Basic Troubleshooting: Autoflex

Cause/Reason

Solution

Caps are splitting

Inspect the caps after they are punctured. There should be one round small hole near the center of the cap that was created when the needle pierced through. If there are any splits, cracks or extra punctures in the cap, new caps or a different manufacturer of cap needs to be purchased. Contact Rudolph or its Agents for additional information or cap orders.

Loose or cross threaded Fittings

Check to ensure all sample line fittings are straight/tight and secure for every instrument in the system.

Sample to Viscous

The sample could not load because the sample itself was too viscous for the sample loading method used. Some samples may need a special method due to their differences in viscosity compared to other samples measured.

Sample Lines clogged

A sample was run through the system that may have solidify due to temperature or solidified from the rinse solutions, IE: Using Acetone to clean out a sugar sample will solidify the sugar in the sample lines. The affected lines need to be removed, cleaned or replaced.

Light Gate calibration

There may have been an issue with the light gate from the previous sample measured. Perform a system clean and a new permanent light gate calibration. Refer to the user manual for instructions to perform the calibration

Light Gate tripped prematurely

There may be leftover residue of cleaning solutions left in the line from the previous sample. When this happens the light gate will be prematurely tripped thinking the sample has been fully loaded. Possible causes of this is a too short dry time for the rinse solutions, wrong rinse solutions or rinse solutions bottles were accidentally swapped in the rinse rack during re-filling.

Needle Alignment not correct

The needle ideally should be puncturing the cap or entering the test tube close to the center. Also, for gas displacement applications, the gas displacement hole on the side of the needle must be positioned completely under the test tube cap. Refer to the user manual for needle alignment procedures

Sample entering the vent (GD) line during sample load

Sample should never enter the needle vent/gas displacement line. If sample is entering this line, the most common cause is too much sample in the test tubes. The gas displacement hole should never be submerged in sample. Recommended to never fill the test tubes more than 75% full.

Pump faulty

If either the vacuum pump or air pump has failed the sample will not load or will not be cleaned. You should hear the pump trying to load the sample. If you do not hear the pump the pump may have failed. NOTE: At first the pumps may be quite due to low speed settings. As the pump speed increases you should be able to hear the pump so wait for a minute or so for the pump sound during sample load or clean. If you suspect a pump failure, contact Rudolph or its Agents for service options

Valve faulty

If all else was checked above you may have a faulty valve and will require service. Contact Rudolph or its Agents for service options

Cause/Reason

Solution

Rinse error, rinse

solution low

Check rinse bottles for enough rinse solutions and fill if needed.

Rinse Error, no rinse solution

Clogged rinse bottle filters. The rinse bottle solutions should be changed periodically and the rinse solutions must be pure and of high quality. If inadequate rinse solutions are used, the filters in the rinse bottles can be clogged causing the rinse solution to not flow.

Rinse Error, Rinse Gate blocked

There is a rinse light gate in the valve box. If this rinse gate is blocked the rinse solution will not pull rinse. Perform a system dry and new permanent light gate calibration, refer to the user manual.

NOTE: If after performing a system dry and new light gate calibration, there may be an issue with a valve or the rinse light gate itself and service will be required. Contact Rudolph or its Agents for service options

Clogged Valve box valve

A valve in the valve box can get clogged if the rinse solution being used is inadequate, for instance, non-laboratory grade Acetone or using tap water instead of distilled/purified water. Also, if the rinse bottle filters were removed. The valve box values are rated for rinse solutions less than 20 microns.

Clogged Sample Lines

A sample was run through the system that solidified. The rinse solutions cannot flow through the clogged lines. The affected lines need to be removed, cleaned or replaced.

Previous Sample was too Viscous

If the previous sample was too viscous and the system cannot remove this sample during the rinse cycle a rinse error will occur. Perform a few system dry’s until the previous sample gets pushed to the waste station.

Wrong Rinse Fluids used

Depending on what type of samples that are measured in the system, you may need specific rinse methods for certain samples. If a sample is trying to be cleaned with a wrong rinse method this will cause a rinsing issue. Repeat the cleaning process with the correct rinse method or change the rinse solution to something the sample is soluble with

Sample/Rinse solutions entering the vent (GD) line during cleaning cycle

If sample is entering the vent line during sample blowout, the most common cause is the return sample to vial speed is set too high, lower the return to vial speed.

If the rinse solutions are entering the vent line during a cleaning cycle, the needle position is too low in the waste station during the cleaning cycle. Adjust either DR1- 2-3 as per the user manual to ensure the vent line is not in in the waste station during the cleaning cycle and is above the internal white O-ring insolating the vent line from cleaning solutions. .

Cause/Reason

Solution

Waste tube

The waste tube from the R837 to the waste container is kinked or clogged and needs to be inspected and replaced if needed.

Waste Container

The waste container is too full and needs to be emptied. Also some waste containers have a valve where the waste line is connected too, this can become sticky or not open properly, the value needs to be inspected and replaced if needed

Needle Cup O-ring

faulty

If the needle cup O-ring (red or black) becomes faulty sample or rinse solution will leak from the waste station because of a faulty seal. Replace the O-ring as needed

Internal Needle    O- ring loose or damaged

Sample or rinse may leak from the top of the needle block. In the needle cup assembly there is a white Teflon O-ring that works as a needle squeegee. If leaking occurs from the top of the needle block assembly during a system clean, the needle cup assembly may need to be tightened by hand or the O-ring replaced. Contact Rudolph or its Agents for service options

Needle alignment in waste station

First, make sure the R837 is on a flat stable bench. When the needle positions itself on the waste station, the alignment must be correct. Any gaps from left to right or front to back will cause leaking during the clean cycle.

If the alignment is off in the front or back, this can be corrected in the software needle alignment calibration, see the user manual for calibration instructions. If the alignment is off left or right, you will need to adjust the needle tower alignment screws to correct, contact Rudolph or its Agents for instructions or service options.

Cause/Reason

Solution

T-Axis errors (Theda)

First step in receiving a Theda axis error is to initialize the automation. DIRECT CONTROL – INITIALIZE AUTOMATION or DIRECT CONTROL – INSTRUMENT - INITIALIZE AUTOMATION

Most common cause of a T-Axis error is the sample platter was manually spun or bumped into. Initialize the automation will resolve this error. The sample plater is not designed to be manually turned to load sample test tubes. The software is designed to rotate the platter to insert test tubes. Refer to the user manual for proper test tube loading in the platter.

Other causes is sample has leaked onto the Theda bearings or the encoder sensor / motor has failed.

Contact Rudolph or its Agents for instructions or service options if performing an automation initialization does not resolve the T-Axis errors.

Cause

Solution

R-Axis Errors (Needle In/Out issues)

First step in receiving an R-Axis error is to initialize the automation. DIRECT CONTROL – INITIALIZE AUTOMATION or DIRECT CONTROL – INSTRUMENT - INITIALIZE AUTOMATION

The In/Out motion of the needle is calibrated so the needle positions properly above the sample tube and the waste station. Any restrictions for the In/Out movement will cause an R-Axis error to occur.

Most common cause of R-Axis errors is a sticky sample has somehow made it on the tooth track that moves the needle back and forth. The tooth track would need to be cleaned and re-installed. 

Other causes are a flag sensor board has failed or the motor has failed. Contact Rudolph or its Agents for instructions or service options if performing an automation initialization or cleaning the tooth track does not resolve the R-Axis errors.

Cause

Solution

Z-Axis Errors (Needle Up/Down)

First step in receiving an R-Axis error is to perform a clean and dry then initialize the automation.

DIRECT CONTROL – SYSTEM CLEAN. Once the clean is complete, DIRECT CONTROL – INITIALIZE AUTOMATION

The Up/Down motion of the needle is calibrated so the needle positions goes up to the correct height over the sample tube and waste station. 

Z-Axis errors can occur if the worm gear is too dirty and is causing restrictions when moving up and down. The worm gear would need to be cleaned and more grease applied.

Other causes are the worm gear pulley has come loose, a flag sensor board has failed or the motor has failed. Contact Rudolph or its Agents for instructions or service options if performing an automation initialization or cleaning the worm gear does not resolve the Z-Axis errors.

Cause

Solution

Valve Faults

First step in receiving any Valve Fault error is to perform a clean and dry then initialize the automation.

DIRECT CONTROL – SYSTEM CLEAN. Once the clean is complete, DIRECT CONTROL – INITIALIZE AUTOMATION

Other causes could be an internal loose connection to a valve, sample has solidified in a valve or a faulty valve itself. Contact Rudolph or its Agents for instructions or service options if performing an automation initialization does not resolve the Valve fault.