TECHNICAL SERVICE BULLETIN: TSB2015-007 To: From: Global Service Organization, ichem VELOCITY and iricell Distributors Iris Diagnostics Service and Support Date: 10 June 2015 Subject: STRIP PROVIDER MODULE (SPM) PART NUMBERS B39124 / 700-7200 / 700-7200S Instruments Affected: ichemvelocity Automated Urine Chemistry Analyzers and iricell Systems Purpose: Provide Global Service Organization and distributor partners with information about how to resolve SPM related issues with lower cost repair parts instead of replacing the entire module. Discussion: The SPM is a high cost module in the ichemvelocity Analyzer. In order to reduce costs associated with servicing this analyzer, information pertaining to resolving SPM related problems with lower cost repair parts instead of replacing the entire module is provided in this Technical Bulletin. IMPORTANT NOTES: 1. Certain repair parts are backwards compatible to specific revision levels of the SPM. For these repair parts, the information will be documented below the section and replacement part number in this bulletin. 2. There will be situations when the entire Strip Provider Module will require replacement; however, this Technical Bulletin provides multiple examples of how the SPM can be repaired at a lower level instead of replacing the entire module. TSB2015-007 Rev AA
1. Strip Load Cylinder, Spare (P/N 700-7250S) Movement or rotation problems related to the Strip Load Cylinder are issues that can many times be resolved by the customer. Replacing the Strip Load Cylinder normally does not require an on-site service visit. This part can be shipped directly to the customer for replacement. 2. PCBA, SPM Strip Loading Cylinder Sensor (P/N 101-7025) This sensor on the back of the SPM for the Strip Load Cylinder can be replaced by unplugging the connector from the sensor, removing the screws/ fasteners holding the sensor in place, removing the old sensor, installing the new sensor and plugging in the connector. The symptoms of this sensor going bad will be the instrument will remain in constant measure mode and will not process samples. 3. SPM Magnet Assembly Retrofit Kit (P/N 799-7033) This kit is used if the magnet on the back of the Strip Loader Module needs to be replaced. The magnet is secured to the Strip Load Cylinder by one screw. If this magnet falls off the back of the strip loader module, the SPM strip loading cylinder sensor will not be able to determine when the Strip Loader Cylinder is in the correct locked position. This will result in the instrument remaining in constant measure mode and the instrument will not process samples. 4. SPM Home Sensor Replacement Kit P/N (799-7029) This kit contains one pre-assembled cable, connector and home sensor that will work for the wiper, extractor, feeder, or flipper. The SPM home sensor replacement procedure can be done with the SPM installed or with the SPM removed from the instrument. The instructions below document how to replace an SPM home sensor with the SPM removed from the instrument. Step a: Turn off all electrical power to the Instrument. Remove the SPM from the Instrument. Step b: Remove the Sensor: Remove the malfunctioning sensor and cable. Discard the screws and washers. Notice how the cable was routed and tied so the pattern can be repeated when installing the replacement cable and sensor. 2
Step c: To Install the Wiper, Flipper or Extractor Sensor: Use the short Screws provided. Washers are not to be used. Route the cable along the same path as the cable just removed. To install the feeder home sensor, Use the white Spacers and the long Screws provided. Washers are not to be used. Route the cable along the same path as the cable just removed. 3
Step d: Secure the cable. Use cable ties provided in the kit to secure the new cable. Step e: Use markers provided to properly identify the new cable. Step f: Before re-installing the SPM, check that the Strip Provider Housing opens and closes freely without pulling on the Cables. Step g: Re-install the SPM, verify the SPM calibrations in accordance with the Service Manual, and conduct the Performance Verification. 4
5. SPM Strip Loading Housing Cover (P/N B39121) This top cover was modified and implemented in instrument serial number V02140. Instruments that experience issues with strips jams when loading strips should be checked to determine if this top cover is installed on the SPM. The Strip Loading Housing Cover (P/N B39121) is backwards compatible from the current SPM P/N B39124 to SPM 700-7200 Revision AD. 6. SPM Cover Crossbar Kit (P/N 800-7023) This part is replaced if the SPM has problems associated with opening and closing the SPM cover. Instrument S/N VO1224 is the first instrument that was manufactured with the SPM Cover Crossbar Kit. All Strip Provider Modules P/N 700-7200 Revision AD and later and Strip Provider Modules P/N B39124 are manufactured with the SPM Cover-Crossbar Kit. This kit contains the following parts: Captive SPM cover screws 2 EA P/N 690-7117 Springs 2 EA P/N 692-7156 Retainer washers 3 EA P/N 690-7119 Crossbar 1 EA P/N 661-7286 Crossbar retaining screws 2 EA P/N 690-3012 Instructions 1 EA P/N 300-5432 Replacing the captive SPM cover screws, springs, washers, crossbar and crossbar retaining screws enable the SPM cover to securely closed and this make it easier for the operator to open and close the SPM. The SPM cover-crossbar kit can be used with SPMs P/N 700-7200 Revision V and later and all SPMs P/N B39124. 5
7. Extractor presence sensor (P/N 101-7008) Extractor presence sensor flat cable (P/N 101-7028) Extractor magnet assembly, spare (P/N 700-7280S) If the SPM wiper is singulating the strip to the extractor but the extractor is ejecting the strip back into the SPM strip housing chamber, the following must be checked: a) Verify the extractor presence sensor flat cable is plugged in at both ends. b) SPM extractor and wiper calibration should be verified. c) If line items 7a and 7b have been verified as correct, verify operation of the extractor presence sensor in chemistry service mode. Make sure the SPM strip at extractor consistently changes state between 1 and 0 when a chemistry strip is inserted and removed from the extractor. d) Problems associated with the chemistry strip being ejected back into the SPM strip housing chamber are normally resolved by replacing the extractor presence sensor, extractor presence sensor flat cable, and extractor magnet assembly. 6
8. For issues related to the ichemvelocity chemistry strip being placed upside down on the Strip Conveyor System, the following items must be checked: a) Make sure the chemistry strips properly loaded into the SPM. If the chemistry strips are loaded with the black marker facing the front of the SPM, the chemistry strips will be placed upside down on the Strip Conveyor System (SCS). This will result in a Chem N/A and Strip Deviate result. b) If the chemistry strips are properly loaded into the SPM but the strips are still being placed upside down onto the SCS, check to ensure the SPM feeder and flipper connectors are properly plugged into the SPM interconnect board (See diagram below - J20 and J21). If the connectors are plugged in properly, verify the SPM feeder and flipper calibration. If the SPM feeder is not stopping at the correct location when the SPM strip presence and orientation sensor is determining the orientation of the chemistry strip, the flipper will fail to rotate the chemistry strip to have the pads facing the upward position. If the feeder calibration is correct, check for proper operation of the SPM flipper. 7
c) If line items 8a and 8b are correct, verify proper operation of the SPM presence and orientation sensor in chemistry service mode. Make sure the SPM strip presence or orientation sensor changes state between 1 and 0 when a strip is placed in front of and removed away from the sensor. If the sensor is not working correctly, replace the sensor (P/N 101-7009). d) Most issues related to the chemistry strips being placed upside down onto the Strip Conveyor System are related to the chemistry strips being loaded backwards into the SPM or the SPM feeder calibration being incorrect. 9. For strip jams at the extractor gate, check the following: a) Determine if there is any debris in the SPM chamber. Make sure to check the inner and outer grooves of the SPM chamber. b) Determine if there is any debris inside the extractor. The extractor crossbar will need to be removed to check for debris inside the extractor. c) Verify the SPM wiper and extractor calibration. d) Verify the extractor gate has both retaining screws holding the gate in place. e) Remove the extractor gate to inspect any debris inside the gate. f) Inspect the extractor gate to ensure the static gate seal is in good condition. g) If there are any issues with the extractor gate, replace using the SPM extractor gate kit (P/N 700-7276). Diagram shown below. 8
SPM EXTRACTOR GATE KIT (P/N 700-7276) Screw, Shoulder: P/N 692-7169 2 EA Spring, Compression: P/N692-7123 1 EA Extractor Gate, Static P/N 661-7266 1 EA Extractor Gate, Dynamic P/N 661-7265 1 EA After installing the SPM extractor gate kit, conduct SPM performance verification in accordance with the ichemvelocity PV Verification Data Sheet 300-5500. 9
10. SPM COUPLING REPLACEMENT KIT (P/N 799-7702) Important Notes: 1. This procedure is documented in TSB2011-044. 2. The SPM coupling replacement kit (P/N 799-7702) can be used with SPM revisions P/N 700-7200 Revision AA and later and all SPMs P/N B39124. 3. There are specific tool requirements for this procedure. The torque screwdriver and hex tools required for this procedure are not included in the SPM Coupling Replacement Kit. 4. The SPM coupling replacement kit contains the coupling assemblies for the SPM wiper and extractor. The SPM feeder and flipper coupling assemblies are made of a different material and have a very low failure rate. Couplings for these assemblies are ordered separately from this kit. The SPM Coupling Replacement Kit is made up of the following parts: P/N 510-7042 Disk, Coupling (2 EA) P/N 692-7212 Coupling with screw (2 EA) P/N 692-7213 Coupling with screw (2 EA) P/N 725-7252 Tool, Shim.010-.005 (1 EA) P/N 300-5430 Instructions, Kit (1 EA) Before you Begin: You must have these tools available: Tools: Calibrated torque screwdriver with 2 mm hex bit 2 mm hex key 5/32 hex key Shim Tool P/N 725-7252 (Provided with the kit) Important Notes: 1. This procedure can be performed with the SPM inside the instrument or with the SPM removed from the instrument. 2. This Technical Service Bulletin shows this procedure being performed on the SPM wiper coupling assembly with the SPM remaining inside the instrument. 3. The procedure to change the SPM extractor coupling assembly is identical to the SPM wiper coupling assembly. 10
CAUTION: When performing the SPM coupling replacement, be careful not to remove the ribbon cable from the SPM extractor presence sensor PCB. Step a: Turn off the instrument. Gain access to the SPM coupling assemblies. Using a 2 mm hex key, loosen screws (2ea) of the wiper coupling assembly. SPM Wiper Coupling Assembly Screw SPM Extractor Coupling Assembly SPM Wiper Motor SPM Extractor Motor Step b. Using a 5/32 hex key, remove and set aside for later use screws (4 per motor) that mount the wiper motor. Carefully remove the motor. SPM Wiper Motor 11
Step c: Install the couplings onto the wiper shaft as shown in the picture below. Clean the wiper shaft and shaft bores. Orient the flags horizontal as shown and slide the Coupling onto the shafts. Note that the heads of the coupling screws are oriented to the top, the same as the screws on the home sensor flags. 510-7042 Nylon Coupling Disk with hole 692-7212 Wiper Coupling Assembly with 2 mm Screw Step d: Slide the couplings onto the wiper shaft until they contact the flags. Maintain the couplings orientation as shown (screw head at top). Tighten the coupling screws so that they grip onto the shaft. Torque the coupling screw to 11 in-lb. (The 11 in-lb. is a requirement on both the wiper coupling and extractor coupling assemblies). Press Disk in place The wiper home flag is horizontal and the screw head for the coupling assembly is facing upward. Extractor Motor Wiper Motor Rotate Wiper Motor Shaft with the D-flat of the shaft in a vertical position. D-flat of the motor shaft. 12
Step e: Align and secure the wiper coupling. Using the shim tool, press the coupling stack to set a.010 inch gap. 725-7252 Shim Tool,.010 in place. D-Flat on motor shaft is vertical Wiper motor Step f: Orient the D-flat shaft of the wiper motor vertically as shown. The coupling hub on the motor must not move from orientation shown. The flat must remain vertical. 1) Squeeze the Coupling stack to set.010 gap 2) Torque the coupling screw to 11 in-lb 725-7252 Shim Tool Gently press on Plastic Rotating Disk inside the SPM Torque the coupling screw on the wiper coupling to 11 in-lb. Rotate the wiper so that the flag is in horizontal orientation as shown. Install the shim tool onto the wiper coupling stack as shown. 13
Step g. Torque the coupling screw on the coupling to 11 in-lb. Remove the shim tool. Step h: Verify SPM calibrations. Pay particular attention to the SPM calibration for the coupling assembly that was just replaced (Wiper or Extractor). Perform SPM calibrations as necessary using the SPM calibration procedure documented in the ichemvelocity service manual. Step i: Conduct SPM performance verification in accordance with the ichemvelocity Performance Verification Data Sheet 300-5500. 11. SPM feeder and flipper coupling assemblies (P/N 692-7194): The Mean Time Between Failure for the feeder and flipper coupling assemblies is very low; however, if either of these coupling assemblies fail, remove the coupling with a 2mm hex key and replace. 14
12. SPM Motors: In the event an SPM motor fails, loosen the associated motor coupling assembly. Use a 5/32 hex key to remove the SPM motor retaining screws. Install the new motor, reinstall the motor coupling assembly, tighten the SPM motor retaining screws, and Conduct SPM performance verification in accordance with the ichemvelocity PV Verification Data Sheet 300-5500. This part is replaced upon failure. 13. To address strip jams between the SPM and SCS, conduct the following: a) Verify the SPM-SCS alignment in accordance with TSB2014-016. b) Verify the SCS links are in good condition. c) Verify the SPM ramp assembly is clean. d) Verify the routine maintenance is being conducted on the SCS and that the SCS is clean. 15
13. SPM TILT RELASE BLOCK KIT P/N 799-7034 While the SPM tilt release block is connected to the foundation plate and not the actual Strip Provider Module, complaints related to the tilt release block will be associated with the Strip Provider Module. See instructions below on how to replace this part. Before you Begin: You must have these tools and parts available: - SPM Tilt Release Block Kit (P/N 799-7034) - 1/8 Allen Wrench - 7/64 Allen Wrench - #1 Phillips Screwdriver - SPM-SCS Alignment Tool (P/N 725-7234) - SPM Ramp Alignment Tool (P/N: 725-7206) - TSB2014-016 (Technical Service Bulletin explaining the SPM-SCS alignment) Step a: Turn off the instrument. Step b: Using a 7/64 Allen Wrench, loosen and remove the SPM tilt release block retaining screw. Set the screw and washers to the side; they will be used to reinstall the new SPM tilt release block kit. 16
Step c: Using a 1/8 Allen Wrench, loosen and remove the SPM Z block retaining screws. Set the screws and washers to the side; they will be used to reinstall the new SPM tilt release block kit. Note: When loosening the SPM tilt wheel, it is recommended to count the number of turns it takes to remove the SPM tilt release block from the SPM tilt wheel. This will provide the service engineer with an approximate calculation of the SPM tilt adjustment when installing the SPM tilt release block kit. Step d: Rotate the SPM tilt wheel counter-clockwise until the threads for the SPM tilt wheel are out of the SPM tilt release block. Step 2: Step 4: Step 3: Step e: Remove the SPM tilt release block kit from the box. The screws and washers in this kit are spares in the event the original screws were misplaced. Step f: Install the new SPM tilt release block kit. Step g: Using TSB2014-016, perform the SPM-SCS alignment. Step h: Make sure all SPM retaining screws are tightened after performing the SPM-SCS alignment. Step i: Conduct SPM performance check and ichemvelocity performance verification to make sure the SPM is aligned and working properly. Step j: After successful performance check and performance verification, return the instrument to normal operating condition. End Procedure. 17