www.gonotec.

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Service Manual

OSMOMAT Auto

OSMOMAT® auto model, series 2005 and later

January 2012 Version 1.0

Gonotec GmbH
Table of Contents

OSMOMAT Auto ........................................................................................................................... 1

Table of Contents ............................................................................................................................ 2
Please read this first ............................................................................................................................. 4
1. Introduction .................................................................................................................................. 4
2. Functionality of the OSMOMAT Auto (physical background) ................................................... 5
2.1. Measurement method ............................................................................................................ 5
2.2. Practical application .............................................................................................................. 5
2.3. Potential errors during measurement ..................................................................................... 5
3. Technical description of the OSMOMAT Auto .......................................................................... 7
3.1. Device design ........................................................................................................................ 7
3.2. Controls and device components........................................................................................... 9
3.2.1. Device rear ..................................................................................................................... 9
3.2.2. Device front.................................................................................................................. 10
3.3. Sample holder ...................................................................................................................... 11
3.4. Front panel with keyboard and control panel ...................................................................... 11
4. Starting up the OSMOMAT Auto.............................................................................................. 13
4.1. Power-up ............................................................................................................................. 13
4.2. Menu structure of the measurement functions .................................................................... 13
4.2.1. Sample Measurement menu ......................................................................................... 14
4.2.1.1. Manual patient entry ................................................................................................. 14
4.2.1.2. Entry using barcode reader ....................................................................................... 14
4.2.1.3. Performing the measurement.................................................................................... 15
4.2.1.4. Printing the readings................................................................................................. 16
4.2.1.5. Serial output of the readings ..................................................................................... 16
4.2.2. Calibration menu .......................................................................................................... 16
4.2.2.1. Performing the calibration ........................................................................................ 16
4.2.2.2. Printing the calibration values .................................................................................. 17
4.2.2.3. Serial output of the calibration values ...................................................................... 17
4.2.3. Memory menu .............................................................................................................. 17
4.2.3.1. Memory capacity ...................................................................................................... 17
4.2.3.2. Look at charge .......................................................................................................... 17
4.2.3.2.1. Patient data display ............................................................................................... 17
4.2.3.2.1. Patient data output ................................................................................................ 18
4.2.3.3. Delete data ................................................................................................................ 18
4.2.3.3.1 Delete charge ........................................................................................................ 18
4.2.3.3.2. Delete all ............................................................................................................... 18
4.3. Menu structure of the setting functions ............................................................................... 18
4.3.1. actuate cryst-motor ....................................................................................................... 19
4.3.2. date / time ..................................................................................................................... 19
4.3.2.1. Insert time ................................................................................................................. 19
4.3.2.2. Insert date ................................................................................................................. 20
4.3.3. New initialisation ......................................................................................................... 20
4.3.4 Thermistor probe adjustment ....................................................................................... 20
4.3.5. Cleaning paper feed ..................................................................................................... 20
4.4. Switching fuses and setting the operating voltage .............................................................. 21
4.5. Replacing consumable and wear and tear parts................................................................... 21

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Osmomat auto Service Manual
4.5.1. Replacing the cleaning paper ....................................................................................... 21
4.5.2. Replacing the ribbon .................................................................................................... 22
4.5.3. Replacing the printer paper .......................................................................................... 23
5. Servicing the OSMOMAT Auto ................................................................................................ 25
5.1. General circuitry description ............................................................................................... 25
5.2. Opening the housing............................................................................................................ 25
5.3. View of the circuitry components: ...................................................................................... 26
5.4. Power supply and housing fan............................................................................................. 27
5.5. Master PCB ......................................................................................................................... 28
5.5.1. General information ..................................................................................................... 28
5.5.2. Power supply (circuit diagram page 1) ........................................................................ 28
5.5.3. Measurement and control assembly (circuit diagram page 2) ..................................... 29
5.5.3.1. Measurement assembly ............................................................................................ 29
5.5.3.2. Control assembly ...................................................................................................... 29
5.5.4. Circuit diagram of master PCB .................................................................................... 33
5.5.5. Layout diagram of the master PCB .............................................................................. 37
5.6. Slave PCB............................................................................................................................ 38
5.6.1. Circuitry of the slave PCB ........................................................................................... 39
5.6.2. Parts list for slave circuitry .......................................................................................... 41
5.6.3. Connections on the slave PCB ..................................................................................... 44
5.6.4. Notes about slave circuitry.......................................................................................... 45
5.6.4.1. Description of circuitry ............................................................................................ 45
5.6.4.2. Reset circuitry for the slave ..................................................................................... 46
5.6.4.3. Diagnostic socket ..................................................................................................... 46
5.6.5. Slave layout diagram................................................................................................... 47
5.7. Control panel with LCD display and keyboard ................................................................... 48
5.7.1. Design of keyboard and display ................................................................................... 48
5.7.2. Replacing the LCD display .......................................................................................... 49
5.8. Sensors and PCB on the device front .................................................................................. 50
5.8.1 Description of the sensors ............................................................................................ 51
5.8.2 Service mode for the sensors ....................................................................................... 53
5.9. Sensor PCB.......................................................................................................................... 53
5.9.1. Circuitry of the sensor PCB ......................................................................................... 54
5.9.2. Parts list for sensor PCB ............................................................................................. 55
5.9.3. Layout diagrams for the sensor PCB ........................................................................... 56
6. Software of the OSMOMAT Auto............................................................................................. 58
7. Replacing and configuring device components ......................................................................... 59
7.1. Replacing the sensor PCB ................................................................................................... 59
7.2. Adjusting the upper limit switch ......................................................................................... 59
7.3. Adjusting the middle lift switch .......................................................................................... 60
7.4. Setting the sample detection ................................................................................................ 60
7.5. Replacing the thermistor probe ........................................................................................... 61
7.6. Adjusting the thermistor probe ............................................................................................ 62
7.7 Replacing the lower cooling system.................................................................................... 66
7.8 Setting the standby temperature .......................................................................................... 66
7.9. Replacing the cryst-needle .................................................................................................. 68
7.10. Replacing the trigger photo sensor .................................................................................. 69
7.11 Adjustment/checking of photo sensor no. 3/ Move error ................................................ 70

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Gonotec GmbH

Please read this first

Please observe the following advice in order to avoid injuries and damage to this product or
any product connected to it.

1. Use a suitable power supply cable. The ground wire must be connected.
2. Do not apply external voltages to the device inputs. The interfaces at the rear are
compliant with the RS232 standard.
3. Do not use the device if it is damaged.
4. Keep the device clean and dry. Please do not wet-clean the device and do not clean it
by submerging it in fluids. Please do not use cleaning agents such as benzene or
acetone because they may damage the plastic parts of the device. The smoked glass
door of the robotic device may develop cracks if exposed to methylated spirits for an
extended period of time.
5. The device is only intended for indoor use. Never use it in wet or explosion-prone
environments.
6. Always replace device fuses with an identically rated fuse.
Do not dispose of the device through the municipal waste at its end of
service life. We are happy to help you find the proper disposal method.

1. Introduction
Gonotec GmbH designed OSMOMAT Auto as a device capable of automatically measuring a
series of samples. This section describes the features of the device. A new circuitry was
created and combined into a new device with the circuitry of the Osmomat O30. This device
features an LCD display for selecting operating modes and data output. The operating mode is
selected from the menu using soft keys. Up to 20 samples can be measured automatically;
patient data can be entered via the keyboard or a barcode scanner. Currently, up to 300
samples can be stored. Storage management enables the displaying, printing, or deleting of
data. In addition, the device provides two calibration modes.
The features of the device have been enhanced continuously during its development. The
OSMOMAT AUTO is equipped with two micro-controllers (µC) on separate PCBs. The µC
of the original device acts as the master while the µC of the additionally developed PCB acts
as the slave, controlling the LCD display and handling data storage and management.
Therefore, different programs exist for master and slave. The intuitive menu makes it easy to
perform changes and enhancements.

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2. Functionality of the OSMOMAT Auto (physical

background)
2.1. Measurement method
To determine the total osmolality in aqueous solutions, comparative measurements of the
freezing points of pure water and solutions are performed. Whereas water has a freezing point
of 0°C, a solution with a saline concentration of 1 osmol/kg has a freezing point of -1.858 °C.

2.2. Practical application

If a liquid is cooled down below freezing, the kinetic energy of the particles is converted into
heat during the transition from the liquid phase into the crystalline phase. This crystallization
heat, or enthalpy—332kJ (80 kcal)—has to be dissipated during the cooling process. If the
liquid (water) is undercooled below freezing (-7 °C) without crystallizing, the liquid loses
more heat energy than it needs to crystallize out. In order to let a sample crystallize, certain
prerequisites need to be met. During the transition from liquid to solid phase, the molecules
are placed into a crystal lattice, and preferred molecule configurations emerge. If a molecule
shape is prescribed for the sample (seed crystal), crystals form immediately upon reaching
freezing point, making it impossible to undercool the liquid. The OSMOMAT Auto triggers
crystallization by inoculating the sample with a stainless steel needle that is cooled by a
secondary cooling system and at the tip of which small ice crystals form due to moisture in
the air. When crystallization begins, ice forms spontaneously. The heat that was removed
during undercooling is released, the temperature rises spontaneously and heats up the liquid to
freezing point. Cooling continues. As long as the sample contains ice and water, this creates
an equilibrium, i.e., the temperature remains constant because further heat dissipation causes
ice formation instead of a temperature drop. The temperature continues to drop only when the
entire sample has been crystallized. The time of temperature equilibrium is called plateau
time.
Solutions work differently. Now, a substance has been diluted in the solvent. The sample is
undercooled to -7 °C again and crystallization begins. The pure water in the solution
spontaneously crystallizes, and the substances move to the remainder of the solution, i.e., the
concentration at the time when freezing point temperature is measured is higher than in the
original solution. Hence, a plateau occurs here as well, but it is inclined because the solvent
crystallizes out and the concentration in the remainder of the sample continues to increase,
thus further lowering the freezing point. This results in a turning point where the osmolality
reading is taken. Therefore, the undercooling method is accompanied by a measuring error.
The error may be avoided if crystallization is initiated directly at freezing point without
undercooling. This would, however, be only feasible in laboratory conditions.

2.3. Potential errors during measurement

Generally, the following errors may occur during measurement:

Spontaneous crystallization:
The sample freezes (crystallizes) prematurely before the actual measurement process begins.
Possible causes:
- Contamination of sample, e.g., salt crystals, soiling, damage to thermistor probe surface
- Cracks inside the measurement vessels
(when reused frequently, ice forms in the cracks of the vessels due to the temperature
gradient)
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No crystallization:
The sample does not crystallize during the measurement process. Therefore, no measured
value can be determined. Possible causes:
– Sample container is empty
– No ice crystals present at the upper cooling system
– Needle guide contains water, preventing the crystals from reaching the sample

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3. Technical description of the OSMOMAT Auto

The OSMOMAT Auto is an enhanced version of our base product. To achieve the
functionality of the OSMOMAT Auto, the base product received various improvements.
However, the OSMOMAT Auto still has the same electronics assembly as the base product.

3.1. Device design

The device includes both mechanical and electrical components. The mechanical components
include the sample transport mechanism, the elevator, the cryst-needle, and the paper
transport mechanism. The electronic components include the power supply, the PCBs, and the
control panel.

The device design is based on a vertical metal support plate, separating the front and rear parts
of the device. This design reduces external interference with the measurement system and
improves noise immunity.

The rear part of the device contains the power supply, consisting of transformer and bridge
rectifier. It supplies the electronics assembly. The electronics assembly is represented by two
PCBs. The upper PCB was taken from the O30 series; the lower PCB contains improvements
for the functionality of the OSMOMAT Auto. The rear also contains the connection plate with
power socket and two serial connectors for barcode scanner and serial output. The LCD
display including keyboard and LEDs for operating the device is located at the top of the
support plate.

The sample rail, which receives the sample holder for 20 samples, is located at the front. It is
covered by a small PCB containing the (photo) sensors for monitoring sample transport.
It also contains two additional sensors monitoring the elevator. The upper cooling system with
motor for triggering the crystallization needle as well as the lower cooling system are
mounted on the elevator. They can be converged using a motor, enclosing the sample
container during measurement. It also contains the thermistor probe.
In addition, it provides access to the cleaning paper roll holder and the printer.

The following page shows an overall schematic:

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Gonotec GmbH

Power Upper PCB Lower PCB

supply Master for Slave for storage and Rear panel
measurement displays, motors
process

Top
LCD display
keyboard

Front Printer
panel Needle motor with
cryst-needle

Motor for
cleaning paper Cleaning
paper
Upper cooling
system and
Thermistor probe

sample rail
LS PCB on

Sample
container
Lower cooling
system (can be
converged with
Elevator motor upper cooling Motor for
system) sample rail

Fig.: OSMOMAT Auto overall schematic

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Gonotec GmbH

3.2. Controls and device components

This section describes the user controls.

3.2.1. Device rear

Fig.: Components on the rear of the device

The following items are located on the rear of the device:

1. Power socket with power switch
For connecting the IEC plug for non-heating devices. It also houses the device switch.
The lower section contains the fuse holder, which is also used to set the operating
voltage. See also: Switching fuses and setting the operating voltage.
2. Port for barcode reader
For connecting a barcode reader.
3. Serial port for data output
For measurement data output. This port can be used to connect a PC and retrieve the
data using a terminal device program.
4. Adjusting bush for sample detection
Please do not modify this setting. Otherwise, device functionality may be adversely
affected!
5. Adjusting bush for standby temperature of the lower cooling system
Please do not modify this setting. Otherwise, device functionality may be adversely
affected!
6. Nameplate

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3.2.2. Device front

The following items are located on the front of the device:

Fig.: OSMOMAT Auto front view

The following items are located on the front of the device:

1. Needle printer
For printing sample readings.
2. Cleaning paper roll
Contains the cleaning paper used to clean the thermistor probe after each
measurement.
3. Needle drive for cryst-needle
This unit consists of needle motor, perforated disc with position sensor and cryst-
needle and guide tube.
4. Elevator with upper cooling system with cover and connector for thermistor probe
This cooling system cools the cryst-needle (underneath the cover), causing crystals to
form for the triggering process. The cooling system should always be covered,
otherwise there will be significant ice buildup.

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5. Thermistor probe
This is the thermistor probe with holder. Caution, fragile!
6. Upper elevator limit switch
For setting the upper end position of the elevator.
7. Sensor for elevator cleaning position.
For setting the thermistor probe park position for cleaning.
8. Motor with roller for cleaning paper transport
This motor advances the cleaning paper.
9. Motor for elevator
This motor raises and lowers the elevator.
10. Front cover
Covers the lower cooling system as well as the PCB with the sensors for sample
transport.
11. Insert for sample holder
The individual components are further described in the respective sections.

3.3. Sample holder

The sample holder 1 is included with the device. It contains 21 positions for 20 measurement
samples. The first position is always used for an internal device measurement and thus cannot
be used for sample measurement. However, it must always be fitted with a measurement
vessel containing water. It is not included in the sample measurement count and labeled with
the number "0." The sample holder includes a stand 2 and a cover 3.

3.4. Front panel with keyboard and control panel

The front panel with keyboard and LCD display is located at the top of the device.
It includes the following components:

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1. LCD display
Displays information and readings. Also used for menu control.
2. Left option key
Provides menu-specific options, e.g., next, OK, print, etc.
3. Right option key
Provides alternative menu options, e.g., cancel, etc.
4. Number pad
For entering values. In addition, keys 2 and 3 let you scroll forward/backward, e.g., in
patient entries. The ESC key is for exiting the current menu to return to the parent
menu or to cancel actions. The CLR key is used for deleting entries.
5. Key for selecting print mode. Pressing the key advances through the print modes:
printer off -> single mode -> charge short -> charge long -> printer off …
The "printer off" mode is shown in red. At times, the print mode cannot be selected,
e.g., while a measurement series is in progress.
6. Key for printer paper feed
Pressing this key feeds a short piece of paper from the printer.
This is useful, e.g., when inserting a new print roll.
7. Key for cleaning paper feed
Pressing this key will feed a short piece of cleaning paper.
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4. Starting up the OSMOMAT Auto

4.1. Power-up
The device is powered up using a switch at the rear panel.
We recommend connecting peripheral devices such as barcode scanner or PC first.
The display flashes twice within a few seconds. After the second flash, it means that both
master and slave components are ready. The display briefly shows the current software
version:

********************
V 1.08.0x-d xx/xx
* ID Nr.: 010203 *
********************

For information about entering the ID number and switching to service mode, see the service
section of this manual.
The device moves all motors to their original position. If a sample holder is present inside the
device, the system tries to move it out backward. Please remove the sample holder once it has
been moved out. Otherwise, the system will prompt you to remove the sample holder. If one
of the motors is stuck or cannot be moved, a corresponding message will display. Please
rectify the problem and restart the device.
Certain parts of the measuring device must reach their operating temperature before
measurement is possible. This takes approx. 2 min. This state is also shown on the display.
You can abort this phase using the ESC key. However, this is not recommended.

After a sort while, the device is ready for measurement, and the start menu will display:
Gonotec GmbH
Welcome 2
P
<- sample adjust ->

Press the left option key to select the measurement function, and the right key to select the
setting functions.

4.2. Menu structure of the measurement functions

Selecting <- sample takes you to the menu for the measurement functions.

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They are divided into "sample measurement", "calibration", and "memory." Press "<- next" to
move forward:

memory Calibration sample

measurement
<- next OK -> <- next OK ->
t OK

Press the ESC key to return to the start menu.

OK lets you select the respective menu.
Sample measurement: Provides access to the measurement function, see Sample
Measurement menu
Calibration: Provides access to the calibration functions, see Calibrate section.
Memory: Provides access to the data memory functions, see section
Memory.

4.2.1. Sample Measurement menu

After selecting the sample measurement, a current batch number will display. This is assigned
by the device automatically. The system also lets you enter a patient number:
Charge 01-xx.xx.xx
Pat 01 insert data
2
_ P
<- ready OK ->

The patient number (optional) can be entered using the device keyboard or a barcode scanner.
You can also enter a partial patient number, which the system will complete automatically. If
there is not enough memory for entering new patients, a message will display. You cannot
enter more patient numbers than available samples. This is detected by the device following
the measurement and indicated by a "memory full clear memory before starting" message. In
this case, please check if the measurement was performed correctly.

4.2.1.1. Manual patient entry

The patient number is entered using the keyboard. You can enter numbers only. If you need to
make a correction, press the CLR key to delete the last character. Press the ESC key to delete
all characters. Pressing the ESC key again after deleting all characters will redisplay the
previously entered patient. This lets you delete patients even after entering them completely.
If no (more) patients are entered, pressing the ESC key will return to the Sample
Measurement selection menu. When all patient numbers have been entered you can start
measuring by pressing the "ready" key. You can enter a maximum of 20 patients at a time.

4.2.1.2. Entry using barcode reader

A serial port for a barcode reader is located on the rear of the device. Depending on the code,
the barcode reader lets you enter alphanumeric characters in addition to numbers. Mixed
keyboard/barcode reader entry is possible, even within a single patient entry.
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The following barcode reader settings are required:

Basic settings:
Transmission type: RS232 standard
Baud rate: 9600 Baud
Number of data bits: 8 bits
Number of stop bits: 1 stop bit
Parity: none
Inter message delay: 500 ms min.

If this setting is not supported, you have to wait until the device has processed
the patient entry before you can enter the next patient.
Message terminator: only CR or Enter

Other settings:
Ack/nack: disabled
FIFO: enabled
Handshaking: none
Code length: not transmitted
Your scanner may have additional settings, which may have to be configured as well. This
also applies to your desired barcode, e.g.: EAN128 or Interleaved 2/5. Please note that with
some codes it is impossible to tell whether readouts are erroneous or have been interrupted.
After successful configuration, the barcode reader can be connected to the OSMOMAT Auto
and tested. When all patient numbers have been entered you can start measuring by pressing
the "ready" key.

4.2.1.3. Performing the measurement

After completing the patient entries, the "put in sampleholder" prompt will display.
You may still abort the measurement by pressing the ESC key, or start it by inserting the
sample holder. The "please wait" message will display while an empty measurement is
performed with the sample in position "0" of the sample holder. This sample should be filled
with distilled water and must ALWAYS be present. This sample is not counted during sample
evaluation and will be considered to be non-existent.
While a current sample is measured, the results will display continually. The display also
indicates potential measuring errors, such as "no crist." or "spont. crist."
A measurement series can be aborted by pressing and holding the ESC key.
If a measurement series is aborted, e.g., due to power failure, obsolete patient entries are
cleared no later than during the next restart of the device. The sample values measured
successfully will be retained. This prevents memory overflow with invalid data.

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4.2.1.4. Printing the readings

The OSMOMAT Auto features a built-in needle printer. It has different operating modes,
which can be selected using the control panel keys.
The following selections are available:
printer off: No data is sent to the printer
Single mode: All sample data will be printed after each sample.
Charge short: After completing the entire measurement series, a header with the
collective data for the batch will be generated on the printout. For each
sample, the readings for the samples will be printed.
Charge long: After completing the entire measurement series, a printout with all sample
data will be generated for each sample.
The system remembers the selected print mode when restarting the device. You may not
always be able to change the print mode, e.g., during a measurement.

4.2.1.5. Serial output of the readings

A serial port labeled COM is located on the rear of the device. It lets you connect a PC or
another device with a terminal device program, such as Hyperterminal. The following
terminal settings are available:
9600 Baud, 8 data bits, one stop bit, no parity.
Serial data output also occurs in "printer off" mode.
Data are output in one row per entry.

4.2.2. Calibration menu

Calibration is used for correctly configuring the system. For this purpose, comparative
measurements with defined samples are performed. One of these samples is always a sample
with 0 milliosmols (distilled water) to define the zero point of the device. In addition, the
gradient of the measurement graph in the device is determined using a second or even a third
calibration value with a defined osmolality. Samples with a defined saline solution are used
for this purpose. Selecting a third calibration point is especially useful to increase accuracy
when measuring higher osmolalities because an additional data point is determined for the
internal measurement graph of the device.

4.2.2.1. Performing the calibration

After selecting the Calibration menu, the system prompts you to select the calibration points,
"2" or "3." Selecting "2" will use a sample of 0,0 milliosmols and a second sample with an
osmol value to be selected from a table as the basis for calibration. Selecting "3" lets you
select an additional third value from the table. The additional third calibration value must
always exceed the second value by at least 200 milliosmols. The values are selected using the
"choose" key and confirmed using the OK menu key.
After all values have been entered successfully, the display indicates the expected sample
sequence. Two samples are required for each value.
Contrary to the sample measurement, the calibration measurement does NOT require an
empty sample (no empty sample must be present).
The further sequence is the same as for sample measurements. If an error is detected during
calibration (e.g., when the sample sequence is mixed up), a corresponding message will
display. This invalidates the calibration measurement, which should be repeated.

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If calibration is successful, the menu prompts you if the calibration measurement should be
repeated. You can either repeat the measurement or press OK to accept it, in which case the
readings are stored internally. You cannot press ESC to exit this menu. After successful
calibration, the number of currently selected calibration points is shown vertically on the
right:

2 for two, 3 for three calibration points

P P

4.2.2.2. Printing the calibration values

The procedure for printing calibration values is the same as that for sample measurements.
The output also lists errors.

4.2.2.3. Serial output of the calibration values

The procedure for serial output of calibration values is the same as that for sample
measurements.

4.2.3. Memory menu

This sub menu contains the data memory functions. The data memory stores readings and
patient data. These include batch number, date, time, patient and sample number, and
readings. The data memory can store data of up to 300 patients. After power-on, it is
automatically cleared of invalid entries, e.g., due to aborted measurements. The data memory
can store data for about 10 years. New entries are assigned to any free slots in the memory,
which means that the data for a measurement series may not necessarily be arranged
sequentially.
Calibration values are not stored in the data memory.

4.2.3.1. Memory capacity

This lets you query the number of free memory slots. The number of free patient entries will
display. You can use "<- next" to exit this menu.

4.2.3.2. Look at charge

This contains the options for viewing and printing the memory contents. After pressing OK to
select the menu, the first batch in the memory will display. A batch is a collection of all the
patient data for a measurement series. The system displays the batch number, date, and
number of samples. You can press OK to accept the displayed batch. Press "+" (on the
keyboard together with the "2") to select a different batch. When you reach the desired batch,
you can view the patient data for this batch. The memory search operation may take a few
seconds because the batch data may be dispersed inside the memory. You can press ESC to
exit this menu.

4.2.3.2.1. Patient data display

The patient data are shown starting with the first patient in the batch. You can use the + and -
keys to search for patients. When you have reached the last patient of the batch the system
will continue with the first patient of the batch. You can press ESC to exit this menu.
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4.2.3.2.1. Patient data output

You can press the PRINT key to print the displayed patient data.
The print results differ depending on the selected mode:
single mode: prints only the current patient entry in its entirety.
charge short: prints a short version of the complete batch, irrespective of the patient
entry currently displayed.
charge long: prints the complete batch, irrespective of the patient entry currently
displayed.
In serial mode, data are also output in one row. Patient data can be output on demand even if
the printer is in "printer off" mode. In this case, data is output using the serial port. The "print"
key changes to "Senden." Data is output per batch.

4.2.3.3. Delete data

This menu contains the memory clearing functions. Data can be deleted per batch or entirely.
You cannot delete individual patient data.

4.2.3.3.1 Delete charge

The batch to be deleted can be selected as described above in "look at charge."
Please note: If the selected batch is confirmed with OK, it will be deleted immediately
without another system prompt.

4.2.3.3.2. Delete all

This lets you delete the entire patient memory. "DELETE?" will appear on the display. After
confirming with OK, the system will display a confirmation prompt. After confirming this
prompt with OK, the entire data memory will be deleted. During this operation, the display
flickers to indicate the system is working.
You can exit all menus by pressing the ESC key.

4.3. Menu structure of the setting functions

Gonotec GmbH
Welcome 2
P
<- sample adjust ->

Selecting adjust -> from the start menu takes you to the menu for the device settings. The
menu structure is as follows:

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date / time

<- next OK ->

actuate cryst- new initialisation

motor
<- next OK -> <- next OK ->

cleaning paper thermistor probe

feed adjustment
<- next OK -> <- next OK ->

Actuate cryst-motor: Actuates the cryst-needle.

Date / time: Sets date and time
New initialisation: Resets the device, see Initialize
Thermistor probe Lets you configure the thermistor probe, see Thermistor probe
adjustment:
Cleaning paper feed: Lets you feed the cleaning paper, see section Cleaning Paper

4.3.1. actuate cryst-motor

This menu lets you actuate the cryst-motor. Pressing the OK key will actuate the cryst-motor
for one revolution. This is necessary after changing the cryst-needle.

4.3.2. date / time

This menu lets you set date and time. After pressing OK, the "insert time" option will display.
You can confirm with OK, press "<- next" to enter the date, or press ESC to exit.

4.3.2.1. Insert time

After confirming with OK, the "insert time:" prompt will display. A time will display with its
first digit flashing. The time display format is HH:MM, where H means hour and M means
minute.
To enter the time, enter the current time setting for the flashing field. The entered number will
display and the next field will flash. You can enter the additional numbers until the spot after
the last number flashes. To correct invalid entries press the << key to move the cursor back
one field. After you have entered the correct time, it will be applied when you press the OK
key. There is no need to complete all the fields. For example, if you want to change the time
from 08:00 AM to 09:00 AM due to daylight saving you only have to enter a 0 followed by a
9 and then confirm with OK.
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Please note: There is no check for incorrect entries.

4.3.2.2. Insert date

After confirming with OK, the "insert date:" prompt will display. A date will display. The
procedure for setting the date is the same way as that for the time.
Please note: There is no check for incorrect entries.

4.3.3. New initialisation

This menu restores the basic settings of the device. In particular, this involves the reset to
2-point calibration mode and to the calibration values for 0 and 300 milliosmols.
Date and time are not changed. The patient data are retained. The printer mode also remains
unchanged.
After selecting the menu, the "Are you sure?" confirmation prompt will display. Selecting the
OK key will perform reinitialization. "<- cancel" lets you abort the operation.
The operation takes a few seconds, during which time the display goes blank. Next, the device
will restart, just like when you power it on. You have to perform a new calibration.

4.3.4 Thermistor probe adjustment

This menu lets you slowly raise or lower the elevator in order to adjust the thermistor probe.
Correct adjustment of the thermistor probe is important for proper measuring accuracy of the
device. The adjustment is described in section Adjusting the thermistor probe.
After selecting the menu item, the „thermistor probe (cancel with ESC)" message will display.
The option keys are assigned the "<- up" and "down - >" functions. The sample chamber is
illuminated.
The "<- up" and "down - >" keys let you raise ("up") or lower ("down") the elevator. Motor
power is limited, so travel speed is slow. This also eliminates any risk of crushing.

Please note: The "<- up" key allows the elevator to move beyond its upper dead center, after
which it is lowered again. Do not press the ESC key during this operation, otherwise the
elevator will become stuck.
If the thermistor probe was successfully configured, press the "down - >" key to lower the
elevator half way. Then press the ESC key. The elevator moves to its standby position, and
the sample chamber illumination shuts off.

4.3.5. Cleaning paper feed

This menu lets you configure if an additional cleaning paper feed should be performed
following a measurement series.
After selecting the menu, the "paper feed (activated)" message or the "paper feed
(deactivated)" message will display. The right option key lets you select the respective
counter option. The "<- next" key lets you exit this menu level.

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4.4. Switching fuses and setting the operating voltage

The power connection is located on the rear of the device. It also houses the fuses. To switch
a fuse, carefully pry out the fuse holder using a screwdriver. Then replace the desired fuse.
Always replace fuses with fuses of the same type. Replacing the fuse holder automatically
restores the supply voltage. Therefore, make sure to install the fuse holder correctly. Numbers
indicating the line voltage are imprinted on the inside of the fuse holder. The currently set line
voltage must be located on the right side of the fuse holder, below the power supply cable.

4.5. Replacing consumable and wear and tear parts

During operation of the OSMOMAT Auto, both cleaning and printer paper are consumed. In
addition, the ribbon must be replaced periodically. Finally, it may be necessary to replace the
O rings for the paper feed mechanism, the cryst-needle, or the thermistor probe.
4.5.1. Replacing the cleaning paper
The cleaning paper is used to clean the thermistor probe following a measurement process. If
the cleaning paper has been used up, you need to install a new role. You should never
continue working without cleaning paper because this may falsify readings. Also, this may
cause excessive wear on the feed mechanism.
To change the cleaning paper, loosen the screw and remove the old cleaning paper roll.
Then thread in the new paper. Push the new paper through the underside of the cover plate for
the sample container:

Fig.: Threading in the cleaning paper under the cover plate

Tip: It is easier to thread in the changing paper before the paper roll has been replaced.
Also, please make sure not to damage the thermistor probe.
Next, the cleaning paper must be fed through the drive roller. To do this, push the paper into
the guide under the feed roller up to the end stop:

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Fig.: Pushing in the cleaning paper

With the device powered on and ready, press the following key:

cleaning paper feed

The paper will be fed.

Next, replace and tighten the cleaning paper roll. This completes the cleaning paper
replacement.
4.5.2. Replacing the ribbon
From time to time the printer paper or ribbon need to be replaced. This procedure is described
here.
To replace the ribbon, push on the ribbon cassette on the right side of the printer:

Fig.: Replacing the ribbon

This lets you remove the ribbon.
The new ribbon must enclose the printer paper. Therefore, feed the printer paper through the
gap between ribbon and housing and then install the ribbon:

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Fig.: Inserting the ribbon

Finally, turn the knurled wheel clockwise to tension the ribbon

4.5.3. Replacing the printer paper

A red printer paper indicator alerts you that the paper is almost used up. You should prepare
to replace the paper at this point. To do this, swing the printer forward and down and remove
the ribbon:

Fig.: Swinging open the printer

Next, remove the old printer paper roll and insert a new role of suitable printer paper. Insert
the paper as shown and not in any other way. Otherwise, a paper jam may occur when the
paper supply is low. Push the paper up to the end stop into the printer gap from above. Next,
turn the rubber feed roller until the paper reappears at the front of the printer:

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Fig.: Inserting printer paper

Next, return the printer to the upright position and replace the ribbon. The printer is again
ready for printing.

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5. Servicing the OSMOMAT Auto

5.1. General circuitry description
Most circuitry components are located on the rear of the device.
They are:
– Power supply with housing fan
– Master PCB
– Slave PCB
– Control panel with LCD display, keyboard, and LEDs

Accessible from the device front:

– Limit switches, sensors, PCB for photo sensors

The circuitry components are only accessible after opening the housing

5.2. Opening the housing

To open the housing, you have to remove screws on the sides and on the rear.
The locations of the screws are as follows:

Fig.: Screws for opening the housing

After loosening the screws, you can carefully remove the housing. To do this, open the front
cover and carefully pry open the housing until it can be lifted off toward the rear. Please note:
The housing fan is still connected.
After the housing has been lifted off toward the rear far enough, the housing fan can be
disconnected. The device rear is now accessible:

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5.3. View of the circuitry components:

Fig.: Rear view, device open

The following components are available:
1. Power supply plate with toroidal transformer and serial ports and adjusting bushes
2. Master PCB
3. Slave PCB
4. Partial view of control panel

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5.4. Power supply and housing fan

The circuitry for the power supply looks as follows:

Fig.: Power supply with toroidal transformer

The housing fan is connected to the transformer and is located inside the housing.
Connector 6, approx. 20 V, is used for the main device power supply; the voltages on
connector 7 are used to generate the auxiliary voltage of +15 V and –15 V.

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5.5. Master PCB

5.5.1. General information
The following circuitry description applies to the KRYO board version 1.3.

5.5.2. Power supply (circuit diagram page 1)

In addition to the standard circuit blocks with linear regulator for +/–15 V (IC 25, IC 26
supply for analog circuits) test connector TE1 (pin 4 and pin 5) and -5 V (1C29 for A/D
transformer AD 7712) test connector TE1 (pin 7), the power supply consists of two blocks
with switching power supplies of a very similar design.

a) Switching power supply around 1C23 with output +5.7 V / 3A fixed voltage (Pe ob', test
connector TE1, pin 2) to supply the upper cooling system and—after dropping the voltage
to 5.0 V by a low dropout linear regulator (IC 18)—for the digital electronics (test
connector TE1, pin 6).

b) Switching power supply around 1C27 with variable output 0–6.5 V / 0–3.5A (U var: test
connector TEI, pin 3) to supply the lower cooling system (cooling of measurement liquid).

The functionality is explained based on a); b) is mentioned only where differences exist.

The switching power supplies are supplied through the secondary coil 20 V/20 A of the
toroidal transformer. This AC is converted into sawtooth DC averaging approx. 24 V
(±24 V nonreg.: test connector TE1, pin 1) by a bridge rectifier and an aluminum electrolytic
capacitor (C33: 2,200 µF). This voltage directly supplies the IC 23 switching power supply
and is stepped down to 5.6 V using a classic step-down circuitry consisting of the following
power elements:
– switch (TR2), freewheel diode (D4), storage coil (L1), and smoothing capacitor (C38).

1C23 regulates the output voltage by periodically switching on TR2 at longer or shorter
intervals. The voltage is regulated by comparing the internal reference voltage of 5 V (pin 16)
with the stepped-down output voltage (R68/R77 voltage divider). The switching frequency of
approx. 30 kHz is determined by R72/C35.
R70, R71, and C34 form the "soft start" portion of the circuitry, enabling the smooth start of
the switching power supply.
The TR2 power switch is an N-channel MOSFET requiring a positive gate source voltage for
switching. However, the 1C23 switching regulator only has open collector outputs. Therefore,
an auxiliary circuitry is necessary for adjustment. It consists of a floating (boot-strap) voltage
generator of 10 V (D3, C52, 1C24, C37) and the TR1 driver transistor (with R73, R74, R75
resistors). The driver transistor switches the 10 V onto the power transistor gate, making it
conductive.
C36 is used to optimize the switching flanks.
The b) switching power supply (around 1C27) differs from a) only by the control of the
internal regulator of the switching power supply IC. Instead of the constant internal reference
voltage (as with a)), a variable control voltage (Uvst) is compared to the output voltage. By
changing Uvst, the output voltage of this switching power supply can be adjusted from 0 to
6.5 V.

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5.5.3. Measurement and control assembly (circuit diagram page 2)

5.5.3.1. Measurement assembly

The measurement assembly includes the generation of the reference voltages +10.0 V (IC12)
test connector TE 1 on pin 8, –10.0 V (IC 15 B) test connector TE 1 on pin 9 and +2.5 V
(IC 15A: UR 25 = bridge supply voltage and reference voltage for A/D transformer IC 1).
Also included is the bridge circuit for the measurement thermistor, consisting of a half-bridge
with 2 precision resistors (R17, R18), featuring a low tolerance (0.1%) and very low
temperature coefficient (5 ppm), as well as the other half-bridge provided by the external
thermistor board.
IC 16 transforms the bridge differential voltage generated by the temperature change at the
measurement thermistor into a voltage related to ground. This voltage is amplified by a factor
of 13 by 1C17 and inverted/scaled to degrees Celsius by IC 15 C (with jumper J 1 removed).
Therefore, a voltage (Umess) is present on test connector TE 1 (pin 10) at the output of
IC 15C with 1 mV = 1milliosmol or 1 mV = 1/1000 degrees Celsius.
At the negative input of IC 15C (pin 9) the backing voltage Ukomp is applied at the R 24
resistor. This is the output voltage of a 12-bit DAC (AD 667, IC 11, circuit diagram page 3),
which can be used to compensate the voltage so that at 0.000 degrees Celsius (at the
measurement thermistor = freezing point of water) an output voltage of precisely 0.00 V can
be achieved (hardware zero adjustment, only populated with the "analog output" option).
With this option, the Umess voltage is switched to the analog output socket via a second order
low-pass filter with a limit frequency of approx. 3 Hz (IC 22B) so that registration with a
recorder is possible without humming (50 Hz) or noise interference (higher frequency).

5.5.3.2. Control assembly

The control assembly is used to set a certain temperature or a certain temperature progression
at the lower cooling system. It consists of the following circuitry elements:

– Set point switch (IC 14)

The following voltages = set points are applied at the IC 20 A summing amplifier, which is
also used to adjust the temperature of the lower cooling system (potentiometer P 1):

a: Set point from AD 557 (IC 9), pin 15, switched through:
The 8-bit DAC can be used to set a certain constant temperature at the lower cooling system

3: Follow Umess: pin 13 and pin 15 have been switched through

The temperature at the lower cooling system follows the temperature at the measurement
thermistor (i.e., Umess) with a temperature offset determined by AD 557 (IC 9).

x: Switch off cooling power

Pin 9 (ground) is switched through to pin 10, the output voltage of the regulator is drawn
to 0.0 V.

– Temperature recording at the lower cooling system (IC 20 B), a thermistor is used as
thermistor probe.

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– Temperature regulator (IC 20 C), type-proportional controller.

– Low-pass and voltage buffer (IC 20 D)

The output of the buffer is bipolar: positive voltage means "cooling," negative voltage
means "heating."

– Power bridge (T 1 to T 4) with peltier element (on ST 5) and comparators IC 21 A to

IC 21 D.
The comparators process the information "positive voltage" = cooling, by switching through a
positive current through the peltier element (T 3 and T 2 switched through); and "negative
voltage" = heating, by switching through a negative current through the peltier element (T 1
and T 4 switched through). At a voltage of zero volts (< 200 mV), all transistors are locked.

– IC 22 A voltage control circuit and absolute-value generator.

This circuit element is used to generate the absolute value of the buffer voltage of IC 20 D
(i.e., always positive); this voltage is used to control the switching power supply and therefore
the Uvar voltage between 0 V and 7 V. D 8 and R 26 generate a negative bias voltage of
approx. –300 mV so that the switching power supply supplies a certain output voltage of
0.0 V with "cooling power switched off."

5.5.3.3. Microprocessor with A/D and D/A transformers (circuit

diagram page 3)
The core microprocessor circuitry consists of the 8032 8-bit microprocessor (IC 2), the IC 3
address latch and the 27128 16 Kbyte EPROM (IC 3). The data/address bus (AD 0–AD 7) is
also connected to the 8-bit DAC AD 557 (IC 9: to set the temperature at the lower cooling
system), the 12-bit DAC AD 667 (IC 11: to compensate the measurement voltage with the
analog output option), the BQ 4287 real-time clock (IC 10: only with the "printer" option) and
the 4 input/output latches (IC 30–32 + IC 36, see section 5.5.5).

The X2444 EEPROM (IC 8) and the MAX 232 RS 232 transceiver (IC 5, only with the "RS
232 output" option) are connected to the serial inputs/outputs of the microprocessor.

The measurement voltage is digitized by the 16-bit AD 7712 SigmaDelta A/D transformer
(IC 1) with a sampling rate of 10 measurements per second. The input voltage range is 10 V.

5.5.3.4. Peripheral (digital input/output) circuit diagram page 4

Digital input/output is handled via 4 latches.

Output latch 74 HC 373 (IC 30)

Used to control the AD 7511 analog switch (IC 14), the "chip enable" input of the EEPROM
(IC 8), and the a. b. c output circuits for decoding the keyboard matrix.

Output latch 74 LS 373 (IC 31)

Used to control the 7 LEDs of the upper front panel and the DIR control output for the RS 232
interface.

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Input latch 74 HC 244 (IC 32)

This latch can be used by the microprocessor to query the status of the photo sensor at the
elevator and the cryst-motor and the u, v, w input circuits of the keyboard matrix and
determine the RS 232 control input DSR and the jumper setting for the options.

Output latch 74 HC 533 (IC 36)

While the type "373" latches mentioned previously are "active low," this latch is "active
high." It is used to control the 4 needle drivers for the printer, switch on/off the printer motor
(only with the "printer" option), and switch the cryst-motor on/off.

5.5.3.5. Electric test and measurement instructions

Measuring points at the 10-pin test socket TE 1:

Pin 1: +24 V non regulated

Set point: DC with superposed sawtooth AC of 100 Hz. Depending on the load, average
varies between just under 22 V (with full cooling) and over 25 V (in stand-by).

In case of error:
– Check board fuse SI 1 (5 A fast-acting)
– Check power fuse
– Is voltage selector set correctly?
– Check connections with bridge rectifier (on transformer) and board (ST 6).

Pin 2: Pe ob = peltier upper

Set point: DC 5.6 V to 5.7 V.
For measurement using a DVM, the voltage has to be stable; for measurement using an
oscilloscope, only one line (no interferences) may be visible in the "DC" setting; in the "AC"
setting, the interferences of the switching power supply (30 kHz) must be below 20 mV.

In case of error: Check if the switching regulator IC 23 is working properly. Use an

oscilloscope to check on pin 8 or pin 11 if the switching output operates at approx. 30 kHz.
Then track the switching signal step by step via the driver transistor TR 1 to the switching
transistor TR 2. Check if the inductor L 1 has low impedance contact with the TR 2 source of
and the Pe ob output pin.

Pin 3: variable voltage U var = peltier lower

Set point: DC, variable between approx. +6.2 V (full cooling) and 2 V (stand-by). After
power-up, the high voltage has to be applied for the first 30-60 seconds. When the cooling
system reaches its set temperature, the voltage returns to its "stand-by" value.

In case of error: Inspection as in item 2, except use IC 27 pin 8 or 11, driver transistor TR 3
and switching transistor T 5. The control voltage Uvst has to be checked as well (on R 81,
R 26 or D 8). This voltage determines the set points for the switching power supply and
otherwise also lies between approx. 6.2 V with full cooling and 2 V in stand-by.

Pin 4: +15 V
Set point: +14.5 V to 15.5 V, DC, constant
In case of error: Check AC on ST 7: 18 V. Check sawtooth DC on C 41. Replace voltage
regulator IC 25.
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Pin 5: -15 V
Set point: –14.5 V to –15.5 V, DC, constant
In case of error: Check AC on ST 7: 18 V. Check sawtooth DC on C 42. Replace voltage
regulator IC 26.

Pin 6: +5 V
Set point: +4.9 V to +5.1 V, DC, constant
In case of error: Is Pe ob voltage at pin 2 OK? (Input voltage of voltage regulator); is there
a short? Replace voltage regulator IC 18.

Pin 7: -5 V
Set point: –4.8 V to –5.2 V, DC, constant
In case of error: Is +15 V voltage at pin 4 OK? (Input voltage of voltage regulator); is there
a short? (Remove IC 1 prior to measurement); replace voltage regulator IC 29.

Pin 8: +Uref
Set point: +9.95 V to +10.05 V, DC, constant
In case of error: Is +15 V voltage at pin 4 OK? (Input voltage of voltage regulator); is there
a short? Replace voltage regulator IC 12.

Pin 9: –Uref
Set point: –9.95 to –10.05 V, DC, constant.
In case of error: Is + U ref voltage at pin 8 OK? (Input voltage for negative reference); is there
a short? Check function of operational amplifier IC 15 B (inverter circuit).

Pin 10: U mess (analog measurement voltage, proportional to temperature of measurement

thermistor)

Set point: Range: –14 V to +14 V. If the elevator is in the upper position and the measurement
thermistor has about room temperature (22 °C), U mess is approx. –8 V to –9 V. Heating of
the measurement thermistor (touching with the hand) results in more negative voltage, cooling
of the measurement thermistor (lowering the thermistor into the cooling clamp) results in
more positive voltage. Rule of thumb: 0 °C 0 V‚ positive voltages correspond to temperatures
below 0 Celsius.

In case of error: Check wires from thermistor to thermistor board and connections on
thermistor board. Check shielded cable to board and board connector ST 3. Check bridge
supply voltage U r25 = 2.5 V (IC 15 A, pin 1). Check output IC 16, pin 6: should behave like
U mess, although the voltages are smaller by a factor of 13 and inverted, i.e.: positive voltage
means positive temperature. Check IC 17 (amplifier with V = 13) and IC 15 C (inverter).

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5.5.4. Circuit diagram of master PCB

The circuitry of the master PCB is illustrated on the following four pages.

Fig.: Circuitry of master PCB, page 1

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Fig.: Circuitry of master PCB, page 2

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Fig.: Circuitry of master PCB, page 3

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Fig.: Circuitry of master PCB, page 4

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5.5.5. Layout diagram of the master PCB

Fig.: Layout diagram of master PCB

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5.6. Slave PCB

The slave PCB enhances the original device with the capability for automated measurement of
multiple samples. This includes the option to actuate multiple motors, lower the thermistor
probe, move the sample carriage through the device, feed the cleaning paper, etc. Therefore,
multiple parallel ports are available for actuating and querying inputs and outputs like motors,
LCD display, photo sensors, etc. Data are stored in a non-volatile RAM module.
Communication with the µC of the original device is interrupt-controlled via a parallel
interface. The master triggers and monitors the communication and controls the slave using
internal commands.

Menu and reading determination are performed by the master while the slave is responsible
for intended commands, showing the values on the LCD display, and storing the readings in a
non-volatile RAM module.

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5.6.1. Circuitry of the slave PCB

Fig.: Circuitry of slave PCB, page 1 of 2

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Fig.: Circuitry of slave PCB, page 2 of 2

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5.6.2. Parts list for slave circuitry

Below is the parts list for the slave portion of the circuitry.
Parts list for OSMOMAT Auto Slave

Part number Rating Type Housing Notes

C1 10µ/16V Tantalum, 2.5mm

C2 10µ/16V Tantalum, 2.5mm
C3 10µ/16V Tantalum, 2.5mm
C4 10µ/16V Tantalum, 2.5mm
C5 22p Ceram. 2.5mm
C6 22p Ceram. 2.5mm
C7 47p Ceram. 5mm
C8 47µ/35 Tantalum / aluminum
5mm
C9 100nF Ceram. 5mm
C10 100nF Ceram. 5mm
C11 100nF Ceram. 5mm
C12 100nF Ceram. 5mm
C13 100nF Ceram. 5mm
C14 100nF Ceram. 5mm
C15 47µ/35 Tantalum / aluminum
5mm
C16 10µ/16 Tantalum 2.5mm
C17 100nF Ceram. 5mm
C18 470µ/35V Aluminum 5mm
C19 100nF Ceram. 5mm
C20 100nF Ceram. 5mm
C29 22pF Ceram. 5mm
C30 22pF Ceram. 5mm
C31 10µ/16V Tantalum, 2.5mm
C32 10µ/16V Tantalum, 2.5mm
C33 10µ/16V Tantalum, 2.5mm
C34 100nF Ceram. 5mm
C35 100nF Ceram. 5mm
C36 100nF Ceram. 5mm
C37 100nF Ceram. 5mm
C38 100nF Ceram. 5mm
C39 47u/35V Aluminum 5mm
C40 100nF Ceram. 5mm
C41 100nF Ceram. 5mm
C42 100nF Ceram. 5mm

D1 1N4001 1N4001 DO41

D2 1N4001 1N4001

D3 1N4001 1N4001 DO41

D4 1N4001 1N4001 DO41
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Part number Rating Type Housing Notes

D5 1N4001 1N4001 DO41
D6 1N4001 1N4001 DO41
D7 1N4001 1N4001 DO41
D8 1N4001 1N4001 DO41
D9 1N4001 1N4001 DO41
D10 1N4001 1N4001 DO41
D11 1N4001 1N4001 DO41
D12 1N4001 1N4001 DO41
D13 1N4001 1N4001 DO41
D14 LED3 red 3mm
D15 LED3 green 3mm
D16 1N4148 1N4148 DO35

F1 Fuse 0.5 A

IC1 80C32 DIL40

IC2 MAX 232 DIL 16
IC3 MAX 1232 CPA DIL 8
IC4 DS 1230 Y SRAM DIL28-6
IC5 7414 HC or HCT DIL14
IC6 7400 HC or HCT DIL14
IC7 74573 HC or HCT DIL20
IC8 74573 HC or HCT DIL20
IC9 74573 HC or HCT DIL20
IC10 74573 HC or HCT DIL20
IC11 74573 HC or HCT DIL20
IC12 74573 HC or HCT DIL20
IC13 74138 HC or HCT DIL16
IC14 74573 HC or HCT DIL20
IC15 7400 HC or HCT DIL14
IC16 7414 HC or HCT DIL14
IC17 7414 HC or HCT DIL14
IC18 27C256AG EPROM DIL28-6
IC19 24C256 EEPROM DIL8 not pop.
IC20 L293 L293 DIL16
IC21 L293 L293 DIL16
IC22 16C450P 16C450P DIL40
IC23 22V10 22V10 DIL24-3
IC24 MAX232 MAX232 DIL16

JP1 1x2 Reset

Q1 1.4832 MHz HC49U-V

Q2 11.0592 MHz HC49U-V

R1 10 K 0207 R-10mm

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Part number Rating Type Housing Notes

R2 10 K 0207 R-10mm
R3 120 R 0207 R-10mm
R4 120 R 0207 R-10mm
R5 5K6 0207 R-10mm
R6 5K6 0207 R-10mm
R7 Potentiometer 10 K Ten-turn Bourns 3296
R8 10 K 0207 R-10mm
R9 2R2 0207 / 0411 R-18mm
R10 2R2 0207 / 0411 R-18mm
R11 330 R 0207 R-10mm
R12 330 R 0207 R-10mm
R13 330 R 0207 R-10mm
R14 330 R 0207 R-10mm
R15 330 R 0207 R-10mm
R16 10 R 0207 R-10mm
R17 100 K 0207 R-10mm
R18 100 K 0207 R-10mm
R23 10 K 0207 R-10mm
R24 10 K 0207 R-10mm
R25 10 K 0207 R-10mm
R26 33 R 0207 R-10mm
R27 33 R 0207 R-10mm
R28 2R2 0207 R-10mm
R29 2R2 0207 R-10mm
R30 2R2 0207 R-10mm
R31 2R2 0207 R-10mm
R32 2R2 0207 R-10mm
R33 2R2 0207 R-10mm
R34 1K 0207 R-10mm
R35 1K 0207 R-10mm
R36 1K 0207 R-10mm
R37 100 K Do not populate Do not populate!
R38 1M 0207 R-10mm
R39 1K 0207 R-10mm
R40 10 K 0207 R-10mm
R41 10 K 0207 R-10mm
RN1 10 K * 4 4x, RM 2.54 RN4
RN2 10 K * 8 8x, RM 2.54 RN8

SV1 1 x 6-pin Crimpflex Keyboard LEDs

SV2 2 x 5-pin DIN41651 Front PCB
SV3 1 x 3-pin e.g., Molex
SV4 1 x 5-pin Barcode
SV5 1 x 5-pin COM
SV6 1 x 6-pin IC contact strip Test socket
SV7 1 x 3-pin e.g., Molex Upper limit switch
SV8 1 x 3-pin e.g., Molex Reflected photo
sensor, middle
SV9 2 x 7-pin DIN41651 LCD display
SV10 1 x 10-pin Crimpflex Keyboard matrix

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Part number Rating Type Housing Notes

SV11 1 x 3-pin e.g. Molex open for additional

ventilator
SV15 1 x 3-pin Interrupt from
master
SV16 2 x 10-pin DIN41651 KBD from master
SV19 1 x 14-pin Master interface
SV20 1 x 3-pin e.g., Molex for add'l LED

U1 7812 78xx TO220 For fan

U2 7805 78xx TO220 For motors
U3 7812 78xx TO220 For LCD display

X1A,B 2-pin 900-SH 10-02 Manufacturer: Weco

X3 2-pin 900-SH 5-02 Weco
X4 2-pin 900-SH 5-02
X5 2-pin 900-SH 5-02 LCD illumination
X6 2-pin 900-SH 5-02 Sample motor
X7 2-pin 900-SH 5-02 Motor cleaning
paper
X8 2-pin 900-SH 5-02

5.6.3. Connections on the slave PCB

This provides an overview of the connectors and their function
SV1: Connection to keyboard: LEDs
SV2: Connection to front PCB, sensor system
SV3: Connection to sample detection setting potentiometer
SV4: Connection to serial port for barcode reader
SV5: Connection to serial port for COM
SV6: Test socket for diagnostic purposes
SV7: Connection for upper elevator limit switch
SV8: Connection for halfway elevator switch
SV9: 14-pin connector for LCD display
SV10: Connection to control panel, keyboard
SV15: Connection for communication with master
SV16: Connection for keyboard decoder to master
SV19: Communication port to master
X1: 20 V supply from power supply
X3: Connection for elevator motor
X5: Connection for 5 V LCD illumination, switchable
X6: Connection for sample carriage motor
X7: Connection for cleaning paper motor
X8: Connection for LED for thermistor probe adjustment

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5.6.4. Notes about slave circuitry

The slave circuitry does not perform any measuring tasks. It consists mainly of digital
components.

5.6.4.1. Description of circuitry

The voltage for the +5 V for the logic gates and the processor is supplied by the master PCB.
Therefore, troubleshooting must be performed on the master PCB.

An auxiliary voltage of 12 V is generated using a voltage regulator U3 (on the base plate)
from the 24 V supply of the power supply. In case this auxiliary voltage fails, the motors and
the illumination of the LCD display are no longer actuated.
The LCD illumination functions with a voltage of 5 V, generated by voltage regulator U2.
The regulator can be switched on/off using a switched 12 V output.
An additional 12 V voltage regulator, U1, handles the power supply for the fan. The reason
for decoupling using separate voltage regulators was to avoid flickering of the display or
speed fluctuations of the fan motor in case multiple motors are in operation.
The power levels for motor and illumination are realized using ICs 20 and 21. These ICs
typically do not heat up during operation. In case the motors or illumination do not work, you
should check these ICs.

The slave PCB also includes the keyboard actuator with a 22V10 module. It is used to actuate
the keyboard. In case this module heats up and the keyboard ceases to work properly, the
malfunction is likely to be found here.

The core component of the slave PCB is IC 1, a 80C32 processor, communicating with the
master via a parallel port consisting of ICs 10 and 11 and a number of auxiliary gates. The
auxiliary gates generate a short signal at processor input INT0, causing the processor to detect
the communication request from the master. This signal can also be tapped on the diagnostic
pins described later.
Processor IC 1 actuates the peripheral modules, inputs and outputs in a memory-mapped
manner via latches, 74(HC)573. The signals for actuating the latches are generated using an
address encoder 74(HC)138. Outputs are mapped to latches as follows:

EXDATIN: IC 11, get data from master.

EXDATOUT: IC 10, send data to master.
IO1: IC 8, actuation of the two power drivers for motors, etc.
IO2: IC 9, read inputs (photo sensors, etc.).
DISPLED: IC 14, actuation of LEDs in control panel.
LCD: IC 12, LCD interface, data to LCD display.
UART2: IC 22, UART for serial terminal port on rear.

UART uses the interrupt line INT1 of the processor. It is connected to one of the two
MAX232 modules.

Gates are used to invert or couple the signals as needed.

The second serial port directly interfaces with the processor via a MAX232 interface module.
It is used for the barcode reader.

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An EPROM 27C256 acts as memory module. It contains the operating program for the slave.
In addition, there is a non-volatile RAM, DS1230, used to store the patient data and other
operating data such as the current printer setting. Its capacity is the data of 300 patients. This
module can be read using an EPROM programming device. Just like the EPROM, it has been
rotated by 180°degrees.
In addition, a slot for a serial EEPROM 24C256 is available. However, this is currently not
needed.

5.6.4.2. Reset circuitry for the slave

An IC MAX1232 is part of the circuitry design for reset purposes. However, for technical
reasons this module is currently not usable. Instead, an 8-pin IC socket needs to be used with
a 10 u/16 V capacitor soldered into pin 5 (–) and 8 (+). The slave can be reset manually be
shortening the two capacitor legs:

Fig.: Substitute for IC 8

5.6.4.3. Diagnostic socket

The parts list includes an item "SV6." This is a 6-pin contact strip used for diagnostic
purposes. Connector "1" is labeled in the layout diagram.
The strip is populated as follows:
Pin 1: Port P1.7 of the 80C32; flashes when the system is initialized and working. It flashes
approximately every second.
Pin 2: Input INT0 of the 80C32; interrupt input from the parallel port for commands from
the master
Pin 3: Input INT1 of the 80C32; interrupt input from the UART 16C450
Pin 4: +12 V power supply
Pin 5: +5 V power supply from master
Pin 6: Ground connection

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5.6.5. Slave layout diagram

Fig.: Slave layout diagram

Please note: IC 4 and IC 18 have been rotated 180°degrees.
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5.7. Control panel with LCD display and keyboard

The control panel with LCD display and keyboard is located at the top of the device.

5.7.1. Design of keyboard and display

To remove the keyboard, you must first loosen the three ribbon cables at the rear of the
device, connecting the PCB to keyboard and display. These cables are secured by latches:

After loosening these cables, the control panel can carefully be lifted up and off. Please note:
It is connected to the device by two more cables.

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After flipping the control panel upside down, these cables can be removed as well:

The control panel has no serviceable parts. In case of malfunction of a key or keyboard LED,
the complete control panel has to be replaced. The only component that can be replaced is the
LCD display.

5.7.2. Replacing the LCD display

The LCD display is equipped with the usual standard controller. It features 4 lines with
20 characters each. The illumination is connected to a 5 V power supply with resistors. To
replace the display:
Loosen the four screws. The two ground straps of the keyboard are located under one of the
screws. They are secured using an eyelet and a lock washer. Be careful not to tear them off.
The display can be removed and replaced after removing the black bracket. The display has
a plastic cover to protect it from scratching. Remember this when re-assembling the display.
The display is relatively large and therefore sensitive to pressure and bending stress. For this
reason, the display is protected using elastic foam holders. They must never be replaced by
fixed bars, etc.
Re-assembly occurs in reverse order.

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5.8. Sensors and PCB on the device front

This PCB is accessible from the front. However, the front cover must be removed first. Please
power off the device beforehand; otherwise, damage to the device may occur. Loosen the
following screws:

Fig.: Opening the front cover for the photo sensors

Before you loosen the screws, please make sure you hold the front cover so that it does not
fall on the floor.

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5.8.1 Description of the sensors

The photo sensor PCB (A) and all the other sensors of the base plate (B) are accessible from
the front.

Fig.: Sensors on the OSMOMAT Auto

*) loosen these screws for replacement

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The sensors have the following function:

Sensor PCB A:
1: Forked photo sensor for sample run-in
2: Photo sensors for sample detection. It consists of a separate transmitter and receiver on
opposite sides of the sample duct. The sensitivity of this photo sensor can be adjusted.
See: Setting the sample detection.
3: Forked photo sensor for detecting the measuring position. This photo sensor determines
the position below the measuring sensor. This position is adjustable. See Setting the
thermistor probe position.
4: Forked photo sensor for sample run-out This photo sensor checks whether the sample
duct still contains a sample holder.
In addition, the PCB includes the connection for the LED illumination which switches on
when setting the thermistor probe.
8: LED illumination
9: Fan connection
10: Connecting cable to slave PCB

Base plate B:
5: Reflected photo sensor for determining the cleaning position of the thermistor probe
After each measurement, the thermistor probe is cleaned by puncturing the cleaning
paper. This is to avoid carryover of sample residue to the subsequent sample. For this
purpose, the thermistor probe is lowered. However, it must not be lowered too much to
prevent it from being re-immersed in the sample. The cleaning position is determined this
way. The position is adjustable. See Setting the cleaning position.

6: Upper limit switch

This limit switch limits the upward travel of the elevator. If this travel is not limited
before the upper turning point, the elevator is lowered again. In this case, automatic free
movement is no longer possible. The position is adjustable. See Setting the upper limit
switch.

7. Cryst-needle with reflected photo sensor for standby position

This photo sensor stops the movement of the cryst-motor as soon as the standby position
of the cryst-needle is reached. See also Needle motor section.

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5.8.2 Service mode for the sensors

In case one of the sensors malfunctions when powering up the device, the operating program
of the OSMOMAT Auto provides a service mode. It is not accessible from the regular menu
tree. The use of the service mode is described below:
Start by powering up the device. The display shows the initialization message, followed by
the message: "cooling down please wait until ready" Immediately (within 4 seconds) press
and hold the "5" key. This launches the service mode. The state of the sensors is indicated as
follows:
6[x]
5[ ]

4[ ] 3[ ][ ]2 [x]1

Activated positions are indicated by an X. In this case, the upper limit switch is active and the
sample run-in is busy. This lets you manually test the function of the individual sensors and
diagnose an error, if applicable. To exit the service mode, power down the device.

5.9. Sensor PCB

The photo sensor actuation for the sample rail is combined on the PCB on the front of the
device. It is connected to the slave PCB on the rear of the device with a ribbon cable.
This PCB also includes a connection for the fan of the lower cooling system.

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5.9.1. Circuitry of the sensor PCB

The circuitry of the sensor PCB is as follows:

Fig.: Circuitry of the PCB on the front of the OSMOMAT Auto

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5.9.2. Parts list for sensor PCB

Parts list for OSMOMAT Auto Sensor PCB

Part number Rating Type Housing Notes

C1 100 n Tantalum, 2.5mm

C2 100 n Tantalum, 2.5mm
C3 100 n Tantalum, 2.5mm
C4 100 n Tantalum, 2.5mm
C10 100 n Ceram. 2.5mm
C20 100 n Ceram. 2.5mm
C30 100 n Ceram. 5mm
C40 100 n Tantalum / aluminum
5mm

D1 SFH409 LED IR 3 mm
D2 LED, white LED, white 3 mm
D3 LED, white LED, white 3 mm Optional

R1 150R 0207 R-10mm Replaces R10

R2 150 R 0207 R-10mm Replaces R20
R3 150 R 0207 R-10mm Replaces R30
R4 150 R 0207 R-10mm Replaces R40
R5 5k6 0207 R-10mm Replaces R50
R6 0207 R-10mm Replaces R60
R7 5k6 0207 R-10mm Replaces R70
R8 5k6 0207 R-10mm Replaces R80
R9 470 R 0207 R-18mm Replaces R90
R10 150 R SMD 1206 Replaces R1
R20 150 R SMD 1206 Replaces R2
R30 150 R SMD 1206 Replaces R3
R40 150 R SMD 1206 Replaces R4
R50 K6 SMD 1206 Replaces R5
R60 SMD 1206 Replaces R6
R70 5k6 SMD 1206 Replaces R7
R80 5k6 SMD 1206 Replaces R8
R90 470 R SMD 1206 Replaces R9

SV1 2 x 5-pin DIN41651 To slave PCB

SV2 1 x 3-pin e.g., Molex Fan connection

U1 TCST1202/TCST1103 Fork coupler RM 7.62 Fitted with socket

U2 TCST1202/TCST1103 Fork coupler RM 7.62 Fitted with socket
U4 TCST1202/TCST1103 Fork coupler RM 7.62 Fitted with socket

The resistors can be wired (R1–R9) or SMD-populated (R10–R90).

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5.9.3. Layout diagrams for the sensor PCB

The sensor PCB is populated on both sides. This is the layout diagram for the populated side:

Fig.: Sensor PCB, layout and connection diagram for populated side

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This is the layout diagram for the interior where the three forked photo sensors are located.
They are plugged into the sockets rather than soldered on:

Fig.: Sensor PCB, layout and connection diagram for interior

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6. Software of the OSMOMAT Auto

The software for the OSMOMAT Auto is different for master and slave, but integrated into a
common EPROM. Therefore, the EPROMs of master and slave can be switched around.
Software version 1.8.xx must be used for the current device version. The current software
version will display during power-up.
Replacing the EPROMs:
The EPROMs have sockets and can easily be replaced, if necessary. However, pay attention
to adjustment: For the master (upper PCB), the indicator notch must point down, while for the
slave it must point up. Also observe the position (see Layout diagram) because the EPROM
may be destroyed if plugged into the wrong slot.

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7. Replacing and configuring device components

7.1. Replacing the sensor PCB
Before replacing the PCB or other components, the device must be in standby position,
i.e., sample holder removed, elevator with thermistor probe in upper limit position.

Prior to replacing the PCB, unsolder the cables for the sample photo sensor and the
illumination LEDs. If necessary, mark the position of the cables using a pen.
Next, remove the connectors. Replacing the PCB requires loosening the four screws used to
secure the PCB. You can now insert a new PCB.
Pre-tighten the PCB and restore the electrical connections. Also, the position of the PCB must
be adjusted prior to starting up the device.

7.2. Adjusting the upper limit switch

The upper limit switch stops the upward travel of the elevator.
If the limit switch is set too far up, the elevator moves past its upper limit position and starts
descending again. From this position, the device cannot move freely automatically. Therefore,
this setting should only be performed by experienced professionals.
If the limit switch is set too far down, there is a risk of damage to the thermistor probe.
Therefore, the optimal position of the limit switch is essential. The device must be ready, but
no sample holder inserted. To adjust the upper limit switch, open the "thermistor probe
adjustment" menu. Next, lower the thermistor probe approximately half way.
Loosen the adjustment screw for the upper limit switch and first slide it down. Make sure that
the holder for the limit switch lies flush against the vertical guide rail and is not tilted:

Fig.: Adjusting the upper limit switch

Use the "<- up" key to raise the elevator until you hear a faint click of the limit switch. This is
the upper limit position that was just set. It is ideal if the brass-colored mounting bracket is in
a vertical position. In addition, the thermistor probe must be positioned above the metal cover
of the sample holder.

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Fig.: Side view: Upper limit switch adjusted correctly

If the optimal adjustment is not achieved, repeat the adjustment procedure until the optimal
result is achieved. To verify the adjustment, lower the elevator half way again and then press
the ESC key to complete the adjustment. The system automatically moves to the upper limit
position. If the result is not satisfactory, repeat the adjustment procedure.

7.3. Adjusting the middle lift switch

The middle lift switch must be adjusted so that the thermistor probe punctures the cleaning
paper during the cleaning procedure following the measurement, but is not immersed in the
sample. The adjustment can be performed during a sample measurement. The adjustment
involves moving the sensor up or down:

Fig.: Adjusting the middle lift switch

7.4. Setting the sample detection

The sample vessels are made of clear plastic and therefore difficult to detect by the photo
sensor. Therefore, the photo sensor can be adjusted for sample detection.
To do this, with clear view of the photo sensor, you need to set a voltage of 3.8 V for sample
detection, using the SP1 potentiometer (device rear). Voltage is measured at connection "E"
(photo receiver emitter), located on the sensor PCB at the front of the device.

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7.5. Replacing the thermistor probe

The thermistor probe is the heart of the system. It is used to determine the readings. However,
it is sensitive to external mechanical exposure.

Fig.: Thermistor probe

This describes the replacement procedure in case the sensor becomes damaged.
Start by sliding up the cover of the lower cooling system and loosening the two screws. Next,
remove the cover and unscrew the thermistor probe:

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Fig.: Replacing the thermistor probe

You can now remove the black connector piece and carefully withdraw the thermistor probe
from the duct.
Important: the bead must be above the stainless steel plate: risk of breaking.
Assembly occurs in the reverse order.

7.6. Adjusting the thermistor probe

To adjust the thermistor probe, loosen the four screws of the front panel.

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Use a 1.5mm Allen key to carefully loosen the four Allen set screws.

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Place the adjustment tool in the lower cooling system.

Select > adjust > thermistor probe adjustment in the initial display. Select ok to start raising
or lowering the thermistor probe.
Raising and lowering are controlled by a stepper motor. The length of the period for which the
key is pressed determines the number of steps.
1. Select <- up to raise the thermistor probe step-by-step.
2. Select down -> to lower the thermistor probe step-by-step.
3. Press ESC to return the thermistor probe to its preset position.

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Please note: The automatic lift limit of the elevator is disabled during this operation.
This can result in overwinding of the Excenter disc and may destroy the
measurement system.

When the bead is directly above the adjustment tool, stop the downward movement. Please be
careful, as there is a risk of destroying the thermistor probe.
Adjust the lower cooling system so that the bead is located precisely in the center of the
adjustment tool bore. After the adjustment, re-tighten the four set screws and replace the front
panel.
Next, it is critical to remove the adjustment tool, otherwise the measurement system will
be destroyed.

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7.7 Replacing the lower cooling system

To replace the lower cooling system, loosen the front panel as described above.

Use a 1.5mm Allen key to carefully loosen the four Allen set screws.
Remove the four cables on the left side (blue, blue, black, red).
You can now remove the lower cooling system and replace it. Make sure to observe the
polarity of the cables.
After replacing the lower cooling system, you have to readjust the thermistor probe and set
the standby temperature.

7.8 Setting the standby temperature

Fill the cooling clamp up to the top with water.

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Use a thermometer to check the standby temperature.

The standby temperature should be between +2 °C and +3.5 °C.

If the standby temperature is too low or too high, it needs to be readjusted.

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Use a screwdriver to reset the standby temperature on potentiometer SP2 (adjustable resistor).

7.9. Replacing the cryst-needle

It may become necessary to replace the cryst-needle due to corrosion or mechanical damage.
This procedure is described below:
Start by sliding up the cover of the cooling system and loosening the two screws (similar
to replacing the thermistor probe). Next, remove the cover.
It is not necessary to loosen the thumbscrews for the thermistor probe.
Next, loosen the indicated screw and remove the individual parts of the needle.

Fig.: Screw for loosening the cryst-needle, individual parts of the cryst-needle

You can then replace the cryst-needle. Make sure to include all parts for reassembly. The new
needle must be carefully aligned. It must move freely after securing to the sleeve bearing.
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The new needle must be trimmed to the proper length.

To do this, move the motor swipe to the upper dead center position, i.e., move the needle all
the way up. Next, trim the needle to the proper length using a pair of pliers—the end of needle
must be located approximately 2 mm below the upper edge of the cooling pin (brass-colored).
Carefully file the cutting edge to round it off and to remove any edges.
You need to avoid at all times that the needle slides out of the top of the cooling pin during
rotation of the cryst-motor. However, it may also not protrude past the lower edge of the
cooling pin in the standby position. It may be helpful to perform an adjustment by moving the
reflected photo sensor vertically. See also Replacing the trigger photo sensor. You can then
reassemble the device.
Use the "actuate cryst-motor" sub menu in the Device settings menu to verify the correct
needle function.
Note: The stainless steel needle is soldered into the needle bar using soft solder. After
removing the needle bar, you can solder a new stainless steel needle into the bar using a
soldering iron. This requires a special flux agent. After soldering the needle, it must be
carefully aligned using adjustment pliers. Generally, it is trimmed to its final length after
installation is complete.

7.10. Replacing the trigger photo sensor

The previous section describes the replacement procedure for the cryst-needle. The standby
position of the cryst-needle is determined by a reflected photo sensor behind the pane of the
needle holder. If it becomes necessary to replace or adjust this photo sensor, proceed as
follows:
Use the adjustment screw to replace or adjust the reflected photo sensor (small PCB).

Fig.: Location of the reflected photo sensor for the cryst-needle.

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7.11 Adjustment/checking of photo sensor no. 3/ Move error

Photo sensor no.3 is adjusted properly when the measurement vessel runs right down to the
middle of the lower cooling system.

Photo sensor no.3 is misaligned when the measurement vessel does NOT meet the middle of
the lower cooling system—see above.

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The following error will display on the screen: Move error restart, please!
The elevator is blocked and does not move in the right position.

Before adjusting the photo sensor no. 3, take a note of the wrong position of the measuring
vessel.

Procedure of adjustment:
Switch the instrument on and then off.
The elevator moves up to stand-by position and the sample holder moves out.
1. Slightly loosen the 4 screws (marked with red circles above).
2. Move the photo sensor circuit board a little in the opposite direction to readjust the photo
sensor no. 3.
3. In the following check the adjustment of the photo sensor by running the sample holder
into the machine and starting a measurement.
4. The photo sensor is adjusted properly when the measurement vessel runs right down into
the center of the lower cooling system.

If the measuring vessel is not in the middle, point 1–4 above should be repeated.
After the photo sensor no. 3 is properly adjusted refasten the relevant 4 screws.
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