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Osmetech Opti 1 Service Manual

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CONTENTS
General Information ....................................................................................................... 1-1
Warnings ....................................................................................................................... 1-1
Specifications ................................................................................................................ 2-1
Principles of Operation .................................................................................................. 2-7
Fluidics Block Diagram ................................................................................................ 2-11
Osmetech OPTI Cassette ............................................................................................. 2-12
Osmetech OPTI Cassette Valve Positions .................................................................... 2-13
Assemblies .................................................................................................................. 2-14
Software Structure ...................................................................................................... 2-15
3 TEST PROGRAMS AND DIAGNOSTICS
Diagnostic 1 ........................................................................................... 3-1
Barometer ..................................................................................................................... 3-1
Battery .......................................................................................................................... 3-1
Temperature .................................................................................................................. 3-2
Gas Pressure ................................................................................................................ 3-2
Cleaning ........................................................................................................................ 3-2
Flow Test ...................................................................................................................... 3-3
Optics Test .................................................................................................................... 3-3
Diagnostic 2 ........................................................................................... 3-4
Printer Test ................................................................................................................... 3-4
Keypad Test .................................................................................................................. 3-4
Display Test .................................................................................................................. 3-4
Barcode Test ................................................................................................................. 3-4
RS232 Test ................................................................................................................... 3-4
Cover Test..................................................................................................................... 3-5
Fset............................................................................................................................... 3-5
Diagnostic 3 ........................................................................................... 3-6
Valve Test ..................................................................................................................... 3-6
Valve Drive Test ............................................................................................................ 3-6
Peristaltic Pump Test ..................................................................................................... 3-6
LED Test ....................................................................................................................... 3-7
Memory Test.................................................................................................................. 3-7
Software Version ........................................................................................................... 3-7
Reports ......................................................................................................................... 3-7
Service Manual - Osmetech OPTI™ Analyzer
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  • Page 1: Table Of Contents

    Specifications ........................ 2-1 Principles of Operation ....................2-7 Fluidics Block Diagram ....................2-11 Osmetech OPTI Cassette ..................... 2-12 Osmetech OPTI Cassette Valve Positions ..............2-13 Assemblies ........................2-14 Software Structure ...................... 2-15 3 TEST PROGRAMS AND DIAGNOSTICS Osmetech OPTI 1 Diagnostic 1 ...................
  • Page 2 VDrive Test........................3-19 Peristaltic Pump Test ....................3-19 Keypad Test ........................ 3-19 4 ADJUSTMENTS Osmetech OPTI 1 Summary ..................4-1 Barometric Pressure ...................... 4-1 Sample Measuring Chamber Temperature ..............4-1 Osmetech OPTI CCA Summary ..................4-2 Barometric Pressure ...................... 4-2 Sample Measuring Chamber Temperature ..............4-3...
  • Page 3 Storage Compartment ......................6-10 Peristaltic Pump Motor ......................6-11 Battery Receptacle ......................6-12 Main Board Assembly .......................6-13 Barcode Reader .........................6-14 Osmetech OPTI™ CCA Systems S/N <4000 ..............6-15 Pump Cartridge .........................6-15 Printer Assembly.......................6-16 Analyzer Housing......................6-19 Sample Measurement Chamber Cover ................6-20 SMC Lower Module ......................6-20 Osmetech OPTI CCA Handle .....................6-20...
  • Page 4 Main Upper Housing (Outer View) .................. 7-2 Main Upper Housing (Inner View) ................... 7-4 Lower Housing Assembly ....................7-6 Printer Assembly......................7-8 Gas Module Assembly....................7-10 Display Assembly......................7-12 8 SERVICE SPARE PARTS Spare Parts List ......................8-1 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 5 Osmetech Inc. While every effort is made to ensure its correctness, Osmetech Inc. assumes no responsibility for errors or omissions, which may occur in this document.
  • Page 6 The instrument is only to be operated by qualified personnel capable of observing these prerequisites. Only accessories and supplies either delivered by or approved by Osmetech Inc. are to be used with the instrument. Due to this instrument‘s operating principle, analytical accuracy not only depends on correct operation and function, but also upon a variety of external influences beyond the manufacturers control.
  • Page 7 Operating Safety Information • Overvoltage Category II when connected to a branch circuit. • This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. Caution: •...
  • Page 8 Symbol Definitions The symbols described below are used on the packaging of Osmetech OPTI related products. Symbol Explanation Attention Symbol – Refer to the Operator’s Manual or Service Manual for further instructions. This symbol is located on the inside of the instruments and product packaging.
  • Page 9 Symbol Explanation Bio-Hazard Symbol – Products and/or components containing this symbol should be handled as bio-hazardous material after use. Temperature Symbol – Products and/or components which contain this symbol must be stored between the specified temperature range. For in vitro diagnostic use This product fulfils the requirements of Directive 98/79/EC on in vitro diagnostic medical devices.

  • Page 10: Introduction

    To ensure proper operation and performance which meets the analyzer specifications, maintenance and repairs must be performed according to the instructions described in this service manual. The use of Osmetech original parts and recommended materials is required to achieve performance specifications.
  • Page 11 • Use approved protective gloves when handling blood specimens of contacting contaminated surfaces. • Adhere to local regulations when disposing of Osmetech OPTI cassettes or contaminated parts. Service Manual – Osmetech OPTI™ Analyzer...

  • Page 12: General Description

    General Description Specifications Measurement Parameters The specifications are described for both the Osmetech OPTI™ 1 and Osmetech OPTI™ CCA analyzers. Certain parameters are specific only to Osmetech OPTI™ CCA analyzers. The specifications listed below are valid for human whole blood, human plasma, serum, and approved QC-material.
  • Page 13 Art, Ven, MixVen, Cap, Cord, CPB Where: Art = Arterial Ven = Venous MixVen = Mixed Venous Cap = Capillary Cord = Cord CPB = Cardio-Pulmonary Bypass Mean corpuscular hemoglobin 29.0 to 37.0 33.3 concentration, MCHC% Service Manual – Osmetech OPTI™ Analyzer...
  • Page 14 Peak Inspiratory Pressure 0 to 140 (PIP) Plateau Pressure(Pplat) 0 to 100 Pressure Support Value (PS) 0 to 99.9 Positive End Expiratory 0 to 50 Pressure (PEEP) Continuous Positive Airway 0 to 50 Pressure(CPAP) Service Manual – Osmetech OPTI™ Analyzer...
  • Page 15 AaD O 0 - 800 mmHg 15 - 35 mmHg Anion Gap AnGp 3 - 30 mmol/L Normalized Ca++ nCa++ 0.1 - 3.0 mmol/L Hematocrit, Calculated Hct(c ) 15 - 75 PCV% Service Manual – Osmetech OPTI™ Analyzer...
  • Page 16 37 °C ± 0.1 °C (98.6 °F ± 0.18 °F) temperature (Osmetech OPTI 1 & Osmetech OPTI CCA) Relative humidity 5 - 95 % non-condensing (Osmetech OPTI 1 & Osmetech OPTI Altitude CCA) up to 3048 m (10,000 ft) Electrical Supply Mains supply 100 ±...
  • Page 17 4.875 inches (12.4 cm) Width 14.25 inches (36.2 cm) Depth 4.75 inches (27.8 cm) Weight 10.5 pounds (4.8 kg ) with battery Acoustic Noise Level standby 28 dbA ready 28 dbA wash/dry 60 dbA measurement 43 dbA Service Manual – Osmetech OPTI™ Analyzer...

  • Page 18: Principles Of Operation

    PC blood gas electrodes employ the Severinghaus C electrode construction. As such, PC optodes suffer from non-selective interference from volatile acids and bases in blood just as conventional PC electrodes. Service Manual – Osmetech OPTI™ Analyzer...
  • Page 19 Like the pH optode, the ion optodes do not need a reference electrode, however they do exhibit a small pH sensitivity that is automatically compensated in the Osmetech OPTI using the measured pH.
  • Page 20 Other values commonly used for the assessment of oxygen and acid- base status are calculated from these measured values. The entire sample path of the Osmetech OPTI cassette is filled with storage buffer to keep the sensors stable during storage. In addition, the cassette pouch is filled with a CO atmosphere, which keeps the pH of the storage buffer stable.
  • Page 21 Once stable readings are obtained, the valve turns to position 8 closing off all ports. The results are calculated and the cassette is ready for disposal. In case of an OPTI-trol measurement (Osmetech OPTI 1 only), the user has the option of terminating the measurement or introducing a subsequent blood sample.

  • Page 22: Fluidics Block Diagram

    2 General Description Fluidics Block Diagram Fig. 2-1: Fluidics Block Diagram Service Manual – Osmetech OPTI™ Analyzer 2-11...

  • Page 23: Osmetech Opti Cassette

    Location of Cassette Detect Sensor (CDETECT) Cassette Valve Key Body Slots Sensor Finger Grip Sensor Cl/Ca/Glu/ Cl/Ca/Glu Input/Output BUN(urea) Sensor Port Sensor Location of Fluid Light gate (L3) Fig. 2-2: Osmetech OPTI Cassette 2-12 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 24: Osmetech Opti Cassette Valve Positions

    2 General Description Osmetech OPTI Cassette Valve Positions Fig. 2-3: Osmetech OPTI Cassette Valve Positions Service Manual – Osmetech OPTI™ Analyzer 2-13...

  • Page 25: Assemblies

    The Osmetech OPTI CCA (only) SMC cover provides optics and processing circuitry for ctHb/SO measurement. • A minimal amount of tubing is used in the Osmetech OPTI system. • Storage compartment. • Liquid crystal display, 2 lines x 24 characters per line.

  • Page 26: Software Structure

    2 General Description Software Structure The Osmetech OPTI software is designed to provide a simple user interface organized in a menu fashion. The operator may select a menu function by using the l and r keys to move to the desired menu selection.

  • Page 27: Barometric Pressure

    2 General Description Main Menu – Osmetech OPTI 1 RUN: SRCs Controls Data Time/Date Setup Diag Controls Data Setup Time/Date Diag Barometric Diag 1 Run SRC Run Controls Pat Reports Pressure Battery Voltage SRC Reports Patient Info Patient Report Temperature...

  • Page 28: Osmetech Opti 1

    2 General Description Sampling Menu – Osmetech OPTI 1 Power Osmetech OPTI 1 Calibrating Please Wait Input Pat. Data <ENTER> Patient Sample Pat ID: Purging Please Wait Calibration OK XXXXXXXXXXX Place Sample Now Patient Sample Please Wait Op ID: XXXXXXXXXXX Please Wait Rev AOPX1.10...
  • Page 29 2 General Description Run Menu – Osmetech OPTI 1 RUN: SRC Controls Data Time/Date Setup Diag Controls Data Time/Date Setup Diag SRC Measurement Run Controls Data: Patient Time: 08:51:23 Please enter PW2 Op ID: XXXX Op ID: XXXXXXXX SRC Controls Export Date: 15-Feb-95 Password <ENTER>...
  • Page 30 2 General Description Data Menu – Osmetech OPTI 1 Data: Patient SRC Controls Export Data - Export Data - Patient Data - SRC Data - Controls Patient Controls Report: Last Last5 Report: Last5 Statistic Ranges Statistics Type (Enter PW2) Last 5: Prints last 5...
  • Page 31 2 General Description Setup Menu – Osmetech OPTI 1 Setup Please enter PW2 Password <ENTER> Setup:Baro Pat.Info Prnt CalcPar. Security Misc. Barometer Patient Info Print Calculated Parameters Security Miscellaneous SETUP - Please enter the SETUP - Patient Info SETUP - Print SETUP - Calc Parameter Baro: 727.3 mmHg...
  • Page 32 2 General Description Diagnostic Menu – Osmetech OPTI 1 RUN: SRC Controls Data TimeDate Setup Diag DIAG1:Baro Batt Temp Gas DIAG2: Printr Keypd Displ DIAG3: Valve VDrive Pump Clean Flow TestOptics > Barcode RS232 Cover Fset > LEDs Mem Vers Reports >...
  • Page 33 2 General Description QC-Range Setup – Osmetech OPTI 1 Data - Controls Ranges Statistics Type Please Enter PW2 Password <ENTER> Data - Control Ranges Control Level: 1 2 Control Level 1 xxxxxx Control Level 2 xxxxxx Control Level 3 xxxxxx...

  • Page 34: Barometric Pressure

    2 General Description Main Menu – Osmetech OPTI CCA RUN: SRCs Controls Data Tim e/Date Setup Diag Controls Data Setup Time/Date Diag Barometric Diag 1 Run SRC Run Controls Pat Reports Pressure Battery Voltage SRC Reports HbCal Patient Report Temperature...
  • Page 35 2 General Description Sampling Menu – Osmetech OPTI CCA Power On Enter Osmetech OPTI CCA Measuring - To input XXX Rev: ROPX2.24 Pat. Data press <ENTER> Osmetech OPTI CCA Patient Sample Patient Sample Please Wait Pat. ID: XXXXXXXXXXX CPAP: 00...
  • Page 36 2 General Description Run Menu – Osmetech OPTI CCA RUN: SRC Controls Data Time/Date Setup Diag Controls Data Time/Date Setup Diag SRC Measurement Run Controls Data: Patient SRC Time: 08:51:23 Password <ENTER> Op ID: XXXX Op ID: XXXXXXXX Controls Export Delete...
  • Page 37 2 General Description Data Menu – Osmetech OPTI CCA Data: Patient SRC Controls Export Delete Data - SRC Data - Controls Data - Export DATA: Delete Data - Patient Report: Last5 Statistic StatsReprt: ALL L1 L2 L3 Patient Controls Patient QC SRC All...
  • Page 38 2 General Description Setup Menu – Osmetech OPTI CCA Setup Password <ENTER> Setup: Baro HbCal Print QC Format Pat.Info Misc. SETUP - HbCal Barometer Print Format Miscellaneous tHb-Calibrator LastBlood SETUP - Please enter the Clean Optics and SETUP - Print SETUP-QC Swipe Barcode Baro: 727.3 mmHg...
  • Page 39 2 General Description Diagnostic Menu – Osmetech OPTI CCA RUN: SRC Controls Data TimeDate Setup Diag DIAG1:Baro Batt Temp Gas DIAG2: Printr Optics LEDs DIAG3: GValve Flow Disp Vers Reports BCode DIAG2 RS232 IR Fan FSET DIAG3 VDrive Pump keypad DIAG1...

  • Page 40: Diagnostic 1

    Chapter 7. Battery The Osmetech OPTI 1 may be powered by an internal battery pack or by an external battery charger, which is supplied with the analyzer. This test allows the user to determine the voltage of either the battery or external battery charger.

  • Page 41: Temperature

    Osmetech OPTI 1 analyzer. If the gas bottle pressure falls below approx. 35 psi, the switch closes (low pressure). The pressure needs to be above approx. 50 psi for the switch to open (high pressure).
  • Page 42 If the time is below 4.0 seconds, replace the gas bottle and check the output pressure of the gas module. If the time exceeds 8.0 seconds, replace the pump cartridge. Service Manual – Osmetech OPTI™ Analyzer...

  • Page 43: Diagnostic 2

    2 & 3 of the 9-pin serial interface connector on the rear panel of the analyzer. When the jumper is in place, press J to start the test. Test results will be displayed indicating either PASS or FAIL. Service Manual – Osmetech OPTI™ Analyzer...

  • Page 44: Cover Test

    Closed. Open the SMC Cover and the display should indicate Open. To exit this test, press the E key and return to the diagnostic menu. FSET The FSET menu contains factory-set values stored in the EEPROM. Service Manual – Osmetech OPTI™ Analyzer...

  • Page 45: Diagnostic 3

    Peristaltic Pump Test The pump test is used to test the function of the peristaltic pump. When the pump test is selected, the Osmetech OPTI 1 will perform an automatic test of the peristaltic pump including clockwise and counter-clockwise rotation and a cycling of each pump speed used in normal operation.

  • Page 46: Led Test

    The third report is an SRC Report, which provides a summary of all stored SRC results. The Configuration Report prints out all user selectable settings. A printout of this report is particularly helpful prior to erasing memory (e.g. software update). Service Manual – Osmetech OPTI™ Analyzer...
  • Page 47 CO must be with 5 units of each other needs to be >93 and < 130 If T is out of limits: Bad Calibration Error If W is out of limits: Bad Cassette Error Service Manual – Osmetech OPTI™ Analyzer...
  • Page 48 Def. RQ : 0.84 Def. P50 : 26.7 mmHg Reference Limits - Controls Info - Printouts - Calculated Parameters - Security - Miscellaneous - Correlation Factors - Communications - Language : English Battery Saver - Service Manual – Osmetech OPTI™ Analyzer...
  • Page 49 Chapter 7. Battery The Osmetech OPTI CCA may be powered by an internal battery pack or by an external battery charger that is supplied with the analyzer. This test allows the user to determine the voltage of either the battery or external battery charger.

  • Page 50: Version

    (9.7 bar) and is regulated and monitored by the gas module assembly. The gas pressure sensor portion of the module provides gas pressure status to the Osmetech OPTI CCA analyzer. If the gas bottle pressure falls below approx. 35 psi, the switch closes (low pressure). The pressure needs to be above approx. 50 psi for the switch to open (high pressure).
  • Page 51 5 units of each other 491.3 -0.9 needs to be >93 and < 130 If T is out of limits: Bad Calibration Error If W is out of limits: Bad Cassette Error 3-12 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 52 PCO2 30.0- 50.0 mmHg 1.000 0.000 70.0-700.0 mmHg PCO2 Na+ 135.0-145.0 mmol/L 3.50- 5.10 mmol/L 95.0-115.0 mmol/L 1.00 0.00 Ca++ 1.12- 1.32 mmol/L 60.0-120.0 mg/dL Ca++ 1.00 0.00 12.0- 17.0 g/dL 90.0-100.0 % Service Manual – Osmetech OPTI™ Analyzer 3-13...

  • Page 53: Barcode

    2 & 3 of the 9-pin serial interface connector on the rear panel of the analyzer. When the jumper is in place, press J to start the test. Test results will be displayed indicating either PASS or FAIL. 3-14 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 54: Ir Test

    Note: The fan may only run for a short time. The software background task is still active in this menu, turning the fan off if the internal temperature is low. Fset The Fset menu contains factory-set values stored in the EEPROM. Service Manual – Osmetech OPTI™ Analyzer 3-15...

  • Page 55: Valve Test

    L1 must detect the trailing edge between 2.3 seconds and 4.5 seconds. The actual time is indicated by the first number on the display at the end of the test. If the number is less than 2.3 seconds, replace the pump cartridge. 3-16 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 56: Display Test

    Peristaltic Pump Test The pump test is used to test the function of the peristaltic pump. When the pump test is selected, the Osmetech OPTI CCA will perform an automatic test of the peristaltic pump including clockwise and counter-clockwise rotation and a cycling of each pump speed used in normal operation.

  • Page 58: Adjustments

    4 Adjustments 4 Adjustments Osmetech OPTI™ 1 System The Osmetech OPTI™ 1 is designed to require only minimal adjustments by field service personnel. The main board contains 6 electrical adjustments; however, field service personnel may make only three adjustments. Three potentiometers (R40, R100, and R136) are sealed and are factory adjustments only.
  • Page 59 T2 which must be 0.15 Osmetech OPTI™ CCA System The Osmetech OPTI CCA is designed to require only minimal adjustments by field service personnel. The main board contains nine electrical adjustments; however, field service personnel may make only three adjustments.

  • Page 60: Barometric Pressure

    Locate R124 and adjust for a display of 37.15 ±. 0.03 °C for temperature T2. Note: Always adjust temperature T1 before adjusting T2 as temperature T2 depends on temperature T1. R124 adjusts the difference between T1 ° and T2 which must be 0.15 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 62: Troubleshooting

    5 Troubleshooting 5 Troubleshooting Osmetech OPTI™ System The Osmetech OPTI™ 1 and Osmetech OPTI™ CCA analyzers are equipped with sensors and diagnostic software that control, monitor and detect analyzer system status. Operator messages indicating system status are displayed to provide the operator with useful information to determine the cause of detected system errors or malfunctions.

  • Page 63: System Stop Messages

    35 psi, too low to perform a successful calibration, this error is displayed. Replace the gas cylinder with a full cylinder to continue normal operation. Access DIAG1 Gas to display the current gas pressure status. Service Manual – Osmetech OPTI™ Analyzer...
  • Page 64 When “New Lot” or “Controls” is selected under QC- STOP - New Cassette Lot Lockout, the Osmetech OPTI will detect a difference in the Must Run Controls <ESC> cassette lot number from the previous cassette. When the difference is detected, the Stop - New Cassette Lot message is displayed.

  • Page 65: System Error Messages

    When two or more parameters continue to drift and do not reach endpoint this message is displayed. When the Osmetech OPTI detects that the SMC Cover has ERROR-Cassette MisSeat 1 been closed, the SMC top light gates LT1 and LT2 are Reinsert <ESC>...
  • Page 66 30 minutes. If no sample has been aspirated during this thirty-minute interval, the cassette must be discarded. For the Osmetech OPTI CCA, the calibration expires in 10 minutes. After the cassette has been repositioned following an initial...
  • Page 67 Select an in-date cassette to perform the measurement. During sample aspiration the SMC light gates LG1 and LG2 ERROR - Possible Clot (LG3 for Osmetech OPTI CCA) are used to detect proper Discard Cassette <ESC> sample aspiration. When LG1 detects sample has been...

  • Page 68: System Warning Messages

    The Gas expiration date is monitored based on the barcode that WARNING – Gas Expires was swiped into the Osmetech OPTI’s memory at the time of Soon! Continue <ENTER> the last gas canister change. This message alerts the operator that there is 2 weeks usage remaining for the gas tank.
  • Page 69 WARNING-Bad Sensor - O2 Continue<ENTER>or<ESC> WARNING-Bad Sensor- Na Continue<ENTER>or<ESC> WARNING-Bad Sensor - K Continue<ENTER>or<ESC> WARNING-Bad Sensor – Cl- Continue<ENTER>or<ESC> WARNING-Bad Sensor– Ca++ Continue<ENTER>or<ESC> WARNING-Bad Sensor- Glu Continue<ENTER>or<ESC> Service Manual – Osmetech OPTI™ Analyzer...
  • Page 70 WARNING - Unstable PO2 Check Cassette WARNING - Unstable Check Cassette WARNING - Unstable Check Cassette WARNING- Unstable – Cl- Continue<ENTER>or<ESC> WARNING- Unstable – Ca++ Continue<ENTER>or<ESC> WARNING - Unstable Check Cassette Service Manual – Osmetech OPTI™ Analyzer...
  • Page 71 5 Troubleshooting This message is displayed when the Osmetech OPTI has WARNING- Bubble Detected detected an air bubble during sample aspiration. This Check Cassette <ENTER> message is displayed before the final results are displayed so the operator can be alerted to check the cassette for possible bubbles.

  • Page 72: System Information Messages

    SRC database this status message will be displayed. (Level The displayed message also identifies the applicable SRC Level for which no SRC records exist. When the Osmetech OPTI analyzer detects a new SRC SRC Database Deleted ID, the operator is prompted to delete all current SRC (Level data (password protected).
  • Page 73 5 Troubleshooting The Osmetech OPTI stores QC results and SRC results in an Not Enough Records internal database. Cumulative statistics printed or displayed (Level in the system software are calculated based on the stored data. A minimum of 2 data points is required in order to calculate statistical results.
  • Page 74 5 Troubleshooting Troubleshooting The Osmetech OPTI provides display messages indicating the status of the analyzer. The previous section describes the conditions in which error, warning or system information messages may occur. This section contains troubleshooting tables to define possible causes and instructions for remedial action.
  • Page 75 Replace gas module assembly. STOP - Low Gas The pressure of the gas cylinder See troubleshooting hints Replace Now <ESC> is empty. No measurements above. can be made. 5-14 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 76 QC Lockout and a new lot of current lot and run cassettes was detected. The measurement. new lot of cassettes must be Run QC material to verify the verified with quality control new lot of cassettes. material. Service Manual – Osmetech OPTI™ Analyzer 5-15...
  • Page 77 Make sure cassette pouch was opened within 10 minutes from start of measurement. Clean glass optics plate. Try a new cassette. 5-16 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 78 Open a new cassette and retry. perform another calibration. This process will be repeated for up to 30 minutes, then the cassette must be discarded. Osmetech OPTI CCA calibrations expire after the first 10 minute period. Service Manual – Osmetech OPTI™ Analyzer 5-17...
  • Page 79 ID for sample results. WARNING - Bubble Detected LG 1 detected sample aspiration Check cassette for air bubbles Check Cassette and detected air prior to sample or insufficient sample volume. reaching LG 2. 5-18 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 80 Press YES to Continue Gas will expire in two weeks. Soon! WARNING - No Pat. ID Entry Patient ID is selected as a Press <ENTER> to continue Continue <ENTER> required entry and enter a Patient ID Service Manual – Osmetech OPTI™ Analyzer 5-19...
  • Page 81 Excessive use of gas Possible leak in gas path. Check for proper sealing of pump cartridge. Check for leak in tubing or tubing not connected. Clean seal in gas module assembly. Replace gas module. 5-20 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 82 If PCO or PO values are out, check the cassette for air bubbles or voids. Verify that the QC vial is not too warm or too cool before performing measurement. Replace calibration gas bottle. Service Manual – Osmetech OPTI™ Analyzer 5-21...

  • Page 83: Troubleshooting Flowcharts

    (Feed & Cover) (Feed & Cover) 15-32°C correctly Initialize Return Return Replace Bar Instrument Instrument Instrument Code Reader (Feed & Cover) (RA) (RA) Install Current Return Software Instrument version (RA) Return Instrument (RA) 5-22 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 84 Na/K > Check DIAG Valve Return Remove Instrument. PumpCart Bad LED in Listen for Optic gas flow Re-run Sample Return Install current Gas Flow Instrument Software (Suspect bad Version Gas Module) Replace Cassettes Service Manual – Osmetech OPTI™ Analyzer 5-23...
  • Page 85 LEDs LT1 & LT2 using new DIAG-Flow with new cass: toggle cassette (use new cass.) 1200 - 2800 Rerun meas. Rerun meas. Return using new using new Instrument Flow Test fails? cassette Cassette (RA) 5-24 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 86 Establish Long cal. New cass. custom assay High Altitude? (blinking '*')? fix problem? ranges Check Return Instr. Replace storage temp (Suspect Temp. Cassettes of Control T1, T2 problem) (18 - 27°C) Replace Cassettes Service Manual – Osmetech OPTI™ Analyzer 5-25...
  • Page 87 Results are ok. sample Na, K Use Results Use pH if unstable? w/in 0.04 Check for Bubble in resp. Sensor Rerun Meas. Very high or w/ new low values? cassette Sample Results are Use Results 5-26 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 88 Values w/in limit (Optics PCB pH, CO2 <1200 humidity effect) O2 < 2000 Leave Instrument on - wait 15 minutes Rerun SRC Test Instrument ok (if Warm-up SRC passes? acceptable) Return Instrument (Bad Optics PCB) Service Manual – Osmetech OPTI™ Analyzer 5-27...

  • Page 90: Osmetech Opti™ Repair Procedures

    Osmetech OPTI™ 1 Systems The Osmetech OPTI 1 is completely housed in a molded plastic case which provides a chassis for the electronic and mechanical assemblies. The analyzer is designed for quick removal of all major assemblies. Some of the components such as the printer, pump cartridge and top plate are accessible from the outside of the analyzer.

  • Page 91: Printer Assembly

    The printer assembly can now be removed. In case the printer mechanism is replaced, unscrew the printer shroud and loosen the four (4) screws holding the printer to the PCB. Disconnect the flex cable from the receptacle. Service Manual – Osmetech OPTI™ Analyzer...
  • Page 92 Then install the printer in reverse order of removal. Make sure the flex cable is plugged in all the way. White transport clip – remove before installation Figure 3: Printer mechanism with transport clip Service Manual – Osmetech OPTI™ Analyzer...
  • Page 93 Remove all debris from printer gear track. Figure 4: Printer assembly Verification Paper advance levers Go to menu DIAG 2 - Printr and perform a test print. Guide rod Service Manual – Osmetech OPTI™ Analyzer...

  • Page 94: Analyzer Housing

    Barcode Reader Gas Manifold Module Storage Compartment SMC motor Cooling Fan Main Board Peristaltic Assembly Pump Motor Battery Receptacle Figure 5: Opened Osmetech OPTI 1 Analyzer Service Manual – Osmetech OPTI™ Analyzer...

  • Page 95: Sample Measurement Chamber (Smc) Cover

    The SMC module can only be replaced by a trained service technician. Osmetech OPTI 1 Handle The Osmetech OPTI 1 is equipped with a carrying handle for easy transport. To remove the handle, first separate the lower portion of the analyzer. To access the handle, remove the battery compartment, gas manifold module and storage compartment (See the respective sections for removal instructions).

  • Page 96: Gas Manifold Module

    To re-install the Aerodyne module, you must use new screws, DS7000. The screws must be tightened such that the two black rubber pads are compressed to a thickness of 1.6mm. Use a feeler gauge to check the compression. Service Manual – Osmetech OPTI™ Analyzer...

  • Page 97: Display Assembly

    Display Assembly Removal The Osmetech OPTI 1 uses a backlit LCD display module to display operating instructions and analyzer results. To remove the LCD display, first open the lower portion of the analyzer and disconnect the ribbon cables J13 on the main board.

  • Page 98: Keypad

    Keypad Removal The keypad on the Osmetech OPTI 1 can be removed by first opening the lower portion of the analyzer. The flex cable from the keypad will now need to be disconnected from the display board. Use a knife to lift off the keypad from the analyzer housing.

  • Page 99: Exhaust Fan

    6 Osmetech OPTI™ Repair Procedures Exhaust Fan Removal The Osmetech OPTI 1 is equipped with an internal exhaust fan which is used for cooling the electronic circuitry. The fan is controlled by the software. T3 measures the air temperature inside the OPTI housing and is displayed in the DIAG1 - Temp menu.

  • Page 100: Peristaltic Pump Motor

    If any of these conditions are not met the pump motor must be replaced. Important Note In case the pump hesitates on the fast speed, replace the pump cartridge and repeat the test. Service Manual – Osmetech OPTI™ Analyzer 6-11...

  • Page 101: Battery Receptacle

    Battery Receptacle Removal The Osmetech OPTI can be operated by either battery or by AC power. To remove the battery receptacle, first remove the battery from the analyzer. The lower housing portion of the analyzer must be opened for access. Locate the battery receptacle and disconnect the internal cable J4 from the main board.

  • Page 102: Main Board Assembly

    BT1 is a rechargeable lithium battery. In case this battery needs replacement, make sure to replace with the same type, Panasonic VL3032. Caution: Danger of explosion, if battery is incorrectly replaced. Replace only with type Panasonic VL3032. Follow local regulations for disposal. Service Manual – Osmetech OPTI™ Analyzer 6-13...

  • Page 103: Barcode Reader

    Verification Go to DIAG2 – BCode and swipe a cassette barcode. The cassette barcode should appear on the display screen. Note: the displayed barcode is preceded by one additional character (signifies barcode type). 6-14 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 104: Pump Cartridge

    6 Osmetech OPTI™ Repair Procedures Osmetech OPTI™ CCA Systems S/N <4000 The Osmetech OPTI™ CCA is completely housed in a molded plastic case which provides a chassis for the electronic and mechanical assemblies. The analyzer is designed for quick removal of all major assemblies. Some of the components such as the printer, pump cartridge and top plate are accessible from the outside of the analyzer.

  • Page 105: Printer Assembly

    The printer assembly can now be removed. In case the printer mechanism is replaced, unscrew the printer shroud and loosen the four (4) screws holding the printer to the PCB. Disconnect the flex cable from the receptacle. 6-16 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 106 Then install the printer in reverse order of removal. Make sure the flex cable is plugged in all the way. White transport clip – remove before installation Figure 15: Printer mechanism with transport clip Service Manual – Osmetech OPTI™ Analyzer 6-17...
  • Page 107 Remove all debris from paper advance lever, grease if necessary Remove all debris from printer gear track. Figure 16: Printer assembly Verification Go to menu DIAG2 - Printr and perform a test print. 6-18 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 108: Analyzer Housing

    Bar Code Reader Gas Manifold Module Storage Compartment SMC motor Main Board Cooling Fan Assembly Peristaltic Pump Motor Battery Receptacle Figure 17: Opened Osmetech OPTI CCA Analyzer Service Manual – Osmetech OPTI™ Analyzer 6-19...

  • Page 109: Sample Measurement Chamber Cover

    The SMC module can only be replaced by a trained service technician. Osmetech OPTI CCA Handle The Osmetech OPTI CCA is equipped with a carrying handle for easy transport. To remove the handle, first separate the lower portion of the analyzer. To access the handle, remove the battery compartment, gas manifold module and storage compartment (See the respective sections for removal instructions).
  • Page 110 To replace the Lee valve, desolder the wires from the old valve. To remove the Aerodyne gas module, remove the two (2) screws holding the gas manifold to the plastic housing. Lee Valve Gas manifold screws Gas Aerodyne Module Figure 19: Gas manifold module Service Manual – Osmetech OPTI™ Analyzer 6-21...

  • Page 111: Display Assembly

    Verification To test the gas module proceed as follows: • Insert the bottle into the Osmetech OPTI to be tested. Power on the unit. • Go to DIAG3 – GValve and press ENTER. This will activate the gas valves and pressurize the entire gas system including the pump cartridge.

  • Page 112: Keypad

    Keypad Removal The keypad on the Osmetech OPTI CCA can be removed by first opening the lower portion of the analyzer. The flex cable from the keypad will now need to be disconnected from the display board. Use a knife to lift off the keypad from the analyzer housing.

  • Page 113: Exhaust Fan

    6 Osmetech OPTI™ Repair Procedures Exhaust Fan Removal The Osmetech OPTI CCA is equipped with an internal exhaust fan which is used for cooling the electronic circuitry. The fan is controlled by the software. T3 measures the air temperature inside the OPTI housing and is displayed in the DIAG1 - Temp menu.

  • Page 114: Peristaltic Pump Motor

    If any of these conditions are not met the pump motor must be replaced. Important Note In case the pump hesitates on the fast speed, replace the pump cartridge and repeat the test. Service Manual – Osmetech OPTI™ Analyzer 6-25...

  • Page 115: Battery Receptacle

    Battery Receptacle Removal The Osmetech OPTI can be operated by either battery or by AC power. To remove the battery receptacle, first remove the battery from the analyzer. The lower housing portion of the analyzer must be opened for access. Locate the battery receptacle and disconnect the internal cable J3 from the main board.

  • Page 116: Main Board Assembly

    The module is held in place by retaining screws which must be removed. Disconnect cable J14 from the main board. Pry out the window of the barcode reader with a screw driver and remove the assembly. Service Manual – Osmetech OPTI™ Analyzer 6-27...
  • Page 117 Verification Go to DIAG1 – Bcode and swipe a cassette barcode. The cassette barcode should appear on the display screen. Note: the displayed barcode is preceded with one additional character (signifies barcode type). 6-28 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 118: Osmetech Opti™ Cca Systems S/N >4000

    6 Osmetech OPTI™ Repair Procedures Osmetech OPTI CCA Systems S/N >4000 The Osmetech OPTI CCA is completely housed in a molded plastic case which provides a chassis for the electronic and mechanical assemblies. The analyzer is designed for quick removal of all major assemblies. Some of the components such as the printer, pump cartridge and top plate are accessible from the outside of the analyzer.

  • Page 119: Printer Assembly

    After the thumb screws have been loosened, the printer can be slid towards the rear of the analyzer. Disconnect the printer ribbon cable that attaches to the printer. The printer assembly can now be removed. 6-30 Service Manual – Osmetech OPTI™ Analyzer...
  • Page 120 (including paper feed) in case paper is not inserted. • If problem continues remove printer shroud, lift grey lever to rear of printer assembly (open position) and clean any remaining debris. • If printer problems persist, replace printer. Service Manual – Osmetech OPTI™ Analyzer 6-31...

  • Page 121: Analyzer Housing

    Caution: When turning the analyzer over to access the lower housing section, place the analyzer on a padded surface to prevent scratches or other damage to the upper housing section. 6-32 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 122: Sample Measurement Chamber Cover

    The SMC cover cannot be replaced due to the necessary tHb and SO2 calibration, which can only be performed by the manufacturer. SMC Lower Module Important Note The SMC module can only be replaced by a trained service technician. Service Manual – Osmetech OPTI™ Analyzer 6-33...

  • Page 123: Osmetech Opti Cca Handle

    6 Osmetech OPTI™ Repair Procedures Osmetech OPTI CCA Handle The Osmetech OPTI CCA is equipped with a carrying handle for easy transport. To remove the handle, first separate the lower portion of the analyzer. To access the handle, remove the battery compartment, gas manifold module and storage compartment (See the respective sections for removal instructions).

  • Page 124: Gas Manifold Module

    To re-install the Aerodyne module, you must use new screws DS7000. The screws must be tightened such, that the two black rubber pads are compressed to a thickness of 1.6mm. Use a feeler gauge to check the compression. Service Manual – Osmetech OPTI™ Analyzer 6-35...

  • Page 125: Display Assembly

    Display Assembly Removal The Osmetech OPTI CCA uses a backlit LCD display module to display operating instructions and analyzer results. To remove the LCD display, first open the lower portion of the analyzer and disconnect the ribbon cable J13 and J5 on the main board.

  • Page 126: Keypad

    Keypad Removal The keypad fitted on the Osmetech OPTI CCA can be removed by first opening the lower portion of the analyzer. The flex cable from the keypad will now need to be disconnected from the display board. Use a knife to lift off the keypad from the analyzer housing.

  • Page 127: Exhaust Fan

    6 Osmetech OPTI™ Repair Procedures Exhaust Fan Removal The Osmetech OPTI CCA is equipped with an internal exhaust fan which is used for cooling the electronic circuitry. The fan is controlled by the software. T3 measures the air temperature inside the OPTI housing and is displayed in the DIAG1 - Temp menu.

  • Page 128: Peristaltic Pump Motor

    If any of these conditions are not met the pump motor must be replaced. Important Note In case the pump hesitates on the fast speed, replace the pump cartridge and repeat the test. Service Manual – Osmetech OPTI™ Analyzer 6-39...

  • Page 129: Battery Receptacle

    Battery Receptacle Removal The Osmetech OPTI can be operated by either battery or by AC power. To remove the battery receptacle, first remove the battery from the analyzer. The lower housing portion of the analyzer must be opened for access. Locate the battery receptacle and disconnect the internal cable J3 from the main board.

  • Page 130: Main Board Assembly

    The module is held in place by retaining screws which must be removed. Disconnect cable J14 from the main board. Pry out the window of the barcode reader with a screw driver and remove the assembly. Service Manual – Osmetech OPTI™ Analyzer 6-41...
  • Page 131 Verification Go to DIAG1 – Bcode and swipe a cassette barcode. The cassette barcode should appear on the display screen. Note: the displayed barcode is preceded with one additional character (signifies barcode type). 6-42 Service Manual – Osmetech OPTI™ Analyzer...

  • Page 132: Table Of Contents Of Figures

    Figure 2: Printer assembly screws..........................6-3 Figure 3: Printer mechanism with transport clip ......................6-3 Figure 4: Printer assembly............................6-4 Figure 5: Opened Osmetech OPTI 1 Analyzer......................6-5 Figure 6: Peristaltic pump nipple connectors ......................6-6 Figure 7: Gas manifold module..........................6-7 Figure 8: LCD Back panel, fastening screws are circled ...................6-8 Figure 9: Peristaltic pump motor mounting screws (circled) ...................6-11...

  • Page 134: Spare Parts List

    8 Service Spare Parts Osmetech OPTI™ System The Osmetech OPTI™ 1 and Osmetech OPTI™ CCA instruments are field repairable. Several assemblies require factory adjustment or alignment and field repair of these assemblies should be limited to assembly replacement. A list of recommended spare parts is provided below.
  • Page 135 SCREW, PPH, M2 X 6, OPTI 1/OPTI CCA DS7012 SCREW, PPH, M3 X 6, OPTI 1/OPTI CCA DS7014 SCREW, SS STEEL, PFH, M2 X 12 OPTI 1/OPTI CCA DS7016 SCREW, PAN HEAD, PHILLIPS, M3 OPTI 1/OPTI CCA DZ7004 WASHER, FLAT, NUMBER 8, OPTI 1/OPTI CCA...

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