5-11: Detector Board Layout 5-19

Section 6

Figure 6-1: VSS Alignment Tools 6-1

Figure 6-2: IL Key 6-3
Figure 6-3: Rear Rack Guide and Vertical Guide Plate Screw Locations 6-4
Figure 6-4: Rear Guide Tool Placement 6-5
Figure 6-5: Rear Rack Guide and Vertical Guide Plate Adjustments 6-5
Figure 6-6: Rear Guide Rail Movement 6-6
Figure 6-7: Front Vertical Guide Plate Screw Locations 6-6
Figure 6-8: Dummy Rack Positioning at Front Guide Plate 6-7
Figure 6-9: Dummy Rack in Rear Rack Carrier Fingers 6-7
Figure 6-10: Rack Carrier Finger Adjustment 6-8
Figure 6-11: Side Rack Guide Adjustment 6-9
Figure 6-12: VSS Adjustment Window 6-11
Figure 6-13: Centering Tool Installation 6-11
Figure 6-14: Vertical Alignment Tool Placement in Front of Spin Head 6-12
Figure 6-15: Spin Head Adjustment Left to Right 6-12
Figure 6-16: Vertical Alignment Tool Placement at Side of Spin Head 6-13
Figure 6-17: Spin Head Adjustment Back to Front 6-13
Figure 6-18: Spin Head Control Option in Adjustment Window 6-14
Figure 6-19: Spin Head Control Window 6-14
Figure 6-20: Spin Head Lowest Position 6-15

x Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 6-21: Spin Head Limit Position 6-16

Figure 6-22: Spin Head Limit Position Adjustment 6-16
Figure 6-23: Sample Head Control and Sample Position Options 6-17
Figure 6-24: Dummy Rack Positioning Under Needle Guide 6-17
Figure 6-25: Removal of Tube Holder Cover 6-18
Figure 6-26: Disconnecting the Tube Holder Sensor 6-18
Figure 6-27: Loosening the Screws on the Tube Holder Base 6-18
Figure 6-28: Tube Holder Adjustment 6-19
Figure 6-29: Rack Guide Bar Positioning 6-19
Figure 6-30: Vertical Alignment Tool at Front of Needle 6-20
Figure 6-31: Sample Needle Front Alignment 6-20

List of Figures
Figure 6-32: Vertical Alignment Tool at Side of Needle 6-21
Figure 6-33: Sample Needle Arm Adjustment 6-21
Figure 6-34: Sample Needle Side Alignment 6-21
Figure 6-35: Wash Port Position Option in Adjustment Window 6-22
Figure 6-36: Wash Tower X-axis Adjustment 6-23
Figure 6-37: Sampling Position Option in Adjustment Window 6-24
Figure 6-38: Needle Positioning in Needle Guide 6-24
Figure 6-39: Manual Window Wash Port Options 6-26
Figure 6-40: Sampling Position Options 6-27
Figure 6-41: Needle at Top of Wash Tower 6-28
Figure 6-42: Z Height at Wash Port 6-29
Figure 6-43: Sample Position Options for Z-axis 6-30
Figure 6-44: Sample Position Z Adjustment 6-30
Figure 6-45: Sampling Height Adjust Position 6-31
Figure 6-46: Adjustment Options for Sample Tube Z Positions 6-32
Figure 6-47: Expanded Needle Height Adjustment Window 6-32
Figure 6-48: Rear Carriage Home and Limit Options 6-34
Figure 6-49: Rear Carrier Home Position at Guide Bar 6-34
Figure 6-50: Rack in Rear Carrier Home Position 6-34
Figure 6-51: Front Carriage Home and Limit Options 6-36
Figure 6-52: Front Carrier Home Position at Guide Bar 6-36
Figure 6-53: Rack in Front Carrier Home Position 6-36
Figure 6-54: Tube Sensor Position in Dummy Rack 6-38
Figure 6-55: Tube Sensor Adjustment 6-38
Figure 6-56: Spinning Position Option 6-39
Figure 6-57: Tube Sensor Position in Second Slit 6-39
Figure 6-58: Rack at Right Finger of Rear Carrier 6-40
Figure 6-59: Sensor Status Window with Rack in Place 6-40
Figure 6-60: Barcode Terminal Option 6-41
Figure 6-61: Barcode Terminal Fields 6-42
Figure 6-62: Barcode Unit Bracket 6-43
Figure 6-63: Barcode Reader Adjustment 6-43
Figure 6-64: Rack Rear Options in Manual Window 6-44
Figure 6-65: Spin Head Block Screws 6-45
Figure 6-66: Spin Head X and Y Adjustment 6-45

702:038 Service Manual xi

 VARIANT II Hemoglobin Testing System

Figure 6-67: Sampling Position and Sample Head Control 6-47

Figure 6-68: Sample Head Control Options 6-47
Figure 6-69: Positioning of Dummy Rack Under Needle Guide 6-47
Figure 6-70: Barcode Options 6-49
Figure 6-71: Syringe Options 6-50
Figure 6-72: Syringe Tip for Home Sensor Position 6-51
Figure 6-73: Flag Position in Sensor 6-51
Figure 6-74: Plunger Tip Position 6-52
Figure 6-75: Plunger Tip Position at Top 6-53
Figure 6-76: Gap at Bottom of Syringe 6-53
List of Figures

Figure 6-77: Prime and Pull Air Option 6-54

Figure 6-78: Tubing Positions in V1 6-54
Figure 6-79: Pull Air Position Between V1 and V2 6-55

Section 7

Figure 7-1: Fixing Plate Over Main CPU Board 7-1

Figure 7-2: Chip Placement on Main CPU 7-2
Figure 7-3: ROM Chip on Pump Board 7-3
Figure 7-4: Power Supply Board Connections 7-4
Figure 7-5: Clips on Power Supply Board 7-4
Figure 7-6: Pump Seal 7-5
Figure 7-7: Tubing Connections at Check Valves 7-6
Figure 7-8: Removing the Pump Head Screws 7-6
Figure 7-9: Pump Seal Removal 7-7
Figure 7-10: Wetting the Pump Seals 7-7
Figure 7-11: Bushing and Seal Set 7-8
Figure 7-12: Extraction Tool and Attachment 7-9
Figure 7-13: Extraction Tool with Bushing and Seal 7-9
Figure 7-14: Installing the Bushing and Seal 7-10
Figure 7-15: Check Valves 7-11
Figure 7-16: Check Valve Removal 7-11
Figure 7-17: Piston and Piston Spring 7-12
Figure 7-18: Removal of Piston and Piston Spring 7-13
Figure 7-19: Motor Photo Sensor 7-14
Figure 7-20: Disconnecting the Pump Tubing 7-15
Figure 7-21: Removing the Cables on the Motherboard 7-15
Figure 7-22: Removing the Pump Assembly Tray 7-15
Figure 7-23: Photo Sensor Cover 7-16
Figure 7-24: Photo Sensor Placement 7-16
Figure 7-25: Pump Cam 7-17
Figure 7-26: Removing the “U” Block 7-18
Figure 7-27: Removing the Pump Cam 7-18
Figure 7-28: Bearing Rings and Roller Bearing 7-18

xii Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-29: Removing the Piston Rod and Cam Follower 7-19
Figure 7-30: Pump Motor Assembly 7-20
Figure 7-31: Removing the Pump 7-21
Figure 7-32: Column Heater Block 7-22
Figure 7-33: Removing the Column Heater Tray 7-23
Figure 7-34: Back of Column Heater Unit 7-24
Figure 7-35: Screws Securing Heat Sink 7-24
Figure 7-36: Thermal Sensor Placement 7-25
Figure 7-37: Removing the Thermal Fuse 7-26
Figure 7-38: Detector Optical Unit 7-27
Figure 7-39: Flow Cell 7-28

List of Figures
Figure 7-40: Removing the Flow Cell 7-29
Figure 7-41: Observing the Lamp Filament 7-29
Figure 7-42: Proper Filament Position 7-30
Figure 7-43: Bad Filament Position 7-30
Figure 7-44: Lamp Assembly 7-31
Figure 7-45: Removing the Lamp Assembly 7-31
Figure 7-46: Lamp Alignment 7-32
Figure 7-47: Mixer Stir Bar and Gasket 7-33
Figure 7-48: Removing the Mixer Cover 7-33
Figure 7-49: Vacuum Pump 7-34
Figure 7-50: Removing the Bottom Panel (S/N < 11131) 7-34
Figure 7-51: Pump Purge Port Tubing 7-35
Figure 7-52: Removing the Degasser Tray 7-35
Figure 7-53: Removing the Vacuum Pump Tubing 7-35
Figure 7-54: Removing the Vacuum Pump 7-36
Figure 7-55: Removing the Vacuum Pump Grommets 7-36
Figure 7-56: Syringe Lead Screw and Flange Nut 7-37
Figure 7-57: Syringe Motor 7-38
Figure 7-58: Bearing Retainer Plate 7-38
Figure 7-59: Flange Nut 7-38
Figure 7-60: Valve Components 7-40
Figure 7-61: Placement of Rotor Seal on Shaft Assembly 7-41
Figure 7-62: Removing the VSS Syringes 7-42
Figure 7-63: Syringe Tubing 7-43
Figure 7-64: Removing the Syringe Tubing 7-43
Figure 7-65: Removing Pinch Valves 1 and 2 7-44
Figure 7-66: Removing the Dilution Chamber Drain Tubing 7-47
Figure 7-67: Loosening the Lead Screw Set Screws 7-50
Figure 7-68: Y-axis Belt Holder Screws 7-52
Figure 7-69: Removing the Needle Arm 7-53
Figure 7-70: Removing the Spinning Head Assembly 7-57
Figure 7-71: Spinning Drive Head Assembly 7-57
Figure 7-72: Removing the Spinning Drive Head Assembly 7-58
Figure 7-73: Complete Tube Holder 7-59
Figure 7-74: Removing the Front Rack Guide and Bracket 7-59

702:038 Service Manual xiii

 VARIANT II Hemoglobin Testing System

Figure 7-75: Screws on Rack Slide Block 7-60

Figure 7-76: Removing the Belt Conveyor 7-61

Section 9

Figure 9-1: A1c Chromatogram 9-2

Figure 9-2: Beta Thalassemia Chromatogram 9-3
Figure 9-3: Noisy Chromatogram 9-10
Figure 9-4: Ramping Baseline 9-11
List of Figures

xiv Service Manual 702:038

VARIANT II Hemoglobin Testing System

List of Tables and Diagrams

Number Title Page

Section 5

List of Tables and Diagrams

Table 5-1: Degasser Settings for Elevations Over 300 Meters 5-4
Table 5-2: Pump Board DSW1 Switch Settings 5-13
Table 5-3: Reservoir Board Adjustment Points 5-16
Table 5-4: Detector Board Adjustments 5-19

Section 6

Table 6-1: VSS Alignment Order 6-2

Section 9

Table 9-1: VCS Error Codes 9-14

Table 9-2: VSS Error Codes 9-17

Diagram 9-1: A1c Early Retention Times Flow Chart 9-4

Diagram 9-2: Late A1c Retention Times 9-6
Diagram 9-3: Late Ao Retention Times 9-7
Diagram 9-4: Detector Flow Chart 9-12
Diagram 9-5: VSS Self Diagnostics Flow 9-21
Diagram 9-6: VARIANT II Timing Chart 9-23
Diagram 9-7: VSS Timing Chart 9-24
Diagram 9-8: Microtube Timing Chart 9-25

Appendix B

Table B-1: Pin Outs for Non Slimline VII Computers B-2
Table B-2: Pin Outs for Slimline VII Computer B-3

702:038 Service Manual xv

 VARIANT II Hemoglobin Testing System
List of Tables and Diagrams

xvi Service Manual 702:038

VARIANT II Hemoglobin Testing System

1.0 Introduction

1.1 Introduction

The VARIANT II Hemoglobin Testing System is a second-generation VARIANT

system with added front-end automation and Clinical Data Management software.
The system is a fully automated, high throughput hemoglobin analyzer that
provides an integrated method for sample preparation, separation and determination
of the relative percent of specific hemoglobins, and their components, in whole

Introduction
blood. It consists of two modules - the Chromatographic Station and the Sampling
Station. In addition, a personal computer is used to control the operations using
Clinical Data Management System software (CDM). The VARIANT II is shown in
Figure 1-1.

Figure 1-1:
The VARIANT II
Hemoglobin Testing System

The VARIANT II Service Manual is intended for Bio-Rad or other appropriately

trained service personnel, as a tool when troubleshooting or performing
maintenance on the VARIANT II Hemoglobin Testing System.

The Procedures section describes procedures to be used when servicing the system.
Please review this section carefully before servicing a VARIANT II system.
A description of Annual Preventive Maintenance, that includes part numbers of all
required replacement parts, is included in the Maintenance section along with a PM
checklist.

The Spare Parts section contains a pictorial list of replacement parts. This list
contains the Bio-Rad part number in addition to the manufacturer’s part number. If

702:038 Service Manual 1 -1

 VARIANT II Hemoglobin Testing System

no Bio-Rad part number is found or the required part is missing from the list,
contact CSD Technical Support or the product manager for assistance in ordering.

1.2 Theory of Operation

The VARIANT II system uses high performance liquid chromatography (HPLC) to

separate normal and variant hemoglobins. HPLC is a method based on interaction
between a stationary phase (cartridge) and mobile phase (buffers). The VARIANT
II system is capable of utilizing 2 different types of HPLC - cation exchange and
affinity.
Introduction

The Hemoglobin A1c and Beta Thalassemia applications on the VARIANT II are
both cation exchange. The principles of cation exchange are based on the ionic
interaction between the sample and the cartridge bed. Hemoglobin in the sample is
positively charged while the cartridge contains negatively charged functional
groups covalently bound to the resin base. Once introduced into the cartridge, the
hemoglobin will bind based on ionic strength. Hemoglobin with a strong positive
charge will bind more tightly than one with a weaker charge.

Separation of the bound hemoglobin is accomplished by introducing buffers

containing positively charged ions to the cartridge at a predefined continuous
gradient. As the buffer gradient, or ionic strength, increases, the buffer ions will be
exchanged with the weaker hemoglobin or its components. The released
hemoglobin will then pass through a detector where a reading of each hemoglobin
or component takes place. The data will be transmitted to CDM for analysis and
the resulting chromatogram will indicate the relative percent of each hemoglobin or
component present in the sample.

The Total GHb application uses the principle of affinity HPLC where separation is
based on the affinity of all glycated hemoglobins present in the sample for the
boronate resin in the cartridge. The first buffer is used to bind glycated hemoglobins
to the resin, while allowing non-glycated hemoglobin to pass through, and the
second is used to displace the bound glycated hemoglobin.

The VARIANT II sampling station aspirates and dilutes whole blood samples by
the use of two syringes. The dilution takes place in a dilution well and is then
aspirated, by syringe, to the chromatographic station for analysis. A segment of the
sample is introduced into the fluid pathway by the use of a 6 port valve (injector).
Between injections the sample needle and tubing are rinsed with wash solution to
prevent carryover to the next sample.

The chromatographic station contains two dual-piston pumps that deliver the
buffers to the flow path. A dynamic mixer smooths the buffer gradient before it
reaches the analytical cartridge. The buffer then passes through the cartridge where
hemoglobin separation occurs. The separated components are carried to the
detector where a dual wavelength reading takes place. The sample components are

1 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

measured at 415nm with a second reading at 690nm to minimize buffer gradient

noise. The absorbance data are transmitted from the PC through CDM and
displayed as a real-time chromatogram (Time vs. Absorbance).

The processed data is incorporated into a printed report, which contains a complete
summary of the detected components including peak identification, retention time,
total area count and relative area percent. In addition, the report contains the
chromatogram, date and time of analysis, vial number and sample identification.

1.3 System Overview

Introduction
Sampling Station (VSS)

Figure 1-2:
VSS Sample Tube
Processing
Components

1. Sample Needle

2. Dilution Tower

4
3. Tube Holder with Needle
Guide

3 4. Spin Head

5 5. Barcode Reader
2
6. Tube Sensors

702:038 Service Manual 1 -3

 VARIANT II Hemoglobin Testing System

Figure 1-3:
VSS Syringes

7. Wash/Diluent
Syringe
Introduction

8. Sample Syringe
7 8

Figure 1-4:
VSS Ports

9. Reservoir Level Sense

Port (RS232)

10. COM Port (RJ45)

11. Sample Transfer Line

Port
11

12. Wash/Diluent Port

9 12

13
13. Waste Port
10

1 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Chromatographic Station (VCS)

Figure 1-5:
VCS
1 Hardware
1. Detector Inlet
Components

2. Cartridge Heater

3. Syringe (Sample
4
Transfer)
2
4. 7 Port Valve

Introduction
5
(Purge/Mixer Bypass)
3
6 5. 6 Port Valve (Injection)

6. Dynamic Mixer

Figure 1-6:
VCS Pump
7. Piston Seal Wash Assembly
7
Port
8 9
8. Pump A

9. Pump B

10. Pump A Purge Port

10 11 11. Pump B Purge Port

702:038 Service Manual 1 -5

 VARIANT II Hemoglobin Testing System

Figure 1-7:
VCS Ports

12. COM Port (RJ45)

12 13. Reservoir Level Sense Port

(RS232)

14. Waste Level Sense Port

13 14 (Serial)
Introduction

15. Fluid Ports: Sample

Transfer, Wash/Diluent,
15 Buffer B, Buffer A

16. Waste Port

17. Piston Wash Outlet

16

17

1.4 Safety Precautions

Electrical

The main source of electrical hazard on the VARIANT II is the primary AC wiring.
The primary AC wiring is located at the back of the chromatographic station and on
the right side of the sampling station. This wiring is used to provide power to the
DC power supplies of each unit and carries a voltage anywhere from 100 v to 240 v.
The wiring after the power supplies carries 24 Volts DC or less and does not
represent a shock hazard. Nevertheless, always treat ANY wire as if it carried a
hazardous voltage.

Mechanical

When servicing the VARIANT II, it is important to remember that it is an

automated instrument with many subsystems. When the instrument is operating,
any of the assemblies within the instrument may start at any time. It is critical to
keep the head, fingers, loose clothing, ties, hair and jewelry out of the way of
moving parts.

1 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Biohazardous

WARNING: The VARIANT II receives and transfers biohazardous fluids

throughout the system; therefore, the instrument must always be treated as
having been exposed to infectious agents. Use caution when servicing the unit
and follow local regulations regarding the treatment of spills and the disposal
of biohazardous materials.

The primary function of the VARIANT II is the analysis of blood samples. Care
must be taken when the instrument is serviced to prevent exposure of service

Introduction
personnel to infectious agents. The decontamination procedure, found in the
VARIANT II Operation Manual, MUST be followed prior to servicing the
instrument. The Sample Needle MUST be removed to avoid puncture when
servicing the Sampling Station.

WARNING: The Sample Needle is EXTREMELY sharp. Caution must be

used during removal or installation.

Safety Procedures

Personal Protective Equipment (PPE) is required for all personnel working on the
VARIANT II. Safety procedures include:

1. Removal of wristwatches and jewelry to facilitate better hand washing and

prevent the puncture of disposable gloves. Double gloving is highly
recommended when handling infectious or potentially infectious material.
Change gloves if they become cut or punctured to prevent skin exposure to
infectious material.

2. Completely protect any cut, abrasion or rash on the skin before working with
potentially infectious material. Seal with a waterproof bandage under
protective clothing. Do not handle potentially infectious material if the
exposed injury cannot be completely sealed.

3. Laboratory coats (cloth or disposable), gowns, smocks or uniforms must be

worn while in the laboratory or clean up room. Remove the protective
clothing if visiting a "clean" area of the laboratory (offices, cafeteria, etc.).
Disposable lab coats should be disposed of in a biohazard container before
permanently leaving the work area.

702:038 Service Manual 1 -7

 VARIANT II Hemoglobin Testing System

4. Wash hands thoroughly with soap and water after working with any
potentially infectious agent or equipment before leaving the work area and
especially if skin is exposed to an infectious agent.

5. Keep hands away from mouth, nose and eyes. Avoid touching the eyes while
working, as it is a common route for infectious agents to enter the body.
Safety glasses with side shields are required especially for individuals who
wear contact lenses. Goggles or face shields are required if there is a potential
for splashing.

6. Do not use gloved hands to write, answer the telephone, turn on a light or
touch anything that ungloved personnel may handle. Only materials needed
Introduction

for immediate procedures should be in the vicinity of the work area. Do not
expose books or other materials that cannot be properly decontaminated.

1 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

2.0 Specifications
2.1 Sampling Station Physical and Electrical Specifications

Dimensions (approx.) 62 cm (W) X 60 cm (D) X 46 cm (H) from

counter top (25” X 24” X 19”)

Weight - Uncrated
(approx.) 63 kg (139 lbs.)

Operating Temperature Ambient (15-35º C)

Humidity 10 - 90%

Storage Conditions -20ºC to 50 ºC; (0º F to 120ºF); Humidity 10 -95%

Line Voltage Selected Automatically

Specifications
100 to 240 volts AC

50/60 Hz

Power Consumption <150 Watts

Communication Port RJ45 connector

RS232C bi-directional serial port

2.2 Sampling Station Component Specifications

Sample Rack Handling

Sample Rack Sysmex #3 (P/N 2702006)

Rack Adapters in 3 sizes: 12 mm (P/N 2702175),

13 mm (P/N 2702174) and 14 mm (P/N 2702173)

10 sample capacity

Capacity 10 racks (5 on each belt)

702:038 Service Manual 2 -1

 VARIANT II Hemoglobin Testing System

Rack Movement Conveyor Belts

Rack Handlers front and back

Sample Tube Handling

Capacity 100 samples, primary tubes or pre-dilutions

Tube Sizes Primary Tubes: 16 mm (no rack adapter)

12, 13 and 14 mm (with rack
adapter)
Pediatric Tubes: 10 mm with Tube Adapter

(P/N 2702017-10)
Pre-Diluted: 1.5 mL microvials (P/N
2702149) in Tube Adapter (P/N
2702016-10)

Tube Sensing Reflective optosensors at 2 heights that

distinguish primary, pediatric and pre-diluted
Specifications

samples

Barcode Reader

Reader Unit Keyence/Model BL-180

Specification ASTM E 1466-92 compatible

Symbologies Code 39 (with and without check digit)

ITF (with and without check digit)
Industrial 2 of 5
Codabar (NW-7) (with and without check digit)
EAN/UPC (-A and -E)
Code 128
COOP 2 of 5
Parsing option available for all barcodes

Barcode Reading Automatic rotation of each sample tube (primary

and pre-diluted) for sample identification

Barcoded Microvial Tube Adapters for Primer,

Blank, Calibrator and Controls

The Rack Barcode, which is placed between the

first and second position on the rack, is read
before the first sample

2 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Liquid Handling

Syringes Two Ito Syringes: 1 mL for sample aspiration and

5 mL for Wash/Diluent Aspiration

Syringe Specifications Sampling Volume: 5 to 200 µL

Increments of 0.1 µL per step
Accuracy is the greater of either + 1 µL or 5%

Diluent Volume: 30 to 600 µL

Increments of 0.5 µL per step
Accuracy is the greater of either + 3 µL or 5%

Primary Tube Dilutions Two step dilution

Sample Volume Aspiration: 15 to 25 µL (Assay
specific)
Initial Diluent Volume: 475 to 482 µL (Assay

Specifications
specific)
Secondary Diluent Volume: 431 to 470 µL (Assay
specific)

Dilution Precision 1:10 to 1:200: < 3%

1:200 to 1:400: < 5%

Carry-over < 1% at 1:20 dilution

Waste per sample Maximum 3 mL for each primary tube sample

Sample Mixing Maximum spinning speed of 1800 rpm

Sample Needle

Needle Description Cap piercing, side port type

Length 122 mm

Material Stainless Steel

Lifetime 10,000 pierces

702:038 Service Manual 2 -3

 VARIANT II Hemoglobin Testing System

Dilution Tower Dilution of primary tube samples or transfer of

pre-diluted samples and separate needle wash port

Evacuation by vacuum pump and regulated by

pinch valve movement

Internal Waste Tank Approximate 200 mL volume with level sensor

Evacuated to external waste by pressure from the

vacuum pump output

External Waste Tank 10 L plastic with level sensor

Fluid Pathway Tubing

Sample Line (needle to Teflon

syringe pump assembly) Length: 550 mm
Specifications

O.D./I.D.: 2.0 x 1.0 mm

Sample Line (dilution Teflon

chamber to sample port) Length: 700 mm
O.D./I.D.: 1.58 x 0.5 mm

Wash/Diluent Line (inlet Silicon rubber

port through syringe Length: 695 mm
assembly, including pinch O.D./I.D.: 4.0 x 2.0 mm (port to syringe)
valves 1 and 2) 3.0 x 1.0 mm (remainder)

Dilution Well Drain Silicon rubber

Line (through PV 3 Length: 765 mm
to 2nd T-fitting) O.D./I.D.: 4.0 x 2.0 mm (to PV3)
3.0 x 1.0 mm (PV3 to union)
5.0 x 3.0 mm (remainder)

Drain Port Drain Line Silicon rubber

(to 1st T-fitting, through Length: 845 mm
PV4 and PV3) O.D./I.D.: 4.0 x 2.0 mm (to PV4)
3.0 x 1.0 mm (through PV 4 and PV3)
5.0 x 3.0 mm (remainder)

Wash Port Drain Line Silicon rubber

(through PV4 to 2nd Length: 635 mm
T-fitting) O.D./I.D.: 4.0 x 2.0 mm (through PV4)

2 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

5.0 x 3.0 mm (remainder)

Waste Line (2nd T-fitting Silicon rubber
to Internal Waste, Length: 810 mm
through PV7) O.D./I.D.: 5.0 x 3.0 mm (through PV7)
7.0 x 4.0 mm (remainder)

Waste Line (internal Silicon rubber

waste to external waste Length: 720 mm
port) O.D./I.D.: 7.0 x 4.0 mm (internal waste through
PV7, T-fitting to union)
5.0 x 3.0 mm (PV7 to T-fitting)
8.0 x 5.0 mm (union to external port)

2.2.1 Regulatory Compliance

EMC

EMI FCC Part 15 Subpart B (Class A)

EN55011 (VDE 0871) (Class B)
EN61326 (Radiated and Conducting Emissions

Specifications
Only) with Compaq Slimline Desk Pro EN PC

Immunity IEC801-2 (Static Discharge)

IEC 801-3 (Radiated electromagnetic field)
IEC801-4 (Fast transient BURST)

Safety Testing EN61010-1 and EN61010-2-010

2.3 Chromatographic Station Physical and Electrical

Specifications

Dimensions (approx.) 28 cm (W) X 41 cm (D) X 53 cm (H) (11” X 17”

X 21”)

Weight - Uncrated
(approx.) 33 kg (73 lb)

Operating Temperature Ambient 15 - 35º C (59 - 95ºF)

Humidity 10 - 90%

Storage Conditions -20º C to 50º C (0º F to 120º F); Humidity 10 -95%

702:038 Service Manual 2 -5

 VARIANT II Hemoglobin Testing System

Line Voltage Selected Automatically

100 to 240 volts AC

50/60 Hz

Power Consumption 200 Watts maximum

Communication Port RJ45 connector

RS232C bi-directional serial port

2.4 Chromatographic Station Component Specifications

Detector

Wavelength Sample: 415 + 3 nm

Reference: 690 + 3 nm
Specifications

Flow Cell Tapered Cell

30 µL Volume

Optical Path Length 10 mm

Light Source Tungsten Halogen lamp (6V, 10 W)

Expected Lamp Life Time 2000 Hours

Linearity + 1% of Theoretical absorbance at 0.8 A.U.

(based on extrapolation from lower
concentrations)

Switching Noise 2.0 mV gradient noise maximum with Dynamic

Mixer in place

Based on Step Gradient of 0%B to 50% B to

100% B to 0% B

Baseline Noise < 200 µV peak to peak (10 minute test period
after 30 minute warmup)

Baseline Drift < 1.0 mV per hour (one hour test period after 30
minute warmup)

2 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Dual Piston Pumps

Flow rate range 0.1 to 3.0 mL in 0.1 mL increments (each pump)

Maximum pressure 4000 psi (280 kg)

Accuracy + 2%

Precision + 1.0%

Test condition for Flow Rate Range: 0.4 to 2.5 mL/min

accuracy and precision
Pressure Range: 0-2000 psi

Pulsation Level Maximum 10% both pumps

Test Condition for QC Flow Rate 2.0 mL/min with 270 µL Dynamic
Mixer and backpressure of 100 kg/cm2

Specifications
Piston Washing Manual washing with piston wash port

Should be performed before and after operation

Expected Lifetime of 2000 hours

Pump Seals

Dynamic Mixer (Gradient System)

Composition 0 to 100% in 0.1% increments

Accuracy of Gradient + 0.5% B

Precision of Gradient + 0.3% B

Test Range for Flow Rate: 0.9 to 2.5 mL/min

accuracy and precision Composition Range: 10-90%

Void Volume 270 µL

Mixing Speed 300 rpm

Mixer Selection Dynamic or T mixer selected automatically via

Rheodyne 7 port valve

702:038 Service Manual 2 -7

 VARIANT II Hemoglobin Testing System

Pressure Sensor

Construction Strain Gauge

Maximum Pressure 350 kg/cm2 (5000 psi)

Accuracy + 5% or 2 kg/cm2 (20 psi), whichever is greater

Precision + 2% or 2 kg/cm2 (20 psi), whichever is greater

Degasser

Construction 2 channel Teflon tubular membrane in vacuum

chamber

Vacuum Level of Chamber 400 - 1000 hpa/10hpa step programmable and

vacuum off
Specifications

Setting Level = 500 hpa

Vacuum Level Accuracy Set level + 35 hpa at 23o C (77° F)

Vacuum Error Detector Allowable Range = + 100 hpa of the set level

Injection Valve (Rheodyne 6 port - RV700123))

Sampling Method Complete loop filling

Loop Size 23 µL

Filling Speed 0.1 - 2.0 mL/min in 0.1 mL /min increments

Overfill Volume > 400µL

Accuracy Dependent on Sample Loop Size (nominal +

10%)

Precision < 1.0%

Line Flush Volume 0 to 4.0 mL in 0.1 mL increments

2 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Carryover <0.1% with 2.0 mL flush volume at 20 µL sample

loop size

Column Holder Unit

Column (Cartridge) Size 2 - 3 cm (assay dependent)

Temperature Range 22º C to 50o C in 1º increments

Accuracy + 1º C

Stability + 0.5º C

Reagent Reservoir Tray

Composition Stainless Steel with 3 bottle capacity and liquid

volume sensor

Tray 1: Buffer A/1

Specifications
Tray 2: Buffer B/2
Tray 3: Wash/Diluent

Liquid Volume Sensor Strain Gauge

Detector performance: 5 - 90%, programmable in
1% increments
Accuracy: + 5% of 2.0 L full scale

Fluid Pathway Tubing

Sample Line Port to Teflon

Injection Valve Length: 500 mm
O.D./I.D.: 1.58 x 0.5 mm

Wash/Diluent Port to Teflon

Syringe Length: 570 mm (through 3-way solenoid)
O.D./I.D.: 3.18 x 1.58 mm

3-way solenoid to Teflon

Injection Valve (6 port) Length: 600 mm
O.D./I.D.: 1.58 x 0.8 mm

702:038 Service Manual 2 -9

 VARIANT II Hemoglobin Testing System

Buffer A Port to Pump A Teflon

Length: 500 mm (through 2-way solenoid; to and
from degasser)
O.D./I.D.: 3.18 x 1.58 mm

Buffer B Port to Pump B Teflon

Length: 330 mm (to and from degasser)
O.D./I.D.: 3.18 x 1.58 mm

Pump T-Fitting (post Stainless Steel

Pressure Sensor) to Total Length: 910 mm (through 7 port valve,
Column Holder dynamic mixer and injection valve)
O.D./I.D.: 1.58 x 0.25 mm

7 port Injector (Purge Stainless Steel

Position) to T-fitting Length: 210 mm
(pre drain line) O.D./I.D.: 1.58 x 0.25
Specifications

Column Holder to PEEK

T-fitting (pre drain line) Length: 630 mm (through flow cell)
O.D./I.D.: 1/16 inch x 0.01 inch

T-fitting (pre drain line) Teflon

to Drain Port Length: 360 mm
O.D./I.D.: 3.18 x 1.58 mm

Piston Wash Line Tygon™

(inlet port to pump drain Length: 950 mm (through siphon break)
port) O.D./I.D.: 1/8 inch x 3/16 inch

Pump Drain Line Silicon

(outlet port to waste) Length: 2.5 m
O.D./I.D.: 8 mm x 5 mm

Drain Line PVC

(outlet port to waste) Length: 2.5 m
O.D./I.D.: 11 mm x 6 mm

2 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

2.4.1 Regulatory Compliance

EMC

EMI FCC Part 15 Subpart B (Class A)

EN55011 (VDE 0871) (Class B)
EN61326 (Radiated and Conducting Emissions
Only) with Compaq Slimline Desk Pro EN pc

Immunity IEC801-2 (Static Discharge)

IEC 801-3 (Radiated electromagnetic field)
IEC801-4 (Fast transient BURST)

UL 3101-1/10.93

2.5 Minimum Computer Specifications

Intel Pentium II or better

Specifications
Processor
350 MHz or faster
Bus speed 100 MHz or faster

Cache 512 KB EEC Level 2 synchronous pipeline

Burst SRAM

Memory 64 MB or greater

Diskette Drive 1.44 MB

Hard Drive SMART Ultra ATA 6 GB or greater

USB Ports 2

Graphics Memory ATI RAGE PRO TURBO AGP 2X with

4 MB SGRAM or greater

Audio Embedded 16 bit audio

Keyboard Compaq Enhanced Keyboard

Mouse PS2

Monitor 15 inch Compaq 110/220 V or larger

702:038 Service Manual 2 -11

 VARIANT II Hemoglobin Testing System

OS Software Windows NT 4.0, SP4 or SP6

(platform dependent)

CD R/W Internal , 6X read, 2X write or

faster

Network Card Compaq 10/100 TXPCI Intel WOL Controller

Serial Card Rocket Port 4 x RJ45 or ConnectTech 4 x DB-9

(platform dependent)
Specifications

2 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

3.0 Installation and De-Installation

3.1 Installation Requirements

1. Choose a location that is away from direct sunlight and is relatively dust free.

2. Room temperature should be between 15 and 30º C (60-85ºF).

3. The bench or table should have a flat, level surface that is free from vibrations
and is capable of supporting up to 115 kg (about 250 lb).

NOTE: All four feet of the VSS MUST be on the counter. If the surface is not
deep enough to accommodate the front feet, obtain removable footpads from a
local hardware or home improvement store. Secure them under the VSS, one
on each side, far enough back so they allow the module to be level and secure
on the counter.

4. A grounded electrical receptacle should be within 1.8 meters (6 feet) of the

system.
The maximum power consumption is 1750 VA (VCS, VSS, CPU, monitor and
printer)

5. The Personal Computer (PC) should be located as close to the VARIANT II as

possible to provide adequate room for communication connections.

Installation
3.2 Unpacking and Inspection

The VARIANT II will arrive in three separate boxes; one for the VSS, one for the
VCS and one for the Accessories. The PC, monitor and printer will also be in
separate boxes. A Customer Acceptance Form and System Warranty Card should
be completed by the customer and returned to Bio-Rad Laboratories after inspection
of the system.

Accessories

Remove all accessories from the box and verify that all components are present.
The following is a list of all accessories supplied at installation:

Waste Tank (10 L)

Waste Tank Tubing (2 for VCS, 1 for VSS)

702:038 Service Manual 3 -1

 VARIANT II Hemoglobin Testing System

Waste Level Sensor

Dummy Cartridge (installed in the cartridge holder)
Sysmex Racks (10)
Sysmex Rack Adapters (12 mm, 13 mm and 14 mm)
Pediatric Tube Adapters (10)
Microvial Adapters (10)
Barcode Labels (Primer, Blank, Cal 1, Cal 2, Control 1, Control 2)
Allen Wrenches (4)
Wrench (2)
Syringe Luer Tube Assembly
Reservoir Unit
Reservoir Unit Cables
Communication Cables: RJ-45 to RJ-45 (2)
Communication Cables: RJ-45 to DB-9 (2)
Power Cables (2)
Extra Fuses
Reagent Tubing and Caps (3)
Sample Tubing
Flangeless Fitting Nut and Ferrule Set
Pump Seal
Pump Seal Remover Tool
Screw Drivers (2)
Decon Tubing
Syringes
Mouse Pad
Operation Manual
Warranty Card

VARIANT II

1. Remove the ties surrounding the two larger boxes. Lift the top box off of each
Installation

base.
Figure 3-2:
Unpacking
the VCS

Figure 3-1:
Unpacking the VSS

2. Remove the protective bags from around the VCS and VSS.

3 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

3. Each module is heavy, requiring at least two people to lift. Carefully lift the
VCS onto the benchtop and position it so that all of the rubber feet are squarely
in position. Repeat with the VSS, PC and printer. Remove the monitor and
place it on top of the PC.

4. Remove the needle cover and front bezel cover from the VSS. Disconnect and
save the sampling arm shipping bracket. Make sure the sample probe is
connected properly. Replace the front bezel cover and needle cover.

3.3 VARIANT II System Setup

NOTE: The remainder of the installation procedure requires a working

knowledge of CDM 3.5 and the VARIANT II Service Software. If needed,
consult the CDM 3.5 Operation Manual and Section 5 of this manual for
additional information.

Communication Cables and Port Settings

1. Connect one end of each communication cable from the back of the VCS and
the back of the VSS to the PC. Use the RJ-45 to DB-9 cables for COM ports 1
or 2 and the RJ-45 to RJ-45 cables for COM ports 4-7. (ConnectTech equipped
computers use RJ-45 to DB-9 communication cables only). Note that the RJ-45
to RJ-45 cables are marked "PC" at one end.

NOTE: Port 3 is the internal modem required to connect to CSN.

2. Connect one end the reservoir cable to the Reservoir Unit and the other end to
the back of the VCS. Place the reservoir unit on the VSS behind the right belt.

Installation
3. Connect the power cords to the VSS, VCS. PC, monitor and printer. Plug all
power cords into power outlets.

4. Turn on the PC. Start CDM from the icon on the desktop. In the
SETUP/Configuration screen verify that the instrument type is VARIANT II
and set the communication ports for the VCS (gradient module) and VSS for
Instrument 1 based on placement at the back of the PC. The system must be in
Inactive state to make changes to the port settings.

Communication Ports for Compaq Slimline DeskPro™ EN

The Compaq Slimline DeskPro EN computer requires the use of a multi-line

communication cable. This line replaces the 4 port rocket board from previous
computers supplied with the VARIANT II. The end of each cable is a DB-9 male

702:038 Service Manual 3 -3

 VARIANT II Hemoglobin Testing System

connector requiring the use of the RJ-45 to DB-9 cables supplied with the system.
Figure 3-3 shows the communication port numbers on the back of this PC.

Figure 3-3:
Compaq
Slimline
DeskPro EN
Ports
7

6
5
2
4

Waste Tank and Lines

1. Remove the caps from the waste tank. Remove the inner seal from the main
cap.

2. Insert the terminal end of the waste tank sensor cable through the main cap.
(Figure 3-4)
Installation

Figure 3-4: Waste

Tank Level Sensor

3. Place the waste sensor into the tank and screw the main cap over the sensor until
it is tight. Connect the waste tank signal cable to the terminal labeled WASTE
on the back of the VCS.

4. Create a small vent hole in the secondary cap and install the cap on the waste
tank.

5. Remove the caps from the barbed fittings for waste at the back of the VCS and
VSS. Retain the caps.

3 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

6. Connect one silicon tube to the Waste port at the back of the VSS. Connect the
other silicon tube to the Pump Drain port at the back of the VCS. Connect both
to the waste tank inlet. The tubing should have sufficient length to reach the
waste tank on the floor. Cut if necessary.

7. Connect the remaining Tygon tube to the Drain port at the back of the VCS.
Connect the opposite end to the waste tank inlet. The tube should have
sufficient length to reach the waste tank on the floor. Cut if necessary.

8. Place the waste tank in a position so the tubing is sloped downward at all times.

Reagent and Sample Lines

1. Remove all inlet port plugs from the reagent and sample ports at the back of the
VCS and VSS and save them.

2. Connect the finger-tight fittings for Buffers A, B and Wash/Diluent tubing to

the appropriate ports on the VCS and VSS. The caps of the buffer lines are
marked accordingly. Make sure the fittings are tight and are not cross-threaded.

3. Connect one end of the sample line at the back of the VSS and the other at the
back of the VCS.

4. Unpack the buffer and wash bottles from the application to be installed. Remove
the caps and replace with the corresponding buffer and wash lines. Make sure
the solvent filter is at the bottom of the bottle and the caps are tight. DO NOT
grasp the tubing below the cap or the solvent filter with bare hands as it may
cause contamination of the buffer.

5. Place the buffer and wash bottles in their appropriate positions on the reservoir

Installation
unit.

Prefilter and Cartridge Installation

Some applications require the use of a prefilter. For systems that will only be
running an application that does not require a prefilter, the prefilter holder should
be removed. If it is not removed the customer will be required to order separate
prefilters, as they are not provided in these kits.

1. Open the cover to the VCS. Locate the column heater in the center of the VCS.
Loosen the thumbscrew and open the cover.

2. Lift the cartridge and prefilter holders (Figure 3-5) out being careful not to bend
the tubing.

702:038 Service Manual 3 -5

 VARIANT II Hemoglobin Testing System

1
1. Cartridge Holder
2
2. Prefilter Holder

Figure 3-5: Cartridge

and Prefilter Holders

3. Grasp the bottom end of the prefilter holder. Grasp the top end and turn
counterclockwise until the two ends are separated. Remove the installed
prefilter. Install the new prefilter from the application to be used by placing it
in the center of the holder. Place the top end back onto the bottom end and
screw together until secure.

4. One end of the cartridge holder moves freely while the other will twist the
tubing when unscrewed. Grasp both ends and turn the free moving end until it
is completely separated from the other end. Remove the dummy cartridge and
save for later use.

5. Install the new cartridge from the application to be used by securely placing it in
one end of the cartridge holder. The arrow on the side of the cartridge points up
in the direction of flow. Place the other end of the cartridge holder over the
cartridge and screw the two ends securely together.

6. Place the prefilter and cartridge holders back into the column heater making sure
the stainless steel tubing is in the grooves. Secure the column heater with the
Installation

thumbscrew. There should be no gaps between the front and back of the
column heater.

Priming the Lines

Prior to shipment the fluid lines within the VCS are filled with a very weak
concentration of phosphoric acid (0.01%). Prime the lines before the first operation
to remove all fluid and air bubbles that may be trapped.

1. Turn the VCS power on. The system will perform a short self-check.

2. Turn the VSS power on. The system will perform an initialization.

3 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

3. In CDM select the Instrument 1 icon at the top left of the screen. Select Return
to Active in the status window. When prompted "Do you want to perform the
automatic warmup operation" select No. The instrument will go into Ready
state. Close the status window by selecting OK.

NOTE: If either the Variant or VSS communication status, in the status

window, says "Not OK" in red, then the communication port for that module
may not be set correctly. Close the status window by selecting OK. Select
MAINTAIN/Instrument and select Make Inactive at the bottom of the screen.
Select either Yes or No when asked about performing a Shutdown. Select
SETUP/Configuration and set the communication ports to the correct settings.
Repeat Step 3. If there is still no communication verify that the cable is
inserted correctly. If using an RJ-45 to RJ-45 cable verify that the end marked
"PC" is connected at the back of the PC.

4. Remove the 25 mL syringe from the accessories box. Place the syringe securely
into either one of the two pump ports. Open the port 1/2 turn counterclockwise.

5. Slowly pull back on the syringe plunger until it is filled to 25 mL. Close the
pump port, remove the syringe and dispose of the fluid.

6. Repeat Steps 4-5 until no bubbles are seen coming from the port.

7. Repeat Steps 4-6 for the other pump port.

Flush the Piston/Seal Wash Port

NOTE: The port will be located below the pump ports on serial numbers

Installation
<11131. All other serial numbers have the port located above and to the left of
Pump A.

1. Remove the 10 mL syringe from the accessories box. Fill the syringe with 10
mL deionized water. Securely insert the syringe into the piston/seal wash port.

2. For serial numbers < 11131 open the wash port 1/2 turn counterclockwise.
Slowly inject all of the water into the port by pushing gently on the syringe
plunger. Close the port. For serial numbers >11132 it is only necessary to insert
the syringe into the port and inject the water.

3. Remove the syringe.

702:038 Service Manual 3 -7

 VARIANT II Hemoglobin Testing System

System Flush

A system flush of all fluid lines is required prior to first operation. The short flush
will take 20 minutes to complete and flushes the buffer and wash lines in both the
VCS and VSS.

1. Select SETUP/Test in CDM. Select the down arrow next to the field Select
New Test and change the test to the application to be run. Acknowledge the
message about making sure the correct reagents and cartridge are in place.

2. Select either the cartridge or reagent radio button. Select Start System Flush at
the bottom of the screen. Select Short flush then OK to begin the flush.

3. When the flush is complete select the Instrument 1 icon at the top left of the
screen. Select Return to Ready. When the instrument status changes to Ready
select OK to close the status window.

NOTE: The 7 port valve will stay in purge position until the system is
returned to Ready state.

Checking Pump Pressures and Leaks

1. Open the MAINTAIN/Instruments window in CDM 3.5. Locate the box

labeled Pump. Check the pressure on Pump A by entering 0 in the %B field.
Set the Flow Rate at the rate defined for the installed cartridge. Refer to the
SETUP/Test/ Edit Test screen for the appropriate test to find the proper flow
rate. Leave the Upper and Lower Pressure Limits at the default settings. Set the
Flow Timer to 5 minutes. Figure 3-6 shows an example of the pump settings.
Installation

Figure 3-6: Pump Settings

3 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

2. Open the front door of the VCS and the column heater.

3. Select Start Flow. Let the pump run for 2-3 minutes and then observe the
pressure reading at the bottom of the screen. The pressure should be stable with
a range of +/- 5% from the mean pressure. If unstable, refer to Section 3.8.

4. Check for leaks at all stainless steel fittings in the VCS, especially the cartridge
and prefilter holders during the remaining time.

5. Check Pump B by changing the %B field to 100. Repeat Step 3 and 4.

6. Close the column heater and front door of the VCS.

7. Select Return to Ready at the bottom of the screen.

Removing Air from the Pumps

Unstable pressure, with no leaks in the fluid path, indicates the presence of air in the
pump. The following procedure should be used to eliminate air from all parts of the
unstable pump.

1. Using the 8 mm and 10mm wrenches, disconnect the stainless steel nuts from
the outlet check valves at the top of the pump. Use the 10 mm wrench to hold
the check valve in place while turning the nut counterclockwise with the 8 mm
wrench. Completely remove the nut and ferrule from the fitting.

2. Open the MAINTAIN/Instruments screen in CDM 3.5. Enter the appropriate

setting for the pump in the %B field (0 for Pump A, 100 for Pump B). Set the
flow rate to 3.0. Leave the default settings for Upper and Lower Pressure Limit.
Set the timer for 1 minute.

Installation
3. Place an absorbent cloth or paper towel under the pump. Select Start Flow. Let
the pump run for 1 minute.

4. Using the wrenches reconnect the outlet lines to the check valves being careful
not to cross thread or over-tighten the fitting. Use a tissue or paper towel to
remove all fluid from around the fitting.

5. Set the flow rate to the flow rate defined for the installed cartridge. Change the
timer setting to 10 minutes. Start the flow. Check for leaks, while the pump is
running, at the outlet check valves by holding a tissue or other thin, absorbent
material up to the fitting. Tighten the fitting further if liquid is absorbed onto
the tissue. Check the pump pressure at the bottom of the screen after the pump
has run almost 10 minutes. If the pressure is still unstable, repeat steps 1-4
above.

702:038 Service Manual 3 -9

 VARIANT II Hemoglobin Testing System

Configuration Fields

Edit the following fields, according to user preference, in SETUP/Configuration

(Figure 3-7) while the system is in Ready state:

System Name - usually includes the serial number of the instrument

Date Format and Separator - default is Month/Day/Year

Unity ID and PC Export Path - for members of the Unity program

LIMS Communication Port - define a port other than 0 only if connected to a

LIMS system

Auto Import from LIMS - select to change from Off to On; used for
downloading additional patient information from LIMS

Instrument Name for Instrument 1 - usually site name

Instrument Name for Instrument 2 - only if 2 systems connected to PC

Auto Report Printing - check to print all data and reports during a run

Automatic LIMS Export - check to upload results automatically when sample

analysis complete

Beep on Alerts - check to hear audible alarm for error messages

Automatic Warm Up - check and set time (24 hour clock) and days of week

Set Barcode - 4 symbologies must be chosen with one being CODE 128 (used
for rack and adapter barcodes provided with the system)
Installation

3 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 3-7: Configuration Screen

Microvial Adapters

1. Remove the microvial adapters and barcodes from the accessories box.

2. Label the adapters with the appropriate barcodes for the application(s) to be

Installation
used.

Hardware Checks

Some parts of the VCS and VSS may need to be checked at time of installation..
These include:

Reagent Tray Level Sensor

2-Way Valve in VCS
Z height for Minimum Dead Volume

Refer to the appropriate part of Section 5 in this manual for details on the
procedure.

702:038 Service Manual 3 -11

 VARIANT II Hemoglobin Testing System

3.4 De-Installation

NOTE: Prior to shipment decontaminate the sample fluid pathway and clean
the sample needle. Refer to the VARIANT II Operation Manual for the
procedures.

The following items are required for shipping a de-installed unit:

Pallet
5-6 Plastic Bags (assorted sizes)
Plastic Coverings (VCS and VSS)
Package Sealing Tape
Strapping material
Plastic wrap

Boxes

VCS (with wooden pallet)

VSS (with wooden pallet)
Monitor
PC (with box for keyboard and mouse)
Printer
Accessories
Reservoir Unit (padded)

1. Remove the buffer and wash bottle lines from their respective bottles. Place the
lines into a container filled with deionized water placed on top of the VSS (not
on the bottles). Cap the buffer and wash bottles but do not remove them from
Installation

the reservoir tray.

2. Perform a Short System Flush. Refer to Section 3.3 - System Flush for the
procedure.

3. Perform the Decontamination procedure from Section 5.6 of the VARIANT II

Operation Manual.

4. Open the MAINTAIN/Instruments screen in CDM 3.5. Select Make Inactive at

the bottom of the screen and select Yes for shutdown. Close CDM 3.5.

5. Remove the buffer and wash bottles from the reservoir tray.

6. Turn off the power on the VCS and VSS. Shut down the computer via the Start
button at the bottom of the screen. Turn off the computer when prompted then
turn off the monitor.

3 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7. Disconnect the communication cables from the VCS, VSS and PC. Disconnect
the reservoir level sense cable. Place all cables in a plastic bag for shipment.

8. Disconnect the power cords from the VCS and VSS and place in a plastic bag
for shipment.

9. Remove the buffer and wash lines from the deionized water and dispose of the
water. Disconnect the buffer and wash lines from the back of the VCS and
VSS. Drain the lines completely and blot the solvent filters on a lint free cloth.
Insert the port plugs, in place at install, into all buffer and wash ports. Place the
lines in a plastic bag for shipment.

10. Disconnect the waste lines from the back of the VCS and VSS. Drain the lines
into the waste container. Disconnect the lines from the waste container and
place them into a plastic bag for shipment. Place the waste port caps, present at
install, on the waste ports at the back of the VCS and VSS.

11. Disconnect the waste level sense cable from the back of the VCS. Remove the
main cap from the waste container and thread the cable through until it clears
the cap. Replace the main cap on the waste container. Place the cable in a
plastic bag for shipment.

12. Remove the secondary cap of the waste bottle. Empty the waste into a sink
designated for biohazard waste. Rinse the empty container with household
bleach followed by deionized water. Place the waste bottle in a plastic bag for
shipment.

13. Remove the reservoir tray from the VSS and place in the foam padded shipping
box. Place the box into the accessories box.

14. Place the waste container along with all the tubing lines and cables from the

Installation
VCS and VSS into the accessories box. Secure the top of the box with package
sealing tape.

15. Remove the needle cover and front bezel cover from the VSS. Re-install the
sampling arm shipping bracket that was removed at installation. Replace the
covers and secure them with tape.

16. Secure the front cover of the VCS with tape.

17. Place the VCS and VSS pallets on the main shipping pallet. The VCS and VSS
require two people to lift them from the counter. Place the VCS and VSS on
their respective pallets. Wrap each with the plastic covers then place the box
covers over the modules. Secure the top to the bottom of each with straps.

702:038 Service Manual 3 -13

 VARIANT II Hemoglobin Testing System

18. Disconnect the keyboard, mouse, printer and monitor cables from the back of
the PC. Disconnect the printer cable from the printer. Place all cables in a
plastic bag for shipment. If the shipment is going by air, the toner cartridge
should be removed from the printer and bagged separately.

19. Disconnect the power cords from the monitor, PC and printer. Place the cables
in a plastic bag for shipment.

20. Place the monitor, printer and PC in their respective boxes. Place the keyboard
and mouse in a box and place inside the box with the PC.

21. Place the cables and power cords from the PC, monitor and printer in the box
with the PC. Secure the top of all boxes with package sealing tape.

22. Place all boxes on top of the VCS and VSS boxes on the pallet. Secure the
boxes together by wrapping them with plastic wrap.
Installation

3 -14 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4.0 VARIANT II Service Software

4.1 Introduction

Service software is a separate application from CDM 3.5. It is used to make

adjustments and alignment changes to both the VCS and VSS and to manually
control both modules. In addition it logs hardware error codes that indicate where a
specific problem exists. These errors may cause non-specific messages in CDM

Service Software
3.5. It is then necessary to access the service software in order to determine the
source of the problem. Refer to Section 7.0 Troubleshooting for a list of the current
error codes.

Each module has its own service software. The current versions are listed below.

VCS: 1.08
VSS: 2.11

NOTE: VCS 1.07 is incompatible with the VARIANT II Compaq Deskpro EN

Slimline computer. All systems with this computer MUST have VCS 1.08
loaded in order to control the VCS. All screens and functionality remain the
same as VCS 1.07. VSS 2.11 service software remains unchanged.

Access either software by selecting the Start button at the bottom of the screen.
Select PROGRAMS/Variant 2 Service and then either VCS 1.08 or VSS 2.11. Both
applications are password protected. Enter the password, all in capital letters,
VARIANT2QC when prompted, after selecting the appropriate software option.

NOTE: CDM 3.5 MUST either be closed or be Inactive in order to use the
COM ports with the service software.

In the service software select the Close button in any open window to close that
option. Multiple windows can be open at any given time. To close the software
select the "x" in the upper, right corner of the Main Menu screen.

702:038 Service Manual 4 -1

 VARIANT II Hemoglobin Testing System

4.2 VCS Service Software

This section describes the various screens and options available in the VCS Service
Software.

Figure 4-1 shows the Main Menu screen. Each option from the Main Menu will be
detailed below. The Tube Volume Option is not used with VARIANT II.

Figure 4-1: VCS

Service Software

Service Software
Main Menu
Options

COMMUNICATION PORT

Before selecting any of the options from the Main Menu the applicable
communication port for the chromatographic station must be selected. The default
setting is port 1. To change to another port select the Now Open button which then
changes to Now Close. All port options are now available. (Figure 4-2) Select the
appropriate port number and then select Now Close. Failure to select Now Close
will result in a communication error that will close out the software.

Figure 4-2:
Communication
Port Settings

NOTE: Port 3 is
the internal
modem for
connecting to
CSN.

4 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

STATUS

There are 2 options in the Status field: Once and /1.0sec. Selecting the Once button
will display the current status of all components in the VCS. Selecting the /1.0sec
button will display an update of the status of all components every second. This
option is useful when monitoring certain components such as pump performance.
Figure 4-3 shows the Status window.

Figure 4-3:
Status

Service Software
Window

The Status window displays the following fields:

ROM Ver.: Obtained from CPU board EPROM

Serial Number: Instrument serial number read from the EEPROM
Tube Volume: Not applicable for VARIANT II
Pump A and Pump B Dip: Dip switch settings on pump board (range 0-30)
Dip switches used to speed up pump movement and
increase flow rate
Pump Activity: Stop or Run
Detector Activity: Status reflects field selected in Detector Option
Raw Data, Zero End or Stop (no activity)
Syringe Activity: Idle or Run
6-port Valve: Inject or Load position
7-port Valve: T-mix, D-mix or Purge position
Syringe Sensor: Home or Not Home
Waste Sensor: Waste level OK or NG (waste full)
Pump Press: System pressure reading obtained from pressure sensor (range 0-350
kg/cm2)
Column Heater: Temperature reading (22 - 50oC)
Degasser Press: Reading from vacuum sensor, converted to an absolute pressure
reading at sea level (400-1000 hpa)

702:038 Service Manual 4 -3

 VARIANT II Hemoglobin Testing System

Degasser Control: Degasser pump is controlled by this value, which is set by pump
command at power up (controlled by 500 if no data)
Limit: On or Off (set in Reservoir option)
Buffer A, Buffer B and Wash Levels: Percent of buffer remaining in bottles (0-
100%)
Error Code: Indication of specific hardware problem
Timeout Stop: Communication timeout detection is On or Off (set in Pump option)

SYRINGE
Service Software

The Syringe option allows for movement of the VCS syringe. Figure 4-4 shows the
Syringe window.

Figure 4-4:
Syringe
Window

Speed: 0-500 Pulses per second (pps) with default of 100 (change value prior to
selecting Start)
Pulse: 0-7200 Pulses (pls) with with 1 µL equaling 2.4pls and a default of 1000
(change value prior to selecting Start)
Direction: Up, Down and Home (change direction prior to selecting Start)
Start: Begins movement in the direction selected.
Stop: Halts movement

4 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

VALVE

The Valve option is used to change the positioning of all valves in the VCS. The
field to set the Column Temperature is also found here. Figure 4-5 shows the Valve
window.

Figure 4-5:
Valve
Window

Service Software
7-port Position: D-mixer (buffer goes through dynamic mixer)
T-mixer (buffer bypasses dynamic mixer)
Purge (buffer goes directly to waste)
6-port: Inject (buffer flows through sample loop)
Load (sample is pulled into sample loop)
2-way Valve: OFF (closed) or ON (open)
3-way Valve: ON (line to wash open)
OFF (line to dilution chamber open)
Column Temperature: Set temperature of column heater (22-50oC)
Control turns heater on, OFF turns heater off

PUMP

The Pump option contains fields for pumps, degasser, dynamic mixer and
communication timeout. Figure 4-6 shows the Pump window.

702:038 Service Manual 4 -5

 VARIANT II Hemoglobin Testing System

Figure 4-6:
Pump
Window
Service Software

Pressure Limit: Set the high and low pressure limits for the system, values apply to
both pumps (range 0 - 350 kg/cm2)
LIMIT SET enters limit changes
Pump A and Pump B: FLOW RATE set in ml/min (range 0.10 - 3.0)
START begins the flow for the selected pump
PUMP STOP halts all pump motion
Degasser Pressure: Setting for degasser (range 400-1000 hpa, default 500)
CONTROL activates the control circuit.
OFF deactivates the control circuit.
Dynamic Mixer: ON (spins the magnet) or OFF (no movement)
Communication Timeout Detection: ON will stop the pump and column heater
automatically when there is no communication for more than 5
minutes between the VCS and PC
OFF turns off this option (pump and column heater remain on) and
results in no communication errors being generated in CDM 3.5
Pressure Compensation: Pressure reading taken every 2.5 seconds with the average
pressure calculated at 10 seconds
Compensated flow rate is calculated, based on the average
pressure and sent to the pump PCB.
Compensation not active with pressure below 10 kg/cm2

4 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

DETECTOR

The Detector option contains fields for checking and setting various detector
parameters. Figure 4-7 shows the Detector window.

Figure 4-7:
Detector
Window

Service Software
Lamp: ON or OFF
A/D Data Check: START (reading every second in µV), value appears in box
STOP to stop the data check
Value 1 Shot: UP or DOWN (adjusts detector A/D in selected direction one shot at
a time – useful when testing autozero function)
Sampling Parameter: RATE in Hz (1, 2, 5 or 10. Usual is 2)
PERIOD of 0-180 seconds
Select START (to begin sampling) or STOP (to halt sampling)
Check Raw Data: Set sampling parameters and start the sampling
Window appears with sampling data
Clear Data: Clears the sampling data buffer (select when detector not working)
Zero 20mV: A/D Auto zero (20 +/- 5 mV adjust)
Wait up to 30 seconds after selecting down

GRADIENT

The Gradient option can be used to create custom gradients in the VCS. Figure 4-8
shows the Gradient window.

702:038 Service Manual 4 -7

 VARIANT II Hemoglobin Testing System

Figure 4-8:
Gradient
Window
Service Software

To set the Gradient Parameters for Time, Flow Rate and %B enter the desired value
and then press Enter on the keyboard to set the parameter.

Time: Start time of gradient step (in seconds)

Flow Rate: Total flow from the pumps (range 0.10 - 3.0 in ml/min)
%B: Percent of Buffer B in the flow rate (range 0 - 100%)
Line set: Creates a step based on the defined Gradient Parameters for Time, Flow
Rate and %B (maximum number of steps is 20)
Clear: Selected step is cleared
All clear: Clears all defined steps
Select after transmitting gradient to set up new data
Data Transmit: Select to transmit programmed steps to VCS (takes about 30
seconds for calculation) and start pumps
Start: Becomes available after transmission is complete and begins the programmed
gradient

LED/BUZZER

The LED/Buzzer option controls all LED and Buzzer functions. Figure 4-9 shows
the LED/Buzzer window.

4 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 4-9:
LED/Buzzer
Window

Service Software
LED-1, LED-2 and LED-3: Main CPU Board ON or OFF
Buzzer: Main CPU Board ON or OFF

RESERVOIR

The Reservoir option is used to adjust level sensing for Buffer A, Buffer B and
Wash. Figure 4-10 shows the Reservoir window.

Figure 4-10:
Reservoir
Window

Level: Calculated levels (in %) for Buffer A, Buffer B and Wash

EEPROM Data: Offset value (displays the set tank adjustment value from the
EEPROM)

702:038 Service Manual 4 -9

 VARIANT II Hemoglobin Testing System

Change: Manually enter the 0 offset in the selected field for each bottle position and
then select to allow adjustment to be stored in EEPROM (Store EEPROM
option becomes available)
Auto Zero: Compensation for the weight of an empty bottle so calculated percent
weight is fluid only (sets all positions at one time)
Stores data to EEPROM automatically
Limit: Limit: ON will automatically restrict levels > 100 to 100% and < 0 to 0%
OFF turns the limit off and keeps calculated values without resetting
them

WARNING: Limit MUST be set to ON when returning to CDM 3.5. CDM

Service Software

does NOT recognize negative values and will interpret them as a level of 100%.

Load EEPROM: Loads the current data stored on the EEPROM

Store EEPROM: Only available if manually setting the offset (Change)
Request Status and /1.0sec: Brings up the Status window

RESET HARDWARE

The Reset Hardware option is used to reset components in the VCS. Figure 4-11
shows the Reset Hardware window.

Figure 4-11:
Reset Hardware
Window

Detector: A/D Sampling is stopped and calibration performed

Pump: Stops pump movement
Injector: Syringe to Home position, 6-port valve to Inject position and 7-port valve
to T-mixer position

4 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4.3 VSS Service Software

This section describes the various screens and options available in the VSS Service
Software.

Figure 4-12 shows the Main Menu screen. Each option from the Main Menu will
be detailed below.

Figure 4-12: VSS

Service Software
Main Menu

Service Software
Options

NOTE: The
Main Menu
screen shows
version 2.10 for
version 2.11

PORT

Select the applicable communication port for the VSS. It is not necessary to close
the current port. If Close is selected before accessing an option a communication
error will occur and the software will close.

NOTE: There are only 6 port options available for the VSS. Port 7 cannot be
used to connect to the VSS in the service software. Port 3 is the internal
modem for access to CSN.

MANUAL

The Manual option controls the movement of all components in the VSS. Figure 4-
13 shows the Manual window.

702:038 Service Manual 4 -11

 VARIANT II Hemoglobin Testing System
Service Software

Figure 4-13: Manual Window

Reset: SAMPLER resets the sample arm and tube holder

RACK resets the rack handlers
Buzz ON OR Buzz OFF: Alarm from Main CPU
Nack Command and Empty Command: Sends a NACK (0x62) or Empty (0x4A)
command to the VSS. Theses are not
normally used for Field Service

Rack Rear: LIMIT moves the rear rack carrier to the far left of the VSS
SIP moves to the next sampling position of a rack under the tube holder
MIXER POS moves to the next mixing position of a rack under the mix
head
RACK CODE moves to the rack barcode read position
HOME moves the rear rack carrier to the far right position of the VSS

Conveyor Left: FORWARD moves the left belt toward the front of the VSS
BACK moves the left belt toward the back of the VSS
STOP halts all movement of the left belt
Conveyor Right: FORWARD moves the right belt toward the front of the VSS
BACK moves the right belt toward the back of the VSS
STOP halts all movement of the right belt

4 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Rack Front: LIMIT moves the front rack carrier to the far left of the VSS
HOME moves the front rack carrier to the far right of the VSS

Mixer: SPIN turns the spin head for 3 seconds in both directions
MID ON turns the spin head at a fast speed
LOW ON turns the spin head at a slow speed
MID/LO OFF turns the spin head off when Mid ON or Low ON is selected

Barcode Reader: READ WITH SPIN moves the barcode reader down while turning
the spin head and then turns barcode reader on (auto stop when
done)

Service Software
READ turns barcode on without movement (auto stop when done)

Mixing Holder: HOLD moves spin head down to hold position

HOLD/SPIN moves spin head down to hold position where it
briefly turns
HOME Returns spin head to uppermost position

Emergency Stop: Halts all VSS movement immediately

Nozzle Y: HOME moves the sample arm to the farthest position at the back of the
VSS
WASH PORT moves the sample arm to the needle wash position of the
dilution chamber
D.WELL moves the sample arm to the dilution well position of the
dilution chamber
TUBE POS moves the sample arm over the needle guide

Tube Holder: HOME moves the tube holder to the upper most position
HOLD moves the tube holder down until spring tension is taken up
after contacting the top of a tube placed underneath. Once the hold
sensor mechanism has moved sufficiently to block the hold
optosensor, the assembly stops.

Nozzle Z

NOTE: Select the appropriate Nozzle Y position before selecting the Nozzle Z
option. Adjust Pos, D. Well and Wash Port are dilution chamber positions.
Primary, Pediatrics and Micro are sample tube positions. DO NOT lower the
needle when in the Y home position as damage to the needle will occur.

HOME moves sample needle to maximum upper position

ADJUST POS moves sample needle to the vertical adjustment position near the top
of the dilution well.

702:038 Service Manual 4 -13

 VARIANT II Hemoglobin Testing System

D.WELL moves the sample needle into the selected position (level for making
sample dilution)
WASH PORT moves the sample needle to the maximum lowest position in the
selected position (level for washing the sample needle)

NOTE: Before moving the sample needle to the Z position for tubes, place the
appropriate tube in a rack and use the Rack Rear option to move the tube to
Sip Position. Then move the Tube Holder to the Hold position to secure the
tube.
Service Software

Primary: SIP moves the needle to the defined position for primary tube sampling
(value set in Adjust menu)
ADJ moves the needle down to the basic sampling height adjustment
position (the top of a Sysmex rack)
PIERCE H moves the needle to the height required to pierce the top of a
100mmtube
PIERCE L moves the needle to height required to pierce the top of a
75mm tube .
Pediatrics: SIP moves the needle to the defined position for pediatric tube sampling
(value set in Adjust menu)
PIERCE moves the needle into the tube until it just clears the cap
Micro: SIP moves the needle to the defined position for microvial sampling (value
set in Adjust menu)

Syringe

All: HOME moves both syringe plungers to their uppermost positions

PRIME moves the sample needle into the dilution well of the dilution
chamber and primes both syringes twice with wash (wash fluid
evacuated from dilution well into waste)
#1 (5ml): HOME moves the 5 mL syringe plunger to the uppermost position
PULL 2000ul moves the 5 mL syringe plunger down to aspirate 2000 µL
PUSH 1000ul moves the 5 mL syringe plunger up to dispense 1000 µL
#2 (1ml): HOME moves the 1 mL syringe plunger to the uppermost position
AIR moves the 1 mL syringe plunger to aspirate air to the defined
position between pinch valves 1 and 2 (value set in the Adjust menu)
PULL 500ul moves the 1 mL syringe plunger down to aspirate 500 µL
PUSH 300ul moves the 1 mL syringe plunger up to dispense 300 µL

Valve 1: AIR changes the position of valve 1 at the top of the syringe assembly to
connect the end of the sample line to the atmosphere.
SYRINGE changes the position of valve 1 at the top of the syringe
assembly to connect the end of the sample line to the syringes.
Valve 2: NEEDLE changes the position of valve 2 at the top of the syringe
assembly to connect the end of the sample line to the syringes.

4 -14 Service Manual 702:038

VARIANT II Hemoglobin Testing System

TANK changes the position of valve 2 to connect the wash/diluent line to

the syringes.
Valve 3: DW changes the position of valve 3 to the dilution well bottom port
DP changes the position of valve 3 to the middle drain port in the dilution
chamber
Valve 4: WP changes the position of valve 4 to the needle wash port in the dilution
chamber
DP changes the position of valve 4 to the middle drain port in the dilution
chamber
Valve 5,6: PRESS changes the position of valves 5 and 6 to apply pressure to the
internal waste tank.

Service Software
VACUUM changes the position of valves 5 and 6 to apply vacuum to the
internal waste tank
Valve 7: OUT changes the position of valve 7 to connect the internal and external
waste tanks.
IN changes the position of valve 7 to connect the internal waste tank to the
dilution chamber bottom ports.
V.Pump: ON turns the vacuum pump on
OFF turns the vacuum pump off
VACUUM changes the position of valves 5, 6 and 7 to apply vacuum to
the internal waste tank for waste removal from the dilution chamber
bottom ports and turns the vacuum on.
PRESS changes the position of valves 5, 6 and 7 to apply pressure on the
internal waste tank for waste removal to the external waste tank and turns
the vacuum on.

702:038 Service Manual 4 -15

 VARIANT II Hemoglobin Testing System

ADJUSTMENT

The Adjustment option is used to control and make adjustments to the components
of the VSS. Figure 4-14 shows the Adjustment window.
Service Software

Figure 4-14: Adjustment Window

The numeric field for each component is the step count to that position. When
redefining the position of any component, move the component to home position
before entering the new step count.

Section 6.0 of this manual covers all adjustment procedures for the VSS.

EEPROM: RELOAD FROM EEPROM reloads the stored data from the EEPROM
STORE DATA TO EEPROM saves displayed values in the software to
the EEPROM.
CLEAR RAM DATA clears all the fields in the adjustment window and
resets them to zero

Emergency Stop: Halts all component movement immediately

Set S/N: Enter the serial number of the VSS in the field below and select this option
to enter the value. This is critical, as a zero entry will code for instrument
dimensions only present in pre-production units.

4 -16 Service Manual 702:038

VARIANT II Hemoglobin Testing System

SY1 (5ml) and SY2 (1ml): Field contains the step value (0.006mm = 1 step or 167
steps/mm) for the adjusted home position of each syringe
plunger.
HOME moves the selected plunger first to the optical
home and then adjusts the position depending on the
entered value (increasing the step value moves the
plunger down while decreasing the step value moves the
plunger up)

Syring2: PRIME performs 2 primes of each syringe

PULL AIR activates the sample syringe (1 mL) to aspirate air to the

Service Software
defined position between pinch valves 1 and 2 (increasing the step value
moves the remaining liquid towards pinch valve 2, decreasing the step
value moves the liquid away from pinch valve 2)

Y-axis: Y_HOME moves the sample arm to the maximum position toward the back
of the VSS
WASH PORT moves the sample arm to the defined needle wash port
position (increasing the step value moves the needle toward the front while
decreasing the step value moves the needle toward the back) (10 steps / mm)
SAMPLING POSITION moves the sample arm to defined position over the
needle guide (decreasing the step value to a more negative number moves
the needle toward the back while increasing it to a more positive number
moves it toward the front)

Z-axis: Z_HOME moves the sample arm to its upper most position
WASH PORT ADJ POS moves the sample needle to the defined adjust at
the needle wash port in the dilution chamber (increasing the step value
moves the needle down) (100 steps / mm)
SAMPLING ADJ POS moves the sample needle to the defined adjust
position through the needle guide to the height of a rack (increasing the step
value moves the needle down)
EXPAND opens the Expanded Needle Height Adjustment window (Figure
4-15)
Left Conv: FORWARD moves the left belt toward the front of the VSS
BACK moves the left belt toward the back of the VSS
STOP halts movement of the left belt
Right Conv: FORWARD moves the right belt toward the back of the VSS
BACK moves the right belt toward the front of the VSS
STOP halts movement of the right belt

NOTE: The Forward and Back motion of the right belt is the opposite of the
movement created in the Manual Menu. The Adjustment Menu options reflect
the direction of movement of a rack during a sample run.

702:038 Service Manual 4 -17

 VARIANT II Hemoglobin Testing System

Front Carriage: LIMIT moves the front rack carrier to the defined position

HOME moves the front rack carrier to the defined position (making
these numbers more positive will move the carriage position to the
left, more negative will move the carriage to the right – 10 steps /
mm)

Rear Carriage: LIMIT moves the rear rack carrier to the defined position

HOME moves the rear rack carrier to the defined position (making
these numbers more positive will move the carriage position to the
Service Software

left, more negative will move the carriage to the right – 10 steps /
mm)

SAMPL POS moves the rack to the defined sampling position under
the tube holder (making this number more positive will move the
carriage position to the left, more negative will move the carriage to
the right – 10 steps / mm). Each additional selection of this option
moves the rack to the next sampling position

SAMPLE HEAD CONTROL opens the Sampling Head Control

window (Figure 4-16)

SPINNING POSITION moves the rack to the defined sampling

position under the spin head (increasing the step count moves the
position to the left). Each additional selection of this option moves
the rack to the next sampling position

SPIN HEAD CONTROL opens the Spinning Head Control window

(Figure 4-17)

BARCODE (RACK) moves rack to the rack barcode step position

(increasing the step count moves the position to the left)

BARCODE TERM opens the Barcode Terminal window (Figure 4-

18)

4 -18 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Expanded Needle Height Adjustment

The Expanded Needle Height Adjustment window is used to set the Z-axis sipping
positions of all sample tubes to be used. It also allows control of the Tube Holder
and the sampling arm Y-axis movement. Select Expand in the Z-Axis field to open
the window. Figure 4-15 shows the Expanded Needle Height Adjustment window.

Service Software
Figure 4-15: Expanded Needle Height Adjustment Window

The fields below the Micro Tube, Pediatric Tube and Primary Tube options indicate
the sample aspiration position of each tube type. Selecting the option lowers the
tube holder to the top of the tube and moves the sample needle to the defined Z
position. Select Z_Home to raise the needle, Tube Holder Up to raise the tube
holder and Y_Home to move the sample arm to home position when done.
Decreasing the step value raises the sample needle to a higher position. Note: all
three positions are based on the basic Z sampling position and will move if the basic
setting is changed.

Sampling Head Control

The Sampling Head Control window contains options for moving the sample arm in
the Y direction (Home or Sample Position), the sample needle in the Z direction
(Home or Adjust Position) and the Tube Holder (Up or Down). Figure 4-16 shows
the Sampling Head Control window.

702:038 Service Manual 4 -19

 VARIANT II Hemoglobin Testing System

WARNING: There is NO Emergency Stop option in this window. Use caution

when verifying functions in this window.

Figure 4-16:
Sampling Head
Control
Window
Service Software

Spinning Head Control

The Spinning Head Control window contains options for moving and setting the Z
position of the spin head. Figure 4-17 shows the Spinning Head Control window.

WARNING: There is NO Emergency Stop option in this window. Use caution

when verifying the functionality of the spin head with a tube in place.

Figure 4-17: Spinning Head Control Window

Slow Spinning: SLOW SPIN turns the spin head slowly

SLOW STOP halts the movement of the spin head

Up: Moves the spin head to the home position

4 -20 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Down: Moves the spin head to the defined position (increasing the step count
lowers the mix head assembly – 100 steps / mm)
Spinning Down: Turns the spin head and lowers it to the defined position
Spinning (3sec 1000rpm): Turns the spin head in each direction at 1000 rpm for 3
seconds

Barcode Terminal

The Barcode Terminal window contains options for checking the barcode reader.
The field shows the barcode identification and the percent read. Figure 4-18 shows
the Barcode Terminal window.

Service Software
Note: The Barcode Label Specifications for VARIANT II can be found in
Appendix A.

Figure 4-18:
Barcode
Terminal
Window

WARNING: There is NO Emergency Stop option in this window. Use caution

when verifying functions in this window.

Communication Mode: Automatically changes to ASCII when a read option is

selected
Rear Rack Home: Moves rack to home position
Barcode Terminal: READING PERCENT (RACK ID) moves the rack to the rack
barcode position and then reads the barcode
SCAN COUNTS (SAMPLE ID) moves the rack to the next
mixing position and then spins the primary or pediatric tube to
read the barcode.

702:038 Service Manual 4 -21

 VARIANT II Hemoglobin Testing System

PERCENT (MICRO VIAL) moves the rack to the next mixing

position and reads the barcode from the tube adapter.
Quit: Halts any read in progress and moves the spin head home

SENSOR STATUS

The Sensor Status window allows the user to check the status of tube, rack and
waste sensors. In addition it also shows the ROM version, Rack and Sampler Error
Codes and Vacuum Pump Status. To obtain the status of these components select
Check Status at the top of the screen. Figure 4-19 shows the Sensor Status window.
Service Software

Figure 4-19: Sensor Status Window

BARCODE

The Barcode window contains options for reading a Sample ID or Rack ID. When
either option is selected the information from the barcode appears in the field to the
right of the Barcode Data field. There are also options for moving Rear Rack Home
and Terminal which opens the Barcode Terminal window (Figure 4-18). Figure 4-
20 shows the Barcode window.

WARNING: There is NO Emergency Stop option in this window. Use caution

when verifying functions in this window.

4 -22 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 4-20:
Barcode
Window

Service Software

702:038 Service Manual 4 -23

 VARIANT II Hemoglobin Testing System
Service Software

4 -24 Service Manual 702:038

VARIANT II Hemoglobin Testing System

5.0 VCS Adjustment Procedures

5.1 Introduction
This section describes the procedures required to adjust the VCS module. Refer to
section 8.0 for the maintenance schedule and checklist.

VCS Adjustment Procedures

Review Section 4 before beginning the adjustment procedures, as they require a
working knowledge of the VCS service software.

5.2 Column Heater

Column heater control circuit adjustment requires the following items:

Digital Voltmeter (DVM)

Digital Thermometer
Temperature Calibration Resistors (270-2208)
100.78 ohm-0.1% (2oC)
119.40 ohm-0.1% (50oC)
1. Remove the VCS cover.
2. Connect the DVM to "Temp" and "AG" (analog ground) on the Main CPU
board. (Figure 5-1)
3. Zero Adjustment (2oC): Disconnect the sensor cable at CN38 on the column
heater connect PCB (#249). Connect the 100.78 ohm resistor to CN38.
4. Adjust TR 1 on the VCS CPU board until the output voltage of "Temp" is
160mV +/- 3mV (Figure 5-1)
5. Scale Adjustment (50oC): Replace the 100.78 ohm resistor with the 119.40
ohm resistor.
6. Adjust TR 2 on the VCS CPU board until the output voltage of "Temp" is
3.910V +/- 3mV. (Figure 5-1)
7. Repeat steps 2 through 5 until the voltages are within the specified limits.
8. Reconnect the sensor cable to CN38.
9. Verify the temperature is calibrated correctly, for the assay in use, using a
digital thermometer. Place the probe in the groove, apply a small amount of
thermal compound to ensure good thermal properties, and close the door.
Allow adequate time for equilibration. The reading must be within 1 degree
of the CDM display. The display in CDM is in whole numbers only. Any
decimal reading will display in CDM as the lowest whole number.

702:038 Service Manual 5 -1

 VARIANT II Hemoglobin Testing System

Figure 5-1:
Column Heater
Adjustment

CN38
VCS Adjustment Procedures

AG
TR1
TR2
TEMP
DG
1MIX-F
11 M
TR3

5.3 Degasser

Adjustments to the degasser board require the following items:

Digital Voltmeter (DVM)

Vacuum Gauge

1. Open VCS Service Software.

2. Select the Pump option. Under the Degasser field select OFF. (Figure 4-6)

5 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

3. Remove the black plug at the degasser vent port while pressing down on the blue
collar. (Figure 5-2)

Figure 5-2:
Degasser
Vent Port

VCS Adjustment Procedures

1 1. Blue Collar

2. Black Plug

4. Attach the DVM to the degasser board; TP2 is ground and TP1 is signal.

5. Adjust TR1 until the meter reads 0 V.

6. Attach a vacuum gauge to the degasser vent port. Degasser testing assembly
270-2266 may be used.

7. In the VCS Service Software degasser field, set the value to 400 hPa and enter
the change by selecting <Enter> on the keyboard.

8. Select the CONTROL option under the degasser field. Once the vacuum pump
stops, click OFF.

9. If the elevation at the site is above 300 meters (1000 ft), consult Table 5-1
below to determine the Desired Degasser Vacuum (DDV) before proceeding to
step 10. Below 300 meters, the setting is 513 hPa.

702:038 Service Manual 5 -3

 VARIANT II Hemoglobin Testing System

ELEVATION ELEVATION DESIRED ATMOSPHERIC ATMOSPHERIC ATMOSPHERIC

(Meters) (Feet) DEGASSER PRESSURE PRESSURE PRESSURE
VACUUM (hPa) (mmHg) (in.Hg)
(hPa)

0 0 513 1013 760 29.92

152 500 499 999 749 29.50
305 1000 485 985 739 29.08
457 1500 470 970 728 28.66
VCS Adjustment Procedures

610 2000 456 956 717 28.24

762 2500 442 942 707 27.82
914 3000 428 928 696 27.40
1067 3500 414 914 685 26.99
1219 4000 399 899 675 26.57
1372 4500 385 885 664 26.15
1524 5000 371 871 653 25.73
1676 5500 357 857 643 25.31
1829 6000 343 843 632 24.89
1981 6500 328 828 622 24.47
2134 7000 314 814 611 24.05
Table 5-1: Degasser Settings for Elevations Over 300 Meters

NOTE: Table 1 in Appendix A shows the correlation between the A/D Converter
values, hPa, mmHG and Voltages.

10. Using the bleeder valve in the testing assembly, reduce the vacuum in the
chamber to equal the DDV. Close the valve.

11. Adjust TR2 to obtain 2.443 V on the DVM. Using the bleeder valve in the
testing assembly, reduce the vacuum in the chamber further. Close the valve.

12. Change the set point back to 500, select <Enter> on the keyboard. Select the
CONTROL option.

13. Wait until the vacuum pump stops and check the vacuum level. If it is not
within 10 hPa of the DDV, repeat from step #6 onward.

14. Remove the vacuum gauge and replace the black plug. Remove the leads to the
DVM.

5 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

5.4 Pump System

Adjustments to the pump board require the following items:

Digital Volt Meter (DVM)

Pressure Gauge or Digital Pressure Meter (range 0 - 5000 PSI)
Pressure Regulator or coil of Stainless Steel Tubing (I.D. 0.25 mm and length
of 40 meters)
5 mL Volumetric Flask

VCS Adjustment Procedures

Stop Watch

System Setup

1. Connect the inlet line of the Pressure Gauge at the top of the T fitting located in
front of the Pressure Sensor. (Figure 5-3)

Figure 5-3: T
Fitting at
Pressure
Sensor

2. Connect the Pressure Regulator or Stainless Steel Tubing to the outlet line of the
Pressure Gauge. Position the end over a waste container.

3. Open the VCS Service Software. Select the Pump option. Select Stop Pump
(Figure 4-6).

NOTE: When testing is complete remove the pressure gauge and reconnect all
tubing to its original location.

702:038 Service Manual 5 -5

VARIANT II Hemoglobin Testing System

Prime the Pumps

1. Attach a 25 mL syringe to the Pump A purge valve located directly below the
pump. Loosen the plastic fitting and slowly pull back on the syringe plunger to
fill the syringe. Repeat until no bubbles are seen coming from the valve.

2. In the Pump screen enter 2.0 in the flow rate field for Pump A and select Start.

3. Select Status /1.0 from the VCS Service Software Main Menu. Observe the

VCS Adjustment Procedures

pump pressure reading for at least 30 seconds and verify that the pressure is
stable (+/- 5%). (Figure 4-3) Select Stop Pump in the Pump screen when done.
If the pressure is unstable repeat step 4 or refer to Section 3.3 Removing Air
from the Pumps for more information. Recheck the pump pressure.

4. Repeat steps 4-6 for Pump B.

5. Leave the Pump and Status windows open.

5.4.1 Zero Pressure Adjustment

1. Remove the pump service panel from the back of the VCS. The pump board is
located behind this panel

2. In the Pump menu verify that the pumps are stopped. Briefly open the
connection at the T fitting shown in Figure 5-3.

3. Attach the ground probe of the DVM to TP4 and the signal probe to TP11 on
the pump board (No. 244). If your DVM has an averaging function you may
want to use it, as the voltage is not terribly stable.

4. The measured voltage between TP11 and TP4 must be 0.0 + 1.0 mV.

5. Adjust VR3 on the pump board if the measured voltage is not within the
specified range.

6. Verify that the pump pressure reading is 0 kg/cm2 in the Status window.

7. Leave the probes attached to the test points on the board and proceed with the
High Pressure Calibration.

5 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

5.4.2 High Pressure Calibration

1. Attach the ground probe of the DVM to TP4 and the signal probe to TP11 on
the pump board (No. 244).

2. Set the flow rates for Pump A and Pump B at 1.0 mL/min. Start both pumps.

3. If using a pressure regulator adjust it until the pressure gauge reads about 1000
+ 5% PSI (approx. 70.32 + 5% kg/cm2).

VCS Adjustment Procedures

4. If using a stainless steel tubing coil adjust the pump flow rates until the pressure
gauge reads about 1000 + 5% PSI (approx. 70.32 + 5% kg/cm2).

5. The measured voltage between TP11 and TP4 must be 330 mV + 5%.

6. Adjust VR4 on the pump board if the measured voltage is not within the
specified range.

7. Verify that the pump pressure reading on the pressure gauge matches the
reading in the Status window.

Table 1 in Appendix A shows the Voltage Reading between TP11 and TP4 at
various pressures.

5.4.3 Pump Drive Current Adjustment

Pump A

1. Attach the ground probe of the DVM to TP0 and the measuring probe to the
"top leg" of R20 on the pump board (No. 244). Refer to Figure 5-4 for proper
placement.

2. Set the flow rate for Pump A at 2.0 mL/min. Start the pump.

3. The voltage must be between 0.55 V and 0.65 V. Adjust VR1 if it is not within
the specified limits.

Pump B

1. Attach the ground probe of the DVM to TP0 and the measuring probe to the
"top leg" of R21 on the pump board (No. 244). Refer to Figure 5-4 for proper
placement.

2. Set the flow rate for Pump B at 2.0 mL/min. Start the pump.

702:038 Service Manual 5 -7

 VARIANT II Hemoglobin Testing System

3. The voltage must be between 0.55 V and 0.65 V. Adjust VR2 if it is not within
the specified limits.

Figure 5-4:
Pump
Current Test
Points
VCS Adjustment Procedures

5.4.4 Pump Flow Rate Adjustment

Flow Rate Adjustment Switches

The flow rate adjustment switches are located on the pump board. The DSW1
switch array consists of 8 switches. Switches 1-4 regulate Pump A and switches 5-
8 regulate Pump B. Figure 5-5 shows the DSW1 Switch Array with all switches in
the off position.

1 2 3 4 5 6 7 8

Figure 5-5: Pump Board Switch Array

5 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Flow Rate Measurement

Flow rate measurements must be done with the cartridge in place to provide back
pressure. This will provide a measurement that mimics actual operating conditions.

The flow rate measurement requires the following tools:

Decon Tubing (P/N 270-2318)

5mL Volumetric Flask

VCS Adjustment Procedures

Stop Watch

Pump A

1. Verify that switches 1 through 4 of the DSW1 Switch Array on the pump board
are in the OFF position.

2. Using the Service Software, set the flow rate for Pump A at 2.0 mL/min. Start
the pump.

3. Open the Status /1.0 window and monitor the pressure for at least 30 seconds.
If the pressure fluctuation exceeds 5%, purge the pump or do other required
pump repairs before continuing. Pump pressure must be steady for flow rate
measurements to be meaningful.

4. In the pump screen of the service software select ON next to the field for
Pressure Compensation (Figure 4-6).

5. Allow the pump pressure to stabilize for 2-3 minutes.

6. Install the decon tubing at the outlet of the cartridge holder. (Figure 5-6)

Figure 5-6:
Tubing Setup for
Flow Rate
Measurement

702:038 Service Manual 5 -9

 VARIANT II Hemoglobin Testing System

Hold the line with one hand and observe that the drops flow freely from the end.
Start the stopwatch after a drop falls from the end of the line and then place the
5 mL flask under the flow to start collecting at the next drop. Make sure the
line is against the inside neck of the flask. (Figure 5-7)

Figure 5-7:
Tubing in
Flask
VCS Adjustment Procedures

Stop the watch when the meniscus (bottom of the fluid line) is even with the 5
mL line on the flask. (Figure 5-8) Note the time in seconds.

Figure 5-8:
Meniscus of
Liquid in
Flask

7. Dry the flask thoroughly inside and repeat the measurement step 6. If the second
measurement is within 1 second of the first, average the 2 times and proceed to
step 8. If not, repeat step 6 until 2 times are within 1 second of each other.
Average the 2 closest times and continue with step 8.

5 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

8. Calculate the flow rate of the pump using the following formula:

Actual Flow Rate (mL/min) = Set Flow Rate x Expected time to fill flask
(seconds)/Actual time to fill flask (seconds)
Example using 5 mL flask at 2 mL/minute: Actual Flow Rate = 300/X seconds

X is the time in seconds to fill the 5 mL flask.

9. Calculate the accuracy error using the following formula:

VCS Adjustment Procedures

Per cent Accuracy Error = [(FA/FS) -1] X 100
FA is the average measured flow rate.

FS is the set flow rate (e.g. 2.0).

10. If the error is negative, make sure that pump pressure is still stable and that
pressure compensation was turned on and there are no leaks. Bypass the 6 and 7
port valves and re-do the flow rate measurement. Pump error is generally
between 0.0% and +2.0% under these conditions. If the error is reproducibly
below 0% with compensation turned ON and stable pressures, set switches 1-4
accordingly to boost the flow rate for Pump A as shown in Table 5-2. Figure 5-6
shows an example of several switch settings.

11. If the percent accuracy is outside the range the flow rate can not be fully
corrected and the procedure should be repeated. If the accuracy is still not
within the specified limits further correction to the pump will be necessary.

Pump B

1. Verify that switches 5 through 8 of the DSW1 Switch Array on the pump board
are in the OFF position.

2. Using the Service Software, set the flow rate for Pump B at 2.0 mL/min. Start
the pump.

3. Open the Status /1.0 window and monitor the pressure for at least 30 seconds.
If the pressure fluctuation exceeds 5%, purge the pump or do other required
pump repairs before continuing. Pump pressure must be steady for flow rate
measurements to be meaningful.

4. In the pump screen of the service software select ON next to the field for
Pressure Compensation (Figure 4-6).

5. Allow the pump pressure to stabilize for 2-3 minutes.

702:038 Service Manual 5 -11

 VARIANT II Hemoglobin Testing System

6. Install the decon tubing at the outlet of the cartridge holder. (Figure 5-6) Hold
the line with one hand and observe that the drops flow freely from the end.
Start the stopwatch after a drop falls from the end of the line and then place the
5 mL flask under the flow to start collecting at the next drop. Make sure the
line is against the inside neck of the flask. (Figure 5-7) Stop the watch when
the meniscus (bottom of the fluid line) is even with the 5 mL line on the flask.
(Figure 5-8) Note the time in seconds.

7. Dry the flask thoroughly inside and repeat the measurement step 6. If the second
VCS Adjustment Procedures

measurement is within 1 second of the first, average the 2 times and proceed to
step 8. If not, repeat step 6 until 2 times are within 1 second of each other.
Average the 2 closest times and continue with step 8.

8. Calculate the flow rate of the pump using the following formula:

Actual Flow Rate (mL/min) = Set Flow Rate x Expected time to fill flask
(seconds)/Actual time to fill flask (seconds)

Example using 5 mL flask at 2 mL/minute: Actual Flow Rate = 300/X seconds

X is the time in seconds to fill the 5 mL flask.

9. Calculate the accuracy error using the following formula:

Per cent Accuracy Error = [(FA/FS) -1] X 100

FA is the average measured flow rate.

FS is the set flow rate (2.0).

10. If the error is negative, make sure that pump pressure is still stable and that
pressure compensation was turned on and there are no leaks. Bypass the 6 and 7
port valves and re-do the flow rate measurement. Pump error is generally
between 0.0% and +2.0% under these conditions. If the error is reproducibly
below 0% with compensation turned ON and stable pressures, set switches 1-4
accordingly to boost the flow rate for Pump A as shown in Table 5-2. Figure 5-9
shows an example of several switch settings.

11. If the percent accuracy is outside the range the flow rate can not be fully
corrected and the procedure should be repeated. If the accuracy is still not
within the specified limits further correction to the pump will be necessary.

5 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Table 5-2:
Pump Board % Switches to be Switches to be
DSW1
Switch Increas Turned on for Turned on for
Settings e Pump A Pump B
0.2 1 5
0.4 2 6
0.6 1,2 5,6

VCS Adjustment Procedures

0.8 3 7
1.0 1,3 5,7
1.2 2,3 6,7
1.4 1,2,3 5,6,7
1.6 4 8
1.8 1,4 5,8
2.0 2,4 6,8
2.2 1,2,4 5,6,8
2.4 3,4 7,8
2.6 1,3,4 5,7,8
2.8 2,3,4 6,7,8
3.0 1,2,3,4 5,6,7,8

Figure 5-9: Switch Settings

5.5 Dynamic Mixer

Adjustments to the Dynamic Mixer require the following items:

Frequency Counter or Digital Voltmeter (DVM) with frequency function

1. Remove the cover from the VCS.

702:038 Service Manual 5 -13

 VARIANT II Hemoglobin Testing System

2. Open the VCS Service Software and select the Pump option. Select OFF in the
Dynamic Mixer field to stop all movement in the mixer. (Figure 4-6)

3. Attach the ground probe of the DVM to DG and the signal probe to MIX-F on
the Main CPU board. Refer to Figure 5-1 for test point locations.

4. Select ON in the Dynamic Mixer field of the pump screen.

VCS Adjustment Procedures

5. The frequency of the mixer should be 2000 + 100 Hz.

6. Adjust the frequency at TR3 on the Main CPU board if the frequency is not
within the specified range.

7. Select OFF in the Dynamic Mixer field of the pump screen to stop the
movement in the mixer.

NOTE: It is common for the mixer to stop during the adjustment to the
frequency. Turn the mixer off and back on again to continue.

5.6 6 Port and 7 Port Valve Check

Mechanical and board adjustments are not performed for the 6 port and 7 port
valves. Only the movement of these valves can be checked from the VCS service
software.

1. Open the VCS service software. Select the Valve option from the main menu.

2. Open the Status /1.0 option from the main menu.

3. Select the D-mixer position in the 7 port position field of the Valve screen.
(Figure 4-5) Listen for the sound as the valve position changes. Note the
position in the 7-port valve field of the Status screen. The field will say D-mix.

4. Select the T-mixer position and listen as the position changes to verify
movement. The 7 port valve field of the Status screen will say T-mix.

5. Select the Purge position and listen as the position changes to verify movement.
The 7 port valve field of the Status screen will say Purge.

6. If no movement is heard, the Error Code field of the Status screen should
display 0x16. It will then be necessary to troubleshoot the valve. A complete
list of Error Codes can be found in Section 9.0 Troubleshooting.

5 -14 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7. Select the Load position in the 6 port position field of the Valve screen. Listen
for the sound as the valve position changes. The 6 port valve field in the Status
screen will say Load.

8. Select the Inject position and listen as the position changes to verify movement.
The 6 port valve field in the Status screen will say Inject.

9. If no movement is heard, the Error Code field of the Status screen should
display 0x09. It will then be necessary to troubleshoot the valve. A complete

VCS Adjustment Procedures

list of Error Codes can be found in Section 8.0 Troubleshooting.

5.7 Syringe Check

This procedure checks the movement of the syringe plunger in the VCS.

1. Open the VCS service software. Select the Syringe option from the main menu.

2. Open the Status /1.0 option from the main menu.

3. Enter the values below in the Speed and Pulse fields of the Syringe screen.
(Figure 4-4)
Speed: 500
Pulse: 7200

4. Select Down in the position field of the Syringe screen. Select Start to begin the
movement. The syringe plunger will move down at the speed and to the extent
defined. The Syringe Sensor field of the Status screen will display Not Home
and the Syringe Activity field will display Run. If no movement is observed the
Error Code field of the Status screen will display 0x08. It will then be necessary
to troubleshoot the syringe movement.

5. Select Home in the position field of the Syringe screen. Select Start to begin the
movement. The syringe plunger will move upward to home position. Once
Home position has been reached the Syringe Sensor field of the Status screen
will display Home and the Syringe Activity field will display Idle. If Home
position cannot be reached the Error Code field of the Status screen will display
0x07. It will then be necessary to troubleshoot the syringe home position.

6. Repeat Steps 4 and 5 and observe that the syringe plunger moves smoothly.

702:038 Service Manual 5 -15

 VARIANT II Hemoglobin Testing System

5.8 Reservoir Unit

Adjustments to the Reservoir Unit board require the following items:

Digital Voltmeter (DVM)

18 microvial adapters
2.0 L full tank (filled with buffer or water)

Verify that the sensor cable is connected at the back of the reservoir unit and also at
VCS Adjustment Procedures

the back of the VCS.

Remove the rear panel from the reservoir unit to access the board (N0. 251). Refer
to Appendix E for the layout of the Reservoir board to identify test point locations.
Table 5-3 shows the Check Pin and Adjust Points for all trays on the reservoir unit.

Tray Check Pin Zero Adjust Point Scale Adjust Point

Buffer A TP4 and TP0 VR1 VR4
Buffer B TP5 and TP0 VR2 VR5
Wash TP6 and TP0 VR3 VR6
Table 5-3: Reservoir Board Adjustment Points

Buffer A Tray

1. Attach the ground probe of the DVM to TP0 and the signal probe to TP4 on the
board.

2. To set the Zero Adjustment remove the Buffer A bottle from the tray (position
closest to the front of the VSS). Adjust VR1 on the board to 53 + 3 mV.

3. To set the Scale (gain) Adjustment place a full 2.0 L bottle on the Buffer A
Tray. Adjust VR4 on the board to 571 + 5 mV.

4. Repeat Steps 2 and 3.

Buffer B Tray

1. Remove the signal probe from TP4 and attach it to TP5.

2. Repeat Steps 2-4 from the Buffer A Tray procedure using the Buffer B Tray
(middle position). The Zero Adjustment is done using VR2 and the Scale
Adjustment is done using VR5.

5 -16 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Wash Tray

1. Remove the signal probe from TP5 and attach it to TP6.

2. Repeat Steps 2-4 from the Buffer A Tray procedure above using the Wash Tray
(position closest to the back of the VSS). The Zero Adjustment is done using
VR3 and the Scale Adjustment is done using VR6.

VCS Adjustment Procedures

Auto Zero Function

Auto Zero must be performed after adjustments to the trays are complete.

NOTE: The Auto Zero function is able to cancel a weight sensor error of -8%
to +10% thus maintaining the reservoir unit quickly without hardware
adjustment.

1. Remove all bottles from the reservoir unit trays.

2. Place 6 microvial adapters on each tray.

3. Select OFF in the Limit field of the Reservoir Adjustment screen.

4. Select Auto Zero from the Reservoir Tank Adjustment screen. The values are
stored in the EEPROM automatically and the fields for all positions display -
6%. This procedure is required in order for CDM to stop the pumps before they
run dry. Note: An empty bottle weighs 6%, strain gauge accuracy is +10% and
CDM doesn’t stop the pumps until 3%, hence the need to add an additional 6%
(the microvial adapters) to the offset.

5. Check the empty tray levels: Remove all microvial adapters from the trays.
Reported levels for Buffers A, B and Wash should be -12 + 2%.

6. Check the full tray levels: Check each tray with the full 2.0 L bottle. The
reading in the Level field must be 94 + 2%.

7. Select ON in the Limit field of the Reservoir Adjustment screen.

NOTE: Failure to turn the limit ON before closing the service software will
cause CDM 3.5 to interpret a negative level sensing value as 100% and no level
sense warning messages will appear when the buffer levels are low.

702:038 Service Manual 5 -17

 VARIANT II Hemoglobin Testing System

5.9 Detector

Detector Board Adjustment

This procedure is required when replacing the Detector Board, Optical Unit or the
Lamp.

Adjustments to the Detector board require the following items:

VCS Adjustment Procedures

Flow Cell Cleaning Kit (P/N 2700197)

Digital Voltmeter (DVM) set to Voltage

1. Follow the procedure in the Flow Cell Cleaning Kit to thoroughly clean the flow
cell.

2. Prime the fluid lines through the detector with 100% Buffer B by using either
CDM 3.5 (MAINTAIN/Instruments) or the VCS service software pump option.

3. Turn off the power to the VCS and remove the main cover.

4. Remove the top (brass) cover. Remove the cover over the detector board.
Refer to Figure 5-10 for the location of the detector board.

2
1. Detector Bench

2. Detector Board

Figure 5-10: Detector Board Location

5. Move the shorting block of JMP3 on the detector board from 2-3 to 1-2.

6. Turn on the power to the VCS.

5 -18 Service Manual 702:038

 VARIANT II Hemoglobin Testing System

7. Attach the DVM to TP7 and TP 8 (GND). Measure the lamp supply voltage. If
it is not 5.50 Volts, adjust using VR-12.
8. Set the flow rate at 1.0 mL/min and start Pump B.

9. Attach the ground probe of the DVM to TP0 and the signal probe to TP4 on the
board. Record the reading in volts. Stop the pump. If the voltage changes by
more than 0.05V, remove the air from the flow cell.

10. Remove the signal probe from TP4 and attach it to TP5. Record the reading in

VCS Adjustment Procedures

volts. Figure 5-11 shows the layout of the detector board.

Figure 5-11:
Detector
Board
Layout

11. Both TP4 and TP5 should fall between 3.0 and 7.0 V. The recommended
voltage is 5.0 V.

12. Adjust TP4 using VR3 and TP5 using VR6 until TP4 and TP5 match as closely
as possible. The allowable voltage difference between the 2 test points is + 0.05
V.

Table 5-4 shows an example of balancing the 2 test points.

Table 5-4:
Detector
Test Point Measured Adjust At Adjusted Voltage Board
Voltage Adjustments
TP4 4.81 V VR3 5.00 V
TP5 5.25 V VR6 5.02 V

13. Return the shorting block of JMP3 to 2-3.

14. Replace the cover over the board.

702:038 Service Manual 5 -19

 VARIANT II Hemoglobin Testing System
VCS Adjustment Procedures

5 -20 Service Manual 702:038

VARIANT II Hemoglobin Testing System

6.0 VSS ADJUSTMENT PROCEDURES

6.1 Alignment Tools

The VSS alignments require the use of 6 alignment tools. Figure 6-1 shows the
alignment tools and their function.

VSS Adjustment Procedures

1. Vertical Alignment Tool (P/N 2702286) vertically aligns the sample
needle and spin head

2. Dummy Rack (P/N 2702288) aligns the tube sensors, rack carrier
fingers, needle guide, and the rack vertical guide plates

3. Conveyor Tool (P/N 2702289) aligns the side guide rails of the conveyor
belt

4. Rear Guide Tools (P/N 2702287) aligns the rear rack guide rails

5. Centering Tool (P/N 2702290) aligns the spin head over a sample tube

6. IL Key (P/N 2702291) is used to bypass the interlock while performing

alignments that require the VSS to be turned on

Figure 6-1: VSS Alignment Tools

702:038 Service Manual 6-1

 VARIANT II Hemoglobin Testing System

6.2 Alignment Order

Table 5-5 shows the order of alignments for the VSS. If the alignments are not
done in this order there is a risk that some of the alignments, already done, will be
altered. The Affects column shows which steps in the table will be affected. SSW
in the Tool Used column is VSS Service Software. Note: Y-axis refers to front to
back motion, X-axis refers to left to right motion and Z-axis is vertical motion.

Alignment Section Tool Used Affects

VSS Adjustment Procedures

1 Rear rack carrier guide rail and vertical guide 6.4 270-2287 6,8,13
plate 270-2288
2 Front rack carrier vertical guide plate 6.5 270-2288
3 Rack carrier ‘fingers’ 6.6 270-2288 17,18,19,20,21,22,23,24
4 Side Rack Guides (Conveyor width) 6.7 270-2289 17,18,19,20,21,22,24
5 Spin head vertical alignment 6.9 270-2286 22
270-2290
6 Spin Head lowest position 6.10 SSW
7 Spin Head Limit (Hold) position 6.11
8 Tube holder Y (mechanical) 6.12 270-2288 13
9 Needle vertical alignment 6.13 270-2286 10,11,12,13,23
10 Wash Tower X-Axis (Needle at Wash Port) 6.14 12
11 Needle Guide, X-axis 6.15 SSW 23
12 Needle Y-axis at Wash Port 6.16 SSW
13 Needle Y-axis at Sampling position 6.17 SSW
14 Needle Z-axis at dilution well 6.18 SSW
15 Needle Z-axis at sampling adjust position 6.19 SSW 16
16 Needle Z-axis at sampling tube positions 6.20 SSW
17 Rear rack carrier Home and Limit 6.21 SSW 19,20,21,22,24
18 Front rack carrier Home and Limit 6.22 SSW
19 Tube sensor (mechanical) 6.23 270-2288
20 Rear rack Spinning position 6.24 270-2288 21,22,24
21 Barcode tube position (bar-code mechanical) 6.25 SSW 24
22 Spin Head X and Y position 6.26
23 Rack sample position 6.27 270-2288
24 Rack bar-code position 6.28 SSW
25 Syringe Home position Flag 6.29 26,27
26 Syringe Home position 6.30 SSW 27
27 Pull Air adjustment 6.31 SSW
Table 6-1: VSS Alignment Order

6.3 Interlock Key

The needle cover of the VSS engages an interlock switch for safety. Once the cover
is removed, all component movement stops. In order to perform certain alignment
procedures, it is necessary to bypass this interlock. The Interlock Key is inserted
into the interlock switch to accomplish this task. Figure 6-2 shows the installation
and removal of the interlock key.

6-2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Interlock Switch
Switch Location

VSS Adjustment Procedures

Installation

Removal

Figure 6-2: IL Key

702:038 Service Manual 6-3

 VARIANT II Hemoglobin Testing System

6.4 Rear Rack Guide Rail and Vertical Guide Plate

The adjustment of the Rear Rack Guide Rail and Vertical Guide Plate requires the
use of the following tools:

Dummy Rack (P/N 2702288)

Rear Guide Tools (P/N 2702287)
VSS Adjustment Procedures

1. Turn off the power to the VSS.

2. Position the alignment tools and assess the alignments as illustrated by Figure 6-
5. If adjustments are required, continue with step 3.

3. Remove all the covers. Loosen the guide rail screws and the four screws on the
left and right sides of the rear vertical guide plate block. (Figure 6-3)

screws
screws

Left Right Belt

Figure 6-3: Rear Rack Guide and Vertical Guide

Plate Screw Locations

4. Place the Dummy Rack between the fingers of the rear rack carrier and
manually move it to center position. Place the Rear Guide Tools on each belt

6-4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

and center them by hand under the rear rack guides. Figure 6-4 shows proper
placement of the tools.

Rear Rack
Carrier Figure 6-4: Rear
Guide Rail Guide Tool
Placement

Rack Carrier

VSS Adjustment Procedures

Guide Plate

5. Gently press the guide rails and the vertical guide plate against the tools until no
gap is seen. Figure 6-5 shows proper positioning. NG means Not Good.

Figure 6-5: Rear

Rack Carrier and
Vertical Guide
Plate Adjustments

6. Adjust the guide rail and guide plate to the best position and tighten the screws
to secure. Figure 6-6 shows the 2 movements to adjust the rear rack guides.
The vertical guide plate requires only a backward or forward adjustment.
(Figure 6-3). Make sure that clearance is left between the front surface of the
guide rail and the back of the rack carrier fingers.

702:038 Service Manual 6-5

 VARIANT II Hemoglobin Testing System

Figure 6-6:
Adjust Rear Guide
Rail
Adjust Movement
screws
screws
VSS Adjustment Procedures

7. Remove the Dummy Rack and Guide Tools.

8. Check the Spin Head lowest position adjustment (Section 6.10), Tube holder Y
mechanical position (Section 6.12) and Needle Y axis at the sampling position
(Section 6.17) as they are affected by this adjustment. Once complete, verify by
checking sample rack movement (Section 6.8).

6.5 Front Rack Vertical Guide Plate

Alignment of the Front Rack Carrier Vertical Guide Plate requires the use of the
following tool:

Dummy Rack (P/N 2702288)

1. Turn off the power to the VSS.

2. Position the alignment tool and assess the alignment as illustrated by Figure 6-8.
If adjustments are required, continue with step 3.

3. Remove all the covers. Loosen the four screws on the left and right sides of the
front vertical guide plate block. (Figure 6-7)

Figure 6-7:
Front
Vertical
Guide Plate
Screw
Locations

6-6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4. Place the Dummy Rack between the fingers of the front rack carrier and
manually move it to center position. (Figure 6-8)

Figure 6-8:
Dummy
Rack
Positioning
at Front
Guide Plate
Right

VSS Adjustment Procedures

5. Adjust the guide plate with a backward or forward motion to the best position,
with no gap, and tighten the screws to secure. Refer to Figure 6-5.

6. Unless access is needed for other alignments, install front and top covers.
Remove the Dummy Rack. Turn on the VSS power.

7. Check the Tube holder Y mechanical position (Section 6-12) and Needle Y axis
at the sampling position (Section 6-17) as they are affected by this adjustment.
Once complete, verify by checking sample rack movement (Section 6-8).

6.6 Rack Carrier Fingers

Each rack carrier has two fingers, which are used to hold the sample rack as it is
moved from side to side. Adjustment to these fingers requires the following tool:

Dummy Rack (P/N 2702288)

1. Turn off the power to the VSS.

2. Move the rear rack carrier to home position (far right).

3. Place the Dummy Rack between the 2 fingers of the rear rack carrier. (Figure 6-
9)

Figure 6-9:
Dummy Rack in
Rear Rack
Carrier Fingers

4. Loosen the screws of the fingers and adjust them until no gap is seen between
the rack and the fingers. (Figure 6-10) Tighten the screws when done.

702:038 Service Manual 6-7

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

Figure 6-10: Rack Carrier Finger Adjustment

5. Remove the Dummy Rack and place it between the fingers of the front rack
carrier. Manually move the rack carrier to the far right or left.

6. Repeat Step 4.

7. Remove the Dummy Rack when adjustment is complete. Turn on the VSS
power.

8. Check the following, in this order, as they are affected by this adjustment:

Rear Rack Carrier Home and Limit (Section 6.21)

Front Rack Carrier Home and Limit (Section 6.22)
Tube Sensor Mechanical adjustment (Section 6.23),
Rear Rack Spinning Position (Section 6.24)
Tube Bar-code Position (Section 6.25)
Spin Head X and Y position (Section 6.26)
Rack Sample position (Section 6.27)

6-8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Rack Bar-code position (Section 6.28)

9. Once complete, verify by checking sample rack movement (Section 6.8).

6.7 Side Rack Guides (Conveyor Width)

The adjustment of the Side Rack Guides requires the following tool:

VSS Adjustment Procedures

Conveyor Tool (P/N 2702289)

1. Place the Conveyor Tool between the tube holder block and the left side rack
guide of the left conveyor belt. If the adjustment is needed (see Figure 6-11)
proceed to step 2.

2. Loosen the screws of the left side rack guide. Adjust the position of the rack
guide until no gap is seen between the Conveyor Tool, the side rack guide and
the tube holder block. Figure 6-11 shows the adjustment to the side rack guide.

Figure 6-11:
Side Rack
Guide
Adjustment

No
Gap

No
Gap

702:038 Service Manual 6-9

VARIANT II Hemoglobin Testing System

3. Tighten the screws when the adjustment is complete.

4. Remove the Conveyor Tool and place it on the right conveyor belt between the
tube holder block and the right side rack guide.

5. Repeat steps 2-3 above.

6. Check the following, in this order, as they are affected by this adjustment:

VSS Adjustment Procedures

Rear Rack Carrier Home and Limit (Section 6.21)
Front Rack Carrier Home and Limit (Section 6.22)
Tube Sensor Mechanical adjustment (Section 6.23)
Rear Rack Spinning Position (Section 6.24)
Tube Bar-code Position (Section 6.25)
Spin Head X and Y position (Section 6.26)
Rack Bar-code position (Section 6.28)

7. Once complete, verify by checking sample rack movement (Section 6.8).

6.8 Checking the Sample Rack Movement

Once all mechanical adjustments are made to the rack carriers, vertical plate guide
and/or rack guides, a rack should be placed on the VSS and moved in a counter
clockwise direction to verify smooth movement.

1. Turn on the power to the VSS. The unit will go through an initialization
process. Once this is complete the rear rack carrier will be in the home position
and the front rack carrier will be in the middle.

2. Open the VSS Service Software and select the Adjustment option from the main
menu.

3. Select Limit in the Front Carriage field.

4. Place an empty sample rack on the right belt. The rack should be centered in
the middle back to front and left to right.

5. Select Forward in the Right Conv. field of the Adjustment window to move the
rack into the rear rack carrier. Select Stop once the rack is all the way to the
back. Select Limit in the Rear Carriage field to move the rack past the rear
vertical guide plate to the limit position. Select Forward in the Left Conv. field
to move the rack into the front rack carrier. Select Stop once the rack is all the
way to the front. Select Home in the Front Carriage field to move the rack past
the front vertical guide plate to the home position. Figure 6-12 shows the
Adjustment window options.

6 - 10 Service Manual 702:038

 VARIANT II Hemoglobin Testing System

Figure 6-12:
VSS
Adjustment
Window

VSS Adjustment Procedures

Observe the rack as it moves around the VSS rack transport area. The rack
should be delivered into the middle of the waiting rack carrier from the
conveyor and pass by the vertical guide plates smoothly and without noise. If
the rack does not perform properly at any point, a re-adjustment of that area is
required.

6.9 Spin Head Vertical Alignment

The Vertical Alignment to the spin head requires the following tools:

Vertical Alignment Tool (P/N 2702286)

Centering Tool (P/N 2702290)

1. Remove the needle cover and front cover.

2. Remove the gum head and replace it with the Centering Tool. (Figure 6-13)

Figure 6-13: Centering Tool Installation

702:038 Service Manual 6 - 11

 VARIANT II Hemoglobin Testing System

3. Place the Vertical Alignment Tool on the right conveyor in front of the spin
head. Align the center line of the tool with the spin shaft. Upward pressure on
the centering tool may be required to place it behind the sight line. (Figure 6-14)

Sight line Figure 6-14:

Vertical
Alignment Tool
Front Placement in
VSS Adjustment Procedures

Spin shaft Front of Spin

Head

Tool
Centering tool

4. If the spin head shaft does not line up with the sight line on the tool, loosen the
4 screws on the spin head mounting plate and adjust until it is aligned properly.
(Figure 6-15) Tighten the screws when the adjustment is complete.

Figure 6-15:
Spin Head
Adjustment
Left to Right

5. Reposition the Vertical Alignment Tool so it is on the right side of the spin
head. Align the center line of the tool with the spin shaft. Push the centering
tool up 5 mm to put operating tension on the assembly. (Figure 6-16)

6 - 12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Sight line

Right side
Spin shaft

VSS Adjustment Procedures

Tool Centering tool

Figure 6-16: Vertical Alignment Tool Placement at side of Spin Head

6. If the spin head shaft does not line up with the sight line on the tool, loosen the
4 screws on the sides of the spin head and adjust until it is aligned properly.
(Figure 6-17) Tighten the screws when the adjustment is complete.

Figure 6-17:
Spin Head
Adjustment
Back to
Front

7. Remove the Centering Tool, replace the gum head and both covers.

8. Check the Spin Head X and Y position (Section 6.26), as it is affected by this
adjustment.

702:038 Service Manual 6 - 13

 VARIANT II Hemoglobin Testing System

6.10 Spin Head Lowest Position

The Spin Head Lowest Position requires the use of the following tool:

IL Key (P/N 2702291)

1. Remove the needle cover and front cover. Insert the IL key to bypass the
interlock switch.
VSS Adjustment Procedures

2. Open the VSS Service Software and select the Adjustment option. (Figure 6-18)
Remove any racks that may be present in the rear rack carrier.

Figure 6-18: Spin Head Control Option in Adjustment Window

3. Select Spin Head Control in the Adjustment window to open the Spin Head
Control window. (Figure 6-19)

Figure 6-19:
Spin Head
Control
Window

6 - 14 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4. Select the Down option in the Spin Head Control window to lower the barcode
reader to the position defined.

5. Visually check that there is a gap of less than 1.0 mm between the bottom of the
reader and the steel guide rail. The reader must not touch the rail. (Figure 6-20)

Figure 6-20:
Spin Head
Lowest

VSS Adjustment Procedures

Position

Barcode Reader
Lowest Position

Gap: Less than 1mm

Guide Rail

6. If the gap is not within the acceptable limits select Up in the Spin Head Control
window to raise the spin head to home position. Change the position by
increasing or decreasing the value in the field below the Down option.
Increasing the number lowers the reader position the defined number of steps
and decreasing the number raises the reader position. Fifty steps is equal to 1
mm. Select Down again to verify repositioning and repeat if necessary until the
gap is less than 1.0 mm.

7. Close the Spin Head Control window when adjustment is complete. Select
Store Data To EEPROM in the Adjustment window to store the new value.

8. Remove the IL key and replace the covers.

6.11 Spin Head Limit (Hold) Position

1. Remove the needle cover and the front cover.

2. Observe the position of the spin head shaft. The top must be 5 mm from the
center of the photo sensor with the centerline of the shaft aligned with the center
of the photo sensor. (Figure 6-21)

702:038 Service Manual 6 - 15

 VARIANT II Hemoglobin Testing System

Adjust Figure 6-21: Spin Head

Photo Limit Position
Sensor board Sensor

Adjust
5mm

Sensor
VSS Adjustment Procedures

Shaft home position adjustment

point

3. If the spin head shaft is not aligned properly in the sensor loosen the 2 sensor
bracket screws and adjust the sensor position until it is aligned properly.
(Figure 6-22) Tighten the screws when adjustment is complete.

Figure 6-22:
Spin Head
Limit photo sensor
Limit
Position
Adjustment
Sensor
bracket

Screwdriver

6.12 Tube Holder Unit Adjustment (Y-axis)

The Tube Holder Y Position Adjustment requires the following tool:

Dummy Rack (P/N 2702288)

IL Key (P/N 2702291)

1. Remove the needle cover and the front cover. Install the IL key to bypass the
interlock switch.

2. Place the Dummy Rack in the rear rack carrier.

6 - 16 Service Manual 702:038

VARIANT II Hemoglobin Testing System

3. Open the VSS Service Software and select the Adjustment option from the main
menu. Select Sampl Pos in the rear rack carriage field until the needle guide of
the Dummy Rack is positioned under the needle guide on the tube holder (8
positions). (Figure 6-23)

VSS Adjustment Procedures

Figure 6-23: Sample Head Control and Sample Position Options

4. Open the Sampl Head Control option from the Adjustment window. (Figure 6-
6-23) Select Down in the Tube Holder field of the Sample Head Control
window. Use the Emergency Stop button, in the Adjustment window, to stop the
needle guide from making contact with the dummy rack. Check the position as
pictured in Figure 6-24.

Figure 6-24:
Dummy Rack
Positioning
Under Needle
Guide

Needle target of
the Rack

5. If no adjustment is required, select Up in the Tube Holder field and close the
Sample Head Control window. Select Home in the rear carriage field of the
adjustment window. Remove the dummy rack. Remove the IL key and replace
the covers. If an adjustment is required, continue to step 6.

702:038 Service Manual 6 - 17

 VARIANT II Hemoglobin Testing System

6. Remove the 4 screws of the tube holder unit cover. (Figure 6-25)

Figure 6-25:
Removal of the
Tube Holder
Cover
VSS Adjustment Procedures

7. Disconnect the sensor cable and remove the cover. (Figure 6-26)

Figure 6-26:
Disconnecting
the Tube
Holder Sensor

8. Loosen the 6 screws at the base of the tube holder unit. (Figure 6-27)

Figure 6-27:
Loosening
the Screws
on the Tube
Holder Base

9. Adjust the tube holder front to back until the hole in the needle guide is over the
hole in the Dummy Rack. (Figure 6-28) NG means not good.

6 - 18 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 6-28:
Tube Holder
Adjustment

Adjust

VSS Adjustment Procedures

NG NG GOOD

10. Tighten the 6 screws on the base when the adjustment is complete. When the
screws are tightened, make sure the rack guide bars under the tube holder base
are parallel, at a right angle to the rear rack guide rail and are seated on the
conveyor belt. (Figure 6-29)

Figure 6-29:
Rack Guide Bar
Positioning

90°

11. Reconnect the sensor and secure the cover with the 4 screws. Move the rear
rack carrier to home position and remove the Dummy Rack. Remove the IL
Key and replace the covers.

12. Check the Needle Y axis at Sampling Position as it is affected by this

adjustment (Section 6.17).

702:038 Service Manual 6 - 19

 VARIANT II Hemoglobin Testing System

6.13 Sample Needle Vertical Alignment

The Vertical Alignment of the sample needle requires the following tool:

Vertical Alignment Tool (P/N 2702286)

1. Turn off the power to the VSS. Remove the needle cover, front and top covers.

2. Manually move the sample needle all the way to the front and place the Vertical
VSS Adjustment Procedures

Alignment Tool on the left conveyor belt. Position the tool so the edge of the
tool is aligned with the sample needle. (Figure 6-30)

Figure 6-30:
Vertical Alignment
Tool at Front of
Needle

Move

Sight line

Needle
Square

3. If the needle is not aligned properly replace it with a new needle. Figure 6-31
shows proper positioning of the needle against the edge of the tool. NG means
not good. If the needle has been replaced, the following alignments will need to
be checked, as they are affected by needle position: Wash tower X-axis (Section
6.14), and Needle guide X-axis (Section 6.15)

Figure 6-31:
Sample
Needle Front
Alignment

6 - 20 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4. Reposition the Vertical Alignment Tool to the left of the sample needle. Check
the vertical alignment against the back line of the tool. (Figure 6-32)

Figure 6-32:
Vertical
Alignment
Tool at Side
of Needle

Needle

VSS Adjustment Procedures

Sight line 1111

5. If the needle is not aligned properly, loosen the screws on the sample needle
arm (Figure 6-33) and adjust the angle. Figure 6-34 shows proper alignment of
the sample needle. NG means not good.

Figure 6-33:
Hexagonal wrench Sample
Needle Arm
Adjustment

Screws

Adjust

Figure 6-34:
Sample
Needle Side
Alignment

702:038 Service Manual 6 - 21

 VARIANT II Hemoglobin Testing System

6. If the needle has been moved in the Y-axis, the following alignments, affected
by needle position, will need to be checked:

Wash Tower X-axis Alignment (Section 6.14),

Needle Guide X-axis (Section 6.15)
Needle Y-axis at Wash Port (Section 6.16)
Needle Y-axis at Sampling Position (Section6.17)
Rack Sample Position (Section 6.27).
VSS Adjustment Procedures

7. Remove the IL key and replace the covers.

6.14 Wash Tower X-axis (Needle at Wash Port)

Adjustment to the Wash Tower along the X -axis requires the following tools:

IL Key (P/N 2702291)

1. Remove the needle cover, front and top covers. Install the IL key to bypass the
interlock switch.

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Wash port option in the Y-axis field. (Figure 6-35)

Figure 6-35: Wash Port Position Option in Adjustment Window

3. Select Wash Port Adj. Pos. in the Z-axis field (Figure 6-35) and note the
position of the needle over the wash port.

6 - 22 Service Manual 702:038

VARIANT II Hemoglobin Testing System

WARNING: The sample needle is extremely sharp. Use caution

when placing fingers around the needle and make sure they are not
under the needle before moving it.

4. If the X-axis of the needle is not centered over the port an adjustment is
required. Loosen the 3 screws on the base plate below the wash port block.
(Figure 6-36)

VSS Adjustment Procedures

Figure 6-36:
Wash Tower
X-axis
Adjustment

Adjust

5. Adjust the wash tower left to right until the needle is centered along the X-axis.
Do NOT adjust for the Y-axis. Y-axis alignment for the sample needle is done
through the VSS Service software. Tighten the 3 screws securely.

6. Select Z_Home and then Y_Home from the Adjustment window to move the
needle to home position.

7. If the wash tower has been moved, the following alignment will need to be
checked, as it is affected by wash tower position: Needle Y-axis at wash port
(Section 6.16).

8. Remove the IL key and replace the covers.

6.15 Tube Holder Head Adjustment (Needle Guide, X-axis)

The Tube Holder Head Adjustment requires the following tools:

IL Key (2702291)

1. Remove the needle cover and front cover. Install the IL key to bypass the
interlock switch.

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Sampling Position option in the Y-axis field. (Figure 6-37)

702:038 Service Manual 6 - 23

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

Figure 6-37: Sampling Position Option in Adjustment Window

3. Loosen the 2 screws on the needle guide mounting bracket. Adjust the guide
left to right until the needle is in the center of the needle guide hole. (Figure 6-
38) Use caution when adjusting to avoid bending the needle or disturbing its Y-
axis alignment.

Figure 6-38:
Needle
Needle
Needle Positioning
in Needle
Adjust Guide
Screws

Adjust

4. Tighten the screws gradually one at a time to avoid turning the guide and losing
the alignment.

5. Select Sampling Adj Pos. in the Z-Axis field and observe the needle as it passes
through the needle guide. The needle should be centered.

6. Select Z_Home and then Y_Home to move the needle to home position.

6 - 24 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7. Check the Rack Sample position (Section 6.27), as it is affected by this

adjustment.

8. Remove the IL key and replace all covers.

6.16 Sample Needle Y-axis at Wash Port

Adjustment to the Sample Needle at the Wash Port position along the Y-axis
requires the following tools:

VSS Adjustment Procedures

IL Key (P/N 2702291)

1. Remove the needle cover, front and top covers. Install the IL key to bypass the
interlock switch.

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Wash port option in the Y-axis field. (Figure 6-35)

3. Select Wash Port Adj. Pos. in the Z-axis field (Figure 6-35) and note the
position of the needle over the wash port. If the needle is not centered, adjust
the value in the field next to the Y-axis Wash Port option and select Wash Port
then Wash Port Adj. Pos. again. Press Enter after the new step value is entered.
Five steps is equal to 1 mm. Increasing the number (more positive value) will
move the needle forward while decreasing the number (more negative value)
moves the needle back. Repeat the process until the needle is centered over the
port. Select Z_Home and then Y_Home when the alignment is complete.

4. Open the Manual option from the main menu. It is not necessary to close the
Adjustment window when opening the Manual window. Select the Nozzle Y
Wash Port option. (Figure 6-39) The needle will move to the wash port
position defined in Step 3.

702:038 Service Manual 6 - 25

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

Figure 6-39: Manual Window Wash Port Options

5. Select the Nozzle Z Wash Port option (Figure 6-39). The needle will drop
completely into the needle wash port. Verify that the needle is centered along
the X-axis and Y-axis in the port. Select Nozzle Z Home and then Nozzle Y
Home to move the needle to the home positions. Repeat Steps 3 - 5 if the
needle is not centered along the Y-axis. Refer to Section 6.14 if the needle is
not centered along the X-axis.

6. Close the Manual window. Select Store Data To EEPROM in the Adjustment
window to store the changes to the Y-axis wash port position.

7. Remove the IL key and replace all covers.

6.17 Needle Y-axis at Sampling Position

Adjustment to the Sampling Position of the Needle along the Y-axis requires the
following tools:

IL Key (P/N 2702291)

6 - 26 Service Manual 702:038

VARIANT II Hemoglobin Testing System

1. Remove the needle cover and front cover. Install the IL key to bypass the
interlock switch.

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Sampling Position option in the Y-axis field. (Figure 6-40)

VSS Adjustment Procedures

Figure 6-40: Sampling Position Options

3. Note the position of the needle over the needle guide. If the needle is not
aiming at the hole in the needle guide adjust the value in the field next to the
Sampling Position option and select Sampling Position again until the needle is
centered over the hole. Press Enter after the new step value is entered. Five
steps is equal to 1 mm. Increasing the number (more positive value) will move
the needle further forward while decreasing the number (more negative value)
moves the needle back.

4. Select the Sampling Adj. Pos. option in the Z-axis field to drop the needle
through the needle guide and verify the needle is aligned properly. (Figure 6-
40)

5. Select Z_Home and then Y_Home to move the needle to home position.

6. If the needle is not centered repeat Steps 3 – 5.

7. Select Store data To EEPROM in the Adjustment window to store the changes
to the Y-axis sampling position.

8. Remove the IL key and replace all covers.

702:038 Service Manual 6 - 27

 VARIANT II Hemoglobin Testing System

6.18 Needle Z-axis at the Dilution Well

Adjustment to the Z-axis Needle positions requires the following tool:

IL Key (P/N 2702291)

1. Remove the needle cover and front cover. Install the IL key to bypass the
interlock switch.
VSS Adjustment Procedures

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Wash Port option in the Y-axis field. (Figure 6-35)

3. Select Wash Port Adj. Pos. in the Z-axis field. (Figure 6-35) The needle will be
positioned over the needle wash port. Adjust the height of the needle if it is not
exactly at the top of the wash tower. (Figure 6-41) Edit the step value in the
box next to the Wash Port Adj. Pos. option to either raise or lower the needle.
Press Enter after entering the new value. One Hundred (100) steps equals 1
mm. Increasing the value will lower the probe while decreasing the value will
raise the probe.

Figure 6-41:
Needle at
Top of Wash
Tower

4. Select Z_Home in the Z-axis field and then Wash Port Adj. Pos. again. Verify
that the needle is at the top of the wash tower by placing a small piece of paper
under the tip. The needle should just rest on the paper and not catch when the
paper is moved. Select Z_Home.

5. The new Wash Port Adjust Position is 4 mm below the top of the wash tower.
(Figure 6-42)

6 - 28 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 6-42:
Z Height at
Wash Port

To drop the needle 4 mm, add 400 to the step value in the Wash Port Adj. Pos.

VSS Adjustment Procedures

box. Press Enter after changing the value.

6. Select Wash Port Adj. Pos. again and verify that the needle has dropped about 4
mm below the top of the wash tower. Select Z_Home and then Y_Home when
done.

7. Select Store Data To EEPROM to store the new value.

8. Remove the IL key and replace the front and needle covers.

6.19 Needle Z-axis at the Sampling Adjust Position

Adjustment to the Z-axis Needle positions requires the following tools:

IL Key (P/N 2702291)

Empty Sample Rack

1. Remove the needle cover and front cover. Install the IL key to bypass the
interlock switch.

2. Select the Sampling Adj. Pos. option in the Z-axis field. (Figure 6-43) The
needle should descend through the needle guide to the height of a sample rack.
Carefully move the sample rack in, by hand, from the left hand side, pressing
down gently on the rack to take up the teflon block spring tension.

702:038 Service Manual 6 - 29

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

Figure 6-43: Sample Position Options for Z-axis

3. Observe the height of the needle over the rack. The needle should be at the top
of the rack. (Figure 6-44)

WARNING: The sample needle is extremely sharp. Use caution

when placing fingers around the needle and make sure they are not
under the needle when moving the rack into position.

Figure 6-44:
Sample
Position Z
Z-Adjust Adjustment

Push

Adjust height
position

4. Adjust the height of the needle by entering a new step value in the Sampling
Adj. Pos. box. Press Enter after the new value has been entered. One Hundred

6 - 30 Service Manual 702:038

VARIANT II Hemoglobin Testing System

(100) steps equals 1 mm. Increasing the value moves the needle down while
decreasing the value moves the needle up. Select the Sampling Adj. Pos. option
again and verify that the needle is now properly positioned at the rack. Repeat
if needed.

5. The Sampling Adjust Position is 2 mm above the top of a sample rack. (Figure
6-45)
Figure 6-45:
Sampling

VSS Adjustment Procedures

Height
Adjust
Position

To raise the needle 2 mm, subtract 200 from the new step value in the Sampling
Adj. Pos. box. Select Sampling Position and then Sampling Adj. Pos. Press
down on the rack and verify that the needle position is above the top of the rack.

6. Select Z_Home and then Y_Home to move the needle to home position.
Remove the rack.

7. Select Store Data To EEPROM to store the new value.

8. Check the Needle Z-axis at the Sampling Tube Positions (Section 6.20) as it is
affected by this adjustment.

9. Remove the IL key and replace all covers.

6.20 Sample Tube Z Positions

The sample height for the Micro, Pediatric and Primary tubes can be adjusted
individually.

Adjustment to the Sample Tube Z positions requires the following tools:

Empty Sample Rack

Microvial Adapter

NOTE: The adjustments can be made without the use of a sample rack and
microvial adapter; however, after selecting the tube option, the tube holder
will go to it’s lowest position and produce an error message on the screen.
Close the message window and proceed with the adjustments.

702:038 Service Manual 6 - 31

VARIANT II Hemoglobin Testing System

1. Open the VSS Service Software and select the Adjustment option from the main
menu.

2. Place the microvial adapter in the first position of the sample rack and place it in
the rear rack carrier. Select the Sample Position option in the Rear Carriage
field once to move the adapter under the tube holder. (Figure 6-46)

Figure 6-46:
Adjustment
Options for Sample

VSS Adjustment Procedures

Tube Z Positions

3. Open the Expanded Needle Height Adjustment window. (Figure 6-46)

4. The default values for each tube type are 0. Enter the following values in the
Expanded Needle Height Adjustment window. (Figure 6-47)

Micro Tube: 800

Pediatric Tube: 0
Primary Tube: 0

Figure 6-47:
Expanded
Needle Height
Adjustment
Window

6 - 32 Service Manual 702:038

VARIANT II Hemoglobin Testing System

NOTE: These values are typical. Further adjustments can be made if needed,
but the depth should not be lower than the dead volume of 500 µL in a primary
sample tube.

5. Select the Micro Tube option in the Expanded Needle Height Adjustment
window. (Figure 6-45) The tube holder will move down and the needle will
move to the sampling position and drop to the depth defined.

VSS Adjustment Procedures

6. Select Z_Home to move the needle out of the microvial adapter.

7. Select Up in the Tube Holder Field to raise the tube holder.

8. Select Y_Home to move the need back to home position.

9. Select Store Data To EEPROM in the Adjustment window.

10. Close the Expanded Needle Height Adjustment window.

NOTE: If adjustments are needed to the Pediatric and Primary Tube sampling
positions, repeat the procedure using a pediatric adapter and primary tube.

6.21 Rear Rack Carrier Home and Limit

The Rear Rack Carrier Home and Limit Position adjustment requires the use of the
following item:

Sample Rack

1. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Home option in the rear carriage field. (Figure 6-48)

702:038 Service Manual 6 - 33

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

Figure 6-48: Rear Carriage Home and Limit Options

2. Check the position of the rack finger against the side guide bar. (Figure 6-49)
NG means not good.

Figure 6-49:
Rear Carrier
Home Position
at Guide Bar

3. Place the sample rack on the right conveyor. Select Forward and then Back in
the Right Conv. field in the Adjustment window. Note the rack as it moves in
and out of the rear rack carrier. Movement should be smooth with no sticking.
(Figure 6-50) NG means not good.

Figure 6-50:
Rack in Rear
Carrier
Home
Position

6 - 34 Service Manual 702:038

VARIANT II Hemoglobin Testing System

If the movement is not smooth or the position of the rack finger to the guide bar
is not aligned properly an adjustment to the home position must be made.

4. Edit the step value in the box below the Home option. Five steps equals 1 mm.
Increasing the value moves the rack carrier to the left while decreasing the value
moves it to the right. Select Home again and repeat Steps 2 and 3.

5. Select Store Data To EEPROM to save the new home position. Remove the
sample rack.

VSS Adjustment Procedures

6. Check the limit position by selecting Limit in the rear carriage field of the
Adjustment window. (Figure 6-48)

7. Repeat Steps 2 and 3 but place the rack on the left conveyor belt instead of the
right.

8. Edit the step value in the box below the Limit option. Select Limit again and
repeat Steps 2 and 3.

9. Select Store Data To EEPROM to save the new limit position. Remove the
sample rack and close the Adjustment window.

10. Check the following, in this order, as they are affected by this adjustment:

Tube Sensor Mechanical adjustment (Section 6.23)

Rear Rack Spinning position (Section 6.24)
Bar-code Tube Position (Section 6.25)
Spin Head X and Y position (Section 6.26)
Rack Bar-code Position (Section 6.28)

6.22 Front Rack Carrier Home and Limit Positions

The Front Rack Carrier Home and Limit Position adjustment requires the use of the
following item:

Sample Rack

1. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Home option in the front carriage field. (Figure 6-51)

702:038 Service Manual 6 - 35

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

Figure 6-51: Front Carriage Home and Limit Options

2. Check the position of the rack finger against the side guide bar. (Figure 6-52)
NG means not good.

Figure 6-52:
Front Carrier
Home Position
at Guide Bar

3. Place the sample rack on the right conveyor. Select Forward and then Back in
the Right Conv. field in the Adjustment window. Note the rack as it moves in
and out of the front rack carrier. Movement should be smooth with no sticking.
(Figure 6-53) NG means not good.

Figure 6-53:
Sticking NG Rack in Front
Carrier Home
Position

Rack

Guide bar

6 - 36 Service Manual 702:038

VARIANT II Hemoglobin Testing System

If the movement is not smooth or the position of the rack finger to the guide bar
is not aligned properly an adjustment to the home position must be made.

4. Edit the step value in the box below the Home option. Five steps equals 1 mm.
Increasing the value moves the rack carrier to the left while decreasing the value
moves it to the right. Select Home again and repeat Steps 2 and 3.

5. Select Store Data To EEPROM to save the new home position. Remove the
sample rack.

VSS Adjustment Procedures

6. Check the limit position by selecting Limit in the front carriage field of the
Adjustment window. (Figure 6-51)

7. Repeat Steps 2 and 3 but place the rack on the left conveyor belt instead of the
right.

8. Edit the step value in the box below the Limit option. Select Limit again and
repeat Steps 2 and 3.

9. Select Store Data To EEPROM to save the new limit position. Remove the
sample rack and close the Adjustment window.

6.23 Tube Sensor

Adjustment to the Tube Sensor requires the following tools:

IL Key (P/N 2702291)

Dummy Rack (P/N 2702288)

1. Remove the sample needle cover and front cover. Install the IL key to bypass
the interlock switch.

2. Place the Dummy Rack in the rear rack carrier. In the Manual screen, select
Rack Rear Home.

3. Check the position of the tube sensor in the first slit of the rack. It must be
located in the center. (Figure 6-54). If the sensor is not in the center of the slit
an adjustment to the sensor bracket is required.

702:038 Service Manual 6 - 37

 VARIANT II Hemoglobin Testing System

Figure 6-54: Tube

Sensor Position in
Dummy Rack
VSS Adjustment Procedures

4. Turn off the power to the VSS. Remove all of the covers. Loosen the screws
securing the tube sensor and adjust until the sensor is in the center of the slit.
(Figure 6-55) The bracket may need to be bent by hand to achieve vertical
alignment. Also move the sensor assembly as high and as far back as possible
to minimize false readings.

Figure 6-55:
Tube Sensor
Adjustment

5. Remove the Dummy Rack, remove the IL Key and replace all the covers.

6.24 Rear Rack Carrier Spinning Position

Adjustment to the Rear Rack Carrier Spinning Position requires the following tool:

Dummy Rack (P/N 2702288)

10 Pediatric Tube Adapters
Sample Rack

1. Place the Dummy Rack in the rear rack carrier.

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select Home and then the Spinning Position option in the rear carriage
field. (Figure 6-56)

6 - 38 Service Manual 702:038

VARIANT II Hemoglobin Testing System

VSS Adjustment Procedures

Figure 6-56: Spinning Position Option

3. Check the position of the sensor through the second slit in the rack. It must be
located in the center of the slit. (Figure 6-57)

Figure 6-57:
Tube Sensor
Position in
Second Slit

Second slit

4. If the tube sensor is not positioned properly the spinning position must be
adjusted. Select Home in the rear carriage field. Edit the step value in the box
below the Spinning Position option pressing Enter after the number is edited.
Five steps equals 1 mm. Increasing the value moves the rack carrier to the left
while decreasing the value moves it to the right. Select Spinning Position again
and check the tube sensor position in the second slit. Repeat the procedure until
the tube sensor is centered properly. Select Home when done and remove the
Dummy Rack.

5. Select Store Data To EEPROM to store the new spinning position value.

702:038 Service Manual 6 - 39

 VARIANT II Hemoglobin Testing System

6. Place a pediatric tube adapter in the sample rack and place it in the rear rack
carrier with the rack positioned so it is touching the right finger. (Figure 6-58)

Figure 6-58:
Rack at Right
Finger of Rear
Carrier
VSS Adjustment Procedures

7. Open the Sensor Status option from the main menu. Select Check Status and
note the status in the TubeHi and TubeLo fields. (Figure 6-59) It is not
necessary to close the Adjustment window.

Figure 6-59: Sensor Status Window with Rack in Place

The sensor status for both fields should be NONE.

8. Manually move the rack until it touches the left finger of the rear rack carrier.
Select Check Status again. The sensor status for TubeHi and TubeLo should be
NONE.

9. If either the TubeHi or TubeLo fields display EXIST when performing Steps 7
and 8, an adjustment to the Tube Sensor (Section 6.8) or Rear Rack Home
Position (Section 6.21) is required.

10. Select Spinning Position in the rear carriage field of the Adjustment window.
Select Check Status. The sensor status for TubeHi and TubeLo should be
NONE.

6 - 40 Service Manual 702:038

VARIANT II Hemoglobin Testing System

11. If either the TubeHi or TubeLo fields display EXIST when performing Step 10
an adjustment to the Spinning Position is required. Repeat Steps 1-5 above.
Verify the position again by using the sample rack with the pediatric tubes and
checking the status. Select Store Data To EEPROM to save the changes.
Remove the sample rack and close the Adjustment window.

12. If adjustments were made to the Rear Rack Carrier Spinning Position, the
following adjustments will need to be checked:

VSS Adjustment Procedures

Bar-code Tube Position (Section 6.25)
Spin Head X and Y Position (Section 6.26)
Rack Bar-code Position (Section 6.28).

6.25 Barcode Reader Unit Adjustment (Barcode Tube Position)

Adjustment to the Barcode Reader Unit requires the following items:

IL Key (P/N 2702291)

Microvial, Pediatric and Primary tubes with various barcode types
Sample Rack

1. Remove the needle cover, front and top covers. Install the IL key to bypass the
interlock switch.

2. Place the tubes with the various barcodes into the sample rack. Be sure to place
an empty microvial in the microvial adapter. Place the rack in the rear rack
carrier.

3. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Barcode Term option in the rear carriage field. (Figure 6-60)

Figure 6-60: Barcode Terminal Option

702:038 Service Manual 6 - 41

 VARIANT II Hemoglobin Testing System

4. The Barcode Terminal window contains 2 options for reading sample barcodes.
Scan Counts (Sample ID) reads Primary or Pediatric tubes and Percent
(Microvial) reads microvial adapters. Select the appropriate option to move the
rack one position. The barcode reader will lower and read the tube. The results
of the reading appear in the box to the left of the Quit option. Figure 6-61
shows the Barcode Terminal window and an example of a barcode scanning
result.

Figure 6-61:
VSS Adjustment Procedures

Barcode
Terminal
Fields Scanning Counter window

For example;
31.982.000314:100
Barcode ID Scanning
result

5. Select one of the two scan options to move the sample type into position for
reading. Note the scanning result in the box. The following results should be
obtained.

Microvials: 100
Pediatric Tubes with Small Labels: approx. 100
Primary Tubes containing labels with a very high contrast: >300

NOTE: The reading rate of the barcode unit is 500 scans/second. If no reads
are missed, and the position of the reader is fixed, the scanning result will
equal 500. Reading while a tube is spinning will show results less than 500.
The barcode quality, label width and positioning on the tube will also affect the
reading rate.

Select Quit to stop the reading and raise the barcode reader.

6. If the barcodes are not being read properly the reader unit must be adjusted.
Turn the power off and remove the top cover of the VSS. Turn the power back
on. Loosen the 2 screws on the bracket to the right of the reader unit. (Figure 6-
62)

6 - 42 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 6-62:
Barcode Unit
Screwdriver
Bracket

VSS Adjustment Procedures

Barcode reader unit

7. Use the Barcode Terminal options to position a tube in front of the reader unit.
Adjust the barcode reader position during the scan to find the best result.
(Figure 6-63) The best position will yield the largest value.

Adjust
Adjust

Figure 6-63: Barcode Reader Adjustment

Tighten the screws to secure the reader unit. Select Quit to stop the read.

8. Select Rear Rack Home. Select Reading Percent (Rack ID) and observe the
scanning result for the rack barcode. Rack ID should read at 100%. If it does
not, adjust the Rear Carriage Rack Barcode position on the adjustment screen of
the service software. Increasing the value in the box will move the rack to the
left, decreasing it will move it to the right. The rack position will change by
1mm for every 5 step change. Once the position is determined, save it to
EEPROM.

9. If adjustments were made to the Bar-code mechanical position, the Rack Bar-
code Position will need to be checked (Section 6.28).

10. Turn off the VSS, remove the interlock key and replace all covers.

702:038 Service Manual 6 - 43

 VARIANT II Hemoglobin Testing System

6.26 Spin Head X and Y Position Adjustment

The X and Y Position Adjustment requires the following items:

IL Key (P/N 2702291)

Sample Rack with Primary Sample Tubes in Positions 1 and 6

1. Turn off the power to the VSS. Remove the needle cover, front and top covers.
VSS Adjustment Procedures

Install the IL key to bypass the interlock switch. Turn on the power.

2. Open the VSS Service Software and select the Manual option from the main
menu. Select Home in the Rack Rear field. (Figure 6-64) Check the gum head
to make sure it is properly seated in the holder.

Figure 6-64: Rack Rear Options in Manual Window

3. Place the sample rack with sample tubes in positions 1 and 6 into the rear rack
carrier. Make sure that appropriate tube adapters are fitted. Select Mixer Pos in
the Rear Rack field. (Figure 6-64) The rack will move the tube in the first
position under the spin head.

6 - 44 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4. Select the Hold/Spin in the Mixing Holder Control field to bring the spin head
down on the top of the sample tube. (Figure 6-64)

5. Turn on the right conveyor by selecting Back in the Conveyor Right field.
Select Spin in the Mixer field to spin the tube. If noise and vibration levels are
acceptable, proceed to step 8. (Figure 6-64)

6. If the spin head is not centered correctly on the tube a mechanical adjustment
must be made. Loosen the 4 screws of the spin head block. (Figure 6-65).

VSS Adjustment Procedures

Select Spin in the Mixer field again and move the assembly as the tube spins to
find the quietest position.

Figure 6-65:
Spin Head
Block Screws

7. Move the block until both the X and Y positions are centered properly. (Figure
6-66)

Figure 6-66: Spin

Head X and Y
Adjustment

Adjust

8. Select Stop in the Conveyor Right field to stop the movement of the right belt.
Select Home in the Mixing Holder field to raise the spin head to home position.

702:038 Service Manual 6 - 45

 VARIANT II Hemoglobin Testing System

9. Click on Mixer Pos in the Rear Rack field 5 more times. The rack will move
tube number 6 into position under the spin head.

10. Repeat Steps 5 and 6 and verify that the spin head is centered properly for this
tube. Note: The conveyor does not need to run for this position. If the spin head
is not positioned properly for position 6 repeat steps 6 and 7 using the tube in
position 6.
VSS Adjustment Procedures

11. Once the best position is found, tighten the mounting screws carefully, select
Home in the Mixing Holder field, Select Home in the Rear Carriage field and
then check tube position 1 starting with step 4 above to verify that the
adjustment at position 6 did not affect position 1.

12. Once the adjustment is optimized, Select Home in the Mixing Holder field to
raise the spin head to home position. Select Home in the Rear Carriage field of
the Adjustment window. Remove the rack.

13. Turn the power to the VSS off and remove the IL key. Replace all covers.

6.27 Rear Rack Carrier Sampling Position

Adjustment to the Rear Rack Carrier Sampling Position requires the following tool:

Dummy Rack (P/N 2702288)

IL Key (P/N 2702291)

1. Remove the sample needle cover and front covers. Install the IL key to bypass
the interlock switch.

2. Place the Dummy Rack in the rear rack carrier.

3. Open the VSS Service Software and select the Adjustment option from the main
menu. Select Sampl Pos in the rear rack carriage field until the needle guide of
the Dummy Rack is positioned under the needle guide on the tube holder (8
positions). (Figure 6-67)

6 - 46 Service Manual 702:038

VARIANT II Hemoglobin Testing System

VSS Adjustment Procedures

Figure 6-67: Sampling Position and Sample Head Control

4. Open the Sampl Head Control option from the Adjustment window. (Figure 6-
67) Select Down in the Tube Holder field of the Sample Head Control window.
(Figure 6-68). Use the Emergency Stop button, in the Adjustment window, to
stop the needle guide from making contact with the dummy rack

Figure 6-68:
Sample Head
Control
Options

Note the position of the tube holder over the Dummy Rack. The hole in the
rack should be centered with the hole in the needle guide on the tube holder.
(Figure 6-69) NG means not good.
Figure 6-69:
Positioning of
Dummy Rack
Under Needle
Guide

702:038 Service Manual 6 - 47

 VARIANT II Hemoglobin Testing System

NG1 requires an adjustment to the Rear Rack Carrier Sampling Position.

Proceed to Step 5.

NG 2 requires an adjustment to the Tube Holder Unit (Section 6.6.1).

NG 3 requires an adjustment to both the sampling position and the tube holder
unit.

5. Select Up in the Sampling Head Control window. Select Home in the rear
VSS Adjustment Procedures

carriage field of the Adjustment window to move the Dummy Rack to home
position. It is not necessary to close the Sampling Head Control window.
Change the step value in the box below the Sampl Pos option. (Figure 6-67)
Press Enter after the number has been edited. Five steps equal 1 mm.
Increasing the value moves the rack to the left while decreasing the value moves
the rack to the right. Select Sampling Position again until the needle guide on
the Dummy Rack is under the needle guide on the tube holder. Select Down in
the Sampling Head Control Window. Repeat the procedure until the holes in
the needle guide and the rack are aligned properly.

6. Chose Up in the Sampling Head Control window and then close the window.
Select Home in the rear carriage field of the Adjustment window and remove
the Dummy Rack.

7. Select Store Data To EEPROM to save the new sampling position. Select Close
to close the Adjustment window.

8. Turn off the VSS, remove the interlock key and replace all covers.

6.28 Rear Rack Carrier Barcode Reading Position Adjustment

Adjustment to the Rear Rack Carrier Barcode Reading Position adjustment requires
the following items:

IL Key (P/N 2702291)

Sample Rack with Rack Barcode

1. Remove the needle cover and front cover. Install the IL key to bypass the
interlock switch.

2. Place the sample rack in the rear rack carrier.

3. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Barcode Term option in the rear rack carriage field. (Figure
6-70)

6 - 48 Service Manual 702:038

VARIANT II Hemoglobin Testing System

VSS Adjustment Procedures

Figure 6-70: Barcode Options

4. Select Reading Percent (Rack ID) in the Barcode Terminal window. (Figure 6-
61) The rack will move to the rack barcode position and the reader will lower
to scan the barcode. The reading in the field next to the Quit option must be
100%. Select Quit to stop the scanning.

5. If the reading is not 100%, an adjustment to the Barcode (Rack) position must
be made. Manually move the rack back and forth within the rack carrier fingers
to determine which direction to move the rack barcode position. Select Home in
the rear carriage field of the Adjustment window. It is not necessary to close
the Barcode Terminal window. Edit the step value in the box below the
Barcode (Rack) option. Press Enter after the number has been edited. Five
steps equal 1 mm. Increasing the value moves the rack to the left while
decreasing the value moves the rack to the right. Select Reading Percent (Rack
ID) in the Barcode Terminal window. Repeat the process until the scanning
value is 100%.

6. Close the Barcode Terminal window. Select Home in the Adjustment window
and remove the rack.

7. Select Store Data To EEPROM to save the new rack barcode position.

8. Remove the interlock key and replace all covers.

702:038 Service Manual 6 - 49

 VARIANT II Hemoglobin Testing System

6.29 Syringe Home Position Flag

The adjustment to the Home Position Sensor requires the following tool:

IL Key (P/N 2702291)

1. Remove the needle cover, front and top covers. Install the IL key to bypass the
interlock switch.
VSS Adjustment Procedures

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select SY1(5mL) Home. (Figure 6-71)

Figure 6-71: Syringe Options

Note the position of the Teflon tip of the syringe plunger. Adjust the top of the
tip by changing the Home position step value in the box below Sy1(5mL) until
it is at the first marking on the syringe barrel. (Figure 6-72) Press Enter after
the number is edited. One step equals 0.006 mm (1 mm is approx. 167 steps).
Increasing the value moves the plunger down while decreasing the value moves
it up.

6 - 50 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 6-72:
Syringe Tip for
Home Sensor
Position

VSS Adjustment Procedures

3. Observe the position of the flag in the sensor; it should be centered. A small
mirror may be required. (Figure 6-73)

Figure 6-73:
Flag Position
in Sensor

4. Repeat Steps 2 and 3 for the sampling syringe by selecting the SY2(1mL)
option.

5. If either of the flags is not positioned properly, turn off the VSS, unscrew the
syringe assembly loosen the screws securing the flag and adjust until the top of
the flag is in the center of the sensor. Tighten the screws to secure.

6. Remove the interlock key and replace the covers.

7. If adjustments were made to the Syringe Sensor Flag Position, the Syringe
Home Position (Section 6.30) and Pull Air Adjustment (Section 6.31) will need
to be checked.

702:038 Service Manual 6 - 51

 VARIANT II Hemoglobin Testing System

6.30 Syringe Home Position

Adjustment to the Syringe Home Position requires the following tool:

IL Key (P/N 2702291)

1. Remove the needle cover and front cover. Install the IL key to bypass the
interlock switch.
VSS Adjustment Procedures

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select the Home option in the SY1 (5ml) field. (Figure 6-71)

3. Look at the position of the Teflon tip of the plunger. The top horizontal part of
the tip must be located between the bottom of the metal band on the syringe and
the first marking on the syringe barrel. (Figure 6-74)

Figure 6-74:
Plunger Tip
Position

4. If the syringe tip is not in the proper position an adjustment is required. Edit the
step value in the box below the SY1(5ml) Home option pressing Enter after the
number is edited. One step equals 0.006 mm (1 mm is approx. 167 steps).
Increasing the value moves the plunger down while decreasing the value moves
it up. Select Home again and check the tip position. Repeat the procedure until
the plunger tip is aligned properly.

Alternatively the adjustment can be made by moving the plunger tip until it is
even with the metal band on the syringe (Figure 6-75) and then subtracting 60
from this step value to achieve the desired home position (Figure 6-74).

WARNING: Use extreme caution when adjusting the home position value.
Increasing the step value in large increments may cause the syringe to
overshoot the home position and break the barrel of the syringe.

6 - 52 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 6-75:
Plunger Tip
Position at
Top

VSS Adjustment Procedures

5. Repeat Steps 2-4 using the SY2 (1ml) option in the Adjustment window. Note
that the adjustment value must always be a negative number. A positive value
means that the flag position needs adjustment - see section 6.29.

6. The final check of the syringe home position is to observe the clearance
between the bottom of the syringe plunger and the platform. Loosen the
knurled nut securing the syringe plunger to the platform. Gently push up on the
nut and note if there is a gap between the platform and the bottom of the
plunger. (Figure 6-76) A slight gap should be seen. Perform this step on both
syringes. If the gap is significant or there is no gap, a readjustment to the home
position of that syringe must be done.

Figure 6-76:
Gap at Bottom
of Syringe

7. Select Store Data To EEPROM when both adjustments are complete to save the
new home positions.

8. Turn off the VSS, remove the interlock key and replace the covers.

9. If adjustments were made to the Syringe Home Position, the Pull Air
Adjustment (Section 6.31) must be performed.

702:038 Service Manual 6 - 53

 VARIANT II Hemoglobin Testing System

6.31 Pull Air Adjustment

The Pull Air Adjustment requires the following tool:

IL Key (P/N 2702291)

1. Remove the needle cover, front and top covers. Install the IL key to bypass the
interlock switch.
VSS Adjustment Procedures

2. Open the VSS Service Software and select the Adjustment option from the main
menu. Select Prime in the Syring2 field. (Figure 6-77) The 5mL Syringe will
go through a priming sequence.

Figure 6-77: Prime and Pull Air Option

3. Observe the position of the tubing at the back of Valve 1 (V1). The tubing must
be positioned as in Figure 6-78. Adjust if needed. This distance is critical for
proper performance.

Figure 6-78:
Tubing
Positions in V1

4. Select Pull Air in the Syring2 field. (Figure 6-74) The 1 mL syringe plunger will
aspirate air into the sample line. Check the end position of the liquid in the

6 - 54 Service Manual 702:038

VARIANT II Hemoglobin Testing System

tubing between V1 and V2. The end of the fluid must be centered between the
2 valves. (Figure 6-79)

Figure 6-79: Pull

Air Position
Between V1 and V2
V1

V2
V
Air

VSS Adjustment Procedures

Liqui
Liquid
Adjustment
air position
Syringe pump unit

5. If the end position of the fluid is not correct, an adjustment must be made. Edit
the step value in the box below the Pull Air option pressing Enter after the
number is edited. One step equals 0.1 µL. Increasing the value moves the
syringe plunger up (liquid moves to the back) while decreasing the value moves
it down (liquid move to the front). Select Prime and then Pull Air again and
check the liquid position. Repeat the procedure until the liquid is aligned
properly.

6. Select Store Data To EEPROM when the adjustment is complete to store the
new value.

7. Remove the interlock key and replace all covers.

702:038 Service Manual 6 - 55

 VARIANT II Hemoglobin Testing System
VSS Adjustment Procedures

6 - 56 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7.0 Replacement Procedures

7.1 VCS Parts Replacement

7.1.1 Main CPU Board (No. 242) P/N 270-2120

Replacement Procedures
1. Turn off the power to the VCS. Disconnect the power cord from the back of the
unit.

2. Remove the VCS cover and the fixing plate on the left side of the unit over the
boards. (Figure 7-1)

Figure 7-1:
Fixing Plate
Over Main
CPU Board

3. The Main CPU board is the one closest to the front of the unit. Use both clips
the board to lift the board from its socket and then pull it straight out. Carefully
remove the EEPROM (U7).

4. Remove the EEPROM (U7) on the replacement board and replace it with the
one taken from the old board. Verify that the version of EPROMS U19 and
U20 on the new board is current. If not remove the EPROMS U19 and U20
from the old board and install them on the new board. (Figure 7-2)

702:038 Service Manual 7 -1

 VARIANT II Hemoglobin Testing System

Figure 7-2:
Chip
Placement on
U7 Main CPU
EEPROM
Replacement Procedures

EPROM U20

EPROM U19

5. Install the new board securely in place.

6. Replace the cover, connect the power cord and turn on the power.

7. Perform the Column Heater adjustment (Section 5.2) and the Dynamic Mixer
adjustment (Section 5.5).

7.1.2 Pump Board (No. 244C) P/N 270-2122

1. Turn off the power to the VCS. Disconnect the power cord at the back of the
unit.

2. Remove the VCS cover and the fixing plate on the left side of the unit over the
boards. (Figure 7-1)

3. The Pump Board is the one closest to the back of the unit. Use both clips on the
board to lift the board from its socket and then pull it straight out.

4. Verify that the ROM chip (M2) on the new board is in place. (Figure 7-3) This
chip should only be changed if a new version of firmware is released. It is not
necessary to replace it with the one from the old board.

7 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-3:
ROM Chip
ROM (M2)
on Pump
Board

Replacement Procedures
5. Verify that the new board has the added resistors in the pressure transducer
circuit. If they are not present, modify the board using the procedure in
Appendix A.

6. Set the dip switches to the same position as they were on the old board (usually
all in the off position) and install the new board securely in place.

7. Replace the cover, connect the power cord and turn on the power.

8. Perform the Zero Pressure adjustment (Section 5.4.1), the High Pressure
Calibration (Section 5.4.2) and the Pump Current adjustment (Section 5.4.3).

7.1.3 Power Supply Board (No. 245B) P/N 270-2123

1. Turn off the power to the VCS. Disconnect the power cord at the back of the
unit.

2. Remove the VCS cover along with the brass cover on the top.

3. Disconnect the cables at CN 27, CN 28 and CN 30. (Figure 7-4)

702:038 Service Manual 7 -3

 VARIANT II Hemoglobin Testing System

CN 30
CN 28

CN 27
Replacement Procedures

Figure 7-4: Power Supply Board Connections

4. Remove the board from the four plastic standoff clips. (Figure 7-5)

Figure 7-5:
Clips on
Power
Supply
Board

Remove the board.

5. Install the new board securing it with the clips. Connect the cables.

6. Connect the power cord and turn on the power. Verify that the voltages
supplied by the board are within specification. Refer to Appendix A for voltage
specifications.

7. Replace the covers.

7 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7.1.4 Degasser Board (No. 246) P/N 270-2098

1. Turn off the power to the VCS. Disconnect the power cord at the back of the
unit.

2. Remove the VCS cover. Locate the degasser board on the left side, next to the
pump assembly.

3. Disconnect the cables at CN 33, CN 59 and CN 32. Remove the board by

opening the 4 white clips that secure it and pulling the board forward.

Replacement Procedures
4. Install the new board and secure the clips. Connect the cables.

5. Perform the Degasser adjustment procedures from Section 5.3.

7.1.5 Pump Unit

The procedure for the Pump Unit describes replacement of the following pump
components:

Pump Seal
Bushing and Seal Set
Check Valve
Piston and Spring
Photo Sensor
Pump Cam
Pump Motor

Replacement of the pump seal, bushing and seal set, check valve, piston spring and
piston do not require the complete removal of the pump assembly.

Pump Seal (P/N 270-0016W)

Replacement of the Pump Seal requires the following tool:

Seal Extraction Tool (P/N 2700211)

Figure 7-6 shows the pump seal.

Figure 7-6:
Pump Seal

702:038 Service Manual 7 -5

 VARIANT II Hemoglobin Testing System

1. Place both buffer bottles at bench level or lower to minimize siphoning.

2. Disconnect the stainless steel tubing from the inlet and outlet check valves of
both pump heads. (Figure 7-7)

Figure 7-7:
Tubing
Connections at
Check Valves
Replacement Procedures

3. Remove the screws from the front of one of the pump heads by using a hex
wrench. Loosen each screw alternately a little at a time in order to avoid
damage to the piston inside. (Figure 7-8) Carefully remove the pump head by
slowly pulling forward.

Figure 7-8:
Removing
the Pump
Head Screws

4. Remove the old pump seal by inserting the extraction tool into the seal and
pulling straight out. (Figure 7-9)

7 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-9:
Pump Seal
Removal

Replacement Procedures
5. Clean the pump head and check valves thoroughly with deionized water.

6. The pump seals must be degassed prior to installation in the pump head. The
seals can be kept in methanol until they are ready to be installed to save time. If
no methanol is available remove the plunger from a 10 mL syringe. Place the
seals into the barrel of the syringe. (Figure 7-10)

Figure 7-10:
Wetting the
Pump Seals

Cover the tip of the syringe with a fingertip, add 3-5 mL of deionized water to
the syringe barrel and replace the syringe plunger. Evacuate all of the air from
the syringe. Cover the syringe tip with a fingertip, pull back the plunger to
create a vacuum in the syringe and then shake vigorously. Release the plunger
quickly. Expel any air from the syringe and repeat this procedure until no air
bubbles are seen in the seal springs. Keep the seals in water until ready to
install.

7. Install the seal, with the spring facing the inside of the pump head, by pressing
down on it firmly. Do NOT use the extraction tool. Installation is best done
under the surface in a small container of deionized or distilled water to avoid
introduction of air.

8. Install the pump head onto the pump assembly being careful not to break the tip
of the piston. Make sure the inlet check valve is at the bottom. Refer to Figure
7-14 to identify the inlet check valve. Tighten the hex screws alternately until
they are tight and the pump head is securely seated with no gaps between the
pump head and the pump wash head behind it.

702:038 Service Manual 7 -7

 VARIANT II Hemoglobin Testing System

9. Connect the stainless steel tubing to the inlet and outlet check valves. Leave the
outlet tubing loose to allow purging of the pump in Step 11.

10. Repeat Steps 3-9 to install the second pump seal. Repeat the procedure for the
second pump if necessary.

11. Make sure an absorbent towel is in place below the pump heads. Attach a 25
mL syringe to the Pump A purge valve located directly below the pump.
Loosen the plastic fitting and slowly pull back on the syringe plunger to fill the
syringe. Repeat until no bubbles are seen coming from the valve. Remove any
Replacement Procedures

air from the syringe and force the buffer back into the purge port. Air in the
pump head will be driven out the loose outlet fitting along with buffer. Tighten
the outlet fittings. Repeat the procedure on the other pump head if it was
disassembled.

12. Disconnect the inlet tubing to the cartridge holder. Connect the tubing to a
backpressure regulator or a long HPLC column (e.g. Diamat A1c,
Catecholamine). Place the end over a waste container.

13. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the new seals to the maximum setting of
3.0. Select Start. Observe the stainless steel connections at the check valves.
There must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

14. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

Bushing and Seal Set (P/N 2700285)

Replacement of the Bushing and Seal Set requires the following tools:

Seal Extraction Tool (P/N 2700211)

Bushing/Seal Tool Attachment (P/N 2700211X)

Figure 7-11 shows the Bushing and Seal set components.

Figure 7-11:
Bushing and
Seal Set

1. Place both buffer bottles at bench level or lower to minimize siphoning.

7 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

2. Disconnect the stainless steel tubing from the inlet and outlet check valves of
both pump heads. (Figure 7-7)

3. Remove the screws from the front of one of the pump heads by using a hex
wrench. Loosen each screw alternately a little at a time in order to avoid
damage to the piston inside. (Figure 7-8) Carefully remove the pump head by
slowly pulling forward.

4. Disconnect the piston wash tubing on the wash head. Remove the screws
securing the wash head by using a hex wrench. Loosen each screw alternately a

Replacement Procedures
little at a time in order to avoid damage to the piston inside. Carefully remove
the pump wash head by slowly pulling forward.

5. Remove the old bushing and seal by inserting the extraction tool, without the
attachment, into the bushing and seal and pulling straight out.

6. Clean the wash head thoroughly with deionized water.

7. Install the attachment onto the extraction tool. (Figure 7-12)

Figure 7-12:
Extraction
Tool and
Attachment

8. Wet the bushing and place it onto the extraction tool attachment with the wide
end against the tool. Place the seal next to the bushing with the spring facing
away from the bushing. (Figure 7-13)

Figure 7-13:
Seal Extraction
Tool with
Bushing and
Seal
Bushing

9. Install the seal and bushing by pressing down on them firmly. (Figure 7-14)

702:038 Service Manual 7 -9

 VARIANT II Hemoglobin Testing System

Figure 7-14:
Installing the
Bushing and
Seal
Replacement Procedures

10. Install the wash head onto the pump assembly being careful not to break the tip
of the piston. Tighten the hex screws alternately until they are tight and the
wash head is securely seated with no gaps between the wash head and the pump
assembly. Connect the piston wash tubing to the ports on the wash head.

11. Install the pump head onto the pump assembly being careful not to break the tip
of the piston. Make sure the inlet check valve is at the bottom. Refer to Figure
7-14 to identify the inlet check valve. Tighten the hex screws alternately until
they are tight and the pump head is securely seated with no gaps between the
pump head and the wash head behind it.

12. Connect the stainless steel tubing to the inlet and outlet check valves. Leave the
outlet tubing loose to allow purging of the pump in Step 16.

13. Repeat steps 3-12 for the second bushing and seal. Repeat the procedure for the
second pump if necessary.

14. Make sure an absorbent towel is in place below the pump heads. Attach a 25
mL syringe to the Pump A purge valve located directly below the pump.
Loosen the plastic fitting and slowly pull back on the syringe plunger to fill the
syringe. Repeat until no bubbles are seen coming from the valve. Remove any
air from the syringe and force the buffer back into the purge port. Air in the
pump head will be driven out the loose outlet fitting along with buffer. Tighten
the outlet fittings. Repeat the procedure on the other pump head if it was
disassembled.

15. Disconnect the inlet tubing to the cartridge holder. Connect the tubing to a
backpressure regulator or a long HPLC column (e.g. Diamat A1c,
Catecholamine). Place the end over a waste container.

16. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the new seals to the maximum setting of

7 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

3.0. Select Start. Observe the stainless steel connections at the check valves.
There must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

17. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

Check Valves

Inlet Check Valve (P/N 270-0056)

Replacement Procedures
Outlet Check Valve (P/N 270-0057)

Figure 7-15 shows the Inlet and Outlet Check Valves.

Figure 7-15:
1 Check Valves

1. Inlet Check Valve

2. Outlet Check Valve

2

1. Place both buffer bottles at bench level or lower to minimize siphoning.

2. Disconnect the stainless steel tubing from the inlet or outlet check valve of the
pump head. (Figure 7-7)

3. Use a wrench to remove the check valve. (Figure 7-16)

Figure 7-16:
Check Valve
Removal
1

1. Inlet Check Valve

2. Outlet Check Valve

702:038 Service Manual 7 -11

 VARIANT II Hemoglobin Testing System

4. Install the new check valve and tighten it securely in place.

5. Connect the stainless steel tubing to the check valve.

6. Loosen the outlet tubing to allow purging of the pump in Step 9.

7. Repeat the procedure for the second check valve if necessary.

8. Make sure an absorbent towel is in place below the pump heads. Attach a 25
mL syringe to the Pump A purge valve located directly below the pump.
Replacement Procedures

Loosen the plastic fitting and slowly pull back on the syringe plunger to fill the
syringe. Repeat until no bubbles are seen coming from the valve. Remove any
air from the syringe and force the buffer back into the purge port. Air in the
check valve will be driven out the loose outlet fitting along with buffer. Tighten
the outlet fittings. Repeat the procedure on the other pump head if it was
disassembled.

9. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the valve to the maximum setting of 3.0.
Select Start. Observe the stainless steel connections at the check valves. There
must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

10. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

Piston and Piston Spring

Piston (P/N 270-0054)

Piston Spring (P/N 270-0108)

Figure 7-17 shows the Piston and Piston Spring.

Figure 7-17:
Piston and Piston
Spring

NOTE: It is recommended that the pump seal (P/N 270-0016W) also be

replaced when replacing the piston.

1 Place both buffer bottles at bench level or lower to minimize siphoning.

7 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

2. Disconnect the stainless steel tubing from the inlet and outlet check valves of
both pump heads. (Figure 7-7)

3. Remove the screws from the front of one of the pump heads by using a hex
wrench. Loosen each screw alternately a little at a time in order to avoid
damage to the piston inside. (Figure 7-8) Carefully remove the pump head by
slowly pulling forward.

4. Disconnect the piston seal wash tubing from the wash head. Remove the screws
securing the wash head by using a hex wrench. Loosen each screw alternately a

Replacement Procedures
little at a time in order to avoid damage to the piston inside. Carefully remove
the pump wash head by slowly pulling forward.

5. Carefully remove the piston and piston spring from the back of the wash head.
(Figure 7-18)

Figure 7-18: Removal of Piston and Piston Spring

6. Thoroughly clean the inside of the wash head with deionized water.

7. Install the new piston and/or piston spring by placing the spring on the piston
and then inserting the tip of the piston into the back of the wash head.

8. Install the wash head onto the pump assembly being careful not to break the tip
of the piston. Tighten the hex screws alternately until they are tight and the
wash head is securely seated with no gaps between the wash head and the pump
assembly. Connect the piston wash tubing to the port on the wash head.

9. Install the pump head onto the pump assembly being careful not to break the tip
of the piston. Make sure the inlet check valve is at the bottom. Refer to Figure
7-15 to identify the inlet check valve. Tighten the hex screws alternately until
they are tight and the pump head is securely seated with no gaps between the
pump head and the wash head behind it.

10. Connect the stainless steel tubing to the inlet and outlet check valves. Leave the
outlet tubing loose to allow purging of the pump in Step 13.

702:038 Service Manual 7 -13

 VARIANT II Hemoglobin Testing System

11. Repeat Steps 2-9 to install the second piston or piston spring if needed. Repeat
the procedure for the second pump if needed.

12. Make sure an absorbent towel is in place below the pump heads. Attach a 25
mL syringe to the Pump A purge valve located directly below the pump.
Loosen the plastic fitting and slowly pull back on the syringe plunger to fill the
syringe. Repeat until no bubbles are seen coming from the valve. Remove any
air from the syringe and force the buffer back into the purge port. Air in the
pump head will be driven out the loose outlet fitting along with buffer. Tighten
the outlet fittings. Repeat the procedure on the other pump head if it was
Replacement Procedures

disassembled.

13. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the valve to the maximum setting of 3.0.
Select Start. Observe the stainless steel connections at the check valves. There
must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

14. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

Motor Photo Sensor (P/N 270-2085)

Figure 7-19 shows the Motor Photo Sensor.

Figure 7-19:
Motor Photo
Sensor

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.
Place both buffer bottles at bench level or lower to minimize siphoning.

2. Remove the 2 stainless steel panels from above and below the pump heads.

3. Disconnect the stainless steel tubing from the inlet check valves at the bottom of
the pump head. (Figure 7-7)

4. Disconnect the piston backwash tubing.

5. Disconnect the stainless steel tubing at the pressure sensor and at the bottom of
the 3 way joint. (Figure 7-20)

7 -14 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-20:
Disconnecting the
Pump Tubing

Replacement Procedures
6. Remove the following cable connections on the motherboard (No. 243D)
located on the right side of the VCS (Figure 7-21): CN 16, CN 17, CN 18 and
CN 19.

Figure 7-21:
Removing the
Cables on the
Motherboard

7. Remove the four screws, two on each side, securing the pump assembly tray.
(Figure 7-22)

Figure 7-22:
Removing
the Pump
Assembly
Tray

8. Slowly and gently pull the pump assembly tray forward to remove it completely
from the VCS. Place the tray on a secure surface.

702:038 Service Manual 7 -15

 VARIANT II Hemoglobin Testing System

9. Remove the sensor cover at the back of the motor. (Figure 7-23)

Figure 7-23:
Photo Sensor
Cover
Replacement Procedures

10. Remove the old sensor (Figure 7-24) and replace it with the new one. Repeat
for the second pump if needed.

Figure 7-24:
Photo Sensor
Placement

Photo Sensor

11. Gently slide the pump assembly tray back into the VCS. Re-install the 2
stainless steel panels. Connect the cables to the motherboard and the stainless
steel tubing at the inlet check valve, three way joint and pressure sensor. Re-
connect the piston backwash tubing. Secure the pump tray with the 4 screws.

12. Loosen the fittings at the outlet check valves of both pumps. Make sure an
absorbent towel is in place below the pump heads. Attach a 25 mL syringe to
the Pump A purge valve located directly below the pump. Loosen the plastic
fitting and slowly pull back on the syringe plunger to fill the syringe. Repeat
until no bubbles are seen coming from the valve. Remove any air from the
syringe and force the buffer back into the purge port. Air in the pump head will
be driven out the loose outlet fitting along with buffer. Tighten the outlet
fittings. Repeat the procedure on Pump B.

7 -16 Service Manual 702:038

VARIANT II Hemoglobin Testing System

13. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the valve to the maximum setting of 3.0.
Select Start. Observe the stainless steel connections at the check valves. There
must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

14. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

Pump Cam (P/N 270-0217)

Replacement Procedures
This procedure requires molybdenum and lithium based grease.

Figure 7-25 shows the Pump Cam.

Figure 7-25:
Pump Cam

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.
Place both buffer bottles at bench level or lower to minimize siphoning.

2. Remove the 2 stainless steel panels from above and below the pump heads.

3. Disconnect the stainless steel tubing from the inlet check valves at the bottom of
the pump head. (Figure 7-7)

4. Disconnect the piston backwash tubing.

5. Disconnect the stainless steel tubing at the pressure sensor and at the bottom of
the 3 way joint. (Figure 7-20)

6. Remove the following cable connections on the motherboard (No. 243D)

located on the right side of the VCS (Figure 7-21): CN 16, CN 17, CN 18 and
CN 19.

7. Remove the four screws, two on each side, securing the pump assembly tray.
(Figure 7-22)

8. Slowly and gently pull the pump assembly tray forward to remove it completely
from the VCS. Place the tray on a secure surface.

702:038 Service Manual 7 -17

 VARIANT II Hemoglobin Testing System

9. Remove the four hex screws holding the pump head "U" block. (Figure 7-26)

Figure 7-26:
Removing the
"U" Block
Replacement Procedures

Gently pull the "U" block forward to completely remove it from the pump
assembly.

10. Two setscrews at two different positions secure the pump cam. Completely
remove the first setscrew at each position and loosen the second ones. Remove
the cam from the shaft by gently pulling forward. (Figure 7-27)

Figure 7-27: Removing the Pump Cam

If the cam is difficult to remove, twist it off while holding the back end of the
motor shaft with an adjustable wrench.

11. Remove the Bearing Rings (P/N 270-0198) and the Roller Bearing (P/N 270-
0199) from the old cam. (Figure 7-28)

Figure 7-28:
Bearing Rings and
Roller Bearing

7 -18 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Wipe the rings and bearing to remove the old grease.

12. Re-grease the roller bearing and bearing rings thoroughly with molybdenum or
lithium based grease making sure the grease gets between the crevices of the
roller bearing. Place one bearing ring on the new cam followed by the roller
bearing and the second bearing ring.

13. Place the cam back onto the shaft with one of the setscrew positions over the
flat part of the shaft. Make sure the bearing ring on the cam is against the back
with no gaps. Securely tighten the first setscrews for each of the two positions.

Replacement Procedures
Insert the second setscrews onto the first setscrews and tighten securely.

14. Repeat steps 9-13 for the second pump if needed.

15.It is recommended to inspect and re-grease the Cam Follower, Piston Rod and
Linear Bearing.

16. Slide the Cam Follower and Piston Rod out of the Linear Bearing. (Figure 7-
29)

1. Piston Rod (P/N 270-0228)

2. Cam Follower (P/N 270-0216)

3 3. Linear Bearing (P/N 270-0229)

Figure 7-29: Removing the Piston Rod and Cam Follower

Wipe the cam follower and piston rod to remove the old grease. Re-grease the
cam follower thoroughly using molybdenum or lithium based grease. Place a
very light film of lithium based grease on the outside surface of the piston rod.
Inspect the linear bearing.

17. Place the piston rod back into the linear bearing making sure the roller on the
side faces toward the center.

702:038 Service Manual 7 -19

 VARIANT II Hemoglobin Testing System

18. Repeat steps 15-17 for the other cam follower and piston rod.

19. Secure the "U" block to the pump assembly using the four hex screws. Make
sure the inlet and outlet check valves of the pump head are in their proper
positions before tightening the hex screws.

20. Gently slide the pump assembly tray back into the VCS. Connect the cables to
the motherboard and the stainless steel tubing at the inlet check valve, three way
joint and pressure sensor. Re-attach the piston backwash tubing and stainless
steel panels.
Replacement Procedures

21. Turn on the power to the VCS.

22. Loosen the fittings at the outlet check valves of both pumps. Make sure an
absorbent towel is in place below the pump heads. Attach a 25 mL syringe to
the Pump A purge valve located directly below the pump. Loosen the plastic
fitting and slowly pull back on the syringe plunger to fill the syringe. Repeat
until no bubbles are seen coming from the valve. Remove any air from the
syringe and force the buffer back into the purge port. Air in the pump head will
be driven out the loose outlet fitting along with buffer. Tighten the outlet
fittings. Repeat the procedure on Pump B.

23. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the valve to the maximum setting of 3.0.
Select Start. Observe the stainless steel connections at the check valves. There
must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

24. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

Pump Motor (P/N 270-2082)

Figure 7-30 shows the Pump Motor Assembly.

Figure 7-30:
Pump Motor
Assembly

7 -20 Service Manual 702:038

VARIANT II Hemoglobin Testing System

NOTE: The Pump Motor Assembly was changed on 25/01/02 and is not
compatible with any previous version or its components.

1. Complete Step 1-10 for removing the Pump Cam on page 7-18.

2. Remove the pump sensor cover at the back of the pump.

3. Turn the pump assembly tray over and remove the 2 screws securing the sensor

Replacement Procedures
bracket. Remove the bracket.

4. Remove the sensor from the bracket.

5. Remove the 2 long pan head screws at the top, left and bottom, right that secure
the motor to the front plate. Do NOT remove the black hexagonal screws.
(Figure 7-31)

Figure 7-31:
Removing
the Pump

6. Install the new motor on the plate securing it with the 2 long pan head screws.

7. Place the new encoder wheel on the shaft and secure it with the setscrews.

8. Secure the sensor to the bracket. Place the bracket on the tray with the encoder
wheel in the sensor. Secure the bracket from underneath the tray.

9. Place the new cover over the sensor and secure it in place.

10. Replace the "U" block.

11. Gently slide the pump assembly tray back into the VCS. Connect the cables to
the motherboard and the stainless steel tubing at the inlet check valve, three way

702:038 Service Manual 7 -21

 VARIANT II Hemoglobin Testing System

joint and pressure sensor. Re-attach the piston backwash tubing and stainless
steel panels.

12. Turn on the power to the VCS.

13. Loosen the fittings at the outlet check valves of both pumps. Make sure an
absorbent towel is in place below the pump heads. Attach a 25 mL syringe to
the Pump A purge valve located directly below the pump. Loosen the plastic
fitting and slowly pull back on the syringe plunger to fill the syringe. Repeat
until no bubbles are seen coming from the valve. Remove any air from the
Replacement Procedures

syringe and force the buffer back into the purge port. Air in the pump head will
be driven out the loose outlet fitting along with buffer. Tighten the outlet
fittings. Repeat the procedure on Pump B.

14. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of the pump with the valve to the maximum setting of 3.0.
Select Start. Observe the stainless steel connections at the check valves. There
must be no leaks at these fittings. Tighten the nuts if any leaks are seen.

15. Select Status /1.0 from the main menu of the VCS Service Software. Observe
the pressure reading. Let the pump continue to run until the pressure is stable.

16. Perform the Pump Current Adjustment in Section 5.4.3.

7.1.6 Column Heater

Column Heater Block (P/N 270-2091)

This procedure requires Thermal Compound.

Figure 7-32 shows the Column Heater Block.

Figure 7-32:
Column
Heater Block

1. Open the door of the column heater block and remove the 4 screws securing it
to the column heater unit. Remove the block.

7 -22 Service Manual 702:038

VARIANT II Hemoglobin Testing System

2. Clean the thermal compound off the aluminum plate on the column heater unit.
Use a small piece of steel wool and water to remove any dried compound being
careful not to scratch or pit the surface.

3. Coat the aluminum plate on the column heater unit with fresh thermal
compound making sure the compound completely covers the plate. Coat the
back of the new column heater block with thermal compound in the area that
will contact the stainless steel plate. The compound must be smooth with no
air pockets.

Replacement Procedures
4. Place the column heater block against the stainless steel plate on the column
heater unit and twist back and forth slightly to make sure the thermal compound
completely contacts all surfaces.

5. Secure the block with the 4 screws that were removed.

Thermal Sensor Assembly (P/N 270-2092)

This procedure requires Thermal Compound.

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.

2. Remove the cover of the VCS.

3. Remove the connectors CN37 from the interconnect board (#249A) at the back
of the column heater unit.

4. Disconnect all cable and tubing connections to the detector, syringe, 6 port
valve, 7 port valve, pressure sensor and mixer.

5 Remove the four screws of the tray holding the column heater unit to the VCS.
(Figure 7-33) Remove the tray.

Left Side Right

RightSide
side

Figure 7-33: Removing the Column Heater Tray

702:038 Service Manual 7 -23

 VARIANT II Hemoglobin Testing System

6. Remove the four screws securing the column heater unit to the tray.

7. Disconnect the sensor cable at CN38 on the interconnect board (#249A) on the
back of the unit. Remove the 4 screws securing the aluminum plate to the back
of the column heater unit. Remove the interconnect board and the pillars
holding it to the column heater unit. (Figure 7-34) Remove the back plate
completely.

Figure 7-34:
Back of
Replacement Procedures

Column
Heater Unit

8. Remove the 4 screws securing the front, aluminum plate to the heat sink.
(Figure 7-35)

Figure 7-35:
Screws
Securing
Heat Sink

9. Remove the spring securing the sensor. Remove the sensor.

10. Remove the old thermal compound from the plate at the sensor position. Place
new thermal compound in the sensor position on the plate and on the back of the
new sensor. The compound must be smooth with no air pockets. Place the
sensor onto the plate and twist slightly to make sure thermal compound contacts
all surfaces. Make sure the sensor cables are coming out the side of the block
where the thermal fuse is inserted. (Figure 7-36)

7 -24 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-36:
Thermal
Sensor
Placement

Replacement Procedures
11. Screw the sensor onto the plate. Place the spring over the sensor.

12. Place the plate back on the assembly with the peltier modules contacting the
thermal compound on the plate. Twist slightly to make sure thermal compound
contacts all surfaces of the modules and plate. Secure the plate to the assembly
with the 4 screws.

13. Replace the back plate of the assembly. Secure the aluminum plate at the
bottom along with the sand-offs and board at the top.

14. Connect the sensor cable to CN38 on the interconnect board.

15. Secure the column heater unit to the tray with the 4 screws that were removed.

16. Install the tray into the VCS and secure it with the 4 screws that were removed.

17. Re-connect all tubing and cable connections that were removed.

18. Replace the cover and plug the power cord into the VCS.

Peltier Modules (P/N 270-0208)

Follow the procedure on Page 7-23 for removal of the Thermal Sensor Assembly.
The sensor does not need to be removed. Clean the old thermal compound off the
aluminum plate and the column heater unit. Coat all of these surfaces with new
thermal compound along with both sides of the new peltier modules. The
compound must be smooth with no air pockets.

702:038 Service Manual 7 -25

 VARIANT II Hemoglobin Testing System

Thermal Fuse Assembly (P/N 270-0127)

This procedure requires Thermal Compound and a heat source.

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.

2. Remove the cover of the VCS.

3. Remove the connector CN37 from the interconnect board at the back of the
column heater unit.
Replacement Procedures

4. Disconnect all cable and tubing connections to the detector, syringe, 6 port
valve, 7 port valve, pressure sensor and mixer.

5 Remove the four screws of the tray holding the column heater unit to the VCS.
(Figure 7-32) Remove the tray.

6. Remove the four screws securing the column heater unit to the tray.

7. Remove the black cover on the side of the column heater unit to expose the fuse
assembly.

8. Disconnect the fuse cables on the interconnect board (#249A). Remove the fuse
from the side of the block. (Figure 7-37)

Figure 7-37: Removing the Thermal Fuse

9. The new fuse assembly has heat shrink tubing covering the fuse. It is necessary
to heat shrink this tubing before installing it into the column heater unit.

7 -26 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Warning: Make sure the entire fuse is completely covered by the heat shrink
tubing. Any exposure of the fuse to the metal part of the column heater unit
will cause damage to the VCS Mother Board.

10. Clean the fuse hole on the column heater unit to remove any old thermal
compound. Place a small dab of thermal compound into the fuse hole. Insert
the covered fuse into the hole.

Replacement Procedures
11. Connect the cables from the fuse to the interconnect board.

12. Install the tray into the VCS and secure it with the 4 screws that were removed.

13. Re-connect all tubing and cable connections that were removed.

14. Replace the cover and plug the power cord into the VCS.

7.1.7 Detector

Optical Unit (P/N 270-0201)

Figure 7-38 shows the Optical Unit.

Figure 7-38:
Detector
Optical Unit

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.

2. Remove the cover of the VCS.

3. Remove the brass cover at the top of the VCS.

4. Disconnect the flow cell inlet and outlet tubing.

5. Remove the cover to the detector board. Disconnect the cables at CN45, CN46
and CN47.

6. Remove the 4 screws securing the optical unit. Remove the unit.

702:038 Service Manual 7 -27

 VARIANT II Hemoglobin Testing System

7. Install the new optical unit and secure it with the 4 screws.

8. Connect the cables from the new unit to the detector board.

9. Connect the flow cell inlet and outlet tubing.

10. Plug the power cable into the receptacle at the back of the VCS. Turn on the
VCS.

11. Perform all detector adjustment procedures in Section 5.9.

Replacement Procedures

12. Replace the detector board, brass and external covers.

Flow Cell (P/N 270-0203)

Figure 7-39 shows the Flow Cell. The bracket is not included with this part
number.

Figure 7-39:
Flow Cell

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.

2. Remove the cover of the VCS.

3. Remove the brass cover at the top of the VCS.

4. Disconnect the flow cell inlet and outlet tubing.

5. Remove the screw at the top of the lamp cover. Loosen the 2 screws at the front
of the lamp cover and carefully slide the cover to the right until the screws
securing the optical unit cover are exposed.

6. Remove the 4 screws securing the optical unit cover. Remove the cover.

7. Remove the 2 hex screws securing the flow cell to the bracket. (Figure 7-40)
Do NOT remove any other screws.

7 -28 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-40:
Removing
the Flow Cell

Replacement Procedures
Carefully slide the flow cell out of the bracket and remove it completely.

8. Clean up any dried buffer in and around the bracket with deionized water on a
soft towel.

9. Install the new flow cell and secure it in place.

10. Connect the inlet and outlet tubing to the new flow cell.

11. Connect the power cord and turn on the VCS.

12. Open CDM Maintain/Instruments screen and prime the buffers through the flow
cell as follows:

Flow Rate: 2 mL/minute

Buffer B: 100%
Time: 5 minutes

13. Place a piece of white paper at the end of the light path to observe the lamp
filament. (Figure 7-41)

Figure 7-41:
Observing the
Lamp Filament

702:038 Service Manual 7 -29

 VARIANT II Hemoglobin Testing System

14. The coils of the lamp filament should be clear and placed in the center of the
surrounding halo. Figure 7-42 shows proper positioning of the filament. Figure
7-43 shows bad positioning of the filament.
Replacement Procedures

Figure 7-42: Proper

Filament Position Figure 7-43: Bad
Filament Position

If the filament is not positioned properly, re-test with a second lamp. If unable
to achieve proper alignment, loosen the screws securing the flow cell bracket to
the optical bench. Adjust the position of the bracket until the alignment is
correct.

15. Replace the optical unit and lamp covers and secure them in place.

16. Open CDM Maintain/Instruments screen and prime the buffers through the flow
cell as follows:

Flow Rate: 2 mL/minute

Buffer B: 100%
Time: 5 minutes

Observe the Light Level reading in the Detector field of the screen. The reading
should be approximately 0.02V. Select Zero 20mV on the screen to zero the
detector. If the light level drifts down repeat Zero 20mV until the level
stabilizes.

17. While Pump B is running select the Monitor option at the top of the screen.
Select Start and monitor the baseline to verify that it is flat. Select Stop when
the pump stops. If the baseline is not flat it indicates air in the flow cell.
Remove the air before proceeding to the next step.

18. Repeat Step 16 above using Buffer A (0% B).

19. Perform all detector adjustment procedures in Section 5.9.

7 -30 Service Manual 702:038

VARIANT II Hemoglobin Testing System

20. Replace all covers when done.

Lamp Assembly (P/N 270-0202)

Figure 7-44 shows the Lamp Assembly.

Figure 7-44:
Lamp
Assembly

Replacement Procedures
1. Turn off the power to the VCS. Remove the power cable at the back of the unit.

2. Remove the cover of the VCS.

3. Remove the brass cover at the top of the VCS.

4. Remove the screw at the top of the lamp cover. Loosen or remove the 2 screws
at the front of the lamp cover. Remove the cover.

5. Remove the screw holding the lamp assembly. Disconnect the cable from the
detector board at CN37. (Figure 7-45)

Figure 7-45:
Removing
the Lamp
Assembly

6. Install the new lamp by securing it with the screw and connecting the cable at
CN37.

7. Disconnect the flow cell inlet and outlet tubing and remove the optical unit
cover. Reconnect the inlet and outlet tubing.

702:038 Service Manual 7 -31

 VARIANT II Hemoglobin Testing System

8. Connect the power cord and turn on the VCS.

9. Draw a line across a piece of white paper or card 25 mm from one edge.
Position the paper in front of the flow cell bracket making sure the paper is
resting on the optical unit and not on the bracket or the bracket screws. Observe
the position of the lamp filament on the line. (Figure 7-46)

Figure 7-46:
Lamp
Alignment
Replacement Procedures

The filament coils must be centered on the line. The filament coils must also be
distinctly visible at the photodiode. Refer to the Flow Cell Replacement
procedure on Page 7-29 to check the clarity of the lamp filament.

The lamp comes pre-aligned and adjustments should not be needed. If the lamp
is not aligned properly, loosen the appropriate hex screw(s) ONLY and make
the adjustment. The two screws behind the lamp and in front of the board
adjust the focus of the lamp while the one screw placed above these screws
attaches the assembly to the optical bench. The middle 2 screws inside the lamp
housing, underneath the lamp, adjust the vertical and axial positions.

WARNING: When adjusting the lamp, use CAUTION as THE LAMP

ASSEMBLY IS HOT.

10. Replace the optical unit cover and lamp cover.

11. Perform all detector adjustment procedures in Section 5.9.

12. Replace all covers when done.

7.1.8 Mixer Stir Bar and Gasket (P/N 270-0131 and 270-0132)

Figure 7-47 shows the Mixer Stir Bar and Gasket.

7 -32 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-47:
Mixer Stir Bar
and Gasket

1. Remove the cover of the VCS.

Replacement Procedures
2. Disconnect the stainless steel tubing from the top of the mixer along with the 4
screws securing the mixer cover. (Figure 7-48) Remove the cover.

Figure 7-48: Removing the Mixer Cover

3. Remove the old magnet and gasket and replace it with the new magnet and
gasket.

4. Open the VCS Service Software. Open the appropriate port and select the
Pump option from the main screen. Select ON in the Dynamic Mixer field and
verify that the stir bar is turning. Select OFF when done.

5. Replace the mixer cover and secure it with the 4 screws. Connect the stainless
steel tubing at the top. Replace the VCS cover.

7.1.9 Vacuum Pump (P/N 270-2097)

Figure 7-49 shows the vacuum pump.

702:038 Service Manual 7 -33

 VARIANT II Hemoglobin Testing System

Figure 7-49:
Vacuum Pump
Replacement Procedures

1. Turn off the power at the VCS. Remove the power cable at the back of the unit.
Place both buffer bottles at bench level or lower to minimize siphoning.

2. Remove the VCS cover.

3. Disconnect CN24 from the motherboard (#243).

4. Remove the stainless steel tubing from the inlet check valves of both pumps.
(Figure 7-50) Remove the 4 screws securing the stainless steel panel at the
bottom of the VCS.

NOTE: For serial numbers 11131 or lower it is necessary to disconnect the

silicone tubing at the side of the piston seal wash port.

Figure 7-50:
Removing the
Bottom Panel
(S/N < 11131)

5. Carefully pull the front panel forward. Disconnect the buffer tubing from the
back of the pump purge ports. (Figure 7-51) Remove the panel.

7 -34 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-51:
Pump Purge
Port Tubing

Replacement Procedures
6. Remove the 4 screws, 2 on each side, that secure the degasser tray. Disconnect
the buffer lines at the back of the degasser. (Figure 7-52) Pull the tray forward
to remove.

Figure 7-52: Removing the Degasser Tray

7. Disconnect the air inlet and outlet tubing from the vacuum pump. Note which
tubing is which so they are not reversed when installing the new vacuum pump.
(Figure 7-53)

Figure 7-53:
Removing the
Vacuum Pump
Outlet
Tubing
Inlet

702:038 Service Manual 7 -35

 VARIANT II Hemoglobin Testing System

Disconnect the motor lines (red and black) noting the positions.

8. Turn the degasser tray over and remove the 3 screws securing the vacuum pump
to the tray. (Figure 7-54)

Figure 7-54:
Removing
the Vacuum
Pump
Replacement Procedures

9. Remove the long rubber grommets from the old pump and place them on the
new pump. (Figure 7-55)

Figure 7-55: Removing

the Vacuum Pump
Grommets

10. Secure the new vacuum pump to the degasser tray with the 3 screws. Connect
the motor lines and the air inlet and outlet tubing in their proper positions.

11. Place the degasser tray into the VCS. Connect the buffer tubing at the back of
the degasser. Secure the tray in place with the 4 screws.

12. Connect the buffer lines at the back of the pump purge ports. Secure the front
panel with the 4 screws. Connect the tubing to the inlet check valves and the
silicone tubing to the piston seal wash port if it was disconnected. Connect CN
24 to the motherboard.

13. Replace the cover and connect the power cable. Turn on the VCS.

14. Attach a 25 mL syringe to the Pump A purge valve located directly below the
pump. Loosen the plastic fitting and slowly pull back on the syringe plunger to

7 -36 Service Manual 702:038

VARIANT II Hemoglobin Testing System

fill the syringe. Repeat until no bubbles are seen coming from the valve.
Repeat for Pump B.

15. Open the VCS Service Software. Select the Pump option from the main menu.
Change the flow rate of Pump A to the maximum setting of 3.0. Select Start.
Observe the stainless steel connections at the inlet check valves. There must be
no leaks at these fittings. Tighten the nuts if any leaks are seen. Select Status
/1.0 from the main menu of the VCS Service Software. Observe the pressure
reading. Let the pump continue to run until the pressure is stable. Repeat for
Pump B.

Replacement Procedures
7.1.10 Syringe Lead Screw and Flange Nut (P/N 270-2221)

This procedure requires a molybdenum-based grease.

Figure 7-56 shows the Syringe Lead Screw and Flange Nut.

Figure 7-56: Syringe

Lead Screw and
Flange Nut

1. Turn off the power to the VCS. Remove the power cable at the back of the unit.

2. Remove the cover of the VCS.

3. Remove the connector CN37 from the interconnect board (#249A) at the back
of the column heater unit.

4. Disconnect all cable and tubing connections to the detector, syringe, 6 port
valve, 7 port valve, pressure sensor and mixer.

5 Remove the four screws of the tray holding the column heater unit and syringe
to the VCS. (Figure 7-33) Remove the tray.

6. Remove the knurl nut that secures the syringe. Unscrew the syringe and remove
it.

7. Loosen the 2 screws that secure the motor at the top of the assembly. (Figure 7-
57)

702:038 Service Manual 7 -37

 VARIANT II Hemoglobin Testing System

Figure 7-57:
Syringe
Motor
Replacement Procedures

Move the motor about until the belt can be removed from the pulley.

8. Remove the 3 screws securing the bearing retainer plate at the top of the lead
screw. (Figure 7-58) Remove the plate.

Figure 7-58:
Bearing
Retainer Plate

9. Manually rotate the lead screw until the flange nut and syringe plunger driver
are completely disengaged from the bottom of the lead screw shaft. Remove the
lead screw from the top of the assembly.

10. Remove the bearing ring and pulley from the lead screw. Remove the upper
bearing retainer nut and the upper bearing.

WARNING: The pulley is made of aluminum, which is easily broken. Do not

pry on the flanges.

11. Remove the 2 screws securing the flange nut to the syringe plunger driver.
Remove the flange nut. (Figure 7-59)

Figure 7-59:
Flange Nut

7 -38 Service Manual 702:038

VARIANT II Hemoglobin Testing System

12. Install the new flange nut and secure it with the 2 screws.

13. Install the upper bearing, retainer nut, pulley and bearing ring from the old lead
screw onto the new lead screw. Do not tighten the setscrews on the pulley.

14. Thoroughly lubricate the new lead screw threads with a molybdenum based
grease and place it in the assembly from the top. Manually raise the syringe
plunger driver and turn the lead screw until the bottom shaft completely clears
the flange nut and plunger driver. Lower the plunger driver until the lead screw
shaft is securely placed into the lower bearing at the bottom of the assembly.

Replacement Procedures
The upper bearing must be completely in the bearing ring. Replace the bearing
retainer plate and secure it to the assembly with the 3 screws.

15. Place the belt over the 2 pulleys on the motor and lead screw. Verify that the
belt is completely horizontal between the 2 pulleys. Pull the motor until the belt
is tight, but do not over tighten. Tighten the screws securing the motor.
Securely tighten the setscrews on the pulley.

16. Manually turn the lead screw from the top to get the grease into the threads.

17. Replace the syringe.

18. Place the tray into the VCS and reconnect all tubing and cables. Secure the tray
with the 4 screws.

19. Plug the power cord into the back of the unit and turn on the power. Verify that
the syringe initializes properly.

20. Open the VCS Service Software. Using the Syringe option, prime the syringe
until no air bubbles are present.

7.1.11 6 Port and 7 Port Valves

The following procedure applies to changing the rotor seal and stator face on either
the 6 or 7 Port Valve.

Required Parts:

VARIANT II Rebuild Kit for 6 Port Rocket Valve RV700-123 (P/N 270-
2169)
VARIANT II Rebuild Kit for 7 Port Rocket Valve RV703-103 (P/N 270-
2170)

Figure 7-60 shows the components of a typical valve.

702:038 Service Manual 7 -39

 VARIANT II Hemoglobin Testing System

Figure 7-60:
Valve
Components
Replacement Procedures

1. Remove all of the stainless steel tubing connected to the stator. For the 6 Port
Valve it is not necessary to remove the sample loop.

2. Remove the 3 stator screws with a 9/64 inch hex key.

3. Remove the stator and stator face assembly from the stator ring. If needed,
remove the stator ring screws.

4. Remove the stator ring.

5. Gently pull the rotor seal off the shaft assembly.

7 -40 Service Manual 702:038

VARIANT II Hemoglobin Testing System

6. Place the new rotor seal onto the shaft assembly with the grooves facing the
stator. The 3 holes on the rotor seal will only fit on the assembly one way.
(Figure 7-61)

Figure 7-61:
Placement of
Rotor Seal
on Shaft
Assembly

Replacement Procedures
7. Replace the stator ring so the 2 short pins on the ring are placed into the
corresponding holes in the body. Replace the stator ring screws if they were
removed.

8. Place the new stator face assembly on the stator matching the pins to the holes
in the stator. The stator face will only fit on the stator one way.

9. Replace the stator and stator face assembly on the valve so that the pin on the
stator ring is in the hole on the stator.

10. Replace the 3 stator screws. Tighten each screw one half turn past fingertight.

702:038 Service Manual 7 -41

 VARIANT II Hemoglobin Testing System

7.2 VSS Parts Replacement

7.2.1 Syringe Plungers 5 mL ITO (P/N 270-2293) and 1 mL ITO (P/N 270-
2294)

NOTE: Life expectancy of the plungers is 10,000 strokes. Life expectancy of

the syringe barrel is 20,000 strokes.
Replacement Procedures

1. Remove the needle cover and front cover of the VSS.

2. Open the VSS Service software.

3. Select the Manual screen and move the both syringes down.

4. Remove the knurled nut and lock washer securing the syringe plunger to the
platform. Unscrew the syringe from the syringe assembly. (Figure 7-62)

Figure 7-62: Removing the VSS Syringes

5. Pull the plunger out of the syringe barrel. Place the barrel into a container of
deionized water. Insert the new plunger into the barrel while it is still in the
water.

6. Place the syringe back onto the syringe assembly by screwing it into the syringe
port. Do Not Overtighten. Replace the lock washer and knurled nut and
secure the plunger to the platform.

7. Use the VSS Service Software to perform a prime of the replaced syringe
plunger.

8. Replace the covers.

7 -42 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7.2.2 Syringe Tubing Replacement (P/N 270-2334)

Figure 7-63 shows the Syringe Tubing.

Figure 7-63:
Syringe
Tubing

Replacement Procedures
1. Remove the needle cover, front and top covers of the VSS.

2. Remove the tubing assembly at the pinch valve connection, the front of the inlet
port behind the pinch valves and from the tops of the syringes. (Figure 7-64)

NOTE: Make note of how the tubing is routed through the pinch valves before
removal.

Figure 7- 64:
Removing the
Syringe Tubing

3. Install the new tubing connecting it at the 4 positions and routing through the
pinch valves.

4. Use the VSS Service Software to prime the syringes.

702:038 Service Manual 7 -43

 VARIANT II Hemoglobin Testing System

5. Perform the procedure from Section 6.4.19 Pull Air Adjustment.

6. Replace all covers.

7.2.3 Pinch Valves 1 and 2 (P/N 270-2070)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

Replacement Procedures

3. Remove the tubing from both valves.

NOTE: Make note of how the tubing is routed through the pinch valves before
removal.

4. Remove the cables at CN 81 and CN 82 on the connection board.

5. Remove the 4 screws securing the pinch valve platform over the syringe
assembly. Turn the platform over and remove the 4 screws securing the valve
to be replaced. (Figure 7-65)
Figure 7-65:
Removing
Pinch Valves
1 and 2

6. Install the new pinch valve by securing it to the platform. Place the platform
over the syringe assembly and secure it with the 4 screws.

7. Replace the tubing in the pinch valves, making sure they are routed correctly.

8. Connect the cables at CN 80 and CN 81 on the connection board.

9. Replace the power cord and turn on the VSS.

10. Perform the procedure in Section 6.31 Pull Air Adjustment.

11. Replace all covers.

7 -44 Service Manual 702:038

VARIANT II Hemoglobin Testing System

7.2.4 Syringe Home Sensor PCB (P/N 270-2038)

1. Turn off the power at the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the cable at CN 850 on the sensor PCB at the back of the syringe
assembly.

4. Remove the 2 screws securing the sensor to the syringe assembly. Make note of

Replacement Procedures
the position of the flags in the sensor before removal.

NOTE: If it is difficult to remove the sensor PCB it will be necessary to remove

the entire syringe assembly first. Follow Steps 3-6 in Section 7.2.5 Syringe
Lead Screw and Flange Nut.

5. Place the new sensor PCB onto the syringe assembly with the flags in the same
positions as on the old PCB. Secure the sensor PCB with the 2 screws. Re-
install the syringe assembly if it was removed.

6. Replace the cable at CN 850 on the sensor PCB.

7. Replace the power cord and turn on the VSS.

8. Perform the procedure in Section 6.30 Syringe Home Position.

9. Replace all covers.

7.2.5 Syringe Pump Lead Screw and Flange Nut (P/N 270-2224)

1. Turn off the power at the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the tubing at the top of both syringes. Leave the tubing in the pinch
valves.

4. Disconnect the Wash/Diluent supply tubing and tape the end above the bottle
level to prevent siphoning.

5. Remove the 4 screws securing the platform holding the pinch valves. Remove
the platform with the pinch valves.

702:038 Service Manual 7 -45

 VARIANT II Hemoglobin Testing System

6. Disconnect the cable at CN 80 from the Syringe Connection PCB (No. 253-1)

7. Remove the 2 screws on the left side of the syringe assembly and loosen the 2
screws on the right side. Remove the assembly.

8. Remove the knurled nut and lock washer of the syringe whose lead screw will
be replaced. Rotate the motor by hand to lower the platform and then remove
the syringe.

9. Remove the 4 screws securing the motor for the lead screw to be replaced.
Replacement Procedures

Remove the motor and the belt.

10. Follow Steps 8-14 in Section 7.1.10 for removal and installation of the VCS
Syringe Lead Screw and Flange Nut.

11. Place the belt over the pulley on the lead screw. Replace the motor and place
the belt over the pulley on the motor. Verify that the belt is completely
horizontal between the 2 pulleys. Pull the motor until the belt is tight, but do
not over tighten. Replace the screws securing the motor and tighten them.

12. Manually turn the lead screw from the top to get the grease into the threads.

13. Replace the syringe.

14. Place the assembly into the VSS and secure it in place with the 4 screws.

15. Connect CN 80 on the Syringe Connection PCB.

16. Replace the pinch valve platform and secure it in place with the 4 screws.
Replace the tubing at the top of the syringes and the Wash/Diluent line.

17. Connect the power cord to the VSS and turn on the power.

18. Perform the procedure from Section 6.30 Syringe Home Position.

19. Replace all covers.

7.2.6 Complete Sampling Head Unit (P/N 270-2039)

Note: Removal of the Complete Sampling Head Unit requires that all Needle
Alignments in Section 6 be completed after replacement. These include Needle
Vertical Alignment (6.13), Wash Tower X-axis (6.14), Needle Y-axis at Wash
Port (6.16), Needle Y-axis at Sampling Position (6.17), Needle Z-axis at
Dilution Well (6.18), and Needle Z-axis at Sampling Adjust Position (6.19).

7 -46 Service Manual 702:038

VARIANT II Hemoglobin Testing System

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the tubing connector at the top of the sample needle. Push the needle
up and completely remove it from the sampling needle holder. Put the needle in
a safe place.

WARNING: Use extreme caution when handling the sample needle as it is a

Replacement Procedures
biohazard and very sharp.

4. Remove the sample tubing at the inlet to the connector behind pinch valves 1
and 2. Remove the 3 screws at the tubing holders along the top of the sampling
head unit. Remove the tubing from the holders and replace the screws.

5. Remove the cables at CN 51, 52 and 54 on the Sampling Head Connection PCB
(No. 254-1).

6. Unlock the clip that holds the dilution chamber drain tubing at the left side of
the sampling head unit. (Figure 7-66)

Figure 7-66:
Removing the
Dilution Chamber
Drain Tubing

7. Using a long #2 Phillips screwdriver remove the 4 screws securing the sampling
head unit.

8. Carefully remove the sampling head unit completely out of the VSS.

9. Install the new unit and secure it with the 4 screws.

10. Place the dilution chamber drain tubing into the clip on the left side. Secure the
clip.

11. Connect cables CN 51, 52 and 54 at the Sampling Head Connection PCB.

12. Connect the sample tubing at the inlet to the connector behind the pinch valves.
Tighten securely. Remove the 3 screws securing the tubing holders at the top of

702:038 Service Manual 7 -47

 VARIANT II Hemoglobin Testing System

the sampling head unit and place the sample tubing into the holders. Secure the
holders in place.

13. Place the needle end of the sample tubing into a container to collect the
Wash/Diluent dispensed during initialization.

14. Connect the power cord to the VSS and turn on the power. Wait for the
initialization to finish.

15. Drop the sample needle into the sample needle holder. Turn the needle until the
Replacement Procedures

hole at the tip is pointing to the left. Connect the sample needle tubing at the
top of the sample needle tightening securely.

16. Perform all needle alignments from Section 6. Refer to the Note at the
beginning of this section for further details.

17. Replace all covers.

7.2.7 Sampling Head Unit Z-axis Belt (P/N 270-2227)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the tubing connector at the top of the sample needle. Push the needle
up and completely remove it from the sampling needle holder. Put the needle in
a safe place.

WARNING: Use extreme caution when handling the sample needle as it is a

biohazard and very sharp.

4. Remove the 2 screws securing the tubing guides and the stainless steel plate
over the Z-axis belt. Remove the plate.

5. Loosen the 2 screws and the 2 stand-offs holding the Z-axis motor. Move the
motor until the belt is loose enough to remove from the pulleys.

6. Place the new belt on the pulleys. Verify that the belt is completely horizontal
between the 2 pulleys. Pull the motor until the belt is tight but do not over
tighten. Secure the 2 screws and 2 stand-offs to the motor.

7. Replace the stainless steel plate and the tubing guides and secure with the 2
screws.

7 -48 Service Manual 702:038

VARIANT II Hemoglobin Testing System

8. Connect the power cord to the VSS and turn on the power.

9. Replace all covers.

7.2.8 Sampling Head Unit Z-axis Motor (P/N 270-2202)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

Replacement Procedures
3. Remove the tubing connector at the top of the sample needle. Push the needle
up and completely remove it from the sample needle holder. Put the needle in a
safe place.

WARNING: Use extreme caution when handling the sample needle as it is a

biohazard and very sharp.

4. Remove the 2 screws securing the tubing guides and the stainless steel cover
over the Z-axis belt. Remove the cover.

5. Disconnect the motor cable at CN 511 from the Z-axis Connection board (No.
254-4).

6. Remove the 2 screws and the 2 stand-offs holding the Z-axis motor. Remove
the motor.

7. Loosen the 2 setscrews on the motor pulley. Remove the pulley.

WARNING: The pulley is made of aluminum, which is easily broken. Do not

pry on the flanges.

8. Place the pulley on the new motor and secure it with the 2 setscrews. Place the
motor in position and loosely secure it with the 2 screws and 2 stand-offs. Place
the belt over the 2 pulleys. Verify that the belt is completely horizontal between
the 2 pulleys. Pull the motor until the belt is tight but do not over tighten.
Secure the 2 screws and 2 stand-offs to the motor.

9. Replace the motor cable at CN 511.

10. Replace the stainless steel plate and the tubing guides and secure with the 2
screws.

702:038 Service Manual 7 -49

 VARIANT II Hemoglobin Testing System

11. Connect the power cord to the VSS and turn on the power.

12. Replace all covers.

7.2.9 Sampling Head Unit Z Lead Screw Set (P/N 270-2226)

This procedure requires a molybdenum-based grease.

Replacement Procedures

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the tubing connector at the top of the sample needle. Push the needle
up and completely remove it from the sampling needle holder. Put the needle in
a safe place.

WARNING: Use extreme caution when handling the sample needle as it is a

biohazard and very sharp.

4. Remove the 2 screws securing the tubing guides and the stainless steel cover
over the Z-axis belt. Remove the cover.

5. Loosen the 2 screws and the 2 stand-offs holding the Z-axis motor. Move the
motor until the belt is loose enough to remove from the pulleys.

6. Loosen the 2 lead screw pulley set screws and remove the pulley. (Figure 7-67)

WARNING: The pulley is made of aluminum, which is easily broken. Do not

pry on the flanges.

Figure 7-67:
Loosening the
Lead Screw
Set Screws

7. Remove the guide rod attachment screws from the top plate.

7 -50 Service Manual 702:038

VARIANT II Hemoglobin Testing System

8. Remove the 4 screws that secure the motor bracket. Set the motor and bracket
back on the top of the sampling head assembly.

9. Remove the 2 screws securing the top plate. Lift the top plate and bearing away
from the lead screw.

10. Remove the 2 screws on the flange nut and lift out the flange nut and lead
screw.

11. Install the new flange nut and lead screw.

Replacement Procedures
12. Secure the flange nut with the 2 screws. Place the bearing on the top of the lead
screw. Replace the top plate and secure it with the 2 screws.

13. Re-attach the motor bracket. Turn the lead screw to bring the assembly to the
topmost position. Replace the 2 guide rod attachment screws and tighten
securely.

14. Thoroughly lubricate the new lead screw threads with a molybdenum-based
grease. Manually turn the lead screw from the top to get the grease into the
threads.

15. Replace the pulley at the top of the lead screw and secure the setscrews.

16. Place the belt on the pulleys. Verify that the belt is completely horizontal
between the 2 pulleys. Pull the motor until the belt is tight but do not over
tighten. Secure the 2 screws and 2 stand-offs to the motor.

17. Replace the stainless steel cover and the tubing guides and secure with the 2
screws.

18. Connect the power cord to the VSS and turn on the power.

19. Replace all covers.

7.2.10 Sampling Head Y-axis Belt (P/N 270-2228)

1. Follow the procedure in Section 7.2.6 for removal of the Complete Sampling
Head Unit.

2. Loosen the 4 screws securing the Y-axis motor to the sampling head unit. Slide
the motor until the belt is removed from the motor pulley.

3. Loosen the 2 screws, at the other end of the belt, that secure the belt holder.
(Figure 7-68) Remove the belt from the holder and the pulley.

702:038 Service Manual 7 -51

 VARIANT II Hemoglobin Testing System

Figure 7-68:
Y-axis Belt
Holder
Screws

4. Place the new belt on both pulleys. Verify that the belt is even between the two
Replacement Procedures

pulleys. Place the belt in the belt holder. Pull the motor until the belt is tight,
but do not over tighten. Secure the motor with the 4 screws. Secure the screws
on the belt holder.

5. Replace the sampling head unit connecting the tubing and cables. Connect the
power cord and turn on the VSS.

6. Perform the following alignments from Section 6, unless the procedure was
performed without removing the sampling head assembly:

Wash Tower X-axis (6.14)

Needle Guide X-axis (6.15)
Needle Y-axis at Wash Port (6.16)
Needle Y-axis at Sampling Position (6.17)

7. Replace all covers.

7.2.11 Sampling Head Y-axis Motor (P/N 270-2203)

1. Follow the procedure in Section 7.2.5 for removal of the Complete Sampling
Head Unit.

2. Remove the 4 screws securing the Y-axis motor to the sampling head unit.
Remove the motor.

3. Loosen the 2 setscrews on the motor pulley and remove the pulley.

WARNING: The pulley is made of aluminum, which is easily broken. Do not

pry on the flanges.

4. Place the pulley on the new motor. Place the motor on the sampling head.
Place the belt over the pulley. Verify that the belt is even between the two

7 -52 Service Manual 702:038

VARIANT II Hemoglobin Testing System

pulleys and secure it in place with the 2 set screws. Pull the motor until the belt
is tight, but do not over tighten. Secure the motor in place with the 4 screws.

5. Reinstall the sampling head unit.

6. Connect the power cord and turn on the VSS.

7. Perform the following alignments from Section 6:

Wash Tower X-axis (6.14)

Replacement Procedures
Needle Guide X-axis (6.15)
Needle Y-axis at Wash Port (Section 6.16)
Needle Y-axis at Sampling Position (Section 6.17)

8. Replace all covers.

7.2.12 Needle Arm (P/N 270-2285)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the tubing connector at the top of the sample needle. Push the needle
up and completely remove it from the sampling needle holder. Put the needle in
a safe place.

WARNING: Use extreme caution when handling the sample needle as it is a

biohazard and very sharp.

4. Loosen the 2 set screws on the needle corral and then remove the corral.
Remove the 2 screws securing the needle arm to the sampling head unit and
remove the arm. (Figure 7-69)

Figure 7-69: Removing the Needle Arm

702:038 Service Manual 7 -53

 VARIANT II Hemoglobin Testing System

5. Install the new arm onto the sampling head unit by securing it with the 2 screws.
Place the needle corral in the new arm and secure it in place with the 2 set
screws.

6. Connect the power cord and turn on the VSS.

7. Check the following alignments from Section 6:

Wash Tower X-axis (6.14)

Needle Guide X-axis (6.15)
Replacement Procedures

Needle Y-axis at Wash Port (6.16)

Needle Y-axis at Sampling Position (6.17)
Rack Sampling Position (6.27)

8. Replace all covers.

7.2.13 Sampling Head Y-axis Sensor Assembly (P/N 270-2041)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the tubing connector at the top of the sample needle. Push the needle
up and completely remove it from the sampling needle holder. Put the needle in
a safe place.

WARNING: Use extreme caution when handling the sample needle as it is a

biohazard and very sharp.

4. Follow the steps in Section 7.2.6 for removal of the Sampling Head Unit.

5. Disconnect the cable at CN 54 on the Sampling Head Connection PCB (No.

254-1).

6. Remove the 2 screws securing the Y-axis Sensor Assembly and then remove the
assembly.

7. Install the new sensor assembly. Secure the sensor assembly with the 2 screws.

8. Re-install the sampling head unit and secure it with the 4 screws. Re-connect
all cables and tubing. Install the sample needle.

9. Connect the power cord to the VSS and turn on the power.

7 -54 Service Manual 702:038

VARIANT II Hemoglobin Testing System

10. Perform all X-axis, Y-axis and Z-axis needle alignments along with all related
alignments from Section 6. Refer to the note in Section 7.2.6 for a list of the
section numbers.

11. Replace all covers.

7.2.14 Sampling Head Z-axis Sensor Assembly (P/N 270-2042)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

Replacement Procedures
2. Remove the needle cover, front and top covers.

3. Disconnect the cable at CN512 from the Z-axis Connection PCB (No. 254-4).

4. Remove the 2 screws securing the Z-axis Sensor Assembly and then remove the
assembly.

5. Install the new sensor assembly. Secure the sensor assembly with the 2 screws.

6. Connect the power cord to the VSS and turn on the power.

7. Perform the Needle Z-axis at Dilution Well and Sampling Position Alignments
from Section 6.

8. Replace all covers.

7.2.15 Complete Mixing Head Unit (P/N 270-2044)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers along with the sample needle.

WARNING: Use extreme caution when handling the sample needle as it is a

biohazard and very sharp.

3. Disconnect the barcode cable at CN 4 on the Main PCB.

4. Disconnect the cables at CN 60 and CN 65 on the Mixer Head Connection PCB

(No. 253-2)

5. Using a long handled #2 Phillips screwdriver, remove the 4 screws securing the
unit to the bottom of the VSS. Carefully remove the unit making sure that all

702:038 Service Manual 7 -55

 VARIANT II Hemoglobin Testing System

cables are released from the clips, located on the other components in the VSS,
before pulling completely out.

6. Install the new unit by securing it with the 4 screws. Connect all cables and
place them into the clips in the VSS.

7. Connect the power cord to the VSS, reinstall the sample needle and turn on the
power.

8. Perform the following alignments from Section 6:

Replacement Procedures

Spin Head Vertical Alignment (6.9)

Spin Head Lowest Position (6.10)
Spin Head Limit (Hold) Position (6.11)
Barcode Tube Position (6.25)
Spin Head X and Y Position (6.26)
Rack Barcode Position (6.28)

9. Replace all covers.

7.2.16 Spinning Head (P/N 270-2047)

1. Turn off the power to the VSS.

2. Remove the needle cover and front cover.

3. Loosen the 2 set screws at the top of the spinning head. Remove the spin head
by gently pulling down. The spring above it will fall when the head is removed.

4. Replace the spring and then install the new spinning head securing it with the 2
set screws.

5. Turn on the power to the VSS.

6. Replace the covers.

7.2.17 Spinning Assembly (P/N 270-2046)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Remove the 4 screws securing the motor. Remove the motor.

7 -56 Service Manual 702:038

VARIANT II Hemoglobin Testing System

4. Remove the 4 screws, 2 on each side, securing the spinning assembly. Remove
the assembly. (Figure 7-70)

Figure 7-70:
Removing
the Spinning
Head
Assembly

Replacement Procedures
5. Install the new spinning head assembly securing it with the 4 screws.

6. Re-install the motor and place the belt over the motor pulley. Pull back on the
motor until the belt is tight but do not over tighten. Verify that the belt is
horizontal and secure the motor in place with the 4 screws.

7. Connect the power cord to the VSS and turn on the power.

8. Perform the following alignments from Section 6:

Spin Head Vertical Alignment (6.9)

Spin Head Limit (Hold) Position (Section 6.11)
Spin Head X and Y Position (Section 6.26)

9. Replace all covers.

7.2.18 Spinning Drive Head Assembly (P/N 270-2045)

Figure 7-71 shows the Spinning Drive Head Assembly.

Figure 7-71:
Spinning
Drive Head
Assembly

702:038 Service Manual 7 -57

 VARIANT II Hemoglobin Testing System

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front and top covers.

3. Disconnect the cables at CN 61 and CN63 from the Mixer Head Connection
PCB (No. 253-2).

4. Remove the 4 screws securing the assembly. (Figure 7-72) Remove the
assembly.
Replacement Procedures

Figure 7-72:
Removing
the Spinning
Drive Head
Assembly

5. Install the new drive head and secure it with the 4 screws. Connect the cables at
CN 61 and CN 63.

6. Connect the power cord to the VSS and turn on the power.

7. Perform the following alignments:

Spin Head Vertical Alignment (6.9)

Spin Head Limit (Hold) Position (Section 6.11)
Spin Head X and Y Position (Section 6.26)

8. Replace all covers.

7.2.19 Complete Tube Holder (P/N 270-2051)

Figure 7-73 shows the Complete Tube Holder.

7 -58 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 7-73:
Complete
Tube Holder

Replacement Procedures
1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front cover and the lower cover across the front.

3. Remove the front rack guide and lower bracket. (Figure 7-74)

Figure 7-74:
Removing the
Front Rack Guide
and Bracket

4. Remove the 4 screws to the front rack carrier and lower the carrier. It is not
necessary to remove it.

5. Remove the front rack vertical guide plate and block.

6. Remove the 4 screws securing the stainless steel cover over the tube holder.
Carefully raise the cover and remove the cable at CN 102 underneath.

7. Disconnect the cables at CN 531 and CN 532 on the Tube Holder Connection
PCB (No. 254-5).

8. Remove the 6 screws securing the tube holder and then carefully remove the
tube holder by lifting and rotating forward. Clip the cable tie securing the
interlock cable.

9. Install the new tube holder connecting CN 531 and 532. Secure the tube holder
with the 6 screws.

702:038 Service Manual 7 -59

 VARIANT II Hemoglobin Testing System

10. Replace the front rack guide and block.

11. Secure the front rack carrier with the 4 screws.

12. Replace the front bracket, rack guide and the 5 screws.

13. Connect the cable at CN 102 under the tube holder cover but do not replace the
cover.

14. Connect the power cord to the VSS and turn on the power.
Replacement Procedures

15. Perform the following alignments from Section 6:

Tube Holder Y (6.12)

Needle Guide X-axis (6.15)
Front Rack Carrier Home and Limit (6.22)
Rack Sample Position (6.27)

16. Replace the tube holder cover and secure it with the 4 screws.

17. Replace the covers.

7.2.20 Conveyor Assembly Units Right (P/N 270-2055) and Left (270-2054)

1. Turn off the power to the VSS. Remove the power cable at the side of the unit.

2. Remove the needle cover, front, top and lower front covers.

3. Remove the Tube Holder Unit. Refer to Section 7.2.20 for the procedure.

4. Disconnect the cable at CN 530 on the Tube Holder Connection PCB (No. 254-
5).

5. Using a long handled #2 Phillips screwdriver, remove the 2 front screws and the
2 back screws of the front rack guide plate and block. (Figure 7-75)

Remove Remove

Remove
Remove Remove
Loose

Figure 7-75: Screws on Rack Slide Block

7 -60 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Remove the block.

6. Using a long handled #2 Phillips screwdriver, remove the 4 screws securing the
vertical guide plate and rear rack block. Remove the block.

7. Remove the 2 screws securing the conveyor assembly to be replaced. (Figure 7-

76)

Figure 7-76:

Replacement Procedures
Removing the
Belt Conveyor

8. Disconnect the cables at CN 93 and CN 94 of the Conveyor Connection PCB

(No. 254-3). If removing the right hand conveyor assembly, clip the cable tie
securing the wiring in the bottom of the assembly.

9. Remove the 2 screws on the outside of the conveyor assembly to be replaced.

For the right assembly it will be necessary to remove the wiring cover first.

10. Remove the conveyor assembly.

11. Install the new conveyor assembly making all cable connections and re-
applying all cable ties.

12. Re-install the rack guide plates and tube holder unit.

13. Install the power cable and turn on the power.

14. Perform all of the alignments from Section 6 in the order listed.

7.2.21 Conveyor Belt (P/N 270-2056)

1. Follow the procedure in Section 7.2.21 for removal of the conveyor assembly.

702:038 Service Manual 7 -61

 VARIANT II Hemoglobin Testing System

2. Remove the inboard stainless steel plate. Note the position of the tension roller
before removal.

3. Remove the tension roller. Note the position at the other end before removal.

4. Remove the front screw securing the outside bearing mount for the front roller.
Loosen the other screw so the mount can be rotated towards the motor lessening
tension on the belt. Remove the front roller.

5. Remove the old belt and replace it with the new one.
Replacement Procedures

6. Reinstall the front roller in reverse order of removal.

7. Replace the tension roller in the same position as it was before removal.

8. Replace the outer plate and place the tension roller in the same position as it was
before removal. Secure the plate.

9. Assess belt tension and adjust if needed.

NOTE: On newer units there are 2 bearing mount attachments for both
rollers, allowing additional adjustment range. Use the same orientation on
both ends of a roller.

10. Re-install the belt conveyor using Steps 12-15 of Section 7.2.21

7.3 References

Section 7.1.11: Rhebuild Kit Package Insert; Rheodyne, Rohnert Park, California.

7 -62 Service Manual 702:038

VARIANT II Hemoglobin Testing System

8.0 Maintenance
This section contains the minimum requirements for performing annual preventive
maintenance on the Variant II. Any additional maintenance items can be performed
based on regional requirements. Refer to the Variant II Operation Manual for daily,
monthly and periodic maintenance procedures.

NOTE: This section assumes the system requiring maintenance has all of the
current upgrades to the hardware, firmware and software.

Maintenance
8.1 Materials

Required Materials

2 Pump Maintenance Kits (P/N 270-2315)

Injection Valve Rebuild Kit (P/N 270-2169)
1 mL Ito Syringe Plunger (P/N 270-2293)
5 mL Ito Syringe Plunger (P/N 270-2294)
Tube Mixer Gum Head (P/N 270-2088)
Molybdenum based grease (e.g. Redline™ CV2)
Light Lithium grease (e.g. Lubriplate ™ DS-ES)
Light oil with Teflon™ (e.g. Triflow™)

Additional Materials as Needed

Detector Lamp (P/N 270-0202)

Flow Cell Cleaning Kit (P/N 270-0197)
Cartridge Holder (P/N 195-5030)
Sample Probe (P/N 270-2020)

*Refer to the VARIANT II Maintenance Report in Section 8.5 for additional parts
that may need replacement. The part numbers can be found in Section 10.

702:038 Service Manual 8 -1

 VARIANT II Hemoglobin Testing System

8.2 VCS

Safety

Turn off the VCS and remove the power cord from the back of the unit.

Detector

1. Clean the flow cell. Follow the package insert provided with the flow cell
cleaning kit. Replace the flow cell only as needed. Refer to the VCS
Maintenance

Replacement Section 7.1.7 Detector/Flow Cell for the procedure

2. Check the inlet and outlet tubing connections for leaks or damage. Clean and
repair as needed.

3. Check the lamp alignment. Refer to VCS Replacement Section 7.1.7

Detector/Lamp Assembly for details.

4. Do NOT adjust the pre-amplifier outputs. Refer to Section 5.9 for details of the
procedure.

Degasser

Check the tubing connections for leaks. Clean and repair as needed.

Pumps

Refer to Section 7.1.5 for pump component replacement procedures.

1. Remove the pump tray. Refer to Section 7.1.5 Pump Unit/Motor Photo Sensor
for details of the procedure.

2. Replace pistons, seals and bushings. Check valves, springs and other pump
components should only be replaced if defective.

3. Remove the front U section of the pump chassis. Remove the pump cam.
Remove the top 2 set screws, loosen the bottom 2 set screws, hold the back of the
motor shaft with an adjustable wrench and twist the cam off. DO NOT PRY IT
OFF. If the cam was difficult to remove, smooth off the shaft before replacing
the cam.

4. Inspect crosshead rods. Clean and lubricate (light film of lithium based grease) if
contaminated. If the crosshead is scored it must be replaced along with a new

8 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

linear bearing. DO NOT remove the guide pin holder unless absolutely
necessary.

5. Clean the thrust bearing and washers. Pack the thrust bearing and coat the
washers with a molybdenum-based grease.

6. Reinstall the pump cam. Restore it to the original position so an additional mark
will not be places on the shaft. Make sure that the set screws over the flat side of
the shaft are centered and that the cam is fully seated against the pump chassis
prior to tightening the set screws.

7. Reassemble the pump.

Maintenance
Injection Valve (6 port)

Replace the rotor and stator face. Flush out the surrounding tubing if the rotor
shows disintegration.

NOTE: The rotor and stator face of the 7 port valve is only replaced or cleaned as
needed.

Mixer

Clean the chamber and stir bar. Replace if damaged.

Syringe Assembly

1. Clean and then lubricate the lead screw with molybdenum-based grease.

2. Clean and then lubricate the guide rods with a light film of lithium-based
grease.

3. Clean the syringe barrel and tip. Replace the syringe plunger if the tip is
damaged.

4. Inspect the drive belt and replace if damaged.

5. Clean the optosensor with compressed air.

6. Check the fittings at the 3-way valve for leaks or damage. Clean and repair as
needed.

702:038 Service Manual 8 -3

 VARIANT II Hemoglobin Testing System

Cartridge Holder

1. Clean the inside with deionized water and a swab. Rinse well. Sonicate in
deionized water if possible to remove all dried residue. Replace the holder if
the threads are corroded.

2. Inspect the tubing to the detector. Replace if damaged or if it has a steel ferrule.

NOTE: The cartridge to detector tubing can also be replaced annually based on
regional requirements.
Maintenance

Tubing

1. Inspect the piston backwash tubing. Replace if discolored.

2. Inspect all internal tubing for signs of leakage. Tighten or replace fittings as
needed.

The following tubing can be replaced annually based on regional requirements:

Sample Delivery (P/N 270-2204)

Teflon Tube 1.58mm x 0.5mm (P/N 270-2137)
Teflon Tube 3.18mm x 1.5 mm (P/N 270-2138)

Cleaning

Clean all interior and exterior surfaces.

Miscellaneous

The components listed below should be inspected. Clean or replace all items as
needed.

Purge Valves (Pumps A and B)

Doors and Latches (lubricate using Light oil with Teflon ™)
All fittings
All tubing internal and external
Level Sensors

8 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Break-in

1. Reconnect the power cord and restart the VCS.

2. Using the service software to run the pumps, purge the pump and run against a
back pressure until the pressure is stable.

3. Check pump drive current, adjust as needed. Refer to Section 5 for details of
the procedure.

Maintenance
8.3 VSS

Safety

1. Remove the sample probe.

Dilution Chamber

1. Remove the dilution chamber and clean it thoroughly using household bleach.
Rinse thoroughly with deionized water. Fill the syringe from a Flow Cell
Cleaning Kit with deionized water and attach the syringe, with the fittings, to
one of the 3 threaded ports on the right side of the tower. Push the water
through the port. Repeat with the remaining ports. Check all fittings for leaks
and repair if needed. Inspect Pinch Valves 3 through 7. Replace if damaged.
Inspect all tubing from the dilution chamber to the internal waste tank. Clean or
replace based on regional requirements. This includes the following:

L10 from Dilution Chamber to Back Panel (P/N 270-2022)

Silicone Waste Tubing from All Drain Ports through Pinch Valves 3, 4
and 7 to the Internal Waste Tank (P/N 270-2023, 270-2024 and 270-2025)

If tubing in the pinch valve was not replaced, reposition the old tubing so the
valve will open and close on a different position.

2. Using the VSS Service Software and a squirt bottle filled with deionized water,
verify that all drain lines evacuate properly. Use the following settings in the
Manual screen:

Valves 5, 6 Valve 7 Vacuum Pump Valve 3 Valve 4

Dilution Well Vacuum In Vacuum DW DP
Waste Port Vacuum In Vacuum DP DP
Wash Port Vacuum In Vacuum DP WP

702:038 Service Manual 8 -5

 VARIANT II Hemoglobin Testing System

Syringe Assembly

1. Turn off the power to the VSS and remove the power cord from the side.

2. Clean and then lubricate both lead screws with molybdenum-based grease.

3. Clean and then lubricate the guide rods with a light film of lithium-based
grease.

4. Assess the amount of wiggle in the lead screw. If the movement is excessive
replace the lead screw and flange nut. Refer to Section 7.1.10 for the
Maintenance

procedure.

5. Inspect the drive belts. Replace if damaged.

6. Clean the optosensors with compressed air.

7. Inspect Pinch Valves 1 and 2. Replace if damaged.

8. Clean the syringe barrels. Replace both syringe plungers. Verify that the
knurled nuts securing the syringe plungers to the platforms contain lock
washers. Install them if missing.

Internal Waste Chamber

Clean the internal waste chamber. Inspect the tubing and fittings. Clean or repair
as needed.

Sampling Assembly

1. Clean and inspect the sample needle. Replace if damaged.

WARNING: The sample needle is very sharp. Use caution when handling to avoid
injury.

2. Clean and then lubricate the lead screw with molybdenum-based grease.

3. Clean and then lubricate the 4 guide rods with a light film of lithium-based
grease.

4. Test the movement of the lead screw. If the movement is excessive replace the
lead screw and flange nut.

8 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

5. Inspect the Y and Z drive belts. Replace if damaged.

6. Clean the optosensors with compressed air.

7. Inspect the fitting and tubing at the sample needle. Repair or replace based on
regional requirements (P/N 270-2021)

Mix Head Assembly

1. Clean the mix head. Replace the gum head.

Maintenance
2. Clean the face of the barcode reader using a water dampened soft cloth. Be
careful not to scratch the surface.

3. Clean and then lubricate the lead screw with molybdenum-based grease.

4. Clean and then lubricate the guide rods with a light film of lithium-based
grease.

5. Inspect the Z and Mix drive belts. Replace if damaged.

6. Clean the Home and Hold optosensors with compressed air.

Rack Transport

1. Clean the 2 front and 4 rear opto and tube sensors with compressed air.

2. Check the rack drives for smooth motion with the power off. Watch for loose
pulleys. Repair if damaged.

3. Clean the left and right conveyor belts with deionized water or isopropyl
alcohol.

Tube Hold Down Assembly

1. Clean the tube hold down plate and needle guide.

2. Clean and then lubricate the lead screw with molybdenum-based grease.

3. Clean and then lubricate the guide rods with a light film of lithium-based
grease.

4. Inspect the drive belt. Replace if damaged.

702:038 Service Manual 8 -7

 VARIANT II Hemoglobin Testing System

5. Clean the Home and Hold optosensors with compressed air.

Alignments

1. Reinstall the sample probe. Attach the power cord and turn on the power.

2. VSS Alignment procedures are found in Section 6. Check the following

alignments and adjust if needed:

Spin Head Vertical Alignment (6.9)

Maintenance

Needle Guide X-axis (6.15)

Needle Y-axis at Wash Port (6.16)
Needle Y-axis at Sampling Position (6.17)
Rear Rack Carrier Home and Limit Positions (6.21)
Front Rack Carrier Home and Limit Positions (6.22)
Rack Sample Position (6.27)

8.4 Performance Verification

1. Set up a sample run using controls and previously analyzed patient samples.

2. Assess the VSS alignments, dilution performance and pump pressure stability
during the run. Make all required adjustments if any component is not
functioning properly.

3. Assess the quality of the chromatogram including sample areas, QC values and
retention times. Correct for any deficiencies.

8.5 Variant II Maintenance Report

Complete a Variant II Maintenance Report and attach a copy of the performance

verification results. Leave a copy at the customer site. A copy of this document is
on the following page. An electronic version can be obtained from CSD Technical
Support or your regional technical support group.

8 -8 Service Manual 702:038

 Variant II Maintenance Report

Date: Site: City:

State: Country: S/N: Assays:
VCS Firmware Version: VSS Firmware Version: CDM Version: Injection Count
‰ Required as part of PM As Needed ~ Lubricants Used: M = Molybdenum L = Lithium T = Light oil with Teflon
Component Replace Clean & Inspect Lubricate
Detector Flow Cell ‰
Pump A / B Cam & Thrust Bearings A / B ‰‰ / ‰‰ M‰‰ ‰‰
Seals 1 / 2 / 3 / 4 ‰/‰/‰/‰
A Left =1 Bushings 1 / 2 / 3 / 4 ‰/‰/‰/‰
A Right=2 Pistons 1 / 2 / 3 / 4 ‰/‰/‰/‰
B Left=3 Push Rod & Cam Follower 1 / 2 / 3 / 4 ‰/‰/‰/‰ L~~ ~~
B Right=4 Pump Heads 1 / 2 / 3 / 4 ‰/‰/‰/‰
Wash heads 1 / 2 / 3 / 4 ‰/‰/‰/‰

Valves Rotors (6 port / 7 port) ‰/~ /‰

& Mixer 3-way valve fittings/ Mixer ‰/‰
VCS Syringe Syringe Tip ‰
Assembly Lead Screw / Guide rails ‰/‰ M‰ / ‰L
Cart. Holder Cartridge Holder ~ ‰
VCS System Purge Valves A / B ‰/‰
Doors and Latches ‰/‰ T~ ~
Fittings / Tubing ‰/‰
Level Sensors, Reagent and Waste ‰/‰
Case Internal / External ‰/‰

Computer Interior / Exterior ‰/‰

Chkdsk-Temp Files / Disk Space ‰/‰
Printer Interior / Exterior ‰/‰

VSS Syringe Syringe Plungers Diluent / Sample ‰/‰

Assembly Lead Screws / Guide rails ‰‰ / ‰‰ M‰‰/‰‰L
Sensor / Sample delivery tube L1 ‰/‰
Sample Head Y Belt / Guide rails ‰/‰ / ‰L
Assembly Z Lead Screw / Guide rails ‰/‰ M‰ / ‰L
Needle / Sensors (Y, Z) ~ ‰ / ‰‰
Needle Corral Vertical Rods ‰ T‰
Tube Holddown Z Lead Screw / Guide rails ‰/‰ M‰ / ‰L
Sensors (home, hold) / Belt ‰‰/‰
VSS Mixer Assy Sensors (home, hold) / Belts (Z, mix) ‰‰ / ‰‰
Z Lead Screw / Guide rails ‰/‰ M‰ / ‰L
Barcode Head ‰
Rack Trans & Rack motion (RR, LR, LF, RF) ‰/‰
Conveyors Belts L/R ‰/‰
VSS Waste Dilution Chamber Assembly / Waste Tubing / ‰/‰/‰
System Internal Tank ~~~~~~~ ‰‰‰‰‰‰‰
Pinch Valve Tubing (V1-V7)
VSS System Doors / Latches / Fittings / Tubing ‰/‰/‰/‰ T~/~/ /
Case Internal / External ‰/‰

Performance Pre PM Post PM Verification

Pressure Reading A / B _____ / _____ _____ / _____

Fluctuation A / B _____ / _____ _____ / _____
Pump Purge A / B and Leak Check ‰/‰ ‰/‰
Slope & Intercept (factor) _____ / _____ _____ / _____
Retention Times: A1c & Ao or F & A2 or Non-Ghb & Ghb _____ / _____ _____ / _____
Baseline Quality _______________________ ______________________

Comments

702:038 Service Manual 8-9

 VARIANT II Hemoglobin Testing System
Maintenance

8 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

9.0 Troubleshooting
This section of the VARIANT II Service Manual contains flow charts, guidelines and
error codes for troubleshooting the VARIANT II. Examples of acceptable
chromatography are included as a reference when evaluating baselines, peaks and
retention times.

NOTE: Retention times are cartridge lot specific. The examples shown below

Troubleshooting
should only be used as a guideline.

9.1 Chromatography Review

Figures 9-1 and 9-2 show examples of acceptable A1c and Beta Thalassemia
chromatography.

702:038 Service Manual 9 -1

 VARIANT II Hemoglobin Testing System

Figure 9-1: A1c

Chromatogram
Troubleshooting

9 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 9-2: Beta

Thalassemia
Chromatogram

9.1.1 Early Retention Times Troubleshooting

The current retention times for each assay can be found in the Setup/Test screen in
CDM 3.5.

Hemoglobin A1c

1. Verify that the buffer and cartridge lot numbers are compatible and that the
buffer lots are sequentially numbered. Replace any component that is
incompatible.

702:038 Service Manual 9 -3

 VARIANT II Hemoglobin Testing System

2. The flow chart in Diagram 9-1 shows the steps to troubleshoot the Hemoglobin
A1c assay.

A1c Peak A0 Peak

R.T < 0.65 R.T < 1.72
minutes minutes

Correct Kit CD Correct Kit CD

? ?
No Yes No Yes
Troubleshooting

Load Correct Kit Load Correct Kit A1c peak also

A1c Area ?
CD CD early ?
<150,000

>150,000

Cartridge No Yes
Re- Re-
Test Holder Clean Test
and Tight ?
Yes

Use Sample with

A1c Area
~100,000 No

Replace Buffer A Replace Buffer B Replace Both

and Purge and Purge Buffers and Purge

Re-
Test

Clean and Tighten

Re-Test Retest Retest
Cartridge Holder

Re-
Test

A1c Peak Still A0 Peak Still

Early ? Early ?
Yes Yes
No No

Diagram 9-1:
Replace Cartridge Replace Cartridge
A1c Early No Problem !
and Prime
No Problem !
and Prime
Retention
Times Flow
Chart
Re- Re-
Test Test

9 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Beta Thalassemia

1. Verify that the buffer and cartridge lot numbers are compatible and that the
buffer lots are sequentially numbered. Replace any component that is
incompatible.

2. Verify that the temperature adjustment run was performed when the cartridge
was installed and that the temperature was set properly. Warm temperatures
will cause the peaks to come off earlier especially at the back end of the
chromatogram.

Troubleshooting
3. Diagram 9-1 can also be used to troubleshoot Beta Thalassemia.

9.1.2 Late Retention Times

The current retention times for each assay can be found in the Setup/Test screen in
CDM 3.5.

Hemoglobin A1c

1. Verify that the buffer and cartridge lot numbers are compatible and that the
buffer lots are sequentially numbered. Replace any component that is
incompatible.

2. The flow charts in Diagrams 9-2 and 9-3 show the steps to troubleshoot late
A1c and Ao peaks.

702:038 Service Manual 9 -5

 VARIANT II Hemoglobin Testing System
Troubleshooting

Diagram 9-2:
Late A1c
Retention
Times

9 -6 Service Manual 702:038

 VARIANT II Hemoglobin Testing System

Troubleshooting

Diagram 9-3:
Late Ao
Retention
Times

702:038 Service Manual 9 -7

 VARIANT II Hemoglobin Testing System

3. If unable to correct the late retention time using the flow chart check the 2 way
solenoid valve.

Beta Thalassemia

1. Verify that the buffer and cartridge lot numbers are compatible and that the
buffer lots are sequentially numbered. Replace any component that is
incompatible.

2. Verify that the temperature adjustment run was performed when the cartridge
was installed and that the temperature was set properly. Cooler temperatures
Troubleshooting

will cause the peaks to come off later, especially at the back end of the
chromatogram.

3. Diagrams 9-2 and 9-3 can also be used to troubleshoot Beta Thalassemia.

4. If unable to correct the late retention time using the flow chart check the 2 way
solenoid valve.

9.1.3 Total Area Counts

The total area count is assay specific. Refer to the Setup/Sample Types screen for
the appropriate assay in CDM 3.5.

When evaluating total area count issues consider what type of sample is being
affected. Samples that are pre-diluted and mixed properly should always have an
area within the specified range. Area counts out of range consistently for pre-
diluted and primary tubes are related to issues in the common pathway for both
samples. Area counts out of range that affect only primary tubes may point to an
issue with the dilution process of patient samples.

Low Area Count

1. Patient sample related:

Insufficient Sample Volume

Clotted Sample
Low Patient Hematocrit (low red cell volume in sample)

2. Primary sample tubes affected:

Air in the VSS Diluent Syringe (5 mL)

Faulty Pinch Valve (PV 1 or PV2)
Needle Depth in Dilution Well Too High
Needle Depth for Primary Tubes Too High

9 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Inadequate Tube Venting

"Sloppy" Sample Syringe (screw shaft or loosened bolt at top)

3. Pre-diluted samples affected:

Inadequate Venting (needle sealing microvial cap)

Needle Depth for Pre-diluted Samples Too High
Improper Sample Rack Alignment (needle piercing through side of vial)

4. Pre-diluted and primary sample tubes affected:

Troubleshooting
Occluded Sample Loop
Leak in Sample Line Fitting
Air in Sample Line
Leak in Dilution Well Drain Line or Fitting
Faulty Pinch Valve (PV1, PV2, or PV3)
Leak in Sample Transfer Line or Fittings (VSS to VCS)
Leak at Sample Line into Injection Valve (6 port)
Leak at VCS Syringe
Leak at Cartridge Holder
Leak at Detector Inlet Line
Light Level of Detector not Aligned Properly (lamp too high or too low)
Faulty 3 way solenoid valve

High Area Count

1. Patient sample related:

Patient with High Hematocrit (too many red cells in sample)

2. Primary sample tubes affected:

Sample Not Mixed Properly

Needle Depth for Primary Tubes Too Low
Faulty VSS Syringe Pump (5 mL)
Inadequate Drain of Dilution Chamber
PV3 or PV7 not Functioning Properly
Clogged L11 Tubing
Clogged Dilution Chamber
Pump Vacuum not Functioning Properly

3. Pre-diluted and primary sample tubes affected:

Inadequate Wash of Sample Needle

702:038 Service Manual 9 -9

 VARIANT II Hemoglobin Testing System

9.1.4 Detector

The baseline on the chromatogram should be relatively flat and the tracing should
be smooth. Figures 9-3 and 9-4 show examples of a noisy tracing and a ramping
baseline.

Figure 9-3:
Noisy
Chromatogram
Troubleshooting

9 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Figure 9-4:
Ramping
Baseline

1. Verify that all tubing connections are intact and not cross-threaded. Troubleshooting

2. The flow chart in Diagram 9-4 shows the steps to troubleshoot detector issues.

702:038 Service Manual 9 -11

 VARIANT II Hemoglobin Testing System

Detector Yes
Ramping,
Operate Pumps @
Noise or
2 mL/min 50%
Drift
Buffer B

A0 Peak
Turn Monitor on
No Properly Yes
and Adjust for
Identified ?
2 mV Full Scale.
Run for 5 minutes

Correct Flow or Detector

Chemistry No ON & Covered
Problem > 30 min. ?
Detector
No Output Noise
Troubleshooting

<50 uV ?
Let the Detector
Equilibrate Flush the Air out of
Re- Thermally the Flow Cell
Test
(Pull with Pumps
ON if Required)

Yes
Re-
Test
Detector
No Output Noise Yes
<50 uV ?

Flush the Air out of

Stop the Pumps
the Flow Cell
and Observe the
(Pull with Pumps
Trace
ON if Required)
Yes

Detector Output
Output Noise Yes Ramping Up No
<50 uV ? or Down ?

Replace Detector Re-

Lamp, Clean Flow Test
No Cell, Check
Optical Alignment
and Re-Balance

Contact CSD Technical Support for

Contact CSD Technical Service for
Further Assistance
further assistance
CSD_Tech
CSD_Tech [email protected]
[email protected]

Diagram 9-4:
Detector
Flow Chart

9 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

9.1.5 Spikes

Spikes on a chromatogram with a normal baseline can be caused by one of the

following:

Air Bubble in Fluid Path

Particulate Matter in the Hemolysate
Faulty Detector Board
Degasser Failure

Troubleshooting
9.1.6 Pressure

Pressure parameters are assay specific. Refer to the Setup/Test/Edit Test screen for
pressure information on the appropriate test.

Pump pressures should be documented daily by the customer on the Daily

Maintenance Log. Refer to this log to verify what the pressure has been reading up
until the pressure issue arose.

Low Pressure

Low pressure can be caused by:

Cross Port Leak in 6 or 7 Port Valve

Dummy Cartridge Left in Cartridge Holder, Test not Decon
Leak in the fluid pathway
Air Bubbles in the Pump
Broken Piston or Piston Spring
Faulty Piston Seal or Check Valve

High Pressure

High pressure can be caused by:

Overtight Fittings
Crimped or Bent Stainless Steel Tubing
Clog in the Fluid Pathway including the Cartridge or Prefilter

702:038 Service Manual 9 -13

 VARIANT II Hemoglobin Testing System

9.2 Error Codes

VCS

Error codes for the VCS can be found in the Status Window of the VCS Service
Software.

Table 9-1 lists the error codes for the VCS. The errors are described using 3 fields.

Detection: Short description of the problem

Activity: Operation that must be done by CDM in order to continue
Troubleshooting

Active - Notify the user (No action required)

Inactive - Stop after completion of the current run
Inactive (Stop Immediately) - Run stops immediately
Recovery: Operation that must be done by the user in order to recover

Table 9-1: VCS Error Codes

Error Code Device Error Description
0x07 Injector Sampler syringe home position error
Detection Syringe can not detect the home position sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x08 Injector Sampler syringe movement error
Detection When Syringe returns to the home position sensor, the
device detects the difference between the actual count
of moving pulses and the calculated count value.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x09 Injector Sampler injection valve does not move to Load/Inject position
Detection Injection valve can not move to Load/Inject
position within the defined time period.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x0B Injector Cartridge thermomodule temperature is out of limits
Detection Allowable range is within +/- 2 deg C of set point.
Activity Inactive
Recovery Repair the cartridge thermomodule.
0x0C Pump Degasser chamber vacuum level is out of limits
Detection Vacuum level is out of the allowable range.
Activity Inactive
Recovery Repair the degasser.

9 -14 Service Manual 702:038

 VARIANT II Hemoglobin Testing System

Table 9-1: VCS Error Codes

Error Code Device Error Description
0x0D Injector Column over heat
Detection Column temperature shows less than 10 deg C or
more than 55 deg C.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x0F Pump Pump A error
Detection Pump motor can not do appropriate turning.
Activity Inactive (stop immediately)

Troubleshooting
Recovery Repair the pump.
0x10 Pump Pump B error
Detection Pump motor can not do appropriate turning.
Activity Inactive (stop immediately)
Recovery Repair the pump.
0x11 Pump System pressure is above high pressure limit
Detection The pressure in the liquid lines is over defined High
Pressure Limit.
Activity Inactive (stop immediately)
Recovery Check and clear the blockage in the fluid lines.
0x12 Pump System pressure is above low pressure limit
Detection The pressure in the liquid lines is below defined Low
Pressure Limit.
Activity Inactive (stop immediately)
Recovery Check and repair leaks in the fluid lines
0x13 Injector Waste tank is full
Detection Fluid level in the waste tank is too high.
Activity Active
Recovery When the user empties the waste tank, it
automatically recovers from the error.
0x14 Detector Detector lamp failure
Detection Detector auto zero can not finish within the defined
time period. Allowable range is
20mV+/-5mV.
Activity Inactive (stop immediately)
Recovery Check lamp burnout or check the electrical circuit.
0x16 Pump Sampler 7 port valve movement error
Detection 7 Port valve can not move to T-Mixer,D-Mixer
and Purge valve position within the defined time
period
Activity Inactive (stop immediately)
Recovery

702:038 Service Manual 9 -15

 VARIANT II Hemoglobin Testing System

Table 9-1: VCS Error Codes

Error Code Device Error Description
0x17 Pump Pump A and B error at the same time
Detection Pump motor can not do appropriate turning
Activity Inactive (stop immediately)
Recover Repair the pumps
0x18 Pump Dynamic mixer moving error
Detection Dynamic mixer can not do appropriate rotation
Activity Inactive (stop immediately)
Recover Repair the dynamic mixer
0x19 Pump Fan moving error
Troubleshooting

Detection Fan can not move

Activity Inactive (stop immediately)
Recover Repair the fan
0x1A Detector A/D converter error
Detection Detector A/D converter has malfunction.
Activity Inactive (stop immediately)
Recovery
0x54 Pump Internal data error
Detection Communication problem occurred between Main
CPU and Sub CPU.
Activity Inactive (stop immediately)
Recovery

VSS

Error codes for the VSS can be found in the Sensor Status Window of the VSS
Service Software.

Table 9-2 lists the error codes for the VSS. The errors are described using 3 fields.

Detection: Short description of the problem

Activity: Operation that must be done by CDM in order to continue
Active - Notify the user (No action required)
Inactive - Stop after completion of the current run
Inactive (Stop Immediately) - Run stops immediately
Recovery: Operation that must be done by the user in order to recover

9 -16 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Table 9-2: VSS Error Codes

Error Code Device Error Description
0x20 Sampler Sampler Y-axis home position error
Detection Y-axis can not detect the home position sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x22 Sampler Sampler Z-axis home position error
Detection Same as Y-axis error
Activity Inactive (stop immediately)
Recovery Same as Y-axis error

Troubleshooting
0x24 Sampler Sampler syringe#1 home position error
Detection Syringe#1 can not detect the home position sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x26 Sampler Sampler syringe#2 home position error
Detection Syringe#2 can not detect the home position sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x28 Rack Rack tube mixer Z-axis home position error
Detection Tube mixer Z-axis can not detect the home position
sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically.
After the repair, the device needs to initialize.
0x2B Sampler Vacuum tank is full
Detection Fluid level in the vacuum tank is too high.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.

0x2C Sampler Sampler tube holder home position error

Detection Tube holder can not detect the home position sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.

702:038 Service Manual 9 -17

 VARIANT II Hemoglobin Testing System

Table 9-2: VSS Error Codes

Error Code Device Error Description
0x2D Sampler Sampler tube holder movement error
Detection Tube holder can not detect the tube head position.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.
0x2E Rack Barcode reading error
Detection Barcode reader can not read the barcode data.
Activity Active(Warning only)
Troubleshooting

Recovery After Error message is sent once, it automatically

recovers from the error.
0x2F Rack Front rack carrier home position error
Detection Front rack carrier can not detect the home position
sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.
0x30 Rack Front rack carrier movement error
Detection Front rack carrier can not detect the limit position
sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.

0x31 Rack Rear rack carrier home position error

Detection Rear rack carrier can not detect the home position
sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.

0x32 Rack Rear rack carrier movement error

Detection Rear rack carrier can not detect the limit position or the
stop position sensor.
Activity Inactive (stop immediately)
Recovery Check the device mechanically and electronically. After
the repair, the device needs to initialize.
0x33 Rack No sample rack error
Detection When MoveRack (or MoveRackToStart Position)
event is executed, Rack sensor can not detect the rack.
Activity Active(TET will be end.)
Recovery After the user places the Rack, they need to send
command for re-start.

9 -18 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Table 9-2: VSS Error Codes

Error Code Device Error Description
0x36 Rack Tube sensor error
Detection 1) Tube sensor always detects even if no tube in self
diagnosis.
2) Tube sensor is checked twice and if two data are
different, then error is generated.
Activity Inactive (stop immediately)
Recovery After replacing sensor or adjusting sensor position,
perform a hardware reset.
0x37 Rack/ Door open error

Troubleshooting
Sampler Detection Hardware Interrupt Stop and Door switch change to
OPEN.
Activity Inactive (stop immediately)
Recovery After the door is closed, the user needs to send
command for HW reset.
0x38 Rack/ Fan stop error
Sampler Detection Fan switch change to NG.
Activity Active(Warning only. )
But VSS can not keep on running very long.
CDM will stop VSS after current sample finishes.
Recovery After the fan can move again and the fan switch
changes to OK, it automatically recovers from the
error.

0x39 Rack Rack Sensor Error

Detection Rack sensor detect, always even when rack is not
present
Activity Inactive (stop immediately)
Recovery After repairing rack sensor or belt conveyer, the user
needs to send command for HW reset.
0x3A Rack Barcode Reader Setting Error / Hardware Error
Detection 1)When VSS receives an error from the barcode
reader.
2)When barcode reader OK signal failure.
3)When barcode reader communication failure.
Activity Active (Warning only)
Recovery After Error message is sent once, it automatically
recovers from the error.

702:038 Service Manual 9 -19

 VARIANT II Hemoglobin Testing System

General Error Codes

Error Code Error Description

0x50 Invalid Command warning
0x51 Parameter Out Of Range warning. The message will be sent once.
0x52 Invalid Status (Device Busy) Sending an execute command or
load TET during reset or Zero operation. The message will be
sent once.
Troubleshooting

0x53 TET Loading Error. Invalid TET sent by CDM will cause moving
to a TET_NONE state not before sending at least one status
message with TET_LOADING state.
0x60 EEPROM load/write error (Variant-II CS, VSS)

9.3 VSS Self Diagnostics Flow

Diagram 9-5 shows the initialization sequence of the VSS. This diagram can be
useful to determine where a problem can be found if the VSS does not complete its
initialization process on power up.

9 -20 Service Manual 702:038

 VARIANT II Hemoglobin Testing System

Diagram 9-5: Power ON

VSS Self Ð
Diagnostics RAM check
Flow
;Ð :Î Error: Audible Alarm device can not communicate
ROM check
;Ð :Î Error: Audible Alarm device can not communicate
Ð Ð
Sampler Movement check Rack Movement check
(Retry = 3 times) (Retry = 3 times)
(Busy Status) (Busy Status)
(Communication Start) (Communication Start)

Troubleshooting
ÐÍ Restart ÐÍ Restart
Needle Z axis Spin Head
;Р:ΐ ;Р:ΐ
Needle Y axis (Waiting until Z & Holder go to Home)
;Ð :ΐ Ð
Tube Holder Rear Carrier
;Р:ΐ ;Р:ΐ
Syringe 1 Rack Sensor (Rear Left, Front Right)
;Р:ΐ ;Р:ΐ
Syringe 2 Tube Sensor
;Р:ΐ ;Р:ΐ
Prime Spin Head (Hold sensor)
;Р:ΐ ;Р:ΐ
Z sensor Front Carrier
;Р:ΐ ;Р:ΐ
(Waiting finish of Rack check) Rack Sensor (Front Left, Rear Right)
Р;Р:ΐ
Tube Holder (limit) Barcode Reader
;Р:ΐ ;Р:ΐ
Normal Normal

Ð
3 times retry finish?
Ð Ð
Yes No
Ð Ð
Error Restart
Ð
VSS sends error code to CDM.
Ð
CDM display error message.
Ð
Check error message.

702:038 Service Manual 9 -21

 VARIANT II Hemoglobin Testing System

9.4 VARIANT II Timing Charts

Diagrams 9-6 through 9-8 show the various timing charts for the VCS and VSS.
Troubleshooting

9 -22 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Troubleshooting

Diagram 9-6: VARIANT II Timing Chart

702:038 Service Manual 9 -23

 VARIANT II Hemoglobin Testing System
Troubleshooting

Diagram 9-7: VSS Timing Chart

9 -24 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Troubleshooting

Diagram 9-8: Microtube Timing Chart

702:038 Service Manual 9 -25

 VARIANT II Hemoglobin Testing System
Troubleshooting

9 -26 Service Manual 702:038

VARIANT II Hemoglobin Testing System

10.0 Spare Parts

10.1 VCS Parts
Pump Assembly
Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2081 VCS1001 VCS PUMP
UNIT

Spare Parts
VCS Complete Pump Unit
270-0055 VCS1002 Variant Pump
Head

Var/V2 Pump Head

270-0016W VCS1003 Var Pump Seal
2/Pk Mod

Var/V2 Pump Seal

270-0056 VCS1005 Variant Inlet
Check Valve

Var/V2 Pump Inlet Check Valve

270-0057 VCS1006 Variant Outlet
Check Valve

Var/V2 Pump Outlet Check Valve

270-0054 VCS1007 Variant Pump
Piston

Var/V2 Pump Piston

702:038 Service Manual 10 -1

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2082 VCS1008 VCS Pump
Motor
Spare Parts

270-2083 VCS1009 VCS Pump

Outlet Tubing
Assy

270-2084 VCS1010 VCS Pump Inlet

Tubing Assy

270-0108 VCS1011 Variant Piston

Spring
Var/V2 Pump Piston Spring
270-0109 VCS1012 Variant Wash
Line Barb Fitting

Var/V2 Pump Backwash Nipple

270-0110 VCS1013 Variant Pump
Guide Pin Holder

Var/V2 Pump Guide Pin Holder

270-0176 VCS1014 Variant Pump
Washing Head

Var/V2 Pump Washing Head

10 -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-0198 VCS1016 Variant Bearing
Ring
Var/V2 Pump Bearing Ring
270-0199 VCS1017 Variant Roller
Bearing

Spare Parts
Var/V2 Pump Roller Bearing
270-0217 VCS1018 Variant Pump
Cam

Var/V2 Pump Cam

270-0216 VCS1019 Variant Pump
Cam Follower

Var/V2 Pump Cam Follower

270-0228 VCS1020 Variant Piston
Rod

Var/V2 Pump Piston Push Rod

270-0229 VCS1021 Variant Linear
Bearing

Var/V2 Pump Linear Bearing

270-2085 VCS1022 VCS MOTOR
PHOTO
SENSOR

VCS Pump Motor Photo Sensor

702:038 Service Manual 10 -3

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2284 VCS1025 VII SIPHON
BREAK

VCS Siphon Break (S/N < 11131)

270-0285 VCS1023/1024 VAR/VII
BUSHING SEAL
(NEW)2PK
Spare Parts

270-2327 VCS1026 VCS Pump

Grommet (1)

270-2328 VCS1027 VCS Siphon Break

S/N >11132

270-2315 Pump Maintenance 1 pack P/N 270-2016W (Pump Seals)

Kit (for one pump) 1 pack P/N 270-0285 (Seal and Bushing)
2 P/N 270-0054 (Piston)

10 -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Detector Unit
Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-0115 VCS6001 Variant Detector
Assy,Ver 2

Spare Parts
Var/V2 Hb.Detector Unit V.2
270-0201 VCS6002 Var Detector
Optical Unit, V 2

Var/V2 Detector Optic Unit V.2

270-0202 VCS6003 Var Detector
Lamp Assy,Vr 2

Var/V2 Detector Lamp Assy

270-0203 VCS6004 Var Hb Detector
Flow Cell, V 2

Var/V2 Detector Flowcell Assy

270-0204 VCS6005 Var Flow Cell
Gasket St,V2
Var/V2 Det.Flowcell Gasket Set
270-2158 VCS6006 VAR/VII FLOW
CELL WINDOW
SET
270-0205 VCS6007 Var Hb Detector
Photosensor
Asy,V 2

Var/V2 Det.Photosensor Assy V2

702:038 Service Manual 10 -5

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-0206 VCS6008 Var Detector
Pcb#182, Ver 2

270-2267 VCS6009 VCS

DETECTOR
DRIP TRAY
Spare Parts

270-2268 VCS6010 VCS PVC TUBE

FOR DET.DRIP
TRAY

270-2278 VCS6011 Detector Isolation

Kit (Grommets
and Screws)

270-2330 VCS6012 VCS Detector

Grommets (8-
pack)

10 -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Syringe Assembly
Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2086 VCS2001 VCS 5ml Syringe

270-2087 VCS2002 VCS Syringe

Pump Unit

Spare Parts
270-2089 VCS2004 VCS No.250-B
SYRNG PMP
SNSR BD

VCS Syringe Pump No.250-B PCB

270-2191 VCS2005 VCS SYRINGE
MOTOR

270-2221 VCS2006 VCS SYRNGE

PUMP LEAD
SCREW SET

270-2222 VCS2007 VCS SYRINGE

PUMP Y-AXIS
BELT

270-2264 VCS2008 VCS SYMG

PMP FLANGE
NUT ONLY

702:038 Service Manual 10 -7

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2263 VCS2009 VCS SYMG
PMP LEAD
SCREW ONLY
270-2293 VCS2010 VII 5ML
PLUNGER
SEAL
V2 ITO 5mL Syringe Plunger Tip
270-2329 VCS2011 Insulation
Spare Parts

Bracket Kit for

Syringe Pump

10 -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Column Holder Unit

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
195-5030 VI/VII Cartridge A1c or Beta Thal, Brownlee Type
Holder
270-0613 VI/VII Cartridge GHb, Brownlee Type
Holder, GHb
270-2090 VCS3001 VCS Column
Holder Unit

Spare Parts
270-2091 VCS3002 VCS Column
Holder Block

270-2092 VCS3003 VCS THERMAL

SENSOR ASSY

VCS Column Heater Sensor Assy

270-0127 VCS3005 Variant Thermo
Fuse Assy

Var/VCS Col Htr Fuse Assy

270-2093 VCS3006 VCS No.249
COLUMN HTR
CONN BD

702:038 Service Manual 10 -9

 VARIANT II Hemoglobin Testing System

Degasser Unit
Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2094 VCS4001 VCS Degasser
Unit
Spare Parts

270-2095 VCS4002 VCS VACUUM

CHAMBER
ASSY

VCS Degas Vacuum Chamber Assy

270-2096 VCS4003 VCS TUBING
SET

VCS Degasser Tubing Set

270-2097 VCS4004 VCS VACUUM
PUMP

VCS Degasser Vacuum Pump

270-2098 VCS4005 VCS No.246
DEGASSER
DRIVER BRD

270-2099 VCS4006 VCS SPARE

GLASS FUSE
VCS Degasser Fuse (1a/250v)

10 -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Dynamic Mixer Unit

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2116 VCS5001 VCS Mixer Unit

Spare Parts
270-2117 VCS5002 VCS Mixer
Chamber

270-2118 VCS5003 VCS Mixer

Motor Assembly

270-0131 VCS5004 Variant Magnetic

Stirrer

Var/V2 Mixer Stir Bar

270-0132 VCS5005 Variant Mixer
Gasket

Var/V2 Mixer Gasket

270-2119 VCS5006 VCS Photo
Sensor- Dynamic
Mixr

702:038 Service Manual 10 -11

 VARIANT II Hemoglobin Testing System

PC Boards and Electronic Components

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2120 VCS7001 VCS NO.242
MAIN CPU
BOARD
Spare Parts

270-2121 VCS7002 VCS NO.243

MOTHER BOARD

270-2122 VCS7003 VCS No.244

PUMP BOARD

270-2123 VCS7004 VCS NO.245

POWER SUPPLY
BD

270-2124 VCS7005 VCS CPU Board

Rack W/Mother Bd

10 -12 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270- VCS7006 VCS Firmware
2215VCS Upgrade

Spare Parts
270- VCS7004 VII Pump
2215PMP Firmware Upgrade

270-2125 VCS8001 VCS MAIN

POWER SUPPLY
UNIT

270-2128 VCS8005 VCS I/O Port Panel

Assy

270-2129 VCS8006 VCS Detector

Output Panel Assy

270-0153 VCS8007 Variant Pressure

Sensor Assy

Var/V2 Pressure Sensor Assy

702:038 Service Manual 10 -13

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2187 VCS8008 VCS NO.247-1
BOARD
Spare Parts

VCS I/O Port Board No. 247-1

10 -14 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Valves, Tubing, Fittings and Liquid Handling Components

Bio-Rad Manufacturer Description Pictures or Additional Description
Part Part
Number Number
270-2168 VCS8002 VCS 3-Way
Solenoid Valve

270-2126 VCS8003 VCS 2-Way

Spare Parts
Solenoid Valve

270-0107 VCS9001 Variant Pump

Purge Valve

Var/V2 Pump Inlet Port Assy

270-2130 VCS9002 VCS WASH PORT
ASSY

VCS Piston Backwash Port Assy

270-0026 VCS9003 Var/VII Pump Inlet
Port Luer

270-0223 VCS9004 Var Low Press "T"

Fitting

Var/V2 Low Pressure "T" M6

702:038 Service Manual 10 -15

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-0136 VCS9005 Variant High
Pressure "T"

Var/V2 High Pressure "T"

270-2131 VCS9006 VCS WASTE
TANK w/
Spare Parts

LEVEL
SENSOR

270-0022 VCS9007 Waste Tank 10 Lt

P E Variant

Var/V2 External Waste Tank

270-2132 VCS9008A VCS WASTE
LEVEL
SENSOR ASSY

V2 External Waste Level Sensor Assy

270-2133 VCS9009 VCS BUFFER
TUBING ASSY

270-2344 A-310/SP-15 VII SOLVENT

FILTER 1/8
Stem

V2 Solvent Filter

10 -16 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2134 VCS9011 VCS BUFFER
TANK CAP SET

9400176- P-307X Flangeless Fitting 1/8

10 (Nut) Tubing M6 (10 pack)

9400173- P-300X Flangeless Fitting 1/8

Spare Parts
10 Tubing M6 (10 pack)
(Ferrule)
940-0015 VCS9013 Flangeless Fitting -S
(Nut) Upchurch
940-0014 P-207X/P-300X
(Ferrule)

270-2171 VCS9014 VCS FINGERTIGHT

FITTINGS

VCS Fingertight Fitting 1/16"

270-0043 VCS9015 VARIANT NUT
(Nut) (PARKER TYPE)
270-0042 VARIANT
(Ferrule) FERRULE
(PARKER TYPE)

9400396- U-310X Fitting for Rheodyne

10 Valve (10 pack)

940-0007 U-312 Ferrule for Rheodyne

Valve (1 pack)

270-0191 Var Superflangeless

Fittings

Var/V2 Superflangeless Fitting

270-2136 VCS9016 VCS PEEK
TUBE:1/16"X0.01"X
1M

702:038 Service Manual 10 -17

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2137 VCS9017 VCS TEFLON
TUBE:1.58 X .5X1M
270-2138 VCS9018 VCS TEFLON
TUBE:3.18 X
1.58X1M
270-2139 VCS9019 VCS Tygon Tube
1/8"X 3/16"X 1m
270-2140 VCS9020 VCS S.STEEL
TUBE:1.58X0.8X1M
Spare Parts

270-2141 VCS9021 VCS S.STEEL

TUBE:1.58X0.25X1M
270-2345 S-2195 VCS SS Tubings (SL9 Includes all 3 Tubings
– SL 11)
270-2346 S-2196 VCS SS Tubings Includes all 6 Tubings
(SL12 – SL 17)
270-2142 VCS9022 VCS SYSTEM
DRAIN TUBE- 1
270-2143 VCS9023 VCS PUMP WASH
DRAIN TUBE - 2
270-2204 VCS9024 VCS TEFLON V2 Samp Tube Assy 1.58x.5x80cm
TUBE:1.58X0.5X80CM
270-2180 VCS9025 VCS TEFLON TUBE; VCS Tef Tube L4: 1.58x0.8x600
1.58x0.8x600
270-2306 10 cm x 0.01 ID Cartridge to Detector (A1c/BTS)
PEEK Tubing with
Fittings
270-2310 15 cm x 0.01 ID Cartridge to Detector (Use with
PEEK Tubing with Total GHb Assay)
Fittings
270-2307 VCS9026 Fitting, 1/16
Cartridge to Det

Lite Touch Fitting, Cartridge to

Detector

10 -18 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Reservoir Unit
Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2145 VCS1301 VCS LEVEL
SENSOR UNIT

Spare Parts
VCS Res Level Sensor Unit
270-2146 VCS1302 VCS No.251
RESERVOIR
BOARD

270-2188 VCS1303 NO.247-3 BOARD

VCS Res Conn PCB No. 247-3

270-2282 VCS1304 VII REAGENT
RESERVOIR

702:038 Service Manual 10 -19

 VARIANT II Hemoglobin Testing System

External Housing Components, Cables and Tools

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2127 VCS8004 VCS COOLING
FAN

VCS Main Cooling Fan

Spare Parts

270-2196 VCS8009 VCS Plastic Door

270-2197 VCS8010 VCS Metal Cover

270-2199 VCS8011 VCS Plastic

Handle

10 -20 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2076 VCS1101 VAR II SPARE
FUSES

V2 Fuse (3.15A/250V) 2ea.

270-2077 VCS1102 Var II Power Cord
For 110v

Spare Parts
270-2078 VCS1103 Power Cord for
220V

270-2079 VCS1104 VAR II CABLE-

A (RJ45/D-SUB)

V2 Comm. Cable-A RJ45-Db9

270-2080 VCS1105 VAR II CABLE-B
(RJ45/RJ45)

270-2144 VCS1106 VAR II

RESERVOIR
CABLE

702:038 Service Manual 10 -21

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2193 VCS1107 VCS Led
Assembly

270-2208 VCS1201 VCS COLUMN

Spare Parts

ADJUSTMENT
TOOL

VCS Temp Adjust Resistor Set

270-2266 VCS1202 VCS DEGASSER
TESTING ASSY

270- VCS1203 VAR/VII

0211X BSHG/SEAL
TOOL
ATTACHM

VAR/V2 Bushing install Tool

270-2292 VCS1204 VII SCREW SET

10 -22 Service Manual 702:038

VARIANT II Hemoglobin Testing System

6 Port and 7 Port Valves

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2011 VAR II 6 Port Injection Valve with 23 µL Sample Loop
Rocket Valve (RV700-123)
Assy
270-2012 VARII 7 Port Switch Valve (RV 703-103)
Rocket Valve
Assy
270-2169 VAR II Rebuild Rotor Seal and Stator Face for Injection

Spare Parts
Kit for 6 Port Valve
Rocket Valve
RV700-123
270-2170 VAR II Rebuild Rotor Seal and Stator Face for Switch
Kit for 7 Port Valve
Rocket Valve
RV703-103

702:038 Service Manual 10 -23

 VARIANT II Hemoglobin Testing System
Spare Parts

10 -24 Service Manual 702:038

VARIANT II Hemoglobin Testing System

10.2 VSS Parts

Syringe Pump Unit

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2033 VSS2003 VSS Syringe
Pump Unit-A

Spare Parts
270-2034 VSS2004 VSS Syringe
Pump Unit-B

270-2036 VSS2006 VSS INLET

PORT

VSS Sample Tubing Inlet Port

270-2037 VSS2007 VSS No.253-1
Syrng Pmp Conn
Bd

270-2038 VSS2008 VSS No.253-5

Syrng Pmp Snsr
Bd

702:038 Service Manual 10 -25

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part Part
Number Number
270-2206 VSS2009 VSS SYRINGE
MOTOR- 1mL
SYRINGE

270-2223 VSS2010 VSS SYRINGE

MOTOR-5ML
Spare Parts

SYNGE

270-2224 VSS2011 VSS SYRNG

PMP Y LEAD
SCREW SET

270-2225 VSS2012 VSS SYRINGE

PUMP Y-BELT

270-2275 VSS2013 VSS SYRINGE

PORT (NEW)

ITO Syringe Port

270-2276 VSS2014 VSS 5 ML
SYRINGE
(NEW)
VSS ITO 5 ML Syringe
270-2277 VSS2015 VSS 1 ML
SYRINGE
(NEW)
VSS ITO 1 ML Syringe
270-2294 VSS2017 VSS 1ML
PLUNGER
SEAL

270-2293 VSS2018 VII 5ML

PLUNGER
SEAL

10 -26 Service Manual 702:038

VARIANT II Hemoglobin Testing System
Bio-Rad Manufacturer Description Pictures or Additional Description
Part Part
Number Number
270-2331 VSS2016 VSS Dilution
Chamber Fitting

270-2332 VSS2019 VSS Cable for

253-5 PCB

270-2333 VSS2020 VSS Cable for

253-1 PCB

Spare Parts
270-2334 VSS2021 VSS Syrng
Tubing Assy
(VSS14)

702:038 Service Manual 10 -27

 VARIANT II Hemoglobin Testing System

Sampling Head Unit

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2039 VSS3001 VSS Complete
Sampling Head
Unt
Spare Parts

270-2040 VSS3002 VSS No.254-4

Samp Head Conn
Bd

270-2041 VSS3003 VSS Y-SNSR

ASSY-
SAMPLING
HEAD

VSS Samp Head Sensor Assy Y-Axis

270-2042 VSS3004 VSS Z-SNSR
ASSY-
SAMPLING
HEAD

VSS Samp Head Sensor Assy Z-Axis

270-2043 VSS3005 VSS FLEXIBLE
CABLE ASSY

270-2226 VSS3006 VSS Smpl Head Z

Lead Screw Set

10 -28 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part Part
Number Number
270-2227 VSS3007 VSS SAMPLING
NEEDLE Z-
BELT

VSS Sample Head Belt Z-Axis

270-2228 VSS3008 VSS SAMPLING
NEEDLE Y-
BELT

Spare Parts
270-2285 VSS3009 VII Z-NEEDLE
ARM

702:038 Service Manual 10 -29

 VARIANT II Hemoglobin Testing System

Mixing Head Unit

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2044 VSS4001 VSS Complete
Mixing Head
Unit
Spare Parts

270-2045 VSS4002 VSS SPINNING

DRIVE HEAD
ASSY

VSS Tube Mixer Assembly

270-2046 VSS4003 VSS SPINNING
ASSY

VSS Mixer Spinning Head Assy

270-2047 VSS4004 VSS SPINNING
HEAD

VSS Mixer Spinning Head-A

270-2088 VSS4004A VSS
REPLACEMEN
T GUM HEAD

270-2048 VSS4005 VSS No.253-2

MIXN HEAD
CONN BD

10 -30 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2049 VSS4006 VSS SENSOR
ASSY-
SPINNING
HEAD

270-2050 VSS4007 VSS Z-SNSR

ASSY-
SPINNING

Spare Parts
HEAD

VSS Mixer Spinhead Sensor Assy

270-2229 VSS4008 VSS MIXN
HEAD SPINNG
SHFT ASSY

270-2230 VSS4009 VSS MIXN

HEAD Z LEAD
SCREW SET

270-2231 VSS4010 VSS MIXING

HEAD BELT- Z
AXIS

270-2232 VSS4011 VSS MIXN

HEAD BELT-
SPINNG SHFT

270-2262 VSS8018 VSS Belt Cover

Upgrade

270-2010 Var II Barcode

Reader

702:038 Service Manual 10 -31

 VARIANT II Hemoglobin Testing System

Tube Holder Unit

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2051 VSS5001 VSS COMPLETE
TUBE HOLDER
KIT
Spare Parts

VSS Tube Holddown Assembly

270-2052 VSS5002 VSS TUBE
HOLDING
PLATE

270-2184 VSS5002A VSS SAMPLE

TUBE HOLDER
ATTACH.

VSS Needle Guide

270-2053 VSS5003 VSS SENSOR
ASSY- TUBE
HOLDER

270-2347 will replace this part.

270-2233 VSS5004 VSS TUBE
HOLDER BELT-
Z AXIS

10 -32 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2347 VSST1008 VSS Tube Holder
Upgr Kit Ver. 4

Spare Parts

702:038 Service Manual 10 -33

 VARIANT II Hemoglobin Testing System

Rack Transport
Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2054 VSS6001 VSS BELT
CONVEYER
UNIT-L
Spare Parts

270-2055 VSS6002 VSS Belt

Conveyer Unit-R

270-2056 VSS6003 VSS CONVEYER

BELT

270-2057 VSS6004 VSS DC-MOTOR

ASSEMBLY
LEFT

VSS Conveyor DC-Motor Assy-L

270-2247 VSS6004A VII DC MOTOR
ASSY -RIGHT

VSS Conveyor DC-Motor Assy-R

10 -34 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2058 VSS6005 VSS TIMING
BELT

270-2066 VSS6006 VSS No.255-12

BOARD

Spare Parts
DC Motor Assembly Board with noise
filter (no cable assembly included)
270-2065 VSS6007 VSS No.255-2
THRU 6 BOARD

Home position sensor - front rack

270-2236 VSS8016 VSS PLATE
CARRIER BELT

VSS Rack Drive Belt

270-2335 VSS6008 VSS Conveyor
Belt, New

Used on S/N >11422

Special VSS6009 Main Shaft
Order

Special VSS6010 Sub Shaft

Order

702:038 Service Manual 10 -35

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
Special VSS6011 Tension Shaft
Order

Special VSS6012 Top Plate - R

Order
Spare Parts

Special VSS6013 Top Plate - L

Order

270-2336 VSS6014 VSS Conveyor

Belt Upg. Kit

Special VSS6015 New Belt Upgrade

Order Kit - R

Special VSS6016 New Belt Upgrade

Order Kit - L

Special VSS6017 Shaft Attachment

Order

10 -36 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2337 VSS6018 VSS Rack Slide
Block Kit Rear

270-2338 VSS6019 VSS Rack Slide

Block Kit Frnt

Spare Parts
270-2339 VSS6020 VSS Rack Carrier
Slide Unit

702:038 Service Manual 10 -37

 VARIANT II Hemoglobin Testing System

PC Boards and Electric Components

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2059 VSS7001 VSS No.240 Main
CPU Board
Spare Parts

270-2060 VSS7002 VSS No.253-3

RJ45 PORT
BOARD

270-2061 VSS7003 VSS No.254-1

Samp Unit Conn
Bd

270-2062 VSS7004 VSS No.254-2

Valve Conn Board

270-2063 VSS7005 VSS No.254-3

Conv&Rack Conn
Bd

10 -38 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2064 VSS7006 VSS No.254-5
Tube Hldr Conn
Bd

270-2065 VSS7007 Sensor PCB for

255-1-9

Spare Parts
Rack carrier, sampling head, mixing head
sensor
270-2066 VSS7008 Noise Filter PCB
for Vacuum
Pump

Board with noise filter, ferrite core and

cable for Vacuum Pump
270-2194 VSS7009A LED Board for
Front Indicator

270-2198 VSS7010 VSS NO.256

BOARD

VSS Interlock Conn PCB #256

702:038 Service Manual 10 -39

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270- VSS7011 VII FIRMWARE
2215VSS UPGRADE -VSS
ONLY

270-2068 VSS8002 VSS Main Power

Spare Parts

Supply

270-2069 VSS8003 VSS PHOTO

SENSOR- RACK
DETECTN

VSS Rack Photo Sensor

270-2250 VSS8017 VSS Photo
Sensor- Tube Det

270-2237 VSS9017 Var II Power

Switch

For VCS and VSS

270-2238 VSS9018 Var II Power
Inlet Noise Flter

10 -40 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Pump, Valves, and Motors

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2067 VSS8001 VSS Vacuum
Pump

Spare Parts
270-2070 VSS8004 VSS Pinch Valve-
A For V1-V4

270-2071 VSS8005 VSS Pinch Valve-

B For V5

270-2072 VSS8006 VSS Pinch Valve-

C For V6

270-2073 VSS8007 VSS Pinch Valve-

D For V7

270-2200 VSS8009 VSS MOTOR

FOR SPINNING

VSS Mixer Spinning Motor

702:038 Service Manual 10 -41

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2201 VSS8010 VSS MOTOR
FOR TUBE
HOLDER

VSS Tube Holddown Motor

Spare Parts

270-2202 VSS8011 VSS MOTOR-

SAMPLG. HEAD
Z-AXIS

270-2203 VSS8012 VSS MOTOR-

SAMPLG. HEAD
Y-AXIS

270-2205 VSS8013 VSS RACK

MOTOR- BACK
CARRIER

VSS Rack Motor Rear

270-2234 VSS8014 VSS RACK
MOTOR- FRONT
CARRIER

10 -42 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2235 VSS8015 VSS MIXING
UNIT MOTOR- Z
AXIS

Spare Parts

702:038 Service Manual 10 -43

 VARIANT II Hemoglobin Testing System

Tubing and Fluid Handling Components

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2020 VSS1001 VSS Piercing Needle

270-2021 VSS1002 VSS L1 Tubing

Assembly
Spare Parts

270-2022 VSS1003 VSS L10 Tubing

Assembly

270-2023 VSS1004 VSS Si-Tube 3.0 X System Tubing

1.0 X 1 M
270-2024 VSS1005 VSS Si-Tube 4.0 X System Tubing
2.0 X 1 M
270-2025 VSS1006 VSS Si-Tube 5.0 X System Tubing
3.0 X 1 M
270-2026 VSS1007 VSS Si-Tube 7.0 X System Tubing
4.0 X 1 M
270-2027 VSS1008 VSS Si-Tube 8.0 X Drain Tubing
5.0 X 2.5 M
270-2075 VSS1008A VSS Si-
Tube:8x5x1m
270-2028 VSS1009 VSS Tube Fitting Set Full Set of Interconnect Tube Fittings for
Pinch Tubing
270-2029 VSS1010 VSS Internal Waste
Tank Assy

10 -44 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part Part
Number Number
270-2340 VSST1011 VSS Waste Tube
Assy PV3/4
270-2341 VSST 1012 VSS Valve Bracket
Kit PV3/4
270-2030 VSS1011 VSS Dilution
Chamber Assy

Spare Parts
270-2207 VSS1012 VSS LVL.SENSR.-
INT.WASTE
TANK

702:038 Service Manual 10 -45

 VARIANT II Hemoglobin Testing System

External Housing Components and Accessories

Bio-Rad Manufacturer Description Pictures or Additional Description
Part
Number Part
Number
270-2074 VSS8008 VSS Main
Cooling Fan
Spare Parts

270-2189 VSS9012 VSS Needle

Cover

270-2190 VSS9013 VSS Plastic Bezel

Cover

270-2195 VSS9015 VSS Metal Top

Cover

10 -46 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part Part
Number Number
270-2192 VSS9014 VSS Front Cover

Spare Parts
270-2006 VSS9016S VSS Sample
Rack (No. 3)

270-2076 VSS9001 VAR II SPARE

FUSES

270-2077 VSS9002 Var II Power

Cord For 110v

270-2078 VSS9003 VII Power Cord

for 220V

270-2079 VSS9004 VAR II CABLE-

A (RJ45/D-SUB)

V2 Comm. Cable-A RJ45-Db9

702:038 Service Manual 10 -47

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2080 VSS9005 VAR II CABLE-B
(RJ45/RJ45)
Spare Parts

270-2174 VSS9008 RACK

ADAPTERS-
13mmTUBE X30
#58

270-2173 VSS9009 RACK

ADAPTERS-
14mmTUBE X30
#56

270-2175 VSS9010 VSS RK

ADAPTR-
12mmTUBE X30
#59

270-2239 VSS9019 VII BARCODE

LABL ST-RACK
1-10

VSS Rack Barcode Labels 1-10

270-2242 VSS9019A VII BARCODE
LABL ST-RACK
11-20
270-2253 VSS9019B VII BARCODE
LBL ST-RACK
21-30
270-2254 VSS9019C VII BARCODE
LBL ST-RACK
31-40
270-2255 VSS9019D VII BARCODE
LBL ST-RACK
41-50

10 -48 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2256 VSS9019E VII BARCODE
LBL ST-RACK
51-60
270-2257 VSS9019F VII BARCODE
LBL ST-RACK
61-70
270-2258 VSS9019G VII BARCODE
LBL ST-RACK
71-80

Spare Parts
270-2259 VSS9019H VII BARCODE
LBL ST-RACK
81-90
270-2260 VSS9019I VII BARCODE
LBL ST-RACK
91-100
270-2240 VSS9020 VII BARCODE
LABEL SET -
TUBE

270-2016-10 Microvial
Adapters 10 PK

702:038 Service Manual 10 -49

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part Part
Number Number
270-2017- Pediatric
10 Adapters 10 PK
Spare Parts

270-2279 Accessories Includes: Waste Tank, Waste Tank Tubing

Pack with for VCS (2), Waste Tank Tubing for VSS,
Reservoir Waste Level Sensor, Sysmex Racks (10),
Sysmex Rack Adapters, Pediatric Tube
Adapters (10), Microvial Adapters (20),
Barcode Labels, VII Manuals (Ops and
CDM), Allen Wrenches (4), Wrench (2),
Syringe Luer Tube Assembly, Reservoir
Unit Cables, Communication Cables (2 x
RJ-45 to RJ-45, 2 x RJ-45 to DB9), Power
Cables (2), Extra Fuses, Reagent Tubing
and Caps (3), Sample Tubing, Flangeless
Fitting Nut and Ferrule Set, Pump Seal,
Pump Seal Remover Tool, Screw Drivers
(2), Nut and Ferrule Reservoir Unit,
Dummy Column (2cm), Syringes and
Mouse Pad
270-2280 Accessories Same as 270-2279 without the Waste Tank
Pack without
Reservoir

10 -50 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Tools and Upgrade Kits

Bio-Rad Manufacturer Description Pictures or Additional Description
Part Part
Number Number
270-2286 VSS1101 VII AC TOOL

Spare Parts
VSS Vertical Alignments Tool
270-2287 VSS1102 VII RG TOOL

270-2288 VSS1103 VII DUMMY

RACK

270-2289 VSS1104 VII CG TOOL

VSS Conveyor Width Tool

270-2290 VSS1105 VII C TOOL

702:038 Service Manual 10 -51

 VARIANT II Hemoglobin Testing System

Bio-Rad Manufacturer Description Pictures or Additional Description

Part
Number Part
Number
270-2291 VSS1106 VII IL KEY

VSS Interlock service key

270-2342 VSS1201 VSS Dust Cover
Update (VSS11)
Spare Parts

270-2343 VSS1202 VSS Syringe

Update Kit
(VSS13)

10 -52 Service Manual 702:038

VARIANT II Hemoglobin Testing System

10.3 Computer and Components

Bio-Rad Description Pictures or Additional Description

Part
Number
270-2019 Variant II
Computer with
Monitor
270-2281 Variant II
Computer Only
270-2320 Connect Tech I/O
Board

Spare Parts
270-2321 Monitor, Flat
Screen, 15" NEC or
Compatible
270-2312 Modem, Internal,
V90 US Robotics
270-2261 CD Writer,
Internal, PlexWriter
12/10/32
270-2212 CDM 3.5 Image
CD
270-2214 CDM 3.5 Boot
Diskette

702:038 Service Manual 10 -53

 VARIANT II Hemoglobin Testing System
Spare Parts

10 -54 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Appendix A

Appendix A
Table of Contents:

Barcode Label Specifications A-1

VCS Test Points A-3

Pressure Voltage Table (Degasser) A-9

Pump Board Modification Procedure A-11

702:038 Service Manual A -i

 VARIANT II Hemoglobin Testing System
Appendix A

A -ii Service Manual 702:038

VARIANT II Hemoglobin Testing System

Barcode Label Specifications

Sample Rack

• BARCODE TYPE : CODE128

• START CHARACTER : CODE - C
• NARROW BAR WIDTH : 0.254mm(0.01in)
• QUIET ZONE(Both Sides) : 5mm
• HEIGHT : 8mm

Appendix A
• Maximum number of rack ID digits: 4

Microvial adapter

• BARCODE TYPE : CODE128

• START CHARACTER : CODE - A
• NARROW BAR WIDTH : 0.296mm(0.0116in)
• QUIET ZONE(Both Sides) : 5mm
• HEIGHT : 20mm

Sample Tube

• ASTM E1466-92 compatible.

• Maximum number of sample ID digits: 20
• Supported Symbolizes:
Code39 no check digit
Code39 check digit
ITF (Interleaved 2 of 5) no check digit
ITF check digit
Industrial 2 of 5 (Code 2 of 5)
Codabar (NW-7) no check digit
Codabar check digit
EAN/UPC/JAN
Code128
Coop 2 of 5

NOTE : The customer can select four symbolizes from the above list in CDM 3.5. Refer
to the CDM 3.5 Operation Manual for details. Code128 MUST be selected for reading
Rack and Microvial labels.

Default settings in CDM 3.5 are:

(1) Code128
(2) Code39 no check digit

702:038 Service Manual A -1

 VARIANT II Hemoglobin Testing System

(3) ITF no check digit

(4) Codabar no check digit

Contrast of Barcodes and Barcode Surface

• PCS (Print Contrast Signal) > 0.5

• Do not coat the surfaces of barcodes by film
• Do not use glossy paper

Print Quality

The print quality of a label printer should be equivalent to a LASER printer.

Appendix A

A -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

VCS Test Points

Power Supply

Check Point Specification Adjust

OUTPUT 24 + 0.1 V Adj-VR

Main CPU (242)

CPU and digital IC works on 5V. 24V is used for sensor measurements. CPU has an

Appendix A
A/D converter that receives column heater temperature, reservoir weight and degasser
pressure. The board also has mixer, injection valve, motor and column heater drivers.

PIN Note Value

CLK CPU clock 20MHz
AG Analog (+/-15V) common 0V
DG Digital (5V) ground 0V
MG Motor (12V) ground 0V
TEMP Thermal module temperature 3.91V at 50 degree
MIX_F Mixer wavelength 2kHz

Pump Board (244)

Pump control CPU circuit (+5V), pump pressure detection (+/-15V) and pump driver
(+24V) are all included on the pump board.

PIN Note Value

TP0 Ground of digital line 0V
TP1 CPU system clock output 2MHz
TP2 Clock for serial communication 153.6KHz
TP3 Pressure sensor output (CN31) voltage 0 to 0.4V
TP4 Analog common 0V
TP5 Pump A motor current check See adjustment manual.
TP6 Pump B motor current check See adjustment manual.
TP7 Digital line 5V
TP8 Analog plus 15V
TP9 Analog minus -15V
TP10 Pump drive 24V
TP11 Pressure sensor output after 0 to 1.2V
amplification
TP12 Pressure sensor output after 0 to 0.5V
amplification over
TP13 AD converter input 0 to 1.2V

702:038 Service Manual A -3

 VARIANT II Hemoglobin Testing System

Mother Board (243)

All the connections are here. There are some check pins here instead of the Main CPU for
easier access. There are four LEDs on the board that describe injection positions. The
meaning is printed on the board.

PIN Note Value

TP1 Main fan stop check 0V : Normal / 5V: stop
TP2 Mixer wavelength 2kHz
TP3 6 port valve position bit 0 0/5 V
TP4 6 port valve position bit 1 0/5 V
Appendix A

TP5 6 port valve position bit 2 0/5 V

TP6 6 port valve position bit 3 0/5 V
TP7 7 port valve position bit 0 0/5 V
TP8 7 port valve position bit 1 0/5 V
TP9 7 port valve position bit 2 0/5 V
TP10 7 port valve position bit 3 0/5 V
TP11 Digital line 5V
TP12 12V line (Thermal module.) 12V
TP13 24V line 24V
TP14 digital ground 0V
TP15 Analog (15V) line 15V
TP16 Analog (-15V) line -15V
TP17 Analog common 0V
TP18 Reservoir buffer A waste sensor output See adjustment manual.
TP19 Reservoir buffer B waste sensor output See adjustment manual.
TP20 Reservoir system flush waste sensor See adjustment manual.
output
TP21 Waste sensor output Waste full : 0V

Degasser Board (246)

Contains a pressure sensor circuit and a vacuum pump on/off circuit.

PIN Note Value

TP1 Pressure sensor output after See adjustment manual.
amplification
TP2 Ground 0V

A -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Power Supply Board (245)

There are 4 different voltages created from the Power Supply Board: +5, +12, +12 and
+/-15V. 24V passes through the board to the mother board.

PIN Note Value

TP1 24V from the primary power supply 24V
(NEMIC) 24V is used at main FAN
and pump, syringe, mixer motor.
TP2 Ground 0V
TP3 5V (main, pump digital ICs and Photo 5V

Appendix A
sensors)
TP4 +15V (reservoir wight, pump pressure, +15V
degasser pressure, Hb detector)
TP5 15V common 0V
TP6 -15V -15V
TP7 12V for thermal module. 12V
TP8 12V for detector lamp 12V

Reservoir Board (251)

Three weight sensor outputs are amplified. Only +/-15V is used.

PIN Note Value

TP0 15V common 0V
TP1 Buffer A primary amplification output
TP2 Buffer B primary amplification output
TP3 Wash buffer primary amplification
output
TP4 Buffer A secondary amplification See adjustment manual.
output
TP5 Buffer B secondary amplification See adjustment manual.
output
TP6 Wash buffer secondary amplification See adjustment manual.
output

702:038 Service Manual A -5

 VARIANT II Hemoglobin Testing System

Detector Board (182D)

Amplifier circuit uses +/-15V. The lamp power supply uses 12V and regulates it to 5.5V.
20 bits A/D converter that is controlled by main CPU uses 5V. 5V created from 15V.
Following pins ,except TP12, are used for the adjustment.

PIN Note Value

TP0 Analog common 0V
TP1 A/D converter reference 1.048V
TP2 Measurement primary amp. output for zero adjustment
TP3 Reference primary amp. output for zero adjustment
Appendix A

TP4 Measurement secondly amp. output secondly amp. adjustment

TP5 Reference secondly amp. output secondly amp. adjustment
TP6 Log amp. output Log amp. adjustment
TP7 Lamp voltage after adjustment 5.5V
TP8 Lamp ground 0V
TP11 Analog output (A/D converter input) for amp. adjustment
TP12 Lamp supply 12V

A -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Pressure Voltage Table (Degasser)

Atmospheric pressure is regarded as 1013 hPa.
0 Digit = 1 hPa
1 Digit = 0.7502 mmHg
A/D Converter Value hPa mmHg Voltage
0 1013 0 0
10 1003 7.50246792 0.048875855
20 993 15.00493584 0.097751711
30 983 22.50740376 0.146627566
40 973 30.00987168 0.195503421

Appendix A
50 933 37.51233960 0.244379277
60 953 45.01480752 0.293255132
70 943 52.51727544 0.342130987
80 933 60.01974336 0.391006843
90 923 67.52221128 0.439882698
100 913 75.02467920 0.488758553
110 903 82.52714712 0.537634409
120 893 90.02961504 0.586510264
120 883 97.53208296 0.635386119
140 873 105.03455088 0.684261975
150 863 112.53701880 0.73313783
160 853 120.03948672 0.782013685
170 843 127.54195464 0.830889541
180 833 135.04442256 0.879765396
190 823 142.54689048 0.928641251
200 813 150.04935840 0.977517107
210 803 157.55182632 1.026392962
220 793 165.05429424 1.075268817
230 783 172.55676216 1.124144673
240 773 180.05923008 1.173020528
250 763 187.56169800 1.221896383
260 753 195.06416592 1.270772239
270 743 202.56663384 1.319648094
280 733 210.06910176 1.368523949
290 723 217.57156968 1.417399804
300 713 225.07403760 1.46627566
310 703 232.57650552 1.515151515
320 693 240.07897344 1.56402737
330 683 247.58144136 1.612903226
340 673 255.08390928 1.661779081
350 663 262.58637720 1.710654936
360 653 270.08884512 1.759530792
370 643 277.59131304 1.808406647

702:038 Service Manual A -7

 VARIANT II Hemoglobin Testing System

A/D Converter Value hPa mmHg Voltage

380 633 285.09378096 1.857282502
390 623 292.59624888 1.906158358
400 613 300.09871680 1.955034213
410 603 307.60118472 2.003910068
420 593 315.10365264 2.052785924
430 583 322.60612056 2.101661779
440 573 330.10858848 2.150537634
450 563 337.61105640 2.19941349
460 553 345.11352432 2.248289345
Appendix A

470 543 352.61599224 2.2971652

480 533 360.11846016 2.346041056
490 523 367.62092808 2.394916911
500 513 375.12339600 2.443792766
510 503 382.62586392 2.492668622
520 493 390.12833184 2.541544477
530 483 397.63079976 2.590420332
540 473 405.13326768 2.639296188
550 463 412.63573560 2.688172043
560 453 420.13820352 2.737047898
570 443 427.64067144 2.785923754
580 433 435.14313936 2.834799609
590 423 442.64560728 2.883675464
600 413 450.14807520 2.93255132
610 403 457.65054312 2.981427175
620 393 465.15301104 3.03030303

A -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Pump Board Modification Procedure

Instruments up to and including serial number 10796

This retrofit will prevent the pump transducer circuit A/D converter from latching. This
causes CDM to report zero pressure when normal pressure is present. There are two ways
to incorporate this retrofit.

1. The board can be modified by soldering two 10K ohm resisters to the back of the
board. The board can be reinstalled with no further adjustments necessary.

2. The circuit board can also be replaced with a previously modified board. This requires

Appendix A
a recalibration of the pressure transducer circuit, pump drive current, and flow rate. Refer
to the appropriate sections in the service manual for board replacement and calibration.

3. Remove the pump driver board from the VCS. Add two10K ohm resisters to the rear
of the circuit board. Solder one resister from M15 pin 6 to the ground side of C61, and
the other resister from M4 pin 4 to the ground side of C19. Reinstall the board.

702:038 Service Manual A -9

 VARIANT II Hemoglobin Testing System
Appendix A

A -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Appendix B

Table of Contents:

Appendix B
Universal LIMS Adapter Configuration Chart B-1

LIMS Connection on VARIANT II B-2

Overview B-2
Windows NT Settings B-3
CDM 3.5 Setup B-4
Testing the Connection: Non Slimline Computers B-4
Testing the Connection: Slimline Computers B-5

Troubleshooting LIMS Transmission B-6

Examples of Transmissions B-7

Low Level Communication B-8

High Level Communication B-9
Making a Loopback Plug for Non Slimline Computers B-10

702:038 Service Manual B -i

 VARIANT II Hemoglobin Testing System
Appendix B

B -ii Service Manual 702:038

VARIANT II Hemoglobin Testing System

Appendix B

702:038 Service Manual B -1

 VARIANT II Hemoglobin Testing System

LIMS CONNECTION ON VARIANT II

Overview

Control of the data sent across a LIMS connection lies in CDM 3.5. Sample results
within CDM 3.5 are sent to an outqueue before transmission to the LIMS. Data present
in the outqueue will then be exported across the defined communication port until the
outqueue is empty.
Appendix B

NOTE: For additional information on CDM™ 3.5 and LIMS connections refer to
the CDM 3.5 Software Operation Manual.

The recommended port connection for LIMS on Variant II is Port 5. This will allow the
user to take full advantage of the Communications Diagnostic Software installed on the
VARIANT II Computer.

On computers other than the Compaq Slimline DeskPro™ EN Port 5 is a non-standard

RS-232 configuration RJ-45 jack. On the Slimline model Port 5 is a non-standard RS-
232 configuration DB-9 jack. The communications signals of both the previous and
Slimline computers are detailed in Tables B-1 and B- 2 below. (The "RJ" or “DB”
designates connector type. The “RS” designates wiring configuration)

(V2) PC-AT Signal Name Signal Description

RocketPort
RJ45 (DTE) (as seen by DTE)
Pin Number
1 RTS Request to Send (=DTE is ready to send)
2 DTR Data Terminal Ready
3 SGND Signal Ground (= PC board ground)
4 TxD- Transmitted Data (=received data by DCE)
5 RxD- Received Data (=transmitted data by DCE)
6 DCD Data Carrier Detect
7 DSR Data Set Ready (=DCE is ready to send)
8 CTS Clear to Send
Table B-1: Pin Outs for Non Slimline VII Computers

B -2 Service Manual 702:038

VARIANT II Hemoglobin Testing System

(V2) Signal Name Signal Description

Connect Tech
DB-9 (as seen by DTE)
1 DCD Data Carrier Detect
2 RxD- Received Data (=transmitted data by DCE)
3 TxD- Transmitted Data (=received data by DCE)
4 DTR Data Terminal Ready
5 SGND Signal Ground (= PC board ground)
6 DSR Data Set Ready (=DCE is ready to send)
7 RTS Request to Send (=DTE is ready to send)

Appendix B
8 CTS Clear to Send
Table B-2: Pin Outs for Slimline VII Computer

NOTE: LIS Providers may have different connection configurations for their
systems. Refer to the Universal LIMS Adapter Configuration Chart on page B-1 for
information on connecting a particular server-wiring configuration to the Variant II
ENL computer.

Windows NT Settings

1. Select the Start button at the bottom, left of the screen.

2. Select Settings.

3. Select Control Panel.

4. Open the Ports Icon and select COM 5.

5. Select Settings and verify the following values:

Baud Rate: 9600

Data Bits: 8
Parity: none
Stop Bits: 1
Flow Control: none

702:038 Service Manual B -3

 VARIANT II Hemoglobin Testing System

CDM 3.5 Set Up

1. Select SET-UP/CONFIGURATION and enter the information below in the

appropriate fields.

LIMS Port: 5
Auto Import from LIMS: OFF unless downloading patient demographics
Automatic LIMS Export: ON
After each: Injection
Appendix B

NOTE: Worklist entry will be independent of LIMS. CDM Software expects the
LIMS computer to send an <ACK> character after the successful receipt of each
packet.

Testing The Connection: Non Slimline Computers

This procedure requires the loopback plug provided with the RocketPort manual at
installation. If the loopback plug is not available refer to page B-10 for details on how to
make one.

NOTE: The following instructions were obtained from the RocketPort Software
Installation and Configuration Guide. Please refer to this guide if more detailed
information is required.

1. CDM software must be shutdown before performing this test.

2. Select the Start button at the bottom, left of the screen.

3. Select Programs/Comtrol Rocketport Rocketmodem/Test Terminal.

4. Select the Port option at the top of the screen. Select Open Port. A list of possible
COM port numbers will be displayed. Select the COM port defined in CDM 3.5.

NOTE: Observe the <loop> button in the terminal window. If this option is
activated, it will be green and uppercase ( LOOP ). This means that the COM port
internal loopback feature is activated and the data is returned by the COM port
hardware. If this option is deactivated, it is gray and lowercase ( loop ). This means
that the internal loopback is deactivated, and the data is being sent out the COM
port.

B -4 Service Manual 702:038

VARIANT II Hemoglobin Testing System

5. Place the loopback plug on the COM port being tested. Make sure it is seated firmly.
Verify that the loop button on the screen is deactivated (lowercase gray). If it is not,
click on it to deactivate it.
6. Select the Port option from the screen. Select Send Test Data. The program sends
out a repeating data stream. To stop this select Send Test Data again.
7. If the loopback plug is in place and the port is working correctly, the test data should
be seen on the screen. If the loopback plug is not in place or the port is not working
correctly, no data or corrupted or distorted data will be seen on the screen.
8. If further testing is required, select Loopback Test from the Port menu. If the
loopback plug is in place and the port is working correctly, the system should return

Appendix B
the message “Passed”. If the loopback plug is not in place or the port is not working
correctly, the system should return the message “Failed”.
9. Close the screen and return to the desktop.

Testing The Connection: Slimline Computers

1. CDM software must be shutdown before performing this test.

2. Select the Start button at the bottom, left of the screen.

3. Select Programs/Connect Tech Applications/Loopback Test.

4. Select Settings at the top of the screen. Select Test from the menu.

5. Set the First Port field to the COM port defined in CDM 3.5.

6. Connect pins 2 (receive) and 3 (transmit) of the COM port selected.

7. Select F5 on the keyboard to begin the Loopback test.

8. If the connection of pins 2 and 3 was done properly and the port is working correctly
the word Success will be displayed on the Status column on the screen. If the
connection was not done properly or the port is not working correctly an error
message will appear in the Status column.

9. Select F8 on the keyboard to end the test.

10. Close the screen and return to the desktop.

702:038 Service Manual B -5

 VARIANT II Hemoglobin Testing System

Troubleshooting LIMS Transmission

This section is designed to troubleshoot LIMS connections that were previously working.

1. Verify that the COM port setting in the Setup/Configuration screen is correct and
does not conflict with VCS and VSS port settings. If the port settings are not correct
change them and transmit sample data to verify the connection. Verify that
Automatic LIMS Export is selected in the Configuration screen.

2. If data does not transmit verify that the connections on the computer are intact and
plugged in to the defined port. If the port setting is correct and the cable is connected
open Windows Explorer. Open D:/CDM35/Outqueue to see if data is present. If no
Appendix B

data is present, select samples in the Data screen of CDM and manually select Export
to LIMS. Watch the Outqueue folder to see if the files appear and then disappear. If
the files appear but do not disappear continue with Step 3.

3. Close CDM 3.5 and shut down the computer. Turn on the computer and open CDM
3.5. Open the Outqueue folder in CDM35. If the connection is working properly the
number of files in the directory will reduce as the data is transmitted. If the data is
not transmitting continue with Step 4.

4. Close CDM and open Explorer. Locate and open the OUTQUE folder in
D:/CDM35/OUTQUE. If there are files in the OUTQUE folder that have not been
cleared…highlight and delete these files. Then reboot the computer and sometimes,
even the LIS server. We have found that if a file does not receive the proper
“handshake”, that file will prevent all other files from exporting to prevent possible
incorrect data from transmitting. If after deleting the OUTQUE files and rebooting,
data still does not transmit, proceed to Step 5.

5. Test the COM port by using the appropriate Testing the Connection procedure on
page B-4 or B-5. If the port is not working properly for the non Slimline computer
then the rocket board will need to be changed. For the Slimline computer use the
procedure to check one of the other ports on the multi-line cable. If the second port
does not work change the entire cable out and retest. If the test still does not work
replace the port card inside the computer. Once the port issue is corrected retransmit
data to verify the connection to LIMS. If the port was working properly after testing
continue to Step 6.

6. This step requires the use of an external computer such as a laptop, universal I/O port
monitor software and the proper cable for connecting between the Variant II
computer and the external computer. Depending on the external computer/dummy
terminal configuration a DB9 –DB9 Null modem adapter may also be necessary. The
software can be obtained locally, via the internet or contact your regional service
group for assistance. The cable and Null modem adapter can be obtained at a local
electronics store. Refer to the Universal LIMS Adapter Configuration Chart on page
B-3 for the pin out information.

B -6 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Install the cable between the LIMS port to be tested and the external computer. Open
the port monitor software and follow the instructions, which came with the software,
for viewing data transmission, Open CDM and transmit data from the Data screen.
Observe that the data is appearing in the software. If data transmission is working the
problem lies in the LIMS itself. If data transmission is not working continue to Step
7.

7. Open CDM 3.5. Select the Reset LIMS Database in the Setup/Configuration screen.
Select OK to the question "Are you sure you wish to remove your current LIMS
database and install the default (empty) database?". The sample data in the Outqueue
and the LIMS database pointer will be reset. Select several samples (2-3) in the Data
screen and select Export to LIMS. Select the D:/CDM35/Outqueue path and verify

Appendix B
there is data in the folder and that it is being transmitted to LIMS. Depending on
connection speeds the data can take up to 1-2 minutes to be transmitted out of the
Outqueue folder. Typical sending time is less than 30 seconds. If the data does not
transmit reload the CDM 3.5 software and follow the procedures on setting up the
connections.

Examples of Transmissions

The examples below illustrate how the patient results are embedded into low and high
level ASTM communication protocols. The information contained in these examples
show a good, working transmission of data to the LIMS.

NOTE: For examples of transmission from LIMS to CDM 3.5 refer to the CDM 3.5
Software Operation Manual.

702:038 Service Manual B -7

 VARIANT II Hemoglobin Testing System

Low Level Communication

The example shows two patient results transmitted to the LIMS using the low level
communication protocol ASTM E1381-91.

CDM LIMS
<ENQ> <ACK>
Header <STX>1H |\^& | | | PSWD | Bio-Rad | 4000 Alfred Nobel Dr.^Hercules^CA^94547 |
| 510 724- 7000 |1998121714562<CR><ETX>8B<CR><LF> <ACK>
Start of 1st Sample <STX>2P | 1 | 10000000000-001 | | | Smith ^John^M. | Jones | 19501201 | M | | | | |
Dr. Fred | | | | | | | | | | | | Hercules | | | | M<CR><ETX>3F<CR><LF> <ACK>
Appendix B

Sample ID <STX>3O | 1 | 12345678910111213141 ^001^01 | ^^^4 | | | | | | | | | | | | | | | | | | | |

1<CR><ETX>5E<CR><LF> <ACK>
<STX>4R | 1 | ^^^A1b ^AREA | 3.6<CR><ETX>DB<CR><LF> <ACK>
LIMS Frame # <STX>5R | 2 |^^^A1b^TIME | 0.24<CR><ETX>23<CR><LF> <ACK>
<STX>6R | 3 |^^^ F ^ AREA | 0.5<CR><ETX>AE<CR><LF> <ACK>
<STX>7R | 4 |^^^ F ^ TIME | 0.49<CR><ETX>F2<CR><LF> <ACK>
<STX>0R | 5 |^^^ LA1c ^ AREA | 1.4<CR><ETX>E5<CR><LF> <ACK>
<STX>1R | 6 |^^^ LA1c ^ TIME | 0.71<CR><ETX>2B<CR><LF> <ACK>
<STX>2R | 7 |^^^A1c ^ AREA | 5.7<CR><ETX>E8<CR><LF> <ACK>
<STX>3R | 8 |^^^A1c ^TIME | 0.86<CR><ETX>33<CR><LF> <ACK>
<STX>4R | 9 |^^^ P3 ^ AREA | 78.3<CR><ETX>57<CR><LF> <ACK>
<STX>5R | 10 |^^^ P3 ^ TIME | 1.69<CR><ETX>89<CR><LF> <ACK>
<STX>6R | 11 |^^^ E, D, S, ^ AREA | 8.5<CR><ETX>07<CR><LF> <ACK>
<STX>7R | 12 |^^^ E, D, S, ^ TIME | 1.94<CR><ETX>53<CR><LF> <ACK>
Total Area=1890000 <STX>0R | 19 |^^^ TOTAL ^ AREA | 1.89<CR><ETX>52<CR><LF> <ACK>
2nd Sample <STX> 1P | 2 | 10000000000-002 | | | Jones ^Mary^Q. | Smith | 19501201 | F | | | | |
Dr. Bob | | | | | | | | | | | | Hercules | | | | S<CR>><ETX>3F<CR><LF> <ACK>
<STX> 2O | 1 | 14131211101987654321^002^01 | |^^^4 | | | | | | | | | | | | | | | | | | | |
1<CR>><ETX>5E<CR><LF> <ACK>
<STX>3R | 1 | ^^^A1b ^AREA | 5.2<CR><ETX>DB<CR><LF> <ACK>
<STX>4R | 2 | ^^^A1b ^TIME | 0.25<CR><ETX>23<CR><LF> <ACK>
<STX>5R | 3 | ^^^F ^AREA | 0.5<CR><ETX>AE<CR><LF> <ACK>
<STX>6R | 4 | ^^^F ^TIME | 0.49<CR><ETX>F2<CR><LF> <ACK>
<STX>7R | 5 | ^^^LA1c ^AREA | 7.0<CR><ETX>E5<CR><LF> <ACK>
<STX>0R | 6 |^^^LA1c^TIME | 0.80<CR><ETX>2B<CR><LF> <ACK>
<STX>1R | 7 | ^^^A1c ^AREA | 6.5<CR><ETX>E8<CR><LF> <ACK>
<STX>2R | 8 | ^^^A1c ^TIME | 0.86<CR><ETX>33<CR><LF> <ACK>
<STX>3R | 9 | ^^^P3 ^AREA | 74.5<CR><ETX>57<CR><LF> <ACK>
<STX>4R | 10 | ^^^P3 ^TIME | 1.69<CR><ETX>89<CR><LF> <ACK>
<STX>5R | 11 | ^^^E, D, S, ^AREA | 9.1<CR><ETX>07<CR><LF> <ACK>
<STX>6R | 12 | ^^^E, D, S, ^TIME | 1.98<CR><ETX>53<CR><LF> <ACK>
<STX>7R | 19 | ^^^TOTAL ^AREA | 1.87<CR><ETX>52<CR><LF <ACK>
<STX>0L | 1 | N<CR><ETX>07<CR><LF> <ACK>
<EOT>

B -8 Service Manual 702:038

VARIANT II Hemoglobin Testing System

High Level Communication

The example shows patient results embedded into the high level protocol ASTM 1395-91
after the low level protocol has been removed.

H|\^& | | | PSWD | Bio-Rad | 4000 Alfred Nobel Dr.^Hercules^CA^94547 | | 510 724- 7000 |
1998121714562
19940809134600<CR>
P|1| 10000000000-001 | | | Smith ^John^M. | Jones | 19501201 | M | | | | | Dr. Fred | | | | | | | | | | | |
Hercules | | | |M<CR>

Appendix B
O | 1 | 12345678910111213141 ^001^01 | | ^^^4 | | | | | | | | | | | | | | | | | | | | 1<CR >
R | 1 | ^^^A1b ^ AREA | 3.6<CR>
R | 2 | ^^^A1b ^ TIME | 0.24<CR>
R | 3 |^^^ F ^AREA | 0.5<CR>
R | 4 | ^^^ F ^TIME | 0.49<CR>
R | 5 | ^^^ LA1c ^AREA | 1.4<CR>
R | 6 | ^^^ LA1c ^TIME | 0.71<CR>
R | 7 | ^^^ A1c ^AREA | 5.7<CR>
R | 8 | ^^^ A1c ^TIME | 0.86<CR>
R | 9 | ^^^ P3 ^AREA | 78.3<CR>
R | 10 | ^^^ P3 ^TIME | 1.69<CR>
R | 11 | ^^^ E,D,S,^AREA | 8.5<CR><ETX>07<CR>
R | 12 | ^^^ E,D,S,^TIME | 1.94<CR><ETX>53<CR>
R | 13 | ^^^ TOTAL^AREA | 1.89<CR><ETX>52<CR>
P | 2 | 10000000000-002 | | | Jones ^Mary^Q. | Smith | 19501201 | F | | | | | Dr. Bob | | | | | | | | | | | |
Hercules | | | |S<CR>
O | 1 | 14131211101987654321 ^002^01 | | ^^^4 | | | | | | | | | | | | | | | | | | | | 1<CR>
R | 1 | ^^^ A1b^AREA | 5.2<CR><ETX>DB<CR>
R | 2 | ^^^A1b^TIME | 0.25<CR><ETX>23<CR>
R | 3 | ^^^ F^AREA | 0 .5<CR><ETX>AE<CR>
R | 4 | ^^^ F^TIME | 0.49<CR><ETX>F2<CR>
R | 5 | ^^^ LA1c^AREA | 7.0<CR>
R | 6 | ^^^ LA1c^TIME | 0.80<CR>
R | 7 | ^^^ A1c^AREA | 6.5<CR>
R | 8 | ^^^ A1c^TIME | 0.86<CR>
R | 9 | ^^^ P3^AREA | 74.5<CR>
R | 10 | ^^^ P3^TIME | 1.69<CR>
R | 11 | ^^^ E,D,S,^AREA | 9.1<CR>
R | 12 | ^^^ E,D,S,^TIME | 1.98<CR>
R | 13 | ^^^ TOTAL^AREA | 1.87<CR>
L | 1| N<CR><ETX>07<CR>
<EOT>

702:038 Service Manual B -9

 VARIANT II Hemoglobin Testing System

Making a Loopback Plug for Non Slimline Computers

1. Obtain an RJ45 plug from a local electronics store.

2. Configure the plug so that the following signals are shorted together:

"RTS" (1)– "CTS"(8)

"DTR"(2) – "DCD"(6) – "DSR"(7)
"TxD"(4) – "RxD"(5)
Appendix B

B -10 Service Manual 702:038

VARIANT II Hemoglobin Testing System

Appendix C

Fluidic Diagrams

Appendix C
Table of Contents:

VCS Tubing Diagram C-1

VSS Tubing Diagram C-2

702:038 Service Manual C -i

 VARIANT II Hemoglobin Testing System
Appendix C

C -ii Service Manual 702:038

 VARIANT II Hemoglobin Testing System

Bio-Rad P/N* Diagram Reflects Serial

270-2136 Numbers >11131
270-2136
270-2137
270-2180
270-2138
270-2138
270-2138
270-2138
270-2138
270-2138
270-2138
270-2138
270-2096
270-2096
270-2139
270-2139
270-2143
270-2142
270-2143
270-2139
270-2139
270-2139
**
270-2140
270-2140
270-2140
270-2141
270-2141
270-2141
270-2141
270-2141

**SL 1-4 270-2084

SL 5-8 270-2083
Pre-cut with fittings

*MUST BE CUT TO LENGTH

702:038 Service Manual C - 1
 VARIANT II Hemoglobin Testing System

Bio-Rad P/N*
270-2021**
270-2023
270-2023
270-2023
270-2023
270-2023
270-2024
270-2022**
270-2024
270-2023
270-2025
270-2025
270-2025
270-2025
270-2026
270-2025
270-2023
270-2023
270-2023
270-2023
270-2025
270-2026
270-2025
270-2026
270-2026
270-2026
270-2075
270-2075

*MUST BE CUT TO LENGTH

**COMPLETE ASSEMBLY WITH FITTINGS

702:038 Service Manual C - 2

VARIANT II Hemoglobin Testing System

Appendix D

Mechanical Drawings

Table of Contents:

Appendix D
VCS
Chassis Assembly D-1

Siphon Break Assembly D-2

Column Holder Unit D-3

Degasser Unit D-4

Detector Unit D-5

Dynamic Mixer Unit D-6

Pump Unit D-7

CPU Board Rack D-8

Reservoir Unit D-9

6 and 7 Port Valves D-10

Syringe Pump Unit D-11

702:038 Service Manual D-i

 VARIANT II Hemoglobin Testing System

VSS

Component Layout A D-12

Component Layout B D-13

Syringe Pump Unit D-14

Appendix D

Spinning Head Unit D-15

Sampling Head Unit D-16

Tube Holder Unit D-17

Dilution Chamber Unit D-18

Rear Rack Carrier Unit D-19

Front Rack Carrier Unit D-20

Belt Comber Unit Right D-21

Belt Comber Unit Left D-22

Rack Carrier 1 D-23

Rack Carrier 2 D-24

D-ii Service Manual 702:038

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 1

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 2

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 3

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 4

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 5

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 6

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 7

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 8

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 9

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 10

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 11

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 12

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 13

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 14

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 15

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 16

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 17

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 18

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 19

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 20

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 21

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 22

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 23

 VARIANT II Hemoglobin Testing System

702:038 Service Manual D - 24

VARIANT II Hemoglobin Testing System

Appendix E

VCS Electronic Diagrams and Layer

Drawings

Appendix E
Table of Contents:

Block Diagram E-1

Main Board 242 - CPU E-2

Main Board 242 - Driver 1 E-3

Main Board 242 - Driver 2 E-4

Main Board 242 - Analog E-5

Main Board 242 - Memory E-6

Main CPU 242A (Layer Drawing) E-7

Pump Board 1 244C E-8

Pump Board 2 244C E-9

Pump Board 244C (Layer Drawing) E-10

Degasser Board 246B E-11

Degasser Board 246B (Layer Drawing) E-12

702:038 Service Manual E -i

 VARIANT II Hemoglobin Testing System

Mother Board 243C E-13

Mother Board 243D (Layer Drawing) E-14

Reservoir Unit 251 E-15

Reservoir Board 251 (Layer Drawing) E-16

Power Supply Board 245B E-17

Appendix E

Power Supply Board 245 B (Layer Drawing) E-18

Connection Boards (247A-1, 247A-2, 247A-3, 249, 250A) E-19

Connection Boards 247A 1-3 (Layer Drawing) E-20

Connection Boards 248, 249, 250 (Layer Drawing) E-21

Detector Board 182D E-22

Detector Board 182D (Layer Drawing) E-23

Pump Sensor 248-C E-24

E -ii Service Manual 702:038

 VARIANT II Hemoglobin Testing System

P/N 270-2199
P/N 270-2089
P/N 270-2191 P/N 270-2011 P/N 270-2012
P/N 270-2126 (includes sensor) (includes sensor)
P/N 270-2127
P/N 270-2168

P/N 270-2125
P/N 270-2123 P/N 270-2188

P/N 270-2122

P/N 270-2093
P/N 270-2082

P/N 270-2085
P/N 270-2121

P/N 270-0127
P/N 270-2120 P/N 270-2092

P/N 270-2085 P/N 270-2082

P/N 270-2188

P/N 270-0153

P/N 270-2098
P/N 270-0206
P/N * see below P/N 270-2146

P/N 270-2187
*Replace
Entire I/O P/N 270-2144
Port
P/N 270-2132 Assembly
P/N 270-2193 P/N 270-2095 P/N 270-2128
P/N 270-0202 for Board
P/N 270-2097 - 247-2

702:038 E - 1
 VARIANT II Hemoglobin Testing System

702:038 E - 2
 VARIANT II Hemoglobin Testing System

702:038 E - 3
 VARIANT II Hemoglobin Testing System

702:038 E - 4
 VARIANT II Hemoglobin Testing System

702:038 E - 5
 VARIANT II Hemoglobin Testing System

702:038 E - 6
 VARIANT II Hemoglobin Testing System

702:038 E - 7
 VARIANT II Hemoglobin Testing System

702:038 E - 8
 VARIANT II Hemoglobin Testing System

702:038 E - 9
 VARIANT II Hemoglobin Testing System

702:038 E - 10
 VARIANT II Hemoglobin Testing System

702:038 E - 11
 VARIANT II Hemoglobin Testing System

702:038 E - 12
 VARIANT II Hemoglobin Testing System

702:038 E - 13
 VARIANT II Hemoglobin Testing System

702:038 E - 14
 VARIANT II Hemoglobin Testing System

702:038 E - 15
 VARIANT II Hemoglobin Testing System

702:038 E - 16
 VARIANT II Hemoglobin Testing System

702:038 E - 17
 VARIANT II Hemoglobin Testing System

702:038 E - 18
 VARIANT II Hemoglobin Testing System

702:038 E - 19
 VARIANT II Hemoglobin Testing System

702:038 E - 20
 VARIANT II Hemoglobin Testing System

702:038 E - 21
 VARIANT II Hemoglobin Testing System

702:038 E - 22
 VARIANT II Hemoglobin Testing System

702:038 E - 23
 VARIANT II Hemoglobin Testing System

702:038 E - 24
VARIANT II Hemoglobin Testing System

Appendix F

VSS Electronic Diagrams and Layer

Drawings

Appendix F
Table of Contents:

Block Diagram F-1

Main Circuit Board DC-DC F-2

Main Circuit Board 240 CPU F-3

Main Board 240B (Layer Drawing) F-4

Main Circuit Board I/O and Control F-5

Main Circuit Board F-6

Main Circuit Board Driver F-7

Syringe Connection Board 253-1 F-8

Mixing Head Connection Board 253-2 F-9

External Connector Board 253-3 F-10

Photo Sensor Boards 255-1, 255-10, 253-4, 253-5, 253-7, 253-8 F-11

Tube Holder Sensor Board 253-7, 253-8 F-12

702:038 Service Manual F -i

 VARIANT II Hemoglobin Testing System

Sensor Board 253-7 (Layer Drawing) F-13

Connection Boards 253A-1 through 253A-7 (Layer Drawing) F-14

Sample Head Connection Board 254-1 F-15

Valve and Pump 254-2 F-16

Conveyor Unit Connection Board 254-3 F-17

Appendix F

Z Axis Connection Board 254-4 F-18

Tube Holder Connection Board 254-5 F-19

Connection Boards 254A-1 through 254A-5 (Layer Drawing) F-20

Noise Filters 255-11, 255-12, 255-13 F-21

Sensor Boards 255A-1 through 255A-14 (Layer Drawing) F-22

Interlock Switch F-23

LED 276 F-24

Sensor Board 276 (Layer Drawing) F-25

F -ii Service Manual 702:038

 VARIANT II Hemoglobin Testing System

P/N 270-2207
P/N 270-2200

P/N 270-2070
P/N 270-2060
P/N 270-2068 (V3 or V4)

P/N 270-2074
P/N 270-2235 P/N 270-2010 P/N 270-2198 (PCB256)

P/N 270-2048
P/N 270-2067

P/N 270-2050 -

P/N 270-2062
P/N 270-2066

P/N 270-2071

P/N 270-2049 -
P/N 270-2072

P/N 270-2073
P/N 270-2250
(either)

P/N 270-2037 (either)

P/N 270-2059
P/N 270-2235

P/N 270-2202

P/N 270-2223

P/N 270-2037
P/N 270-2042

P/N 270-2203 - P/N 270-2065

(Applies to 255-1
Through 255-6) P/N 270-2206
P/N 270-2061

P/N 270-2201
P/N 270-2064

P/N 270-2063

P/N 270-2038

P/N 270-2194
P/N 270-2247 (either)
P/N 270-2041

P/N 270-2065
(Applies to 255-1
Through 255-6) P/N 270-2234 P/N 270-2205

P/N 270-2053 (Contains both Hold P/N 270-2069 (for any)

and Home Sensors)
P/N 270-2057 P/N 270-2247

702:038 Service Manual F - 1

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 2

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 3

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 4

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 5

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 6

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 7

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 8

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 9

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 10

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 11

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 12

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 13

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 14

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 15

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 16

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 17

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 18

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 19

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 20

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 21

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 22

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 23

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 24

 VARIANT II Hemoglobin Testing System

702:038 Service Manual F - 25