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What This Guide Helps With
Troubleshoots wash, waste, and fluidics faults caused by empty supplies, full waste, tubing connections, external leaks, consumables, or accessible obstructions.
Step-by-Step Troubleshooting
1. Protect Patient Testing and Confirm the Fault
Stop patient testing if the analyzer cannot reliably wash, aspirate, dispense, or manage waste.
Determine whether the message involves:
- Wash solution
- Waste
- Fluid supply
- Aspiration
- Drainage
- Pressure or flow
- A general fluidics condition
Record the exact message.
Expected outcome: The fluidics fault is clearly identified and patient testing is moved to another verified analyzer if necessary.
2. Inspect for Leaks or Spills
Check around and beneath the analyzer and accessible fluid containers for:
- Liquid leakage
- Overflow
- Wet tubing
- Loose external connections
- Damaged containers
- Unusual odor
Use appropriate PPE and follow laboratory spill procedures.
Expected outcome: No uncontrolled leak is present. If leakage cannot be safely contained or its source is internal, remove the analyzer from service immediately.
3. Verify Wash or Supply Fluids
Check externally accessible fluid supplies required for analyzer operation.
Confirm:
- Adequate fluid is present
- Correct container is installed
- Container is positioned correctly
- Caps and pickup connections are secure
- Accessible tubing is not visibly kinked or pinched
Expected outcome: Required supply fluids are available and connected correctly. If correcting the supply restores normal operation, proceed to verification.
4. Check Waste Capacity and Connections
Inspect the waste container or waste connection according to the installed configuration.
Confirm:
- Waste is not full
- Container is correctly positioned
- Connections are secure
- Accessible tubing is not kinked
- No obvious blockage or overflow is present
Handle waste using appropriate laboratory precautions.
Expected outcome: Waste can be safely collected and the analyzer no longer detects an external waste condition.
5. Inspect External Tubing and Connections
Without opening protected service areas, inspect accessible tubing for:
- Kinks
- Compression
- Loose fittings
- Visible air gaps where clearly abnormal
- Leakage
- Disconnection
Do not disconnect internal tubing or open fluidic assemblies without authorized service procedures.
Expected outcome: Accessible fluid connections are intact.
6. Check Related Consumables and Covers
Verify any associated wash, rinse, waste, or fluid consumables are installed correctly.
Confirm covers or compartments associated with external consumables are fully closed and nothing is interfering with normal operation.
Expected outcome: All externally serviceable consumables are correctly installed.
7. Resume the Normal Fluidics Sequence
After correcting an external condition, use normal analyzer controls to allow the system to perform its standard recovery or readiness process.
Do not repeatedly restart a leaking or mechanically abnormal system.
Expected outcome: The fluidics fault clears and the analyzer returns to normal readiness.
8. Perform Functional Verification
Before returning to patient use, verify:
- No fluidics alarms recur
- No leakage is present
- Samples or QC are aspirated normally
- Required QC passes
Expected outcome: Fluid handling is stable and required QC is acceptable. Troubleshooting can stop.
If the Problem Persists
If fluids, waste capacity, consumables, accessible tubing, and external connections are correct but the fluidics fault continues, common external causes have been ruled out.
The remaining cause may involve pumps, valves, pressure or vacuum systems, internal tubing, sensors, wash mechanisms, drainage components, or other service-level fluidics assemblies.
The analyzer should be:
- Removed from service
- Labeled Out of Service
- Sent for repair or bench evaluation
- Evaluated using current Werfen documentation and approved test equipment
- Repaired only by qualified personnel
Do not operate an analyzer with unresolved leakage, waste-control problems, or unreliable fluid movement.
Return the analyzer to service only after leak-free operation, stable fluidics, and required QC have been demonstrated.
Knowing when to stop external troubleshooting is proper troubleshooting.
Clinical Use Tip
Treat any uncontrolled analyzer-fluid or waste leak as both an equipment problem and a potential laboratory exposure hazard.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Laboratory staff reported a wash-system fault and the ACL TOP 750 LAS would not return to ready status."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found the external wash-fluid connection was not fully seated."
Resolution
What action was taken.
Example:
"Clinical Engineering secured the connection, verified the fluidics fault cleared without leakage, and confirmed acceptable QC before the analyzer returned to service."
Helpful Details to Include (If Known)
- Exact fluidics message
- Supply-fluid status
- Waste level
- Container and tubing condition
- Leak location if present
- Loose or kinked connections
- Related aspiration errors
- Recovery result
- QC result
- Final analyzer status
Final Thought
Start with fluid supply, waste, connections, and visible leaks before assuming an internal fluidics failure, and remove the analyzer from service whenever safe and reliable fluid handling cannot be confirmed.
That is successful troubleshooting.