acl-top service manual.book - claudio alvarez top.pdfacl-top service manual.book - claudio alvarez

ACL-TOPService Manual

PN 28166900 Rev 03October, 2006

IL, ACL-TOP, and ACL-TOP CTS are a trademark of Instrumentation Laboratory.© Instrumentation Laboratory, 2006.

This publication and any and all materials (including software) concerning the products of IL Coagulation Systems are of proprietary nature and are communicated on a strictly confidential basis; they may not be reproduced, recorded, stored in a retrieval system, transmitted or disclosed in any way and by any means whatsoever, whether electronic, mechanical through photocopying or otherwise, without IL’s prior written consent.

Information contained herein is believed to be accurate. In any event, no responsibility, whether express or implied, is assumed by IL for or in connection with the use thereof, or for infringement of any third party rights which might arise therefrom, or from any representation or omissions contained therein. Information is subject to change and/or update without notice.

Contents

Table of Contents

Chapter 1 Instrument Overview Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Instrument Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

AM Safety Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 AM Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 Cuvette Loading Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 Cuvette Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5 Bar Code Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6 Sample Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7 Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8 Closed Tube Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9 Diluent Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11 Reagent Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12 Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13 Probe Syringes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13 Incubators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14 Optical Reading Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14 System Fluids – Rinse and Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14 Fluid Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16 Waste Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17 Cuvette Waste Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17

Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18 Coagulometric (Turbidimetric) Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18 Chromogenic (Absorbance) Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19 Immunological Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19

Chapter 2 Pre-Installation and Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

Reception Area and Transportation Pathway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Working Area / Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Ambient Conditions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4

DMS / LIS Interface Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5 Site Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5 Software Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13

Software Version Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13 Touch Screen Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14

ACL-TOP Service Manual 1

Contents

Ghost Image Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14 Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16

ACL TOP Pre - Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17 Start Up Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18

Chapter 3 Troubleshooting Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Warning-Level Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Error-Level Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

System Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 General Log List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 Temperature Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 SW Version Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10 Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11 Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12 Alarms Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 130

Chapter 4 Enclosure/Chassis Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Sample and Reagent Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4

Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

Cover Status Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5 Door Lock/Unlock Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7

Sample Door Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Reagent Door Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7

Locking/Unlocking the Sample and Reagent Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Removal/Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7

Sample Door Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 Sample Door Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8 Sample Door Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9

Reagent Door Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10 Reagent Door Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10 Reagent Door Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10

Sample Door Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10 Sample Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 Sample Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13

Reagent Door Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 Reagent Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13 Reagent Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15

2 ACL-TOP Service Manual

Contents

Top Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 Top Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 Top Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16

Front Panel Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16 Front Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16 Front Panel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19

Monitor Control Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19 Monitor Control Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19 Monitor Control Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20

Sample Area Interior Skins Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20 Sample Area Interior Skins Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20 Sample Area Interior Skins Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22

Inner Left Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22 Inner Left Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22 Inner Left Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23

Left Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23 Left Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23 Left Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24

Reagent Area Interior Skins Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24 Reagent Area Interior Skins Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24 Reagent Area Interior Skins Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26

Inner Right Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 Inner Right Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26 Inner Right Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27

Right Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28 Right Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28 Right Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29 Center Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29

Center Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29 Center Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30 Upper Back Wall Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30 Lower Back Wall (Power Supply Assembly) Removal/Replacement . . . . . . . . . . . . . . . . . . . . . 4 - 30

Chapter 5 Processor / Software Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Analytical Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

Theory of Operation/Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 Upgrades: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7 Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9

LIS Specifications (ASTM E 1381-95 Protocol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11

Chapter 6 Power Management Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4

Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4


Contents

Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5 Fuse Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6

Fuse Board Diagram for the Non-CTS TOP Model (Cavro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6 Fuse Board Diagram for the CTS TOP Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10 Volt-Amps Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11

Volt-Amps Specifications for the TOP Analytical Module (AM) . . . . . . . . . . . . . . . . . . . . . . 6 - 11 Volt-Amps Specifications for the TOP Computer Module (CM) . . . . . . . . . . . . . . . . . . . . . . 6 - 12 Volt-Amps Specifications for the TOP Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12

Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12 Verification and Adjustment of the 5Volt Rail on the ACL TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14 ORU Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15 Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16 Arm Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17

Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18 Power Entry Module Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18

Power Entry Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18 Power Entry Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18

Non-adjustable Power Supply Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Non-adjustable Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19 Non-adjustable Power Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20

Fuse Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21 Fuse Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21 Fuse Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22

Chapter 7 Fluid Movement Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3

Aspirating and Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 The Precision Fluidic Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3

Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4 Syringe Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5 Syringe Pump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 Cavro Syringe Pump Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8 Hamilton Syringe Pump Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9 Syringe Pump Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Probes and Precision Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12

Probes and Tubing, non-CTS, Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12 Probes and Tubing, CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13

The Bulk Fluidic Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Onboard Rinse Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14 Rinse Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15 Rinse and Clean Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17

Rinse/Clean Cups, non-CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 Rinse/Clean Cups, CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18

Clean Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19 Clean Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 CTS Bulk Fluids Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22


Contents

Air Pump/Air Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23 Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24

CTS Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25 PCB Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25

Fluidic Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Fluidics Driver/Connector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Fluidic LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26

Fluidics Diagrams for the TOP Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26 Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29

Syringe Pump Addressing and Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29 Priming the Rinse System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30 Priming the Clean System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30 Performing the Rinse Flow Rate Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31 Verifying the Fluidics after Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 32 Adjusting the CTS Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35 Clean Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37 Clean Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37

The Select Pull-down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37 The Set Valve Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38 The Duration Selection Field and the Start and Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . 7 - 38

Stirring Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38 Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39 Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39 Shipping Preparation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39 Fluid Precision Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40

Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43 Cavro Syringe Pump Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43

CTS Sample Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43 CTS Sample Cavro Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45 Base TOP Sample Arm Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47 Base TOP Cavro Sample Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49 Reagent Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51 Reagent Cavro Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53

Cavro Syringe Tip Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Cavro Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55 Cavro Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 56

Cavro Syringe Valve Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58 Cavro Syringe Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58 Cavro Syringe Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 59

Hamilton Syringe Pump Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 60 CTS Sample Hamilton Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 60 CTS Sample Hamilton Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 62 Base TOP Hamilton Sample Arm Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64 Base TOP Hamilton Sample Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67 Reagent Hamilton Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69 Reagent Hamilton Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 71

Hamilton Syringe Tip Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 74 Hamilton Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 74 Hamilton Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 76

Hamilton Syringe Valve Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78 Hamilton Syringe Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78 Hamilton Syringe Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79 Rinse Pump Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80


Contents

Rinse Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80 Rinse Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81

Precision Tubing Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82 Precision Tubing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82 Precision Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 85

Chapter 8 Robotic XYZ Arms Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7

Cavro Arms (Used on ACL-TOP model 0000280000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7 X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7 Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11 Arm Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12 X, Y, Z Travel Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14 CCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14 ADRI-9 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15 Probe Interconnect PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17 DC Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17 Heater Probe PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17

CTS Sample Arm (Used on ACL-TOP model 0000280020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18 X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18 Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21 Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23 Arm Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24 CTS Probe Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27

PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27 XYZ Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28 Y Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28 X Axis Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29 Z Axis Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30

Probe Alignment and Coordinates Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31 Reference Point Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32 Reference Point Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34

Measurement of the Reference Screw Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34 Waste stations – Reagent and Cavro Arm Sample Probes . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35 Waste Stations – CTS Sample Arm Sample Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36

Air gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36 Coordinates File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36 Coordinate Calculation and Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37 CTS Instruments – Alignment of Piercer Probe Foot to the Wash Station . . . . . . . . . . . . . . . . . 8 - 37

Probe and Arm Initialization Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40 Probe and Arm Initialization on CTS Sample and/or IL Double Arm . . . . . . . . . . . . . . . . . . . . . 8 - 40 Probe and Arm Initialization on CTS Sample Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 42 IL Double Arm Homing Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43 Probe and Arm Initialization on Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44 Coordinates Checking Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45 Tube Release Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 46


Contents

Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47 Verifying a CTS Arm or a Universal Dual Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47 Alidum Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47 Probes Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47

Initialize All Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Home All Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Disable Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Disable Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Coordinate Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49 Set Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50 LLD Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50 Rinse Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 51 Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 52 Move Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53

Probe Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55 Probe LLD Error Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57

Cavro Probe Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57 Universal Arm Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 58

Sample Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60 Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60 Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60 LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60

Intermediate Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61 Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61 Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61 LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61

Start Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62 Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62 Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62 LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62

ZDAC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62 Removal/Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63

CTS Arm (283777-00) Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Closed Tube Sample (CTS) Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63 Closed Tube Sample (CTS) Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 67

Reagent IL Double Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 72 Reagent IL Double Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 72 Reagent IL Double Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75

Cavro Sample Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79 Cavro Sample Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79 Cavro Sample Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81

Cavro Reagent Arm Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85 Cavro Reagent Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85 Cavro Reagent Arm Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87

Individual Cavro Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95 Individual Cavro Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95 Individual Cavro Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95

Cavro Arm Insulation Block/Cable Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . 8 - 96 Insulation Block/Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96 Insulation Block/Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96


Contents

Cavro Arm Flex Cable Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97 Cavro Arm Flex Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97 Cavro Arm Flex Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97

Cavro Arm Y- and Z-axis Optical Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98 Y- and Z-axis Optical Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98 Y- and Z-axis Optical Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99

Cavro Arm X-Axis Optical (SLD) Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99 X-Axis Optical (SLD) Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99 X-Axis Optical (SLD) Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 100

Cavro Arm ALIDUM Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 100 ALIDUM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 100 ALIDUM Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 101

Cavro Arm ADRI-9 Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102 ADRI-9 Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102 ADRI-9 Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103

CCU-9000 Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103 CCU-9000 Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103

CAVRO Arm Belt Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105 CAVRO Arm X-Axis Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105 CAVRO Arm X-Axis Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 106 CAVRO Arm Y-Axis Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107 CAVRO Arm Y-Axis Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107

Chapter 9 Cuvette Handling System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4

Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4 Gripper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5 Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5 Shuttle Pivot Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6

Cuvette Loader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7 Transport Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 Indexer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9 Pusher Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10

CTS Hold and Incubator #2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 CTS Incubator #1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11 Optical Read Unit (ORU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11

Reader Head Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12 Emitter Subassembly and Fiber Bundle Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13

Sensors in the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13 Cuvette Loader Sensors and How They Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13 Cuvette Shuttle Sensors and How They Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13

Shuttle Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13 Gripper Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14 Cuvette In Slot Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Shuttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Cuvette in Shuttle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Cuvette Loader PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16 Cuvette Shuttle Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16


Contents

Cuvette Handling/Rack Handling X-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16 ORU Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16 ORU Detector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17 ORU Emitter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17

Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18

Shuttle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 Disable Shuttle Motors Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 Initialize Shuttle Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19 Cuvette Shuttle Temperature Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20

Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20 Grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Clear All Cuvettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21

Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21 Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22

Start, Stop, and Clear Accumulator Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 Virtual LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22 Other Sensors in the Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23

Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23 Initialize Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23 Move Indexer (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23 Move Indexer (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24 Up Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24 Down Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24 Virtual LEDs in the Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24

Cuvette Shuttle and Loader Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26

Cuvette Loader Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26 Cuvette Loader Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26 Loader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26

CTS Hold/Incubator #2 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26 CTS Hold/Incubator #2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27 CTS Hold/Incubator #2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27

Incubator #1 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27 Incubator #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27 Incubator #1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28

Optical Reading Units Cradle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28 Cuvette Shuttle Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28

Cuvette Shuttle Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28 Cuvette Shuttle Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30

Cuvette Shuttle Y-Axis Motor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30 Y-Axis Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30 Y-Axis Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32

Cuvette Shuttle Solenoid Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34 Aligning the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35

Cuvette Shuttle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35 Z Height and Tilt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 36 Y Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37 X Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38


Contents

Chapter 10 Reaction Detection Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1

ORU Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1 Emitter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 Optical paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 Detector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 ORU Light Generation, Flow and Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4

Adjustments/Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6 Verifying the ORU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6 Testing/Correcting Voltage Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14 Enabling ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17 Testing/Correcting Dark Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19 Testing/Correcting Optical Blanking Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 22 Temperature Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 23

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 24 ORU Diagnostics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 24

Optical Blanking Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25 ORU Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 26 ORU Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 26 Optical Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 27 ORU Air Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 27

Temperatures Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 28 Reference Readings Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29 Dark Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29

Linearity Test Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 30 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31

Removing/Replacing the ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31 Removing the ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31

Installing the ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 33 Removing/Installing the Emitter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36

Removing the Emitter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36 Connecting the ORU for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 38 Tuning ORU Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 43 Installing the ORU Optics Alignment Kit (PN 280033-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 45

Chapter 11 Rack Handling Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4

Sample Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4 Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5 Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6

Reagent Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7 Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8 Reagent Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9 Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9


Contents

Reagent Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10 Bar Code Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11

Rack Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11 Rack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 Remote Travel Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 Bar Code Reader Travel Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 Bar Code Reader Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13 Bar Code Reader Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13 Bar Code Reader Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13

Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14

Rack Handling Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14 Racks area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16

Encoder Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16 Perform Loop Back Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16 Track Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17 Bar Code Label Reading and Rack Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17

Reagent temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17 Stirrers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17

Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 18 Sample Module Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 18

Sample Module Assembly Removal (Both CTS and non-CTS models) . . . . . . . . . . . . . . . . . . 11 - 18 Sample Module Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19

Sample Presence PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19 Sample Presence PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19 Sample Presence PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20

Sample Flag Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20 Sample Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20 Sample Flag Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21

Reagent Module Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21 Reagent Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21 Reagent Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24

Reagent Drain Tube Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24 Reagent Module Tubing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24 Reagent Module Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25

Reagent Presence PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26 Reagent Presence PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26 Reagent Presence PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27

Reagent Cooling with Fan Speed Controller PCB Removal/Replacement . . . . . . . . . . . . . . . . . . 11 - 27 Reagent Cooling with Fan Speed Controller PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27 Reagent Cooling with Fan Speed Controller PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27

Reagent Flag Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27 Reagent Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27 Reagent Flag Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28

Bar Code Reader Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28 Bar Code Reader Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28 Bar Code Reader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30

Bar Code Reader Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30 Bar Code Reader Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30 Bar Code Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 32

RTI PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33 RTI PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33 RTI PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33

X Axis PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 34


Contents

X Axis PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 34 X Axis PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 35 Earlier version X Axis PCB Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 35

Encoder Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36 Encoder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36 Encoder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37

Curtain Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37 Curtain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37 Curtain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 38

Bar Code Reader Drive Belt Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 40 Bar Code Reader Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 40 Bar Code Reader Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 41

Bar Code Reader Drive Motor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 42 Bar Code Reader Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 42 Bar Code Reader Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 43

Chapter 12 Thermal Control Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2

Thermal Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3 Thermal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3 Cuvette Shuttle Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4 Incubator #1 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5 Incubator #2 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 6 Optical Reading Unit (ORU) Cradle Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7 Reagent Module Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7

Reagent Cooling with Fan Speed Controller PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9 Reagent Probes for Cavro Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9 Reagent Probes for Universal Arms Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10 Cavro Sample Probe Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11 CTS Sample Probe Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11

Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11 ThermalCal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12 Mode Selection and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14 Temperature Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14 ACL-TOP Connection and Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14 Calibration Status and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15 Display Coefficients Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19 Other Handled Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20

ThermalCal Instructions for Adjusting Coefficients/Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21 Load the ThermalCal Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21 Test the Thermal Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23 Save the Coefficients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 29

Inputting Thermal Coefficients using ThermalCal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 31 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 35

Temperature Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 37 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 41


Contents

Chapter 13 Waste Management System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3

Bulk Fluid Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3 Sample and Reagent Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3

Reagent Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4 Sample Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 5 Waste Fluid Removal in the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 6

Cuvette Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7 Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9

Fluidics Connector/Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9 Fluidic LED Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9 Cuvette Waste Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9

Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 10 Verification of the Bulk Fluid Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 10 Verification of the Cuvette Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 10

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 11 Bulk Fluid Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 11 Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13 Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13 Diagnostics for the Cuvette Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14 Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15

Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15 Clear All Cuvettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16

Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16 Start, Stop, and Clear Accumulator Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16 Virtual LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17 Other Sensors in the Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17

Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17 Waste Shelf Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17

Waste Shelf Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17 Sample Accumulator Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 20

Sample Accumulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 21 CTS Accumulator Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 22

CTS Accumulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23 Reagent Accumulator Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23

Reagent Accumulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25 Waste Pump Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25

Waste Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25 Waste Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 26

Chapter 14 Preventive Maintenance Base TOP Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 1 CTS PreventiveMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 27

Chapter 15 CTS Piercer


Contents

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 1 Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 2 Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4

Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5 CTS X Axis Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5 CTS Controller Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5 CTS Y Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5 CTS Z Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6 CTS Travelling Signal Interconnect) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6

CTS Piercer Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6 Piercer and Sample Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6 Probe Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7 Sample and Piercer LLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8 Probe Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8 Piercer Lock/Lock Solenoid/Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 9 Cap Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10 Piercer Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10 Operation of the CTS Piercer Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 11

Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 13 Initialize Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15 Adjust Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15 Disable CTS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17 Piercer Loop Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17 Foot Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17 Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17 Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18

Air Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18 Air Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19 Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19

Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19 Probe-n-Seal Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19

Probe-n-Seal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19 Probe-n-Seal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21

Piercer Probe Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24 Piercer Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 25 Piercer Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 26

Telescoping CTS Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 27 Telescoping CTS Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 27 Telescoping CTS Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30

Chapter 16 Schematics Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1

Chapter 17 Assembly Drawings/Part Numbers Saleable Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 1 Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 8


List of IllustrationsChapter 1 - Instrument OverviewFigure 1-1. ACL TOP Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2Figure 1-2. Analytical Module with Open Safety Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3Figure 1-3. Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4Figure 1-4. Cuvette Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5Figure 1-5. Cuvette Strip being picked up by Cuvette Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6Figure 1-6. Bar Code Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7Figure 1-7. Sample Area with Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8Figure 1-8. Sample Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8Figure 1-9. Sample Arm CTS probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9Figure 1-10. CTS Cap Piercing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9Figure 1-11. CTS Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10Figure 1-12. Diluent Area with Sample Probe (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11Figure 1-13. Diluent Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11Figure 1-14. Reagent Area Showing Intermediate (left) and Start (right) Reagent Arms . . . . . . . . . . . . 1 - 12Figure 1-15. Reagent Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12Figure 1-16. Probe (in foreground) and Syringe (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13Figure 1-17. Sample Probe and Incubator Slots (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14Figure 1-18. Rinse (left) and Clean Bottles on ACL TOP with Fluid Waste Container Underneath . . . . 1 - 16Figure 1-19. Cuvette Waste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17Figure 1-20. Cuvette Waste Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18

Chapter 2 - Pre-Installation and InstallationFigure 2-1. Duch Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5Figure 2-2. Shipping Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6Figure 2-3. Reagent Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7Figure 2-4. Reagent Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7Figure 2-5. Sample/Reagent Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8Figure 2-6. Probe/Arm Tie Wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8Figure 2-7. TOP Sample Arm Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9Figure 2-8. CTS Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9Figure 2-9. CTS Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10Figure 2-10. CTS Assy. tie wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10Figure 2-11. Shuttle tie wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11Figure 2-12. Monitor Arm Mounting Studs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11Figure 2-13. Computer/Monitor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12Figure 2-14. System Software Versions Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13Figure 2-15. Software Version Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13

Chapter 3 - TroubleshootingFigure 3-1. Maintenance Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3Figure 3-2. The Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4Figure 3-3. General Log List Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5Figure 3-4. General Log List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6Figure 3-5. General Log Entry Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7Figure 3-6. Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8Figure 3-7. Temperature Tab on Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9


Figure 3-8. SW Versions on Instrument Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10Figure 3-9. Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11Figure 3-10. Status Tab on Statistics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12Figure 3-11. Alarms Tab on Statistics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

Chapter 4 - Enclosure/ChassisFigure 4-1. ACL-TOP Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2Figure 4-2. ACL-TOP Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4Figure 4-3. Diagnostics Screen, Controllers, Covers and Racks Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6Figure 4-4. Cover Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7Figure 4-5. Sample Door Lower Right Sensor (upgradable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9Figure 4-6. Sample Door Upper Right Sensor (current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9Figure 4-7. Reagent Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10Figure 4-8. Sample Door Hinge Attaching Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11Figure 4-9. Sample Door ground Wire/Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12Figure 4-10. Sample Door Hinge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12Figure 4-11. Flag/Ground Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13Figure 4-12. Reagent Door Left Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14Figure 4-13. Reagent Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14Figure 4-14. Reagent Door Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15Figure 4-15. Top Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16Figure 4-16. Front Panel Lower Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17Figure 4-17. Front Panel Upper Right Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17Figure 4-18. Front Panel Center Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18Figure 4-19. ACL-TOP Enclosure Upper Left Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18Figure 4-20. Front Panel Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19Figure 4-21. Monitor Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20Figure 4-22. Sample Module Interior Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21Figure 4-23. Interior Skin Ground Lug/Snap Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21Figure 4-24. Brackets for Snap Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22Figure 4-25. Sample Side Upper Skin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22Figure 4-26. Inner Left Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23Figure 4-27. Left Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24Figure 4-28. Reagent Area Inner Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25Figure 4-29. Interior Skin Ground Lug/Snap Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25Figure 4-30. Brackets for Snap Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26Figure 4-31. Upper Skin Above the Reagent Side Robotic Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27Figure 4-32. Inner Right Skin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27Figure 4-33. Right Skin Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28Figure 4-34. Right Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29Figure 4-35. Center Skin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30

Chapter 5 - Processor / SoftwareFigure 5-1. System Software Version Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1Figure 5-2. Software Version Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2Figure 5-3. Software Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3Figure 5-4. Processor Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6Figure 5-5. Software, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8Figure 5-6. Controller Status Area of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9Figure 5-7. Software Version Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10


Chapter 6 - Power ManagementFigure 6-1. Layout of the Power Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2Figure 6-2. Interconnect Diagram for Power Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3Figure 6-3. The Power Entry Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4Figure 6-4. The Power Supply Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5Figure 6-5. The +5V/+15V/-15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5Figure 6-6. The +24V/+28V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6Figure 6-7. Fuse Diagram for the ACL TOP/Cavro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7Figure 6-8. Fuse Diagram for the CTS TOP Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9Figure 6-9. Power Supply Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13Figure 6-10. +5/+15/-15V Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13Figure 6-11. The Voltages Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14Figure 6-12. The ORU Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15Figure 6-13. The Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16Figure 6-14. The Arm Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17Figure 6-15. Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18Figure 6-16. Non-Adjustable Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19Figure 6-17. Wire Terminals on a +5/+15/-15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20Figure 6-18. The Power Supply Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20Figure 6-19. The Fuse Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22

Chapter 7 - Fluid MovementFigure 7-1. Layout of the Fluid Movement System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1Figure 7-2. Fluid Movement System Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2Figure 7-3. Cavro XP3000 Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4Figure 7-4. Hamilton PSD4 Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5Figure 7-5. Cavro Syringe Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6Figure 7-6. Hamilton Syringe Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6Figure 7-7. Syringe Pump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7Figure 7-8. Syringe Valve Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7Figure 7-9. Cavro Syringe Pump Communication/Valve Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8Figure 7-10. Cavro Syringe Pump Lower Jumpers and Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9Figure 7-11. Hamilton Syringe Pump Jumpers/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10Figure 7-12. The Probe for the non-CTS instrument with Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12Figure 7-13. The Onboard Rinse Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14Figure 7-14. Rinse, Clean Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15Figure 7-15. Rinse Pump Box Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16Figure 7-16. Cavro Sample/Reagent Rinse/Clean Cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17Figure 7-17. CTS Sample Rinse/Clean Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18Figure 7-18. CTS Reagent Rinse/Clean Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18Figure 7-19. The Clean Fluid Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20Figure 7-20. Clean Fluid Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20Figure 7-21. Clean Fluid LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21Figure 7-22. Clean Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21Figure 7-23. CTS Sample Clean Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22Figure 7-24. CTS Bulk Fluids Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23Figure 7-25. CTS Air Pump/Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23Figure 7-26. Air Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24Figure 7-27. Location of Fluidics Controller/Connector PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25Figure 7-28. Fluidic LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26Figure 7-29. CTS ACL-TOP Fluidic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27


Figure 7-30. Non-CTS Fluidic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28Figure 7-31. Maintenance Screen Run Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30Figure 7-32. Maintenance Screen Run Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31Figure 7-33. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31Figure 7-34. Flow Rate Test Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31Figure 7-35. Flowchart for Fluidic Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33Figure 7-36. Sensor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 34Figure 7-37. Fluids Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 36Figure 7-38. Clean Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37Figure 7-39. Clean Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37Figure 7-40. Stirring Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38Figure 7-41. Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39Figure 7-42. Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39Figure 7-43. Shipping Preparation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40Figure 7-44. Fluid Precision Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40Figure 7-45. Sample Cavro Syringe Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43Figure 7-46. CTS Fluidics Mounting (Cavro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 44Figure 7-47. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45Figure 7-48. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 46Figure 7-49. Cavro Syringe Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 46Figure 7-50. Cavro Sample Arm Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47Figure 7-51. Cavro Sample Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 48Figure 7-52. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 48Figure 7-53. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49Figure 7-54. Sample Arm Cavro Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50Figure 7-55. Sample Arm Cavro Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 50Figure 7-56. Reagent Cavro Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51Figure 7-57. Reagent Arm Cavro Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 52Figure 7-58. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 52Figure 7-59. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53Figure 7-60. Reagent Arm Cavro Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 54Figure 7-61. Reagent Cavro Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 54Figure 7-62. Removing the Cavro Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55Figure 7-63. Cavro Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 56Figure 7-64. Cavro Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57Figure 7-65. Cavro Syringe Valve Assembly/Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 57Figure 7-66. Cavro Syringe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58Figure 7-67. Cavro Syringe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 59Figure 7-68. Hamilton CTS Sample Syringe Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 60Figure 7-69. CTS Fluidics Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 61Figure 7-70. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 62Figure 7-71. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 63Figure 7-72. Hamilton Syringe Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64Figure 7-73. Hamilton Sample Arm Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 65Figure 7-74. Hamilton Sample Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 66Figure 7-75. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 66Figure 7-76. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67Figure 7-77. Hamilton Sample Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68Figure 7-78. Hamilton Sample Arm Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 68Figure 7-79. Hamilton Reagent Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 70Figure 7-80. Reagent Arm Hamilton Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 70Figure 7-81. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 71Figure 7-82. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 72Figure 7-83. Reagent Arm Hamilton Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 73


Figure 7-84. Reagent Hamilton Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 74Figure 7-85. Removing the Hamilton Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75Figure 7-86. Hamilton Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 76Figure 7-87. Hamilton Syringe Tip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77Figure 7-88. Hamilton Syringe Valve Assembly/Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78Figure 7-89. Hamilton Pump Syringe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79Figure 7-90. Hamilton Syringe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80Figure 7-91. Rinse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81Figure 7-92. Rinse Pump Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81Figure 7-93. Rinse Pump Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82Figure 7-94. The Probe Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 83Figure 7-95. Precision Tubing Strain Relief on CTS Sample Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 83Figure 7-96. Precision Tubing Strain Relief on Base TOP Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84Figure 7-97. Precision Tubing Strain Relief on Intermediate (R1) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84Figure 7-98. Precision Tubing Strain Relief on Start (R2) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 85Figure 7-99. Dressing the Tubing on CTS Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 86Figure 7-100. Dressing the Tubing on Base TOP Sample Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 87Figure 7-101. Dressing the Tubing on Intermediate (R1) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 88Figure 7-102. Dressing the Tubing on Start (R2) Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 88

Chapter 8 - Robotic XYZ ArmsFigure 8-1. XYZ Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1Figure 8-2. Layout of the Robotic XYZ Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2Figure 8-3. Interconnect Diagram - CTS/IL Double Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4Figure 8-4. Interconnect Diagram - CTS/IL Double Reagent Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5Figure 8-5. Interconnect Diagram - Sample-side Cavro Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6Figure 8-6. Interconnect Diagram - Reagent-side Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6Figure 8-7. ACL-TOP with Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7Figure 8-8. X Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8Figure 8-9. Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8Figure 8-10. X Axis Rollers and Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8Figure 8-11. Motor, drive belt and encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9Figure 8-12. X Axis Motors - Reagent Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9Figure 8-13. X Axis Belts - Reagent Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10Figure 8-14. Y Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10Figure 8-15. Y Axis Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11Figure 8-16. Z Axis Motor, Pulley and Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11Figure 8-17. Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12Figure 8-18. X Limit Flags and Travel Limit Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13Figure 8-19. Y Limit Flag and Travel Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14Figure 8-20. Central Control Unit (CCU) for Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15Figure 8-21. ADRI-9 PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16Figure 8-22. ADRI 9 Dip Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16Figure 8-23. Heater Probe PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18Figure 8-24. ACL-TOP CTS with CTS Sample and IL Double Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18Figure 8-25. X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19Figure 8-26. X Axis Drive Belt (Sample Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19Figure 8-27. X Axis Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20Figure 8-28. Reagent Side Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20Figure 8-29. Reagent Side X Axis Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21Figure 8-30. Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21Figure 8-31. Y Axis Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22


Figure 8-32. Y Axis Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22Figure 8-33. Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23Figure 8-34. CTS Piercer Z-Axis Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24Figure 8-35. Z Axis Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24Figure 8-36. CTS Sample and/or IL Double Arm X Flag and Travel Limit Sensors . . . . . . . . . . . . . . . . 8 - 25Figure 8-37. Flags and Sensors Between Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 26Figure 8-38. CTS Sample and/or IL Double Arm Y Flags and End of Limit Sensors . . . . . . . . . . . . . . . 8 - 26Figure 8-39. CTS Sample and/or IL Double Arm PCB Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28Figure 8-40. XYZ Controller Interface PCB, Y-Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29Figure 8-41. X Axis Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30Figure 8-42. Z-Axis Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31Figure 8-43. Reference Point Positions for Base TOP Instruments (Cavro Arms) . . . . . . . . . . . . . . . . . 8 - 33Figure 8-44. Reference Point Positions for CTS Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33Figure 8-45. Reference Screw Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34Figure 8-46. Well Area Cutout Reference Points for Non-CTS Probes. . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36Figure 8-47. Well Area Cutout Reference Points for CTS Probes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36Figure 8-48. CTS Sample and/or IL Double Arm Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40Figure 8-49. Probe Initialization for CTS Sample Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 41Figure 8-50. Probe Initialization for CTS Sample Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 42Figure 8-51. IL Double Arm Homing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43Figure 8-52. Probe Initialization for Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44Figure 8-53. Coordinates Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45Figure 8-54. Tube Release Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 46Figure 8-55. The Probes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 48Figure 8-56. LLD Area of Probes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50Figure 8-57. The Rinse Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 51Figure 8-58. The Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 52Figure 8-59. The Move Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 54Figure 8-60. Probe Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 56Figure 8-61. LLD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57Figure 8-62. DVM Probe Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57Figure 8-63. Probe Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 58Figure 8-64. Diagnostic Screen - Universal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 59Figure 8-65. CTS Bulk Fluid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63Figure 8-66. Sample CTS X Axis Driver Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 64Figure 8-67. Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 65Figure 8-68. CTS Fluidics Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 65Figure 8-69. Syringe Pump Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 66Figure 8-70. Air Tubing to Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 66Figure 8-71. CTS Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 67Figure 8-72. CTS Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 68Figure 8-73. CTS X Axis Driver PCB Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69Figure 8-74. Syringe Pump Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 69Figure 8-75. CTS Fluidics Module Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 70Figure 8-76. Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 70Figure 8-77. Rinse Input/Output Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71Figure 8-78. Connecting the Air Tubing to the Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 71Figure 8-79. Reagent Syringe Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 73Figure 8-80. Reagent IL Double Arms X Axis Driver PCB Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 74Figure 8-81. Reagent IL Double Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75Figure 8-82. Reagent IL Double Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75Figure 8-83. Reagent IL Double Arms X Axis Driver PCB Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 76Figure 8-84. Syringe Pump Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77Figure 8-85. Reagent Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 77


Figure 8-86. Reagent Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 78Figure 8-87. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 78Figure 8-88. Cable Clamp on Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79Figure 8-89. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80Figure 8-90. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80Figure 8-91. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81Figure 8-92. Ground Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81Figure 8-93. Ground Wire and Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 82Figure 8-94. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 82Figure 8-95. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 83Figure 8-96. Heater Probe PCB and Heater Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 83Figure 8-97. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84Figure 8-98. Coax Cable Connection to Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84Figure 8-99. Flex Cable to Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85Figure 8-100. Cable Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86Figure 8-101. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86Figure 8-102. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87Figure 8-103. Ground Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87Figure 8-104. Cavro Reagent Ground Wire, Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 88Figure 8-105. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 89Figure 8-106. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 89Figure 8-107. Probe Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 90Figure 8-108. Probe Top Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 90Figure 8-109. R2 Heater Probe PCB and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 91Figure 8-110. Coax Cable Connection to R2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 91Figure 8-111. R2 Flex Cable to Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 92Figure 8-112. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 92Figure 8-113. Flex Cable Routing for Left Reagent Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93Figure 8-114. Left Reagent Arm Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93Figure 8-115. Cable Bracket Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93Figure 8-116. Reagent Left Arm LLD Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 94Figure 8-117. Coax Cable Connection to Left Reagent Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 94Figure 8-118. Removing the Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95Figure 8-119. ALIDUM Coax Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96Figure 8-120. Installing the Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97Figure 8-121. Slotted Optical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98Figure 8-122. Optical Switch Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99Figure 8-123. ALIDUM Coax Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 101Figure 8-124. Diagram of the ADRI-9 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102Figure 8-125. SW Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103Figure 8-126. CCU-9000 Board Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 104Figure 8-127. Tensioner Screw Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105Figure 8-128. Belt Bracket Screw Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 106Figure 8-129. Y-Axis Tensioning Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107Figure 8-130. Y-Axis Belt Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107

Chapter 9 - Cuvette Handling SystemFigure 9-1. Layout of the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2Figure 9-2. Interconnect Diagram for the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3Figure 9-3. The Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4Figure 9-4. The Gripper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5Figure 9-5. The Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6


Figure 9-6. The Shuttle Pivot Assembly and the Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7Figure 9-7. The Cuvette Loader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8Figure 9-8. The Transport Deck Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9Figure 9-9. The Indexer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9Figure 9-10. The Cuvette Rotating Platform (in Horizontal Down Position) . . . . . . . . . . . . . . . . . . . . . . 9 - 10Figure 9-11. The Incubators and the Cuvette Indexer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11Figure 9-12. The ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12Figure 9-13. ORU Subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12Figure 9-14. The Left and Right End-of-limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14Figure 9-15. Sensors on the Front of the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14Figure 9-16. Sensors on the Rear of the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15Figure 9-17. The Cuvettes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18Figure 9-18. The Shuttle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19Figure 9-19. The Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22Figure 9-20. The Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23Figure 9-21. Cuvette Shuttle and Loader Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25Figure 9-22. The Cuvette Loader Assembly (seen from above and behind). . . . . . . . . . . . . . . . . . . . . . 9 - 26Figure 9-23. Captive Screws on the CTS Hold/Incubator #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27Figure 9-24. Captive Screws on the Incubator #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28Figure 9-25. The Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 29Figure 9-26. The Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30Figure 9-27. Y-Axis PCB Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31Figure 9-28. Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31Figure 9-29. Cables and Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32Figure 9-30. Motor Bracket Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32Figure 9-31. Cables and Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33Figure 9-32. Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33Figure 9-33. Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34Figure 9-34. Completed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34Figure 9-35. The Left and Right End-of-limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35Figure 9-36. Location of the Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 36Figure 9-37. The Z Height and Tilt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37Figure 9-38. The Y-Axis LED and the Turning Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38Figure 9-39. The Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38Figure 9-40. The X-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 40Figure 9-41. LEDs on the Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 40

Chapter 10 - Reaction DetectionFigure 10-1. ORU Light Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3Figure 10-2. Reaction Detection Block Diagram/Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5Figure 10-3. Overall ORU Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7Figure 10-4. Voltage Tab in Diagnostics Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8Figure 10-5. ORU Tab of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10Figure 10-6. ORUs Enabled Indicators Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11Figure 10-7. Dark Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11Figure 10-8. Reference Readings Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11Figure 10-9. Optical Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12Figure 10-10. Temperature Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12Figure 10-11. Air Blanking of All ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13Figure 10-12. Factor Diluent Blanking for all ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14Figure 10-13. Testing/Correcting Voltage Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15Figure 10-14. ORU Controller Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17


Figure 10-15. Emitter Voltage Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17Figure 10-16. Enabling ORUs Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 18Figure 10-17. ORU Enabling Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19Figure 10-18. Sample, Reagent, Diluent Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19Figure 10-19. Testing/Correcting Dark Readings Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 20Figure 10-20. Dark Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21Figure 10-21. ORU Head Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21Figure 10-22. Testing/Correcting Optical Blanking Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 22Figure 10-23. Temperature Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 23Figure 10-24. ORU Diagnostic Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25Figure 10-25. Optical Blanking Area of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 26Figure 10-26. Temperature Area of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 28Figure 10-27. Reference Readings Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29Figure 10-28. Dark Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 30Figure 10-29. ORU Linearity Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31Figure 10-30. ORU Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 32Figure 10-31. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 33Figure 10-32. Calibration Offsets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 34Figure 10-33. ORU Backplane PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 35Figure 10-34. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 35Figure 10-35. ORU Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36Figure 10-36. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36Figure 10-37. Emitter Head Attachment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 38Figure 10-38. Backplane Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 39Figure 10-39. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 40Figure 10-40. Power Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 41Figure 10-41. ORU Positioned For Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 41Figure 10-42. Tuning ORU Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 42Figure 10-43. Fiber Bundle Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 43Figure 10-44. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 44Figure 10-45. Fiber Bundle Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 44Figure 10-46. ORU Cover Attachment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 46Figure 10-47. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 46Figure 10-48. Cover Hardware Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 47Figure 10-49. Bracket Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 47Figure 10-50. New Cover Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 48

Chapter 11 - Rack HandlingFigure 11-1. Rack Handling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2Figure 11-2. Rack Handling Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3Figure 11-3. Sample Module (CTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4Figure 11-4. Sample Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5Figure 11-5. Sample Rack Sensing Indications (all positions filled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5Figure 11-6. Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6Figure 11-7. Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6Figure 11-8. Reagent Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7Figure 11-9. Reagent Rack Sensing Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8Figure 11-10. Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8Figure 11-11. Reagent Mounting Plate Stirrers and Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9Figure 11-12. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10Figure 11-13. Reagent Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10Figure 11-14. Bar Code Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11


Figure 11-15. RTI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12Figure 11-16. Bar Code Reader Travel Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13Figure 11-17. SW, Covers, and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15Figure 11-18. Racks Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16Figure 11-19. Reagent Temperature Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17Figure 11-20. Stirring Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17Figure 11-21. Sample Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19Figure 11-22. Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20Figure 11-23. Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21Figure 11-24. Reagent Module Screws (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 22Figure 11-25. Reagent Module Screws (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 22Figure 11-26. Reagent Cooling with Fan Speed Controller PCB Mounting. . . . . . . . . . . . . . . . . . . . . . 11 - 23Figure 11-27. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 23Figure 11-28. Barb Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24Figure 11-29. Double Clamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25Figure 11-30. Reagent Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25Figure 11-31. Secured Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26Figure 11-32. Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26Figure 11-33. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27Figure 11-34. Reagent Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28Figure 11-35. Bar Code Reader Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 29Figure 11-36. BCR Mounting Screws Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 29Figure 11-37. Mounting Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30Figure 11-38. Barcode Scanner Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31Figure 11-39. Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31Figure 11-40. Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 32Figure 11-41. Bar Code Reader Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 32Figure 11-42. RTI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33Figure 11-43. X Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 35Figure 11-44. Jumper Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36Figure 11-45. Encoder Assembly Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36Figure 11-46. Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37Figure 11-47. BCR Curtain Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 38Figure 11-48. Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 38Figure 11-49. Right Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 39Figure 11-50. Left Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 39Figure 11-51. Bar Code Reader Drive Belt Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 40Figure 11-52. Bar Code Reader Drive Belt Fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 41Figure 11-53. Bar Code Reader Drive Belt Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 41Figure 11-54. Bar Code Reader Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 42Figure 11-55. Bar Code Reader Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 43

Chapter 12 - Thermal ControlFigure 12-1. System Temperature Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1Figure 12-2. Temperature Tab of Instrument Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2Figure 12-3. Thermal Sensing Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3Figure 12-4. Thermal Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3Figure 12-5. Cuvette Shuttle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4Figure 12-6. Cuvette Shuttle Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5Figure 12-7. Incubator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 6Figure 12-8. Incubator 2 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 6Figure 12-9. Optical Reading Unit Thermal Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7


Figure 12-10. Cooling Fan Ductwork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8Figure 12-11. Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8Figure 12-12. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9Figure 12-13. Cavro Reagent Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10Figure 12-14. Universal Arms Reagent Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10Figure 12-15. Cavro Sample Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11Figure 12-16. ThermalCal Dialog Initial State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13Figure 12-17. Thermal Dialog after Changing to Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14Figure 12-18. Screen after connecting to the TOP AM. (Manual Mode) . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15Figure 12-19. Calibration Process for a Single Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 16Figure 12-20. Display of the Soaking Time Remaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17Figure 12-21. Time-out Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17Figure 12-22. Temperature Stable Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 18Figure 12-23. Screen showing Offset (Coefficient) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19Figure 12-24. Display Coefficient Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19Figure 12-25. Message Box Confirming a Stop Calibration Request . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20Figure 12-26. Message Warning that a Second Module cannot be Selected . . . . . . . . . . . . . . . . . . . 12 - 20Figure 12-27. Complete Calibration before Exiting message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20Figure 12-28. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21Figure 12-29. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 22Figure 12-30. Connecting ThermalCal Application to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23Figure 12-31. Time-out Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23Figure 12-32. AM Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24Figure 12-33. ICU1 Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24Figure 12-34. ICU2 Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25Figure 12-35. ORU Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25Figure 12-36. Thermistors and Futura Test Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 26Figure 12-37. Soak Time Remaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27Figure 12-38. Temperature Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27Figure 12-39. Temperature Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28Figure 12-40. Save Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28Figure 12-41. Calibration Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28Figure 12-42. Done Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 29Figure 12-43. Display Coefficients. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 30Figure 12-44. Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 30Figure 12-45. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 31Figure 12-46. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 32Figure 12-47. Connecting ThermalCal to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 33Figure 12-48. Connection Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 34Figure 12-49. Thermal Coefficient Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 34Figure 12-50. Controllers, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 36Figure 12-51. Reagent Temperature Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 37Figure 12-52. ORU Tab of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 38Figure 12-53. Temperature Portion of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 39Figure 12-54. Software, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 40Figure 12-55. Reagent Block Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 40

Chapter 13 - Waste Management SystemFigure 13-1. Layout of the Waste Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 2Figure 13-2. The Sample and Reagent Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4Figure 13-3. The Reagent Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4Figure 13-4. The Sample Side Accumulator (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 5


Figure 13-5. The Parts of the Waste Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 6Figure 13-6. The Waste Shelf Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7Figure 13-7. Tilt Adjustment and Positional Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 8Figure 13-8. The Fluids Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 12Figure 13-9. The Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13Figure 13-10. The Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13Figure 13-11. The Cuvettes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14Figure 13-12. The Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15Figure 13-13. The Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16Figure 13-14. Connectors on the Cuvette Waste PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 18Figure 13-15. Three Captive Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 18Figure 13-16. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 20Figure 13-17. The Sample Accumulator (with the Sample Module Removed) . . . . . . . . . . . . . . . . . . . 13 - 21Figure 13-18. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 22Figure 13-19. CTS Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23Figure 13-20. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 24Figure 13-21. The Reagent Accumulator (with the Reagent Module Removed). . . . . . . . . . . . . . . . . . 13 - 24Figure 13-22. Waste Pump Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25Figure 13-23. Waste Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 26Figure 13-24. Waste Pump Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 27Figure 13-25. Assembly with Waste Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 27

Chapter 14 - Preventive MaintenanceFigure 14-1. Use of Precision Tubing as Threader for Rinse Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 3Figure 14-2. I/O Fluidics Panel Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 4Figure 14-3. I/O Fluidic Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 5Figure 14-4. Fluidics Panel Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 6Figure 14-5. I/O Fluidics Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 7Figure 14-6. Waste Pump Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 8Figure 14-7. Flex Cable Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 9Figure 14-8. X Frame and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 10Figure 14-9. Y Frame and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 10Figure 14-10. .ORUs Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 11Figure 14-11. ORU Enabling Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 11Figure 14-12. Air Blanking of All ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 12Figure 14-13. Air Blanking Value Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 12Figure 14-14. Factor Diluent Blanking for all ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13Figure 14-15. Factor Diluent Blanking Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13Figure 14-16. Left and Right End-of-Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 14Figure 14-17. Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15Figure 14-18. Z Height and Tilt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15Figure 14-19. Y Axis LED and Turning Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16Figure 14-20. Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16Figure 14-21. X-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 18Figure 14-22. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19Figure 14-23. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19Figure 14-24. Flow Rate Test Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19Figure 14-25. System Software VersionsDisplay Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 20Figure 14-26. Software Revisions Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21Figure 14-27. System Temperature Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21Figure 14-28. Temperature Tab of Instrument Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 22Figure 14-29. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 22


Figure 14-30. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 23Figure 14-31. Connecting ThermalCal to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 24Figure 14-32. Connection Status - Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 24Figure 14-33. Thermal Coefficient Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 25

Chapter 15 - CTS PiercerFigure 15-1. CTS Piercer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 2Figure 15-2. CTS Piercer Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 3Figure 15-3. CTS Piercer Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4Figure 15-4. Piercer Probe in Piercer and Sample Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7Figure 15-5. Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8Figure 15-6. LLD Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8Figure 15-7. Piercer Lock Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 9Figure 15-8. Cap Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10Figure 15-9. Piercer Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10Figure 15-10. Z-Drive Rack and Brake Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 11Figure 15-11. Retraction Shaft and Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 12Figure 15-12. Probes Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 14Figure 15-13. CTS Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 16Figure 15-14. Piercer Loop Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17Figure 15-15. Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18Figure 15-16. Air Valve, Pressure Release Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19Figure 15-17. Probe-n-Seal Assembly Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20Figure 15-18. Sampling Probe LLD Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20Figure 15-19. CTS Assembly Thumbscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21Figure 15-20. Probe-n-Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21Figure 15-21. Probe-n-Seal Hold Down Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 22Figure 15-22. Inserting the Probe-n-Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 23Figure 15-23. CTS Thumbscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 23Figure 15-24. Sampling Probe LLD Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24Figure 15-25. Probe-n-Seal Assembly Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24Figure 15-26. Piercer Probe Knurled Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 25Figure 15-27. CTS Piercer Probe Removal/Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 26Figure 15-28. Removal of Telescoping CTS Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28Figure 15-29. CTS Piercer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28Figure 15-30. Brake Rack Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29Figure 15-31. Telescoping CTS Assembly Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29Figure 15-32. Z-Drive Rack Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30Figure 15-33. Z-Drive Rack Screw (Bottom View of Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30Figure 15-34. Brake Rack Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 31Figure 15-35. Telescoping CTS Assembly Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 32Figure 15-36. CTS Piercer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 32Figure 15-37. Ribbon Cable Routing/Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 33Figure 15-38. Connection of Telescoping CTS Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 34Figure 15-39. Connecting Air Tube to the Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 34

Chapter 16 - SchematicsFigure 16-1. Power Interconnect Fuse PCB (Drawing # 27501100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 3Figure 16-2. Back Plane PCB (Drawing # 27502100, Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 4Figure 16-3. Back Plane PCB (Drawing # 27502100, Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 5Figure 16-4. Back Plane PCB (Drawing # 27502100, Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 6


Figure 16-5. Back Plane PCB (Drawing # 27502100, Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 7Figure 16-6. Back Plane PCB (Drawing # 27502100, Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 8Figure 16-7. Back Plane PCB (Drawing # 27502100, Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 9Figure 16-8. Front Panel Disconnect PCB (Drawing # 27503100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 10Figure 16-9. PC104 Can Bus PCB (Drawing # 27504100, Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . 16 - 11Figure 16-10. PC104 Can Bus PCB (Drawing # 27504100, Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . 16 - 12Figure 16-11. PC104 Can Bus PCB (Drawing # 27504100, Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . 16 - 13Figure 16-12. PC104 Can Bus PCB (Drawing # 27504100, Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . 16 - 14Figure 16-13. Fluidics Controller PCB (Drawing # 27505100, Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 15Figure 16-14. Fluidics Controller PCB (Drawing # 27505100, Sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 16Figure 16-15. Fluidics Controller PCB (Drawing # 27505100, Sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 17Figure 16-16. Fluidics Controller PCB (Drawing # 27505100, Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 18Figure 16-17. Fluidics Controller PCB (Drawing # 27505100, Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 19Figure 16-18. Fluidics Connector PCB (Drawing # 27506100, Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 20Figure 16-19. Fluidics Connector PCB (Drawing # 27506100, Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 21Figure 16-20. Fluidics Connector PCB (Drawing # 27506100, Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 22Figure 16-21. Fluidics Connector PCB (Drawing # 27506100, Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 23Figure 16-22. Fluidics LED PCB (Drawing # 27507100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 24Figure 16-23. ORU Detector PCB (Drawing # 27552100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 25Figure 16-24. ORU Detector PCB (Drawing # 27552100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 26Figure 16-25. ORU Detector PCB (Drawing # 27552100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . 16 - 27Figure 16-26. ORU Interface PCB (Drawing # 27554100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 28Figure 16-27. ORU Interface PCB (Drawing # 27554100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 29Figure 16-28. ORU Interface PCB (Drawing # 27554100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 30Figure 16-29. Incubator Heater PCB (Drawing # 27555100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 31Figure 16-30. Emitter PCB (Drawing # 27556100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 32Figure 16-31. Y-Axis PCB (Drawing # 27600100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 33Figure 16-32. Y-Axis PCB (Drawing # 27600100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 34Figure 16-33. Shuttle/Barcode X-Axis PCB (Drawing # 27601100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 35Figure 16-34. Cuvette Loader Interface PCB (Drawing # 27602100) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 36Figure 16-35. Cuvette Sensor PCB (Drawing # 27604100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 37Figure 16-36. Cuvette Waste Interface PCB (Drawing # 27605100) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 38Figure 16-37. Heated Probe PCB (Drawing # 27607100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 39Figure 16-38. Probe DC Driver PCB (Drawing # 27608100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 40Figure 16-39. Probe DC Driver PCB (Drawing # 27608100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 41Figure 16-40. Probe Interconnect PCB (Drawing # 27609100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 42Figure 16-41. Cuvette Loader Flex Cable PCB (Drawing # 27611100) . . . . . . . . . . . . . . . . . . . . . . . . 16 - 43Figure 16-42. Sample Rack Presence PCB (Drawing # 27700100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 44Figure 16-43. Reagent Rack Presence PCB (Drawing # 27701100, Sheet 1 of 2) . . . . . . . . . . . . . . . 16 - 45Figure 16-44. Reagent Rack Presence PCB (Drawing # 27701100, Sheet 2 of 2) . . . . . . . . . . . . . . . 16 - 46Figure 16-45. Reagent KeyBoard PCB (Drawing # 27702100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 47Figure 16-46. Reagent Cooling PCB (Drawing # 27703100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 48Figure 16-47. Magnetic Stirring PCB (Drawing # 27704100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 49Figure 16-48. Magnetic Stirring PCB (Drawing # 27704100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 50Figure 16-49. Sample Key Board PCB (Drawing # 27705100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 16 - 51Figure 16-50. Sample Key Board PCB (Drawing # 27705100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . 16 - 52Figure 16-51. Remote Travel Interface PCB (Drawing # 27710100) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 53Figure 16-52. Rack Controller CPU PCB (Drawing # 27800100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . 16 - 54Figure 16-53. Rack Controller CPU PCB (Drawing # 27800100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . 16 - 55Figure 16-54. Rack Controller CPU PCB (Drawing # 27800100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . 16 - 56Figure 16-55. Rack Controller Interface PCB (Drawing # 27810100, Sheet 1 of 7) . . . . . . . . . . . . . . . 16 - 57Figure 16-56. Rack Controller Interface PCB (Drawing # 27810100, Sheet 2 of 7) . . . . . . . . . . . . . . . 16 - 58Figure 16-57. Rack Controller Interface PCB (Drawing # 27810100, Sheet 3 of 7) . . . . . . . . . . . . . . . 16 - 59Figure 16-58. Rack Controller Interface PCB (Drawing # 27810100, Sheet 4 of 7) . . . . . . . . . . . . . . . 16 - 60


Figure 16-59. Rack Controller Interface PCB (Drawing # 27810100, Sheet 5 of 7) . . . . . . . . . . . . . . . 16 - 61Figure 16-60. Rack Controller Interface PCB (Drawing # 27810100, Sheet 6 of 7) . . . . . . . . . . . . . . . 16 - 62Figure 16-61. Rack Controller Interface PCB (Drawing # 27810100, Sheet 7 of 7) . . . . . . . . . . . . . . . 16 - 63Figure 16-62. Cuvette Waste Interface PCB (Drawing # 27605100). . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 64Figure 16-63. X Motion Control PCB W/ out Dip (Drawing # 27613100). . . . . . . . . . . . . . . . . . . . . . . . 16 - 65Figure 16-64. CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 of 9) . . . . . . . . . . . . . . . . 16 - 66Figure 16-65. CTS Controller Interface PCB (Drawing # 28630100, Sheet 2 of 9) . . . . . . . . . . . . . . . . 16 - 67Figure 16-66. CTS Controller Interface PCB (Drawing # 28630100, Sheet 3 of 9) . . . . . . . . . . . . . . . . 16 - 68Figure 16-67. CTS Controller Interface PCB (Drawing # 28630100, Sheet 4 of 9) . . . . . . . . . . . . . . . . 16 - 69Figure 16-68. CTS Controller Interface PCB (Drawing # 28630100, Sheet 5 of 9) . . . . . . . . . . . . . . . . 16 - 70Figure 16-69. CTS Controller Interface PCB (Drawing # 28630100, Sheet 6 of 9) . . . . . . . . . . . . . . . . 16 - 71Figure 16-70. CTS Controller Interface PCB (Drawing # 28630100, Sheet 7 of 9) . . . . . . . . . . . . . . . . 16 - 72Figure 16-71. CTS Controller Interface PCB (Drawing # 28630100, Sheet 8 of 9) . . . . . . . . . . . . . . . . 16 - 73Figure 16-72. CTS Controller Interface PCB (Drawing # 28630100, Sheet 9 of 9) . . . . . . . . . . . . . . . . 16 - 74Figure 16-73. Y Axis U Arm PCB (Drawing # 28631100, 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 75Figure 16-74. Y Axis U Arm PCB (Drawing # 28631100, 2of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 76Figure 16-75. Z Driver PCB (Drawing # 28633100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 77Figure 16-76. Z Driver PCB (Drawing # 28633100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 78Figure 16-77. Z Driver PCB (Drawing # 28633100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 79Figure 16-78. CTS Traveling Interconnect PCB (Drawing # 28634100) . . . . . . . . . . . . . . . . . . . . . . . . 16 - 80Figure 16-79. U Arm Fuse Board PCB (Drawing # 28641100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 81

Chapter 17 - Assembly Drawings/Part NumbersFigure 17-1. 2811001, ASSY, WASTE SHELF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 10Figure 17-2. 28116301 ASSY, WASTE DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 11Figure 17-3. 28116401 ASSY, WASTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 12Figure 17-4. 28141701 ASSY, LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 13Figure 17-5. 28161601 X-MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 14Figure 17-6. 28165001 ASSY CUVETTE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 15Figure 17-7. 28200001 ASSY, BARCODE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 16Figure 17-8. 28201501 MOTOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 17Figure 17-9. 28209001 ASSY, MONITOR/KEYBOARD SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 18Figure 17-10. 28200300 ASSY, 2-ARM RIGHT CAVRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 19Figure 17-11. 28300500 ASSY, 1-ARM, LEFT CAVRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 20Figure 17-12. 28321001 ASSEMBLY, ARM, DOUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 21Figure 17-13. 28320901 ASSEMBLY, ARM, CTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 22Figure 17-14. 28395001 PROBE, HEATED, ACL-TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 23Figure 17-15. 28445001 ASSY SAMPLE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 24Figure 17-16. 28446001 ASSY REAGENT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 25Figure 17-17. 28512501 ASSY, REAGENT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 26Figure 17-18. 28519700 DUCT ASSY, REAGENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 27Figure 17-19. 28578601 ASSY, SAMPLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 28Figure 17-20. 28578621 ASSY, CTS SAMPLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 29Figure 17-21. 28602701 ASSY, COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 30Figure 17-22. 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY). . . . . . . . . . . . . . . . 17 - 31Figure 17-23. 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY). . . . . . . . . . . . . . . . 17 - 32Figure 17-24. 28608101 ASSY, BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 33Figure 17-25. 28608201 ASSY, COMPUTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 34Figure 17-26. 28608301 DC DRIVER ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 35Figure 17-27. 28612000 ASSY, FRONT, TOP SKIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 36Figure 17-28. 28612701 SNAP DETENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 37Figure 17-29. 28621201 PCB, CUVETTE ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 38


Figure 17-30. 28621301 PCB, RACK ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 39Figure 17-31. 28621401 PCB, ORU ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 40Figure 17-32. 28660002 ASSY, TELESCOPE CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 41Figure 17-33. 29403701 CRU, SAMPLE PROBE N SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 42Figure 17-34. 29403601 PIERCER PROBE, CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 43Figure 17-35. 28715801 ASSY, RINSE PUMP, BASE TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 44Figure 17-36. 28715821 ASSY, RINSE PUMP, CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 45Figure 17-37. 28735500 ASSY, PUMP SINGLE XP3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 46Figure 17-38. 28759501 ASSY, CWR STATION, SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 47Figure 17-39. 28759601 ASSY, CWR STATION, REAGENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 48Figure 17-40. 28774601 ASSY, WASTE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 49Figure 17-41. 28775900 ASSY, ACL TOP PROBE HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 50Figure 17-42. 28816801 ASSY, INCUBATOR #1 (REAGENT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 51Figure 17-43. 28817201 ASSY, INCUBATOR #2 (SAMPLE SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 52Figure 17-44. 28820501 8 POS INC INDEXER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 53Figure 17-45. 28821501 7 POS INC INDEXER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 54Figure 17-46. 28825000 ASSY, ORU CRADLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 55Figure 17-47. 27501001 ASSY, FUSE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 56Figure 17-48. 27503001 PCB ASSY FRONT PANEL DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 57Figure 17-49. 27605001 PCB CUVETTE WASTE INTERFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 58Figure 17-50. 27613010 PCB ASSY X-MOTION CONTROL BD W/OUT DIP . . . . . . . . . . . . . . . . . . . 17 - 59Figure 17-51. 27700001 PCB SAMPLE RACK PRESENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 60Figure 17-52. 27707001 SAMPLE KEYPAD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 61Figure 17-53. 27707101 REAGENT KEYPAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 62Figure 17-54. 28366901 CTS Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 63Figure 17-55. 28383001 Assy CTS Bulk Fluidics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 64Figure 17-56. 28641001 CTS Sample & IL Double Arm Fuse Board . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 65


1

Safety and Compliance

This section describes the Safety and Compliance Requirements for the ACL TOP, including Site Require-ments, Environmental Requirements, Reagent Specifications, Limitations, Important Symbols, and Certifi-cations.

Site RequirementsOnly IL personnel or other person(s) duly authorized by IL must install the ACL TOP.

CAUTION: The ACL TOP weighs over 158 Kg (350 lbs). Extreme care should be exercised in the event that the ACL TOP needs to be lifted or moved. A total of four people should be used; two people should lift using the two molded handles in the rear of the unit; the third and fourth persons should each lift a front corner.

Limited WarrantyInstrumentation Laboratory is responsible for the safety and electrical performance of this equipment if and only if:

• Persons authorized by IL carry out assembly operations, extensions, adjustments, modifications orrepairs.

• The electrical installation of the room complies with the local, state, or national requirements (includ-ing power supply circuit with independent grounding).

• The equipment is used in accordance with these instructions for use.

• IL brand products are used. Non-IL brands are not covered.

Spatial RequirementsThe maximum external dimensions for the analytical module (AM) are:

Height: 73 cm 29 inches

Width: 151 cm 59 inches

Depth (at footprint): 76 cm 30 inches

Weight (approx.): 158.76 Kg 350 lbs

ACL-TOP Service Manual

2

The instrument must be positioned so that a waste tube can be connected to the right side of the unit without any kinks or bends that could lead to an obstruction.

The instrument must be positioned so that there is at least 15.2 cm (6 inches) clearance on all sides, back and top for proper air circulation.

The maximum external dimensions for the control module (CM) are:

The maximum external dimensions for the monitor are:

Environmental ConditionsThe instrument will function correctly in an ambient temperature of 15°C to 32°C (59°F to 89°F) with a rela-tive humidity of 5% to 85% (non-condensing).

In accordance with the IEC regulations, no instrument failures will occur in the presence of short-term ambi-ent temperatures as low as 5°C or as high as 40°C.

The instrument has been tested per Mil Spec to 2000 meters and functioned per the specification. The ACL TOP should not be used at an altitude greater than 2000 meters.

The audible noise emission passes the safety requirements for electrical and laboratory equipment, EN61010.1.

Reagent SpecificationsReagent specifications for the ACL TOP are published separately and distributed in the reagent packaging.

Non-IL Reagents

The use of non-IL brand reagents or supplies for testing may cause a clinically significant degradation of performance and results. IL does not assume any obligation or warranty engagement concerning precision and/or accuracy of the measurements nor for any damage to the instrument directly or indirectly resulting from the use of reagent, consumables and/or expendable supplies other than those produced by IL.

Height: 44.4 cm 17.5 inches

Width: 19.0 cm 7.5 inches

Depth: 48.2 cm 19 inches

Weight (approx.): 16.8 Kg 37.0 lbs

Height 43.1 cm 17 inches

Width: 35.5 cm 14 inches

Depth: 7.6 cm 3 inches


3

LimitationsInstrumentation Laboratory, Co. (IL) is responsible for the safety and electrical performance of this equip-ment if and only if:

• Assembly operations, extensions, adjustments, modifications or repairs are carried out by personsauthorized by IL.

• The electrical installation of the room complies with the local, state or national requirements (includ-ing a power supply circuit with independent grounding).

• The equipment is used in accordance with these instructions for use.

IL does not assume any obligation or warranty engagement concerning precision and/or accuracy of the measurements or for any damage to the instrument directly or indirectly resulting from the use of reagents and/or consumables other than those produced by IL.

THIS WARRANTY IS GIVEN EXPRESSLY AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. PURCHASER AGREES THAT THERE IS NO WARRANTY OR MERCHANTABILITY AND THAT THERE ARE NO OTHER REMEDIES OR WARRANTIES, EXPRESSED OR IMPLIED, WHICH EXTEND BEYOND THE CONTENTS OF THIS AGREEMENT.

No agent or employee of IL is authorized to extend any other warranty or to assume for IL any liability except as above set forth.

Disclaimer Regarding User-Defined Tests

A user with the appropriate security level can create new tests or copy an existing test. All responsibility for parameter development and validation of new or copied tests belongs to the user alone.

Document SymbolsOnly trained operators following the procedures described in this manual should use the ACL TOP. IL declines any responsibility otherwise.

Good laboratory practices dictate that biohazard precautions are taken while operating the ACL TOP and when handling patient samples, controls, calibrators, or similar materials.

Throughout this manual, you should pay particular attention to paragraphs marked "WARNING", "CAU-TION", "NOTE", and "BIOHAZARD." These paragraphs are labeled with the following symbols and contain important information:

WARNING Warning statements provide information about electrical hazards.

CAUTION Caution statements provide information about per-sonal injury hazards and product damage hazards.


4

Label SymbolsThe following symbols appear on the labels of ACL TOP components.

NOTE Note statements contain important user information.

BIOHAZARD Biohazard statements alert you to potentially biohazardous conditions.

WARNING Use extreme caution. (CTS Probe is moving) – Can cause potential cutting or piercing injury.

Symbol Description

CE Mark

Temperature Limitation

Use by

Manufacturer

Batch Code

Biological Risk

Attention: See Instructions for Use


5

Caution: Risk of Electric Shock

Note: Important User Information

Attention: Consult Documents

Catalog Number

Serial Number

In Vitro Diagnostic Device

Authorized Representative

Contents sufficient for <n> tests

Protective Conductor Terminal - Earth

Earth Ground

Off (supply)

On (supply)


6

CertificationCE Certification:

The CE label on the back of the instrument indicates that the ACL TOP conforms to the European Directives as stated in IL’s Declaration of Conformity,

EU Directive:

IVD - 98/79/EC (27/10/1998) – Annex I and III

Applicable standards:

• EN 61326-1: 1998 (Class A)

• EN 61010-2-04

CSA Certification:

The CSA label on the back of the instrument indicates that the Canadian Standards Association (CSA) has certified the ACL TOP to the applicable standards.

Applicable standards:

• CAN/CSA C22.2 No. 1010.1-92

• UL Std. No. 61010-1, 2nd Edition

LOPD (Data Protection Organic Law):

Directive 95/46/CE of the European Parliament and the Council Directive of October 24th, 1995.

Bar Code Reader Hazard

Stop Action – Instrument will stop all moving parts immediately

Warning: Personal Injury


7

European regulation on data protection, concerning:

European parliament and council directives and regulations on data protection

Spanish Constitution of 1978

Organic Law 15 of December 13th, 1999, on Personal Data Protection (LOPD)

Royal Decree 994/1999 on Security Measures. Royal Decree 1332/1994

Regulation of the Computerized Processing of Personal Data

Spanish Data Protection Agency instructions

Other Certification:

The ACL TOP meets CEI/IEC 61010-2-04, 2001 Mod, Second Edition, for the following:

• External Surface Temperature

• Flame Resistance

• Fluid Resistance

• Internal Air Flow and Temperature

• Audible Noise

• Product Labeling

The ACL TOP shipping package, US or overseas, complies with the International Safe Transit Packaging Testing Procedure ISTA 1B (June, 1999) and ASTM 999.

CAUTION: Only authorized service personnel should perform field service on the instrument. The instrument contains potentially hazardous electrical voltages and many mechanical parts.

CAUTION: The ACL-TOP contains moving parts, and hazardous chemicals, which can cause injury if handled improperly. Only authorized service personnel should perform service on the ACL-TOP.

NOTE: Throughput performance is established based on a 100 second PT acquisition time and a 120 second APTT acquisition time.

§ Luxembourg § Ireland § Greece

§ United Kingdom § Belgium § Portugal

§ Austria § Germany § Italy

§ Denmark § France § Netherlands

§ Sweden § Finland § Spain


8

CAUTION: Do not bypass safety switches. The moving CTS Pierce Probe can cause serious personal injury.

AM Safety CoversThe locking sample and reagent access covers are designed to provide increased operating safety. The sample area cover is on the left and the reagent area cover is on the right. These covers must remain closed during system operation.

The covers enhance operator safety and reduce the effect of the external environment on the instrument when operating at environmental extremes and minimize the evaporation from samples and reagents. They help to maintain temperature control and reduce the effect of stray light on sample data acquisition.

The software controls the unlocking of the sample and reagent access covers. The ACL TOP is able to detect whether one or both of the access covers are open or closed. If it detects that an access cover is open, an emergency stop is automatically initiated. The ACL TOP will not operate with either of the access covers open.


Chapter 1 – Instrument Overview 1 - 1

Chapter 1 –Instrument Overview

1-1 Intended Use

The ACL TOP is a bench top, fully automated, random access analyzer designed specifically for in vitro diagnostic clinical use in the hemostasis laboratory for coagulation and fibrinolysis testing in the assessment of thrombosis and hemostasis.

The system provides results for both direct hemostasis measurements and calculated parameters.

The ACL TOP is used to perform the following types of tests:

• Coagulometric (Turbidimetric) Tests

• Chromogenic (Absorbance) Tests

• Immunological Tests

1-2 Instrument Description

The ACL TOP system is composed of two modules:

• Control Module (CM) - User interface and operation control

• Analytical Module (AM) - Primarily sample and reagent handling hardware

The CM consists of a personal computer running Windows software, keyboard, touch screen display moni-tor, mouse, and communications interfaces to the AM and external devices/systems. The CM provides the major functionality associated with the User Interface (UI) including data management, data reduction, LIS (Laboratory Information System) communications, sample identification, test materials management, fluid management, reporting, test tracking and QC management, and monitoring.

The AM consists of the functionality required to handle and process reagents and auxiliary materials. It can perform coagulometric (turbidimetric), chromogenic (absorbance), and immunological measurements.

The major parts of the ACL TOP instrument are the Control Module and the Analytical Module as shown on Figure 1-1 "ACL TOP Instrument".

The Control Module includes:

• personal computer running Windows software

• keyboard

• touch screen display monitor

• mouse


1 - 2 Chapter 1 – Instrument Overview

The Analytical Module includes:

• AM Computer

• Cuvette Handling

• Sample Area

• Diluent Area

• Reagent Area

• Bulk Fluids

• Waste Handling

• Sample Handling

• Reagent Handling

• Reaction and Detection

• Interconnect and Power Supply

• Access-restricting Cover with Safety Interlocks

• Instrument-supporting Structure-chassis

• Safety Interlock for Cuvette Waste Drawer

Figure 1-1 ACL TOP Instrument

AM Safety Covers

The locking sample and reagent access covers, as shown on Figure 1-2 "Analytical Module with Open Safety Covers", provide increased operating safety. The sample area cover is on the left and the reagent area cover is on the right. These covers must remain closed during system operation.

The covers enhance operator safety and reduce the effect of the external environment on the instrument when operating at environmental extremes and minimize the evaporation from samples and reagents. They help to maintain temperature control and reduce the effect of stray light on sample data acquisition.



The software controls the unlocking of the sample and reagent access covers. The ACL TOP is able to detect whether one or both of the access covers are open or closed. If it detects that an access cover is open, an emergency stop is automatically initiated. The ACL TOP does not operate with either of the access covers open.

Figure 1-2 Analytical Module with Open Safety Covers

AM Power Connector

The ACL TOP AM power switch is located on the right side of the analytical module, adjacent to the power cord connection. This switch is for the main power supply and controls all power to the AM.

CAUTION: This switch must be turned off prior to service and the power cord must be disconnected.

During normal operation, the ACL TOP is powered on continuously. Please note the following concerning the AM power connector:

• The power supply carries UL/CSA approvals.

• Maximum power requirements for the AM do not exceed 1100 watts.

• The power supplies in both the AM and CM incorporate a power factor correction in order to prevent harmonic distortions in the power lines and to satisfy requirements for EMC/EMI Standard 61326.

• The AM incorporates a standard AC input IEC 1010.1-92 connector.



Emergency Stop Button

The ACL TOP has a red Emergency Stop button, as shown on Figure 1-3 "Emergency Stop Button", located on the front center of the AM just below the bar code reader. This button is for use whenever the instrument must be immediately stopped. Pressing the Emergency Stop button while the instrument is oper-ational causes an immediate cessation of all movements. Any tests that were in progress need to be restarted.

Figure 1-3 Emergency Stop Button

Cuvette Loading Area

The cuvette loading area, as shown on Figure 1-4 "Cuvette Loader Area", is on the left-most side of the AM. A conveyor belt moves the cuvette strips to the cuvette shuttle, which places them in position to be used by the AM for sample handling.



Figure 1-4 Cuvette Loader Area

Cuvette Loader

The cuvette loader can be filled with up to 20 clips of 10 cuvette strips each, for a maximum of 200 cuvette strips (800 cuvette cells).

• A conveyor belt transports the cuvette clips to the front of the loading area.

• Electrical sensors detect when additional cuvette clips need to be loaded onto the instru-ment and inform the operator.

• The indexer pushes the cuvette clip to the right to position it so one strip can be picked up by the cuvette shuttle.

• As the cuvette strips are used, new cuvette clips are brought forward and positioned for pickup. Additional cuvette strips can be added in the loading area while the analyzer is run-ning.

Cuvette Shuttle

The cuvette shuttle, as shown on Figure 1-5 "Cuvette Strip being picked up by Cuvette Shuttle", picks up a single cuvette strip from the cuvette clip and transports it from one position or slot to another.



Figure 1-5 Cuvette Strip being picked up by Cuvette Shuttle

Bar Code Reader

The bar code reader, as shown on Figure 1-6 "Bar Code Reader", moves to each track position to allow for insertion of the sample, diluent or reagent racks. Bar coded information on sample tubes or diluent or reagent bottles is scanned into the instrument as the racks are inserted.

The bar code reader is moved to the desired track using the track buttons on the front of the AM or by click-ing the virtual track buttons displayed on the Reagent Area screen on the CM. With the bar code reader positioned in front of the track position, the rack can be inserted. A track guides the insertion of the rack into its correct position.

After the bar code reader has been at a track position for 30 seconds, it moves back to its home position.

CAUTION: A flashing red LED on the front of the bar code reader indicates that the bar code reader is about to move. When the red LED is flashing, keep the bar code reader path clear of obstacles, keep hands away and do not attempt to load racks.

NNOTE:In the event of a Bar Code Reader Blocked error, wait 30 seconds until the bar code reader homes itself; do not attempt to move the bar code reader manually.



Figure 1-6 Bar Code Reader

Sample Area

On the left side of the instrument, as shown on Figure 1-7 "Sample Area with Sample Arm", is the sample area where patient samples are placed on the AM. The sample material is placed on racks, as shown on Figure 1-8 "Sample Rack", that are inserted through a bar code reader.

The sample area is at ambient temperature and can hold 12 racks, each capable of holding 10 samples.

When the rack is in use (during aspiration of sample material) it is locked and an amber LED (Light Emitting Diode) is displayed for the track position. When the rack is no longer in use, the LED changes to green.

The sample rack holds both sample tubes and sample cups.

CAUTION: When using sample cups they must be Instrumentation Laboratory’s 2.0 mL sample cups. The use of non-IL sample cups may lead to improper sampling and incorrect results.

The wash station for the sample probe is located in the back right side of the sample area.



Figure 1-7 Sample Area with Sample Arm

Figure 1-8 Sample Rack

Sample Arm

The sample arm consists of a heated probe and syringe used for aspirating and dispensing samples. The CTS uses an unheated probe.



Closed Tube Sampling

The CTS probe is a specially designed unit comprised of both a piercer and a sample probe, which is located within the piercer as shown in Figure 1-9 "Sample Arm CTS probe". The Sample Arm CTS probe has a foot to hold the sample tube in place, allowing the piercer to cut through the cap. After the piercer cuts through, it remains in the cap long enough to allow the probe to move down and into the tube to aspirate material as shown in Figure 1-10 "CTS Cap Piercing".

Figure 1-9 Sample Arm CTS probe

Figure 1-10 CTS Cap Piercing

CAUTION: Due to the force of the piercing, glass sample tubes may break. To avoid this potential breakage please use plastic tubes where possible.

1 2



Following aspiration the CTS/Sample arm moves to the wash station and performs a deep wash. Pressur-ized air is released through the piercer/probe to blow out any material that might remain following a wash or rinse.

Special CTS racks are used for cap piercing; these racks are identified by labels having "CTS" in bold on the front of the rack as shown in Figure 1-11 "CTS Rack".

Figure 1-11 CTS Rack

CTS mode is Enabled/Disabled in the Global Definitions screen. With the CTS mode enabled, the instru-ment accepts both CTS racks and open tube racks. Only closed tubes may be used on CTS racks. Regular uncapped sample tubes, and sample cups belong on open tube racks.

With the CTS mode disabled, the instrument does not accept CTS racks; if a CTS rack is inserted an error message is displayed with "CTS rack rejected". In the disabled mode, the instrument runs uncapped tubes and sample cups on open tube racks only.



Diluent Area

The diluent area, as shown on Figure 1-12 "Diluent Area with Sample Probe (non CTS)", includes the 2 right-most tracks in the sample area and the left-most track in the reagent area. This area holds up to 24 calibration plasmas, QC materials, and dilution materials in original bottles placed on diluent racks as shown on Figure 1-13 "Diluent Rack".

When the rack is in use (during aspiration of material) it is locked and an amber LED is displayed for the track position. When the rack is no longer in use, the LED changes to green and the rack is released.

The sample arm aspirates and dispenses materials from diluent racks placed in the sample area.

The reagent arm aspirates and dispenses materials from the diluent rack placed in the reagent area.

Figure 1-12 Diluent Area with Sample Probe (non CTS)

Figure 1-13 Diluent Rack



Reagent Area

The reagent area, as shown on Figure 1-14 "Reagent Area Showing Intermediate (left) and Start (right) Reagent Arms", is on the right side of the AM. This area has 6 tracks that hold up to 36 reagents in original bottles placed on reagent racks as shown on Figure 1-15 "Reagent Rack". As with samples, reagent racks are inserted into reagent tracks by means of the bar code reader assembly.

The reagent area is cooled to 15oC ± 3oC and positions 1 and 2 of each rack (rearmost positions) are enabled for the use of magnetic stir bars.

Figure 1-14 Reagent Area Showing Intermediate (left) and Start (right) Reagent Arms

Figure 1-15 Reagent Rack

Reagent Arms

There are two reagent arms. The left reagent arm is used for aspirating/dispensing materials placed in the diluent rack in the reagent area and intermediate reagents from positions 1-24 of the reagent area. (An inter-mediate reagent is one that when mixed with sample activates certain constituents of the sample but is not enough to bring the reaction to completion.)



The right reagent arm is used for aspirating/dispensing start reagents from positions 13-36 of the reagent area. (A start reagent is one that when mixed with the sample or sample mixture begins the reaction of inter-est. It must be the final reagent added to the cuvette cell.)

Both reagent arms can access positions 13-24 in the reagent area.

The wash station for the left reagent probe is located in the back left side of the reagent area; the wash sta-tion for the right reagent arm is located in the back right side of the reagent area.

Probe

The probes, as shown on Figure 1-16 "Probe (in foreground) and Syringe (non CTS)", are the vertical part of the sample and reagent arms that are in contact with the liquid.

Each probe has a sensor that recognizes the presence of liquids and stops at the optimized liquid level. Each is preheated and heats liquids being pipetted to 37°C ± 1°C. A Teflon tube connects the probe to a syringe that is capable of delivering 4 to 250 µL. The CTS sample probe is not heated.

The probes on non CTS instruments are interchangeable, but if they are replaced, arm coordinates need to be recalibrated.

If a probe appears to be damaged, bent, shows visible corrosion, or if frequent liquid level detection failures are being detected, the probe may need to be replaced.

Figure 1-16 Probe (in foreground) and Syringe (non CTS)

Probe Syringes

There are three syringe pumps in the AM. Each probe has its own syringe pump to enable the separate movement of rinse, clean, sample or reagent through the probe. The syringe has plastic tips that may wear out and need to be replaced. It is recommended they be replaced annually. The knob located at the bottom of each syringe is used when changing tips.



Incubators

There are two incubators, one behind the right side of the sample rack area and the other behind the left side of the reagent rack area, see Figure 1-17 "Sample Probe and Incubator Slots (non CTS)".

An incubator can hold up to 8 cuvette strips (32 cells) for the sample or reagent incubation phase. The tem-perature for both incubators is maintained at 37.0°± 0.5°C.

In the first incubator, sample material is pipetted into the cuvette cells. The cuvette strips are moved into the second incubator where intermediate reagents are dispensed.

Figure 1-17 Sample Probe and Incubator Slots (non CTS)

Optical Reading Unit

There are four optical reading units (ORU’s), each with four reading stations, located to the right of thereagent incubator where start reagents such as APTT CaCl2 are dispensed into the cuvette cells to start thereaction. Readings are taken of the reaction using wavelengths of 671 nm (Red) for Coagulometric, 405 nm(Blue) for Chromogenic, and either 671 or 405 nm for Immunologic measurements.

System Fluids – Rinse and Clean

The rinse solution system and the clean solution system remove contaminants from the system to reduce the risk of carryover affecting test results. Figure 1-18 "Rinse (left) and Clean Bottles on ACL TOP with Fluid Waste Container Underneath" provides a view of the rinse and clean elements.

These fluids clean not only the internal surfaces of the probe and the related tubing, but also the external surface of each probe tip, removing contaminants that may have contacted the probe during fluid aspiration.



The rinse solution is used to rinse the probes after the aspiration and dispensation of a test fluid. Typically, the probe is rinsed after each syringe pump cycle. However, in instances where a common reagent is being dispensed into consecutive cells, the rinse pump may not be operated until after the final dispense. The amount of rinse solution used is not test-dependent.

The rinse solution system is comprised of the system rinse solution bottle, the rinse solution tubing, three rinse pumps, the rinse pump tubing, the rinse/clean stations in the sample and reagent areas, and the waste fluid. For CTS, an additional rinse pump is used to rinse the outside of the sample probe and the inside of the piercer probe. An air pump is also used to aid in drying the piercer and sample probes.

Each probe is connected to a dedicated rinse pump and has a dedicated rinse/clean station at which it is positioned during the operation of the rinse cycle. The probe is positioned above the rinse cup and rinse is dispensed through the probe into the rinse cup. Rinse dispensed from the probe enters the rinse cup, dis-placing any rinse that is in the rinse cup. Any excess fluid that overflows from the rinse cup drains into the accumulator through an opening in the bottom of the rinse/clean station.

The rinse solution is placed on the ACL TOP in a 4L rinse bottle. A sensor (Rinse Fluid) located on the front of the AM monitors the level of rinse solution and displays an amber warning light when the level drops below 1000 mL and displays a red error light when the level drops below 600 mL. If the Rinse Fluid sensor changes to red while busy (conducting testing), the instrument performs a controlled stop to finish running the active tests. The remaining tests are not run until the operator replaces the rinse and presses Start again. If the rinse solution drops below 100 mL the system performs an Emergency Stop.

CAUTION: Do not replace the Rinse Fluid during Busy (while tests are being conducted) or Controlled Stop.

The clean solution system is comprised of the system clean solution bottle, the clean solution tubing, a pump, a manifold, three valves, clean cup tubing, the rinse/clean stations and fluid waste. A pump is used to transport clean solution from the clean solution bottle to the clean stations. Each rinse/clean station con-tains a clean cup that serves as a reservoir for the clean solution. The clean cups are filled from the bottom.

The probe enters the clean solution and aspirates fluid from the clean cup, the pump is operated and the valve dedicated to the clean cup is opened. Clean solution is pumped into the clean cup. The volume of clean solution pumped into the clean cup is sufficient to not only fill the clean cup, but to also flush any con-taminants from the clean cup. Any excess fluid that overflows from the clean cup drains into the accumulator through an opening in the bottom of the rinse/clean station.

A cleaning cycle is used to clean the probe at specific times during the operation of the instrument. It cleans the probe more completely than the rinse system. The probe aspirates clean solution from the clean cup in the rinse/clean station or from a bottle of clean material place on a rack and dispenses the clean solution into the rinse/clean station.

A sensor (Clean Fluid) located on the front of the AM monitors the level of clean solution and displays an amber warning light when the level drops to 75 mL and displays a red error light when the level drops to 25 mL. If the Clean Fluid sensor changes to red during busy, the instrument performs a controlled stop to finish running the active jobs. Wait until the system comes to a complete stop, replace the bottle with a new one, then restart the testing.

CAUTION: Do not replace the Clean Fluid during Busy or Controlled Stop.



Figure 1-18 Rinse (left) and Clean Bottles on ACL TOP with Fluid Waste Container Underneath

Fluid Waste

The fluid waste pump is used to remove fluid from the internal waste reservoirs located under the clean and rinse stations in the sample area and the reagent area. There is a sensor in each reservoir that senses when the accumulator is full and turns on the pump for a predetermined amount of time to empty the waste into the waste container.



Waste Container

The waste container is a 10 liter container that holds the fluid waste that is pumped from the accumulators. A "Waste Fluid" sensor on the front of the AM warns the operator when the waste container is nearly full by turning amber (warning), and turning red (error) when the waste container is full. Once the sensor turns red the instrument performs a controlled stop. If the waste container is not replaced with an empty one, the instrument eventually performs an Emergency Stop and the operator must empty or change the waste con-tainer before running more tests.

BIOHAZARD: System fluid waste is biohazardous. Use precautions when changing or emptying the fluid waste bottle.

Refer to local and state regulations for disposal of potentially hazardous materials.

Cuvette Waste Container

The cuvette waste container is located on the lower right side of the instrument behind the cuvette waste door as shown on Figure 1-19 "Cuvette Waste". The figure shows the area with the waste door open. The cuvette waste module includes an accumulator that allows the cuvette waste drawer to be emptied without shutting down the instrument. Six used cuvette strips are moved onto the accumulator as readings are fin-ished, then deposited all at once into the cuvette waste drawer.

BIOHAZARD: Cuvette waste is biohazardous. Use precautions when emptying the cuvette waste drawer.

Refer to local and state regulations for disposal of potentially hazardous materials.

Cuvette waste liners are used in the cuvette waste drawer to contain used cuvette strips, keep the waste drawer clean and free of contaminants, and ensure proper disposal of the waste cuvettes.

Figure 1-19 Cuvette Waste



When the waste drawer is removed, the analyzer performs a controlled stop, allowing completion only of tests that have been started, providing the cuvette accumulator is not full. If the drawer is re-inserted before the in-process tests are completed, the AM revokes the controlled stop and finishes running all the samples. If the active tests are completed before the drawer is reinserted, the AM goes to the "Ready" state and the operator needs to restart the run to finish the remaining tests. If the cuvette waste drawer is not reinserted, the ACL TOP does not restart and informs the operator.

There are two status indicators on the front of the AM for the cuvette waste. The "Door Open" indicator turns green when the waste door is opened and the "Cuvette Waste" indicator turns amber (warning) when the drawer is nearly full, and red (error) when the waste drawer is full or removed as shown in Figure 1-20 "Cuvette Waste Drawer".

Figure 1-20 Cuvette Waste Drawer

1-3 Operating Principles

Coagulometric (Turbidimetric) Measurements

The principle of coagulometric (turbidimetric) clot detection is used in the system to measure and record the amount of time required for a plasma specimen to clot. This technique assesses coagulation endpoint by measuring change in optical density.

Clot detection is based on the principle that light passing through a medium in which fibrinogen is converted to fibrin is absorbed by the fibrin strands. Light (671 nm) is transmitted though a sample onto a photodetec-tor, which is positioned 180° incident to the source.

Light absorption increases as fibrin clot formation progresses. Consequently, light transmittance through the sample continuously decreases and is measured by the photo detector.

The corresponding electrical signal output from the photo detector changes according to the detected light. The signal output is processed via software through a series of algorithms to determine the clot point.



Chromogenic (Absorbance) Measurements

Chromogenic tests can be either direct or indirect.

• Direct tests are those in which the analyte of interest (e.g. protein C, plasminogen) acts directly on a specified synthetic substrate.

• Indirect tests are those in which the analyte of interest (antithrombin, plasmin inhibitor) reacts with a fixed quantity of enzyme to form inactive complexes. Under optimized test conditions, residual enzyme activity is then measured using a specific synthetic substrate.

In most cases, the reaction is monitored at 405 nm by the continuous release of paranitroaniline (pNA) from the synthetic substrate.

The chromogenic channels use the colorimetric principle of measuring absorbance in the cuvette. An optical sensor reads light (405 nm) that passes through the cuvette. The light is absorbed by the solution in the cuvette in direct proportion to the concentration of pNA. The amount of light reaching the photodetector is converted into an electrical signal that is proportional to the enzyme activity.

Immunological Measurements

The principle of immunological measurement is used on the system to directly measure and record the amount of an analyte. This technique assesses the physical concentration of the analyte (and not its activity) by measuring change in optical density.

Although similar to the turbidimetric method, the immunological method relies on the formation of antigen-antibody complexes to affect light transmission.

Immunological testing of the ACL TOP uses the 405 nm or the 671 nm channels depending on the test and the reagent formulation.

Both the 405 nm and the 671 nm channels use the principle of measuring absorbance in the cuvette. An optical sensor reads the light (405 nm or 671 nm) that passes through the cuvette. The light is absorbed by the solution in the cuvette in direct proportion to the concentration of antigen-antibody complexes. The amount of light reaching the photodetector is converted into an electrical signal that is proportional or inversely proportional to the analyte concentration.



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Chapter 2 – Pre-Installation and Installation 2 - 1

Chapter 2 –Pre-Installation and

Installation

2-1 Overview

This chapter guides the IL authorized engineer through the process of ensuring the facility can accommo-date and is ready for the installation of the ACL TOP. This chapter also guides the IL authorized engineer through the installation process.

2-2 Pre-Installation

This document guides the Service Representative through all aspects of the on-site verification to be made prior to installing the ACL TOP. The physical dimensions as well as power requirements are such that a suit-able working environment must be established prior to delivery and installation of the system.

All checks listed in Table 2-1 "Table One Pre-Installation Check List" should be carefully executed and the checklist completed during the pre-installation visit by the installing engineer.

Reception Area and Transportation Pathway

Verification of the reception and uncrating area, as well as transportation pathway from reception area to installation location to allow easy and safe transport once the system is uncrated is of the utmost impor-tance. For that specific purpose the following items should be carefully verified:

• Adequate access to loading dock.

• Facilities to offload the crates from the truck or lift gate truck required for delivery.

• Space available to uncrate the system at the unloading site.

• Transportation pathway from reception / uncrating area to final installation site meets the following conditions:

• Minimum acceptable doorway width 91.44 cm or 36 inches.

• The customer has facilities to dispose of the shipping crate.


2 - 2 Chapter 2 – Pre-Installation and Installation

Table 2-1 Table One Pre-Installation Check List

The physical dimensions for the shipping crate are as follows:

Table 2-2 Crated Instrument Size/Weight Specifications

Item to be Checked Acceptable Unacceptable Construction In Progress

Comments

Reception Area

Transportation Pathway

Working Area

Environment

Direct Waste Drain

Electrical PowerRequirements

DMS / LIS InterfaceFunctional

Customer TrainingComplete

Supplies on Order

Total height 172.8 cm (68 inches)

Width 180.4 cm (71 inches)

Depth 96.6 cm (38 inches)

Weight (approximate) 484.4 Kg. (1068 lbs)



Working Area / Environment

The physical dimensions of the system are as follows:

The instrument must be positioned so that a waste tube can be connected to the right side of the unit without any kinks or bends that could encourage the formation of biological obstructions.

The instrument must be positioned so there is at least 15.2 cm (6 inches) clearance on all sides, back and top for proper air circulation

The maximum external dimensions for the control module are:

Table 2-3 Control Module Size/Weight Specifications

The maximum external dimensions for the Monitor are:

Table 2-4 Monitor Size Specifications

The maximum external dimensions for the Analytical Module on the shipping table are:

Table 2-5 Analytical Module Size Specifications

Total height 44.5 cm. (17.5 inches)

Width 19 cm. (7.5 inches)

Depth 48.2 cm. (19 inches)

Weight (approximate) 16.8 Kg. (37.0 lbs.)

Total height 43.1 cm (17 inches)

Width 35.5 cm (14 inches)

Depth 7.6 cm (3 inches)

Total height 73 cm (29 inches)

Width 151 cm (59 inches)

Depth 76 cm (30 inches)

Weight (approximate) 158.76 Kg. (350 lbs)

Width of table 152.4 cm. (60 inches)

Height of Instrument on table 154.7 cm. (60.5 inches)

Height of instrument on table with doors open 189.25 cm. (74.5 inches)



Ambient Conditions:

The instrument functions correctly in an ambient temperature of 15° C to 32° C with relative humidity up to 85% (noncondensing). The instrument should be placed in a position free from dust, fumes, vibrations and excessive variations in temperature. The TOP operates to elevations of 2,000 meters.

NOTE:The instrument should not be exposed to direct sunlight.

The TOP produces 2,049 BTU per hour

Electrical Power Requirements

The instrument works using an AC mains voltage line meeting the requirements specified below. Inspect the working area and verify, with the support of the electrician (from Hospital Technical Department), that the fol-lowing conditions are met.

Electrical Requirements

The instrument operates correctly with electrical variations of up to ±10% on the nominal supply and with supply frequencies between 47 and 63 Hz.

NOTE: Check that the supply voltage in the laboratory is compatible with the label on the rear of the instrument as shown in the following table:

Table 2-6 Supply Voltage Values

Power Consumption

The analytical module is rated at 115 Vac at 10 amps and at 230 Vac at 5 amps. The power cords used for the analytical and control modules are in accordance with IEC and /or national safety requirements. Should the dedicated cords supplied have plugs that do not conform to the national standard, replace only with appropriately conforming cords, bearing in mind the power consumption at the local supply voltage.

NOTE: The average power consumption of the analytical module is approximately 230 W; for the control module it is 100 W. However, during peak loads or when turning power on, the instrument can temporarily exceed these values.

Power should be stable and free from line noise. If this cannot be assured, consideration should be given to the installation of a line conditioner.

Value of supply voltage for normal function

Value as shown on the label

230 Vac ± 10% 230 Vac

115 Vac ± 10% 100-115 Vac



DMS / LIS Interface Requirements

If the TOP is to be interfaced to DMS / LIS system, review the following.

• Will the TOP be interfaced to an LIS system?

• Is the communication software (driver) being written for the LIS interface?

• Does the customer need a copy of the TOP data stream protocol?

Site Modifications

Document all site modifications required to be completed prior to installing the ACL TOP. Also include the expected completion date for each.

2-3 Installation

NOTE:THE INSTALLATION OF THE ACL TOP SHOULD BE PERFORMED ONLY BY AN AUTHORIZED INSTRUMENTATION LABORATORY REPRESENTATIVE!

It is highly desirable to perform the unpacking and transporting of the unit with two people.

• Inspect the crate for damage.

• Remove the unit from the shipping crate by:

• Opening the Dutch door on the rear wall of the crate (See Figure 2-1 "Duch Door Open").

Figure 2-1 Duch Door Open



• Lower the front door / ramp as shown on Figure 2-2 "Shipping Packaging".

• Remove the molded polystyrene foam from the top of both ends.

• Unlock the wheel brakes and turn the wheels so they are positioned under the cart toward the back of the crate.

• Remove the front blocks by utilizing the 2” x 4” board located in the shipping crate

• Remove the two retaining boards from the ramp side of the unit.

Figure 2-2 Shipping Packaging

• Slowly and carefully remove the unit from the crate.

• Observe if the “Tip and Tell” indicators have been tripped or if the shock watches have registered an impact. They are adhered to the inside walls of the shipping crate. In the event of shipping damage, stop the installation and make the proper notifications.

• Transport the unit to its installation location.

• Remove the packaging from the exterior of the unit.

• Remove the cardboard box used to restrain the bar code reader.

PolystyreneFoam

Retaining Boards



• Open the sample and reagent door covers. Note: The sample and reagent cover may be locked forshipping. To unlock the reagent cover, remove the waste drawer and manually release the solenoiddoor lock located under the lower right hand corner of the reagent cover. With the reagent door openit is possible to unlock the sample door. The sample door solenoid is located under the lower lefthand side of the reagent cover.

• Remove the cardboard support boxes under the sample and reagent arms. (See Figure 2-3"Reagent Internal Packing Material" and Figure 2-4 "Reagent Internal Packing Material".)

Figure 2-3 Reagent Internal Packing Material

Figure 2-4 Reagent Internal Packing Material

CardboardSupport Box



• Remove the shipping brackets from the sample and reagent arms. (See Figure 2-5 "Sample/Reagent Shipping Brackets".)

Figure 2-5 Sample/Reagent Shipping Brackets

• Carefully remove the tie wraps around the probes and arms. (See Figure 2-6 "Probe/Arm TieWraps".)

Figure 2-6 Probe/Arm Tie Wraps

• For non CTS units, remove the cardboard boxes under the sample arm. (See Figure 2-7 "TOPSample Arm Packing".)

• Remove the shipping bracket from the sample arm. (See Figure 2-7 "TOP Sample Arm Packing".)

• Carefully remove the tie wraps around the probe and arm. (See Figure 2-7 "TOP Sample ArmPacking".)

ShippingBracket

Tie Wraps



Figure 2-7 TOP Sample Arm Packing

• For TOP CTS units remove the cardboard support boxes under the CTS arm (See.Figure 2-8 "CTSInternal Packing Material")

Figure 2-8 CTS Internal Packing Material

Shipping

Tie Wrap

CardboardSupport forArm

Bracket

CardboardSupport Boxes



• Carefully remove the tie wraps around the CTS Piercer/Probe assembly. (See Figure 2-9 "CTSAssy. tie wraps")

Figure 2-9 CTS Assy. tie wraps

• Remove the shipping bracket from the CTS arm. (See Figure 2-10 "CTS Shipping Brackets")

Figure 2-10 CTS Shipping Brackets

• Remove the interior covers.

ShippingBracket

Tie Wrap

Tie Wrap

ShippingBracket



• Cut and remove the nylon tie wrap from around the shuttle (see Figure 2-11 "Shuttle tie wraps").

Figure 2-11 Shuttle tie wraps

• Loosen the shuttle shipping and alignment tool and slide it out of the shuttle and into its normal stor-age position.

• Install the monitor arm support to the left side mounting studs and install the monitor on the arm(See Figure 2-12 "Monitor Arm Mounting Studs").

Figure 2-12 Monitor Arm Mounting Studs

Monitor ArmMounting Studs



• Connect the monitor, keyboard and mouse as shown on Figure 2-13 "Computer/Monitor Con-nections".

Figure 2-13 Computer/Monitor Connections

• Install the correct fuses ( 2 required) into the fuse holder (5 Amp for 220VAC and 10 Amp for 110VAC).

• Install the waste presence sensor assembly (00028762900) onto the waste bottle. Connect thewaste presence sensor signal cable. Connect tubing bulkhead connector to the instrument.

• Insert the clean bottle aspirator (00028713200) into the clean bottle. Place the bottle on to the sys-tem and connect the bulkhead connector.

• Insert the rinse bottle aspirator (00028713400) into the clean bottle. Place the bottle on to the sys-tem and connect the bulkhead connector.

• Close both sample and reagent doors, boot up the Command module and power up the Analyticalmodule. Log in using the password provided at training session. The instrument initializes and goesto Adjusting Thermal and then to Ready.

• Enter the diagnostic mode and Initialize and perform the coordinate adjustment for each arm (see“Probe Alignment and Coordinates Adjustment” in Chapter 8).

• Initialize the Loader and Cuvette Shuttle (see “Initialize Shuttle Button” in Chapter 9 and “Ini-tialize Loader” in Chapter 9).

• Check and adjust the Cuvette shuttle alignments (see “Cuvette Shuttle Alignment Check” inChapter 9).

• Reinstall and close all of the covers and blank the Optical Reading Unit (ORU) with air and factordiluent (PN 9757600). Refer to “Optical Blanking” in Chapter 10 for specific instructions on howto blank the ORU.

• Exit diagnostics and allow the system to initialize and stabilize the temperatures normally.

• Observe while the customer calibrates and runs at least one chromagenic and one coagulation test.

Power

Sound TouchscreenMonitor

Keyboard

MouseSound

Monitor

Touchscreen



2-4 Software Verification

Software Version Verification

Software version display is provided on the ACL-TOP system display by clinking on System -> Instrument Status as shown on Figure 2-14 "System Software Versions Display Selection".

Figure 2-14 System Software Versions Display Selection

Clicking on the Software Version tab in the resulting screen display lists the present version of all installed software as shown in Figure 2-15 "Software Version Area of Diagnostic Screen"

Figure 2-15 Software Version Area of Diagnostic Screen



Touch Screen Calibration

Touch Screen Calibration can be done by one of two methods.

• The first method is to use the shortcut on the windows desktop, select “Align” and follow the prompts.

• The second method, if the short cut is missing, is Start->Settings->Control Panel->Select Elo, click on “Align” and follow the prompts.

Ghost Image Verification

The “Ghost Image” procedure creates an image of the entire Control Module hard drive content including Windows 2000 and all ACL-Top application software. This image must be created any time there is a major system upgrade or during PM and can be used to restore the CM computer to its condition at the time of the “ghost Image” generation.

NOTE: It is highly recommended that Medical Grade Media be used to store the image created by this procedure. Always store the media according to manufac-tures specifications.

Per the Symantec Ghost license agreement, this tool may only be used on ONE CM PC for each CMRecovery Kit obtained from IL.

NOTE: Read through this entire process before beginning. Be sure to read each step fully before executing.

1. Click on Start -> Shutdown ->Shutdown -> OK to power off the computer (if it is not already shutdown).

2. Turn on the CM computer and immediately insert the Symantec Ghost Boot CD into the CD/DVD Drive.

3. Select “OK” in the Ghost message box.

4. In the Ghost application, select Local Partition To Image

5. When the “Select local source drive by clicking on the drive number” window is displayed, select the correct drive (only one should be available), and select “OK”.

6. When the “Select source partition(s) from Basic drive: 1” window is displayed, select the correct par-tition (only one should be available), and select “OK”.

7. The “File name to copy image to” window is displayed.

8. Insert a blank CD-R into the CD Drive.

NOTE: If the CM has a DVD R/RW Drive, the door of the drive will have “DVD R/RW” label, then a DVD-R may be used to create the image.

9. Select the CD/DVD Drive (@CD-R1…. DVD Drive) from the “Look in:” dropdown list, and then select Save

10. A message box is displayed asking to compress the image. Select High.

11. A message box is displayed asking to copy a bootable floppy to the CD/DVD disc. Select “NO”.

12. A message box is displayed asking to proceed. It also provides an estimate of the number of CD’s or DVD’s that are needed to store the image, although the estimate is usually very high. Select “Yes”.



13. A warning message about spanned NTFS images is displayed. Select “Yes”.

14. The image starts to be created, and a progress bar is displayed indicating how long it will take the image to be created.

15. If more than one CD/DVD is necessary to save the image file, a prompt is displayed requiring another blank CD/DVD to be inserted.

16. Label each CD/DVD with the name of the CM computer, the number of the CD/DVD used, and the date.

17. After completion of the Ghost image, it must be verified for correct content. In the Ghost application, select Local Check Image File.

18. Insert the Ghost image CD/DVD (Disk 1 if there are multiple discs) into the CD/DVD Drive.

19. Select the CD/DVD Drive (@CD-R1…) from the “Look In” dropdown menu, and click on “Open”.

20. A message box is displayed asking to proceed with the image file integrity check. Select “Yes” and the verification process begins. A progress indicator is displayed showing what percentage of the validation has been completed.

NOTE: If more than one CD/DVD is required to store the image file, a prompt is displayed to insert the next CD/DVD at the appropriate time.

21. When the validation has completed successfully, a message box is displayed, “Image file passed integrity check”. Click on “Continue”.

22. If the integrity check fails, the Ghost Image procedure must be re initiated using high-quality media. If it fails again, contact technical support.

23. Exit Ghost by selecting “Quit” from the menu, remove the CD/DVD, and restart the computer.

24. Provide the CD/DVD(s), labeled as stated in step 16, to the Lab Supervisor for proper storage.



2-5 Pre-Installation Checklist

The Pre-Installation Checklist is used at the service office to verify operation prior to installation at the end users' site under the following circumstances:

• New shippers have been used

• A demo is scheduled

• Previous units have sustained damage in shipment

• Units have Installation failures



ACL TOP Pre - Installation Checklist

Serial Number:__________________________Date Received:___________________________

Inspected By: __________________________ Date Inspected:___________________________

Set configurations as necessary. Refer to ACL TOP Service Manual. Check overall instrument appearance.

Test Number

Action to Check / Perform Pass/Adjust/ Check

1 Check Start Up kit for completeness.

2 Check Computer for damage and for proper operation.

3 Check Touch Screen for damage and for proper operation.

4 Check Keyboard and Mouse for proper operation.

5 Check Software Version in Status Screen

6 Check Cuvette Loader / Shuttle movement / Accumulator via Diagnostics

7 Perform Arm Coordinate in Diagnostics

8 Check Liquid Level Detection (LLD) in Diagnostics

9 Check sample / diluent / Reagent racks for ease of Insertion.

10 Check Barcode movement.

11 Check Magnetic Stirrer Bar Rotation.

12 Perform Air / Factor diluent Blanking via Diagnostics.

13 Check Voltages via Diagnostics.

14 Check Temperatures via Status Screen.

15 Check Sensors via Diagnostics.

16 Check Barcode Reader using Customer Sample Labels.

17 Check Waste Line Efficiency by Running Waste Pump in Diagnostics.

18 Check Rinse / Clean Solution Line Efficiency.

19 * Verify Air Pressure Maintains Pressure

20 * Perform 25 Switches of Loop Test in Diagnostics

21 * Perform Brake Test in Diagnostics

22 * Run Open and Closed Tubes in all S1, S6, and S12 positions

23 Calibration (PT / Fib)

24 Analytical Test (PT / Fib)

25* Check Piercing of Customer Sample Tubes. (CTS Units Only)

* CTS Units Only



2-6 Start Up Kit Contents

28623500 KIT START-UP,ACL TOPComponent Description Quantity

5575100 CUP SAMPLE 2 ML, 1000/PK 19746606 MAGNETIC, STIR BARS, ACL 6/PK 1

28713400 ASSY, 4L RINSE, ASPIRATOR, ACL TOP 128713200 ASSY, CLEAN ASPIRATOR, ACL TOP 118902000 BOTTLE, PLASTIC 30ML W/ CAP, FUTURA/ADVANCE 19831704 CLEANING AGENT, ACL, 4X500 ML 0.259832700 Critical Care/HemosIL CLEANING AGENT80ML 1

14871705 FUSE, 2.0AMP 250 VOLT, 682 514871713 FUSE 12.5A 250V 5x20MM TLAG 514871708 FUSE 4A 250V 5x20MM TLAG 514871711 FUSE 8A 250V 5x20MM TLAG 529400100 CUVETTES, ACL TOP, 6X100X4 128739800 SYRINGE, 250UL FOR XP3000 PUMP 328911600 SEAL (TIP), 250 UL SYRINGE 618924100 BOTTLE, GLASS, 10/PK, ACL FUTURA/ADVANCE 118924104 BOTTLE KIT, 10X4 ML 119006300 TOOL, STYLET, ACL FUTURA/ADVANCE 129400501 SAMPLE RACK SET 01-12, ACL TOP 129400711 ACL TOP DILUENT RACK SET DA-DC 129400601 RACK SET REAGENT, RA-RF ACL TOP 120009700 HEMOSIL RINSE SOLUTION, 4 LITER 128520500 ADAPTER FOR 4 ML VIAL ACL TOP 1228520900 ADAPTER 10 ML VIAL, ACL TOP 1218794300 TOOL, SYRINGE TIP INSTALLATION, ACL FUTURA/ADVANCE 128741600 ASSY, PUMP/PROBE TUBE 327764900 CABLE ASSY CAT5E CROSSOVER 114871709 FUSE 5A 250V 682 514871702 FUSE 1.25A 250V 5x20MM TLAG 527540300 CORD, POWER 115VAC, 15A SHIELDED 319725500 VDE APPROVED LINE CORD 220V 329401100 CUVETTE WASTE LINER 10 PK, ACL TOP 128525200 BARCODE SHEET, SOLUTIONS ACL TOP 128771800 ASSY WASTE BOTTLE PRESENCE SENSOR 118901300 BOTTLE, WASTE 10L, ACL FUTURA 114871712 FUSE 10A 250V 5x20MM TLAG 519085463 VIAL GLASS 8-PK 20ML 128525100 START-UP, ALIQUOT SET 128766600 CONTAINER, 10L WASTE BOTTLE 129240902 KIT SOFTWARE ACL V2.1/P4.6 INSTALL 19757600 DILUENT, FACTOR, 1X100ML 1

28780200 TRAY 6 SAMPLE RACKS ACL TOP 1 PCS 128526000 ADAPTER, DILUENT, 4ML, ACL-TOP 628526100 ADAPTER, DILUENT, 10ML, ACL-TOP 628526200 ADAPTER, DILUENT, 20ML, ACL-TOP 6



28760500 TUBE, WASTE PUMP ASSY, WASTE 329411100 CUSTOMER NOTICE WASTE CONT DECONTAMINATE 128470400 L-KEY WRENCH SET, METRIC 1.5MM TO 5.0MM 128001500 DOC., ACL TOP PHASE 1 VALUE ASSIGNMANT 128210900 KIT, 2D BARCODE ACL TOP 129242300 KIT, ACL TOP LANGUAGE TRANSLATION 128119500 SPEC. PRECISION PERFORMANCE REQUIREMENT ACL TOP 1

28623520 KIT START-UP,ACL TOP CTSComponent Description Quantity

5575100 CUP SAMPLE 2 ML, 1000/PK 19746606 MAGNETIC, STIR BARS, ACL 6/PK 1

28713400 ASSY, 4L RINSE, ASPIRATOR, ACL TOP 128713200 ASSY, CLEAN ASPIRATOR, ACL TOP 118902000 BOTTLE, PLASTIC 30ML W/ CAP, FUTURA/ADVANCE 1

9831704 CLEANING AGENT, ACL, 4X500 ML 0.259832700 Critical Care/HemosIL CLEANING AGENT80ML 1

14871705 FUSE, 2.0AMP 250 VOLT, 682 514871713 FUSE 12.5A 250V 5x20MM TLAG 514871708 FUSE 4A 250V 5x20MM TLAG 514871711 FUSE 8A 250V 5x20MM TLAG 529400100 CUVETTES, ACL TOP, 6X100X4 128739800 SYRINGE, 250UL FOR XP3000 PUMP 328911600 SEAL (TIP), 250 UL SYRINGE 618924100 BOTTLE, GLASS, 10/PK, ACL FUTURA/ADVANCE 118924104 BOTTLE KIT, 10X4 ML 119006300 TOOL, STYLET, ACL FUTURA/ADVANCE 129400501 SAMPLE RACK SET 01-12, ACL TOP 129400711 ACL TOP DILUENT RACK SET DA-DC 129400601 RACK SET REAGENT, RA-RF ACL TOP 120009700 HEMOSIL RINSE SOLUTION, 4 LITER 128520500 ADAPTER FOR 4 ML VIAL ACL TOP 1228520900 ADAPTER 10 ML VIAL, ACL TOP 1218794300 TOOL, SYRINGE TIP INSTALLATION,FUTURA /ADVANCE 127764900 CABLE ASSY CAT5E CROSSOVER 114871709 FUSE 5A 250V 682 514871702 FUSE 1.25A 250V 5x20MM TLAG 527540300 CORD, POWER 115VAC, 15A SHIELDED 319725500 VDE APPROVED LINE CORD 220V 329401100 CUVETTE WASTE LINER 10 PK, ACL TOP 128525200 BARCODE SHEET, SOLUTIONS ACL TOP 128771800 ASSY WASTE BOTTLE PRESENCE SENSOR 118901300 BOTTLE, WASTE 10L, ACL FUTURA 114871712 FUSE 10A 250V 5x20MM TLAG 519085463 VIAL GLASS 8-PK 20ML 128525100 START-UP, ALIQUOT SET 128766600 CONTAINER, 10L WASTE BOTTLE 1

9757600 DILUENT, FACTOR, 1X100ML 1



28780200 TRAY 6 SAMPLE RACKS ACL TOP 1 PCS 128526000 ADAPTER, DILUENT, 4ML, ACL-TOP 628526100 ADAPTER, DILUENT, 10ML, ACL-TOP 628526200 ADAPTER, DILUENT, 20ML, ACL-TOP 628760500 TUBE, WASTE PUMP ASSY, WASTE 328366800 FILTER, MOLDED 1228666400 PIERCER PROBE, CTS 128660102 CRU, SAMPLE PROBE N SEAL 128470400 L-KEY WRENCH SET, METRIC 1.5MM TO 5.0MM 129315200 TUBE ASSY, PRECISION, UNIV. 329400901 SAMPLE RACK SET 01-12, ACL CTS 128386300 ASSY, FILTER CHANGER, CTS 128529400 ASSY, CTS TUBE ADAPTER 128210900 KIT, 2D BARCODE ACL TOP 129411100 CUSTOMER NOTICE WASTE CONTAINER DECONTAMINATION 129240920 KIT, ACL TOP V2.5.5 MAIN SYSTEM SOFTWARE INSTALLATION 1


Chapter 3 – Troubleshooting 3 - 1

Chapter 3 –Troubleshooting

3-1 Overview

The troubleshooting chapter provides information on troubleshooting resources the ACL TOP software pro-vides to the field engineer and end user located under the menu tool bar. The information contained in this chapter is intended for use by IL authorized personnel only.

Alarm Messages

In normal mode, the user is notified of alarm messages via Alarm Buttons on the status bar of the ACL TOP. screens. The system notifies the user of new alarm messages in the following ways:

• A blinking red or yellow exclamation point appears within the alarm button category on the status bar

• The system provides an audible beep

The ACL TOP produces two types of alarm messages:

• Warning

• Error

Message Windows are displayed as pop-up windows when information needs to be conveyed to the oper-ator or operator intervention is required.

Alarm messages can be either warning-level or error-level.

Warning-Level Alarm Messages

This type of alarm message indicates that some user action may be required. Warnings do not affect the operation of the instrument. However, an error condition may eventually occur if the operator does not per-form the required action.

To view an Alarm Message:

• Click the alarm button at the bottom of the screen for the specific type of alarm desired and openthat Alarm window. A list of all archived alarm messages can also be viewed by selecting System-> General.

Warning-level alarms are indicated by a yellow exclamation point on the alarm button, for example:


3 - 2 Chapter 3 – Troubleshooting

Error-Level Alarm Messages

This type of alarm message indicates that a condition has been detected that requires immediate action. Failure to act may result in the instrument performing an Emergency Stop.

Error-level alarms display a red exclamation point on the alarm button, for example:

When the button is enabled but has no exclamation point superimposed over it there are no new alarms, for example:

The following alarm buttons appear on the status bar:

Alarm Button Alarm Name Description

Materials Alarms related to the availability of materials on board the AM. This button is displayed with the warning symbol.

Job Frequency Alarms related to the ability of the analyzer to complete a test. For example, the materials to run a test may not be availible on the instrument. This button is displayed with the error symbol.

Quality Control Alarms related to the Quality Control functionality.

Maintenance Alarms that indicate a maintenance operation must be performed. This button is displayed without an exclamation point, indicating no new messages.

Analyzer Alarms related to the AM functionality.

LIS Alarms related to the host connection.



3-2 System Selections

Maintenance

The Maintenance screen is accessed under "System" on the menu tool bar or using the icon of the book in the lower right hand side of the tray area. See Figure 3-1 Maintenance Selection

Figure 3-1 Maintenance Selection

The Maintenance screen is used to perform various maintenance tasks. Place a check mark next to the desired maintenance activity. Click the Perform icon and enter a comment in the Comment dialog box if appropriate. Click OK. Refer to the On Line Help for a detailed description of the Maintenance screen. See Figure 3-2 "The Maintenance Screen".


hapter 3 – Troubleshooting 3 - 4


C

Figure 3-2 The Maintenance Screen


General Log List

The General Log List is accessed under "System" on the menu tool bar or using the icon of the book in the lower right hand side of the tray area. See Figure 3-3 "General Log List Selection"

Figure 3-3 General Log List Selection

The General Log contains system information including alarms, errors, warnings, and instrument mode changes. Each line includes the associated date/time they occurred, functional area affected, user logged in, and a brief description. Reviewed sequentially the general log can provide an account of recent events. See Figure 3-4 "General Log List".




C

Figure 3-4 General Log List



Do d descriptions, causes, and operator actions to

No Line Number should be sent to the Software

C

uble clicking on an error brings up the General Log Detail pop up screen. This pop up screen contains tabs with detailecorrect the error as well as a tab for the end user to leave comments. See Figure 3-5 "General Log Entry Details".

te: On occasion, additional information on a particular error is requested. In that event the Error code, File name andDepartment of Instrumentation Laboratory per normal procedures.

Figure 3-5 General Log Entry Details


Instrument Status

Selecting Instrument Status (Figure 3-6 "Instrument Status") from the pull down menu displays a two tab screen. The tabs are labeled “Temperature” and “SW version” as shown in the following descriptions.

Figure 3-6 Instrument Status



Temperature Tab

The Temperature Tab displays a snap shot of the thermally regulated modules and their temperatures. The tab can be refreshed and printed. See Figure 3-7 "Temperature Tab on Instrument Status".

Figure 3-7 Temperature Tab on Instrument Status



SW Version Tab

The SW Version tab lists all of the software versions in the TOP (see Figure 3-8 "SW Versions on Instru-ment Status."). This tab can be printed.

Figure 3-8 SW Versions on Instrument Status.



Statistics

Selecting Statistics from the pull down brings up another two tab screen Status and Alarms.(see Figure 3-9 "Statistics").

Figure 3-9 Statistics



Status Tab

The Status Tab (see Figure 3-10 "Status Tab on Statistics Screen") lists all of the different instrument states and the time and percentage of total time the instrument has been in that state.

Figure 3-10 Status Tab on Statistics Screen



Alarms Tab

The Alarms Tab lists all of the alarms the instrument has experienced as well of the percentage each alarm accounts for as part of the total (see Figure 3-11 "Alarms Tab on Statistics Screen"). This tab can be reset to restart monitoring.

Figure 3-11 Alarms Tab on Statistics Screen

3-3 Alarm List

The tables below represents a partial list of error codes. The errors listed are beyond the expertise of the operator to resolve and require service resolution. The common service resolutions are listed with the error code in the column titled Service Action.

Error codes for alarms resolvable at the operator level can be found in the Online Help .

NOTE: The Alarm List is sorted in ascending order by Error Code Number.




Action Service Manual Section

System Response

Where raised

D Server, Processor/Software

Perform an emergency stop and shutdown the application.

CM

ACcaE

over cable, nnector, CPU PCB.

Processor/Software

- Notify the alarm via the UI- Perform an emergency stop

AM Mas-terCM

PIn(Fm

II CPU, PC omputor

nections.

Processor/Software


AM Mas-ter

(Psoiz(FSA

ware defect. n the log s and sub-int into the stem for ttention.

Processor/Software

- Notify the alarm via the UI (if possible)- Do not go to READY state

AM Con-trollers

(Psoiz(FInatRA


Processor/Software


AM Con-trollers

C

Alarm/Error Name

Alarm Description Code Message Cause Operator Action Service

B down The database service is down and it is not accessible.

An unrecoverable data base excep-tion has occurred.

The database ser-vice got discon-nected.

Start SQL service.Start CM applica-tion.

1) Start SQL2) Restart CM

M-CM ommuni-tion

rror

A non-recoverable error occurred in the CM/AM Communica-tions Manager (e.g. loss of connection).

0 Analyzer / Control Module loss of communication.

Communication cable disconnec-tion. Software or electronic failure.

Check communica-tion cable.Power off and restart the instru-ment.If the problem per-sists, call Service.

Check crossbulk head coand Level II

rogram tegrity ailure): aster

Failure of LRC or CRC check.

0005 Master controller failure.

Master controller board malfunction.

Power off and restart the instru-ment.If the problem per-sists, call Service.

Check level104 and all chousing con

roces-r) Initial-

ation ailure): ample rm

One of the AM proces-sors failed to initialize, due to an Invalid Con-troller ID.

0008 Sample Arm con-troller initialization failure.

Sample Arm con-troller board did not pass initialization tests.


This is a softPlease obtaifiles / backupmit a complacomplaint syimmediate a

roces-r) Initial-

ation ailure): termedi-e eagent rm


0009 Intermediate Reagent Arm con-troller initialization failure.

Intermediate Reagent Arm con-troller board did not pass initialization tests.





AlEN

ction Service Manual Section

System Response

Where raised

(Prosor) izatio(FailStartReaArm

re defect. he log and sub- into the m for tion.

Processor/Software


AM Con-trollers

(Prosor) izatio(Failcuve


Processor/Software


AM Con-trollers

(Prosor) izatio(Failrack


Processor/Software


AM Con-trollers

(Prosor) izatio(FailORU


Processor/Software


AM Con-trollers

InvaParater: m


Processor/Software


AM Mas-terAM Con-trollers

C

arm/rror ame

Alarm Description Code Message Cause Operator Action Service A

ces-Initial-n

ure): gent


0010 Start Reagent Arm controller initializa-tion failure.

Start Reagent Arm controller board did not pass initializa-tion tests.


This is a softwaPlease obtain tfiles / backups mit a complaintcomplaint systeimmediate atten

ces-Initial-n

ure): tte


0011 Cuvettes controller initialization failure.

Cuvettes controller board did not pass initialization tests.



ces-Initial-n

ure):


0012 Racks controller ini-tialization failure.

Racks controller board did not pass initialization tests.



ces-Initial-n

ure):


0013 Optical Reading Units controller ini-tialization failure.

Optical Reading Units controller board did not pass initialization tests.



lid me-aster

Invalid parameter pro-vided in a function call, message queue or inter-task communica-tion mechanism.

0015 Master Controller software error.

Built-in checks in the software detected an unre-coverable error.






System Response

Where raised

InPte


Processor/Software



InPte


Processor/Software



InPte


Processor/Software



InPteA


Processor/Software



CCE

II CPU, controller l software

Processor/Software



C

Alarm/Error Name


valid arame-r: cuvette


0016 Cuvettes Control-ler software error.




valid arame-r: rack


0017 Racks Controller software error.




valid arame-r: ORU


0018 Optical Reading Units Controller software error.




valid arame-r: Sample rm


0019 Sample Arm Con-troller software error.




TRL omm rror

A non-recoverable error occurred in the Controller Communica-tions Manager or the low level CAN bus driver (master or con-troller side).

0020 Analyzer internal communication error.



Check LevelPC104, ALLPCBs and alrevisions.




System Response

Where raised

InPtemRA


Processor/Software



InPteRA


Processor/Software



MA(Fm


Processor/Software



Ourte


Processor/Software



Ourcu


Processor/Software



C

Alarm/Error Name


valid arame-r: Inter-ediate eagent rm


0021 Intermediate Reagent Arm Con-troller software error.




valid arame-r: Start eagent rm


0022 Start Reagent Arm Controller software error.




emory llocation ailure): aster

Memory allocation failed or stack usage exceeds limit.





S (Fail-e): mas-r

Error detected when calling kernel facilities.





S (Fail-e): vette









System Response

Where raised

Our


Processor/Software



Our


Processor/Software



SLourte


Processor/Software



SLourcu


Processor/Software



SLour


Processor/Software



C

Alarm/Error Name


S (Fail-e): rack






S (Fail-e): ORU






oftware gic (Fail-e): mas-r

Software logic error such as an invalid path in a switch statement or if else branch.





oftware gic (Fail-e): vette






oftware gic (Fail-e): rack









System Response

Where raised

SLour


Processor/Software



InStte


Processor/Software



InStcu


Processor/Software



InSt


Processor/Software



InS


Processor/Software



C

Alarm/Error Name


oftware gic (Fail-e): ORU






valid ate: mas-r

Invalid state for an event, function call, message, etc.





valid ate: vette






valid ate: rack






valid tate: ORU









System Response

Where raised

Stm


Processor/Software


AM Con-trollers

Stcu


Processor/Software


AM Con-trollers

Stra


Processor/Software


AM Con-trollers

StO


Processor/Software


AM Con-trollers

UCmm


Processor/Software



C

Alarm/Error Name


ack Low: aster

It was detected that there is a potential for a stack problem.





ack Low: vette






ack Low: ck






ack Low: RU






nknown om-and: aster

The command received is not sup-ported.








System Response

Where raised

UCmcu


Processor/Software



UCm


Processor/Software



UCmO


Processor/Software



Aco

II CPU, able, CM ions.

Processor/Software

- Notify the user as appropriate.- The AM on its side performs an emergency stop

CM

C

Alarm/Error Name


nknown om-and: vette






nknown om-and: rack






nknown om-and: RU






M Dis-nnection

The CM has lost the connection with the AM module.

0056 Interrupted commu-nication between the Analyzer and the Control Module.

Communication cable discon-nected. Analyzer powered off. Other hardware/software communication problems.

Check communica-tion cable connec-tion. Verify that the Analyzer is pow-ered on. Restart the system (both Ana-lyzer and Control Module); if the problem persist call Service.

Check Levelcross over cand connect




System Response

Where raised

CUFa

re versions r card flash troller flash not be com-

Processor/Software

- Notify user through alarms area.

CM

Ourpl


Processor/Software



OurmRA


Processor/Software



OurRA


Processor/Software



SLourpl


Processor/Software



C

Alarm/Error Name


ontroller pgrade iled

Controller Upgrade has failed since down-loaded SW version does not match SW version actually used.

0058 Downloaded con-troller Software ver-sion (<Downloaded File Name>) is dif-ferent than Soft-ware version actually used by AM (<Used File Name>).

Controller Upgrade has failed.

Call Service. Verify softwaand controlleversion. Conversion maypatible.

S (Fail-e): Sam-e Arm






S (Fail-e): Inter-ediate eagent rm






S (Fail-e): Start eagent rm






oftware gic (Fail-e): Sam-e Arm









System Response

Where raised

SLourmRA


Processor/Software



SLourRA


Processor/Software



InStSA


Processor/Software



InStInatRA


Processor/Software



InStRA


Processor/Software



C

Alarm/Error Name


oftware gic (Fail-e): Inter-ediate eagent rm






oftware gic (Fail-e): Start eagent rm






valid ate: ample rm






valid ate: termedi-e eagent rm






valid ate: Start eagent rm









System Response

Where raised

StSA


Processor/Software


AM Con-trollers

StInatRA


Processor/Software


AM Con-trollers

StStRA


Processor/Software


AM Con-trollers

UCmSA


Processor/Software



UCmInatRA


Processor/Software



C

Alarm/Error Name


ack Low: ample rm






ack Low: termedi-e eagent rm






ack Low: art eagent rm






nknown om-and: ample rm






nknown om-and: termedi-e eagent rm









System Response

Where raised

UCmStRA


Processor/Software



A(DFaE

bling in the m, CCU 900 rs.

Robotic XYZ


AM Mas-ter

A(DFaE

bling in the m, CCU sensors

Robotic XYZ


AM Mas-ter

A(DFaE

9000. Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


nknown om-and: art eagent rm






rm evice ult) -

RR 1

The CAVRO arm is inoperable

1001 <Arm> Arm failure. Software or mechanical error. Initialization error.

The system per-formed an Emer-gency stop: perform a Recov-ery.If the problem per-sists call Service.

Check all caCavro Systeand all senso

rm evice ult) -

RR 2


1002 <Arm> Arm failure. Software or mechanical error.Invalid Command.


Check all caCavro Syste9000 and all

rm evice ult) -

RR 3


1003 <Arm> Arm failure. Software or mechanical error.Invalid Operand.


Suspect CCU




System Response

Where raised

A(DFaE

9000. Robotic XYZ


AM Mas-ter

A(DFaE

9000. Robotic XYZ


AM Mas-ter

A(DFaE

se connec-ables and alfunction-odule may is error.

Robotic XYZ


AM Mas-ter

A(DFaE

CU 9000 ling to it.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm evice ult) -

RR 4


1004 <Arm> Arm failure. Software or mechanical error.Invalid command sequence.


Suspect CCU

rm evice ult) -

RR 5


1005 <Arm> Arm failure. Software or mechanical error.Device not imple-mented.


Suspect CCU

rm evice ult) -

RR 6


1006 <Arm> Arm failure. Software or mechanical error.Timeout error.


Check for lootions at the csensors. A ming syringe malso cause th

rm evice ult) -

RR 7


1007 <Arm> Arm failure. Software or mechanical error.Device not initial-ized.


Inspect the CPCB and cab




System Response

Where raised

A(DFaE

9000. Robotic XYZ


AM Mas-ter

A(DFaE

caused by more likely .

Robotic XYZ


AM Mas-ter

A(DFaE

9000. Robotic XYZ


AM Mas-ter

A(DFaE

caused by more likely, .

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm evice ult) -

RR 8


1008 <Arm> Arm failure. Software or mechanical error.Command over-flow.


Suspect CCU

rm evice ult) -

RR 9


1009 <Arm> Arm failure. Software or mechanical error.No liquid detected with ZX command.


Error may beCCU 900 or the DRI PCB

rm evice ult) -

RR 10


1010 <Arm> Arm failure. Software or mechanical error.Entered move for Z-axis out of range.


Suspect CCU

rm evice ult) -

RR 11


1011 <Arm> Arm failure. Software or mechanical error.Not enough liquid detected with ZX command.


Error may beCCU 900 or,the DRI PCB




System Response

Where raised

A(DFaE


Robotic XYZ


AM Mas-ter

A(DFaE


Robotic XYZ


AM Mas-ter

A(DFaE

ensors. Robotic XYZ


AM Mas-ter

A(DFaE

ding and .

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm evice ult) -

RR 12


1012 <Arm> Arm failure. Software or mechanical error.No liquid detected with ZZ command.



rm evice ult) -

RR 13


1013 <Arm> Arm failure. Software or mechanical error.Not enough liquid detected with ZZ command.



rm evice ult) -

RR 17


1017 <Arm> Arm failure. Software or mechanical error.Arm collision avoided.


Check Arm S

rm evice ult) -

RR 20


1020 <Arm> Arm failure. Software or mechanical error.Step loss on X axis.


Check for binobstructions




System Response

Where raised

A(DFaE

ding and .

Robotic XYZ


AM Mas-ter

A(DFaE

ding and .

Robotic XYZ


AM Mas-ter

A(DFaE

ding and .

Robotic XYZ


AM Mas-ter

A(DFaE

aldium or Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm evice ult) -

RR 21


1021 <Arm> Arm failure. Software or mechanical error.Step loss on Y axis.



rm evice ult) -

RR 22


1022 <Arm> Arm failure. Software or mechanical error.Step loss on Z axis.



rm evice ult) -

RR 23


1023 <Arm> Arm failure. Software or mechanical error.Step loss detected on X-axis of oppos-ing arm.



rm evice ult) -

RR 24


1024 <Arm> Arm failure. Software or mechanical error.ALDIUM pulse time out.


Suspect the DRI PCB.




System Response

Where raised

A(DFaE

and check ections.

Robotic XYZ


AM Mas-ter

A(DFaE

and check ections.

Robotic XYZ


AM Mas-ter

A(DFaE

and check ections.

Robotic XYZ


AM Mas-ter

A(DFaEU

bling in the m, CCU 900 rs.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm evice ult) -

RR 25


1025 <Arm> Arm failure. Software or mechanical error.Tip not fetched.


Clean probeall LLD conn

rm evice ult) -

RR 26


1026 <Arm> Arm failure. Software or mechanical error.Tip crash.



rm evice ult) -

RR 27


1027 <Arm> Arm failure. Software or mechanical error.Tip not clean.



rm evice ult) -

RR NDEF


1028 <Arm> Arm failure. Software or mechanical error.Undefined error code reported.


Check all caCavro Systeand all senso




System Response

Where raised

A(DFaTI

se cable onnections. ning sryinge also cause

Robotic XYZ


AM Mas-ter

SP(FE

error. This when the initialize. ckages and

ctions pting to he pump pt com-it has been initialized. n only be uccessfully e probe.

Fluid Movement


AM Mas-ter

SP(FE

and. This when an d command

re defect or ion error.

Fluid Movement


AM Mas-ter

C

Alarm/Error Name


rm evice ult) - ME OUT


1029 <Arm> Arm failure. Software or mechanical error.Communication timeout.


Check for looand sensor cA malfunctiomodule maythis error.

yringe ump ault) - RR 1

The pump used to aspirate/dispense flu-ids is inoperable.

1031 <Syringe> Syringe failure.

Software or mechanical error. Initialization error.

The system per-formed an Emer-gency stop: perform a Recov-ery. If the problem persists call Ser-vice.

Initialization error occurs pump fails toCheck for bloloose connebefore attemreinitialize. Twill not accemands until successfullyThis error cacleared by sinitializing th




Software or mechanical error. Invalid command.


Invalid commerror occurs unrecognizeis issued. Either Softwacommunicat




System Response

Where raised

SP(FE

nd. This when an eter (<n>)

a com-


Fluid Movement


AM Mas-ter

SP(FE

and his error the com-re or com-rotocol is


Fluid Movement


AM Mas-ter

C

Alarm/Error Name





Software or mechanical error. Invalid operand.


Invalid operaerror occurs invalid paramis given withmand.Either Softwacommunicat




Software or mechanical error. Invalid command sequence.


Invalid commsequence. Toccurs whenmand structumunication pincorrect.Either Softwacommunicat




System Response

Where raised

SP(FE

on. This when the detects

s caused by out of the alve.error:the pumphe valveny detect- sensor a cotton n insert the

h the valve he front ently wipe

the valve is put a new pump.e the pump

Fluid Movement


AM Mas-ter

SP(FE

ilure. This when the faulty.

Fluid Movement


AM Mas-ter

C

Alarm/Error Name



Fluid Detection Error. This error occurs when the sensor board detects fluid, which is caused by leaking out the back of the valve.


The sensor board detects fluid, which is caused by leak-ing out the back of the valve.


Fluid detectierror occurs sensor boardfluid, which ifluid leaking back of the vTo clear the 1. Power off 2. Remove t3. Wipe up aable fluid onboard using swab. You caswab througopening on tpanel, and gthe circuit.4. Assumingleaking fluid,valve on the5. Reinitializ


EEPROM Failure. This error occurs when the EEPROM is faulty.


EEPROM is faulty. The system per-formed an Emer-gency stop: perform a Recov-ery. If the problem persists call Ser-vice.

EEPROM Faerror occurs EEPROM is




System Response

Where raised

SP(FE

itialized. curs when not initial- a command syringe inge is in

error, reini-ringe.

Fluid Movement


AM Mas-ter

SP(FEUFI

d error code orted by the

an be a ion error, a e syringe or oftware.

Fluid Movement


AM Mas-ter

SP(FTI

ion timeout

an be

error condi-

ication fail- master vro module the syringe wn the

ations

Fluid Movement


AM Mas-ter

OabC

95 Reaction Detection

- Notify the alarm via the UI.

AM Mas-ter

C

Alarm/Error Name





Software or mechanical error. Device not initial-ized.


Device not inThis error octhe pump is ized or whenis sent to thewhen the syrerror status.To clear the tialize the sy

yringe ump ault) - RR NDE-NED



Software or mechanical error. Undefined error code reported.


Unrecognizehas been repsyringe.The cause ccommunicatproblem in tha defect in s

yringe ump ault) - ME OUT



Software or mechanical error. Communication timeout.


Communicatexpired.This failure ccaused by:1. a previoustion2. a communure betweenboard and ca3. A defect inthat slows dosyringe oper

RU Dis-led -

ause 2

The ORU Head has been disabled due to low air limit.

1042 The Optical Read-ing Unit <ORU ID> has been disabled.

The ORU has been disabled. Air read-ing out of range (low).

Call Service. See code 12




System Response

Where raised

OabC



AM Mas-ter

OabC



AM Mas-ter

OabC



AM Mas-ter

OabC

r cables, wer supply. s correct, module.

Reaction Detection


AM Mas-ter

SP(FE

load. THis when move-yringe

ocked by ck pres-mp must be efore nor-

n can

Fluid Movement


AM Mas-ter

C

Alarm/Error Name


RU Dis-led -

ause 3

The ORU Head has been disabled due to due to a high air limit.


The ORU has been disabled. Air read-ing out of range (high).


RU Dis-led -

ause 4

The ORU Head has been disabled due to air drift low limit.


The ORU has been disabled. Air read-ing drift (low) detected.


RU Dis-led -

ause 5

The ORU Head has been disabled due to air drift high limit.


The ORU has been disabled. Air read-ing drift (high) detected.


RU Dis-led -

ause 6

The ORU Head has been disabled due to an ORU voltage prob-lem.


The ORU has been disabled. Detector voltage error detected.

Call Service. Check powefuses, and poIf power lookreplace ORU


Plunger Overload. This error occurs when movement of the syringe plunger is blocked by excessive pressure.


Movement of the syringe plunger was blocked by excessive pres-sure.


Plunger overerror occurs ment of the splunger is blexcessive basure. The pureinitialized bmal operatioresume.




System Response

Where raised

SP(FE

ad. This when the ses steps or excess re. The e reinitial-ormal oper-ume.lve overload indication uld be

Fluid Movement


AM Mas-ter

SP(FE

e Not en the valve or through-plunger ommands ed.n be caused s error con- defect in

Fluid Movement


AM Mas-ter

SP(FE

verflow. curs when d buffer con-ny charac-

n be caused s error con-ct in soft-munication

Fluid Movement


AM Mas-ter

C

Alarm/Error Name



Valve Overload. This error occurs when the valve drive loses steps by blockage or excess back pressure. Contin-ual valve overload errors are an indication the valve should be replaced.


Valve drive loses steps by blockage or excess back pressure.


Valve Overloerror occurs valve drive loby blockage back pressuvalve must bized before nation can resContinual vaerrors are anthe valve shoreplaced.


Plunger Move Not Allowed. When the valve is in bypass or throughput position plunger movement commands are not allowed.


Plunger Move Not Allowed. When the valve is in bypass or throughput posi-tion plunger move-ment commands are not allowed.


Plunger MovAllowed. Whis in bypass put position movement care not allowThis error caby a previoudition of by asoftware.


Command Overflow. This error occurs when the command buffer contains too many characters.


Command Over-flow. This error occurs when the command buffer contains too many characters.


Command OThis error octhe commantains too maters.This error caby a previoudition, a defeware or comerror.




System Response

Where raised

CCE

then check and power O control the problem t, then plaint to cidence as mented lem.

Processor/Software

- Notify the alarm via the UI- Execute an emergency stop


InTetu(In#1

wire could e thermistor rted, or the

d require o help trou-e Diagnos-ab. If the is fluctuat-ly out of , then re-he tempera-solid then ires could cted or bro-perature is en the ther-

are proba-

Thermal Control

- Notify the alarm via the UI- Turn off power to affected heater.- Perform Con-trolled Stop

C

Alarm/Error Name


AVRO omm rror

RS232 communica-tions error with CAVRO arms

1105 Arm communica-tion error.

Software or Hard-ware failure.

Call Service. If consistent,both cablingto the CAVRunit board. Ifis intermittenreport a comrecord the inthis is a docuCAVRO prob

cubator mpera-re Error cubator )

Incubator temperature defined to be out of range for a period exceeding the fatal error limits.

1110 Cuvettes incubator No. 1 temperature control failure.

Temperature out of range in cuvette incubator.

Call Service. The heating be broken, thcould be shomodule coulcalibration. Tbleshoot, ustics > ORU Ttemperatureing and barespecificationcalibrate. If tture is stuck the heating wbe not conneken. If the temfluctuating, thmistor wires bly okay.




System Response

Where raised

InTetu(In#2



are proba-

Thermal Control


C

Alarm/Error Name


cubator mpera-re Error cubator )

Incubator temperature defined to be out of range for a period exceeding the fatal error limits.


Temperature out of range in cuvette incubator.





System Response

Where raised

OpeE#1



are proba-

Thermal Control


C

Alarm/Error Name


RU Tem-rature

rror (ORU )

ORU temperature defined to be out of range for a period exceeding the fatal error limits.

1115 Optical reading unit No. 1 temperature control failure.

Temperature out of range in optical reading unit.





System Response

Where raised

OpeE#2



are proba-

Thermal Control


C

Alarm/Error Name


RU Tem-rature

rror (ORU )








System Response

Where raised

OpeE#3



are proba-

Thermal Control


C

Alarm/Error Name


RU Tem-rature

rror (ORU )








System Response

Where raised

OpeE#4



are proba-

Thermal Control


C

Alarm/Error Name


RU Tem-rature

rror (ORU )








System Response

Where raised

CSTe


d require o help trou-e Diagnos-es Tab. If ure is fluctu-rely out of , then re-he tempera-solid then ires could cted or bro-perature is en the ther-

are proba-

Thermal Control

- Notify the alarm via the UI- Turn off power to affected heater.- Perform an controlled stop

RTe

ermistor for t. If temp is ck the fans eration and

Thermal Control

- Notify the alarm via the UI- Turn off power to affected heater.- Perform a con-trolled stop

DA(F

sistent, then RU mod-

ent, report a

Reaction Detection


AM Con-trollers

C(ESA

universal controller.

Processor/Software


AM Con-trollers

C

Alarm/Error Name


uvette huttle mp Error

Cuvette Shuttle tem-perature defined to be out of range for a period exceeding the fatal error limits.

1120 Cuvette shuttle temperature control failure.

Cuvette shuttle temperature out of range.

The system per-formed a controlled stop: the run has to be re-started. If the problem persists call Service.

The heating be broken, thcould be shomodule coulcalibration. Tbleshoot, ustics > Cuvettthe temperatating and baspecificationcalibrate. If tture is stuck the heating wbe not conneken. If the temfluctuating, thmistor wires bly okay.

eagent mp Error

Reagent Area temper-ature defined to be out of range for a period exceeding the fatal error limits.

1125 Reagent area tem-perature control failure.

Reagent area tem-perature out of range.


Check the Thopen or shorout high, chefor proper opbloackage.

ata cquisition ault)

Detector interface fault, e.g. conversion did not complete, emitter light source not correct.

1130 Optical reading units data acquisi-tion control failure.

Built-in checks detected an error.

Call Service. If error is perreplace the Oule. If infrequcomplaint.

RC rror):

ample rm

CRC Error detected in writing to or reading from a permanent stor-age device (e.g. EEPROM)

1132 Sample Arm con-troller failure.

Sample Arm con-troller board mal-function.

Call Service. Replace the sample arm




System Response

Where raised

C(EInatRA

universal reagent r.

Processor/Software


AM Con-trollers

C(EStRA

universal arm con-

Processor/Software


AM Con-trollers

C(Ecu

cuvette con-te thermal r the s.

Processor/Software


AM Con-trollers

C(Era

rack control-thermal cali-e cuvette

Processor/Software


AM Con-trollers

C(EO

ORU con-te thermal r the s.

Processor/Software


AM Con-trollers

StW(Fcu

5. Processor/Software


AM Con-trollers

StW(Fra



AM Con-trollers

C

Alarm/Error Name


RC rror): termedi-e eagent rm


1133 Intermediate Reagent Arm con-troller failure.

Intermediate Reagent Arm con-troller board mal-function.

Call Service. Replace the intermediatearm controlle

RC rror): art eagent rm


1134 Start Reagent Arm controller failure.

Start Reagent Arm controller board malfunction.

Call Service. Replace the start reagenttroller.

RC rror): vette


1135 Cuvettes controller failure.

Cuvettes controller board malfunction.

Call Service. Replace the troller. Execucalibration focuvette area

RC rror): ck


1136 Racks controller failure.

Racks controller board malfunction.

Call Service. Replace the ler. Execute bration for thareas.

RC rror): RU


1137 Optical Reading Units controller fail-ure.

Optical Reading Units controller board malfunction.

Call Service. Replace the troller. Execucalibration focuvette area

orage rite ault): vette

Error detected in updating data on a per-manent storage device (e.g. EEPROM)

1140 Cuvettes controller failure.


Call Service. Refer to 113

orage rite ault): ck


1141 Racks controller failure.






System Response

Where raised

StW(FO



AM Con-trollers

StW(FSA



AM Con-trollers

StW(FInatRA



AM Con-trollers

StW(FStRA



AM Con-trollers

C

Alarm/Error Name


orage rite ault): RU


1142 Optical Reading Units controller fail-ure.



orage rite ault): ample rm


1144 Sample Arm con-troller failure.



orage rite ault): termedi-e eagent rm


1145 Intermediate Reagent Arm con-troller failure.



orage rite ault): art eagent rm


1146 Start Reagent Arm controller failure.






System Response

Where raised

VoM(FSA

could be , cabling, y, or the ard itself. kins and items in the f the system Diagnostics ab to exam-es of the

gainst their ltage is mar- limits, upply.

Power Manage-ment


AM Con-trollers

VoM(FInatRA



Power Manage-ment


AM Con-trollers

C

Alarm/Error Name


ltage onitor ault): ample rm

Voltage out-of-range fault detected on a con-troller.

1152 Sample Arm con-troller voltage out of range.


Call Service. The problemwith the fusepower supplcontroller boRemove all scheck these order listed. Iallows, enter> Voltages Tine the voltagcontrollers alimits. If a voginally out ofreplace the s

ltage onitor ault): termedi-e eagent rm


1153 Intermediate Reagent Arm con-troller voltage out of range.






System Response

Where raised

VoM(FStRA



Power Manage-ment


AM Con-trollers

VoM(Fcu



Power Manage-ment


AM Con-trollers

C

Alarm/Error Name


ltage onitor ault): art eagent rm


1154 Start Reagent Armcontroller voltage out of range.



ltage onitor ault): vette


1155 Cuvettes controller voltage out of range.






System Response

Where raised

VoM(Fra



Power Manage-ment


AM Con-trollers

VoM(FO



Power Manage-ment


AM Con-trollers

C

Alarm/Error Name


ltage onitor ault): ck


1156 Racks controller voltage out of range.



ltage onitor ault): RU


1157 Optical Reading Units controller voltage out of range.






System Response

Where raised

FMCesMceAFa

tes check

etallic edge lean station nitialize

ference diagnostics the "Coordi-ent" routine

Robotic XYZ

- Notify the alarm via the UI

AM Mas-ter

FMCesad

nostics a coordi-ment of the

Robotic XYZ

- Notify the alarm via the UI- Impossible to start jobs, there-fore the instru-ment cannot go to ready

AM Mas-ter

(OInCtio

e incuba- heads are

ke sure ubator backplane Otherwise, module ators.

Reaction Detection

- Notify the alarm via the UI- Impossible to start jobs, there-fore the instru-ment cannot go to ready

AM Con-trollers

C

Alarm/Error Name


ov oor(dinat) aint(enan)

utocheck il

Automatic coordinates check failure

1160 Arm <Arm> coordi-nates error or CTS foot coordinates error.

Arm coordinates mismatch.

The arm cannot ini-tialize.Perform a probe alignment.If the problem per-sists call Service.

The coordinafails.- Clean the mof the rinse/cand try to reiagain- Clean all repoints, go toand performnate Adjustm

ov oor(dinat) not justed

AM coordinates have never been adjusted using the "Coordinate adjustment" proce-dure.

1165 Arm <Arm> coordi-nate adjust required.

Coordinate adjust-ment procedure not executed or failed.

Service or Lab Administrator to run the Coordinate Adjust procedure.

Use the diagmode to run nates adjustinstrument.

RU) valid onfigura-n

Invalid emitter, detec-tion, or incubator mod-ule configuration detected, or reference channel not on installed detection module.

1170 Invalid system con-figuration.

System detected a hardware configu-ration that cannot support the current system configura-tion settings: miss-ing or inactive optical reading unit(s), cuvettes incubator or CTS module.

Check system con-figuration settings.Power off and restart the instru-ment.If the problem per-sists, call Service.

Check that thtors and ORUinstalled. MaORU and inccables to theare secured.replace ORUand/or incub




System Response

Where raised

SPPHTetu

n probe, e.

Thermal Control

- Notify the alarm via the UI- Turn Power off to the affected heater- Perform a con-trolled stop

RPPHTetu

n probe, e.

Thermal Control


RPPHTetu

n probe, e.

Thermal Control


CplPHTetu

probe is not rror will not

normal con-act IL if error

Thermal Control


C

Alarm/Error Name


ample robe re(-eater) mpera-re Error

Probe Pre-Heater tem-perature defined to be out of range for a period exceeding the fatal error limits.

1175 Sample probe pre-heater temperature control failure.

Probe pre-heating system malfunc-tion.

The system per-formed a controlled stop. Call Service.

Check fuse oreplace prob

eagent 1 robe re(-eater) mpera-re Error


1176 Reagent 1 probe pre-heater temper-ature control fail-ure.




eagent 2 robe re(-eater) mpera-re Error


1177 Reagent 2 probe pre-heater temper-ature control fail-ure.




TS sam-e Probe re(-eater) mpera-re Error


1178 CTS sample probe pre-heater temper-ature control fail-ure.



CTS Sampleheated, this eoccur under ditions. Contoccurs.




System Response

Where raised

LAplPHTetu

eserved. Thermal Control


SPTetu



Thermal Control


RPTetu

n probe, e.

Thermal Control


RPTetu

n probe, e.

Thermal Control


C

Alarm/Error Name


S sam-e Probe re(-eater) mpera-re Error


1179 LAS sample probe pre-heater temper-ature control fail-ure.



Error Code R

ample robe mpera-re Error

Probe temperature defined to be out of range for a period exceeding the fatal error limits.

1180 Sample probe tem-perature control failure.

Probe heating sys-tem malfunction.


This Sampleheated, this eoccur under ditions. Contoccurs.

eagent 1 robe mpera-re Error


1181 Reagent 1 probe temperature control failure.




eagent 2 robe mpera-re Error


1182 Reagent 2 probe temperature control failure.







System Response

Where raised

CplTetu



Thermal Control


LAplTetu

eserved. Thermal Control


CVaInStSA

diagnostics est. reproduc-the valve is case the working) or ase the

orking).

Fluid Movement


CVaInStRA


orking).

Fluid Movement


C

Alarm/Error Name


TS Sam-e Probe mpera-re Error


1183 CTS sample probe temperature control failure.



CTS Sampleheated, this eoccur under ditions. Contoccurs.

S Sam-e Probe mpera-re Error


1184 LAS sample probe temperature control failure.



Error Code R

lean Fluid lve (in

correct ate): ample rm

Valve commanded ON(OFF) but sensor did not indicate ON(OFF) state.

1185 Sample arm clean fluid valve failure.

Clean fluid valve not responding.


Perform the clean valve tIf the error isible, verify if moves (in thsensor is notnot (in this cvalve is not w

lean Fluid lve (in

correct ate): eagent rm 1


1186 Reagent arm 1 clean fluid valve failure.







System Response

Where raised

CVaInStRA


orking).

Fluid Movement


CPInStS

diagnostics test. reproduc-the pump case the working) or ase the working).

Fluid Movement


CPInStR

diagnostics test. reproduc-the pump case the working) or ase the working).

Fluid Movement


SRPInSt

diagnostics

reproduc-the rinse n this case not work- this case ot working).

Fluid Movement


C

Alarm/Error Name


lean Fluid lve (in

correct ate): eagent rm 2


1187 Reagent arm 2 clean fluid valve failure.




lean ump (in correct ate): ample

Pump commanded ON(OFF) but sensor did not indicate ON(OFF) state.

1190 Sample clean pump failure.

Clean pump not responding.


Perform the clean pump If the error isible, verify if runs (in this sensor is notnot (in this cpump is not

lean ump (in correct ate): eagent


1191 Reagent clean pump failure.

Clean pump not responding.


Perform the clean pump If the error isible, verify if runs (in this sensor is notnot (in this cpump is not

ample inse ump (in correct ate)


1200 Sample rinse pump failure.

Rinse pump not responding.


Perform the rinse test.If the error isible, verify if pump runs (ithe sensor ising) or not (inthe pump is n




System Response

Where raised

RRPInSt

diagnostics


Fluid Movement


RRPInSt

diagnostics


Fluid Movement


LAplPInSt

eserved - Notify the alarm via the UI- Perform an emergency stop

C

Alarm/Error Name


eagent 1 inse ump (in correct ate)


1201 Reagent arm 1 rinse pump failure.




eagent 2 inse ump (in correct ate)


1202 Reagent arm 2 rinse pump failure.




S Sam-e Rinse ump (in correct ate)


1204 LAS sample arm rinse pump failure.



Error Code R




System Response

Where raised

WPInSt

ste pump is l or the sen- the state of mp are not nter Diag-ids tab to ste pump. pump sec-duration of and press on. After the is pressed, should be the waste ing. If the t be heard, the covers e waste peat the mp contin-en check

and power. s moving, re is proba-

tection sen-re the on virtual s state pump is On

Waste Manage-ment


AM Mas-ter

C

Alarm/Error Name


aste ump (in correct ate)


1205 Waste pump fail-ure.

Waste pump not responding.


Either the wanot functionasors to checkthe waste pufunctional. Enostics > Flucheck the waIn the Wastetion, enter a 10 seconds the Start buttStart button the operatorable to hear pump operatpump cannothen removeto expose thpump and retest. If the puues to fail, thboth cablingIf the pump ithen the failubly in the desor. Make suWaste pumpLED changewhether the or Off.




System Response

Where raised

CnaWur

rk cables ions are reli-

server is

Robotic XYZ


AM Mas-ter

OStRFiFa

e software correct for nd that the is running nal com- incorrect -boot the puter as an

start the

Reaction Detection


AM Mas-ter

CplPInSt

pump is on instrument not pres-

accumula-

S Diagnos-nd open the es.r pumps blem is in ulator sen-

mp doesn't lem is the

Fluid Movement


AM Mas-ter

C

Alarm/Error Name


oordi-tes File rite Fail-e

Failure saving coordi-nates file on the FTP server

1206 Coordinate File Saving Failure.

Invalid FTP server configuration, AM/CM connection net-work not working.

Call Service. Check netwoand connectable.

Ensure FTP running.

RU ored eading le Write ilure

Failure saving ORU stored reading file on the FTP server

1207 ORU Stored Read-ing File Saving Fail-ure.

Invalid FTP server configuration, AM/CM connection net-work not working.

Call Service. Check that thversions arethe release aFTP service on the persoputer. Fix allversions. Repersonal comattempt to reFTP service.

TS Sam-e Air ump (in correct ate)


1208 CTS sample arm air pump failure.

Air pump not responding.


If the vacuumtoo long; theassumes it issurizing the tor.Go to the CTtics screen aCTS air valvIf the CTS airuns, the prothe air accumsor; if the purun, the probpump.




System Response

Where raised

CtoDW

he foot is nected to rm/probeosition of ash stationordinates rocedure

rmetection

Fluid Movement


AM Mas-ter

CLeso

k signal sonic

was not sure that all onnected d has iagnostics b > Waste > te Level) to evel different vettes in the

Cuvette Movement

- Notify the alarm via the UI- Perform a con-trolled stop

AM Con-trollers

C

Alarm/Error Name


TS Failed Enter eep ash

The foot hit the wash station edge when the CTS probe was inserted inside the wash station. This would have caused a probe mode switch fail-ure at the end of the wash cycle.

1209 CTS Failed to Enter Deep Wash.

The foot hit the wash station edge when the CTS probe was inserted inside the wash sta-tion.


- Verify that tproperly conthe sample a- Verify the pthe sample w- Perform CoAdjustment pfor sample a- Verify cap dsensors

uvette vel Sen-r (Error)

Cuvette Waste Level Sensor Not Respond-ing.

1210 Cuvette waste level sensor failure.

Cuvette waste level sensor not responding.


The feedbacfrom the ultracuvette leveldetected. Encables are cand the boarpower. Use d(Cuvettes TaCuvette Wascheck if the lchanges withamount of cudrawer.




System Response

Where raised

W(AtoSSt

ccumulator container is ull, then this . Or if the ulator is full pt to empty

aste accu-ll and the ot present.

es, the ensors and ed to be

luids tab to aste sen-umulator e accumu-

y, but the ensor is

there is a the sensor in front of f the accu-ll, set the duration econds. p. Ensure

owing ube to the ner. If the working and good, test ntainer nsor.

Waste Manage-ment

- Notify the alarm via the UI- Perform Emer-gency stop

AM Mas-ter

C

Alarm/Error Name


aste ccumula-r Full ensor) uck

Waste Accumulator Full Sensor remains in ON state despite cycling of Waste Pump.

1215 Unable to empty internal waste res-ervoir.

Peristaltic pump failure.Waste drain path obstruction.Liquid sensor mal-function.

Call Service. If the waste ais full, wastepresent and falarm occurswaste accumafter an attemit. Or if the wmulator is fucontainer is nIn these caswaste fluid sthe tubing nechecked.Enter Diag>Fcheck the Wsors and accdraining. If thlator is emptLED on the sactive, then problem withor an object the sensor. Imulator is fuWaste pumpsuch as 60 sStart the pumthat fluid is flthrough the twaste contaisensors are the tubing isthe waste copresence se




System Response

Where raised

StB

hat monitors all the stir- a failure. nsor is bad circuitry check, ith stir bars stir loca-e positions roperly, then malfunc-y of the stir not stirring, he reagent itry.

Rack Han-dling

- Notify the alarm via the UI- Disable all stir-ring positions in diagnostics screen.

AM Con-trollers

StBP

er develop-eded in the

ual

Rack Han-dling

- Notify the alarm via the UI- Disable that stirring position in diagnostics screen.

AM Con-trollers

(CInFa

structions revent the rom drop-e loader. gnostics to e cuvette sensor is

When the into pickup

sensor is that the clip

Cuvette Movement

- Notify the alarm via the UI- Perform a con-trolled stop- Deschedule and cancel jobs requiring new cuvettes

AM Con-trollers

C

Alarm/Error Name


ir Power ad

A check on the power required for stirring returned an error

1220 Reagent stirring failure.

Reagent stirring system malfunc-tion.

Call Service. The sensor tthe power toring detectedEither the seor the stirringhas failed. Toplace vials winto all of thetions. If all thare stirring pthe sensor istioning. If anpositions arethen check tstirring circu

ir Power ad: by osition

A check on the power required for stirring position returned an error

1221 Reagent stirring failure in position <rackposition #>, track # <rack track #>.

Reagent stirring system malfunc-tion.

Call Service. Product undment - Not neservice man

uvette) dexing ilure

Failure during cuvette indexing detected.

1239 Cuvette Loader fail-ure.

Cuvette loader mal-function. The cuvette clip may not have fallen flat for pickup by the shut-tle. The cuvette strips on the clip may not be aligned evenly or there may be debris on the pivot arm.


Check for obthat would pcuvette clip fping flat in thAlso use diaverify that thclip presencefunctioning. clip is movedposition, theread to verifyis ready.




System Response

Where raised

CN

ean pump est and ver- well are an solutionD test in d verify that ctede clean bot- that the port the .

Fluid Movement

- Notify the alarm on UI

AM Mas-ter

CSMC

tics to verify tte position

erational in slot). If ctional, per- shuttle align

Cuvette Movement

- Turn off power to stepper motor.- Notify the alarm via the UI- Perform an emergency stop

AM Con-trollers

CSMC

or the shut- slot sensor either slots

ators or the sition slot diagnostics all cuvette detected.

Cuvette Movement


AM Con-trollers

CSMC

ware defect e submitted evelop-

Processor/Software


AM Con-trollers

C

Alarm/Error Name


lean Well ot Full

Validate LLD height in Clean well. If too low, short sipping may occur.

1240 Cleaning solution low in clean well.

Air bubbles in the clean solution line. Undetected clean solution shortage. Clean pump mal-function.

Perform a Clean prime cycle (Main-tenance). If the problem persists call Service.

- Perform Cldiagnostics tify that cleanfilled with cle- Perform LLclean cup anliquid is dete- Remove thtle and verifyinstrument reproper alarm

uvette huttle otor - ause 3

The motor did not com-plete the requested move.

1245 Cuvettes shuttle movement failure.

The motor moved to the left limit then to the home posi-tion at the loader and the home posi-tion was not found.


Use diagnosthat the cuvesensor is op(color when sensor is funform cuvetteprocedure.




Incorrect # slots found.


A slot is dirtytle in positionis dirty. Cleanon the incubshuttle in posensor. Use to verify thatslots can be




Home Required. A cuvette shuttle operation was requested before the shuttle was ini-tialized into a known state.


This is a softthat should bto software dment.




System Response

Where raised

CSMC

ocessor or a malfunc- the cuvette ard and ilure sce-

Processor/Software


AM Con-trollers

CSMC

not Cuvette Movement


AM Con-trollers

CSMC

e a problem e motor direction.

Cuvette Movement


AM Con-trollers

CSMC

m to alert gripper fail-be accom- detailed

Cuvette Movement


AM Con-trollers

C

Alarm/Error Name





Cuvettes shuttle movement timeout. Move Timeout. This occurs if the soft-ware does not com-plete the move profile.


Either the prsoftware hastion. Replacecontroller borepeat the fanario.




Cuvettes shuttle movement stalled.


This alarm isenabled.




Cuvettes shuttle movement hit unex-pected travel limit.


This could bwith either thstep size or




Cuvettes shuttle movement timeout. Gripper move fail-ure.


General alarthere was a ure. Should panied with aalarm.




System Response

Where raised

BRMC

level alarm at some-eader home s not com-ssfully. ader to see ilure occurs. ting an In Diagnos-section, use ar Code r button to ower to the he power ve the nd to look ts. While

rough sure that ft Travel,

avel virtual e state at te time.

Rack Han-dling

- Turn off power to stepper motor.- Notify the alarm via the UI

AM Con-trollers

C

Alarm/Error Name


ar Code eader otor - ause 1

The motor did not com-plete the requested move prior to a motor move time out (bar code).

1255 Barcode reader movement failure.

Barcode reader movement timeout. Home Not Found.

Clear obstruction and wait for bar-code reader time-out to occur (homing of bar-code). If problem persists disable the barcode reader in Global Definitions and call Service.

This is a highthat alerts ththing in the roperation wapleted succeWatch the rewhere the faListen for hitobstruction. tics > Racks the Disable BReader Motodisable the pmotor. With tdisabled, moreader by hafor rough spochecking forspots, make the Track, Leand Right TrLEDs changthe appropria




System Response

Where raised

BRMC

g to a posi-t number of t detected. ports the ots he number less than n the motor or hit an If the num-s a large false trips en e false trips m a bad

mittent nsor to slot Diagnos-section, use ar Code r button to ower to the ower dis-

the reader ok for rough checking for ensure the ravel, and virtual LEDs at the ime. Also, ck LED on a slot

Rack Han-dling


AM Con-trollers

C

Alarm/Error Name





Barcode reader movement timeout. Incorrect Slots Found.


When movintion the exacslots were noThe alarm renumber of sldetected. If tof slots was expected, theeither stalledobstruction. ber of slots inumber, thenmay have bedetected. Thcan come frosensor, intercabling, or sealignment. Intics > Racks the Disable BReader Motodisable the pmotor. With pabled, moveby hand to lospots. While rough spots,Track, Left TRight Travel change stateappropriate tsee if the Traflickers whenlocation.




System Response

Where raised

BRMC

produced mand is e the reader ition prior to d. This sce-

If this uld be

complaint.

Rack Han-dling


AM Con-trollers

BRMC

as a very ty. Either that

ramp speed y problem software at is loading amp profile. ould be to ack control-e this will fix problems.

Rack Han-dling


AM Con-trollers

C

Alarm/Error Name





Barcode reader movement timeout. Home Required.


This alarm iswhen a comgiven to movto a rack posit being homenario is rare.occurs, it shoentered as a




Barcode reader movement timeout.Move Timeout.


This alarm hlow probabilithe hardwarechanges thehas a circuitror there is a logic error than incorrect rA solution wreplace the rler card sinceither of the




System Response

Where raised

BRMC

reported der hits an etected by e encoder ove opera-blem is itting an encoder Diagnostics tion, use the Code r button to ower to the he power ve the nd to look ts. While

rough sure that ft Travel,

avel virtual e state at te time. o verify that value n the

ved.

Rack Han-dling


AM Con-trollers

C

Alarm/Error Name





Barcode reader movement timeout.Stalled.


The alarm iswhen the reaobject. It is dmonitoring thduring the mtion. The proeither with hobject or thefeedback. In> Racks secDisable Bar Reader Motodisable the pmotor. With tdisabled, moreader by hafor rough spochecking forspots, make the Track, Leand Right TrLEDs changthe appropriaAlso, watch tthe Encoderchanges whereader is mo




System Response

Where raised

BRMC

hould be ld. The

le cause is r direction rsed hence

motor in the ction than this prob-check the

Rack Han-dling


AM Con-trollers

AD

agnostic empt to able ORUs. g to ORU ne. Replace dule.

Reaction Detection

- Notify the alarm via the UI- Enter the Error Status- If there are active jobs, per-form an Emer-gency Stop

AM Mas-ter

C

Alarm/Error Name





Barcode reader movement timeout.Unexpected Travel Limit.


This alarm srare in the fiemost probabthat the motowiring is revesending the opposite direrequested. Iflem occurs, wiring.

ll ORUs isabled

All the ORU have been disabled, either manu-ally or automatically.The instrument cannot perform any tests.

1261 All the Optical Reading Units are disabled. Analysis cannot be per-formed.

All the ORUs have been disabled, either automati-cally or manually.- Automatically: ORU real-time check failed- Manually: opera-tor disabled ORU through Diagnos-tics

If the ORUs have been automatically disabled, call Ser-vice.When all the ORUs are disabled the system cannot per-form analysis.If this occurs during a run, the system performs an Emer-gency Stop.

Use ORU Discreen to attmanually enCheck cablinfrom backplathe ORU mo




System Response

Where raised

CWacto

if the e accumula- the down ay has got annot return osition to cuvettes. In k the sen-

agnostics > . In the n of the tab nsor named Up. cuvette r and check or changes ing the e accumula-wn. Also, in

use the ulator but-the dump the accumu-

Waste Manage-ment

- Notify the alarm via the UI- Disable the accumulator solenoid- Perform an Emergency Stop

AM Con-trollers

C

Alarm/Error Name


uvette aste cumula-r stuck

The accumulator does not return to the up position within 2 sec-onds of being emptied.

1263 Cuvettes accumu-lator failure.

Cuvettes accumu-lator movement timeout.


Check to seecuvette wasttor is stuck inposition. If mcaught and cto the level pgather more order to checsor, enter DiCuvettes tabWaste sectiothere is a seAccumulatorRemove thewaste drawethat the sensstate by movcuvette wasttor up and doDiagnostics,Clear Accumton to verify operation of lator.




System Response

Where raised

OpeW(O



are proba-

Thermal Control


AM Con-trollers

C

Alarm/Error Name


RU Tem-rature arning RU #1)

Temperature out of range in a reading unit







System Response

Where raised

OpeW(O



are proba-

Thermal Control


AM Con-trollers

C

Alarm/Error Name










System Response

Where raised

InTetuin(in#1



are proba-

Thermal Control


AM Con-trollers

C

Alarm/Error Name


cubator mpera-re Warn-g cubator )

Temperature out of range in an incubator


Temperature out of range in cuvettes incubator.





System Response

Where raised

InTetuin(in#2



are proba-

Thermal Control


AM Con-trollers

PTetuin(S

est(s) error k test vol-ally if not an ult with

Thermal Control


PTetuin(R1)

est(s) error k test vol-ally if not an ult with

Thermal Control


C

Alarm/Error Name


cubator mpera-re Warn-g cubator )

Temperature out of range in an incubator


Temperature out of range in cuvettes incubator.


robe mpera-re Warn-g ample)

Probe temperature or dispense temperature defined to be out of warning range but within failure range.

1270 Sample probe tem-perature or dis-pense temperature out of range.


Call Service. Verify what toccurs. Checumes especiIL test. ConsApplications

robe mpera-re Warn-g eagent

Probe temperature dis-pense temperature defined to be out of warning range but within failure range.

1271 Reagent arm 1 probe temperature or dispense tem-perature out of range.


Call Service. Verify what toccurs. Checumes especiIL test. ConsApplications




System Response

Where raised

PTetuin(R2)

at test(s) Check test ecially if not onsult with .

Thermal Control


PHPTetuin


Thermal Control


PHPTetuin


Thermal Control


PHPTetuin


Thermal Control


RTeW


Thermal Control


C

Alarm/Error Name


robe mpera-re Warn-g eagent

Probe temperature dis-pense temperature defined to be out of warning range but within failure range.

1272 Reagent arm 2 probe temperature or dispense tem-perature out of range.


Call Service. Verify on wherror occurs.volumes espan IL test. CApplications

re(-eater) robe mpera-re Warn-g

Probe Pre-Heater tem-perature defined to be out of warning range but within failure range

1273 Sample probe pre-heater temperature out of range.





1274 Reagent arm 1 probe pre-heater temperature out of range.





1275 Reagent arm 2 probe pre-heater temperature out of range.



eagent mp arning

Reagent area tempera-ture defined to be out of warning range but within failure range.

1276 Reagent area tem-perature out of range.

Reagent cooling system malfunc-tion.





System Response

Where raised

CSTeW


d require o help trou-e Diagnos-es Tab. If ure is fluctu-rely out of , then re-he tempera-solid then ires could cted or bro-perature is en the ther-

are proba-

Thermal Control


(OHLo

ORU mod-he Start but-d in ORU tab >

eadings AC value is

240.

Reaction Detection


AM Con-trollers

(OH

issing or vers that light into the k for possi-of light into If covers y, then module.

Reaction Detection

- Notify the alarm on UI- Remove the associated ORU module from the scheduling pro-cess????

AM Con-trollers

C

Alarm/Error Name


uvette huttle mp arning

Cuvette shuttle tem-perature defined to be out of warning range but within failure range.

1277 Cuvette shuttle temperature out of range.

Cuvette shuttle heating system malfunction.

Call Service. The heating be broken, thcould be shomodule coulcalibration. Tbleshoot, ustics > Cuvettthe temperatating and baspecificationcalibrate. If tture is stuck the heating wbe not conneken. If the temfluctuating, thmistor wires bly okay.

RU) Ref igh or w

Optical Reference readings not within expected range, possi-bly due to LED aging or failure.

1278 Optical reading units reference readings out of range for ORU <ORU ID>.

LED or electronic failure.

Call Service. Replace the ule if: when tton is presseDiagnostics >Reference Rsection, the Dgreater than

RU) igh Dark

ORU dark readings are too high, possibly indi-cating excessive stray light.

1279 Optical reading unit <ORU ID> dark readings too high.

Stray light interfer-ence or electronic failure.

Call Service. Check for mdamaged cowould allow system. Looble sources the system. have integritreplace ORU




System Response

Where raised

(Oreto

ORU mod- Reaction Detection


- Create Log Entry.

AM Con-trollers

(OS

ORU mod- Reaction Detection

- Notify the alarm on UI- Create Log Entry.

AM Con-trollers

(OM

em into the stem. This defect that dressed by

ossible, perator make sug-hange the ich could ftware path.

Reaction Detection

- Notify the alarms through the UI.

AM Con-trollers

C

Alarm/Error Name


RU) A/D adings o noisy

Optical readings too noisy, possibly due to LED aging or failure.

1280 Optical reading units readings too noisy for ORU <ORU ID>.

LED or electronic failure.

Call Service. Replace the ule.

RU) A/D aturated

ORU amplifier and/or A/D converter satu-rated

1281 Optical reading unit <ORU ID> readings out of range.

ORU LED or elec-tronic failure. Amplifier and/or A/D converter satu-rated.

Call Service. Replace the ule.

RU) ath

Math exception error (e.g. attempt to divide by zero, overflow, result not reasonable).

1283 Optical reading unit raw data calcula-tion error.

If the problem per-sists call Service.

Report problcomplaint syis a softwarecannot be adthe field. If pmonitor the oworkflow andgestions to cworkflow whavoid the so




System Response

Where raised

LiLeD

ine if the sed by liquid or by a false .tecting liq-vestigated iagnostics rack con-ttes and

e LLDs can performing LD test

target loca-ce point".

Robotic XYZ

- Notify the alarm through the UI- Complete cur-rent job as failed, with no results if all determinations are failed. Also, if on a measure-ment check, another mea-surement is per-formed.If an LLD failure is during aspi-rating any sam-ple or material, 1. If the aspi-rate/dispense step is a dilution step, the job is descheduled and canceled:(continued)

AM Mas-ter

C

Alarm/Error Name


quid vel

etection

LLD error occurred during pipetting opera-tion.

1285 Probe <probe name> Liquid Level Detection error in rack position <X>, track <YY>.

This alarm is reported by the analyzer when, aspirating a liquid from a rack con-tainer, one of the following conditions is detected.- Liquid not found- LLD monitor fail-ure

Check probe condi-tions. If the problem persists call Ser-vice.

Try to determfailure is caunot detectedpositive LLDProblems deuid can be inperforming dLLD test intotainers, cuveclean cups.False positivbe detected diagnostics Lselecting as tion "Referen




System Response

Where raised

LiLeD(c

(all replicates for the current con-centration are affected)marked as 'failed', the job is descheduled and canceled. 2. If the aspirate/dispense step is a predilution step or a sam-ple/reagent step, the current determination is marked as 'failed' and its results are flagged.3. If all replicate of one concen-tration are In case there is not enough liquid in the dispense location to per-form the requested mix, the same rules 1, 2 and 3 apply.

C

Alarm/Error Name


quid vel

etection ontinued)

LLD error occurred during pipetting opera-tion. (continued)

1285 (con-tinued)




System Response

Where raised

Der

has issing post

se/clean

n hardware

Fluid Movement

- Notify the alarm through the UI- Do the same like an LLD- Create Log Entry

AM Mas-ter

LiLeD(C

ine if the sed by liquid or by a false .tecting liq-vestigated iagnostics cuvettes.e LLDs can performing LD test


Robotic XYZ

- Notify the alarm through the UI - Complete the current job as failed, with no results if all determinations are failed.

AM Mas-ter

C

Alarm/Error Name


ispense ror

Dispense error 1286 Probe <probe name> Dispense error.

Dispense error. Check probe condi-tions. If the problem persists call Ser-vice.

The system detected a mdispense rinoperation.This is not aproblem.

quid vel

etection uvette)

LLD error in cuvette 1293 Probe <probe name> Liquid Level Detection error in cuvette position <X>, slot <YY>.

This alarm is reported by the analyzer when, aspirating a liquid from a cuvette cell, one of the following conditions is detected.- Liquid not found- LLD monitor fail-ure


Try to determfailure is caunot detectedpositive LLDProblems deuid can be inperforming dLLD test intoFalse positivbe detected diagnostics Lselecting as tion "Referen




System Response

Where raised

LiLeD(CR

ine if the sed by liquid or by a false .tecting liq-vestigated iagnostics the clean

e LLDs can performing LD test


Robotic XYZ

- Notify the alarm through the UI - Complete the current job as failed, with no results if all determinations are failed. - If the location of the liquid level detection error is the clean cup, and the pipetting operation is part of a test, the instrument per-forms an emer-gency stop.

AM Mas-ter

AFaOR

ign obstruc-RU head. If slot is sert a piece er. The have 4

e light. If red blue light

blue only, light is miss- ORU mod-tion was not

Reaction Detection

- Notify the alarms through the UI- Disable the ORU head when the instru-ment status is not BUSY

AM Mas-ter

C

Alarm/Error Name


quid vel

etection lean/

inse)

LLD error in well 1294 Probe <Probe name> Liquid Level Detection error in well position <well pos>.

This alarm is reported by the analyzer when, aspirating a liquid from a well, one of the following condi-tions is detected.- Liquid not found- LLD monitor fail-ure


Try to determfailure is caunot detectedpositive LLDProblems deuid can be inperforming dLLD test intocup.False positivbe detected diagnostics Lselecting as tion "Referen

ir Read ilure -

ut Of ange

Current air read for this wavelength, read head and read channel is out of range

1295 Air read out of range for ORU# <ORU ID> Chan-nel# <CHAN ID> Wavelength# <WAVE ID> Read-ing: <ORU READ-ING>

ORU air reading out of range.

Call Service. Look for foretion in the OORU cuvetteclear, then inof white pappaper shoulddots of purplonly, then theis missing. Ifthen the red ing. Replaceule if obstrucdetected.




System Response

Where raised

InTrMFo

el format not the ACL

Reaction Detection

Notify the alarm via the UI. Per-form an emer-gency stop.

AM Con-trollers

RTrH

ace serial mand Mod-

Reaction Detection


AM Con-trollers

Cprdr

tics b > Move tion) to s and verify

ette in shut-anges state.

Cuvette Movement


AM Con-trollers

Csoem

ware defect. ator or erator for d and pro-tem. After how the operated, ferent order wing the ath in soft-

Cuvette Movement


AM Con-trollers

C

Alarm/Error Name


valid ansmit essage rmat

Invalid transmit mes-sage format for the bar code reader.

1296 Bar code reader invalid message format.


Bar code labsupported byTOP.

eader ansmit ardware

Communications trans-mission hardware is not functional.

1297 RS232 transmit hardware error.

The serial port hardware is not functioning prop-erly.


Repair / replport on Comule.

uvette not esent to op off

A request was made to drop off a cuvette, but no cuvette is detected in the shuttle.

1318 No cuvette strip in shuttle to drop off.

Either a cuvette is really not present, the presence sen-sor is not function-ing properly (ex. dirty), or a cable has come unplugged.


Use diagnos(Cuvettes Tacuvettes secmove cuvettethat the Cuvtle sensor ch

uvette urce pty

The source position for picking up a cuvette is empty.

1323 Cuvette not present to pickup.

Either a scheduler error or operator error in diagnostics.


This is a softAsk the operwatch the ophow they loagram the sysdetermining instrument issuggest a difto avoid follosame logic pware.




System Response

Where raised

Cdefu

ware defect. ator or erator for d and pro-tem. After how the operated, ferent order wing the ath in soft-

Cuvette Movement


AM Con-trollers

Innucusl

C104 dip set to the ment con-

Cuvette Movement


AM Con-trollers

Cslto

connec-e sure sen-isy. In this ve com-ing the cor-of slots, but traveled t.

Cuvette Movement


AM Con-trollers

C

Alarm/Error Name


uvette stination ll

The destination posi-tion for placing a cuvette is occupied.

1324 Cuvette destina-tion position full.

Either a scheduler error or operator error in diagnostics.


This is a softAsk the operwatch the ophow they loagram the sysdetermining instrument issuggest a difto avoid follosame logic pware.

valid mber of vette

ots

The number of cuvette slots detected is not a valid configuration

1328 Invalid number of cuvette slots.

Either a module is incorrect or the configuration dip switch is set incor-rectly.


Ensure the Pswitches areproper instrufiguration.

uvette ots found o early.

The number of required slots was detected too early in move distance.

1329 Cuvette slot found too early.

Either there are too many mechanical slots or the sensor has picked up noise.


Check cabletions to maksor is not nocase, the mopleted in findrect number the distance was too shor




System Response

Where raised

Gbaso

tics b) to check ack sensor.

sable Shut-tton to

uttle freely. of the shut-

otor wheel gripper in e the grip-

ay to the rify that the sensor e.

Cuvette Movement


AM Con-trollers

Gbasofo

tics b) to check ack sensor.

sable Shut-tton to

uttle freely. of the shut-


ay to the rify that the sensor e.

Cuvette Movement


AM Con-trollers

C

Alarm/Error Name


ripper ck sen-r On

During initialization (home), the gripper attempts to move off the back sensor, but the sensor is still detected or extend gripper operation per-formed, but the back sensor is still detected.

1330 Gripper back sen-sor still active.

Either a sensor fail-ure, cabling failure, or motor stall.


Use Diagnos(Cuvettes Tathe Gripper BPress the Ditle Motors bumove the shOn the side tle, turn the mto move the and out. Movper all the wback and veGripper backchanges stat

ripper ck sen-r not und

During initialization (home), the gripper moves off the back sensor. Once detected to be off the sensor, the motor moves towards the sensor to make sure it can be detected. If the back sensor is not detected during this search then the alarm is generated.

1331 Gripper back sen-sor not found.



Use Diagnos(Cuvettes Tathe Gripper BPress the Ditle Motors bumove the shOn the side tle, turn the mto move the and out. Movper all the wback and veGripper backchanges stat




System Response

Where raised

Gwso

tics b) to check ront sen-

e Disable rs button to uttle freely. of the shut-


ay out and e Gripper changes

Cuvette Movement


AM Con-trollers

Gwsofo

tics b) to check ront sen-

e Disable rs button to uttle freely. of the shut-


ay out and e Gripper changes ensor is en re-align s it may not far enough nsor.

Cuvette Movement


AM Con-trollers

C

Alarm/Error Name


ripper for-ard sen-r On

After the gripper has completed a retract move the forward sen-sor is still detected.

1332 Gripper forward sensor still active.



Use Diagnos(Cuvettes Tathe Gripper Fsor. Press thShuttle Motomove the shOn the side tle, turn the mto move the and out. Movper all the wverify that thfront sensor state.

ripper for-ard sen-r not und

Extend gripper opera-tion did not detect the front sensor.

1333 Gripper forward sensor not found.



Use Diagnos(Cuvettes Tathe Gripper Fsor. Press thShuttle Motomove the shOn the side tle, turn the mto move the and out. Movper all the wverify that thfront sensor state. If the sfunctional, ththe shuttle abe extendingto trip the se




System Response

Where raised

CTrD

structions in aste drawer

revent the ving. Use (Cuvettes section) to y with the ulator but-

Cuvette Movement


AM Con-trollers

CTrU

structions in aste drawer

revent the ving. Use (Cuvettes section) to y with the ulator but-

Cuvette Movement


AM Con-trollers

C

Alarm/Error Name


uvette ay Not own

The accumulator is energized to be in the down position to drop the cuvettes on the tray, but the tray is still detected in the up posi-tion. Allowed 250 ms to move.

1334 Cuvette waste tray did not dump.

Tray mechanically stuck or solenoid malfunction.


Check for obthe cuvette wthat would ptray from moDiagnostics Tab > Wastemove the traClear Accumton.

uvette ay Not p

The accumulator is deenergized to go to the up position to get more cuvettes onto the tray, but the tray is still detected in the down position. Allowed 250 ms to move.

1335 Cuvette waste tray not ready to receive cuvettes.

Tray mechanically stuck or solenoid malfunction.


Check for obthe cuvette wthat would ptray from moDiagnostics Tab > Wastemove the traClear Accumton.




System Response

Where raised

Aur

e software correct for in particular d Universal r that pro-rm. Ensure

service is e personal

x any incor-. Re-boot computer in restart the and allow itiate repro- the control-

Robotic XYZ


AM Mas-ter

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 1

X Axis - Invalid Profile Parameter

1341 X Axis - Invalid Pro-file Parameter

The universal arm controller reporting the alarm was sent a velocity profile parameter(s) for the X axis motor that exceeded max-imum/minimum cri-teria or was incompatible with other profile param-eters.


Check that thversions arethe release -the Master anArm controlleduced the alathat the FTPrunning on thcomputer. Firect versionsthe personalan attempt toFTP service the CM to ingramming oflers.

rm Fail-e 2

Y Axis - Invalid Profile Parameter

1342 Y Axis - Invalid Pro-file Parameter

The universal arm controller reporting the alarm was sent a velocity profile parameter(s) for the Y axis motor that exceeded max-imum/minimum cri-teria or was incompatible with other profile param-eters.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 3

Z Axis - Invalid Profile Parameter

1343 Z Axis - Invalid Pro-file Parameter

The universal arm controller reporting the alarm was sent a velocity profile parameter(s) for the Z axis motor that exceeded max-imum/minimum cri-teria or was incompatible with other profile param-eters.



rm Fail-e 4

X Axis - Speed Exceeds Profile Maxi-mum

1344 X Axis - Speed Exceeds Profile Maximum

The universal arm controller reporting the alarm was sent a command to move in the X axis at a speed that would exceed the maximum stored in the velocity profile.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 5

Y Axis - Speed Exceeds Profile Maxi-mum

1345 Y Axis - Speed Exceeds Profile Maximum

The universal arm controller reporting the alarm was sent a command to move in the Y axis at a speed that would exceed the maximum stored in the velocity profile.



rm Fail-e 6

Z Axis - Speed Exceeds Profile Maxi-mum

1346 Z Axis - Speed Exceeds Profile Maximum

The universal arm controller reporting the alarm was sent a command to move in the Z axis at a speed that would exceed the maximum stored in the velocity profile.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 7

X Axis - Cannot Pro-cess Steps Required

1347 X Axis - Cannot Process Steps Required

The universal arm controller reporting the alarm was sent a command to set the velocity profile for the X axis but the parameters will generate a profile that will exceed allocated memory.



rm Fail-e 8

Y Axis - Cannot Pro-cess Steps Required

1348 Y Axis - Cannot Process Steps Required

The universal arm controller reporting the alarm was sent a command to set the velocity profile for the Y axis but the parameters will generate a profile that will exceed allocated memory.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 9

Z Axis - Cannot Pro-cess Steps Required

1349 Z Axis - Cannot Process Steps Required

The universal arm controller reporting the alarm was sent a command to set the velocity profile for the Z axis but the parameters will generate a profile that will exceed allocated memory.



rm Fail-e 10

X Axis - Selected Pro-file Is Invalid

1350 X Axis - Selected Profile Is Invalid

The universal arm controller reporting the alarm was sent a command to select a particular profile for the X axis motor but the pro-file does not exist.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 11

Y Axis - Selected Pro-file Is Invalid

1351 Y Axis - Selected Profile Is Invalid

The universal arm controller reporting the alarm was sent a command to select a particular profile for the Y axis motor but the pro-file does not exist.



rm Fail-e 12

Z Axis - Selected Pro-file Is Invalid

1352 Z Axis - Selected Profile Is Invalid

The universal arm controller reporting the alarm was sent a command to select a particular profile for the Z axis motor but the pro-file does not exist.






System Response

Where raised

Aur

connections related to p pulse are

connections related to rification ctioning.

ct in soft-

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 13

X Axis - Move Took Too Long To Complete

1353 X Axis - Move Took Too Long To Com-plete

The universal arm controller reporting the alarm has detected that the an X axis move is tak-ing longer than expected to com-plete.

Possible causes:1. The universal arm controller receives a verifica-tion pulse from the X axis motor cir-cuitry for each step pulse. The control-ler assumes that an X axis move is complete when the number of verifica-tion pulses received is equal to the step pulses sent. Therefore a malfunction in the step clock/step ver-ification circuitry will cause this alarm.2. Software defect especially TPU loading complica-tions.


Ensure that and circuitrythe X axis stefunctioning.

Ensure that and circuitrythe X axis vepulse are fun

Suspect defeware.




System Response

Where raised

Aur



ct in soft-

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 14

Y Axis - Move Took To Long To Complete

1354 Y Axis - Move Took Too Long To Com-plete

The universal arm controller reporting the alarm has detected that the an Y axis move is tak-ing longer than expected to com-plete.

Possible causes:1. The universal arm controller receives a verifica-tion pulse from the Y axis motor cir-cuitry for each step pulse. The control-ler assumes that an Y axis move is complete when the number of verifica-tion pulses received is equal to the step pulses sent. Therefore a malfunction in the step clock/step ver-ification circuitry will cause this alarm.2. Software defect especially TPU loading complica-tions.


Ensure that and circuitrythe Y axis stefunctioning.

Ensure that and circuitrythe Y axis vepulse are fun

Suspect defeware.




System Response

Where raised

Aur



ct in soft-

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 15

Z Axis - Move Took Too Long To Complete

1355 Z Axis - Move Took Too Long To Com-plete

The universal arm controller reporting the alarm has detected that the an Z axis move is tak-ing longer than expected to com-plete.

Possible causes:1. The universal arm controller receives a verifica-tion pulse from the Z axis motor cir-cuitry for each step pulse. The control-ler assumes that an Z axis move is com-plete when the number of verifica-tion pulses received is equal to the step pulses sent. Therefore a malfunction in the step clock/step ver-ification circuitry will cause this alarm.2. Software defect especially TPU loading complica-tions.


Ensure that and circuitrythe Z axis stefunctioning.

Ensure that and circuitrythe Z axis vepulse are fun

Suspect defeware.




System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 16

X Axis - Movement Generates Too Many Steps

1356 X Axis - Movement Generates Too Many Steps

The universal arm controller reporting the alarm was sent a command to move the X axis motor to a position which would require exceeding the number of steps that can be pro-cessed.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 17

Y Axis - Movement Generates Too Many Steps

1357 Y Axis - Movement Generates Too Many Steps

The universal arm controller reporting the alarm was sent a command to move the Y axis motor to a position which would require exceeding the number of steps that can be pro-cessed.






System Response

Where raised

Aur




Robotic XYZ


AM Mas-ter

Aur

limit sen-er operation nt.

ckages or of slippage - especially itialization.

tware

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 18

Z Axis - Movement Generates Too Many Steps

1358 Z Axis - Movement Generates Too Many Steps

The universal arm controller reporting the alarm was sent a command to move the Z axis motor to a position which would require exceeding the number of steps that can be pro-cessed.



rm Fail-e 19

X Axis - Invalid Limit State While Homing

1359 X Axis - Invalid Limit State While Homing

The universal arm control reporting the alarm was attempting to initial-ize the X axis motor but encountered a limit sensor that did not change state as expected.Could be caused by slippage in the X axis, software defect, or malfunc-tioning or mis-placed limit sensor(s).


Check X axissors for propand placeme

Check for bloother causesin the X axisduring arm in

Possible sofdefect.




System Response

Where raised

Aur



tware

Robotic XYZ


AM Mas-ter

Aur


ckages or of slippage

- especially itialization.

ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 20

Y Axis - Invalid Limit State While Homing

1360 Y Axis - Invalid Limit State While Homing

The universal arm control reporting the alarm was attempting to initial-ize the Y axis motor but encountered a limit sensor that did not change state as expected.Could be caused by slippage in the Y axis, software defect, or malfunc-tioning or mis-placed limit sensor(s).


Check Y axissors for propand placeme

Check for bloother causesin the Y axisduring arm in

Possible sofdefect.

rm Fail-e 21

Z Axis - Invalid Limit State While Homing

1361 Z Axis - Invalid Limit State While Homing

The universal arm control reporting the alarm was attempting to initial-ize the Z axis motor but encountered a limit sensor that did not change state as expected.Could be caused by slippage in the X axis, software defect, or malfunc-tioning or mis-placed limit sensor(s).


Check Z axissors for propand placeme

Check for bloother causesin the Z axisduring arm in

Suspect soft




System Response

Where raised

Aur



lfunctioning n encoder

circuits.

ware defect.

Robotic XYZ


AM Mas-ter

Aur




circuits.

ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 22

X Axis - Limit Detected During Move

1362 X Axis - Limit Detected During Move

The universal arm control reporting the alarm has detected that the X axis motor tripped a travel limit sensor during a move.Could be caused by:1. slippage in the X axis.2. software defect3. malfunctioning or misplaced limit sen-sor(s)4. X axis Encoder malfunction.


Check X axissors for propand placeme

Check for bloother causesin the X axisduring arm in

Check for maX axis positioand support

Suspect soft

rm Fail-e 23

Y Axis - Limit Detected During Move

1363 Y Axis - Limit Detected During Move

The universal arm control reporting the alarm has detected that the Y axis motor tripped a travel limit sensor during a move.Could be caused by:1. slippage in the Y axis.2. software defect3. malfunctioning or misplaced limit sen-sor(s)4. Y axis Encoder malfunction.


Check Y axissors for propand placeme

Check for bloother causesin the Y axisduring arm in

Check for maY axis positioand support

Suspect soft




System Response

Where raised

Aur


ckages or of slippage

- especially itialization.


circuits.

ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 24

Z Axis - Limit Detected During Move

1364 Z Axis - Limit Detected During Move

The universal arm control reporting the alarm has detected that the Z axis motor tripped a travel limit sensor during a move.Could be caused by:1. slippage in the Z axis.2. software defect3. malfunctioning or misplaced limit sen-sor(s)4. Z axis Encoder malfunction.


Check Z axissors for propand placeme

Check for bloother causesin the Z axisduring arm in

Check for maZ axis positioand support

Suspect soft




System Response

Where raised

Aur

axis block-ictions.

position supporting alfunction.

current ver-ter and uni-ontrollers le with the ion of the

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 25

X Axis - Slippage Detected

1365 X Axis - Slippage Detected

The universal arm control reporting the alarm has detected that the X axis motor did not reach the expected position at the com-pletion of a move.Could be caused by:1. Blockage or restricted move-ment in the X axis.2. Faulty X axis position encoder.3. X axis velocity profile parameters are incompatible with current sys-tem.


Check for X ages or restr

Check X axisencoder andcircuitry for m

Ensure that sions of masversal arm care compatibcurrent revisinstrument.




System Response

Where raised

Aur

axis block-ictions.



Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 26

Y Axis - Slippage Detected

1366 Y Axis - Slippage Detected

The universal arm control reporting the alarm has detected that the Y axis motor did not reach the expected position at the com-pletion of a move.Could be caused by:1. Blockage or restricted move-ment in the Y axis.2. Faulty Y axis position encoder.3. Y axis velocity profile parameters are incompatible with current sys-tem.


Check for Y ages or restr

Check Y axisencoder andcircuitry for m





System Response

Where raised

Aur

axis block-ictions.



Robotic XYZ


AM Mas-ter

Aur

e software correct for in particular d Universal r that pro-

arm. Re-onal com-ttempt to TP service CM to ini-

amming of rs.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 27

Z Axis - Slippage Detected

1367 Z Axis - Slippage Detected

The universal arm control reporting the alarm has detected that the Z axis motor did not reach the expected position at the com-pletion of a move.Could be caused by:1. Blockage or restricted move-ment in the Z axis.2. Faulty Z axis position encoder.3. Z axis velocity profile parameters are incompatible with current sys-tem.


Check for Z ages or restr

Check Z axisencoder andcircuitry for m


rm Fail-e 28

X Axis - Cannot Store More Ramps

1368 X Axis - Cannot Store More Ramps

The universal arm controller reporting the alarm ran out of memory allocated for storage of ramps for the X axis motor.


Check that thversions arethe release -the Master anArm controlleduced the alboot the persputer in an arestart the Fand allow thetiate reprogrthe controlle




System Response

Where raised

Aur



amming of rs.

Robotic XYZ


AM Mas-ter

Aur



amming of rs.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 29

Y Axis - Cannot Store More Ramps

1369 Y Axis - Cannot Store More Ramps

The universal arm controller reporting the alarm ran out of memory allocated for storage of ramps for the Y axis motor.



rm Fail-e 30

Z Axis - Cannot Store More Ramps

1370 Z Axis - Cannot Store More Ramps

The universal arm controller reporting the alarm ran out of memory allocated for storage of ramps for the Z axis motor.






System Response

Where raised

Aur

axis block-ictions.


current ver-ter and uni-ontroller compatible ent revision

ent.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 31

X Axis - Motor Stalled 1371 X Axis - Motor Stalled

The universal arm controller reporting the alarm is report-ing that periodic readings of the X axis motor position encoder indicate that the current move is being restricted or blocked.Could be caused by:1. Blockage or restricted move-ment in the X axis.2. Faulty X axis position encoder.3. X axis velocity profile parameters are incompatible with current sys-tem.


Check for X ages or restr

Check X axisencoder andcircuitry for m

Ensure that sions of masversal arm csoftware arewith the currof the instrum




System Response

Where raised

Aur

axis block-ictions.



ent.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 32

Y Axis - Motor Stalled 1372 Y Axis - Motor Stalled

The universal arm controller reporting the alarm is report-ing that periodic readings of the Y axis motor position encoder indicate that the current move is being restricted or blocked.Could be caused by:1. Blockage or restricted move-ment in the Y axis.2. Faulty Y axis position encoder.3. Y axis velocity profile parameters are incompatible with current sys-tem.


Check for Y ages or restr

Check Y axisencoder andcircuitry for m





System Response

Where raised

Aur

axis block-ictions.



ent.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 33

Z Axis - Motor Stalled 1373 Z Axis - Motor Stalled

The universal arm controller reporting the alarm is report-ing that periodic readings of the Z axis motor position encoder indicate that the current move is being restricted or blocked.Could be caused by:1. Blockage or restricted move-ment in the Z axis.2. Faulty Z axis position encoder.3. Z axis velocity profile parameters are incompatible with current sys-tem.


Check for Z ages or restr

Check Z axisencoder andcircuitry for m





System Response

Where raised

Aur



ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 34

X Axis - Operation Tim-eout

1374 X Axis - Operation Timeout

The universal arm controller reporting the alarm has detected that the X axis motor is taking too long to com-plete a move.

Possible causes:1. The universal arm controller receives a verifica-tion pulse from the X axis motor cir-cuitry fro each step pulse. The control-ler assumes that an X axis move is complete when the number of verifica-tion pulses received is equal to the step pulses sent. Therefore a malfunction in the step clock/step ver-ification circuitry will cause this alarm.2. Software defect especially TPU loading complica-tions.


Ensure that and circuitrythe X axis stefunctioning.

Ensure that and circuitrythe X axis vepulse are fun

Suspect soft




System Response

Where raised

Aur



ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 35

Y Axis - Operation Tim-eout

1375 Y Axis - Operation Timeout

The universal arm controller reporting the alarm has detected that the Y axis motor is taking too long to com-plete a move.

Possible causes:1. The universal arm controller receives a verifica-tion pulse from the Y axis motor cir-cuitry fro each step pulse. The control-ler assumes that an Y axis move is complete when the number of verifica-tion pulses received is equal to the step pulses sent. Therefore a malfunction in the step clock/step ver-ification circuitry will cause this alarm.2. Software defect especially TPU loading complica-tions.


Ensure that and circuitrythe Y axis stefunctioning.

Ensure that and circuitrythe Y axis vepulse are fun

Suspect soft




System Response

Where raised

Aur



ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 36

Z Axis - Operation Tim-eout

1376 Z Axis - Operation Timeout

The universal arm controller reporting the alarm has detected that the Z axis motor is taking too long to com-plete a move.

Possible causes:1. The universal arm controller receives a verifica-tion pulse from the Z axis motor cir-cuitry fro each step pulse. The control-ler assumes that an Z axis move is com-plete when the number of verifica-tion pulses received is equal to the step pulses sent. Therefore a malfunction in the step clock/step ver-ification circuitry will cause this alarm.2. Software defect especially TPU loading complica-tions.


Ensure that and circuitrythe Z axis stefunctioning.

Ensure that and circuitrythe Z axis vepulse are fun

Suspect soft




System Response

Where raised

Aur

ernal soft-

ware defect.

Robotic XYZ


AM Mas-ter

Aur

ernal soft-

ware defect.

Robotic XYZ


AM Mas-ter

Aur

ernal soft-

ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 37

X Axis - Operation Failed

1377 X Axis - Operation Failed

This is an internal software error.Cause is always software defect.Incorrect message was placed on a queue.


This is an intware error

Suspect soft

rm Fail-e 38

Y Axis - Operation Failed

1378 Y Axis - Operation Failed




Suspect soft

rm Fail-e 39

Z Axis - Operation Failed

1379 Z Axis - Operation Failed




Suspect soft




System Response

Where raised

Aur

axis move-stricted.

sensors are specially iercer lock, ion, and

cessive fric- piercer be.

oper opera-r latch and

(if the a cap) there ive force xtract the the cap.

ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 40

Tube Release Proce-dure Failed

1380 Tube Release Pro-cedure Failed

(CTS Only)

The controller has detected in initial-ization the tube release failed.The tube release attempts to extract the piercer from a capped tube during initialization by locking the foot and moving the piercer up until the cap detect is no longer active.The failure can be:1. Faulty cap, limit, piercer position, or piercer latch sen-sors.2. Restricted or blocked movement in the Z axis.3. Piercer latch solenoid.4. Excessive fric-tion between piercer latch and probe.5. Excessive force required to extract the piercer from the cap.6. Software defect.


Ensure that Zment is unre

Ensure CTSfunctioning ecap detect, ppiercer posittravel limit.

Check for extion betweenlatch and pro

Check for prtion of piercesolenoid.

Ensure that piercer is in is not excessrequired to epiercer from

Suspect soft




System Response

Where raised

Aur

axis move-stricted.

sensors are specially iercer lock, ion, and

cessive fric- piercer be.

oper opera-r latch and

Robotic XYZ


AM Mas-ter

Aur

D circuitry liquid level particular he circuitry for interrupt-ssor is func-rly.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 41

Sensor Or Motor Fail-ure Caused Latch Off-set Measurement To Fail

1381 Sensor Or Motor Failure Caused Latch Offset Mea-surement To Fail

The universal arm controller reporting the alarm has detected that the latch offset mea-surement opera-tion failed.This is only applica-ble to CTS instru-ments.The failure can have many causes:1. Faulty cap, limit, piercer position, or piercer latch sen-sors.2. Restricted or blocked movement in the Z axis.3. Piercer latch solenoid.4. Excessive fric-tion between piercer latch and probe.5. Software defect.


Ensure that Zment is unre

Ensure CTSfunctioning ecap detect, ppiercer posittravel limit.

Check for extion betweenlatch and pro

Check for prtion of piercesolenoid

rm Fail-e 42

LLD Hardware Failure 1382 LLD Hardware Fail-ure

The universal arm controller reporting the arm has detected that the LLD circuitry is not interrupting the pro-cessor at the required rate.


Check all LLinvolved withdetection. Inensure that tresponsible ing the procetioning prope




System Response

Where raised

Aur

ercer latch excessive

ercer spring nsion.

oper opera-tch solenoid cuitry.

ware defect.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 43

Piercer Was Not In The Expected State

1383 Piercer Was Not In The Expected State

The universal arm controller reporting the alarm was sent a command to ver-ify that the piercer was in a particular state (CTS or Sam-ple). The verifica-tion failed.i.e. There is a mis-match between the state that the Mas-ter SW expects the Piercer to be in and the state that the universal arm con-troller thinks the piercer is in.


Check the pisolenoid for friction.

Check the pifor proper te

Check for prtion of the laand drive cir

Suspect soft




System Response

Where raised

Aur

upply volt-ctioning and ecifications. eference e Z axis n specifica-

nsure that wer DAC is expected applied

Z axis DAC containing

C if the nctioning

Robotic XYZ


AM Mas-ter

Aur

connec-AVRO

p.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 44

Z Axis - Power DAC failed

1384 Z Axis - Power DAC failed

The universal arm controller reporting the alarm has detected that DAC controlling the amount of power to the Z axis motor is not performing within tolerances.


Check that sages are funare within spEnsure the rvoltage to thDAC is withitions. If possible, ethe Z axis posupplying theoutput for theinput data.Replace the or the boardthe Z axis DADAC is not fuproperly.

rm Fail-e 45

Syringe Is Always Busy 1385 Syringe Is Always Busy

The universal arm controller reporting the alarm is waiting for the CAVRO syringe to complete an operation but it is taking too long.


Check serialtions to the Csyringe pum




System Response

Where raised

(u connec-AVRO

p.

Robotic XYZ


AM Mas-ter

Aur

connec-AVRO

p.

Robotic XYZ


AM Mas-ter

Aur

ckages and ctions pting to he pump pt com-it has been initialized. n only be uccessfully e probe.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


nused) Syringe Is Always Busy 1386 Syringe Is Always Busy

The universal arm controller reporting the alarm sent a command to the CAVRO syringe to determine if it was busy but it syringe took too long to respond.



rm Fail-e 47

Syringe Took Too Long To Respond

1387 Syringe Took Too Long To Respond

The universal arm controller reporting the alarm is waiting for the CAVRO syringe to respond to a previous com-mand but it took too long.



rm Fail-e 48

Syringe Could Not Be Initialized

1388 Syringe Could Not Be Initialized

The universal arm controller reporting the alarm could not initialize the CAVRO syringe pump.


Check for bloloose connebefore attemreinitialize. Twill not accemands until successfullyThis error cacleared by sinitializing th




System Response

Where raised

Aur

re defect or ion error.e serial

ions cables connec-

Robotic XYZ


AM Mas-ter

Aur


ions cables connec-

Robotic XYZ


AM Mas-ter

Aur


ions cables connec-

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 49

Syringe Does Not Understand The Com-mand

1389 Syringe Does Not Understand The Command

The universal arm controller reporting the alarm received an error message from the CAVRO syringe indicating that the syringe did not understand the last command sent to it.


Either SoftwacommunicatCheck syringcommunicatfor unreliabletions.

rm Fail-e 50

Syringe Command Parameter Is Invalid

1390 Syringe Command Parameter Is Invalid

The universal arm controller reporting the alarm received an error message from the CAVRO syringe indicating that the last com-mand sent to it con-tained an invalid parameter.



rm Fail-e 51

Syringe Must Be Initial-ized

1391 Syringe Must Be Initialized

The universal arm controller reporting the alarm received an error message from the CAVRO syringe indicating that it must be ini-tialized before any further commands can be performed.






System Response

Where raised

Aur

ckages of lunger or ck pres-mp must be efore nor-

n can

Robotic XYZ


AM Mas-ter

Aur

lve block-s back pres-lve must be efore nor-

n can

lve overload indication uld be

Robotic XYZ


AM Mas-ter

Aur

n be caused s error con- the valve is or through-

ct in soft-

of the iagnostics very is

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 52

Syringe Plunger Is Overloaded

1392 Syringe Plunger Is Overloaded

The universal arm controller reporting the alarm received an error message from the CAVRO syringe indicating that the plunger is overloaded.


Check for blothe syringe pexcessive basure. The pureinitialized bmal operatioresume.

rm Fail-e 53

Syringe Valve Is Over-loaded

1393 Syringe Valve Is Overloaded

The universal arm controller reporting the alarm received an error message from the CAVRO syringe indicating that the valve is overloaded.


Check for vaage or excessure. The vareinitialized bmal operatioresume.Continual vaerrors are anthe valve shoreplaced.

rm Fail-e 54

Syringe Move Is Not Permitted

1394 Syringe Move Is Not Permitted

The universal arm controller reporting the alarm received an error message from the CAVRO syringe indicating that a plunger move is not permitted.When the valve is in bypass or throughput position plunger movement commands are not allowed.


This error caby a previoudition whereleft in bypassput position.

Suspect defeware.

Initialization syringe via dmode or recorequired.




System Response

Where raised

Aur

munica- software patibility.

O syringe ctions for

software correct for in particular nd univer-are as well

yringe revi-

uired.

Robotic XYZ


AM Mas-ter

Aur

O syringe ctions for

ect - possi-st be

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 55

Syringe Error With Unknown Source

1395 Syringe Error With Unknown Source

The universal arm controller reporting the alarm received an error message from the CAVRO syringe but it is not a recognized pub-lished error.


Suspect comtions error orversion incom

Check CAVRserial connereliability.

Ensure that versions arethe release -the master, asal arm softwas CAVRO ssion.Correct if req

rm Fail-e 56

Error Communicating With The Syringe

1396 Error Communicat-ing With The Syringe

The universal arm controller reporting the alarm is indicat-ing that either -1. The buffer used for receiving serial data from the CAVRO syringe has overflowed.2. The control sig-nals used for coor-dinating serial data transmission to the syringe are not in the correct state.


Check CAVRserial connereliability.

Software defbly buffer muincreased.




System Response

Where raised

Aur

inge Mod- Robotic XYZ


AM Mas-ter

Aur

latch sole-e circuitry eration.

r spring for n.

r latch for ction.

Robotic XYZ


AM Mas-ter

C

Alarm/Error Name


rm Fail-e 57

Syringe Hardware Mal-function

1397 Syringe Hardware Malfunction

Not used. The system per-formed an Emer-gency stop: perform a Recov-ery. If the problem persists call Ser-vice.

Replace Syrule.

rm Fail-e 74

Cts piercer lock not locked

1414 Cts piercer lock not locked

The AM has detected that the piercer latch is not in one of it's detent positions.


Check CTS noid and drivfor proper op

Check pierceproper tensio

Check pierceexcessive fri




System Response

Where raised

Aur


r spring for n.

r latch for ction.

Robotic XYZ


AM Mas-ter

CnoFa


r spring for n.

r latch for ction.

Robotic XYZ


AM Con-trollers

C

Alarm/Error Name


rm Fail-e 75

Cts probe mode switch failure

1415 Cts probe mode switch failure

The AM attempted to set the CTS mode (sample or CTS) but after veri-fying determined that the piercer was not in the expected mode.

Possible causes:1. CTS spring ten-sion too light.2. Faulty CTS posi-tion,or latch sensor3. Faulty latch sole-noid or circuitry.





TS Sole-id Latch ilure

The CTS hardware used to change the probe between pierc-ing mode and sample mode failed to switch.

1416 Cannot switch CTS between piercing and sample mode.

The sensor was not seen after perform-ing the CTS mode switch operation. Failure could be sensor, spring, solenoid, or soft-ware.

Perform a recovery. If the problem per-sists, call service.







System Response

Where raised

LoUabplre

oordinates ferenced to e position

at the home e arm that larm is in cation.nostics run adjustment.

Robotic XYZ

- Notify the alarm through the UI

AM Mas-ter

(CLoUab

oordinates ferenced to e position.

at the home e arm that larm is in cation.nostics run adjustment.

Robotic XYZ


AM Mas-ter

Upeui

ounts in check coordi-

- Notify alarm through the UI- Flag results with LLD_ERROR

AM Mas-ter

Upeui(C



AM Mas-ter

C

Alarm/Error Name


cation nreach-le (sam-

e or agent)

Vial Location Unreach-able

1417 Location unreach-able by <Probe>: track # <Rack>,position <Position>.

Invalid arm homing position or coordi-nate adjustment failure.

Perform Coordi-nates Adjustment. If the problem per-sists, call service.

Instrument care closely rethe arm homsensor. 1. Ensure thsensor for threports the athe proper lo2. From diagcoordinates

uvette) cation

nreach-le

Cuvette Location Unreachable

1418 Location unreach-able by <Probe>: cuvette <Cuvette Slot ID>, well <well position>.

Invalid arm homing position or coordi-nate adjustment failure.

Perform Coordi-nates Adjustment. If the problem per-sists, call service.

Instrument care closely rethe arm hom 1. Ensure thsensor for threports the athe proper lo2. From diagcoordinates

nex-cted Liq-

d Level

The probe detects liq-uid but the measured position of the liquid is unexpected.

1419 Probe <probe name> unexpected liquid level in rack position <X>, track <YY>.

The probe detects liquid but the mea-sured position of the liquid is unex-pected.


Check LLD cDiagnostics,probe, rerunnates.

nex-cted Liq-

d Level uvette)


1420 Probe <probe name> unexpected liquid level in cuvette position <X>, slot <YY>.







System Response

Where raised

Upeui(CR



AM Mas-ter

PtiolinFa



AM Mas-ter

PtiolinFa(C



AM Mas-ter

PtiolinFa(CR



AM Mas-ter

ABCurtio



AM Mas-ter

C

Alarm/Error Name


nex-cted Liq-

d Level lean/

inse)


1421 Probe <Probe name> unexpected liquid level in well position <well pos>.




re Aspira-n Base-e Check ilure

Invalid liquid detection: difference in baseline values read before and after liquid detection is too low.

1422 Probe <probe name> Pre Aspira-tion Baseline Check Failure in rack position <X>, track <YY>.

Invalid liquid detec-tion: difference in baseline values read before and after liquid detec-tion is too low.



re Aspira-n Base-e Check ilure uvette)


1423 Probe <probe name> Pre Aspira-tion Baseline Check Failure in cuvette position <X>, slot <YY>.




re Aspira-n Base-e Check ilure lear/

inse)


1424 Probe <Probe name> Pre Aspira-tion Baseline Check Failure in well position <well pos>.




spiration aseline heck Fail-e (Posi-n)

Invalid liquid detection: difference in baseline values read before and after aspiration is too high.

1425 Probe <probe name> aspiration baseline check fail-ure in rack position <X>, track <YY>.

Invalid liquid detec-tion: difference in baseline values read before and after aspiration is too high.






System Response

Where raised

ABCur(C



AM Mas-ter

ABCur



AM Mas-ter

PraBCurtio



AM Mas-ter

PraBCur(C



AM Mas-ter

PraBCur



AM Mas-ter

C

Alarm/Error Name


spiration aseline heck Fail-e uvette)


1426 Probe <probe name> aspiration baseline check fail-ure in cuvette posi-tion <X>, slot <YY>.




spiration aseline heck Fail-e (Well)


1427 Probe <Probe name> aspiration baseline check fail-ure in well position <well pos>.




ost Aspi-tion aseline heck Fail-e (Posi-n)

Invalid liquid aspira-tion. LLD Baseline read after liquid level detec-tion and after liquid aspiration is too high: the probe did not stay submerged.

1428 Probe <probe name> Post Aspira-tion Baseline Check Failure in rack position <X>, track <YY>.

The probe did not stay submerged.



ost Aspi-tion aseline heck Fail-e uvette)


1429 Probe <probe name> Post Aspira-tion Baseline Check Failure in cuvette position <X>, slot <YY>.




ost Aspi-tion aseline heck Fail-e (Well)


1430 Probe <Probe name> Post Aspira-tion Baseline Check Failure in well position <well pos>.







System Response

Where raised

(CInM

larm and s a com- a software quires cor-

Processor/Software

- Notify the alarm through the UI- Perform an emergency stop

AM Con-trollers

(CInLi

alignment; tics "Coordi-ment" for t reported

Fluid Movement


AM Mas-ter

SinV

larm and s a com- a possible

ect that ection. It the speed

are. h cuvette ement for

Processor/Software

- Notify the alarm through the UI- Perform Emer-gency Stop

AM Mas-ter

C

Alarm/Error Name


uvette) valid ove

The requested Cuvette move is not allowed

2040 Cuvettes strip posi-tioning failure.

Invalid positioning command.


Report this abackup log aplaint. This isdefect that rerection.

uvette) sufficient quid

Insufficient Liquid detected when mixing is performed in a cuvette.

2075 Insufficient liquid in cuvette <Cuvette Slot ID> well <well position>.

This error flag is set by the analyzer when, aspirating from a rack cuvette cell, liquid is not found or the avail-able liquid volume is less than the vol-ume to be aspi-rated.

Call Service. Verify probe run Diagnosnates Adjustthe probe thathe alarm.

chedul-g Time iolation

The actual execution did not meet a critical scheduling time. The job failed and it is not possible to recover

2080 Unrecoverable scheduling time violation.

Internal scheduling conflict.


Report this abackup log aplaint. This issoftware defrequires corrcould also beof the hardwObserve botand arm movspeed.




System Response

Where raised

LIsaag

ystem is tached and If possible , verify con-s. Verify uration the LIS ven-tion.

Processor/Software

- Notify user through alarms area.- Create Log Entry

CM

LIsaagOlo

0 Processor/Software


CM

UMR

0 Processor/Software


CM

C

Alarm/Error Name


S Mes-ge Stor-e Full

The UDC storage is almost full of mes-sages waiting to be sent to LIS.

3200 Storage of mes-sages sent to LIS <%> full.

Number of mes-sages pending to be uploaded to LIS is reaching capac-ity.

Check communica-tion status in both ends. If communi-cations cannot be restored disable them and call ser-vice.

Ensure LIS sphysically atpowered on.from the LISnection statuwiring configaccording todor specifica

S Mes-ge Stor-e

ver-aded

The UDC storage is almost full of mes-sages waiting to be sent to LIS. No more messages are accepted.

3201 Storage of mes-sages sent to LIS overloaded. New uploaded mes-sages will be rejected.

Number of mes-sages pending to be uploaded to LIS has reached stor-age limit.


Refer to 113

pload essage ejected

UDC Rejected Uploaded Message

3202 Upload message was rejected and therefore not sent to LIS.

Communications are not properly configured or stor-age of messages sent to LIS over-loaded. No more messages can be accepted.


Refer to 113




System Response

Where raised

AFa

actions rator's n, Check

- Notify user through UI.- Retry Auto Start after 1 minute.

CM

C

Alarm/Error Name


uto Start iled

Auto Start could not be started.

3211 Auto Start failed. Possible causes are:- The instrument was in a status that did not allow for the auto start to be initi-ated.- CTS Filter was not detected (for CTS configuration only).- Enhanced clean required.- Temperatures are out of range.- There is a ORU disabled.

The system looks for an opportunity to auto start every 1 minute. Certain conditions might change without operator's interven-tion.Identify the cause among the follow-ing and resolve:- Instrument status: the auto start can-not be initiated when the status is Initializing, Warm-ing Up, Error, Emergency Stop, Controlled Stop, Maintenance or Diagnostics.- CTS Filter miss-ing: install a new fil-ter (Maintenance activity).

Recheck all listed in Opeactions columLIS settings




System Response

Where raised

AFa(c

In(Rto

abling is ted to the tus boards. orrect, ack status

Rack Han-dling

- Notify the alarm through the UI- trace the error for debug pur-pose

AM Con-trollers

C

Alarm/Error Name


uto Start iled

ontinued)

Auto Start could not be started. (continued)

3211 (con-tinued)

(continued)

- Temperatures are out of range: wait until the tempera-tures stabilize (depending from the system and ambient condi-tions, this might take more than 30 minutes); if they do not stabilize, call Service.- Enhanced Clean required: perform Enhanced Clean for all probes (Maintenance activ-ity).- ORU disabled: call Service.

valid ack) But-n

The rack button pressed is not a valid code.

4015 Rack button identi-fication failure.

Rack position key-pad malfunction.

Call Service. Check that cproperly searack LED staIf cabling is creplace the rboards.




System Response

Where raised

SCca

the cables roperly. To the wiring is the reader ter, turn off nt power, over of the nnect the reader, and opback con- the connec-d, restart nt and enter On the SW, ks tab, rform Loop If the test of Pass, uld be a the reader he reader. If Fail, then cabling.

Rack Han-dling

- Notify the alarm through the UI- work without positive id

AM Con-trollers

C

Alarm/Error Name


canner ommuni-tions

Cannot communicate with the bar code reader.

4020 Barcode reader communication fail-ure.

Cable discon-nected. Barcode reader malfunction.Rack controller or Reader Traveling board malfunction.

Call Service. Ensure that are seated pdetermine if correct from to the computhe instrumeremove the creader, discocable to the attach the lonector. Aftertor is attachethe instrumediagnostics. Covers, Racpress the PeBack Check.has a result then there coproblem withor power to tthe result is check all the


3-4 Troubleshooting Procedures

Please refer to individual chapters for detailed troubleshooting procedures.


Chapter 4 – Enclosure/Chassis 4 - 1

Chapter 4 –Enclosure/Chassis

The ACL-TOP instrument is built on a base/chassis foundation to which the functional modules of the instru-ment are precisely aligned and mounted. Enclosing the instrument are 18 internal and external urethane skins. The chassis and the internal and external skins provide the structural support for the ACL-TOP instru-ment. On the front panel of the instrument are two assemblies, the Sample and the Reagent doors, that pro-vide operator access to the instrument. This chapter describes the chassis, enclosure, covers and doors for the ACL-TOP instrument and their removal and replacement. This chapter also includes the removal/replacement procedures for the monitor control arm.

4-1 Overview

Chassis

The chassis, as shown in Figure 4-1 "ACL-TOP Chassis", is a precision machined casting. To ensure accuracy of the instrument, the top and bottom horizontal surfaces are machined to a very close tolerance. In addition, to further ensure accuracy of the instrument, all functional modules, e.g., Robotic Arm Assem-blies, Cuvette Handling System, Rack Handling System, are carefully aligned to the chassis by the use of dowel pins in the chassis. The top horizontal surface is machined to establish a flat reference plane to which the Cuvette Handling System and Rack Handling System are mounted. (The Cuvette Handling System is composed of the Loader Assembly, Shuttle Assembly, Incubators #1 and #2, ORU Assembly and the Cuvette Waste Assembly and is described in Chapter 9 “Cuvette Handling System”. The Rack Handling System is composed of the Sample Assembly, Reagent Assembly and the Bar Code Reader Assembly and is described in Chapter 11 “Rack Handling”.) The bottom horizontal surface of the chassis is mounted to a urethane base that establishes the footprint (or base) of the ACL-TOP Instrument.


4 - 2 Chapter 4 – Enclosure/Chassis

4-2 Physical Layout

Figure 4-1 ACL-TOP Chassis

To the rear of the chassis are three aluminum sand castings, called pylons, to which the Robotic Arms are attached. The three pylon assemblies have dowel pins to align them to the chassis to ensure their precise location. The pylon assemblies provide the attachment and alignment of the robotic arms and the sub mod-ules secured to the horizontal plane of the chassis. The foundation to which the entire ACL Top instrument is built is composed of the chassis, pylon assemblies, and the base skin which establishes the instrument footprint.

Chassis

Pylons

Rear Walls

Base Skin



As stated, the ACL-TOP foundation is composed of the chassis and pylon assemblies installed on a base. The foundation assembly also has two rectangular sheet metal panels mounted to the back of the pylon assemblies that create the back wall of the ACL-TOP Instrument, as shown on Figure 4-1 "ACL-TOP Chas-sis". The lower back wall assembly houses 2 power supplies for the instrument and is also referred to as the Power Supply Assembly. The chassis, pylon assemblies, card cage/backplane assembly, two back wall assemblies, along with some miscellaneous brackets, interconnection cables, and fluidic routing tubes make up the foundation assembly to which the functional modules are attached.

Enclosure

Once the functional modules, including the Robotic Arm Assemblies, have been mounted, the external and internal skins complete the instrument. As shown on Figure 4-2 "ACL-TOP Enclosure", there are four external skins, and three internal skins that provide ACL-TOP structural integrity. The inner right skin and inner left skin reinforce the right and left outer walls creating a solid foundation for the front panel assembly. The right skin assembly, the left skin and the center skin establish the vertical references for the front panel assembly. Once the front panel assembly is in place, the top panel is mounted to both the back wall and the top of the front panel assembly and completes the structural integrity of the instrument. The remaining skins are internal and are used for equipment protection and cosmetic reasons.



SaDo

Figure 4-2 ACL-TOP Enclosure

Sample and Reagent Doors

The Sample and Reagent doors provide operator access to the ACL-TOP instrument. Each of the doors can be opened, closed, and locked closed. For normal operation, the doors are required to be closed and locked. Each door has a sensor to determine whether it is open or closed and each of these sensors output to a virtual LED on the diagnostic screen. The Diagnostic section describes the operation of the door sens-ing during diagnostics and the Removal/Replacement section describes the removal and replacement of the sensors.

4-3 Interconnect Diagrams

Interconnect diagrams are not applicable to this chapter.

mpleor

ReagentDoorFront Panel

Top Skin

Center Skin

Inner RightSkin

RightSkin

Left Skin

Inner Left SkinUpper Skin(Sample Side)

Upper SkinReagent Side



4-4 Theory of Operation

Theory of operation is not applicable to this chapter.

4-5 Adjustments/Verification

There are no specific adjustment or verification procedures for the enclosure or chassis. Visual verification of the proper alignment and operation by the service engineer at the end of the service visit is sufficient.

4-6 Diagnostics

Cover Status Area

The diagnostic area for the covers is the door closed indications and the door lock indications and switches. These indications and switches are shown on the Controllers, Covers and Racks tab of the Diagnostics screen as seen on Figure 4-3 "Diagnostics Screen, Controllers, Covers and Racks Tab". The indicators and switches specific to the covers are described following the figure.



Figure 4-3 Diagnostics Screen, Controllers, Covers and Racks Tab

Figure 4-4 "Cover Status", expands the Cover area of the diagnostic window and shows there are two LEDs indicating the door status.

•The Sample cover virtual LED turns green when the sample door is closed

•The Reagent cover virtual LED turns green when the reagent door is closed.

Covers Area



Figure 4-4 Cover Status

Door Lock/Unlock Buttons

Sample Door Sensing

The Sample Door has a sensor located on the upper right corner of the door or the lower right corner of the door, depending on the unit. To check the sensor operation, unlock the door (by selecting the “Sample Cover” radio button and clicking the “Unlock” button) and open and close the door. The LED should be lit when the door is closed and not be lit when the door is open. The sensor can also be manually pressed to cause the LED to go on (falsely) indicating the door is closed.

NOTE: Instruments below serial number 05070377 have the sensor located in the lower right corner of the door. Those units can be upgraded by ordering IL P/N 00027765500.

Reagent Door Sensing

The Reagent door sensor is a slot sensor, that uses a push button to break the beam. The push button is located at the bottom right corner where the door closes. To check the sensor operation, unlock the door (by selecting the “Reagent Cover” radio button and clicking the “Unlock” button), and open and close the door. The LED should be lit when the door is closed and not be lit when the door is open. You can also push the button with a finger to (falsely) indicate the door is closed.

Locking/Unlocking the Sample and Reagent Doors

The sample and reagent doors can also be individually locked and unlocked by selecting the radio button for the appropriate door and clicking on the “Lock” or “Unlock” button.

4-7 Removal/Replacement Procedures

The following lists the steps to be performed to remove each door, panel, cover, and/or skin of the ACL-TOP enclosure as well as the sensors on the sample and reagent covers. In addition to the enclosure items, the removal/replacement of the Monitor Control Arm is included although it is not physically a part of the enclo-sure.

Virtual LEDs



NOTE: Removing portions of the enclosure must be performed in a specific sequence to avoid personal injury or damage to the skins. For each removal procedure, there may be pre-requisites that are identified and must be met before the specific item can be removed.

Sample Door Sensor Removal/Replacement

Sample Door Sensor Removal

Perform the following steps to remove the sample door sensor.

1. Open the sample door.

2. There are one of two types of sensors for the Sample door. One sensor is mounted in the lower right of the door as shown on Figure 4-5 "Sample Door Lower Right Sensor (upgradable) ". (This sensor is upgradable by ordering part number 0002776500.) The other type of sensor is mounted in the upper right of the Sample door as shown in Figure 4-6 "Sample Door Upper Right Sensor (current)".



Figure 4-5 Sample Door Lower Right Sensor (upgradable)

Figure 4-6 Sample Door Upper Right Sensor (current)

3. Unplug, at connector (J2/P2) under the reagent door, the two wires that lead from the back of the sen-sor.

4. If the instrument has the lower sensor, using a 3.0mm Allen wrench, remove the two screws holding the sensor and remove the sensor and the wires leading to connector (J2/P2).

5. If the instrument has the upper sensor, using a 2.5mm Allen wrench, remove the two screws holding the sensor and remove the sensor and the wires leading to connector (J2/P2).

Sample Door Sensor Replacement

To replace the Sample Door Sensor, perform the preceding removal instructions then perform the following steps.

1. Attach the new sensor with the two screws removed and reroute the wire to the connector (J2/P2).

2. Reconnect the connector.

Sensor

Door Sensor



3. Close and open the door and verify the virtual LED on the SW, Covers and Racks tab of the Diagnostics screen lights when the door is closed and goes out when the door is open.

Reagent Door Sensor Removal/Replacement

Reagent Door Sensor Removal

Perform the following steps to remove the reagent door sensor.

1. Open the reagent door.

2. Disconnect the two wires from the sensor as shown on Figure 4-7 "Reagent Door Sensor".

3. Using a 3.0mm Allen wrench, remove the two screws holding the sensor.

Figure 4-7 Reagent Door Sensor

4. Remove the sensor.

Reagent Door Sensor Replacement

To replace the Reagent Door Sensor, perform the preceding removal instructions then perform the following steps.

1. Connect the two wires to the back of the new sensor.

2. Attach the new sensor with the two screws.

3. Close and open the door and verify the virtual LED on the SW, Covers and Racks tab of the Diagnostics screen lights when the door is closed and goes out when the door is open.

Sample Door Removal/Replacement

Removal/replacement of the sample door includes the removal of a sensor flag and a ground wire.

Sensor MountingScrews



Sample Door Removal

Perform the following steps to remove the sample door.


2. Using a 1.5mm Allen wrench, remove the screw securing the left hinge of the sample door.as shown on Figure 4-8 "Sample Door Hinge Attaching Screw".

Figure 4-8 Sample Door Hinge Attaching Screw

3. Using a 3.0mm Allen wrench, remove the screw securing the ground wire and flag to the right hinge assembly as shown on Figure 4-9 "Sample Door ground Wire/Flag".

Holding Screw



Figure 4-9 Sample Door ground Wire/Flag

4. Using a 2.5mm Allen wrench, remove the two screws securing the hinge and remove the lower portion of the hinge as shown on Figure 4-10 "Sample Door Hinge".

Figure 4-10 Sample Door Hinge

5. Move the Sample door to a horizontal position; lift the right end off the hinge while sliding it off the left hinge assembly.

Ground Wire/FlagScrew

Hinge AttachmentScrews

Lower Portion of Hinge



Sample Door Replacement

To replace the sample door, perform the preceding removal instructions then install the door by performing the removal instructions in reverse order. Note that the installation of the flag, ground wire are important and must be as shown in Figure 4-11 "Flag/Ground Wire Installation". The small tab of flag is inserted into the space at end of molded hinge. The (2) M3 Star Washers are to be located on both sides of the flag followed by the ground lug, then the 3rd star washer and finally the M3x8 socket head cap screw. Also note that the Ground wire must be parallel with flag and the Ground wire should run under the white optical sensor cable.

Figure 4-11 Flag/Ground Wire Installation

Reagent Door Removal/Replacement

There are no prerequisites to removing the reagent door.

Reagent Door Removal

Perform the following steps to remove the reagent door.

1. Open the Reagent Door.

2. Using a 1.5mm Allen wrench, loosen the screw on the left hinge of the door as shown in Figure 4-12 "Reagent Door Left Hinge".

Ground Wire

FlagTab

Optical Sensor Cable



Figure 4-12 Reagent Door Left Hinge

3. Using a 4.0mm Allen wrench, remove the screw attaching the right hinge to the reagent door as shown on Figure 4-13 "Reagent Door Hinge".

Figure 4-13 Reagent Door Hinge

4. Insert a flat tip screwdriver into the removal pocket (if necessary) to pry the hinge loose from the align-ment pins on the reagent door.

5. Remove the hinge by sliding it to the left as shown on Figure 4-14 "Reagent Door Hinge Removal".

Holding Screw

RemovalPocket

AttachmentScrew



Figure 4-14 Reagent Door Hinge Removal

6. Move the reagent door to a horizontal position; lift the right end off the hinge while sliding the door off the left hinge assembly.

Reagent Door Replacement

To replace the reagent door, perform the preceding removal instructions then install the door by performing the removal instructions in reverse order. Ensure the two alignment pins for the hinge are aligned with the hinge before attempting to move the door for insertion of the attachment screw.

Top Skin Removal/Replacement

Prerequisites: There are no items that must be removed prior to removing the top skin.

Top Skin Removal

Perform the following steps to remove the Top Skin.

1. Using a 3.0mm Allen wrench, remove the five screws (and washers) at the front and the three screws (and washers) at the rear of the top skin as shown on Figure 4-15 "Top Skin".

Hinge Arm



Figure 4-15 Top Skin

2. Lift the top skin and remove it from the instrument.

Top Skin Replacement

To replace the top skin, perform the preceding removal instructions then install the assembly by performing the removal in reverse order.

Front Panel Assembly Removal/Replacement

The front panel assembly requires the removal of the top skin prior to its removal. However, there are also a number of ribbon cables, sensor connections, and ground connections that need to be disconnected to physically remove the front panel.

Front Panel Assembly Removal

Perform the following steps to remove the Front Panel Assembly.

1. Open both the Sample and Reagent doors of the ACL-TOP instrument.

2. Remove the top skin as described in "Top Skin Removal/Replacement".

3. Using a 4.0mm Allen wrench, remove the two screws (and washers) at the bottom left and right of the front panel as shown on Figure 4-16 "Front Panel Lower Screws".

Top Skin Screws



Figure 4-16 Front Panel Lower Screws

4. Using a 3.0mm Allen wrench, remove the three screws (and washers) in the upper right, middle and left of the front panel as shown on Figure 4-17 "Front Panel Upper Right Screw", Figure 4-18 "Front Panel Center Screw", and Figure 4-19 "ACL-TOP Enclosure Upper Left Screw".

Figure 4-17 Front Panel Upper Right Screw

Front Panel Screws

Attachment Screw



Figure 4-18 Front Panel Center Screw

Figure 4-19 ACL-TOP Enclosure Upper Left Screw

5. Carefully move the front panel off the unit approximately six inches and rest it vertically for disconnection of the cables.

6. Disconnect the two ribbon cables for the Sample and Reagent keypads and the signal cable for the door sensors and locks (labeled Safety Cover Interlock) that extend from the lower right of the panel to the Disconnect PCB. These cables are as shown on Figure 4-20 "Front Panel Cable Connections".

NOTE: The two ribbon cable connectors have tabs on the end to lock them in place. The tabs must be lifted from the jack before the plug can be removed. The signal cable has a lock on the connector that must be released by pressing on the tab on the left side of the plug to release it.

Attachment Screw

Attachment Screw



Figure 4-20 Front Panel Cable Connections

7. Disconnect the ground connections from the front cover to the chassis.

Front Panel Assembly Replacement

To replace the front panel assembly, perform the preceding removal instructions then install the front panel by performing the removal in reverse order. Note that the top skin needs to be installed following the front panel.

Monitor Control Arm Removal/Replacement

Prerequisites: There are no items that must be removed prior to removing the monitor control arm.

Monitor Control Arm Removal

Perform the following steps to remove the Monitor Control Arm.

1. Remove the connectors for the monitor and keyboard from the monitor control arm and place the wires on the PC or the shelf.

2. Move the mouse to the PC or the shelf.

3. Using a 6.0mm Allen wrench, remove the two screws (and washers) securing the Monitor Control Arm as shown on Figure 4-21 "Monitor Control Arm"

FrontPanelConnections



Figure 4-21 Monitor Control Arm

4. Remove the Monitor Control Arm from the instrument by pulling it away from the instrument.

CAUTION: The Monitor Control arm is heavy.

Monitor Control Arm Replacement

To replace the monitor control arm, perform the preceding removal instructions then install the assembly by performing the removal in reverse order.

Sample Area Interior Skins Removal/Replacement

Sample Area Interior Skins Removal

Perform the following steps to remove the sample module interior skins in the order listed. (Refer to Figure 4-22 "Sample Module Interior Skins").

NOTE: Removal of the front panel assembly is not necessary.


2. Move probe housing to its highest position and foremost front position.

3. Move the arm to the leftmost position.

4. Grasp the Sample Area Module Cover at the top and pull straight up to remove it.

Attachment Screws



Figure 4-22 Sample Module Interior Skins

5. Grasp the Sample Syringe Pump Interior Skin at the top with two hands (one on each side of the skin) and pull toward the front of the instrument to release the skin from its retaining flanges.

6. Disconnect the connection to the ground lug on the back of the skin as shown in Figure 4-23 "Interior Skin Ground Lug/Snap Detent".

NOTE: The latest version of the CTS version of ACL-TOP include magnets rather than the snap detents to hold the cover in place.

Figure 4-23 Interior Skin Ground Lug/Snap Detent

7. Carefully remove the skin from the instrument using caution to avoid hitting the probe assembly.

8. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Sample Accumulator/Wash Station Interior Skin.

Sample SyringePump InteriorSkin

Sample Accumulator/Wash StationInterior Skin

Sample AreaModule Cover

Ground Lug Snap Detent




Sample Area Interior Skins Replacement

To replace the sample area interior skins, perform the preceding removal instructions then install the module by performing the removal in reverse order. Ensure the ground wire is attached to the Sample Syringe Pump Interior Skin and the snap detents are properly aligned in the brackets on the rear as shown in Figure 4-24 "Brackets for Snap Detents".

Figure 4-24 Brackets for Snap Detents

Inner Left Skin Removal/Replacement

Prerequisites: Prior to removing the Inner Left skin, the top panel and front panel must be removed as pre-viously described.

Inner Left Skin Removal

Perform the following steps to remove the inner left skin.

1. Power down the ACL-TOP instrument and remove the plug from the AC Main.

2. Remove the top skin and front panel assembly.

3. Using a 3.0mm Allen wrench, remove the four screws (and washers) securing the upper skin above the sample side robotic arm and remove the skin as shown on Figure 4-25 "Sample Side Upper Skin."

Figure 4-25 Sample Side Upper Skin.

4. Using a 3.0mm Allen wrench, remove the six screws (and washers) on the inside of the instrument attaching the inner left skin to the chassis as shown on Figure 4-26 "Inner Left Skin".

Cover Holding Brackets

UpperSkin

AttachmentScrews

ScrewsAttachment



Figure 4-26 Inner Left Skin

5. Slide the skin toward the front and the interior of the instrument and remove it from the instrument.

WARNING: Be careful the tinted window does not fall out which isglued in place to the inner left wall.

Inner Left Skin Replacement

Install the inner left skin in reverse order of its removal followed by installing of the left skin and the front panel assembly.

Left Skin Removal/Replacement

Prerequisites: Prior to removing the left skin, the top skin, front panel assembly, monitor control arm, and inner left skin must be removed.

Left Skin Removal

Perform the following steps to remove the left skin.1. Remove the top skin, front panel assembly, monitor control arm, and inner left skin.

2. Using a 3.0mm Allen wrench, remove the two screws (and washers) at the back and the two screws at the bottom attaching the left skin to the chassis as shown on Figure 4-27 "Left Skin".

Inner Left Skin

Inner Left SkinAttachment Screws

Attachment Screws



Figure 4-27 Left Skin

3. Remove by sliding the skin sideways (away from the instrument).

Left Skin Replacement

To replace the left skin, perform the preceding removal instructions then install the skin by performing the removal in reverse order. Note that the front panel assembly, monitor control arm and inner left skin need to be installed following the left skin.

Reagent Area Interior Skins Removal/Replacement

Reagent Area Interior Skins Removal

Perform the following steps to remove the Reagent Area Interior Skins. See Figure 4-28 "Reagent Area Inner Skins".

NOTE: Removal of the front panel assembly is not necessary for removal of the reagent area interior skins.

1. Open the reagent door.

NOTE: Throughout this procedure, the arm(s) need to be manually moved (as necessary) to ensure they are not damaged during the removal of the skins.

2. Move probe housing to its highest position and foremost front position.

3. Move the arm to the leftmost position.

4. Grasp at the top and pull straight up to remove the reagent module assembly cover.

5. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Peristaltic Pump Inte-rior Skin.

AttachmentScrews



6. Lift (straight up) and remove the peristactic pump interior skin.

Figure 4-28 Reagent Area Inner Skins

7. Grasp the Reagent Syringe Pump Interior Skin at the top with two hands (one on each side of the skin) and pull toward the front of the instrument to release the skin from its retaining flanges.

8. Disconnect the connection to the ground lug on the back of the skin as shown in Figure 4-23 "Interior Skin Ground Lug/Snap Detent".

NOTE: The latest version of the CTS version of ACL-TOP include magnets rather than the snap detents to hold the cover in place.

Figure 4-29 Interior Skin Ground Lug/Snap Detent


10. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Reagent Accumula-tor/Wash Station Interior Skin.


ReagentAccumulator/Wash Station Interior Skin

Reagent SyringePump InteriorCover

PeristalticPumpInteriorSkin

Reagent Module Assembly Cover

Ground Lug Snap Detent



Reagent Area Interior Skins Replacement

To replace the Reagent Area Interior Skins, perform the preceding removal instructions then install the skins by performing the removal in reverse order. Ensure the ground wire is re-attached to the Reagent Syringe Pump Interior Skin and the snap detents are properly aligned in the brackets on the rear as shown in Figure 4-30 "Brackets for Snap Detents".

Figure 4-30 Brackets for Snap Detents

Inner Right Skin Removal/Replacement

Prerequisites: Prior to removing the inner right skin, the top skin, front panel assembly, and reagent area interior skins must be removed as previously described.

Inner Right Skin Removal

Perform the following steps to remove the inner right skin.


2. Remove the top skin and front panel assembly.

3. Remove the Reagent Area Interior Skins as previously described.

4. Using a 3.0mm Allen wrench, remove the two screws in the upper left (accessible from the sample side of the divider) and the one screw in the upper right holding the upper skin above the reagent side robotic arm as shown on Figure 4-31 "Upper Skin Above the Reagent Side Robotic Arms".

Cover Holding Brackets



Figure 4-31 Upper Skin Above the Reagent Side Robotic Arms

5. Using a 3.0mm Allen wrench, remove the four screws (and washers) on the inside of the instrument attaching the right skin to the inner right skin as shown on Figure 4-32 "Inner Right Skin".

Figure 4-32 Inner Right Skin

6. Slide the skin toward the interior of the instrument and remove it from the instrument.

Inner Right Skin Replacement

To replace the inner right skin, perform the preceding removal instructions then install the skin by performing the removal in reverse order. Note that the right skin and the front panel assembly need to be installed fol-lowing the top skin.

AttachmentScrews

ScrewsAttachment

AttachmentScrews



Right Skin Removal/Replacement

Prerequisites: Prior to removing the right skin, the top skin, front panel assembly, and reagent area interior skins must be removed.

Right Skin Removal

Perform the following steps to remove the right skin.


2. Remove the top skin, front panel assembly, reagent area interior skins, and the inner right skin.

3. Remove all external connections on the right side of the instrument (I/O Panel Assembly) from their respective plugs.

4. Disconnect the plug on the I/O PCB (J1/P1) for the Rinse and Clean Bottle Fluid Level Sensors as shown on Figure 4-33 "Right Skin Removal".

Figure 4-33 Right Skin Removal

5. Using a 3.0mm Allen wrench, remove the two screws (and washers), at the bottom, and the two screws (and washers) at the rear attaching the right skin to the chassis as shown in Figure 4-34 "Right Skin".

Connector (J1/P1) for sensors



Figure 4-34 Right Skin

6. Slide the right skin away from the instrument to remove it from the instrument.

Right Skin Replacement

To replace the right skin, perform the preceding removal instructions then install the skin by performing the removal in reverse order.

Center Skin Removal/Replacement

Prerequisites: Prior to removing the center skin, the top skin, and front panel assembly must be removed.

Center Skin Removal

Perform the following steps to remove the Center Skin.

1. Remove the top skin and front panel from the instrument.

2. Using a 4.0mm Allen wrench, remove the two screws (and washers) from the center mounting bracket as shown in Figure 4-35 "Center Skin Attachment".

3. Remove the skin by lifting it straight up and toward the front of the instrument.

AttachmentScrews



Figure 4-35 Center Skin Attachment

Center Skin Replacement

To replace the center skin, perform the preceding removal instructions then install the new skin by performing the removal in reverse order.

Upper Back Wall Removal/Replacement

Removal/replacement of the upper back wall is not considered to be a field service activity.

Lower Back Wall (Power Supply Assembly) Removal/Replacement

Removal/replacement of the lower back wall is not considered to be a field service activity.

AttachmentScrews


Chapter 5 – Processor / Software 5 - 1

Chapter 5 –Processor / Software

5-1 Overview:

The ACL-TOP software architecture is comprised of two modules, (1) the Control Module (CM) consisting of the touchscreen monitor, keyboard, mouse, and the personal computer and (2) the Analytical Module (AM) consisting of the ACL-Top instrument itself. The Control Module’s primary responsibilities include

• processing user input

• presenting status / results

• storing data

• communicating with a Laboratory Information System (LIS)

• printing

Note that a software version display is provided on the ACL-TOP system display by clinking on System -> Instrument Status as shown on Figure 5-1 "System Software Version Selection".

Figure 5-1 System Software Version Selection

Clicking on the Software Version tab in the resulting screen display lists the present version of all installed software as shown in Figure 5-2 "Software Version Tab".


5 - 2 Chapter 5 – Processor / Software

Figure 5-2 Software Version Tab

The Analytical Modules responsibilities include controlling and coordinating devices in the instrument to pro-duce results (patient, quality control, diagnostics, maintenance) as requested by the operator. Both the Con-trol and Analytical modules include a number of software components working together to achieve the instrument’s features. Figure 5-3 "Software Components" displays an overview of the components that reside in each module. The module description provides a brief description of each component within the module.



Figure 5-3 Software Components

Control Module

The control module resides in the personal computer and is composed of the following software compo-nents. The function of each component is also briefly described.



• Job Ordering accepts patient, QC, and calibration requests from the operator or Laboratory Infor-mation System.

• Reagent Management provides for the placement and stability of placed materials.

• Data Reduction processes optical results according to the rules in the test definition to produce aspecific result.

• Results Management provides access to lists of results of tests that are completed or pendingcompletion.

• Printed Reports produces hard copies of requested information on a local or network printer.

• Quality Control provides a mechanism for users to define rules to ensure samples are of high qual-ity.

• Maintenance provides a collection of actions that must be executed at different intervals to maintaina healthy instrument.

• Diagnostic Ordering enables the service engineer or customer to identify and correct an instru-ment malfunction.

• Log Management records operator and instrument actions providing an audit history and assis-tance in troubleshooting any problems.

• Alarm Management alerts the operator to an action that needs to be taken to keep the instrumentexecuting efficiently.

• Test Definition enables a specialist to define the steps needed to perform a new test or to edit anexisting test.

• Material Definition enables a specialist to define a material used in test processing.

• Global Definition permits the setting of information that is used across many elements.

• Database Management controls access to storing and retrieving data.

• LIS Interface provides communications between the TOP personal computer and the LaboratoryInformation System.

• AM Interface provides communications between the TOP personal computer and the AnalyticalModule (the instrument).

Analytical Module

The analytical module resides on various processors in the instrument and is composed of the following software components. The function of each component is also briefly described.

• CM Interface provides communications between the ACL-TOP personal computer and the instru-ment (AM).

• Job Processing controls job sorting and job submission.

• Device Scheduling provides and coordinates the steps needed to have devices in the instrumentperform their function at the scheduled time.

• Alarm Management supplies alarm information to the personal computer for user notification andchanges the instrument state based on the alarm.



• Safety detects when a safety violation occurs and it places the instrument into a safe state if a vio-lation is detected.

• Rack Management controls and tracks rack insertion, bar code reading, and removal.

• Cuvette Management controls cuvette status and moving cuvettes from the cuvette loader to thecuvette waste.

• Fluid Movement conducts all tasks needed to move fluid from one point to another. These tasksinclude coordinate determination, aspiration, mixing, dispensing, rinsing, and cleaning.

• Material Management is a database used to track the contents of both rack and cuvette materials.

• Instrument Status tracks the instrument state and thereby controls what operations can be per-formed.

• Maintenance executes maintenance routines as requested by the operator.

• Waste Management monitors instrument waste and changing the instrument to the appropriatestate if waste is full.

• Diagnostics executes operator requested maintenance and testing actions.

• Motor Control is a device control component and supplies the operations to control stepper motors.

• Thermal Control is a device control component and provides either heating or cooling control toensure sample processing is collected at the necessary temperature.

• Optical Reading is a device control component and performs data acquisition of different opticalwavelengths during the chemical reaction.

5-2 Theory of Operation/Block Diagram

The ACL-TOP processor architecture is four levels as shown in Figure 5-4 "Processor Architecture". The hardware included in this architecture includes:

• personal computer

• master processor

• sub-system controllers

• functional controllers.

The personal computer is a Windows based, Intel Pentium class processor and provides the primary inter-face between the operator and the ACL-Top instrument. The master processor, in the Analytical Module, is an Intel Pentium class processor that operates in a real-time mode controlling the ACL-Top instrument. The subsystem controller processors are Motorola 68332 processors or CAVRO processors, and are used for Rack Handling, Cuvette handling, Optical Reading, and Fluid Movement. At present, there is one functional controller. The functional controller is a Probe Integrated Controllers and its purpose is probe heating.



Figure 5-4 Processor Architecture

The personal computer communicates to the master processor via an Ethernet connection. The master pro-cessor communicates to the sub-system controllers via a CAN Bus interface, which enables future expan-sion. The probe heating controller communicates to the sub-system controller via a serial communications interface. If the instrument contains CAVROTM robotic arms, then the probe heating controller communicates to the rack handling controller, otherwise it communicates to the fluid movement controller.

The personal computer level uses a Windows operating system. It is responsible for user interface and does not have any real time constraints. The master processor contains a real time operating system to ensure timeliness when scheduling and controlling device operations. The sub-system controllers directly control instrument devices and are able to handle interrupts from those devices on a real time basis. To ensure proper device control, the controllers use a real time operating system. The functional controllers perform an exact function, are typically small in code size, and do not require an operating system.

Upgrades:

All TOP software may be field upgraded to a new version. However, there is no support to downgrade the software by going back to a previous version.



Each field upgrade is unique as new functionality may also require hardware modification. Therefore, there is no generic procedure for software field upgrades. Field upgrades should follow the installation instructions provided with the release media (typically a CD or DVD). Additional operations such as Export / Import will also be contained in the installation instructions. Export / Import is also described in the Operator’s Manual.

WARNING: Never downgrade after a successful upgrade.

5-3 Diagnostics

There are two areas of the SW, Covers and Racks diagnostic screen that are applicable to the processorand software. They are the Controller Status and Software Version portions as shown in Figure 5-5 "Soft-ware, Covers and Racks Diagnostic Screen" and described below.


ter 5 – Processor / Software 5 - 8


Chap

Figure 5-5 Software, Covers and Racks Diagnostic Screen


Controller Status

The Controller Status area, as shown on Figure 5-6 "Controller Status Area of Diagnostic Screen",contains three virtual LEDs The Controller Status portion of the screen, displays the status of the Cuvette,Rack, and ORU controllers. The color of the virtual LEDs can display the following states of the controller.

• Green - Ready

• Yellow - In process of resetting

• Red - An error has been detected

• Grey - Unavailable

The Reset buttons to the right of the virtual LEDs enable the cuvette controller, rack controller, or ORU con-troller to be reset from the Ready or Error controller state.

Figure 5-6 Controller Status Area of Diagnostic Screen

Software Version

For each Software Component, the corresponding Software Version is displayed for user reference asshown on Figure 5-7 "Software Version Area of Diagnostic Screen".



Figure 5-7 Software Version Area of Diagnostic Screen



5-4 LIS Specifications (ASTM E 1381-95 Protocol)

ASTM LLP CM STS

Revision History: (Printed: 01/Sep/2000 16:09)

Author Date Version CommentBerenguer Torelló September 1, 2000 R0.1 Initial versionBerenguer Torelló February 5, 2001 R0.1.1 Minor style changes added to change from SRS to

STS.Berenguer Torelló March 23, 2001 R0.1.2 Comments from Carolina Altafulla added.Xavier Ramirez November 26, 2001 R0.1.3 Some minor changes added after first implementation.Néstor Silveira July 4, 2002 R0.1.4 Baud rate has been extended to match Window’s

configuration.Xavier Ramirez October 11, 2002 R 1.0 Updated diagram with a new state when the instrument

don’t accept the connectionFutura data removed and redirected to apendix A where still needs to be added the futura required changes



TABLE OF CONTENTS

1. Overview..................................................................... 5 - 122. Physical layer .............................................................. 5 - 123. Data link layer............................................................. 5 - 13

3.1 OVERVIEW

3.2 ESTABLISHMENT PHASE – LINK CONNECTION

3.3 TRANSFER PHASE

3.4 TERMINATION PHASE – LINK RELEASE

3.5 ERROR RECOVERY

3.6 CHECKING CHANNEL STATUS

3.7 RESTRICTED MESSAGE CHARACTERS

3.8 STATE DIAGRAM FOR THE INSTRUMENT

4. Appendix A – Futura Compatibility mode ................. 5 - 25

1. OVERVIEW

1.1 PURPOSE

This document is intended to be a guide for implementing the protocol referred as ASTM E 1381-95 (refer-ence R1) for the TOP device.

Also, note that TOP supports the Futura compatible mode that allows TOP to communicate with external systems using the same protocol as Futura. See appendix A for the differences between the Futura imple-mentation and the new implementation of the driver.

1.2 REFERENCES

Xavier Ramirez December 9, 2002 R 1.1 Added Section 3.6 with information about the pooling performed by TOP to know the status of the connection. Section 4 updated with Futura mode information

Xavier Ramirez February 10, 2003 R 1.2 New socket physical layer addedXavier Ramirez March 5, 2003 R 1.2.1 Fixed two typos

Ref Description

R1ASTM E 1381-95 Standard specification for low-level protocol to transfer messages between clinical laboratory instruments and computer systems Approved Oct. 10, 1995 – Published January 1996

R2ISO 7498-1984 (E), Information Processing Systems – Open Systems Interconnection – Basic Reference Model

R3 ACL Futura Host Communication Message Protocol



2. PHYSICAL LAYERTOP can be connected to an external system using a RS-232 serial connector or a RJ45 network connector using sockets. These are the details of each type of connectivity.

2.1 SERIAL CONNECTION

2.1.1 OVERVIEW

This section describes those issues related to mechanical and electrical connection between the CLI and the LIS. The topology is point-to-point, a direct connection between both devices. This section referred as “Physical layer” matches the Physical layer established in the ISO Reference model for Open Systems Inter-connection (OSI) (see reference R2).

2.1.2 CHARACTER STRUCTURE

The method of data transmission is serial-by-bit start/stop. A character is compound by the following bit sec-tions: start bit, data bits, parity bit and stop bit(s).

The configurable bit sections are:

The default character structure consists of one start bit, eight data bits, no parity bit, and one stop bit.

2.1.3 SPEED – BAUD RATE

The data transmission rate for the instrument can be configured. The allowed values are showed below:

The default baud rate is 9600 baud.

2.1.4 INTERFACE CONNECTIONS

The serial port of the instrument is a PC-standard DB-25 (EIA/TIA 232-E) or a DB-9 (EIA/TIA 574) male con-nector (also known as RS-232 connectors both of them).

The following are the PIN connections for a standard PC serial communications interface. Note that these ports are wired as DTE (Data Terminal Equipment), role that corresponds to the instrument.

R4ACL-Futura II Control Module Laboratory Information System (LIS) Interface Software Requirements – ASTM Low Level Protocol (RS-232)

R5 LIS Control Module Software Functional Specification (LIS CM SFS)

Bit sections Parameter Allowed valuesData bits Number of data bits coding a character 8 7Parity bit Parity type No parity Odd Even Mark SpaceStop bit(s) Number of stop bits 1 2

Baud rate 300 1200 2400 4800 9600 19200 3840057600 115200

MnemonicEIA/TIA Name

CCITT V.24

Signal direction

DB-9 Pin

DB-25 Pin

DescriptionUsed by the Instrument



2.1.5 SERIAL PORTS

The instrument will allow one of these serial ports: COM1, COM2, COM3 and COM4.

2.2 NETWORK CONNECTION

When top is connected to a network, it uses the TCP/IP sockets as its transport layer. TOP can act as a cli-ent or a server depending on a configuration parameter. When TOP is configured to act as a client, you have to specify the IP address of the server you want to connect to and the port number. When TOP is used as a server you only have to specify the port number clients will use to connect to TOP. Only one client can be connected to a TOP device acting as a server.

3. DATA LINK LAYER

3.1 OVERVIEW

This section covers the services described in the Data link and Transport layers, of the ISO Reference model for Open Systems Interconnection (OSI) (see reference R2). Network services, as the ISO/OSI Ref-erence model describes, are not required because this protocol works over a point-to-point topology.

The content for this section is a set of procedures for link connection and release, delimiting and synchro-nizing, sequential control, error detection, and error recovery, which are briefly described below.

• Link connection and release enables and disables respectively the system, for sending and receiv-ing information.

• Delimiting and synchronizing provide for data framing and frame recognition.

• Sequence control maintains the sequential order of information across the connection.

• Error detection senses transmission or format errors.

• Error recovery attempts to recover from detected errors by retransmitting defective frames or return-ing the link to a neutral state from otherwise unrecoverable errors.

The data link layer uses a character-oriented protocol to send messages between directly connected sys-tems.

The data link mode of operation is one-way transfer of information with alternate supervision. Information flows in one direction at time. Replies occur after information is sent, never at the same time. It is a simplex stop-and-wait protocol.

There are three distinct phases in transferring of information between instrument (ACL-TOP) and the com-puter system (HOST). In each phase one system directs the operation and is responsible for continuity of the communication. The three phases assure the actions of the sender and the receiver are coordinated. The three phases are establishment, transfer and termination.

3.2 ESTABLISHMENT PHASE – LINK CONNECTION

TD BA 103 Out 3 2 Transmitted Data YesRD BB 104 In 2 3 Received Data YesRTS CA/CJ 105/133 Out 7 4 Request To Send YesCTS CB 106 In 8 5 Clear To Send YesDSR CC 107 In 6 6 Data Ready Set YesSG AB 102 - 5 7 Signal Ground YesDCD CF 109 In 1 8 Carrier Detect NoDTR CD 108/1, /2 Out 4 20 Data Terminal Ready YesRI CE 125 In 9 22 Ring Indicator No



3.2.1 OPERATION

The establishment phase determines the direction of the information flow and prepares the receiver to accept the information.

The sender notifies the receiver that information is available sending an <ENQ>. The receiver responds that it is prepared to receive transmitting an <ACK> before any information is transmitted. A receiver that cannot immediately receive information replies to the sender with the <NAK> transmission control character.

A system, which does not have information to send, normally monitors the data link to detect the establish-ment phase. It acts as a receiver, waiting for connections of the other system.

3.2.2 CONTENTION

Contention takes place when both systems (Instrument and LIS host) simultaneously try to establish link connection by transmitting an <ENQ> transmission control character.

Sender Receiver

[Idle state]: Monitor data link()

[information_available AND data_link_in_neutral_state]: Send <ENQ>()

[Idle state]: Monitor data link()

[ready_to_receive]: Send <ACK>()

[unable_to_receive]: Send <NAK>()

{OR}

[ready_to_receive]: Begin transfer phase()

[<ACK> received]: Begin transfer phase()

Wait 10 seconds()

Set timer to 15 secs()

[Timeout]: Begin termination phase()

{OR}

Enter Idle state()



The Instrument has priority to transmit information when contention occurs.

3.3 TRANSFER PHASE

3.3.1 OPERATION

During the transfer phase, the sender transmits messages to the receiver, until all messages are sent.

Messages are sent in frames.

3.3.2 FRAMES

Each frame contains a maximum of 247 characters (240 characters including message text and 7 control characters).

Messages with a text longer than 240 characters are divided between two or more frames.

Multiple messages are never merged in a single frame or connection. Every message must begin in a new frame.

There are two kinds of frames, the intermediate frames and the end frames. Their only difference relies on one transmission control character, but they are semantically different.

Intermediate frame <STX> FN Text <ETB> C1 C2 <CR> <LF>

End frame <STX> FN Text <ETX> C1 C2 <CR> <LF>

A message containing 240 characters or less is sent in a single end frame.

Longer messages are sent in intermediate frames with the last part of the message sent in an end frame.

Each message is transmitted in a new connection. That means that ACL-TOP will never send two consec-utive messages without restarting the connection with an <ENQ>.

A brief description for every part of a frame is given in the table below.

Instrument (CLI) LIS host

[...]: Send <ENQ>()

[Contention]: Set timer to 1 second()

[...]: Send <ENQ>()

[Contention]: Set timer to 20 seconds()

[...]: Send <ENQ>()

Monitor data link()

See details on how the processcontinues after solving contention,

in the diagram above



3.3.3 FRAME NUMBER

The frame number (FN) permits the receiver to distinguish between new and retransmitted frames.

The frame number begins at 1 with the first frame of the Transfer phase. The frame number is incremented by one for every new frame transmitted. After 7, the frame number rolls over to 0, and continues in this fash-ion.

3.3.4 CHECKSUM

The checksum permits the receiver to detect a defective frame. The checksum is encoded as two charac-ters.

The checksum is computed by adding the binary values of the characters, and keeping the least significant eight bits of the result. It is an addition module 256.

The checksum is initialized to zero with the <STX> character. The checksum computation uses the FN, all characters belonging to Text and <ETB> or <ETX>. The computation for the checksum does not include <STX>, the checksum characters, or the trailing <CR> and <LF>.

The checksum is an integer of eight bits, and can be considered as two groups of four bits. Both groups of four bits are converted to the ASCII characters of the hexadecimal representation, and transmitted as the message checksum.

Example: A checksum of 89 can be represented as 01011011 in binary or 5B in hexadecimal. The check-sum is transmitted as the ASCII character 5 followed by the ASCII character B.

Frame part Frame part description<STX> Start of Text transmission control characterFN Frame Number (single digit comprised in the range 0-7) – See details in section Frame Num-

berText Data content of Message<ETB> End of Transmission Block transmission control character<ETX> End of Text transmission control characterC1 Most significant character of checksum (belonging to {0-9, A-F}) – See details in section

ChecksumC2 Least significant character of checksum (belonging to {0-9, A-F}) – See details in section

Checksum<CR> Carriage Return ASCII character<LF> Line Feed ASCII character



Sender Receiver

Send frame()

[valid_frame] : Send <ACK>()

Check frame validity()

Set timer to 15 seconds()

Send frame()

Set frame number to 1 .()

Increase frame number()


[wrong_frame] : Send <NAK>()

Send frame()





Set frame retransmissions to 0 .()


Increase frame retransmissions()

The process continues untilall frames have been transmitted

[all_frames_transmitted] : Begin termination phase()







3.3.5 ACKNOWLEDGEMENTS

After a frame is sent, the sender stops transmitting until a reply is received (stop-and-wait protocol). The receiver can reply to each frame in three ways.

• A reply of <ACK> means the last frame was successfully received and the receiver is ready toreceive the next one. The sender must send a new frame or terminate.

• A reply of <NAK> signifies the last frame was not successfully received and the receiver is preparedto receive the frame again.

• A reply of <EOT> means the last frame was successfully received and the receiver is ready toreceive the next one, but is also a request to the sender to stop transmitting. ACL-TOP will send an<EOT> only when it wants to send a message with high priority. ACL-TOP will dismiss <EOT> untilthe message is finished. Once the message is finished ACL-TOP will allow the other system toretrieve the message.

Sender Receiver

Send frame()



Set frame number to 1.()



[valid_frame AND receiver_interrupt_request] : Send <EOT>()

[sender_not_attend_the_receiver_interrupt_request] : Send frame()

[valid_frame AND receiver_interrupt_re-request] : Send <EOT>()


Set frame retransmissions to 0.()

Set frame retransmissions to 0.()

[sender_attend_the_receiver_interrupt_request] : Begin termination phase()





3.3.6 RECEIVER INTERRUPTS

The receiver can request to the sender to stop transmitting messages by sending an <EOT>, in place of the usual <ACK>. The sender does not have to stop transmitting after receiving the <EOT>.

If the sender chooses to ignore the <EOT>, the receiver must re-request the interrupt for the request to remain valid.

If the receiver chooses to honor the <EOT>, it must first enter the termination phase to return the data link to the neutral state. The original sender must not enter the establishment phase for at least 15 seconds or until the receiver has sent a message and returned the data link to the neutral state.

ACL-TOP ignores the <EOT> until the message transmission is completed. If ACL-TOP receives and <EOT> as an answer to the last frame, it waits 15 seconds until it goes to the establishment phase.

3.4 TERMINATION PHASE – LINK RELEASE

3.4.1 OPERATION

The termination phase returns the data link to the neutral state.

The sender notifies the receiver that all messages have been sent, by sending an <EOT>, and then sets up the data link to be in a neutral state.

The receiver, upon receiving <EOT>, also considers the line to be in a neutral state.

3.5 ERROR RECOVERY

3.5.1 DEFECTIVE FRAMES

A receiver checks every frame to guarantee it is valid. A reply of <NAK> is transmitted for invalid frames. Upon receiving the <NAK>, the sender retransmits the last frame with the same frame number.

A frame should be rejected because take place some of the following situations:

• Any character errors are detected (parity errors, framing error…).

Sender Receiver

Send <EOT>()

Enter idle state()

Enter idle state()



• The frame checksum does not match the checksum computed on the received frame.

• The frame number is not the same as the last accepted frame or one number higher (module 8).

• There are invalid characters in the message body. See section 3.6 for invalid characters

Any characters occurring before <STX> or <EOT>, or after the end of the block characters (<ETB> or <ETX>), are ignored by the receiver when checking for frame validity.

3.5.2 RETRANSMISSIONS

Every time the sender tries to transmit a particular frame, and receives a <NAK> or any other character dif-ferent from <ACK> or <EOT> (a <NAK> condition), a retransmission counter for the given frame is increased. If this counter shows a single frame was sent and not accepted six times, the sender must abort this message by proceeding to the termination phase.

3.5.3 TIME-OUTS

The sender and the receiver use timers to detect loss of coordination between them. ACL-TOP uses the time-out specified for instruments.

3.5.3.1 ESTABLISHMENT PHASE

The sender sets a timer when transmitting the <ENQ>. A time-out occurs if a reply of an <ACK>, <NAK> or <ENQ> is not received within 15 seconds. After a time-out, the sender enters the termination phase.

3.5.3.2 TRANSFER PHASE

Send frame()




Send frame()





Set frame retransmissions to 0 .()The receiver is unable

to communicate with the sender

[Timeout] : Begin termination phase()

Sender Receiver




The sender sets a timer when transmitting the last character of a frame. If a reply is not received within 15 seconds, a time-out occurs. After a time-out, the sender aborts the message by entering to the termination phase.

The receiver sets a timer when first entering the transfer phase or when replying to a frame. If a frame or an <EOT> is not received within 30 seconds, a time-out occurs. After a time-out, the receiver discards the last incomplete message and regards the line to be in the neutral state.

3.6 CHECKING CHANNEL STATUS

One of the major goals we wanted to achieve with the connectivity with external systems was to allow TOP to know the status of the connection. The status of the connection allows users of TOP to know if there is a physical connection or not with the LIS system, or if the connection is being rejected.

To allow this feature we have used the rules in ASTM to detect this status. This is how we did it:

• When the LIS connectivity is started TOP send and <ENQ> until an <ACK> is received.

•If an <ACK> is received TOP assumes the connection is established. If no messages are pendingto send an <EOT> is sent.

•If a <NAK> is received TOP assumes the connection is rejected by the LIS and retries every 10seconds as specified in the standard until the connection is accepted.

•If no data is received the application assumes there is no connection with the LIS system. The<ENQ> is sent every 15 seconds as specified in ASTM until the connection is enabled

• When the connection is accepted, TOP sends and accepts any messages exchanged with the LIS.If the connection is idle for more than 60 seconds TOP will check if the channel is still up sendingand <ENQ> and after receiving the response sends an <EOT> to finish the transmission.

3.7 RESTRICTED MESSAGE CHARACTERS

Send frame()






The sender is unableto communicate with the receiver

[Timeout] : Enter idle state()


[Timeout] : Discard incomplete message()

Sender Receiver



The data link protocol is designed for sending character-based message text. Some restrictions are placed on the characters that can appear in the message content. The following characters must not appear in the message text:

The <LF> character can appear only as the last character of a frame.

3.8 STATE DIAGRAM FOR THE INSTRUMENT

Following is the state diagram for the instrument. Note that the figure is side reading and can be viewed online by clicking on View ->Rotate View ->Clockwise or pressing Shift+Ctrl+Plus.

Transmission control characters Format effector control character Device control characters<SOH>, <STX>, <ETX>, <EOT>, <ENQ>, <ACK>, <DLE>, <NAK>, <SYN>, <ETB>

<LF> <DC1>, <DC2>, <DC3>, <DC4>


ter 5 – Processor / Software 5 - 24


Sleeping

ildNextFrame,SendFrame,SetTimerTo15

uildNextFrame,SendFrame,SetTimerTo15

erTo1,Send<ACK>,SetTimerTo30

ber,Send<ACK>,SetTimerTo30

/ Send<ACK>,SetTimerTo30

EOT>,SetTimerTo30

Send<EOT>,SetTimerTo30

e] / Send<NAK>,SetTimerTo30

T> [no_pending_frames] / Send<EOT>

Chap

Idle

ConnectingDataToSend / SetFrameNumberTo1,Send<ENQ>,SetTimerTo15

Timeout / Send<EOT>

Receive<ENQ> / SetTimerTo1

Receive<NAK> / SetTimerTo10

Sending

Receive<ACK> [pending_frames] / ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15

Receive<ACK> [pending_frames] / IncrementFrameNumber,ZeroRetryCount,Bu

Receive<EOT> [interrupt_ignored] / IncrementFrameNumber,ZeroRetryCount,B

<NAK> condition [RetryCount=6] / Send<EOT>

Receive<ACK> [no_pending_frames] / Send<EOT>

Receiving

Receive<ENQ> [instrument_ready] / SetFrameNumb

FrameReceived [good_new_frame AND no_data_to_send] / IncrementFrameNum

FrameReceived [good_repeat_frame AND no_data_to_send]

FrameReceived [good_new_frame AND data_to_send] / IncrementFrameNumber,Send<

FrameReceived [good_repeat_frame AND data_to_send] /

FrameReceived [bad_fram

Receive<EOT>

Timeout

/ Startup

/ Shutdown

State diagram for the Instrument

Timeout / Send<EOT>

<NAK> condition [RetryCount<6] / IncrementRetryCount,SendFrame,SetTimerTo15

Receive<EO

Receive<ENQ> [instument don't accept connection] / Send<NAK>


APPENDIX A – FUTURA COMPATIBILITY MODEThe low-level protocol implementation of TOP acting in Futura mode is fully compliant with the last imple-mentation of the Futura device.



ASTM HLP CM STS



Revision History: (Printed: 22/Jul/2004 12:06)

Author Date Version CommentBerenguer Torelló October 10, 2000 R0.1 Initial versionBerenguer Torelló December 22,

2000R0.1.1 · Section 5.Transmission scenarios reorganized.

· Minor modifications in section 2.4.Delimiters.· Sections 4.6.Manufacturer information record and 5.2.1. Test results delivery carried out by the instrument reworked to accommodate the uploading of calibration mathematical models to the LIS host.· Scenarios using “Test Order” record, revised to accommodate the use of the field “Instrument Specimen ID”.· Diagrams belonging to Section 6.Transmission scenarios relationships, reworked.

Berenguer Torelló February 5, 2001 R0.1.2 Minor style modifications to change from SRS to STS.Xavier Ramirez June 28, 2002 R 1.0 Document updated with TOP implementationFrancesc Fernandez July 10, 2002 R1.1 · Section Demographic Data updated.

· Section Sample Identification added.· Table of contents updated.

Francesc Fernandez July 29, 2002 R1.2 Updated after NTE internal review.Xavier Ramirez July 31, 2002 R 1.2.1 Errors section updated. Some fields added to give at least the

same functionality delivered by Futura.Francesc Fernandez August 30, 2002 R 1.2.2 Describe logic for setting ordered date and time to current

date when ordered date and time received from the LIS is empty.

Maite Burrel September 04, 2002

R 1.3 Add changes in instrument test order autocancelation message. Section 4.1.2Update in Header Record specification the correct ASTM version field max length to 7.

Xavier Ramirez September 08, 2002

R 1.4 Added comments about the futura driver

Xavier Ramirez October 11, 2002 R 1.5 Changes to note that error messages sent to the HOST can be disabledField 012 removed in 4.5.1 – Instrument uploads test result

Xavier Ramirez December 9, 2002

R 1.6 Removed an incorrect field in the sample in section 4.5.1Added Patient laboratory ID in messages coming from the LIS. This field is still not used in TOP, but may be used in the future

Xavier Ramirez January 7, 2003 R 1.7 Section 4.1.3 and section 4.2 removed option ‘N’ from field 12 in order record. The field has also been changed from mandatory to optional.

Xavier Ramirez January 31, 2003 R 1.8 Length of field O5 has been change to 6 characters.Title in section 4.1.4 has been changed to a more understandable title.Added comment in 4.3.3 specifying that anything is required when in a multiple host query there is not data for one of the specimens.

Xavier Ramirez February 7, 2003 R 1.8.1 Section 2.3.3 added



Xavier Ramirez March 5, 2003 R 1.8.2 Updated 2.2.3 with the information of codepagesUpdated 2.3.2 with allowed escape values and use of the local escape delimiterUpdated 2.3.3 with the detail of the possible escaped charactersUpdated 2.3.4 with how local escape delimiter worksSection 6 added units mapping between TOP and Futura (still not completed)

Xavier Ramirez April 8, 2003 R 1.8.3 Section 3.3 added that the consistency among values in different fields is not checked. Added information about the tracing systemSection 4.5. Result unit max size have changed from 50 chars to 15 charsSection 6 has been updated with more differences between TOP and Futura compatible driver and the final units mapping from TOP to Futura.

Francesc Fernandez June 17, 2003 R 1.8.4 Updated section 2.4 Patient Demographics for specifying that Patient demographics are not updated from LIS unless Samples are identified through Instrument Sample Id.

Xavier Ramírez June 27, 2003 R 1.8.5 Appendix A: added restriction to reject messages with t sample id bigger than 16 characters in Futura modeUpdated section 4.5: A new flag has been added in R9 and O26 to allow TOP to send preliminary results. Preliminary results are tests that will be rerun by TOP. Updated section 3.3: Notification of response when no request is performed is also notified to TOP.

Xavier Ramírez July 2, 2003 R 1.8.6 Appendix A: Futura does not support ‘V’ flag in R9Maite Burrel July 2, 2003 R 1.8.7 Appendix A: ERRORS Add the exemption of non-validation

of H14 date field.Xavier Ramírez July 15, 2003 R 1.8.8 Max length for Attending physician ID has changed from 30

to 14 as specified in TOPChanged the way reruns are notified in section 4.5.1

Xavier Ramírez November 26, 2003

R 1.9 Added field “Laboratory patient ID” in TOP uploaded messages (section 4.4.1, 4.5.1, 4.7.2) that is uploaded by TOP when has previously sent by the LIS host

Daniel Moncusí January 27, 2004 R 1.10 Documented use of message storage by TOP (section 3.3) Section 3.1 and 3.2 has been unified in a single one (take it into account when consulting Revision History references)

Daniel Moncusí July 22, 2004 R 1.11 Added clarifying note to section 4.3.3Changed diagrams of section 5



TABLE OF CONTENTS

1. Overview ............................................................................12. Message structure and content..........................................303. Message transmission control...........................................354. Transmission scenarios.....................................................38

4.1 TOP REQUEST TEST ORDERS TO HOST ........................................................................................................394.2 LIS HOST INITIATED TEST ORDERS DELIVERY ............................................................................434.3 HOST QUERY PERFORMED BY THE INSTRUMENT .........................................................................444.4 INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST ..............................................................464.5 INSTRUMENT UPLOADS TEST RESULTS ........................................................................................................474.6 LIS HOST REQUEST RESULTS TO THE INSTRUMENT ......................................................................494.7 INSTRUMENT UPLOADS ERROR INFORMATION.............................................................................................51

5. Transmission scenarios relationships ...............................535.1 MANUAL OR AUTOMATIC JOB ORDERS DOWNLOADING ................................................................535.2 HOST-INITIATED JOB ORDERS DOWNLOADING ............................................................................................545.3 HOST QUERY ...............................................................................................................................................555.4 MANUAL OR AUTOMATIC JOB RESULTS UPLOADING ....................................................................56

6. Appendix A – Futura Compatibility mode .......................57



1. OVERVIEW

1.1 PURPOSE

This document is a guide for implementing the protocol ASTM E 1394-97 for the TOP device. In this guide, you will find detailed information of all the data that can be exchanged between TOP and laboratory infor-mation systems (LIS).

Also, note that TOP supports the Futura compatible mode that allows TOP to communicate with external systems using the same protocol as Futura did. See appendix A for the differences between the Futura implementation and the new implementation of the driver included in TOP.

1.2 OVERVIEW

The implementation of the TOP protocol follows as much as possible the rules described in the ASTM stan-dard, but some interpretation of it has been done when the standard wasn’t detailed enough to complete the implementation. This guide describes any interpretation done in the development of TOP connectivity in order to easy the development of any interface.

1.3 REFERENCES

2. MESSAGE STRUCTURE AND CONTENT

2.1 RECORDS

2.1.1 ORGANIZATION AND HIERARCHY OF RECORDS

Messages consist of a hierarchy of records of various types. A record can be defined as an aggregate of fields describing one aspect of the complete message. A field can be seen as a specific attribute of a record, which may contain aggregates of data elements further refining the basic attribute.

The hierarchy of records is composite by several levels. The record types allowed in each hierarchy level, and the hierarchical dependencies between record types, are showed below.

Ref Description

R1

ASTM E 1394-97 Standard specification for transferring information between clinical instruments and computer systems

Approved December 10, 1997 – Published March 1998

R2 ACL-Futura manual

R3 LIS Functional Specifications

Level 0 records Level 1 records Level 2 records Level 3 records Level 4 recordsMessage Header (H)

Comment (C)Request Information (Q)



Due to the he use of this hierarchical structure, some rules have been established:

• A message shall be always headed by a message header record (H), and finished by a messageterminator record (L).

• An order record (O) may never appear without a preceding patient information record (P).

• A result record (R) may never appear without a preceding order record (O).

• Comment records (C) may be inserted at any level in the hierarchy (except after a Message Ter-minator), and it refers to the prior higher-level record.

An example of a message structure and content, according to the records hierarchy described before, is the following:

(Level 0)MESSAGE HEADER(Level 1) PATIENT_1(Level 2) COMMENT_1 (Level 2) ORDER_1(Level 3) COMMENT_1(Level 3) RESULT_1(Level 3) RESULT_2(Level 4) COMMENT_1(Level 4) COMMENT_2

.

.

.(Level 3) RESULT_N(Level 2) ORDER_2 (Level 3) RESULT_1(Level 3) RESULT_2

.

.

.(Level 3) RESULT_N

.

.(Level 2) ORDER_N(Level 3) RESULT_1

.

.

.(Level 1) PATIENT_2

.

.

Comment (C)Patient Information (P)

Comment (C)Test Order (O)

Comment (C)Result (R)

Comment (C)Message Terminator (L)



(Level 1) PATIENT_N(Level 0)MESSAGE TERMINATOR

A sequence of patient information records, order records, or result records at one level, is terminated by the appearance of a record type of the same or higher level.

2.1.2 LENGTH

The standard does not impose a maximum record length. The implementation within the IL instruments restricts the maximum length for incoming messages to 200 KB. Outgoing messages can be of any size.

2.2 FIELDS

2.2.1 STRUCTURE

A field can be seen as a specific attribute of a record, which may contain aggregates of data elements fur-ther refining the basic attribute. There are two kinds of aggregates within a message, the repeat field and the component field.

Repeat field – a single data element that expresses a duplication of the field definition. Each element of a repeat field is to be treated as heaving equal priority to associated repeat fields.

Component field – single data element or data elements that express a finer aggregate or extension of data elements, which precede it.

Example: A patient’s name is recorded as last name, first name, and middle initial, each of which is sepa-rated by a component delimiter.

2.2.2 LENGTHS

The standard does not impose a maximum field length, and assumes that all fields are variables in length. The implementation within the IL instruments scope restricts the maximum field length to a concrete value depending on the field, but never uses more characters than required by the given field value (according to the standard).

Example: For a ten characters length field, only ten characters space will be used in the message to allow the field content, delimiters space apart.

2.2.3 CHARACTER CODES

All data is represented as eight bit values and single-byte as defined in ISO 8859-1:1987. The eight-bit val-ues within the range from 0 to 127 of ISO 8859-1:1987 correspond to the ASCII standard character set (ANSI X3.4-1986). Values between 128 and 255 are undefined by this standard and are sent using the codepage specified in the configuration of TOP. The use of different codepages allows characters from dif-ferent cultures to be exchanged without problems. Other characters not representable using the specified codepage are sent escaped using UTF-16 as described in Hexadecimal escaping

Allowed characters in the message: 9, 13, 32-126, 128-254Disallowed characters in the message: 0-8, 10-12, 14-31, 127, 255

The Latin-1 character 13 is reserved as the record terminator.

2.3 DELIMITERS

2.3.1 TYPES

Delimiters are used to establish separate sections within a message. There are five different delimiters.



• Record delimiter: It signals the end of any of the defined record types. It is fixed to carriage returncharacter Latin-1 (13) (ASCII 13).

• Field delimiter: It is used to separate adjacent fields. It is configurable, and is specified in the mes-sage header record. It shall be a single character excluding Latin-1 (13) (ASCII 13).

• Repeat delimiter: Used to separate variable number of descriptors for fields containing parts ofequal members of the same set. It is configurable, and is specified in the message header record.It shall be a single character, excluding Latin-1 (13) (ASCII 13) and the value used by the field delim-iter.

• Component delimiter: It is used to separate data elements of fields of a hierarchical or qualifiernature. It is configurable, and is specified in the message header record. It shall be a single char-acter, excluding Latin-1 (13) (ASCII 13), the value used by the field delimiter and the value used bythe repeat delimiter.

• Escape delimiter: Used within text fields to signify special case operations. It is configurable, and isspecified in the message header record. It has a complex structure, but mainly use a single char-acter. The chosen character shall be different from Latin-1 (13) (ASCII 13) and the field, repeat, andcomponent delimiter values.

2.3.2 CONSIDERATIONS

Alphanumeric characters should not be used as delimiters, according to the standard. The implementation within the IL instruments allows the use of the following characters as delimiters. (Boundary values are also included)

• Any value from ASCII (33) to ASCII (47)




The default delimiters used within the IL instruments scope is the following set (this values can be changed from TOP):

• Record delimiter – carriage returnLatin-1 (13) (ASCII 13)

• Field delimiter – vertical bar( | ) Latin-1 (124) (ASCII 124)

• Repeat delimiter – at( @ ) Latin-1 (64) (ASCII 64)

• Component delimiter – caret( ^ ) Latin-1 (94) (ASCII 94)

• Escape delimiter – backslash( \ ) Latin-1 (92) (ASCII 92)

Fields shall be identified by their position, obtained by counting field delimiters from the front of the record. This position-sensitive identification procedure requires that when the contents of the field are null, its cor-responding field delimiter must be included in the record to ensure that the i’th field can be found by counting (i-1) delimiters. Delimiters are not included for trailing null fields.

The following escape sequences are pre-defined.



• \H\ (*)start highlighting text

• \N\ (*) normal text (end highlighting)

• \F\embedded field delimiter character

• \S\embedded component field delimiter character

• \R\embedded repeat field delimiter character

• \E\embedded escape delimiter character

• \Xhhhh\hexadecimal data See Hexadecimal escaping for more information

• \Zcccc\Local defined escape sequences, used to send characters not representable in the config-ured codepage. See Local escape sequence for more information.

No escape sequence contains a nested escape sequence, according to the standard.

(*) The following escaping sequences are ignored by TOP

2.3.3 HEXADECIMAL ESCAPING

The escaping of ASTM disallowed characters happens when TOP wants to send a character that is not allowed in ASTM. Characters that can be escaped are the ASCII characters 10, 13, 127, 255. In this case, the character will be escaped using the hexadecimal escaping. For example, if TOP wants to send the char-acter 127 it will be escaped to \X7F\.

2.3.4 LOCAL ESCAPE SEQUENCE

Local escape sequence is used to exchange characters not representable using the configured codepage. For example, if TOP wants to send a Japanese character (for example the Unicode character U+34C8) using the English codepage, the character would be lost in a normal transmission because it cannot be rep-resented in that specific codepage.

To avoid loosing any character, characters not representable in the selected codepage are escaped using the local escape sequence. In that case, the Japanese character will be sent in four hexadecimal digits as \Z34C8\. Also note, that many non-representable codepage characters can be added in the same escape sequence.

2.4 DEMOGRAPHIC DATA

Given a sample, patient demographics shall never be updated from the LIS Host. Patient Demographics can only be updated through the application unless Samples are identified through Instrument Sample ID (see [R3] for further information).

2.5 SAMPLE IDENTIFICATION

ACL TOP instrument shall be capable to support LIS hosts that reuse Specimen ID(s). Reusing Specimen ID(s) means that different patients can have the same Specimen Id in different periods. If this period is short enough, for instance two consecutive days, some care is required in samples management.

Usually, these laboratories reuse their Specimen Id(s) every day, every week, or even several times in a day. If laboratory operates in this way, it is possible to find different samples with the same Specimen Id in the normal operation of ACL TOP. In order to support these potential situations, TOP uses the concepts “Instrument Specimen ID” and “Sample Life” to avoid conflicts in correct samples identification.



Thus, samples can be identified from the LIS host either through the Instrument Specimen Id or the Speci-men Id + Sample Life.

2.5.1 SPECIMEN IDSince the Specimen ID can be reused by the LIS host for different patients, the TOP uses the concept Sam-ple Life for determining whether new test orders shall be added to an existing sample or not.

Given a Specimen ID, test orders received from the LIS are added to the same sample if the time frame since the sample was created till the test order was ordered (Requested/Ordered Date and Time) is < Sam-ple Life and all patient demographic (First Name, Last Name, Birth Date, Gender, Sender ID) information is the same.

Given a Specimen ID, test orders received from the LIS are added to a new same sample if the time frame since the sample was created till the test order was ordered (Requested/Ordered Date and Time) is >= Sample Life or one or more fields belonging to the patient demographic information are different.

2.5.2 INSTRUMENT SPECIMEN IDThe rules defined above section regarding the Sample Life are not applicable if the application and the LIS Host are identifying samples by means of the Instrument Specimen ID. In this way, new test orders can be programmed for existing expired samples.

Instrument Specimen ID is generated by the TOP and reused by the LIS Host. Through the TOP, the user will be able to disable the usage of the Instrument Specimen ID. If disabled, the TOP will not provide to the LIS Host any Instrument Sample ID as feedback of incoming test orders.

Instrument Specimen ID is unique within the scope of one instrument. Although in practice it is almost impossible to reproduce, different samples might have the same Instrument Specimen ID in different instru-ments.

If Instrument Specimen ID is used, no comparison of patient demographics shall be performed.

If Instrument Specimen ID received from the LIS does not match any Instrument Specimen Id kept by the system, test order shall be rejected.

2.5.3 CONCLUSION

The use of the instrument Specimen ID is recommended due to the following reasons:

• Instrument Specimen ID is not reused and therefore test orders are always properly assigned to thecorresponding sample.

• New tests can be ordered for existing and expired Specimen Ids.

• Patient demographics are not compared because Instrument Specimen Id is not reused and italways identifies univocally a sample.

3. MESSAGE TRANSMISSION CONTROL



3.1 ERROR RECOVERY

In order to ensure proper error logging and error recovery, the next rule is followed according to the stan-dard.

Storage Rule: Since data content is structured in hierarchical fashion, any decreasing change in the hierar-chical level triggers storage of all data transmitted prior to said level change, and not previously saved.

An example of the prior rule application is the following.

Record # Record Type Level (level variation) Storage action

1 Message Header L0 (0)2 Patient1 L1 (+1)3 Order1 L2 (+1)4 Result1 L3 (+1)5 Order2 L2 (-1) {Save 1 – 4}6 Order3 L2 (0)7 Patient2 L1 (-1) {Save 5 – 6}8 Order1 L2 (+1)9 Comment1 L3 (+1)10 Result1 L3 (0)11 Comment1 L4 (+1)12 Result2 L3 (-1) {Save 7 – 11}13 Order2 L2 (-1) {Save 12}14 Patient3 L1 (-1) {Save 13}15 Order1 L2 (+1)16 Result1 L3 (+1)17 Message Terminator L0 (-3) {Save 14 – 16}

Note: Record # 17 is assumed as saved by virtue of the record type function

If a transmission failure occurs, transmission starts at the last record not presumed saved as outlined in sec-tion 3.1 (Storage), but under one restriction. In order to fulfill hierarchical record level requirements, all records necessary to reach the restart record point are repeated prior to transmitting the record where the line failure originally occurred.

An example of required retransmissions is showed below.

Line failure at: Record Type Level (variation)Storage action Retransmission of:1 Message Header L0 (0) 12 Patient1 L1 (+1) 1, 23 Order1 L2 (+1) 1, 2, 34 Result1 L3 (+1) 1, 2, 3, 45 Order2 L2 (-1) {Save 1 – 4} 1, 2, 3, 4, 56 Order3 L2 (0) 1, 2, 5, 67 Patient2 L1 (-1) {Save 5 – 6} 1, 2, 5, 6, 78 Order1 L2 (+1) 1, 7, 89 Comment1 L3 (+1) 1, 7, 8, 910 Result1 L3 (0) 1, 7, 8, 9, 10



11 Comment1 L4 (+1) 1, 7, 8, 9, 10, 1112 Result2 L3 (-1) {Save 7 – 11} 1, 7, 8, 9, 10, 11, 1213 Order2 L2 (-1) {Save 12} ‘ 1, 7, 8, 12, 1314 Patient3 L1 (-1) {Save 13} 1, 7, 13, 1415 Order1 L2 (+1) ‘ 1, 14, 1516 Result1 L3 (+1) 1, 14, 15, 1617 Message Terminator L0 (-3) {Save 14 – 16} 1, 14, 15, 16, 17

3.2 ERROR MESSAGES

Any error detected by TOP is traced in the UDC folder in the ‘Windows Event Viewer’ in Settings\Control Panel\Administrative Tools. If you have any problem, this is the first place you have to check to find error information.

Optionally TOP can notify the HOST of any incorrect message received by the LIS host. Check the “Report errors to LIS” check box in the HOST configuration screen in TOP if you want to activate this feature.

If error notification is active, TOP sends ASTM messages with information about the error occurred (see Upload message – Request rejected by the instrument for detailed information about the message). Top distinguishes the syntactic and semantic errors and they are treated differently:

Syntactic errors happen when the ASTM received by TOP doesn’t follow the general ASTM rules, or the more specific rules defined by TOP. This is the list of errors TOP notifies to the LIS host:

Invalid message: The incoming message is invalid and TOP doesn’t know what information is being deliv-ered. This may happen when there are invalid characters in the message, or when an unexpected message is received. For example, when TOP receives a response and hasn’t done any request.

Invalid syntax: The incoming message has an invalid syntax, for example if the hierarchy of records is not followed appropriately

Invalid value: The incoming message has a value that is not supported by TOP. Consistency among values in different fields is not checked.

Missing mandatory value: The incoming message doesn’t provide a value for a TOP mandatory field

Incomplete message: The incoming message was uncompleted

Semantic errors are errors that are syntactically correct, but the action cannot be executed by the instru-ment. This is the list of semantic errors TOP notify to the LIS host:

• Invalid host ID: The host ID received in the message is not the same as the one specified in TOP.The message is discarded

• Invalid instrument ID: The instrument ID received in the message is not the same as the one spec-ified in TOP. The message is discarded

• Duplicated test: A test has been received twice. The test is removed.

• Invalid test: The test ordered by the LIS host is unknown to TOP. The order is removed.

• Disabled or inconsistent test: The test ordered by the LIS host is disabled or is inconsistent. Theorder is removed.



• Invalid instrument sample id: The LIS host retrieved an invalid instrument sample id. The test isremoved.

• Cancellation of pending test request could not be performed: The LIS host can cancel a previouslyordered test if this hasn’t been executed yet. This message specifies the test could not be cancelledbecause its execution has started. The result will be delivered to the LIS host as any other test.

• LIS request not allowed: TOP doesn’t allow the LIS host to perform requests for any data. If arequest from the LIS is received, the request is cancelled and no data is retrieved.

When any of the previous errors is found, TOP skips the wrong part of the message, and continues inter-preting it as if no error existed. For extended error information for the skipped part, check the TOP commu-nication tracing system where you will get the ASTM part of the message discarded and the reason.

These are the rules followed that describe the part of the message rejected when an error is found:

• An error in a header record invalidates the whole message.

• An error in a patient record invalidates all the orders below that patient in the ASTM hierarchy.

• An error in a order record invalidates only that order record.

An error in a comment record invalidates only the comment record but the patient or order record is accepted if more orders or results exist for that patient/order.

3.3 MESSAGE STORAGE

Messages that need to be uploaded to the LIS are physically persisted when the communications cannot be performed due to hardware or software problems. This is done to avoid loosing any message even if the application is shut down. If necessary, the user can delete all the stored messages clicking the specific but-ton in the communications configuration screen.

This are the more specific rules implemented by TOP to manage the storage of messages:

• The maximum number of messages that are allowed in the storage is 7200 messages.

• Once the storage is at 75% of its capacity TOP triggers the alarm < LIS Message Storage Full> pro-viding information of the percentage of the storage that is full. This alarm is reported during start-upas well and every time there is a 5% increment or decrement between 75% and 100%.

• Once the storage is 100% full TOP trigger the alarm < LIS Message Storage Overloaded> and nomore messages are accepted in the storage. This alarm will also be reported every time the com-munications are restored.

• Once the storage is full (100% of its capacity) the upload of any new messages will be rejected andTOP triggers the following two alarms < Upload Message Rejected> and < LIS Message StorageOverloaded>

4. TRANSMISSION SCENARIOSThis section details all the possible scenarios to exchange data between TOP and a LIS host.



4.1 TOP REQUEST TEST ORDERS TO HOST

This scenario takes place when the instrument, via a manual or an automatic command, launches a request to the LIS host with the intention to download all available test orders.

4.1.1 UPLOAD MESSAGE – TEST ORDER REQUEST PERFORMED BY THE INSTRUMENT

Message structure

Message Header Record

Request Information Record

Level 0 records Level 1 records Level 2 records Level 3 records Level 4 recordsMessage header (H)

Request information (Q)Message terminator (L)

Field No. Field Name Description

Comp

onent Data type

Max.

Length

Req

Allow

Repeat Allowed values

1 Record Type ID

Identifies the record 1 String 1 Y N H

2 Delimiter Defi-nition

Define the delimiters to be used throughout the subsequent records of the message

1 String 4 Y N See section Delimiters for more information

3 Message ID Uniquely identifies the message

1 String 50 Y N

5 Sender Name or ID

Name or ID of the sender1 String 14 Y N The value defined in TOP configuration’s

10 Receiver ID Name or ID of the receiver

1 14 Y N The value defined in TOP configuration’s

12 Processing ID Indicates how this mes-sage is to be processed.

1 String 1 Y N P (Production)

13 Version No. Version level of the cur-rent ASTM version speci-fication.

1 String 7 Y N 1394-97

14 Date and Time of Mes-sage

Date and time the mes-sage was generated

1 ASTM Date

Y N


Component Data type

Max.Length

ReqAllowRepeat Allowed values

1 Record Type ID Identifies the record 1 String 1 Y N Q2 Sequence

NumberDefines the i’th occurrence of the associated record type

1 String 1 Y N 1

3 Starting Range ID Number

3 String Y N ALL

13 Request Information Status Codes

1 String 1 Y Y O (req. test order and demogs),N (request new/edited results)



Message Terminator Record

ExampleH | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-07 | | | | | LIS-HOST-06 | | P | 1394-97 | 20000913174650 <CR>Q | 1 | ALL | | | | | | | | | | O@N <CR>L | 1 | N <CR>

4.1.2 UPLOAD MESSAGE– TEST ORDER REQUEST CANCELLED BY THE INSTRUMENT

The instrument can cancel the last request performed while it hasn’t received any message from the LIS host. The cancellation for the last request allows the instrument to perform another request with higher pri-ority.

Note: Remember that only one request can be performed at the same time. The sender cannot transmit another request until the previous one has been answered by the receiver or cancelled by the sender. TOP will automatically cancel the request when no answer is received in 60 seconds.

Message structure

Message Header RecordField No.Request Information Record


Comp

onent Data type

Max.

Length

Req

Allow

Repeat Allowed values

1 Record Type ID

Identifies the record 1 String 1 Y N L

2 Sequence Number

Defines the i’th occur-rence of the associated record type

1 String 1 Y N 1

3 Termination Code

Provides explanation of end of session

1 String 1 Y N N (normal termination)


Request information (Q)Comment (C)

Message terminator (L)


Component Data type

Max.Length




1 String 1 Y N 1


1 String 1 Y N A (abort last request)



Comment Record

Message Terminator Record Field No. Example

H | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-11 | | | | | LIS-HOST-93 | | P | 1394-97 | 20010414182154 <CR>Q | 1 | | | | | | | | | | | A <CR>C | 1 | I | timeout ^ last request has been cancelled | P <CR>L | 1 | N <CR>

4.1.3 DOWNLOAD MESSAGE – TEST ORDER DELIVERY BY THE LIS HOST

Message structure


Patient Information Record


Component Data type

Max.Length


1 Record Type ID Identifies the record 1 String 1 Y N C2 Sequence


1 String Y N 1,2,3 … n

3 Comment Source Comment origination point 1 String 1 Y N I4 Comment Text Comment id 1 String 50 N N timeout

Comment description 2 String 500 N last request has been cancelled5 Comment Type Comment type qualifier 1 String 1 Y N P (information)


Patient Information (P)Test Order (O)…

…Message terminator (L)


Component Data type

Max.Length


1 Record Type ID Identifies the record 1 String 1 Y N H2 Delimiter

DefinitionDefine the delimiters to be used throughout the subsequent records of the message

1 String 4 Y N See section Delimiters for more information

3 Message ID Uniquely identifies the message 1 String 50 N N5 Sender Name or

IDName or ID of the sender 1 String 14 Y N The value defined in TOP

configuration’s10 Receiver ID Name or ID of the receiver 1 14 Y N The value defined in TOP

configuration’s12 Processing ID Indicates how this message is to

be processed. 1 String 1 Y N P (Production)

13 Version No. Version level of the current ASTM 1394-91 specification.

1 String 7 Y N 1394-97

14 Date and Time of Message

Date and time that the message was generated

1 ASTM Date

N N



Test Order Record



Component Data type

Max.Length


1 Record Type ID Identifies the record as PIR 1 String 1 Y N P2 Sequence


1 Numeric Y N 1,2,3 … n

4 Laboratory patient ID

A unique processing number assigned to a patient by the LAB

1 String 15 N N

6 Patient Name Patient last name 1 String 20 N NPatient first name 2 String 20 N

8 Birth date Date of birth 1 ASTM Date

N N

9 Patient Sex Sex 1 String 1 N N M (male), F (female), U (unknown)

14 Attending physician ID

Id of the attending physician 1 String 14 N N


Component Data type

Max.Length


1 Record Type ID Identifies the record 1 String 1 Y N O2 Sequence



3 Specimen ID A unique identifier for the specimen assigned by the HOST

1 String 16 Y N

4 Instrument Specimen ID

A unique identifier for the specimen assigned by TOP. This must be retrieved from the LIS if it is known.

1 String 30 N N

5 Universal Test ID TOP defined Test ID 4 Numeric 6 Y Y 0 - 9999996 Priority 1 String 1 N N S (Stat), R (normal)7 Requested/

Ordered Date and Time

Date and time the order was received or recorded

1 ASTM Date

N N If empty, Requested/Ordered Date and Time is set to current date and Time.

12 Action code The action that needs to be taken with the order

1 String 1 N Y A (Added in previous specimen or creates a new specimen following the rules of the sample life cycle),C (Cancel a previous test request)

16 Specimen Descriptor

Sample type 1 String 1 Y N P (plasma)

26 Report Type Intention of the information contained in the record

1 String 1 Y Y Q (Response to query),


Component Data type

Max.Length


1 Record Type ID Identifies the record as MTR 1 String 1 Y N L2 Sequence


1 String 1 Y N 1

3 Termination Code


1 String 1 Y N F (last request processed)



ExampleH | @ ^ \ |<0_0> <1025080549_50> | | LIS-HOST-03 | | | | | ACL-TOP-21 | | P | 1394-97 | 20000614080500 <CR>P | 1 | | 80501 | | Anderson ^ Jim | | 19800228 | M | | | | | 542 <CR>O | 1 | 6483 | | ^ ^ ^ 211 @ ^ ^ ^ 063 | R | 20000614043211 | | | | | A | | | | P | | | | | | | | | | Q <CR>O | 2 | 8651 | | ^ ^ ^ 310 | S | 20000614043514 | | | | | A | | | | P | | | | | | | | | | Q <CR>P | 2 | | | | Foster ^ Rene | | 19740717 | F | | | | | 374 <CR>O | 1 | 0012 | | ^ ^ ^ 512 | R | 20000614044212 | | | | | A | | | | P | | | | | | | | | | Q <CR>O | 2 | 0012 | | ^ ^. ^ 254 | R | 20000614044325 | | | | | A | | | | P | | | | | | | | | | Q <CR>P | 3 | | | | Clinton ^ Jeremy | | 19580223 | M <CR>O | 1 | 6537 | 310648 | ^ ^ ^ 076 | S | 20000614044212 | | | | | A | | | | P | | | | | | | | | | Q <CR>O | 2 | 6537 | 310648 | ^ ^ ^ 098 | R | 20000614045021 | | | | | C | | | | P | | | | | | | | | | Q <CR>O | 3 | 6912 | | ^ ^ ^ 301 @ ^ ^ ^ 357 | R | 20000614052158 | | | | | A | | | | P | | | | | | | | | | Q <CR>P | 4 | | | | Turner ^ Jim | | 19890821 | M | | | | | 271 <CR>O | 1 | 0509 | 479481 | ^ ^ ^ 002 | | 20000614055734 | | | | | C | | | | P | | | | | | | | | | Q <CR>L | 1 | F <CR>

4.1.4 DOWNLOAD MESSAGE – TEST ORDER RESPONSE WHEN NO DATA AVAILABLE FROM THE LIS HOST

It can happen when there is no information to download. Also note, that if the LIS host doesn’t transmit any-thing and the timeout is reached (60 seconds), the instrument will assume that the LIS host has no test orders to program. In that case, TOP will cancel the request as specified in Upload message– test order request cancelled by the instrument.

Note: It is recommended to the LIS host implementers to always response to a request from TOP, otherwise the communication will be stopped until the 60 seconds timeout is reached.

Message structure

Message Header RecordField No.Message Terminator Record

ExampleH | @ ^ \ | <0_0> <1025080549_50> | | LIS-HOST-04| | | | | ACL-TOP-12 | | P | 1394-97 | 20030330033003 <CR>L | 1 | I <CR>

4.2 LIS HOST INITIATED TEST ORDERS DELIVERY

This scenario takes place when the LIS host, decides to download all available test orders to the instrument.

Level 0 records Level 1 records Level 2 records Level 3 records Level 4 recordsMessage header (H)Message terminator (L)


Component Data type

Max.Length




1 String 1 Y N 1

3 Termination Code


1 String 1 Y N I (no info from last query)



4.2.1 DOWNLOAD MESSAGE – LIS HOST INITIATED TEST ORDER DELIVERY

Message structure

Message Header RecordField No.Patient Information Record Field No.Test Order Record

Message Terminator RecordField No. ExampleH | @ ^ \ | <0_0> <1025080549_50> | | LIS-HOST-11 | | | | | ACL-TOP-09 | | P | 1394-97 | 20000715180000 <CR>P | 1 | | | | Dillon ^ Jennifer | | 19820414 | F <CR>O | 1 | 8201 | | ^ ^ ^ 900 | S | 20000715143243 | | | | | N | | | | P | | | | | | | | | | O <CR>O | 2 | 8201 | | ^ ^ ^ 444 @ ^ ^ ^ 666 | R | 20000715143725 | | | | | N | | | | P | | | | | | | | | | O <CR>P | 2 | | | | Carter ^ Rudy | | 19620121 | F | | | | | 985 <CR>O | 1 | 5438 | 690008 | ^ ^ ^ 369 | R | 20000715143912 | | | | | A | | | | P | | | | | | | | | | O <CR>O | 2 | 5438 | 690008 | ^ ^ ^ 963 | R | 20000715144127 | | | | | A | | | | P | | | | | | | | | | O <CR>P | 3 | | | | Stendal ^ Jeremy | | 19321002 | M <CR>O | 1 | 5009 | 324879 | ^ ^ ^ 209 | | 20010913215702 | | | | | C | | | | P | | | | | | | | | | O <CR>L | 1 | N <CR>

4.3 HOST QUERY PERFORMED BY THE INSTRUMENT

This scenario is triggered when the user performs the host query functionality in the instrument. Host query allows selective downloading of test orders, taking as input, a single Specimen ID (Sample ID) or a set of them.


Patient Information (P)Test Order (O)…



Component Data type

Max.Length






1 String 16 Y N


A unique identifier for the specimen assigned by TOP

1 String 30 N N

5 Universal Test ID TOP defined Test ID 4 Numeric 6 Y Y 0 - 9999996 Priority 1 String 1 N N S (Stat), R(normal)7 Requested/



1 ASTM Date



1 String 1 N Y A (Added in previous specimen or creates a new specimen following the rules of the sample life cycle),C (Cancel a previous test request)




1 String 1 Y Y O (Order record)



4.3.1 UPLOAD MESSAGE – HOST QUERY PERFORMED BY THE INSTRUMENT

Message structure


Field No.Request Information Record

Message Terminator RecordField No. ExampleH | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-03 | | | | | LIS-HOST-04 | | P | 1394-97 | 19990913174650 <CR>Q | 1 | ^ 4243 ^ 876271 @ ^ 0434 @ ^ 0435 @ ^ 6742 ^ 878432 | | | | | | | | | | O@N <CR>L | 1 | N <CR>




Component

Data type

Max.Length Re

q

AllowRepeat

Allowed values

1 Record Type ID Identifies the record 1 String 1 Y N H

2 Delimiter Defi-nition

Define the delimiters to be used throughout the subsequent records of the message

1 String 4 Y N See section 2.3 for more informa-tion

3 Message ID Uniquely identifies the mes-sage

1 String 50 Y N

5 Sender Name or ID

Name or ID of the sender 1 String 14 Y N The value defined in TOP config-uration’s

10 Receiver ID Name or ID of the receiver 1 14 Y N The value defined in TOP config-uration’s

12 Processing ID Indicates how this message is to be processed.

1 String 1 Y N P (Production)

13 Version No. Version level of the current ASTM version specification.

1 String 7 Y N 1394-97

14 Date and Time of Message

Date and time the message was generated

1 ASTM Date

Y N


Component Data type

Max.Length




1 String 1 Y N 1

3 Starting Range ID Number

Specimen ID 2 String 16 Y Y

Instrument specimen ID 3 String 30 N13 Request

Information Status Codes

1 String 1 Y Y O (req. test order and demogs),N (request new test orders still not downloaded)



4.3.2 UPLOAD MESSAGE – TEST ORDER REQUEST CANCELLED BY THE INSTRUMENT

See section Upload message– test order request cancelled by the instrument for more information.

4.3.3 DOWNLOAD – HOST QUERY RESPONSE FROM LIS HOST

The LIS host retrieves data for the specified sample IDs. See section Download message – test order deliv-ery by the lis host for more information. Note that if in a multiple host query, there are specimens that have pending orders and there are others that don’t, the host query response only need to retrieve the pending specimens. TOP will assume that there are no orders for the specimens no listed in the host query response. If multiple messages are send as response only the first will be processed and the rest will be dis-carded.

If the LIS host doesn’t have anything to answer, because it doesn’t know the sample IDs or because there are no test orders to retrieve, it must follow the same rules described in section Download message – test order response when no data available from the lis host.

4.4 INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST

This scenario takes place when the instrument receives a list of test orders from the LIS host. For every new sample received, the instrument generates an internal sample ID (known as “Instrument Specimen ID” in ASTM terminology) and sends it back to the LIS host.

Future LIS host references to these samples will be performed using both identifiers: “Specimen ID” and “Instrument Specimen ID”. In the same way, all information sent back to the LIS host by the instrument will be accompanied by both identifiers.

This scenario can be launched after tests orders are delivered to the instrument.

4.4.1 UPLOAD MESSAGE – INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST

Message structure

Note: Only one test order record will be placed under a patient information record.

Message Header RecordField No. Patient Information Record


Patient Information (P)Test Order (O)



Component Data type

Max.Length


1 Record Type ID Identifies the record as PIR 1 String 1 Y N P2 Sequence



4 Laboratory patient ID

A unique processing number assigned to a patient by the LAB

1 String 15 N N



Test Order Record

Message Terminator RecordField No. ExampleH | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-21 | | | | | LIS-HOST-03 | | P | 1394-97 | 20000614080624 <CR>P | 1 | | | | Anderson ^ Jim | | 19800228 | M | | | | | 542 <CR>O | 1 | 6483 | 312890 | ^ ^ ^ 063 | R | 20000614043211 | | | | | P | | | | P | | | | | | | | | | O@I <CR>P | 2 | | | | Foster ^ Rene | | 19740717 | F | | | | | 374 <CR>O | 1 | 0012 | 312892 | ^ ^ ^ 512 | R | 20000614044212 | | | | | P | | | | P | | | | | | | | | | O@I <CR>L | 1 | N <CR>

4.5 INSTRUMENT UPLOADS TEST RESULTS

This scenario takes place when the instrument is requested to send available test results to the LIS host. This scenario can be executed because the action is triggered manually or automatically. This scenario can-not be triggered by a request from the LIS host. Remember, IL instruments do not support a request mes-sage for test results uploading.

4.5.1 UPLOAD MESSAGE – TEST RESULTS DELIVERY CARRIED OUT BY THE INSTRUMENT

Message structure

6 Patient Name Patient last name 1 String 20 N NPatient first name 2 String 20 N

8 Birth date Date of birth 1 ASTM Date

N N

9 Patient Sex Sex 1 String 1 N N M (male), F (female), U (unknown)

14 Attending physician ID

Id of the attending physician 1 String 14 N N


Component Data type

Max.Length






1 String 16 Y N



1 String 30 Y N

5 Universal Test ID TOP defined Test ID 4 Numeric 6 Y Y 0 - 9999996 Priority 1 String 1 N N S (Stat), R(normal)7 Requested/



1 ASTM Date



1 String 1 Y Y P (pending specimen)




1 String 1 Y Y O (Order record),I (Pending in instrument)



Result (R)



Message Header RecordField No.Patient Information Record Field No. Test Order Record

Result Record

Comment (C)…

……



Component Data type

Max.Length






1 String 16 Y N



1 String 30 N N

5 Universal Test ID TOP defined Test ID 4 Numeric 6 Y Y 0 - 9999996 Priority 1 String 1 N N S (Stat), R (normal)7 Requested/



1 ASTM Date

N N


1 String 1 N N Q (mandatory when quality control)




1 String 1 Y Y O (Order record),F (All tests results are Final or could not be done - see R9), P (This test triggers a rerun)


Component Data type

Max.Length


1 Record Type ID Identifies the record 1 String 1 Y N R2 Sequence



3 Universal Test ID

TOP defined Test ID 4 Numeric Y N 0 – 999999999

4 Data or Measurement Value

Observed, calculated or implied result value

1 String 30 N Y

5 Units Abbreviation of units for numerical results

1 String 15 N Y For information on specific unit values see section 6

7 Result Abnormal Flags

Indicates the normalcy status of the result

1 String 2 Y N L (Below low normal),H (Above high normal),N (Normal),< (Below absolute low),> (Above absolute high)

9 Result Status 1 String 1 Y Y F (final result),P (preliminary result, because a rerun has been set),V (result validated),X (result cannot be done)



Comment Record

Message Terminator RecordField No. Example

H | @^\ | 123 | | ACL-TOP-52 | | | | | LIS-HOST-31 | | P | 1394-97 | 20000614060520P | 1 | | | | | | | | | | | |O | 1 | Normal Control | <1034241923_260> | ^ ^ ^ 555 | R | | | | | | | | | | P | | | | | | | | | | O @ FR | 1 | ^ ^ ^ 555 | 106.01 | % | | N | | F @ V | | ^ IL | | 20021211163215 | ACL-TOP-21 ^ B ^ 5C | 1 | I | 1025 ^ reagent temperature warning ^ HW | IC | 2 | I | 1030 ^ cuvette shuttle temp warning ^ HW | IR | 2 | ^ ^ ^ 555 | 12.65 | sec | | N | | F @ V | | ^ IL | | 20021211163215 | ACL-TOP-21 ^ F ^ 3R | 3 | ^ ^ ^ 555 | 0.97 | INR | | L | | F @ V | | ^IL | | 20021211163215 | ACL-TOP-21 ^ G ^ 2C | 1 | I | 1017 ^ probe temperature warning ^ HW | IL | 1 | N

4.5.2 DOWNLOAD MESSAGE – TEST RESULTS DELIVERY REJECTED BY THE LIS HOST

In case there is an error in the information retrieved by the instrument to the LIS host, the LIS host cannot retrieve any error information to the instrument

4.6 LIS HOST REQUEST RESULTS TO THE INSTRUMENT

This scenario takes place when the LIS host launches a request to the instrument, for uploading available test results. IL instruments do not support to operate in this way, consequently, all requests for test results received from LIS host will be rejected.

4.6.1 DOWNLOAD MESSAGE – TEST RESULTS REQUEST PERFORMED BY THE LIS HOST

Message structure

11 Operator Identification

Operator ID for the test performer

1 String 30 N N

Operator ID for the test verifier 2 String 30 N13 Date Time Test

CompletedDate and time the instrument completed the test

1 ASTM Date

Y N

14 Instrument Identification

Identifies the instrument that performed this measurement

1 String 14 Y N Instrument ID as specified in TOP

Rack id 2 String 2 Y NRack position 3 String 2 Y N


Component Data type

Max.Length





3 Comment Source Comment origination point 1 String 1 Y N I4 Comment Text Comment ID 1 String 50 N N

Comment description 2 String 500 NComment area 3 String 50 N

5 Comment Type Comment type qualifier 1 String 1 Y N I (instrument flag comment),N (negative comment)




Message Header RecordField No.Request Information Record

Message Terminator RecordField No. Example

H | @ ^ \ | <0_0> <1025080549_50> | | LIS-HOST-05 | | | | | ACL-TOP-17 | | P | 1394-97 | 20010518123841 <CR>Q | 1 | ALL | | | | | | | | | | I <CR>L | 1 | N <CR>

4.6.2 UPLOAD MESSAGE – REQUEST REJECTED BY THE INSTRUMENT Message structure

Message Header RecordField No.Comment Record



Component Data type

Max.Length




1 String 1 Y N 1


1 String 1 Y Y C (correction of previous values),P (preliminary results),F (final results),X (results cannot be done),I (request results pending),S (request partial results),M (results a MIC level),R (result previously transmitted),A (abort last request),N (request new/edit results),O (request tests and demog data),D (request demographic data only)


Comment (C)Message terminator (L)


Component Data type

Max.Length





3 Comment Source Comment origination point 1 String 1 Y N I4 Comment Text Comment id 1 String 50 N N invalidTransmissionInformation

Comment description 2 String 500 N Request not allowed5 Comment Type Comment type qualifier 1 String 1 Y N N (negative result/error info)




ExampleH | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-02 | | | | | LIS-HOST-01 | | P | 1394-97 | 20020421073718 <CR>C | 1 | I | invalidTransmissionInformation ^ Request not allowed | N <CR>L | 1 | Q <CR>

4.7 INSTRUMENT UPLOADS ERROR INFORMATION

This scenario takes place when the instrument receives an invalid message from the LIS host. See Error messages for more information on this topic.

4.7.1 UPLOAD MESSAGE – ERROR INFORMATION MESSAGE (1)This message is retrieved when there is a syntactic error, or when the host ID or instrument ID doesn’t match the values configured in TOP.

Message structure

Message Header RecordField No.Comment Record



Component Data type

Max.Length




1 String 1 Y N 1

3 Termination Code


1 String 1 Y N Q (error in last request)




Component Data type

Max.Length





3 Comment Source Comment origination point 1 String 1 Y N I4 Comment Text Comment id 1 String 50 N N invalidMessage

invalidSyntaxinvalidValuemissingMandatoryValueincompleteMessageinvalidTransmissionInformation

Comment description 2 String 500 N5 Comment Type Comment type qualifier 1 String 1 Y N N (negative result/error info)



ExampleH | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-02 | | | | | LIS-HOST-01 | | P | 1394-97 | 20020421073718 <CR>C | 1 | I | InvalidTransmissionInformation ^ Invalid host ID | N <CR>L | 1 | E <CR>

4.7.2 UPLOAD MESSAGE – ERROR INFORMATION MESSAGE (2)This message is retrieved when there is an action that cannot be executed by the instrument.

Message structure

Message Header RecordField No.Patient Information Record Field No.Test Order Record

Comment Record


Component Data type

Max.Length


1 Record Type ID Identifies the record 1 String 1 Y N L2 Sequence


1 String 1 Y N 1

3 Termination Code


1 String 1 Y N E (unknown system error)





Component Data type

Max.Length






1 String 16 N N



1 String 30 N N

5 Universal Test ID TOP defined Test ID 4 Numeric 6 N Y 0 - 9999996 Priority 1 String 1 N N S (Stat), R(normal)7 Requested/



1 ASTM Date

N N


Sample type 1 String 1 N N P (plasma)


1 String 1 N Y O (Order record),X (Order cannot be done),Y (No order/test in record)



Message Terminator RecordField No. ExampleH | @ ^ \ | 123 | | ACL-TOP-02 | | | | | LIS-HOST-01| | P | 1394-97 | 20020421073718P | 1 | | | | | | | | | | | |O | 1 | 8642 | | ^ ^ ^ 1234 | R | | | | | | | | | | P | | | | | | | | | | O @ YC | 1 | I | invalidTestData ^ duplicated test | NL | 1 | N

5. TRANSMISSION SCENARIOS RELATIONSHIPS

5.1 MANUAL OR AUTOMATIC JOB ORDERS DOWNLOADING


Component Data type

Max.Length





3 Comment Source Comment origination point 1 String 1 Y N I4 Comment Text Comment id 1 String 50 N invalidDemographicData

invalidSpecimenDatainvalidTestDataduplicatedTest

Comment description 2 String 500 N5 Comment Type Comment type qualifier 1 String 1 Y N N (negative result/error info)



5.2 HOST-INITIATED JOB ORDERS DOWNLOADING

I n s t r u m e n t L I S H o s t

t e s t o r d e r r e q u e s t ( 4 . 1 . 1 )

[ t e s t o r d e r s a v a i l a b l e ] : t e s t o r d e r d e l i v e r y ( 4 . 1 . 3 )

[ n o t e s t o r d e r a v a i l a b l e ] : n o d a t a a v a i l a b l e ( 4 . 1 . 4 )

T h e L I S H o s t r e s p o n d s t h e r e q u e s t

T h e I n s t r u m e n t c a n c e l s t h e r e q u e s t

[ r e q u e s t t i m e o u t ] : t e s t o r d e r r e q u e s t c a n c e l a t i o n ( 4 . 1 . 2 )

{ O R }

s t o r e r e c e i v e d o r d e r s

r e j e c t r e c e i v e d o r d e r s

[ b a d t e s t o r d e r ] :

[ t e s t o r d e r O K ] :

[ u p l o a d e r r o r s a c t i v a t e d ] : e r r o r i n f o r m a t i o n m e s s a g e ( 4 . 7 . 1 / 4 . 7 . 2 )

[ i n s t r u m e n t s p e c i m e n t - I D a c t i v a t e d ] : u p l o a d i n s t r u m e n t s p e c i m e n t I D ( 4 . 4 . 1 )

M a n u a l o r a u t o m a t i c j o b o r d e r s d o w n l o a d i n g



5.3 HOST QUERY

Instrument LIS Host

test order delivery (4.2.1)

store received orders

[instrument speciment-ID activated]: upload instrument speciment ID (4.4.1)

reject received orders

[bad test order]:

[test order OK]:

[upload errors activated]: error information message (4.7.1/4.7.2)

Host initiated job orders downloading



5.4 MANUAL OR AUTOMATIC JOB RESULTS UPLOADING

I n s t r u m e n t L I S H o s t

H o s t q u e r y ( 4 . 3 . 1 )

[ t e s t o r d e r s a v a i l a b l e ] : t e s t o r d e r d e l i v e r y ( 4 . 1 . 3 )

[ n o t e s t o r d e r a v a i l a b l e ] : n o d a t a a v a i l a b l e ( 4 . 1 . 4 )

T h e L I S H o s t r e s p o n d s t h e r e q u e s t

T h e I n s t r u m e n t c a n c e l s t h e r e q u e s t

[ r e q u e s t t i m e o u t ] : h o s t q u e r y c a n c e l a t i o n ( 4 . 3 . 2 )

{ O R }

s t o r e r e c e i v e d o r d e r s

[ i n s t r u m e n t s p e c i m e n t - I D a c t i v a t e d ] : u p l o a d i n s t r u m e n t s p e c i m e n t I D ( 4 . 4 . 1 )

r e j e c t r e c e i v e d o r d e r s

[ b a d t e s t o r d e r ] :

[ t e s t o r d e r O K ] :

[ u p l o a d e r r o r s a c t i v a t e d ] : e r r o r i n f o r m a t i o n m e s s a g e ( 4 . 7 . 1 / 4 . 7 . 2 )

H o s t q u e r y



6. APPENDIX A – FUTURA COMPATIBILITY MODEWhen the communication module for TOP was designed, it was thought to ease the communication for both new users, that can use a new protocol with extended capabilities, and old users who can reuse the old Futura developed driver. For any information of the Futura implementation see [R2].

The Futura driver should only be used by institutions that currently have a developed driver and can reuse it with the changes produced in this adapted version. New users should always use the new implementation of the protocol that provides more functionality.

The Futura driver for TOP works exactly as the Futura instrument except for the following issues:

GENERAL DIFFERENCES

• TOP uses the host query mechanism to request tests immediately when a rack is inserted in theinstrument. Futura did not support this feature in its original version and it has been disabled in thenew Futura driver implementation for TOP. To allow the Futura driver to work as originally, you haveto activate the automatic downloading of test orders.

• The Futura documentation does not require LIS drivers to respond to all test orders requests byTOP. Due to that, when a request is not responded in Futura compatibility mode no error messageis displayed.

DATA MAPPINGS

Instrument LIS Host

test result upload (4.5.1)

Manual or automatic results uploading

Instrument LIS Host

test results request (4.6.1)

request rejected by instrument (4.6.2)

LIS Host requests results

All requests for test results received from LIS host will be rejected.This instrument doesn't support to operate in this way.



• Futura test IDs and TOP test IDs have changed. The communication will be performed using thenew test IDs defined by TOP. Changes may be required in the LIS/driver to accommodate to thesenew identifiers.

• Futura result units and TOP result units have changed. Futura driver for TOP implements therequired mapping to conform as much as possible to the original Futura units. Units not supportedby Futura are sent in TOP original’s format and the limitation of 6 digits detailed in the Futura doc-umentation has been changed to 15 characters. These are the mappings performed by TOP inFutura mode:

Top Futura/Advance

Comment

Measured s secMean Not supportedT Not supported%T Not supportedD T delta "delta" for Delta Deriv. AlgorithmT/min ct/minD %T delta%T/min Not supportedmAbs Not Supported Used by Endpoint Algorithm - not available on Futura/

AdvanceD mAbs mA

delta

"mA" maps to Top Final - Initial Algorithm"delta" maps to Top Delta Derivative Algorithm. The use of the unit in this case is always mapped to “mA”

mAbs/min mA/minCalculated Ratio R

INR INR% %

Calibrated g/L g/Lmg/L Not supportedmg/dL mg/dLng/mL ng/mLU/mL U/mLIU/mL IU/mLmU/mL Not supportednmol/L Not supported%vWF:Ag Not supportedUser Defined Not supportedNot supported µM/L equivalent to: nmol/l x 103 (never sent by TOP in

Futura mode)Not supported µg/L equivalent to: g/l x 10-6 (never sent by TOP in Futura

mode)Statistical %CV Not supported

SD Not supportedSlope Not supported

Paired TR Not supported%NTR Not supportedD Not supportedD N Not supported



• Error descriptions have changed in TOP, but they will be sent using the old Futura format. Only onecomment record with all flags and errors concatenated with a ‘+’ sign. The number used to indicatethe determination where the error was found has also been removed.

CHANGES IN MESSAGES

• Now the patient name and last name is now separated by a component delimiter (patient recordfield 6). In the original version of futura, the patient name and last name was stored in the first com-ponent.

• Specimen ID length has changed from 20 characters to 16. 16 is the maximum number of char-acters supported by the TOP device. In case the number of characters sent by the LIS is bigger than16 the messages is rejected.

• When uploading test results Futura added the Rack ID and the Sample position in the field four inthe ASTM Order record. This field now includes the same data but the Rack ID and Sample positionhas changed to the new values in TOP.

• Futura supported the uploading of calibrations and checkpoints. These features have beenremoved in TOP

• TOP is not capable to distinguish automatically validated and manually validated results. Futura didthat sending an ‘F’ or an ‘V’ flag in R9 respectively. Due to that limitation in TOP, the driver of Futuraalways send results with an ‘F’ and ‘V’ is never used.

ERRORS

• Ill formed test orders messages downloaded from host are validated. If an error occurs in one mes-sage, no error information is sent to the HOST system. These are some of the actions performed:

•Fields with a maximum length longer than the value expected by TOP are truncated to the max-imum length allowed.

• Invalid date in a record makes the complete record to be invalidated and error info is sent to theapplication. With the exemption of H14 which value won’t be validated.

•Empty order date in O7 is filled with current date.

•Missing mandatory parameters are added when possible.

Parallelism mean of 100% Not supported In Futura, unit label corresponds to the Unit label selected by the user as primary unit.

mean CR aveCRmean CR 100%Not supportedslope sloper2 Not supported r equivalent to: (r2)1/2

y-intercept y-int%CV of CR %CV-CR%CV of CR 100%

Not supported


Chapter 6 – Power Management 6 - 1

Chapter 6 –Power Management

6-1 Overview

The Power Management consists of the +5V/+15V/-15V Power Supply, the +24V/+28V Power Supply, the Fuse Board, and the Power Entry Module, which includes the Instrument power switch and the attach-ment point for the line cord.


pter 6 – Power Management 6 - 2


6

Fig The +5V/+15V/-15V Power Supply is shown in dule is shown in yellow.

Power Entry Module

ower Supply

Cha

-2 Physical Layout

ure 6-1 "Layout of the Power Management System" shows the physical layout of the Power Management System.blue, the +24V/+28V Power Supply is shown in magenta, the Fuse Board is shown in green, and the Power Entry Mo

Figure 6-1 Layout of the Power Management System

+24V/+28V P+5V/15V/-15V Power SupplyFuse Board



6

Fig ement.

Cha

-3 Interconnect Diagrams

ure 6-2 "Interconnect Diagram for Power Management" contains the Interconnect Diagram for the Power Manag

Figure 6-2 Interconnect Diagram for Power Management

6 - 4 Chapter 6 – Power Management


This section describes the operation of the four major components: the Power Entry Module, the Fuse Board, the +5V/+15V/-15V Power Supply, and the +24V/+28V Power Supply.

Power Entry Module

The Power Entry Module includes the Instrument power switch, a Fuse Block, and the attachment point for the line cord (see Figure 6-3 "The Power Entry Module").

Note: In Figure 6-3 "The Power Entry Module" the Right Skin of the Instrument has been removed.

Figure 6-3 The Power Entry Module

Fuse Block Attachment Point for the Line Cord

Instrument Power Switch



Power Supplies

The output of the Power Entry Module goes to the primary (input) side of the +5//+15/-15 Power Supply and to the primary (input) side of the +24V/+28V Power Supply. Both Power Supplies are located in the rear wall of the Instrument, behind the Power Supply Covers (see Figure 6-4 "The Power Supply Covers").

Figure 6-4 The Power Supply Covers

The Power Supplies are auto ranging and are compatible with a wide range of input voltages and frequen-cies. Refer to "Electrical Requirements" for more information.

Figure 6-5 "The +5V/+15V/-15V Power Supply" shows the +5V/+15V/-15V Power Supply; Figure 6-6 "The +24V/+28V Power Supply" shows the +24V/+28V Power Supply.

Note: Figure 6-5 "The +5V/+15V/-15V Power Supply" and Figure 6-6 "The +24V/+28V Power Supply"show Power Supplies that are in the process of being removed from the Instrument.

Figure 6-5 The +5V/+15V/-15V Power Supply

+5V/15V/-15V Power Supply Cover

+24V/+28V Power Supply Cover



Figure 6-6 The +24V/+28V Power Supply

Fuse Boards

The secondary (output) side of the Power Supplies terminate at the Fuse Board. The Fuse Board provides over-current protection for the modules contained within the Instrument.

"Fuse Board Diagram for the Non-CTS TOP Model (Cavro)" describes the Fuse Board for ACL TOP/Cavro units; "Fuse Board Diagram for the CTS TOP Model" describes the Fuse Board for CTS TOP units.

The fuses on the Fuse Board are removable and can be replaced with fuses of the same rating. Spare fuses are included on the Fuse Board and may be used to replace any fuses that have opened.

WARNING: To ensure user safety, and proper system operation,fuses must be replaced with those that have the same rating and areof the same type.

Fuse Board Diagram for the Non-CTS TOP Model (Cavro)

Figure 6-7 "Fuse Diagram for the ACL TOP/Cavro" contains the fuse diagram for the ACL TOP/Cavro.



Figure 6-7 Fuse Diagram for the ACL TOP/Cavro

The following table shows the secondary voltages for the ACL TOP/Cavro.

**Current schematic and board notation refers to this value as 10A.

Table 6-1 Fuse Ratings and Secondary Voltages for the Non-CTS TOP Model

FUSE SIGNAL NAME RATING PART NUMBER

F1 BP_FANS_FUSE 2A/250V TIME DELAY IL #00014871705

F2 +28V_COOLING_BD 12.5A/250V SLOW BLOW** IL #00014871713

F3 +5V_LEVEL_III_CPU 4A/250V TIME DELAY IL #00014871708

F4 +24V_BACKPLANE 8A/250V TIME DELAY IL #00014871711


F6 +24V_CAVRO 8A/250V TIME DELAY IL #00014871711

F7 +24V_DC_DRIVER 8A/250V TIME DELAY IL #00014871711

F8 +5V_LEVEL_II_CPU 4A/250V TIME DELAY IL #00014871708


F18 -15V_BACKPLANE 2A/250V TIME DELAY IL #00014871705



The following table lists the spares for the ACL-TOP board.


CAUTION: Use terminal block J1 along the bottom edge of the board to check voltages. Refer to the voltage labels from the diagram above and marked on the board in silkscreen.

Fuse Board Diagram for the CTS TOP Model

Figure 6-8 "Fuse Diagram for the CTS TOP Model" contains the fuse diagram for the CTS TOP Model of the TOP.

Table 6-2 Spare Fuses for the Non-CTS TOP Board

SPARE FUSES RATING PART NUMBER

F11, F15 2A/250V IL # 00014871705

F16 12.5A/250V** IL # 00014871713

F9, F10, F13 4A/250V IL # 00014871708

F12, F14 8A/250V IL # 00014871711



Figure 6-8 Fuse Diagram for the CTS TOP Model

The following table shows the secondary voltages for the CTS TOP Model. Table 6-3 Fuse Ratings and Secondary Voltages for the CTS TOP Model


F1 BP_FANS_FUSE 2A/250V TIME DELAY IL #00014871705

F2 +28V_COOLING_BD 12.5A/250V SLOW BLOW** IL #00014871713

F3 +5V_LEVEL_III_CPU 4A/250V TIME DELAY IL #00014871708



F6 +24V_CAVRO 8A/250V TIME DELAY IL #00014871711

F7 +24V_DC_DRIVER 8A/250V TIME DELAY IL #00014871711

F8 +5V_LEVEL_II_CPU 4A/250V TIME DELAY IL #00014871708


F18 -15V_BACKPLANE 2A/250V TIME DELAY IL #00014871705

F19 +24V_SYS_F_UA1 8A/250V TIME DELAY IL #00014871711

F20 +24V_SYS_F_UA2 8A/250V TIME DELAY IL #00014871711



The following table lists the spares for the CTS TOP board.


CAUTION: Use terminal block J1 along bottom edge of board to check voltages. Refer to voltage labels from the diagram above and marked on the board in silkscreen.

Electrical Requirements

The instrument operates correctly with electrical variations of up to ±10% in an ambient temperature of 15°C to 32°C (59°F to 89°F) with a relative humidity of 5%-85% (non-condensing). The instrument should be placed in a position free from dust, fumes, vibrations and excessive variations in temperature. Using this instrument at an altitude greater than 2000 meters is not recommended.

The INSTRUMENT is single phase, has current leakage of less than 500 µAmps, and produces 2,049 BTU's per hour.

In accordance with IEC 1010 safety standard, paragraph 1.4, there is no safety hazard in the temperature range 5-40° C.

The instrument operates correctly with electrical variations of up to ±10% on the nominal supply and with supply frequencies between 47 and 63 Hz.

NOTE: The fuse board diagram and the secondary voltages for the CTS Instrument are found are found in "Fuse Board Diagram for the CTS TOP Model".

NOTE: The fuse board diagram and the secondary voltages for the standard ACL TOP/Cavro Instrument are found are found in ""Fuse Board Diagram for the Non-CTS TOP Model (Cavro)".

F21 +15V_PWR_F_UA1 2A/250V TIME DELAY IL #00014871705




F25 CAN_BUS_FUSE 2A/250V TIME DELAY IL #00014871705

Table 6-4 Spare Fuses for the Non-CTS TOP Board

SPARE FUSES RATING PART NUMBER

F11, F15 2A/250V IL # 00014871705

F16 12.5A/250V** IL # 00014871713

F9, F10, F13 4A/250V IL # 00014871708

F12, F14 8A/250V IL # 00014871711

Table 6-3 Fuse Ratings and Secondary Voltages for the CTS TOP Model




CAUTION: Ensure that the supply voltage in the laboratory is compatible with the label on the rear of the analyzer as shown in Table 6-5 "Supply Voltages" (below).

The voltages and current values in Table 6-5 "Supply Voltages" apply to all configurations of the TOP Instrument.

The PC requires an input voltage between 100-240V and an amperage of 3.5A.

The monitor requires an input voltage between 100-240V and an amperage of 1.8-0.9A.

The power cord provided with the instrument is a certified cord and three-prong, double insulated, grounded (NEMA) receptacle and plug.

Volt-Amps Specifications

This section contains the Volt-Amps specifications for all configurations of the TOP Instrument.

Volt-Amps Specifications for the TOP Analytical Module (AM)

Table 6-6 "TOP AM Volt-Amps Specifications" contains the Volt-Amps specifications for all configura-tions of the TOP AM.

Table 6-5 Supply Voltages

Value of supply voltage for normal function

Current (A) Value as shown on the label

240V AC ± 10% 5 A 100-240 VAC

115V AC ± 10% 10 A 100-240 VAC

100V AC ± 10% 10 A 100-240 VAC

Table 6-6 TOP AM Volt-Amps Specifications

Volts AC Amps Volts/Amp Watts Frequency

100 VAC 10A 1000 VA 600 W 50/60Hz

115VAC 10A 1150 VA 600 W 50/60Hz

240VAC 5A 1200 VA 300 W 50/60 Hz



Volt-Amps Specifications for the TOP Computer Module (CM)

Table 6-7 "TOP CM Volt-Amps Specifications" contains the Volt-Amps specifications for all configura-tions of the TOP CM.

Volt-Amps Specifications for the TOP Monitor

Table 6-8 "TOP Monitor Volt-Amps Specifications" contains the Volt-Amps specifications for all configu-rations of the TOP Monitor.

NOTE: DC voltage has no phase difference so VA = Watts

6-5 Adjustments and Verifications

Verification and Adjustment of the 5Volt Rail on the ACL TOP

NOTE: ONLY the 5 volt rail is adjustment.

1. Power down the unit and open the Sample and reagent covers.

CAUTION: Instantaneous and extensive damage can result if adjustment to the power supplies is attempted with the power on!

2. The +5V, +15V, -15V power supply is on the right hand side (facing the rear of the unit). Refer to Figure 6-9 "Power Supply Access". Remove the four mounting screws that secure the Power Supply to the rear wall.

Table 6-7 TOP CM Volt-Amps Specifications

Volts AC Amps Volts/Amp Watts Frequency

100 VAC 6A 600 VA 600 W 50/60Hz

115VAC 6A 690 VA 600 W 50/60Hz

240VAC 3A 720 VA 300 W 50/60 Hz

Table 6-8 TOP Monitor Volt-Amps Specifications

Volts DC Amps Volts/Amp Watts Frequency

12 VDC 4.16A 50 VA * 50 W 50/60Hz



Figure 6-9 Power Supply Access

3. Carefully pull the Power Supply away from the back wall enough to access the wire terminals.

4. Power on the Analytical Module (AM).

5. Measure the voltage across the red and black wires as shown on Figure 6-10 "+5/+15/-15V Power Supply Wiring".

Figure 6-10 +5/+15/-15V Power Supply Wiring

6. Power off the AM.

7. Turn the 5V adjustment potentiometer, see Figure 6-10 "+5/+15/-15V Power Supply Wiring", ¼ turn (clock wise to increase the voltage, counter clockwise to decrease the voltage).

8. Power up the Analytical Module (without closing the Sample and Reagent covers so the AM does not attempt to initialize) and measure the 5 volts at the red and black wires on the supply.

9. Repeat steps 5 through 8 until the 5 volts is measured to be from 5.20 volts to 5.25 volts, adjusting the potentiometer appropriately.

10. Secure the power supply with all mounting screws.

11. Reboot and initialize the system .

+5V/15V/-15V Power Supply Mounting Screws

+5V Adjustment Potentiometer

Red and Black Wires




6

Th rea, and the Controllers area, and the Arm Co

Cha

-6 Diagnostics

e diagnostics for Power Management are on the Voltages tab. The Voltages tab contains three main areas: the ORU antrollers area. Figure 6-11 "The Voltages Tab" shows the Voltages Tab.

Figure 6-11 The Voltages Tab


ORU Area

Figure 6-12 "The ORU Area" shows the ORU area. See “Testing/Correcting Voltage Errors” in Chapter 10 for further information on ORU voltage.

Figure 6-12 The ORU Area

The ORU area displays voltage information for each of the four Detectors and for the Emitter. For each of the four Detectors, the information includes the current voltage, the Lower Limit, and the Upper Limit for the three Detectors (12V, 5V, and -12V). For the Emitter, the information consists of the current voltage, the Lower Limit, and the Upper Limit for the 12V voltage.

NOTE: Ensure voltages are checked in the following order because voltages being incorrect in one area could cause voltages to be incorrect in the following area.



Controllers Area

Figure 6-13 "The Controllers Area" shows the Controllers area.

Figure 6-13 The Controllers Area

The Controllers area displays voltage information for the Cuvette, Rack, and ORU Controllers. For each Controller, the information includes the current voltage, the Lower Limit, and the Upper Limit for the four Controller supplies (24V, 15V, 5V, and -15V).



Arm Controllers Area

Figure 6-14 "The Arm Controllers Area" shows the Arm Controllers area.

Figure 6-14 The Arm Controllers Area

The Arm Controllers area displays voltage information for the Sample Arm, Intermediate Reagent Arm, and Start Reagent Arm. For each Arm Controller, the information includes the current voltage, the Lower Limit, and the Upper Limit for the three Arm Controller supplies (24V, 15V, and 5V).



6-7 Removal/Replacement

Power Entry Module Removal/Replacement

Power Entry Module Removal

Refer to Chapter 4 ("Chassis and Enclosure") for details on cover removal. To remove the Power Entry Mod-ule, the following covers must be removed: Right Skin, Inner Skin, Top Skin, Front Panel, and all four Interior Reagent Covers. First power down the Instrument and remove the power cord.

CAUTION: Before removing the Right Skin, the Rinse Bottle, Clean Bottle, Crossover Cables, and the fluidic waste lines must be removed.

After the covers have been removed, do the following to remove the Power Entry Module:

1. Remove the two screws that secure the Power Entry Module to the Instrument Frame (see Figure 6-15 "Power Entry Module").

Note:The Power Entry Module is mounted on the upper right side of the Instrument.

Figure 6-15 Power Entry Module

2. Remove the wires attached to the rear of the Power Entry Module (see Figure 6-15 "Power Entry Mod-ule").

3. Carefully pull the Power Entry Module from the Instrument.

Power Entry Module Installation

1. Place the Power Entry Module on the Instrument Frame as shown in Figure 6-15 "Power Entry Mod-ule".

2. Replace the two screws shown in Figure 6-15 "Power Entry Module".

3. Re-connect the wires, in the following fashion, to the rear of the Power Entry Module• White wire to Terminal N• Black wire to Terminal L• Non-insulated wire to the remaining terminal on the Power Entry Module

Mounting Screws

Wires Attached to the Power Entry Module



4. Reconnect the power cord to the Instrument.

5. Power on the Instrument in order to verify that the Power Entry Module is working properly.

6. Reinstall the covers.

Non-adjustable Power Supply Removal/Replacement

NOTE: The Instrument has two Non-adjustable Power Supplies, the following procedure applies to either supply.

Non-adjustable Power Supply Removal

1. Power down the Instrument.

2. Disconnect the power cord.

3. Remove the four mounting screws that secure the Power Supply to the rear wall (see Figure 6-16 "Non-Adjustable Power Supplies").

Figure 6-16 Non-Adjustable Power Supplies

+24V/+28V Power Supply

Mounting Screws

+5V/+15V/-15V Power Supply

Mounting Screws



4. Carefully pull the Power Supply far enough back to access the wire terminals (see Figure 6-17 "Wire Terminals on a +5/+15/-15V Power Supply").

Figure 6-17 Wire Terminals on a +5/+15/-15V Power Supply

NOTE: The +24V/+28V Power Supply has wires connected to both ends of the unit; the +5V/+15V/-15V Power Supply only has wires connected to one end of the unit.

5. Remove each of the wires from the Power Supply.

6. Place the Power Supply (with attached cover) on a sturdy flat surface with the cover facing up (see Fig-ure 6-18 "The Power Supply Cover").

7. Remove the four mounting screws from the Power Supply Cover (see Figure 6-18 "The Power Supply Cover").

8. Lift the Power Supply Cover off the Power Supply.

Figure 6-18 The Power Supply Cover

Non-adjustable Power Supply Installation

1. Place the new Power Supply on a sturdy, flat surface. The holes for the mounting screws should be fac-ing upward.

2. Use the four mounting screws to secure the Power Supply Cover to the Power Supply (see Figure 6-18 "The Power Supply Cover").

Mounting Screws for the +5V/+15V/-15V Power Supply



3. For a +5V/+15V/-15V Power Supply, re-connect the wires in the following fashion (terminals as indi-cated with supply installed):

• Leftmost screw terminals: Blue - top terminalBlack - bottom terminal

• Middle screw terminals: Black - top terminalBrown - bottom terminal

• Rightmost screw terminals: Black - top terminalRed - bottom terminal

• Three-pin connector: AC input cable

4. For the +24V/+28V Power Supply, re-connect the wires in the following fashion(terminals as indicated with supply installed):

• Left (fan) side: GND – green, or green with yellowNEW – whiteLINE – black

• Right side: Leftmost screw terminals: Black on top terminalYellow on bottom terminal

Rightmost screw terminals: Black on top terminalWhite on bottom terminal

NOTE: The 10-pin connectors are not used on the +24V/+28V Power Supply

5. Carefully place the Power Supply into the back wall of the Instrument.

6. Fasten the four mounting screws to secure the Power Supply to the rear wall of the Instrument (see Fig-ure 6-16 "Non-Adjustable Power Supplies").

CAUTION: Make sure the right model of Power Supply (+15V/-15V/+5V or +24V/+28V) is installed in the correct location as shown in Figure 6-16 "Non-Adjustable Power Supplies".

Fuse Board Removal/Replacement

Fuse Board Removal

Refer to “Removal/Replacement Procedures” in Chapter 4 for details on cover removal. To remove the Fuse Board, the Sample Side interior covers must be removed.

After the covers have been removed, do the following to remove the Fuse Board:

1. Power down the Instrument before removing covers.

2. Disconnect the power cord.

3. Remove all connectors and wires to the Fuse Board. (Note: The Fuse Board is located on the upper-left portion of the Instrument rear wall.)

4. Remove the four screws that secure the Fuse Board to the rear wall of the Instrument (see Figure 6-19 "The Fuse Board").

5. Carefully pull the Fuse Board from the rear wall of the Instrument.



Figure 6-19 The Fuse Board

Note: Figure 6-19 "The Fuse Board" shows the Fuse Board for the CTS TOP. The Fuse Board for the ACLTOP/Cavro does not have the Reagent Arm fuses, which are located on the lower right-hand side ofthe Fuse Board for the CTS TOP.

Fuse Board Installation

1. Place the Fuse Board on its screw standoffs on the rear wall of the instrument.

2. Fasten the four mounting screws in their locations at the corners of the Fuse Board.

3. Fasten the wires and cables to the Fuse Board.

Be aware of the following as wires and cables are re-connectd to the Fuse Board:

• The screw terminals for the Power Supply wires are not keyed. Connect the wires as follows:+24VA – White twisted with Black+24V GNDA – Black twisted with white+28VRC – Yellow twisted with Black+28V GND – Black twisted with Yellow+5V GND – Black twisted with Red+5V – Red twisted with Black+15V GND – Black twisted with Brown+15V – Brown twisted with Black-15V GND – Black twisted with Blue-15V – Blue twisted with Black

• The Reagent Arm Connectors, and the Reagent Arm cables, are labeled but are not keyed. Ensurethat the Intermediate Reagent Arm cable is connected to the Intermediate Reagent Arm connector,and the Start Reagent Arm cable to the Start Reagent Arm connector. (Note: The Reagent Armconnectors exist only on the CTS Fuse Board.)

Mounting Screws


Chapter 7 – Fluid Movement 7 - 1

Chapter 7 –Fluid Movement

7-1 Overview

The ACL-TOP contains two distinct fluid movement systems, the Precision fluid movement system and the Bulk fluid movement systems.

• The "The Precision Fluidic Subsystem" is responsible for moving the patient samples, calibra-tors, diluents, and reagents from rack locations to the cuvette wells.

• The "The Bulk Fluidic Subsystem" provides the necessary fluids to maintain precision and accu-racy, and to clean the probes and remove waste fluid and condensation from the instrument.

7-2 Physical Layout

Figure 7-1 "Layout of the Fluid Movement System" shows the physical layout of the Fluid Movement System.

Figure 7-1 Layout of the Fluid Movement System


7 - 2 Chapter 7 – Fluid Movement


Figure 7-2 "Fluid Movement System Interconnect Diagram" contains the Interconnect Diagram for the Fluid Movement System. Interconnect diagrams for the robotic arms and their fluidic connections are pro-vided in “Interconnect Diagrams” in Chapter 8.

Figure 7-2 Fluid Movement System Interconnect Diagram

Backplane

Fluidics Connector Board

27506000

Clean

Pump #1

Sample Clean

Valve

CTS Clean

Valve

0002

77

60

40

0

Clean

Pump #2

Accumulator 2

Full Sensor

Reagent

Solenoid

Valve 1

Reagent

Solenoid

Valve 2

00027760600

0002

77

60

70

0

0002

77

60

30

0

Accumulator 1

Full Sensor

CTS Rinse

Pump

Reagent Rinse

Pump 2

Waste Pump

Sample Rinse

Pump

Reagent Rinse

Pump 1

Rinse Bottle # 2

Empty Sensor

Rinse Bottle #2

Warn Sensor

Clean Bottle

Warn

Rinse Bottle #1

Warn Sensor

Rinse Bottle #1

Empty Sensor

Clean Bottle

Empty

189510-01

J1 J2 J3

J3 J4

286400

CAN Bus LAS

PC/104 CAN Bus

Digital I/O

J1, J2

CAN Bus

J3

J7

J8

J4

PC/104

J1

Waste

Fluid

Full

CAN BUS

Video

Ethernet

J4

Speaker

J8

Battery

J3

Mouse

J18

IDE HD

J15

Floppy

J6

SVGA CRT

J2

Keyboard

J3

COM1/2

J9

Ethernet

J3

Power

J7

PC Video

J5

Flat Panel

J16

LPT1

J17

COM5 SCSI

J12

EZ I/O

J11 OPTOA/OPTOB

J14

COM3/COM4

FLOPPY DRIVE

P1

P2

INSTRUMENT

SIDE PANEL

From Fluid

Driver Board

From

Backplane

J14

277626-00

277624-00

Power FromFuse Board

J8

278000

Level 2 CPU

Speaker Battery

277582

TO J3 OF 28632000

X-AXIS DRIVER

DUAL ARM

TO J3 OF 28632000

X-AXIS DRIVER

CTS ARM

277552

277608

J1

J3

J2J25

277551

J36 Power J32

To Front Panel

Disconnect Board

277621

J1

J19

Fluidics LED

275070

277518

277519

14 Pin Ribbon

Fluidic and

System

Status LED’s and

Cavro Reset

277536

14 Pin Cable

FLUIDICS

CONTROLLER

BOARD

275050

J14

CANBUS

277

62

6

To S

ide

Pa

ne

l

277587-00

P1

P11277625-00

J6

J8

J5

J1J2

J2 J9

00027754000

To Cavro CCU9000

J15(Both) 00027758300

Waste Sensor

Disconnect Board




To maintain precision and accuracy of the system, the Precision Fluid Lines and the Sampling Probes are filled with a working fluid, HemosIL Rinse solution, that limits the compressibility of the system fluid. The working fluid ensures that displacements created in the Syringe Pump are precisely replicated at the probe tip when samples are aspirated or dispensed.

NOTE: The HemosIL Rinse solution is also used by the instrument to clean the probes.

Aspirating and Dispensing

Prior to aspirating a sample, the Syringe Pump draws an air gap to create a separation zone between the working fluid and the sample. After the sample is aspirated, the Syringe Pump draws a second air gap, known as a transport air gap, to create a buffer between the sample and the outside environment and to move the sample up the tube. (Moving the sample up the tube also moves the sample closer to the Probe heater, in instruments that are equipped with a Probe Heater.)

During the dispensing of the sample, the entire transport air gap and 50% of the first air gap is dispensed along with the sample. The remaining 50% of the first air gap (an accumulated volume in the syringe) is dis-pensed over waste at the end of the test. When beginning a test, the Syringe Pump always starts at zero volume.

The sizes of the air gaps can differ depending on the sample size. The air gaps for IL-approved assays are stored in the parameter files. Users who create their own assays can define their own air gaps and generate their own parameter files.

For customer-defined assays, the use of a Head Volume may be desired. A Head Volume allows the aspi-ration of an additional volume of sample. (IL-defined assays do not typically use a Head Volume.)

The Precision Fluidic Subsystem

The Precision Fluidic Subsystem consists of the following components, addressing, and settings:Table 7-1 Components of the Precision Fluidic Subsystem

Component

"Syringe Pump"

"Syringe Drive Motor"

"Syringe Pump Valve"

"Cavro Syringe Pump Settings"

"Hamilton Syringe Pump Settings"



The following subsections provide descriptions of the above listed components of the Precision Fluidic Sub-system and their operation.

Syringe Pump

The syringe pump assemblies used on CTS and non-CTS ACL-TOP instrument types are the Cavro XP3000, as shown in Figure 7-3 "Cavro XP3000 Syringe Pump" or the Hamilton PSD4 as shown on Fig-ure 7-4 "Hamilton PSD4 Syringe Pump". Either assembly contains a PCB, a 24-volt DC motor, and a pump to which a three-way Y valve, and a syringe are attached. The PCB includes a processor that receives commands from the X-Axis Driver PCB in the CTS system using an RS-232 protocol. The processor receives commands from the master processor in the Base TOP system and uses RS-485 protocol. The syringe pump provides the precision fluid movement for the ACL-TOP and controls the aspiration and dis-pensing operations in the probe.

The following descriptions of syringe pump operation apply to both the Cavro and Hamilton pumps. Differ-ences between the two are clearly defined.

Figure 7-3 Cavro XP3000 Syringe Pump

"Syringe Pump Addressing"

"Probes and Tubing, non-CTS, Cavro Arms"

"Probes and Tubing, CTS"

Table 7-1 Components of the Precision Fluidic Subsystem(Continued)

Component

Syringe

MotorSyringe Drive



Figure 7-4 Hamilton PSD4 Syringe Pump

Syringe Drive Motor

The Syringe Drive Motor is a stepper motor that controls the movement of the syringe. Each time the arm is initialized, the Syringe Drive Motor is initialized and places the syringe in the home position. The syringe is in its home position, all the way up, when the syringe is at zero volume. When the syringe reaches zero vol-ume, the circuit board-mounted home sensor is triggered by a flag mounted to the Syringe Plunger Holder.

Step loss in the Syringe Drive Motor is monitored by a quadrature encoder. The encoder can detect both step loss and direction of travel. The Stepper Motor provides 30 mm travel length for the Syringe and has a resolution of 3,000 steps. The full range of travel for the syringe is equivalent to its volume of 250uL.

Syringe

Each Syringe Pump has a syringe, a Teflon tip, and a capacity of 250uL. A portion of the syringe volume is used to aspirate the air gap and the transport air gap as described in "Aspirating and Dispensing". Both the Cavro and Hamilton syringes have a Kel-F Body and a Teflon Plug as shown in Figure 7-5 "Cavro Syringe Parts" and Figure 7-6 "Hamilton Syringe Parts". As shown on the Figure, the Cavro and Hamil-ton syringes have a different design to the syringe mounting; however their function is identical.

Syringe DriveMotor

Syringe



Figure 7-5 Cavro Syringe Parts

Figure 7-6 Hamilton Syringe Parts

Syringe Pump Valve

The Syringe Pump Valve is mounted to the upper front of the Syringe Pump by two Phillips pan head screws as shown in Figure 7-7 "Syringe Pump Valve".

Kel-F Body

Teflon Tip

Plunger

Kel-F Body

Teflon Tip

Plunger



Figure 7-7 Syringe Pump Valve

The valve has three ports and each port has a ¼-28 UNF female thread designed for a bottom seal fitting. The plug within the pump rotates within the body to connect any 2 ports together. As shown on Figure 7-8 "Syringe Valve Ports", the upper right valve position is for the sample tubing, the upper left is for rinse input and the lower position is for the syringe.

Figure 7-8 Syringe Valve Ports

Valve

Teflon Plug

Pan HeadScrews

Rinse InputPort

SyringeConnection

Probe (Sample OutputTubing)



The valve is turned by a stepper motor with an encoder coupled to the motor that provides positional feed-back. Attached to the valve shaft is a flag to recognize the home position during initialization of the valve. The valve home sensor shares a circuit board with the syringe home sensor. During initialization, the valve spins until the flag is recognized by the home sensor. The valve is then placed in “output” mode in which the syringe port is linked to the probe for sample aspiration and dispensing. Valve initialization can cause some fluid to leak past the valve. To prevent uncontrolled fluid dispensation, the valve is only initialized by the ACL-TOP software when the probe is over the accumulator rinse/waste location. Table 7-2 "Valve Posi-tions for All ACL-TOP Configurations" lists the three available valve positions and their function.

Cavro Syringe Pump Settings

On the rear panel of the Syringe Pump are two sets of jumpers and a rotary switch. The jumpers are used to determine the communications used to communicate with the pump (RS485, RS232, baud rate) as well as some selectable operations of the pump. The rotary switch is used to set the address of the valve.

The upper set of jumpers are Termination jumpers and should be in the position shown on Figure 7-9 "Cavro Syringe Pump Communication/Valve Jumpers". As shown on the figure, the two jumpers on the left configure the pump for RS-485 communication if inserted. The lower jumper on the right is used to set the Valve Mode in Normal Mode (jumper inserted) versus programming mode (without the jumper). The fourth jumper, between pins 3 and 4 of JP4, is an extra jumper.

Figure 7-9 Cavro Syringe Pump Communication/Valve Jumpers

Table 7-2 Valve Positions for All ACL-TOP Configurations

MODE CONNECTION FUNCTION

OUTPUT SYRINGE TO PROBE SAMPLE ASPIRATION & DISPENSE

INPUT RINSE PUMP TO SYRINGE PRIMING THE SYRINGE

BYPASS RINSE PUMP TO PROBE PRIMING

Extra Jumper

JP2 JP4

Pin 4

Pin 1

Pin 3

Pin 2Pin 1

Pin 2Pin 3

Valve Mode

RS-485-B

RS-485-A



The lower set of Cavro jumpers are configuration jumpers and should be in the position shown on Figure 7-10 "Cavro Syringe Pump Lower Jumpers and Rotary Switch" to provide the functionality as identified on the right side of the figure. The rotary address switch for the pump is also shown in Figure 7-10 "Cavro Syringe Pump Lower Jumpers and Rotary Switch" and should be set as defined in "". As shown on the figure, the hex number at the top of the dial indicates the address.

Figure 7-10 Cavro Syringe Pump Lower Jumpers and Rotary Switch

The preceding figures show the correct placement of the jumpers for the Cavro pump. For clarification, Table 7-3 "Jumper Settings" shows the correct settings of the Cavro Syringe Pump jumpers.

Hamilton Syringe Pump Settings

On the rear panel of the Hamilton Syringe Pump are eight DIP switches, a set of jumpers, and a rotary switch. The DIP switches are used to determine the communications protocol used to communicate with the pump as well as some selectable operations of the pump. The jumpers are configuration jumpers and the rotary switch is the address switch for the pump.

Table 7-3 Jumper Settings

JUMPER SETTING

JP1-1 OUT

JP1-2 IN

JP1-3 OUT

JP1-4 OUT

JP2- Pin1 to Pin 2 IN

JP2- Pin 3 to Pin 4 IN

JP4- Pin 1 to Pin 2 IN

JP4 - Pin 3 to Pin 4 Unused

JP1-2

JP1-4

Address switch(Rotary dial)

JP1-3

JP1-1

- EEPROM Mode

- Protocol

- Overload Detection

- Baud Rate

(Enabled)

(OEM)

(EEPROM Autostart)

(9600 Baud)

Address



The lower set of jumpers are configuration jumpers and should be in the position shown on Figure 7-11 "Hamilton Syringe Pump Jumpers/Switches" and defined in Table 7-4 "Hamilton Configuration Jump-ers". The rotary address switch for the pump is also shown in Figure 7-11 "Hamilton Syringe Pump Jumpers/Switches" and should be set as defined in "Syringe Pump Addressing". Note that the center portion of the switch has an arrow head. The arrowhead points to the address that is selected.

Figure 7-11 Hamilton Syringe Pump Jumpers/Switches

Table 7-4 Hamilton Configuration Jumpers

Pins Setting

J1 -J2 No Jumper

J3 - J4 No Jumper

J5 - J6 Jumper Inserted

J7 - J8 Jumper Inserted

Address Switch

ConfigurationJumpers

J1 - J2J3 - J4J5 - J6J7 - J8

SW 8

SW 1

Address Selection



The Dip switches should be in the position shown on Figure 7-11 "Hamilton Syringe Pump Jumpers/Switches".

Syringe Pump Addressing

Communication between the syringe pump and the ACL-TOP is via RS-232 at 9600 baud for the Universal arms and via RS-485 for the Cavro arms. For communication to occur, each pump is individually address-able and must have its address set properly so the ACL-TOP can recognize it. The rotary address switch is located on the lower rear of the syringe pump housing as shown on Figure 7-10 "Cavro Syringe Pump Lower Jumpers and Rotary Switch". The address is properly set on all instruments prior to leaving man-ufacturing; however, a replacement syringe pump must have its address set to properly communicate with the ACL-TOP. Table 7-6 "Syringe Pump Addresses (CTS Instruments)" shows the syringe pump addresses for ACL-TOP CTS units. Table 7-7 "Syringe Pump Addresses (Base TOP Instruments)" shows the syringe pump addresses for ACL-TOP non-CTS units.

Table 7-6 Syringe Pump Addresses (CTS Instruments)

Table 7-7 Syringe Pump Addresses (Base TOP Instruments)

Table 7-5 Hamilton DIP Switches

Switch Description Setting for ACL-TOP

1 Syringe Overload Detection Off

2 EEPROM AutoStart/Self Test Off

3 Baud Rate 9600 or 3840Baud Off

4

Valve Settings

Off

5 Off

6 Off

7 Off

8 Rs-485 Communication Termination Off

ARM LOCATION SYRINGE PUMP ADDRESS

SAMPLE 1

INTERMEDIATE REAGENT 1

START REAGENT 1


SAMPLE 4

INTERMEDIATE REAGENT 0

START REAGENT 4



Probes and Precision Tubing

The probes and precision tubing are responsible for contacting, acquiring, transporting, and, if the probes are heated, heating the samples, reagents, and calibrators as they are moved from rack positions to cuvette wells. All probes have liquid level detection (LLD) capability. The LLD capability enables the ACL-TOP sys-tem software to perform volume tracking on reagents and diluents and to maintain the precision and accu-racy of probe tip wetting depths and coordinate adjustments. An explanation of the LLD circuitry is provided in “Sample and Piercer LLD” in Chapter 15 for CTS units and in “ADRI-9 PCB” in Chapter 8 for non-CTS units.

The precision tubing connects the probe to the syringe pump valve and enables the displacements created in the syringe pump to be transferred to the probe tip. The precision tubing is made of chemically compatible Teflon. Leak-tight connections are maintained between the precision tubing and the sampling probes, as well as between the precision tubing and the syringe pump valve. The precision tubing is routed in a manner to add flexibility during arm movement and to prevent kinking and changes in tubing internal diameter.

Depending on whether the ACL-TOP is a non-CTS or a CTS instrument, there are different probes required for each arm. The probes and tubing required by different versions are described below.

Probes and Tubing, non-CTS, Cavro Arms

The non-CTS instrument (Cavro Arms) uses three identical probes. Each probe has Liquid Level Detection (LLD), heating, and a continuous stainless steel center with a formed tip. A pure copper tube surrounds the steel tube to maintain thermal stability. The fitting welded to the top end of the stainless steel tube is the con-nection for the precision tubing.

Figure 7-12 The Probe for the non-CTS instrument with Cavro Arms

A circuit board is mounted within the probe housing that can be accessed by sliding the probe cover upward. The circuit board contains software necessary to drive the probe heater control. Values attained during cal-ibration of the probe are stored on the probe circuit board.

Each probe has two heaters and two thermistors to regulate temperature. The Control Loop of the probe is designed to maintain the sample temperature at 37ºC. There are eight discrete wires that transfer heater and thermistor data between the Probe Circuit Board and the Probe body. For a further description of ther-mal control of the probe, refer to “Reagent Probes for Cavro Thermal Regulation” in Chapter 12 and “Cavro Sample Probe Thermal Regulation” in Chapter 12.



The LLD sensing for the probe is driven by a capacitance differential circuit. The LLD sensor (Alidum) is located on the Cavro Arm Y-Axis ADRI-9 PCB. The LLD signal is carried from the probe tip to the Alidum by a coaxial cable. The stainless steel probe tube is directly tied to the center conductor of the coaxial cable. A 0.22 Ohm resistor is hard wired between the coaxial cable center conductor and the probe body. The resis-tor maintains the proper resistance for the Alidum's RC network to function properly. The ground plane in the coaxial cable is tied to the isolation block at the top of the probe. If a failure in the isolation of the two signals occurs, the probe will not perform LLD properly.

The precision tubing used on the probe has a threaded fitting on each end. The purple fitting threads onto the probe, and the white ¼-28 fitting threads into the right port on the syringe pump valve. The purple fitting is meant to be torqued to 10 in-oz. Without using a torque wrench, this amount of torque can be achieved by tightening the fitting by hand and then further tightening ¼ turn with a wrench. This torque is required to properly preload the o-ring attached to the fitting. The O-ring provides compression to the Teflon flange as it seals against the bottom of the valve's threaded port.

Probes and Tubing, CTS

The ACL-TOP with CTS uses two heated Reagent Probes and a non-heated Sample Probe. The Sample Probe is assembled into the CTS Telescoping Assembly. All three probes have Liquid Level Detection (LLD) and a continuous Stainless Steel center with a formed tip. A pure copper tube surrounds the steel tube on the Reagent Probes to maintain thermal stability. There is a straight end at the top of the stainless steel tube that has a rough surface finish. This straight end is the connection for the precision tubing.

A circuit board is mounted directly to the probe housing. You can access the board by sliding the cover of the probe upwards. Due to design requirements, access to the CTS probe board is limited by protective sheet metal covers. On both the Sample and Reagent Probes, the circuit board contains software necessary to drive the LLD circuit. The Reagent Probe circuit boards also drive the heater control. Values attained dur-ing calibration of the probe are stored on this circuit board.

Each Reagent Probe has two heaters and two thermistors to regulate temperature. The control loop of the probe is designed to maintain the sample temperature at 37ºC. There is a 9-pin connector with eight discrete wires that transfer heater and thermistor data between the probe circuit board and the probe body, with an additional blue wire that carries the ground signal for the LLD circuit. For a further description of thermal con-trol of the probe, refer to “Reagent Probes for Cavro Thermal Regulation” in Chapter 12.

The CTS sample probe is unique in ACL-TOP CTS instrument. There are no heaters, thermistors, or copper jacket assembled onto the CTS Sample Probe. The Sample Probe Circuit Board does not have the heater control software and is therefore not compatible with the heated Reagent probes.

The Liquid Level Detection (LLD) for the probe is provided by capacitance differential sensing. The LLD sensing circuit is mounted on the probe circuit board. The LLD signal is carried to the arm controllers via the probe flex cable. Note that the CTS probe is completely described in Chapter 15 “CTS Piercer”.

CTS instruments have tubing on the probe that has a compression seal. The compression connection slides over the stainless steel tube on the probe, and the white ¼-28 fitting threads into the right port on the 3-way valve. The flared end of the compression connection slides over the stainless steel approximately 10 mm. The compression band is then slid around the flare end. Once compression is on the flare, the Teflon tubing “cold flows” around the roughened surface finish on the stainless steel tube. The ¼-28 fitting should be tight-ened by hand and then given ¼ turn with a wrench to properly seal the O-ring attached to the fitting. The O-ring provides compression to the Teflon Flange as it seals against the bottom of the threaded valve port.



The Bulk Fluidic Subsystem

The Bulk Fluidic Subsystem consists of the following components:

The following subsections provide detailed descriptions of the components, and operation, of the Bulk Flu-idic Subsystem.

Onboard Rinse Fluid Bottle

The ACL-TOP gets its HemosIL Rinse fluid from the Onboard Rinse Bottle on the right side of the instrument as shown on Figure 7-13 "The Onboard Rinse Fluid Bottle". An arm-specific Rinse Pump draws the HemosIL Rinse fluid into the ACL-TOP. The HemosIL Rinse fluid enters the system via an Aspirator inserted into the Onboard Rinse Bottle. The fluid height in the Onboard Rinse Bottle is checked by two capacitance sensors mounted on the inside of the right outer panel as shown on Figure 7-14 "Rinse, Clean Sensors".

Figure 7-13 The Onboard Rinse Fluid Bottle

Table 7-8 Components of the Bulk Fluidic Subsystem

Component

"Onboard Rinse Fluid Bottle"

"Rinse Pumps"

"Rinse and Clean Cups"

"Clean Fluid Bottle"

"Clean Pumps"

"CTS Bulk Fluids Module"

"CTS Air Flow"

Onboard RinseFluid Bottle



Figure 7-14 Rinse, Clean Sensors

The warning and empty sensors are monitored by the ACL-TOP system software. The LED above the waste door indicates when the onboard rinse bottle is low or empty. When the Onboard Rinse Bottle is low, the LED turns amber; when the Onboard Rinse Bottle is empty, the LED turns red. A warning is also sent to the CM software that displays a red exclamation point on the Analyzer Alarm button of the Status bar.)

A low rinse bottle warning causes the instrument to enter a controlled stop where it schedules a finite num-ber of tests that can be run prior to the instrument stopping and allowing no additional tests until the rinse bottle is replaced. An empty rinse bottle warning causes the instrument to enter an emergency stop.

The rinse fluid performs two functions during the fluidic cycle. First, the rinse fluid washes the internal and external surfaces of all probes that come in contact with patient samples to prevent any carryover from one sample to another. Second, the rinse fluid acts as the working fluid for the system. The compressibility of the rinse fluid is far less than that of air. There is a uninterrupted column of rinse fluid between the syringe and probe tip. When sample aspiration or dispense is required, the rinse fluid acts as the medium for transferring the fluid displacement within the syringe. Without rinse fluid, or with air bubbles in the precision tubing, the ACL-TOP would not meet its precision and accuracy specifications. It is critical to overall performance that priming of the fluid lines occurs on a regular basis. The fluid lines are primed each time the arms are initial-ized and during regularly scheduled maintenance activities. See "Priming the Rinse System" and "Prim-ing the Clean System".

Rinse Pumps

All ACL-TOP instruments have three Rinse Pumps that supply HemosIL Rinse fluid to the probes. There is a dedicated Rinse Pump for each arm. The Rinse Pumps are contained in the Rinse Pump box that is located under the Waste Pump Box to the left of the Waste drawer as shown on Figure 7-15 "Rinse Pump Box Location". The Sample arm has one pump mounted in the rinse box while the Reagent arm has two pumps mounted in the rinse box. There is a Rinse Input line leading from the Rinse Aspirator to the Rinse Pump Box.

Clean EmptySensor

Clean WarningSensor

RinseWarningSensor

Rinse Empty Sensor



Figure 7-15 Rinse Pump Box Location

NOTE: The rinse fluid should never be replaced by pouring into the onboard bottle. This causes bubbles and/or air pockets. When a low or empty rinse bottle is removed and replaced, the rinse system auto primes itself.

NOTE: The Rinse Aspirator is in the Onboard Rinse Fluid Bottle.

On the output side of each pump is a check valve to prevent siphoning of the rinse bottle in an error state or during instrument service. On CTS equipped units, an additional line is included to supply rinse fluid to the CTS Bulk Fluidic module as described in "CTS Bulk Fluids Module".

The three Rinse Pumps in the assembly are identical diaphragm pumps with 24V DC brushed motors. All three Rinse Pumps in the Rinse Pump box are provided voltage from the same cable harness. The cable harness terminates at a bulkhead-mounted connector on the left rear of the Rinse Pump Box. The Rinse Pump Box is connected to the centrally located fluidic connector PCB by means of an interconnect cable.

The Rinse Pumps are not serviceable items in the ACL-TOP.

The Rinse Pumps supply the HemosIL Rinse fluid to the probes and have an average flow rate of approxi-mately 1.02 ml/sec. To maintain fluidic precision and accuracy, the Rinse Pumps prime the precision fluid lines on a periodic basis and during all arm Initializations. The syringe pump valve must be in bypass mode (where the rinse pump is connected to the probe output) for the Rinse Pumps to prime the precision fluid lines. See "Priming the Rinse System".

Waste Pump Cover

RinsePumpBox

Waste Pump Waste

Drawer



Rinse and Clean Cups

Rinse/Clean Cups, non-CTS

On ACL-TOP instruments with Cavro Arms, one Rinse/Clean cup is located in the Sample area and two are located in the Reagent area. The Rinse/Clean Cup Assembly is made of chemically compatible PVC. A drain is threaded into the bottom of the Rinse/Clean Cup to allow excess fluid to flow into the accumulator reservoir. The Rinse/Clean Cup and the area around it should be cleaned regularly with an isopropyl alcohol wipe.

Figure 7-16 Cavro Sample/Reagent Rinse/Clean Cups

Each Clean Cup has its own 24VDC solenoid valve and motor that energizes when fluid is required in the cup. The Clean Cup is primed each time the Arms are initialized.

The Sample Probe aspirates Clean A Fluid by first performing a Liquid Level Detection on the Clean A Fluid and then traveling down as it aspirates fluid. If the clean fluid line is not adequately primed, there is potential for an LLD error on the clean fluid. If this error occurs, verify that there are no bubbles in the Clean aspirator line and prime the Clean Pumps as described in "Priming the Clean System".

NOTE: It is necessary to prime the Clean Pump whenever bubbles are present in the clean line. Refer to "Priming the Clean System".

The Rinse Cup has a flat bottom. The HemosIL Rinse Fluid is supplied by the pumps as described in "Rinse Pumps". During rinsing, the Three-way Valve of the syringe Pump is in Bypass Mode. The diaphragm pump is also turned on to provide flow through the Sample Probe. Fluid exits the probe tip and hits the bottom of the Rinse Cup. The flow is redirected to rinse the outside of the probe tip. Probe tip height, relative to the Rinse Cup, is critical to provide adequate cleaning of the probe. Height is set during the coordinate adjust routine. The duration of the rinse routine can be configured by the user, and it must be a minimum of one second.

NOTE: Rinse fluid should not wet the black covering of the probe. If it does, troubleshoot to determine the source.

The alignment of the Sample Probe to the Waste Location and to the rinse/Clean Cups is controlled by the ACL-TOP system software. The coordinates for the Waste Location and the Rinse/Clean Cups are verified each time the Arms are initialized. The Coordinates Adjust routine should be run if an Arm Coordinates error is reported during initialization.

Drain

Rinse CupClean Cup



NOTE: Each Sample and Reagent Probe performs its coordinates check on the metal sur-face around the Rinse/Clean Cup. To ensure accurate coordinates checks, regular cleaning, with an isopropyl alcohol of the Rinse/Clean Cup and the metal areas around them is recom-mended.

Rinse/Clean Cups, CTS

On CTS ACL-TOP instruments, there is one Rinse/Clean cup in the Sample area and two in the Reagent area. To accommodate the piercer probe, there is a well for a Deep Wash on the left of the Sample Rinse/Clean cup as shown in Figure 7-17 "CTS Sample Rinse/Clean Cup". In the Reagent area, each Rinse/Clean Cup has a Rinse cup on the right and a Clean cup on the left as shown in Figure 7-18 "CTS Reagent Rinse/Clean Cup".

Figure 7-17 CTS Sample Rinse/Clean Cup

Figure 7-18 CTS Reagent Rinse/Clean Cup

The Clean Cup has a flat bottom with a fill hole on the bottom. Clean A Fluid is pumped into the Clean Cup by the Clean Pump. The Clean Cup is primed each time the Arms are initialized.

NOTE: If the clean fluid line is not adequately primed, there is potential for an LLD error on the clean fluid. If this error occurs, verify that there are no bubbles in the clean aspirator line then prime the Clean Pumps if necessary. See "Priming the Clean System".

Fluid level in the Clean Fluid Bottle is monitored by the ACL-TOP system software. The sample and reagent probes aspirate Clean A Fluid from the cup by first performing a Liquid Level Detection on the fluid and then traveling down as it aspirates the fluid.

Rinse CupDeep Wash

Drain Hole

Rinse CupClean Cup



The Deep Wash location on the left of the Rinse/Clean Cup provides a drain to the Reservoir. A filter is installed in the Deep Wash location to collect core particles generated during closed tube sampling. The Clean cup and Deep Wash cups need to be cleaned weekly and the filter should be changed after 5,000 pierces.

NOTE: In particularly high-volume installations, the filter should be changed more often based on usage. After cleaning the clean cup and Deep Wash, the filter should be removed and replaced. The filter should be removed and installed using the tool located on the left side of the Sample Side Accumulator.

The Deep Wash process consists of an External Wash and an Internal Wash. The exterior of the CTS Piercer Probe, and the exterior of the Sample Probe tip, are rinsed during the External Wash and the interior of the Sample Probe is rinsed during the Internal Wash.

The External Wash is done according to the following procedure:

1. The Sample Probe, and the CTS Piercer Probe, are brought to wash depth within the Deep Wash location.

2. The External Rinse Pump is turned on as the CTS Piercer Probe is brought down.

3. As the CTS Piercer Probe travels up, the radial rinse stream washes the entire exterior of the CTS Piercer Probe, the interior of the CTS Piercer Probe tip, and the exterior of the Sample Probe tip.

4. Once the probe tips have cleared the radial rinse stream, the External Rinse Pump is turned off, stopping the flow of the radial rinse stream.

NOTE: The Internal Sample Probe Rinse is not run during the External Wash to minimize the foaming which may occur with a directed flow so deep in the filter.

During the internal wash, the interior of the sample probe is washed by a stream of rinse fluid that is sent through the sample probe by the rinse pump.

1. The valve of the syringe pump is set to bypass mode for the rinse pump to send rinse fluid through the sample probe.

2. Rinse fluid exits the sample probe and drains directly through the filter and into the reservoir. During the internal wash, the flow rate of rinse fluid is 1.05 ml/second.

3. The minimum duration of the internal wash is similar to that of the non-CTS instrument configura-tion. However, this value can not be defined in the same manner as the non-CTS instrument because of the software timing of the operation.

Clean Fluid Bottle

The ACL-TOP gets its Clean A Fluid from the Clean Fluid Bottle on the right side of the instrument. The Clean A Fluid is drawn into the ACL-TOP by either of the three Clean Pumps located on the Waste Accu-mulators.

The Clean A Fluid enters the system via a chemically compatible Aspirator inserted into the Clean Fluid Bot-tle (see Figure 7-19 "The Clean Fluid Bottle"). The fluid height in the Clean Fluid is checked by two capac-itance sensors mounted on the inside of the right outer panel (see Figure 7-19 "The Clean Fluid Bottle").



CAUTION: Clean A Fluid contains Hydrochloric Acid and must be handled carefully. DO NOT ALLOW CLEAN FLUID A TO COME IN CONTACT WITH SKIN OR EYES! When handling or changing Clean Fluid Bottles, you must wear protective eyewear, protective gloves, and protective garments.

Figure 7-19 The Clean Fluid Bottle

Figure 7-20 Clean Fluid Sensors

The sensors are monitored by the ACL-TOP system software. An LED as shown on Figure 7-21 "Clean Fluid LED Indicator" indicates when the Clean Fluid Bottle is low or empty. (When the Clean Fluid Bottle is low, the LED turns amber; when the Clean Fluid Bottle is empty, the LED turns red.) A warning is also sent to the CM software. (The warning appears as a red exclamation point on the Analyzer Alarm button of the Status bar.)

Clean FluidBottle

Clean EmptySensor

Clean WarningSensor

RinseWarningSensor

Rinse Empty Sensor



Figure 7-21 Clean Fluid LED Indicator

An empty warning will send the instrument into a controlled stop where it schedules a finite number of tests that can be run prior to the instrument stopping tests.

Clean Pumps

The ACL-TOP uses three solenoid pumps to draw Clean A Fluid from the Clean Fluid Bottle. The Clean Pumps are self-checking and are driven by 24 VDC solenoids with a 2 Hz pulse. There is one pump for each clean well. The clean wells for the non-CTS sample and reagent modules, as well as the CTS reagent mod-ule are as shown on Figure 7-22 "Clean Pumps", with the clean pump mounted just below the clean well.

Figure 7-22 Clean Pumps

The Clean Pump for the CTS Sample module is different from the others due to the CTS requirements that are the Deep Wash and the Deep wash filter. The Clean Pump for the CTS Sample modules is as shown in Figure 7-23 "CTS Sample Clean Pump", with the clean pump mounted to the side of the clean well.

Clean Fluid LED

Clean Well

Clean Pump



Figure 7-23 CTS Sample Clean Pump

The clean pumps are powered via the cable assembly for the Sample Accumulator or the Reagent Accumu-lator, both of which plug into the Fluidic Connector Board.

The clean pump moves Clean A Fluid into a cup located at each accumulator rinse/waste station. The Clean A Fluid wells up from the bottom of the cup on the Reagent and non-CTS Accumulator. On CTS sample accumulators, the Clean A Fluid enters the cup from the side.)

Clean Pumps are controlled by the ACL-TOP software and when a clean is scheduled, the Clean Pump turns on to ensure the cup is full of Clean A Fluid prior to the probe's arrival. The probe performs an LLD in the Clean A Fluid and aspirates the desired amount of fluid. After a specified dwell time inside the probe, the Clean A Fluid is dispensed into the waste on the Accumulator.

Clean A Fluid is used to clean the inside of a Sample Probe when additional washing of the probe is desired. Following any use of Clean A Fluid, the probe is rinsed with Rinse Fluid to prevent Clean A Fluid from com-ing in contact with any sample.

NOTE: No fluid other than Clean A Fluid should be run through the Clean Pumps. In the event HemosIL Rinse Fluid is inadvertently run through the Clean Pump, the Clean Pump should be immediately purged with Clean A Fluid. Refer to "Adjustments and Verifications" for information on purging the Clean Pump. If Clean A fluid is not available, the Clean Pump can be purged with De-ionized Water. If HemosIL Rinse Fluid is not immediately purged from the Clean Pump, it will crystallize, causing permanent damage to the Clean Pump.

CTS Bulk Fluids Module

The CTS Bulk Fluids Module is located to the left of the Sample Syringe Pump (see Figure 7-24 "CTS Bulk Fluids Module"). The module contains the Rinse pump for the CTS Deep wash and is mounted on vibration isolators.

The Rinse Pump provides HemosIL Rinse Fluid to the Deep Wash location on the CTS Accumulator. The pump is identical to the three rinse pumps located in the Rinse Pump Box to the right of the Reagent Module beneath the Waste pump. The output of the Bulk Rinse Pump has a check valve to prevent siphoning of rinse fluid through the open port of the CTS Deep Wash. Fluid is fed to the pump from a supply line routed through the Rinse Pump Box. The supply line runs through the steel guide tube along the rear chassis of the ACL-TOP. The output line of the pump goes through a bulkhead interconnect on the Bulk Fluidics Module and is routed through both the drip tray on the Syringe Pump and the right support bracket of the Sample Accumulator.

CTS Sample Clean Well CTS Sample Clean Pump



Figure 7-24 CTS Bulk Fluids Module

Air Pump/Air Cylinder

The Air Pump, as shown on Figure 7-25 "CTS Air Pump/Cylinder" is mounted on the rear of the instru-ment behind the Sample module. The Air pump maintains the pressure in the air cylinder. The output of the air pump leads directly to the air cylinder mounted to the side of the left pylon support (see Figure 7-25 "CTS Air Pump/Cylinder"). The air cylinder is connected via black polyurethane tubing to the Sample Arm Air Valve that is used to aid in cleaning the rinse liquid from the piercer and piercer probe as stated below.

Figure 7-25 CTS Air Pump/Cylinder

Fluidics

Rinse Pump

Module

Air Pump

Air Cylinder



Air Pump

The two valves on the CTS Z-axis assembly release air from the cylinder and direct the air flow to the CTS probe foot or to the area between the CTS piercer and sample probes during cleaning. The air flow to the probe purges any residual fluid from the circular area between the Sample and Piercer Probe after a Deep Wash. The air flow to the foot removes any droplets that might be on the foot. The Air Pump is a 24V N86-style diaphragm pump and is integral to the functioning of closed tube sampling, because it maintains the clear vent path needed during aspiration in closed tubes. The Air Pump pressurizes the air cylinder to 26 psig (179 kPa, 1.8 bar). Pressure is held in the cylinder by the two valves mounted on the CTS Z-axis assembly. The pressure in the closed system is monitored and controlled by a pressure transducer mounted next to the air clinder as shown in Figure 7-26 "Air Pressure Transducer". The sensor/switch is a digital switch, as shown on that triggers the ACL-TOP software to start and stop the Air Pump. The Air Pump is capable of charging the air cylinder in 7-10 seconds. The output of the air pump has a diaphragm check valve to prevent backflow of air into the pump. Care should be taken during servicing of all air lines to ensure airtight connections. Tube connections must be made with properly cut tubing to maintain the pressure capabilities of the barb fittings. Cable ties are applied to each barb fitting to provide an additional safety mar-gin to the fittings.

Figure 7-26 Air Pressure Transducer

The two valves located on the CTS Z-axis Assembly direct air flow to the CTS probe foot and to the area between the Sample Probe and the CTS Piercer Probe. The output of the air cylinder is connected to the CTS air valve using polyurethane tubing that is routed through the steel tubing guide and into the Common (COM) port on the front valve (Accumulator Valve). The Normally Closed (N/C) port is routed down to the CTS probe foot. The Normally Open (N/O) port is connected to the N/C port on the rear (Air Pressure) Valve. The N/C port on the rear valve maintains the air pressure for the air cylinder. The rear valve N/O port is left open to act as an atmospheric vent during closed tube aspirations. The COM port on the rear valve leads to the CTS probe port and provides the air flow to clear the circular opening between the probes. Proper tubing connections should be performed based on the fluidic diagram as shown in Figure 7-29 "CTS ACL-TOP Fluidic Diagram".

CAUTION: The pneumatic system is pressurized to 26 psig (179 kPa, 1.8 bar). Use caution when disconnecting air lines. Bleed down the system using Diagnostics before servicing.



CTS Air Flow

When the CTS Piercer Probe performs a Deep Wash, there is usually a small volume of fluid that gets trapped between the Sample Probe and the CTS Piercer Probe. Due to capillary action, the fluid will propa-gate up some portion of the interior of the CTS Piercer Probe. The area filled with fluid is also the pathway for the atmospheric vent of the piercing probe and can create a blockage in the tube so the air pressure dif-ferentials cannot travel freely through the CTS Piercer Probe.

The CTS Piercer Probe pierces a closed tube to aspirate sample volume without the need of removing caps. After the top of the tube is pierced, the Sample Probe (located within the piercing probe) telescopes out sev-eral millimeters to contact the sample and perform a Liquid Level Detection (LLD). The CTS Piercer Probe maintains the opening in the rubber seal as the two probes move down. Once an LLD has occurred, the Syringe Pump aspirates sample into the Sample Probe. If a clear vent path does not exist through the CTS Piercer Probe and up to the rear valve on the CTS Z-axis, then the internal pressure of the sample tube will not be at atmospheric pressure and the aspiration of sample will occur at other than atmospheric pressure. A tube pressure above atmospheric leads to over aspiration; a partial vacuum leads to under aspiration. The clear vent path allows the immediate pressure equalization inside the sample tube and maintains precision and accuracy results for the ACL-TOP CTS.

The air purge system on the CTS Piercer Probe releases a short burst of high pressure air (26 psig at initial release), which clears excess fluid from the circular area between the Sample Probe and the CTS Piercer Probe. This operation occurs immediately after the Deep Wash routine on the CTS Piercer Probe. In addi-tion, the air purge system supplies a short burst of air through the probe foot to the outside of the piercer tip. This removes any residual rinse fluid that may remain after the Deep Wash.

PCB Descriptions

The following are high-level descriptions of the PCBs in the Fluid Handling System.Figure 7-27 "Location of Fluidics Controller/Connector PCBs" and Figure 7-28 "Fluidic LED PCB" shows where the Fluidics PCBs are located within the instrument. Note that the Fluidics Controller Board and the Fluidics Driver/Con-nector Board are ordered as one assembly.

Figure 7-27 Location of Fluidics Controller/Connector PCBs

Fluidics Controller,Driver/ConnectorPCBs(under cover)



Figure 7-28 Fluidic LED PCB

Fluidic Controller PCB

• Interfaces directly to the PC104 board and the Fluidics Driver/Connector Board.

• Provides Address and Data decoding from the PC104 board and translates to Digital I/O to the Flu-idic Driver/ Connector Board.

• Mounted under the Fluidics Controller PCB. (The cover protecting the PCBs from any fluid must beremoved to access the Fluidic Controller or Fluidics Driver/Connector PCBs.)

Fluidics Driver/Connector PCB

• Interfaces to the Fluidic controller board to provide control of all fluidic pumps and solenoid valves.

• Provides sensor inputs for the liquid sensors: rinse, clean, and liquid waste in the internal accu-mulators and external liquid waste bottle.

• Provides solenoid power to cover interlocks, Sample and Reagent front cover sensors, and emer-gency stop button.

• Mounted on top of the Fluidics Controller PCB. (The cover protecting the PCBs from any fluid mustbe removed to access the Fluidic Controller or Fluidics Driver/Connector PCBs.)

Fluidic LED PCB

• Provides a visual indication of the liquid level status of Clean, Rinse and liquid waste.

• Provides Visual indication of waste cuvette height.

• This board is mounted to the front panel behind the Fluidic Indicator panel.

Fluidics Diagrams for the TOP Instrument

The following are the Fluidics Diagrams for the ACL-TOP instrument. (See Figure 7-29 "CTS ACL-TOP Fluidic Diagram" and Figure 7-30 "Non-CTS Fluidic Diagram".

Fluidic LED PCB


hapter 7 – Fluid Movement 7 - 27


C

Figure 7-29 CTS ACL-TOP Fluidic Diagram



C

Figure 7-30 Non-CTS Fluidic Diagram



Syringe Pump Addressing and Jumpers

The address and jumpers on a Syringe Pump must be set properly so the ACL-TOP instrument can com-municate with the pump. The address is set by turning the rotary switch with a small, flat-blade screwdriver. The jumpers are set by inserting or removing the jumpers as necessary to connect the pins. (A description of the address setting and jumper settings in provided in "Cavro Syringe Pump Settings" and "Hamilton Syringe Pump Settings".)

Table 7-9 "Syringe Pump Addresses for CTS Instruments" lists the Syringe Pump Addresses for ACL-TOP instruments equipped with Universal Arms, including CTS Models.

Table 7-10 "Syringe Pump Addresses non-CTS Instruments" lists the Syringe Pump Addresses for ACL-TOP instruments equipped with Cavro Arms.

Table 7-11 "Syringe Pump Jumper Settings"shows the correct settings of Cavro Syringe Pump jumpers.

Table 7-9 Syringe Pump Addresses for CTS Instruments


Sample 1

Intermediate Reagent 1

Start Reagent 1

Table 7-10 Syringe Pump Addresses non-CTS Instruments


Sample 4

Intermediate Reagent 0

Start Reagent 4

Table 7-11 Syringe Pump Jumper Settings

JUMPER SETTING

J1-1 OUT

J1-2 IN

J1-3 OUT

J1-4 OUT

J2-1 IN

J2-2 IN

J4-1 IN



Priming the Rinse System

Priming of the Rinse system can be done in one of three ways.

1. Initialize all Arms

• Click the “Initialize All Arms” button on the Probes tab of the Diagnostic screen.

2. Running the Rinse Pump

• Select the appropriate arm in the Select portion of the Fluids diagnostic screen.

• Enter a duration of 10 seconds.

• Press the “Start” button in the (Rinse) lower left portion of the Probe screen.

• Continue the above until the fluid coming into the rinse cup flows in a steady stream.

3. Execute “Automatic Fluidic Line Priming Cycle” from the ACL-TOP application’s maintenance screen.

• Initiate the ACL-TOP application.

• Open the Maintenance screen.

• Click on System --> Maintenance.

• Click on the box preceding “Automatic Fluidic Line Priming Cycle”

• Click on the Run icon as shown on Figure 7-31 "Maintenance Screen Run Button".

Figure 7-31 Maintenance Screen Run Button

Priming the Clean System

Priming of the Clean system can be done in one of three ways.

1. Initialize all Arms

• Click the “Initialize All Arms” button on the Probes tab of the Diagnostic screen.

2. Running the Clean Pump

• Select the appropriate arm in the Select portion of the Fluids diagnostic screen.

• Enter a duration of 10 seconds.

• Press the “Start” button.

• Continue the above until the fluid coming into the clean cup flows in a steady stream.

3. Execute “Automatic Fluidic Line Priming Cycle” from the ACL-TOP application’s maintenance screen.

• Initiate the ACL-TOP application.

• Open the Maintenance screen.

• Click on System --> Maintenance.

• Click on the box preceding “Automatic Fluidic Line Priming Cycle”



• Click on the Run icon as shown on Figure 7-32 "Maintenance Screen Run Button".

Figure 7-32 Maintenance Screen Run Button

Performing the Rinse Flow Rate Test

The Flow Rate Test is used to determine if the rinse fluidics are functioning properly. Perform the followingsteps to execute the test.

1. Open the Probes tab of the Diagnostic screen.

2. Select the arm to be adjusted from the drop down “Probe:” selection box as shown in Figure 7-33 "Arm Selection".

Figure 7-33 Arm Selection

3. Click on the Flow Rate Test button in the Rinse portion of the screen (lower left) as shown in Fig-ure 7-34 "Flow Rate Test Buttons".

Figure 7-34 Flow Rate Test Buttons

4. Based on the arm selected, the system displays a message stating where to place a graduated con-tainer. The locations are:

Sample Arm: Sample Track 6, Position 5

Reagent Arm 1: Reagent Track 3, Position 3

Reagent Arm 2: Reagent Track 3, Position 3 5. Place the graduated container in the indicated position.



6. Select the number of seconds for the pump to run (5 seconds) in the Duration: box in the (lower left) of the Probes tab as shown on Figure 7-34 "Flow Rate Test Buttons".

7. NOTE: If necessary, the “Stop” button can be clicked on to discontinue the test.

8. Click the Start button in the Rinse area of the screen.

9. After the probe has dispensed Rinse solution into the graduated container for the set length of time, measure the volume of solution in the graduated beaker. The flow rate must be as shown in Table 7-12 "Rate Flow Measurements".

Table 7-12 Rate Flow Measurements

If the flow rate is too low, i.e., not enough Rinse is deposited in the beaker; check the fluidic rinse tubes for any restrictions and the rinse pump for proper operation. If the flow rate is too high, check the rinse pump and check valves.

Verifying the Fluidics after Repair or Replacement

The flowchart in Figure 7-35 "Flowchart for Fluidic Functional Test" shows the functional tests after the repair or replacement of any Fluid System component.

Base Top CTSVolume After 5 Seconds Flow Rate Volume After 5 Seconds Flow Rate

5.15±0.5ml (4.65 to 5.65ml) 1.03ml/sec (±0.10ml)

5.58±1.04ml (4.54 to 6.61ml) 1.12 ml/sec ± (0.20ml)



Figure 7-35 Flowchart for Fluidic Functional Test

Adjusting the CTS Air Pressure

The air purge system on the CTS Piercer Probe releases a short burst of high pressure air (24 psig at initial release), which clears excess fluid from the circular area between the Sample Probe and the CTS Piercer Probe. This operation occurs immediately after the Deep Wash routine on the CTS Piercer Probe. In addi-tion, the air purge system supplies a short burst of air through the probe foot to the outside of the piercer tip. This removes any residual rinse fluid that may remain after the Deep Wash. This air pressure is maintained at 26psig via a transducer located next to the air cylinder.

The transducer is used to set the air pressure and is adjusted using the following steps.

Verify the Pressure Sensor Set Points using the chart below to navigate the sensor keys as shown on Fig-ure 7-36 "Sensor Keys" to set the pump to turn on at 22psig and turn off at 24psig.

Verify that the

Virtual LED for

the Sample Clean

Pump is on

Perform the

Clean Pump Test

Verify that the

Virtual LEDs for

the Waste

Sensors are all

off

Verify that the

Virtual LED for

the Waste Pump

is on

Fluidic Precision

Test

Replace ProbesReplace Probe

Rinse Tubing

Replace/Repair

Pumps or Valves

Perform the LLD

test inside a

cuvette (100 ul)

and inside a cup

(200 ul)

Perform Coordinates Adjustment

Visually verify

alignment by

moving material

to several

locations with the

Move function.

Perform the

Rinse Flow Rate

Test

Replace/Repair

Accumulator,

Tubing or Valves

Replace Syringes

and tubing

Perform the Flow

Rate Test



Figure 7-36 Sensor Keys

Confirm or set the following:

• "Press and hold the 'SET' button for > 2 seconds.

• "Verify/Set pressure to 'PSI'

• "Press 'SET'.

• "Verify/Set OVT1 to 'InC'

• "Press 'SET'.

• "Verify/Set OVT2 to '2nO'

• "Press 'SET'.

• "Verify/Set Response Time to '24'

• "Press 'SET'.

• "Verify/Set mode to 'mAn' (where the m is displayed as an n with a line over it due to the limi-tations of the display)

• "Press 'SET'.

• "Verify/Set P_1 to '24'

• "Press 'SET'.

• "Verify/Set P_2 to '22'

• "Press 'SET'.

• "Verify/Set N_3 to '0'

• "Press 'SET'.

• "Verify/Set N_4 to '0'

• "Press 'SET' to end the settings.

Sensor Keys



7-6 Diagnostics

The diagnostics for the Fluid Movement System are on the Fluids tab. The Fluids tab contains seven main areas:

• "Clean Sensors Area",

• "Clean Pump Area",

• "Stirring Area",

• "Waste Sensors Area",

• "Shipping Preparation Area",

• "Waste Pump Area",

• "Fluid Precision Test Area".

Figure 7-37 "Fluids Tab" shows the entire Fluids tab.




C

Figure 7-37 Fluids Tab


Clean Sensors Area

The Clean Sensors area contains virtual LEDs for the cleaning-related valves and pumps in the Fluid Move-ment System. When a specific pump or valve is in use, the corresponding virtual LED turns green. Figure 7-38 "Clean Sensors Area" shows the Clean Sensors area.

Figure 7-38 Clean Sensors Area

Clean Pump Area

The Clean Pump area enables the testing the Sample and Reagent Probes and opening of the cleaning related valves. (Note: A valve is opened to test it.) Figure 7-39 "Clean Pump Area" shows the Clean Pump area. The descriptions below the figure describe each of the buttons and indicators.

Figure 7-39 Clean Pump Area

The Select Pull-down List

Use the Select pull-down list to select a valve to test, or a probe to clean. The Select pull-down list contains the following options:

• Sample arm – Select this option to open the Sample valve or clean the Sample Probe.

• Intermediate Reagent arm – Select this option to open the Reagent 1 valve or clean the Reagent1 Probe.

• Start Reagent arm – Select this option to open the Reagent 2 valve or clean the Reagent 2 Probe.

Select Pull-downList



The Set Valve Button

The “Set Valve” button test the opening of the selected valve. When the “Set Valve” button is clicked, the valve selected from the Select pull-down is opened and the corresponding virtual LED turns green (see Fig-ure 7-38 "Clean Sensors Area").

NOTE: This action does not close the valve; the valve remains open, and the virtual LED remains green, until the Clean Pump utility is run.

The Duration Selection Field and the Start and Stop Buttons

The Duration box determines the length of time (in seconds) the selected pump runs. For example, with “Sample arm” selected in the Select pull-down list, select 60 in the Duration field to run the Sample Pump for 60 seconds.

The “Start” button is clicked to start the selected pump. The pump runs until the end of the duration time unless the “Stop” button is clicked, in which case, the pump immediately stops.

Stirring Area

The Reagent Module contains stirrers for position 1 and 2 in each of the six Reagent Tracks. The Stirring Area contains an LED that, when red, indicates that none of the stirrer positions are working and indicates a problem with the voltage to the stirrers or the Reagent module. The Stirring Area also contains a a check-box for each stirrer position. A checked box indicates that a material requiring stirring is to be placed in that position. Unchecking a box the indicates that a material not requiring stirring is to be placed in that position. Figure 7-40 "Stirring Area" shows the Stirring area.

Figure 7-40 Stirring Area

Unchecking or checking a box and clicking the “Save” button causes the system to save the status for each of the positions and continues into normal ACL-TOP operation. A stirring error alarm is displayed by the sys-tem if a material requiring stirring is placed in a position in which the box is not checked or, by placing a material not requiring stirring into a position where the box is checked.



Waste Pump Area

The Waste Pump area contains a “Waste pump on” LED that turns green when the Waste Pump is running, a “Start” button to start the pump, a “Stop” button to stop the pump, and a setting to determine how long the pump runs. Figure 7-41 "Waste Pump Area" shows the Waste Pump area.

Figure 7-41 Waste Pump Area

The Duration box determines the length of time (in seconds) the Waste Pump runs. The “Start” button starts the Waste Pump. The pump runs for the time specified unless the “Stop” button is clicked to immediately stop the pump.

The automatic activation of the Waste Pump is disabled upon opening the Fluids Diagnostic screen; it is re-enabled upon exiting the screen and when the Fluid Precision Test is started.

Waste Sensors Area

The Waste Sensors area contains virtual LEDs that are green when the Sample Accumulator, Reagent Accumulator, or the Waste Container is below the warning level. The sensor turns yellow when the container reaches the warning level and turns red when the container is full. Figure 7-42 "Waste Sensors Area" shows the Waste Sensors area.

Figure 7-42 Waste Sensors Area

Shipping Preparation Area

The Shipping Preparation area contains a utility for performing a Decontamination Shutdown. The virtual LED, Status, in this area turns amber when the decontamination is process, green when the decontamina-tion is successfully completed, and red when there was a problem during the decontamination. Figure 7-43 "Shipping Preparation Area" shows the Shipping Preparation area of the Fluids screen.



Figure 7-43 Shipping Preparation Area

The “Start” button initiates the Decontamination Shutdown.

The “Stop” button stops a Decontamination Shutdown in progress.

The Decontamination Shutdown does the following:

• Clears all cuvettes

• Disables the bar code reader motor

• Disables all heaters

• Runs each probe line dry

• Runs each clean line dry

• Empties each syringe

• Empties the waste accumulator

To avoid unintentional shipping preparation, the user is prompted to confirm the request to start shipping preparation and is prompted to disconnect the rinse and clean bottle.

Fluid Precision Test Area

The Fluid Precision Test area contains a utility for performing a test in which the instrument calculates the mean of 25 ORU readings at 405nm for 6 dilutions of optical control fluid with factor diluent. For each dilu-tion, four replicates are prepared and measured and one reading is collected from each of the 4 ORU chan-nels. Figure 7-44 "Fluid Precision Test Area" shows the Fluid Precision Test area.

Figure 7-44 Fluid Precision Test Area

The probe used to perform the test is selected in the “Probe” box and, for both factor diluent and optical con-trol, the head volume, air gap, and transport air gap can be specified.



When the Precision Fluid test is initiated, a prompt is displayed to place a set of materials in the positions described below, and to Confirm (OK) or to Reject (Cancel) the start of the procedure. Depending upon the Probe selected, material should be placed in the position as shown in Table 7-13 "Precision Fluid Test Materials".

Table 7-13 Precision Fluid Test Materials

The instrument does not start the procedure if any of the following conditions are true:

• The selected probe is not initialized and ready to move.

• The cuvette shuttle is not initialized and ready to move.

• Any of the 4 ORU's are disabled.

• Cuvettes are not present in the loader area.

When the procedure starts, four cuvettes are moved from the Cuvette Loader into the positions described in the following list, depending on the selected probe:

• Sample Arm – Incubator 1 slots 1, 2, 3 and 4

• Reagent Arm 1 – Incubator 2 slots 1, 2, 3 and 4

• Reagent Arm 2 – ORU 1, 2, 3 and 4

The selected probe aspirates and then dispenses the Factor Diluent to each cell of the loaded cuvettes. At the end of the dispensation in the last cuvette, a rinse cycle (one second) of the probe is executed. Upon completion of the rinse, the selected probe aspirates and then dispenses the Optical Control to each cell of the loaded cuvettes. At the end of every dispensation, a mix (60% of volume) followed by a rinse (one sec-ond) is executed.

When all materials have been dispensed for all the replicates, for each dilution the cuvette is moved to the ORU, unless it is already at the ORU based on the arm selected.

Before starting ORU readings, a 15-second delay is performed.

The instrument executes 25 ORU readings for each cell of both cuvettes and calculates the mean for each cell.

When the ORU readings have been executed, the cuvette is moved to the cuvette waste.

The procedure is then repeated for the other concentrations of Optical Fluid and Factor Diluent.

At the end of the procedure, the instrument displays the absolute absorbance for all replicates and all dilu-tions with a mean, SD, CV with regression statistics, slope intercept and R^2.

Absolute absorbance for all dilutions and replicates is compared to a predefined range; all values out of range are displayed in red.

Probe Selection Material Position

Sample Arm Factor Diluent in track D2 position 1; Optical Control in track D2 position 2.

Reagent Arm 1 Factor Diluent in track R1 position 1; Optical Control in track R1 position 2.

Reagent Arm 2 Factor Diluent in track R5 position 1; Optical Control in track R5 position 2.



The user can select the dilution they want to test or repeat. All six dilutions must be performed to pass regression analysis but P6 A specifications should always pass. If not, corrective action must be taken.

For each dilution, mean, Standard deviation (SD) and %CV of absolute absorbance of all replicates are cal-culated and displayed. Values out of range are displayed in red.

The following table specifies the upper limits for SD and %CV for the various dilutions of Optical Fluid and diluent.

To ensure the proper amount of each material has been placed on the instrument for testing all cells of the ORU, the procedure terminates if a liquid level detection failure is detected.

Table 7-14 Upper Limits for SD and %CV

Dilution SD %CV

100% 0.01 1.0

75% 0.008 1.1

50% 0.006 1.1

25% 0.005 2.7

12.5% 0.005 4.6

6.25% 0.005 8.3



7-7 Removal and Replacement

Cavro Syringe Pump Assembly Removal/Replacement

CTS Sample Cavro Syringe Pump Removal

CAUTION: Ensure the instrument is powered OFF before you perform the following procedure.

1. Remove the Sample Area interior skins as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4.

2. Move the Probe serviced by the Syringe Pump over the Rinse Cup. (This ensures that any fluid that drips out of the Probe will drip into the Rinse Cup.)

3. Remove the aspirator from the Rinse bottle. Unscrew and remove the precision (probe) tubing from the Syringe Pump Valve (see Figure 7-45 "Sample Cavro Syringe Pump Assembly"). (Fluid will drain from the probe.)

Figure 7-45 Sample Cavro Syringe Pump Assembly

4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-45 "Sample Cavro Syringe Pump Assembly").

CAUTION: Do not unscrew the barbed fitting on the Rinse tubing line of the Syringe Pump Valve. The barbed fitting is torqued to a precise specification. If the torque is changed, it could cause the Syringe Pump to malfunction.

Mounting

Precision(Probe)Tubing

Rinse Tubing

BarbedFitting

Screws



5. Using a tubing cutter, trim the rinse tubing by 1/4”. (This removes the part of the line that was stretched over the barbed fitting.)

6. Move the probe to the side so it will not be damaged when removing the pump assembly.

7. Unscrew and disconnect the front fluidic fitting on the top of the CTS Bulk Fluid Assembly, labelled Rinse Input. See Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly". (This is neces-sary to obtain clearance to slide out the CTS Bulk Fluidics Assembly.)

8. Loosen the three captive mounting screws securing the CTS Bulk Fluidics Assembly to the Sample Arm, as shown on Figure 7-69 "CTS Fluidics Mounting", and slide the module out only far enough to access the two screws securing the top front of the syringe pump.

9. While holding the Syringe Pump Asssembly from the bottom, remove the two screws that hold the front of the syringe pump and remove the pump from the mounting bracket..

Figure 7-46 CTS Fluidics Mounting (Cavro)

MountingScrews



10. Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as shown on Figure 7-47 "Cavro Syringe Pump Back".

Figure 7-47 Cavro Syringe Pump Back

11. Carefully remove the syringe pump from the instrument.

12. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate from the pump.

CTS Sample Cavro Syringe Pump Installation


See Figure 7-48 "Cavro Syringe Pump Back" for steps 1 through 4.

1. Ensure that the Syringe Pump address is set to an address of 1. The Syringe Pump address is speci-fied with the address switch (rotary) at the rear of the Syringe Pump. Refer to "Cavro Syringe Pump Settings" for more information on the proper settings for Syringe Pump addresses.

15 Pin ElectricalConnector

Jumpers

Jumpers

Address Switch(Rotary)




2. Ensure that the Syringe Pump jumpers are at the proper settings. Refer to "Cavro Syringe Pump Settings" for more information on the proper settings for Syringe Pump jumpers.

3. Attach the drip plate to the bottom of the pump using the screws previously removed.

4. Re-connect the 15-pin electrical connector(s) to the back of the Syringe Pump(s).

5. Slide the CTS Bulk Fluid Assembly toward the front of the instrument and engage the pin on the rear bracket in the Syringe pump so the front bracket openings align with the screw holes.

6. Insert, and tighten, the two mounting screws that fasten the front of the Syringe Pump Assembly to the CTS Bulk Fluid Assembly.

7. Slide the CTS Bulk Fluid Assembly toward the rear of the instrument and tighten the three mounting screws as shown on Figure 7-49 "Cavro Syringe Pump Assembly".

Figure 7-49 Cavro Syringe Pump Assembly


Jumpers

Jumpers


Mounting


Rinse Tubing

BarbedFitting

Screws



8. Attach the Rinse Input Tube to the CTS Bulk Fluid Assembly, labelled Rinse Input.

9. Carefully attach the Rinse tubing to the barbed fitting ensuring it is pushed all the way on the fitting (see Figure 7-49 "Cavro Syringe Pump Assembly").

10. Screw the Probe tubing onto the Syringe Pump Valve (see Figure 7-49 "Cavro Syringe Pump Assembly").

11. Re-install the Sample Area interior skins.

Base TOP Sample Arm Cavro Syringe Pump Removal



2. Move the Probe(s) serviced by the Syringe Pump over the Rinse Cup. (This ensures that any fluid that drips out of the Probe will drip into the Rinse Cup.)

3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-50 "Cavro Sam-ple Arm Syringe Pump Tubing"). (Fluid will drain from the probe.)

4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-50 "Cavro Sample Arm Syringe Pump Tubing").

NOTE: Do not unscrew the barbed fitting on the Rinse tubing line of the Syringe Pump Valve. The barbed fitting is torqued to a precise specification. If the torque is changed, it could cause the Syringe Pump to malfunction.


Figure 7-50 Cavro Sample Arm Syringe Pump Tubing

6. Move the arms to the side so they will not be damaged when removing the pump assembly.

Rinse Tubing




7. While holding the pump assembly by the bottom, remove the four mounting screws securing the syringe pump mounting bracket to the standoffs from the Reagent Arm, as shown on Figure 7-51 "Cavro Sample Arm Pump Assembly Mounting".

Figure 7-51 Cavro Sample Arm Pump Assembly Mounting





Mounting ScrewsMounting

Screws


Jumpers

Jumpers





Base TOP Cavro Sample Syringe Pump Installation



1. Ensure that the Syringe Pump address is properly set. Refer to "Cavro Syringe Pump Settings" for more information on the proper settings for Syringe Pump addresses. The Syringe Pump address is specified with the address switch (rotary) at the rear of the Syringe Pump.





5. Engage the pin on the rear bracket in the Syringe pump so that the front bracket openings align with the screw holes.

6. Insert, and tighten, the two mounting screws that secure the front of the Syringe Pump Assembly


Jumpers

Jumpers




7. Insert the screws and fasten the mounting bracket to the standoffs as shown on Figure 7-54 "Sample Arm Cavro Pump Assembly Mounting".

Figure 7-54 Sample Arm Cavro Pump Assembly Mounting

8. Ensure the rinse supply tube(s) is routed through the mounting bracket as shown on the figure and attach it to the syringe pump valve(s) (upper left port) by carefully pressing it onto the barbed fitting. (See Figure 7-55 "Sample Arm Cavro Syringe Pump Tubing".)

9. Screw the Probe tubing onto the Syringe Pump Valve(s) (see Figure 7-55 "Sample Arm Cavro Syringe Pump Tubing").

Figure 7-55 Sample Arm Cavro Syringe Pump Tubing


Mounting ScrewsMounting

Screws

Rinse Tubing




Reagent Cavro Syringe Pump Removal


1. Remove the Reagent Area interior skins as described in “Reagent Area Interior Skins Removal/Replacement” in Chapter 4.

2. Move the Probes over the Rinse Cups. (This ensures that any fluid that drips out of the Probes will drip into the Rinse Cup.)

NOTE: If removing both Reagent Syringe Pumps, ensure the tubes that are connected to Pump R1 and those connected to Pump R2 are identified. This can be done by placing a small mark on the tubes for one Syringe Pumps (R1 or R2). (It is recommended that the mark be made with a soft-tip marking pen.) When re-connecting the tubes, ensure the tubes are connected to the proper pumps.

3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-56 "Reagent Cavro Syringe Pump Tubing"). (Fluid will drain from the probe.)

4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-56 "Reagent Cavro Syringe Pump Tubing").



Figure 7-56 Reagent Cavro Syringe Pump Tubing

6. .Move the probes to the side so they will not be damaged when removing the pump assembly.

Rinse Tubing




7. Loosen the three captive mounting screws securing the syringe pumps to the Reagent Arm, as shown on Figure 7-57 "Reagent Arm Cavro Pump Assembly Mounting".

Figure 7-57 Reagent Arm Cavro Pump Assembly Mounting





Mounting Screws


Jumpers

Jumpers





Reagent Cavro Syringe Pump Installation



1. Ensure that the Syringe Pump address is properly set. Refer to "Cavro Syringe Pump Settings" for more information on the proper settings for Syringe Pump addresses. The Syringe Pump address is specified with the address switch (rotary) at the rear of the Syringe Pump.





NOTE: If installing both Reagent Syringe Pumps, ensure the 15-pin connector with two extra wires (black twisted with blue) is connected to the R2 (rightmost) Syringe Pump.

5. Engage the pin on the rear bracket in the Syringe pump so that the front bracket openings align with the pump screw holes.

6. Insert, and tighten, the two mounting screws that secure the front of the Syringe Pump Assembly.


Jumpers

Jumpers




7. Slide the mounting bracket toward the rear of the instrument and tighten the three mounting screws as shown on Figure 7-60 "Reagent Arm Cavro Pump Assembly Mounting".

Figure 7-60 Reagent Arm Cavro Pump Assembly Mounting

8. Ensure the rinse supply tubes are routed through the mounting bracket as shown on the figure and attach them to the syringe pump valve(s) (upper left port) by carefully pressing them onto the barbed fitting. (See Figure 7-61 "Reagent Cavro Syringe Pump Tubing".)

9. Screw the Probe tubing onto the Syringe Pump Valves (see Figure 7-61 "Reagent Cavro Syringe Pump Tubing").

Figure 7-61 Reagent Cavro Syringe Pump Tubing

10. Re-install the Reagent Area interior skins.

Mounting Screws

Rinse Tubing




Cavro Syringe Tip Removal/Replacement

Cavro Syringe Tip Removal


1. Remove the Sample Area or Reagent Area interior skins as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4 or “Reagent Area Interior Skins Removal/Replace-ment” in Chapter 4.


Reference Figure 7-62 "Removing the Cavro Syringe" for steps 3 through 8.

3. Unscrew and remove the probe tubing from the Syringe Pump Valve. (Fluid will drain from the probe.)

4. Carefully pull the Rinse tubing from the barbed fitting.



6. Loosen the Thumbscrew at the bottom of the Syringe Tube.

7. Slide the Thumbscrew Block Assembly down to the Syringe Pump Bottom Plate.

8. Unscrew the Syringe Glass Screw.

Figure 7-62 Removing the Cavro Syringe

Probe TubingRinse Tubing

Barbed Fitting

Syringe Glass Screw

Thumbwheel

Syringe



9. Remove the glass tube containing the Syringe.

10. Pull the metal plunger from the glass tube.

11. Using pliers, pull the Teflon syringe tip from the metal plunger (see Figure 7-63 "Cavro Syringe Tip Removal").

Figure 7-63 Cavro Syringe Tip Removal

Cavro Syringe Tip Installation


See Figure 7-64 "Cavro Syringe Tip Installation" for steps 1 through 5.

1. With the open side of the Teflon tip facing up, slide the Teflon tip into the “ISE” slot on the installation block.

2. Place the rubber o-ring on the tip of the metal plunger.

3. Insert the end of the plunger with the rubber o-ring into the “ISE” slot of the installation block. (Push the plunger in so that the Teflon tip snaps onto the tip of the metal plunger.)

4. Remove the plunger from the “ISE” slot, rinse it with 70% isopropyl alcohol and then rinse with DiH2O.

5. Insert the plunger, with the Teflon tip attached, into the Syringe glass tube.

Glass Tube

Teflon Tip

Plunger



Figure 7-64 Cavro Syringe Tip Installation

See Figure 7-65 "Cavro Syringe Valve Assembly/Tubing" for steps 6 through 12.

6. Screw the Syringe Glass tube onto the Syringe Pump Valve.

7. Raise the thumbscrew block so that the metal knob at the bottom of the syringe plunger seats in the thumbscrew block.

8. Tighten the thumbwheel until it is finger-tight.

9. Use pliers to tighten the thumbwheel an additional 1/4 turn (ensure it is tightened ONLY 1/4 turn) to ensure tightness.

10. Attach the Rinse tubing to the barbed fitting.

11. Screw the Probe tubing onto the Syringe Pump Valve.

Figure 7-65 Cavro Syringe Valve Assembly/Tubing

12. Install the Reagent or Sample area interior skins.

Glass Tube

Teflon TipPlunger

O-Ring

Syringe TipInstallationTool Syringe

Rinse Tubing

Barbed Fitting

Syringe Glass Screw

Thumbwheel

Probe Tubing

Syringe PumpValve



Cavro Syringe Valve Removal/Replacement

Cavro Syringe Valve Removal


1. Remove the Sample or Reagent area interior skins as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4 or “Reagent Area Interior Skins Removal/Replacement” in Chapter 4.


See Figure 7-66 "Cavro Syringe Removal" for steps 2 through 11.

Figure 7-66 Cavro Syringe Removal






7. Slide the Thumbscrew Block Assembly down to the Syringe Pump Bottom Plate.

8. Unscrew the Syringe Glass Screw.


Barbed Fitting

Phillips Screws

Thumbscrew

Syringe Glass Screw

Syringe Glass Tube



9. Remove the glass tube containing the Syringe.

10. Remove the two Phillips screws on the Syringe.

11. Gently pull the Valve from the front face of the Syringe Pump Assembly.

Cavro Syringe Valve Installation

1. Mount the Syringe Valve on the front face of the Syringe Pump Assembly.

See Figure 7-67 "Cavro Syringe Installation" for steps 2 through 8.

2. Fasten the two Phillips screws that secure the Syringe Valve.


Figure 7-67 Cavro Syringe Installation

4. Raise the thumbscrew block so that the metal knob at the bottom of the syringe plunger seats in the thumbscrew block.

5. Tighten the thumbscrew until it is finger-tight.

6. Use pliers to tighten the thumbscrew an additional 1/4 turn (ONLY 1/4 turn) to ensure tightness.



9. Install the sample or Reagent area interior skins.


Barbed Fitting

Phillips Screws

Thumbscrew

Syringe Glass Screw

Syringe Glass Tube



Hamilton Syringe Pump Assembly Removal/Replacement

CTS Sample Hamilton Syringe Pump Removal




3. Remove the aspirator from the Rinse bottle. Unscrew and remove the precision (probe) tubing from the Syringe Pump Valve (see Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly"). (Fluid will drain from the probe.)

Figure 7-68 Hamilton CTS Sample Syringe Pump Assembly

4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly").




BarbedFitting

Rinse Tubing

Mounting Screws

RinseInputFitting



6. Move the probe to the side so it will not be damaged when removing the pump assembly.

7. Unscrew and disconnect the front fluidic fitting on the top of the CTS Bulk Fluid Assembly, labelled Rinse Input. See Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly". (This is neces-sary to obtain clearance to slide out the CTS Bulk Fluidics Assembly.)

8. Loosen the three captive mounting screws securing the CTS Bulk Fluidics Assembly to the Sample Arm, as shown on Figure 7-69 "CTS Fluidics Mounting", and slide the module out only far enough to access the two screws securing the top front of the syringe pump.


Figure 7-69 CTS Fluidics Mounting

MountingScrews

Syringe PumpMountingScrewsRinse

InputFitting



10. Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as shown on Figure 7-70 "Hamilton Syringe Pump Back".

Figure 7-70 Hamilton Syringe Pump Back



CTS Sample Hamilton Syringe Pump Installation


See Figure 7-71 "Hamilton Syringe Pump Back" for steps 1 through 4.

1. Ensure that the Syringe Pump address is set to an address of 1. The Syringe Pump address is speci-fied with the address switch (rotary) at the rear of the Syringe Pump. The arrow on the center dial of the switch indicates the address setting. Refer to "Hamilton Syringe Pump Settings" for more infor-mation on the proper settings for Syringe Pump addresses.

Address Switch


J1 - J2J3 - J4J5 - J6J7 - J8

SW 8

SW 1

Address Selection


(shown at 0)




2. Ensure the Configuration jumpers are at the proper settings. Refer to "Hamilton Syringe Pump Set-tings" for more information on the proper jumper settings.

3. Set the DIP switches for the pump as stated in "Hamilton Syringe Pump Settings".



6. Slide the CTS Bulk Fluid Assembly toward the front of the instrument and engage the pin on the rear bracket in the Syringe pump so the front bracket openings align with the screw holes.

7. Insert, and tighten, the two mounting screws that fasten the front of the Syringe Pump Assembly to the CTS Bulk Fluid Assembly.

Address Switch


J1 - J2J3 - J4J5 - J6J7 - J8

SW 8

SW 1

Address Selection


(shown at 0)

DIP Switches



8. Slide the CTS Bulk Fluid Assembly toward the rear of the instrument and tighten the three mounting screws as shown on Figure 7-72 "Hamilton Syringe Pump Assembly Mounting".

NOTE: Use caution to ensure the Rinse Input tube is routed across the top of the assembly, is inside the rear bracket, and does not get damaged.

Figure 7-72 Hamilton Syringe Pump Assembly Mounting

9. Attach the Rinse Input Tube to the CTS Bulk Fluid Assembly, labelled Rinse Input.

10. Carefully attach the Rinse tubing to the barbed fitting ensuring it is pushed all the way on the fitting (see Figure 7-72 "Hamilton Syringe Pump Assembly Mounting").

11. Screw the Probe tubing onto the Syringe Pump Valve (see Figure 7-72 "Hamilton Syringe Pump Assembly Mounting").


Base TOP Hamilton Sample Arm Syringe Pump Removal





BarbedFitting

Rinse Tubing

Mounting Screws

RinseInputFitting



3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-73 "Hamilton Sample Arm Syringe Pump Tubing"). (Fluid will drain from the probe.)

4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-73 "Hamilton Sample Arm Syringe Pump Tubing").



Figure 7-73 Hamilton Sample Arm Syringe Pump Tubing

6. Move the arm to the side so they will not be damaged when removing the pump assembly.

Rinse Tubing




7. While holding the pump assembly by the bottom, remove the four mounting screws securing the syringe pump mounting bracket to the standoffs from the Reagent Arm, as shown on Figure 7-74 "Hamilton Sample Arm Pump Assembly Mounting".

Figure 7-74 Hamilton Sample Arm Pump Assembly Mounting

8. While holding the Syringe Pump Asssembly from the bottom, remove the two screws that hold the front of the syringe pump and remove the pump from the mounting bracket.





Mounting Screws

MountingScrews

Address Switch


J1 - J2J3 - J4

J5 - J6J7 - J8

SW 8

SW 1

Address Selection




Base TOP Hamilton Sample Syringe Pump Installation



1. Ensure that the Syringe Pump address is properly set. Refer to "Hamilton Syringe Pump Settings" for more information on the proper settings for Syringe Pump addresses. The Syringe Pump address is specified with the address switch (rotary) at the rear of the Syringe Pump.


2. Ensure that the Syringe Pump jumpers are at the proper settings. Refer to "Hamilton Syringe Pump Settings" for more information on the proper settings.

3. Set the DIP switches for the pump as stated in "Hamilton Syringe Pump Settings".



6. Engage the pin on the rear bracket in the Syringe pump so that the front bracket openings align with the screw holes.

7. Insert, and tighten, the two mounting screws that secure the front of the Syringe Pump Assembly

8. Insert the screws and fasten the mounting bracket to the standoffs as shown on Figure 7-77 "Hamil-ton Sample Arm Pump Assembly Mounting".

Address Switch


J1 - J2J3 - J4J5 - J6J7 - J8

SW 8

SW 1

Address Selection

15-PinElectricalConnector

(shown at 0)



Figure 7-77 Hamilton Sample Arm Pump Assembly Mounting

9. Ensure the rinse supply tube(s) is routed through the mounting bracket as shown on Figure 7-77 "Hamilton Sample Arm Pump Assembly Mounting"and attach it to the syringe pump valve(s) (upper left port) by carefully pressing it onto the barbed fitting. (See Figure 7-78 "Hamilton Sample Arm Syringe Pump Tubing".)

10. Screw the Probe tubing onto the Syringe Pump Valve(s) (see Figure 7-78 "Hamilton Sample Arm Syringe Pump Tubing").

Figure 7-78 Hamilton Sample Arm Syringe Pump Tubing


Mounting Screws

MountingScrews

Rinse Tubing




Reagent Hamilton Syringe Pump Removal


1. Remove the Reagent Area interior skins as described in “Reagent Area Interior Skins Removal/Replacement” in Chapter 4.


NOTE: If removing both Reagent Syringe Pumps, ensure the tubes that are connected to Pump R1 and those connected to Pump R2 are identified. This can be done by placing a small mark on the tubes for one Syringe Pumps (R1 or R2). (It is recommended that the mark be made with a soft-tip marking pen.) When re-connecting the tubes, ensure the tubes are connected to the proper pumps.

3. Unscrew and remove the probe tubing from the Syringe Pump Valve(s) (see Figure 7-79 "Hamilton Reagent Syringe Pump Tubing"). (Fluid will drain from the probe.)

4. Carefully pull the Rinse tubing from the barbed fitting(s) (see Figure 7-79 "Hamilton Reagent Syringe Pump Tubing").


5. Using a tubing cutter, trim the rinse tubing(s) by 1/4”. (This removes the part of the line that was stretched over the barbed fitting.)



Figure 7-79 Hamilton Reagent Syringe Pump Tubing

6. Move the probes to the side so they will not be damaged when removing the pump assembly.

7. Loosen the three captive mounting screws securing the syringe pump(s) to the Reagent Arm, as shown on Figure 7-80 "Reagent Arm Hamilton Pump Assembly Mounting" and slide the module forward enough to access the two screws securing the top front of the pump.

Figure 7-80 Reagent Arm Hamilton Pump Assembly Mounting

Rinse Tubing


Mounting Screws







11. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate.

Reagent Hamilton Syringe Pump Installation



1. Ensure that the Syringe Pump address is properly set. Refer to "Hamilton Syringe Pump Settings" for more information on the proper settings for Syringe Pump addresses. The Syringe Pump address is specified with the address switch (rotary) at the rear of the Syringe Pump.

Address Switch


J1 - J2J3 - J4J5 - J6J7 - J8

SW 8

SW 1

Address Selection


DIP Switches




2. Ensure that the Syringe Pump jumpers are at the proper settings. Refer to "Hamilton Syringe Pump Settings" for more information on the proper settings for Syringe Pump jumpers.

3. Set the DIP switches for the pump(s) as stated in "Hamilton Syringe Pump Settings".

4. Attach the drip plate to the bottom of the pump(s) using the screws previously removed.


CAUTION: If installing both Reagent Syringe Pumps, ensure the 15-pin connector with two extra wires (black twisted with blue) is connected to the R2 (rightmost) Syringe Pump.

6. Engage the pin on the rear bracket in the Syringe pump so that the front bracket openings align with the pump screw holes.

7. Insert, and tighten, the two mounting screws that fasten the front of the Syringe Pump Assembly.

Address Switch


J1 - J2J3 - J4J5 - J6J7 - J8

SW 8

SW 1

Address Selection


DIP Switches



8. Slide the mounting bracket toward the rear of the instrument and tighten the three mounting screws as shown on Figure 7-83 "Reagent Arm Hamilton Pump Assembly Mounting".

Figure 7-83 Reagent Arm Hamilton Pump Assembly Mounting

9. Ensure the rinse supply tube(s) is routed through the mounting bracket as shown and attach it to the syringe pump valve(s) (upper left port) by carefully pressing it onto the barbed fitting. (See Figure 7-84 "Reagent Hamilton Syringe Pump Tubing".)

10. Screw the Probe tubing onto the Syringe Pump Valve(s) (see Figure 7-84 "Reagent Hamilton Syringe Pump Tubing").

Mounting Screws



Figure 7-84 Reagent Hamilton Syringe Pump Tubing

11. Re-install the Reagent Area interior skins.

Hamilton Syringe Tip Removal/Replacement

Hamilton Syringe Tip Removal


1. Remove the Sample Area or Reagent Area interior skins as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4 or “Reagent Area Interior Skins Removal/Replace-ment” in Chapter 4.


Reference Figure 7-85 "Removing the Hamilton Syringe" for steps 3 through 8.




Rinse Tubing






7. Raise the plunger within the syringe.

8. Unscrew and remove the Syringe.

Figure 7-85 Removing the Hamilton Syringe

9. Pull the metal plunger from the glass tube.

10. Using pliers, pull the Teflon syringe tip from the metal plunger (see Figure 7-86 "Hamilton Syringe Tip Removal").

Thumbwheel

Syringe

Rinse Tubing

Barbed Fitting

Probe Tubing

Syringe Screw Connection



Figure 7-86 Hamilton Syringe Tip Removal

Hamilton Syringe Tip Installation


See Figure 7-87 "Hamilton Syringe Tip Installation" for steps 1 through 5.

1. With the open side of the Teflon tip facing up, slide the Teflon tip into the “ISE” slot on the installation block.

2. Place the rubber o-ring on the tip of the metal plunger.

3. Insert the end of the plunger with the rubber o-ring into the “ISE” slot of the installation block. (Push the plunger in so that the Teflon tip snaps onto the tip of the metal plunger.)

4. Remove the plunger from the “ISE” slot, rinse it with reagent-grade alcohol and then rinse with DiH2O.

5. Insert the plunger, with the Teflon tip attached, into the Syringe glass tube.

Glass Tube

Teflon Tip

Plunger



Figure 7-87 Hamilton Syringe Tip Installation

See Figure 7-88 "Hamilton Syringe Valve Assembly/Tubing" for steps 6 through 12.


7. Manually lower the plunger so the metal knob at the bottom of the syringe plunger seats in the thumb-wheel block.


9. Use pliers to tighten the thumbwheel an additional 1/4 turn (ensure it is tightened ONLY 1/4 turn) to ensure tightness.



SyringeGlass Tube

Syringe TipInstallationTool

Plunger

Teflon Tip

O-Ring



Figure 7-88 Hamilton Syringe Valve Assembly/Tubing

12. Install the Reagent or Sample area interior skins.

Hamilton Syringe Valve Removal/Replacement

Hamilton Syringe Valve Removal


1. Remove the Sample or Reagent area interior skins as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4 or “Reagent Area Interior Skins Removal/Replacement” in Chapter 4.


See Figure 7-89 "Hamilton Pump Syringe Removal" for steps 2 through 10.




Thumbwheel

Syringe Glass Tube

Syringe PumpValve

Barbed Fitting

Rinse Tubing Probe Tubing




6. Loosen the Thumbwheel at the bottom of the Syringe Tube.

7. Raise the Syringe Plunger.

8. Unscrew and remove the Syringe glass tube.

9. Remove the two Phillips screws on the Syringe.

10. Gently pull the Syringe Pump Valve from the front face of the Syringe Pump Assembly.

Figure 7-89 Hamilton Pump Syringe Removal

Hamilton Syringe Valve Installation

See Figure 7-90 "Hamilton Syringe Installation" for steps 1 through 8.

1. Mount the Syringe Valve on the front face of the Syringe Pump Assembly.

2. Fasten the two Phillips screws that secure the Syringe Valve.


Thumbwheel

Syringe Glass Tube

Syringe PumpValve

Barbed Fitting


Phillips Screws



Figure 7-90 Hamilton Syringe Installation

4. Lower the syringe plunger so the metal knob at the bottom of the syringe plunger seats in the thumb-wheel block.


6. Use pliers to tighten the thumbwheel an additional 1/4 turn to ensure tightness.



9. Install the sample or Reagent area interior skins.

Rinse Pump Removal/Replacement

Rinse Pump Removal

1. Remove the Waste Pump as described in “Waste Pump Removal” in Chapter 13.

NOTE: It is not necessary to completely remove the Waste Pump from the instrument. The connections to the accumulators can be left on the pump and the pump placed on to of the reagent accumulator during removal of the Rinse Pump Assembly.

1. Verify that all tubes are clearly marked to ensure proper placement in the installation.

2. Disconnect the tubing and Fluidics cable from the connectors at the top of Rinse Pump Box as shown on "Rinse Box Connections".

NOTE: The CTS fitting, as identified in the figure, has a red cap on it in a non-CTS unit.

Thumbwheel

Syringe Glass Tube

Syringe PumpValve

Barbed Fitting


Phillips Screws



Figure 7-91 Rinse Box Connections

3. Remove the two captive screws that secure the Runse pump to the cover as shown on Figure 7-92 "Rinse Pump Screws".

Figure 7-92 Rinse Pump Screws

4. Lift and remove the Rinse Pump Assembly out of the cover and the instrument.

Rinse Pump Installation

1. Lower the Rinse Pump assembly into the cover and tighten its two captive screws as shown on Fig-ure 7-93 "Rinse Pump Retaining Screws".

NOTE: Ensure all tubing and cabling are within the cover and the Bracket for the Rinse Pump Connector is outside the Rinse Pump cover as shown in Figure 7-93 "Rinse Pump Retain-ing Screws".

CTS Fitting

Retaining Screws



Figure 7-93 Rinse Pump Retaining Screws

2. Connect the Rinse Pump cable to the Rinse Pump connector.

3. Connect the tubing to the top mounted Rinse Box fittings based on the labeling on the tubing, i.e., Sample to Sample, R1 to INTERMED., R2 to START, Rinse Input to Rinse Input, and CTS to CTS.

4. Replace the Waste Pump as described in “Waste Pump Installation” in Chapter 13.

Precision Tubing Removal/Replacement

Precision Tubing Removal

CAUTION: Ensure that the instrument is powered OFF before you perform the following procedure.

1. Remove the sample or Reagent area interior skins as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4 or “Reagent Area Interior Skins Removal/Replacement” in Chapter 4.


3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-94 "The Probe Tubing"). (Fluid will drain from the probe.)

Retaining ScrewsCaptive Screws

Rinse PumpConnector



R

Figure 7-94 The Probe Tubing

4. depending on whether the tubing is being changed for a CTS Sample Arm, non-CTS Sample Arm, Intermediate Arm or Start Arm, remove the Phillips screws securing the Strain Relief Bracket for the probe tubing as shown in:

• Figure 7-95 "Precision Tubing Strain Relief on CTS Sample Arm".

• Figure 7-96 "Precision Tubing Strain Relief on Base TOP Sample Arm"

• Figure 7-97 "Precision Tubing Strain Relief on Intermediate (R1) Arm"

• Figure 7-98 "Precision Tubing Strain Relief on Start (R2) Arm"

Figure 7-95 Precision Tubing Strain Relief on CTS Sample Arm

Probe Tubing

inse Tubing



Figure 7-96 Precision Tubing Strain Relief on Base TOP Sample Arm

Figure 7-97 Precision Tubing Strain Relief on Intermediate (R1) Arm

Strain Relief Bracket




Figure 7-98 Precision Tubing Strain Relief on Start (R2) Arm

5. Move the Probe down in the Z direction until the Probe tip touches the Sample (or Reagent) Plate.

6. Slide the Probe Cover up the Z-Drive Rack until the Probe Cover is above the Probe.

7. Using a 1.5 mm Allen Wrench, loosen the two set screws on the Probe.

8. Slide the Z-Rack up until the Probe tubing and the purple fitting are exposed.

9. Unscrew the purple fitting from the probe.

10. Pull the tubing out of the machine.

Precision Tubing Installation

1. If you are installing the precision tubing on a CTS Sample Arm,

a. Route the precision tubing through the corrugated plastic sleeve for the fluid line.

b. Attach the ends of the precision tubing to the appropriate connectors on the Syringe Pump.

c. Dress the tubing as shown in Figure 7-99 "Dressing the Tubing on CTS Sample Arm".

d. Install the Sample Area interior skins.

2. If you are installing the precision tubing on a Reagent Arm, or on a Cavro or Sample Arm,

a. Route the precision tubing through their stainless steel conduits.

b. Attach the ends of the precision tubing to the appropriate connectors on the Syringe Pump and theprobe.

c. Dress the tubing as shown in the appropriate figure below.

d. Install the Sample or Reagent area interior skins.




3. To allow the probes a full range of motion in all three planes (X, Y, and Z), the precision tubing must be routed as shown in the following figures.

NOTE: For the probes to function properly, the tubing must be routed through the Strain Relief Brackets exactly as shown. For each tube, there must be a sufficient service loop to allow unimpeded Z-Axis movement in all positions.

• Figure 7-99 "Dressing the Tubing on CTS Sample Arm"

• Figure 7-100 "Dressing the Tubing on Base TOP Sample Arm"

• Figure 7-101 "Dressing the Tubing on Intermediate (R1) Arm"

• Figure 7-102 "Dressing the Tubing on Start (R2) Arm"

Figure 7-99 Dressing the Tubing on CTS Sample Arm



Figure 7-100 Dressing the Tubing on Base TOP Sample Arm



Figure 7-101 Dressing the Tubing on Intermediate (R1) Arm

Figure 7-102 Dressing the Tubing on Start (R2) Arm


Chapter 8 – Robotic XYZ Arms 8 - 1

Chapter 8 –Robotic XYZ Arms

8-1 Overview:

The ACL-TOP uses three XYZ robot arms for the movement of fluids during analysis. One robot arm assem-bly is mounted on the sample side of the instrument and is referred to as the Sample Arm. The other robot arm assembly contains two reagent arms, and is on the reagent side of the instrument. The reagent arms are the left reagent arm, or Intermediate Reagent Arm, and the right reagent arm, or Start Reagent Arm.

The robotic arms of the ACL-TOP system allow the probes to move in the X (left to right), Y (front to back) and Z (up and down) direction as shown on Figure 8-1 "XYZ Axes"

Figure 8-1 XYZ Axes

CAUTION: When manually moving the XYZ arms, grasp the arms as close to the rear of the instrument as possible. Damage may result if arm is moved improperly.

X Axis

ZAxis

YAxis


8 - 2 Chapter 8 – Robotic XYZ Arms

The arms installed on an ACL-TOP and the probes associated with the arms differ depending on the instru-ment configuration as shown on Table 8-1 "Robotic Arm/Probe Configurations".

* Note that the heated probes used with the Cavro arms and the heated probes used with the CTS Sample arms are not compatible.

8-2 Physical Layout

Figure 8-2 "Layout of the Robotic XYZ Arms" shows the physical layout of the Robotic XYZ Arm Assem-blies including the sample and reagent arms as well a the X-Axis Assembly on which they move.

Figure 8-2 Layout of the Robotic XYZ Arms

Table 8-1 Robotic Arm/Probe Configurations

Instrument TypeArms Probes

Sample Arm

Reagent Arm

Sample Probe Left Reagent Probe

Right Reagent Probe

ACL-TOP with Cavro Arms

(000028000)

Cavro Cavro Heated Heated* Heated*

ACL-TOP Closed Top System

(0000280020)CTS

IL Double

Piercer (Non-Heated)

Heated* Heated*

Sample Arm Left Reagent Arm Right Reagent Arm




The Interconnect Diagrams for the CTS, Cavro, and IL Double Arms differ in both the PCBs used and the input requirements for the arm due to the different type of arms and probes used within the arms. Figures 8-3 through 8-6 show the interconnect diagrams for the following arms:

• Closed Tube Sampling (CTS) Arm (Figure 8-3 "Interconnect Diagram - CTS/IL Double Sample Arm")

• Reagent IL Double Arm (Figure 8-4 "Interconnect Diagram - CTS/IL Double Reagent Arm")

• Sample Cavro Arm (Figure 8-5 "Interconnect Diagram - Sample-side Cavro Arm")

• Reagent Cavro Arm (Figure 8-6 "Interconnect Diagram - Reagent-side Cavro Arms")



Figure 8-3 Interconnect Diagram - CTS/IL Double Sample Arm

Figure 8-4 Interconnect Diagram - CTS/IL Double Reagent Arm


apter 8 – Robotic XYZ Arms 8 - 5


J

3

J

1

J

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J

4

J

8

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Ch

J

9J

4

J14

J

7J

8J

1

J

2

J15

J16

J12

J10J13

J11

J

3

J

5

J

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J

3J

1

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6J

2J

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To

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Figure 8-5 Interconnect Diagram - Sample-side Cavro Arm

Figure 8-6 Interconnect Diagram - Reagent-side Cavro Arms

J1 +24V OUT

J2 +24V IN

J7 Diagnostics

J15232 External

PC

J16232 Aux

Device

J17 RS 485 / 422

EXT

J21 RS 485 Diluter

Cavro Single Arm Module

CCU9000

XP3000

Diluter

Pump27756500

MODULO 1

X-AXIS MODULO 1

Z-AXIS

00027763300

To Sample Probe

From Fuse Board J5

00027751100

To LEVEL 2 CPU (278000)

J14 00027758300

Cavro Arm Module

CCU9000

MODULO 1

Y-AXIS

ALIDUM

ADRI-9

MODULO 1

Z-AXIS

MODULO 1

Y-AXIS

ALIDUM

ADRI-9

J1 +24V OUT

J2 +24V IN

J7 Diagnostics

J15 232 External PC

J16 232 Aux

Device

J17 RS 485 / 422

EXT

J21 RS 485 Diluter

XP3000

Diluter

Pump

27756500

MODULO 1

X-AXIS

00027763300

Reagent 1 ProbMODULO 1

X-AXIS

00027763300 T

Reagent 2 Prob

3000

iluter

ump

From Fuse Board J5

00027751100

To LEVEL 2 CPU (278000)

J14 00027758300

Cavro Arm Module

CCU9000Cavro Dual Arm Module

CCU9000

MODULO 1

Z-AXIS

MODULO 1

Y-AXIS

ALIDUM

ADRI-9

MODULO 1

Z-AXIS

MODULO 1

Y-AXIS

ALIDUM

ADRI-9




Cavro Arms (Used on ACL-TOP model 0000280000)

Each Cavro arm is a robot controlled by three stepper motors with step loss (“slippage”) detection capability. The stepper motors control probe movement in the X, Y, and Z direction. Communication with the Cavro arms is via RS-232 from the ACL-TOP master processor that controls the positioning of the arms and probes. Hardware and software errors encountered by the arm are communicated to the operator via the ACL-TOP error log.

Figure 8-7 ACL-TOP with Cavro Arms

X-Axis Assembly

The main structural member for the X-Axis Assembly is the X-Frame, as shown on Figure 8-8 "X Frame", that is mounted to the ACL-TOP pylons through vibration isolators. Each X-Axis Assembly (Sample and Reagent) is mounted with four vibration isolators. Examples of the vibration isolators are shown in Figure 8-9 "Vibration Isolators". In the figure, the four vibration isolators in the middle of the instrument are shown. The two isolators on the right are for the Reagent Arm Assembly and the two on the left are for the Sample Arm Assembly.

The X-Frame is made of a machined aluminum extrusion and attached to it are:

• two guide rails,

• the X-Axis Stepper Motor,

• X-Axis Idler Pulley/Encoder Assembly,

• and the CCU PCB.

Cavro Reagent ArmsCavro Sample Arm



Figure 8-8 X Frame

Figure 8-9 Vibration Isolators

The Y Axis assembly is attached to the X Axis guide rails (X Rails) by three rollers creating a carriage assembly that rides along the rails. The drive belt attached to the X axis motor pulley provide the X axis movement for the carriage. The rollers are adjusted by the OEM supplier and should not be adjusted in the field. Figure 8-10 "X Axis Rollers and Drive Belt" shows two of the three rollers (there are two rollers on the front of the carriage), the X-Rails on which the rollers ride, and the drive belt and its attachment to the arm to move the arm in the X direction. On the left end of the X axis assembly is the X Axis Stepper Motor (drive motor), with its attached encoder, that powers the drive belt.

Figure 8-10 X Axis Rollers and Drive Belt

X Frame

VibrationIsolators

ReagentLeft

Sample ArmRightVibrationIsolators

X Axis

Drive Belt Rollers

X Frame

X Rails

Y Axis Assembly

Drive Belt

Carriage Attachment



The X-Axis Stepper Motor is attached to the underside of the X-Frame Extrusion. The encoder disk for the motor is located under the drive pulley mounted on the upper side of the X-Frame Extrusion, and is read by a slotted optical sensor. Figure 8-11 "Motor, drive belt and encoder" shows the motor. the drive pulley, the encoder, and the optical sensor for the encoder.

Figure 8-11 Motor, drive belt and encoder

For the X-Axis Assembly on the Reagent side, the two arms require two motors and two drive belts. The lay-out of these motors and belts are as shown on Figure 8-12 "X Axis Motors - Reagent Side".

Figure 8-12 X Axis Motors - Reagent Side

Optical Sensor

Encoder

Drive Belt

Drive Pulley

Disk

R1 (Left Arm) Motor

R2 (Right Arm) Motor



Figure 8-13 X Axis Belts - Reagent Side

Y-Axis Assembly

The Y-Axis Assembly attaches to the X-Axis Assembly by the three rollers that allow it to move along the X axis. Figure 8-14 "Y Axis Assembly" depicts the parts of the Y-Axis Assembly. As shown in the figure, the Y-Axis Assembly has 2 guide rails and the Z carriage assembly attaches to the guide rails with three rollers. The rollers are adjusted by the OEM supplier and should not be adjusted in the field. Driven by the Y drive belt and guided by the guide rails, the Z carriage rides along a square shaft that runs the length of the Y axis. The square shaft should never be lubricated or greased in any way.

The Y drive belt is rotated through a set of tandem pulleys that enables the motor to reside on the top of the Y-Axis Assembly while powering the belt on the bottom of the assembly.

Figure 8-14 Y Axis Assembly

R1 (Left Arm) Belt

R2 (Right Arm) Belt

Y Drive BeltRoller

Guide Rail

Z Axis Drive Belt

Square Shaft

Z Carriage

Tandem Pulleys



As shown on Figure 8-15 "Y Axis Stepper Motor", the Y Axis Stepper Motor is mounted on top of the Y-Axis Extrusion. The encoder for the motor is mounted to the motor shaft on top of the drive pulley. The encoder disk is read by a slotted optical sensor. A set of tandem pulleys redirects the motion of the Y-Motor to the Y-Axis drive belt as previously shown above in Figure 8-14 "Y Axis Assembly".

Figure 8-15 Y Axis Stepper Motor

Z-Axis Assembly

The Z-Axis Assembly attaches to and moves along the Y-Axis Assembly via the three rollers and rides along the square shaft. The square shaft is driven by the Z axis motor and drive belt and turns a pinion gear inside the aluminum block of the Z-Axis Assembly. The pinion gear teeth engage the teeth on the Z-Rack Drive that provides the Z axis (up and down) motion of the probe. As shown on Figure 8-16 "Z Axis Motor, Pulley and Encoder". the Z Axis Stepper Motor is mounted to the Y Axis Extrusion. The encoder for the motor is mounted to the motor shaft and is directly in front of the drive pulley. The encoder disk is read by a slotted optical sensor. A short closed loop belt drives a pulley rigidly mounted to the square shaft that runs along the Y axis.

Figure 8-16 Z Axis Motor, Pulley and Encoder

Z Axis Motor

Z Axis Encoder Y Axis Motor

Z Axis Drive Belt

Square Shaft

Z axis Drive Belt

Z axis MotorZ axis Encoder

that drives theZ-Axis Assembly



Figure 8-17 "Z-Axis Assembly" depicts the Z-Axis Assembly. As shown, the Z Rack mounting hole pro-vides the alignment of the teeth in the Z Rack to engage the square shaft that drives the rack and probe up and down.

Figure 8-17 Z-Axis Assembly

Properly cleaning the Z Axis Assembly with an isopropyl alcohol wipe on a regular basis is recommended. The square shaft should never be lubricated or greased in any way.

Arm Initialization

On a Cavro arm, each of the three axes (X, Y, and Z) have sensors to indicate the arm has properly moved to the designated home position on that axis. The X and Y home sensors are the slotted optical travel limit sensors (see "X, Y, Z Travel Limit Sensors" below) that are interrupted by a flag attached to each axis assembly. The Z axis home sensor is a capacitive sensor tied to the Liquid Level Detection (LLD) circuit in the probe. When an electrical contact is made between the probe bracket and collar on the arm, the probe is considered home. The home positions are as shown in Table 8-2 "Cavro X, Y, Z Home Positions".

Table 8-2 Cavro X, Y, Z Home PositionsTable 8-3

Arm/ Axis Home Position

All Z Up

Sample arm X Rear, right side of the Sam-ple Area

Left Reagent arm X Rear, left side of the Reagent Area

Right Reagent arm

X Rear, right side of the Reagent Area

Y axis Drive Belt

Square Shaft

Z-Axis Assembly

Z Rack Mounting Hole



During the Initialization sequence, the Z axis initialization occurs first. This is done to raise the probe and prevent damage to it when moving the probe along the X and Y axes. The probe initialization routine involves raising the probe until it triggers the LLD circuit by a metal tab on the probe contacting a steel ring on the Z-Axis Assembly. Once the LLD circuit is triggered, the probe is considered home and the probe is moved down several steps to offset it from the sensor. During normal operation, the software only enables the probe to be raised to the upper limit minus the offset to avoid false indications by the LLD circuit.

When all three arms have initialized, the ACL-TOP runs a coordinates check on the metal openings around the rinse/clean stations. This action is performed each time the ACL-TOP is initialized to verify that no changes have occurred to the probe tip positions since the last coordinates check. If an error occurs during this check, the operator is prompted to run the coordinates adjustment routine in the Diagnostics Menu.

X, Y, Z Travel Limit Sensors

Both the X and Y axes have travel limit flags and sensors used to sense the limits of the carriage travel and avoid any damage to the equipment in case of an error. These sensors are slotted optical sensors whose sensing is interrupted by the flag which goes between the two halves of the sensor. The X limit flags are mounted on the X-Axis Assembly and the sensor is mounted on one of the boards that travel along the X axis with the arm as shown in Figure 8-18 "X Limit Flags and Travel Limit Sensors".

Figure 8-18 X Limit Flags and Travel Limit Sensors

The Y limit flag is mounted on the rear of the Z carriage and the limit sensor is mounted on the Y-Axis Assembly as shown on Figure 8-19 "Y Limit Flag and Travel Limit Sensor", There is no travel limit sensor on the front of the Y-Axis Assembly. This limit is controlled by the software tracking of the encoder output and ensuring the count never reaches a point indicating the arm has passed its limit.

FlagSensorSlotted

Flags

Sensors

Left RightFlag/Sensor Flag/Sensor



Figure 8-19 Y Limit Flag and Travel Limit Sensor

For the X and Y axes, if the arm exceeds normal system travel range, the flag blocks the slotted travel limit sensor. This sensor indication is communicated to the software that stops the arm movement prior to it hit-ting its rubber stop.

Limiting travel for the Z axis is managed by the software monitoring of the Stepper Motor Encoder.

Communications

Communication with the Cavro arm is through RS232 communication between the master processor in the right rear of the ACL-TOP and the Cavro Central Control Unit (CCU) located below the X-rails. The Cavro CCU sends commands to the Cavro devices and completion messages are sent back to the master proces-sor. There is one CCU for the Sample arm and one CCU that controls both Reagent Arms as shown on the Interconnect diagrams. The communication cable for the arms goes from connector J15 on the CCU to con-nector J14 on the Level2 CPU (Master Processor).

CCU PCB

The Central Control Unit (CCU) PCB is mounted below the X-Axis Assembly on four standoffs, as shown on Figure 8-20 "Central Control Unit (CCU) for Cavro Arms" and controls communication between the Cavro arms and the Master Processor in the right rear of the instrument. The electronics that drive the X-Axis motor(s) are located on the CCU and communication to the syringe pumps is routed through the CCU PCB to the master processor. The syringe pump communication cable plugs into J21 on the right side of the CCU, 24V power for the syringe pumps plugs into J1 on the CCU, and 24V power for the arms plugs into J2 on the CCU.

To Be Added.

Sensor

Flag



Figure 8-20 Central Control Unit (CCU) for Cavro Arms

As shown on the figure, there are four LEDs on the CCU PCB to help identify error states of the arm. The LEDs blink slowly if the arms are functioning properly. If the LEDs blink quickly (twice per second) there is a problem with step loss (“slippage”). If the LEDs are on constantly, there is a problem with the arm hardware.

ADRI-9 PCB

The ACL-TOP contains two ADRI-9 PCBs, one for the Sample Arm and one for the Reagent Arms. The ADRI-9 PCB contains the motor drivers for the Y and Z axes, the end of limit sensors for the X axis, and the liquid level sensing circuit that is contained within a metal casing and is referred to as the Alidum. The Ali-dum is connected to the probe via a coaxial cable. The Alidum sensitivity can be varied by changing a dip switch setting on the ADRI-9 PCB. The sensitivity of the Alidum is set and verified during manufacture and should not be modified in the field.

The ADRI 9 PCB consists of two PCBs “stacked” one atop the other and located on the traveling Y-Axis as shown on Figure 8-21 "ADRI-9 PCBs". (Note that the PCB is shown from the back. The PCBs are not vis-ible from the front of the instrument as they are behind the Y and Z Axis Stepper Motors.) The ADRI-9 PCB has a series of dip switches that allow the arm position (Sample, Left Reagent, Right Reagent) to be defined and the sensitivity of the LLD circuit to be selected. The dip switches not meant to be changed in the field. The switches are shown in Figure 8-22 "ADRI 9 Dip Switches", and their settings are shown in Table 8-4 "Cavro ADRI-9 Dip Switch Settings", for verification purposes.

NOTE: There is an extra ADRI-9 board on the Sample side X-Axis Assembly that is required for software checking.

LEDs

CCU Board



Figure 8-21 ADRI-9 PCBs

Figure 8-22 ADRI 9 Dip Switches

For reference purposes, the configuration of the dip switch settings are shown in Table 8-4 "Cavro ADRI-9 Dip Switch Settings".

Table 8-4 Cavro ADRI-9 Dip Switch SettingsTable 8-5

S1 S2 S3 S4

Sample Arm On On Off On

Reagent 1 Arm On On On Off

Reagent 2 Arm On On Off On

S1S2S3S4



If LLD issues arise and are not isolated to the sampling probe or coaxial cable connection, the resistance of the Alidum should be measured to ensure that the RC network of the Alidum is functioning properly. Refer to "Alidum Resistance Check" for measuring the resistance of the Alidum.

Probe Interconnect PCB

The probe interconnect PCB is located on the Y-Axis carriage. The PCB is an interconnect PCB that reduces the white flex cable down to the orange flex cable that leads to the probe. The probe interconnect PCB has two strain relief brackets mounted to it to prevent damage to the two flex cables. When servicing the probe interconnect PCB, care should be taken to reinstall the strain relief brackets and manually verify that there are no interferences between the flex cable and Y-Axis covers.

DC Driver Board

The DC Driver board is part of the thermal control system that regulates the temperature of up to three probes in the ACL TOP system. It provides variable DC voltages for driving two heaters on each of the three probes. One DC driver board accommodates all three probes on an instrument.

The circuit consists of six Buck regulator circuits, one for each heater. The Buck regulator uses an FET, an inductor, a capacitor, and a schottky diode.

When the FET is turned on, the full voltage is present across the coil but falls exponentially while the current in the inductor decreases to discharge the capacitor to ground. When the FET is turned off, the voltage across the inductor becomes reversed in polarity to maintain the current flow to the capacitor. The reversed voltage is now conducted through the diode, thus offering the FET protection. Unless the FET is turned on again, the current in the inductor diminishes and the voltage charges back to +24V.

The DC voltage is derived from a 30KHZ pulse train. To maintain any given voltage output, the duty cycle of the 30KHz is varied with the voltage output directly proportional to the duty cycle, i.e., an increased duty cycle offers higher voltage. For example: with a circuit powered from +24V and the 30KHz at a 50% duty cycle, the output from the buck regulator circuit is 12V.

The power capacity of each Buck regulator is limited to the current capability of the coil which is 1.5A. With each heater at 32 ohms, the maximum current draw per heater does not exceed 0.75A.

Heater Probe PCB

The heater Probe PCB is located within the probe, as shown on Figure 8-23 "Heater Probe PCB", and pro-vides control of the two heaters within the probes. The probe fuses are protective measures that prevent overheating and burning in the probe. If a fuse blows under normal operation, it indicates a problem with the probe and the probe should be replaced. When a probe fuse is blown a thermal warning is generated and the red LED on the fuse PCB goes on. If the fuse blows because of a problem other then normal operation, the fuse can be removed and replaced with tweezers.

Sensitivity Standard N/A N/A Off N/A

Sensitivity High N/A N/A On On

Sensitivity Very High N/A N/A On On

Table 8-5



Figure 8-23 Heater Probe PCB

CTS Sample Arm (Used on ACL-TOP model 0000280020)

The CTS Sample arm is a robot controlled by three stepper motors with step loss (“slippage”) detection capability. The stepper motors control motion in the X, Y, and Z axis. Communication with the CTS Sample arm is via Can-bus from the ACL-TOP master processor. The ACL-TOP system software controls the posi-tioning of the arms and hardware and software errors encountered by the arm are communicated to the operator via the ACL-TOP error log.

Figure 8-24 ACL-TOP CTS with CTS Sample and IL Double Arms

X-Axis Assembly

The main structural member for the X-Axis of the arm is the X-Frame, as shown on Figure 8-8 "X Frame", that is mounted to the three pylons on the ACL-TOP chassis. The X-Frame is made of extruded aluminum and designed to accept the additional loading created by closed tube sampling (CTS). Attached to the X-Frame are:

• two rails

• X-Axis Stepper Motor/encoder assembly

Probe HeaterBoard

Probe Fuse

CTS SampleArm

ReagentIL Double Arm



• X-Axis idler pulley

• X-Axis PCB.

Figure 8-25 X-Axis Assembly

The X-Carriage is attached to the X-Axis bearing rails by two bearing blocks and the drive belt that provides the X axis movement for the Y-Axis Assembly. The bearing blocks are fixed and are not field adjustable. Fig-ure 8-26 "X Axis Drive Belt (Sample Side)" shows the rails and the drive belt.

Figure 8-26 X Axis Drive Belt (Sample Side)

On the right end of the X-Axis Assembly is the X axis stepper motor (drive motor), with its attached encoder, that powers the X Axis Stepper Motor(s) and is attached to the underside of the X-Frame. The encoder disk for the motor is mounted to the motor shaft on the rear of the motor casing. As opposed to the other encod-ers that are visible, the Y Axis motor encoder is enclosed and not visible. The encoder disk is read by an optical sensor.

X Axis Assembly

X Axis Rails

DrivePulley

X Drive Belt



Figure 8-27 X Axis Drive Motor

The Reagent X-Axis Assembly supports two arms and requires separate motors and drive belts for each arm. While each assembly can travel the length of the X axis, the software controls the arms and ensures there is no collisions between them. Note that there are also flags on each arm and sensors on the other arm, as described in "CCU PCB", that protect them from collision in the event of a failure in the software or hardware. Figure 8-28 "Reagent Side Drive Belts" shows the X axis drive belts while Figure 8-29 "Reagent Side X Axis Motors" shows the X axis motors.

Figure 8-28 Reagent Side Drive Belts

X Axis MotorEncoder

X Axis Motor

X AxisFrame

End of LimitTravel Sensor

R2 (Right) Drive Belt R1 (Left)Drive Belt



Figure 8-29 Reagent Side X Axis Motors

Y-Axis Assembly

The Y-Axis Assembly mounts to the X carriage. The main structural member of the Y-Axis Assembly is the Y frame that is made of extruded aluminum and designed to minimize deflection during sample acquisition. The Y-Axis Assembly has a single bearing rail running the length of the extrusion and the Z carriage attaches to the bearing rail with one bearing block and the Y drive belt as shown on Figure 8-30 "Y-Axis Assembly".

Figure 8-30 Y-Axis Assembly

Reagent SideX Axis Motors

Y Axis Drive BeltY Axis Drive Motor

Y Axis Drive Pulley



The Y Axis Stepper Motor is mounted on the top of the Y Axis Extrusion in front of the Y Axis PCB stack. The encoder disk for the motor is mounted to the motor shaft on the rear (top) of the motor casing. As opposed to the other encoders that are visible, the Y Axis motor encoder is enclosed and not visible. The encoder disk is read by an optical sensor. The motor shaft passes through the Y-Axis Assembly and is attached to a drive pulley that powers the Y drive belt. The Y drive belt moves the Z-Axis Assembly forward and backward on the arm as shown on Figure 8-32 "Y Axis Drive Belt".

Figure 8-31 Y Axis Stepper Motor

Figure 8-32 Y Axis Drive Belt

Y Axis StepperMotor

Y Axis BeltDrive

Drive Motor

Drive Pulley

Front Pulley



Z-Axis Assembly

The Z-Axis Assembly attaches through the Y Axis carriage. The Z-Axis Assembly include the mounting bulk-head, Z axis motor/encoder assembly, bushings and Z axis circuit PCB. A pinion gear is attached to the Z motor shaft to drive the Z-Rack. The CTS Sample arm differs due to the additional requirements of the CTS Piercer. These requirements include:

• accommodation of the Brake Rack that is used on the CTS Piercer

• increased torque for the Z drive motor to enable the piercing of the top of the sample

• additional air and cleaner controls to ensure proper cleaning of the piercer probe.

Cleaning the Z-Rack with an isopropyl alcohol wipe on a regular basis is recommended.

The Z Axis Stepper Motor travels with the Z-Axis Assembly as shown on Figure 8-35 "Z Axis Controller PCB". The encoder disk for the motor is mounted to the motor shaft on the rear of the motor casing. As opposed to the other encoders that are visible, the Z axis motor encoder is enclosed and not visible. The encoder disk is read by an optical sensor.

Figure 8-33 Z-Axis Assembly

For the CTS Piercer Arm, a number of changes are made as shown on Figure 8-34 "CTS Piercer Z-Axis Assembly". The bottom of the Z-Axis Assembly is modified to accommodate the Brake Rack and additional hardware (and circuitry) that is used to lock the Brake Rack, and CTS Piercer Foot, when a cap is detected on the sample. The motor assembly is also modified with a gearbox used to increase the torque of the motor (by a factor of almost 4 to 1) to accommodate the piercer action. In addition, there are two solenoid valves added to an extension of the Z-Axis Assembly to accommodate requirement for the additional air and fluid needs in cleaning of the CTS Piercer.

Z AxisMotor

Z-AxisAssembly(BottomView)

Z DriveRack



Figure 8-34 CTS Piercer Z-Axis Assembly

As shown in Figure 8-35 "Z Axis Controller PCB", the Z Axis controller PCB, which is enclosed in a cas-ing, also travels with the Z-Axis Assembly. The figure also shows the top portion of the Z-Axis Assembly.

Figure 8-35 Z Axis Controller PCB

Arm Initialization

On a CTS Sample Arm, each of the three axes (X, Y, and Z) have a home sensor to indicate the arm has properly moved to the home position on that axis. The X and Y home sensors are the slotted optical travel limit sensors (see "X, Y, Z Travel Limit Sensors" below) that are interrupted by a flag attached to each axis assembly. The Z home sensor is a capacitive sensor tied to the Liquid Level Detection (LLD) circuit in the probe. When an electrical contact is made between the probe bracket and collar on the arm, the probe is considered home. The home positions are as shown in Table 8-2 "Cavro X, Y, Z Home Positions".

Brake Rack Opening

Piercer Air & FluidSolenoid Valves

Gear Box

Z-AxisAssembly(Top View)

Z AxisControllerPCB



Table 8-6 CTS Sample and IL Double Arm X, Y, Z Home Positions

During the Initialization sequence, the Z-Axis initialization occurs first. This is done to raise the probe and prevent damage to it when moving the probe along the X and Y axes. The probe initialization routine involves raising the probe until it triggers the LLD circuit by a metal tab on the probe contacting a steel ring on the Z-Axis. Once the LLD circuit is triggered, the probe is considered home and the probe is moved down several steps to offset it from the sensor. During normal operation, the software only enables the probe to be raised to the upper limit minus the offset to avoid false indications by the LLD circuit.

The X and Y axes also have an travel limit flags and sensors in both the X and Y directions. The sensors are slotted optical sensors that sense the flag on the arm. The X limit flag are mounted on the assembly and the sensors are mounted on each side of the Y Driver Board that travel along the X axis with the arm as shown in Figure 8-18 "X Limit Flags and Travel Limit Sensors".

Figure 8-36 CTS Sample and/or IL Double Arm X Flag and Travel Limit Sensors

Table 8-7

Arm/ Axis Home Position

All Z Up

Sample X Rear, right side of the Sample Area

Left (R1) Reagent Arm

X Rear, left side of the Reagent Area

Right (R2) Reagent Arm

X Rear, right side of the Reagent Area

Left Side Travel Limit Flag

Travel Limit Sensors

RightSideTravelLimitFlag



For the Reagent Arms, in addition to the left and right travel limit sensors and flags on the X-Axis Assembly, there are also limit flags and sensors that ensure there is no collision between the two reagent arms. These flags and sensors are mounted on the traveling board stacks on the arms as shown in Figure 8-37 "Flags and Sensors Between Reagent Arms". As shown in the figure, the flags and sensors are duplicated with two flags and two sensors.

Figure 8-37 Flags and Sensors Between Reagent Arms

There is one flag and sensor located on both the rear and front of the Y-Axis Assembly. The Y flag is mounted on the front and rear of the travelling Z-Axis Assembly with the limit sensors mounted on the Y-Axis Assembly as shown on Figure 8-19 "Y Limit Flag and Travel Limit Sensor".

Figure 8-38 CTS Sample and/or IL Double Arm Y Flags and End of Limit Sensors

X Travel LimitSensor

X Travel LimitFlag

X Travel Limit

X Travel Limit

Flag

Sensor

Sensors

FlagsFront of Arm Rear of Arm



CTS Probe Initialization

The CTS probe initialization is more complex. Home for the probe is similar to other probes, but several more initialization steps are performed to prepare the CTS probe to run samples. For more information regarding the initialization routing of the CTS probe see Chapter 15 “CTS Piercer”.

In addition to the home sensors, the X and Y axes also have travel limit sensors. These sensors functions the same as the home sensor (and, in fact are used as the sensors for the home position). In the event the arm exceeds its normal system operating range, the travel limit sensor stops the movement prior to the assembly hitting its rubber bumper stop. Over travel in the Z-Axis is controlled by software monitoring of the Stepper Motor and encoder.

When all three arms have initialized, the ACL-TOP runs a coordinates check on the metal openings around the rinse/clean stations. This action is performed each time the ACL-TOP is initialized to verify that no changes have happened to the probe tip positions since the last coordinates check. If an error occurs during this check, the operator prompted to run the coordinates adjust routine in the Diagnostics Menu.

Communications

Communication with the CTS Sample and/or IL Double Arm is through the Can-Bus for the communication between the master processor in the right rear of the ACL-TOP and the X-Axis Controller PCB. The X-Axis controller sends commands to the different axes through the white flex cables and completion messages back to the master processor. The communication cable for the sample arm goes directly from the master processor to the connector on the sample X-Axis Controller PCB. The communication cable for the reagent arm goes from the master processor to reagent connector on the reagent arm X-Axis Controller PCB.

PCBs

There are four PCBs that provide control for the CTS Sample and/or IL Double Arms. They are the XYZ Controller PCB, X Axis Driver PCB, Y Axis Driver PCB, and Z Axis Controller PCB. The interconnections for these PCBs are shown in 8-3 "Interconnect Diagrams", and their location within the instrument is shown in Figure 8-39 "CTS Sample and/or IL Double Arm PCB Locations". The following paragraphs describe the operation of the PCBs.



Figure 8-39 CTS Sample and/or IL Double Arm PCB Locations

XYZ Controller PCB

The XY Z Controller PCB, as shown on Figure 8-40 "XYZ Controller Interface PCB, Y-Driver PCB", is the top PCB of the two PCBs located on the back of the CTS Sample and/or IL Double Arm. It controls all pro-cessing operations pertaining to the single arm to which it is attached. This PCB contains control circuitry for all three axes of motion for the arm. Due to the level of resources required to control the arm, there is one PCB for each Sample and Reagent arm. The PCB contains circuitry to provide for the following functions: stepper motor drive signals, motion encoders, DIO, voltage monitoring, Liquid Level Detection (LLD), EEPROM, SPI communications, CAN communications, and RS232 communications.

Y Driver PCB

The Y Driver PCB, as shown on Figure 8-40 "XYZ Controller Interface PCB, Y-Driver PCB", is the bottom PCB provides of the two PCBs located on the back of the CTS Sample and/or IL Double Arm. It provides Y axis stepper motor control and Probe DC heating. One PCB accommodates one arm in a two arm assembly. The Y Driver PCB interfaces directly with the CPU controller to provide software controlled motion and Y axis positioning. It provides an interface for a motion encoder and interfaces both Phase A and Phase B to the controller. It provides an interface to the heated probe PCB and provides proportional pulse width mod-ulated DC heating for two heaters on the probe boards. The Y Driver PCB also provides interconnection for Y End of travel and Home detection sensors. The X travel limit sensors are directly mounted to the PCB.

Controller PCB

Z Axis Controller PCB X Axis Driver PCB(under cover)

Y Driver PCB

XYZ



Figure 8-40 XYZ Controller Interface PCB, Y-Driver PCB

X Axis Driver PCB

The X Axis Driver PCB is mounted below the X-Axis Assembly on five standoffs, as shown on Figure 8-41 "X Axis Driver PCB". It interfaces and drives the X stepper motor for the arm and provides the interface for the encoders of those stepper motors. If installed on the Reagent assembly, the PCB provides the interface, drive circuitry, and encoder interface for both arms. The PCB provides CTS capability for the right arm. The X Driver directly interfaces with the Level III CPU to provide software controlled motion and module position-ing.

The X Driver PCB drives, using logic FETs, the two solenoid valves located on the Z-Axis Assembly, used during CTS operation. It interfaces the air pump and fluid pump on the Z-Axis Assembly and provides the interface for the air pressure sensor.

The X Driver PCB provides the Can Bus interface to the Level II CPU (Master Processor) and two RS232 connections for communication with the diluter pumps.

XYZControllerPCB

Y Driver PCB

X TravelLimit Sensor



Figure 8-41 X Axis Driver PCB

The Can Bus interface splits to both arms while the RS232 ports are specific to one arm. The RS232 con-nections also provides the +24V power for two syringe pumps.

As shown on the figure, there are four LEDs on the CCU PCB to help identify error states of the arm. The LEDs blink slowly if the arms are functioning properly. If the LEDs blink quickly (twice per second) there is a problem with step loss (“slippage”). If the LEDs are on constantly, there is a problem with the arm hardware.

Z Axis Controller PCB

The Z Axis Controller PCB is located on the Z axis carriage. The PCB is an interconnect PCB that reduces the white flex cable down to the orange flex cable that leads to the probe. The PCB contains connectors for the valves and sensors required for Z home sensing and by CTS equipped arms. The Z Driver PCB is uti-lized on each of the arms contained in the CTS instrument. This PCB is responsible for signal buffering, probe RS485 translation for SPI, open-collector sensors, motor encoder, PWM solenoid driving, MOSFET control, as well as stepper motor control with adjustable power control. The PCB moves with the Z carriage assembly along the Y axis of the instrument during typical operation.

LEDs



Figure 8-42 Z-Axis Controller PCB

The Z-Axis Controller PCB has a strain relief cover made of PVC that attaches to the top of the PCB. The PVC cover provides strain relief to the two flex cables and manages the cable harnesses that route between the Z-Axis Controller PCB and the probe below. When servicing the Z-Axis Controller PCB, care should be taken to reinstall the strain relief brackets and manually verify that there are no interferences between the cable and Y-Axis components.

Probe Alignment and Coordinates Adjustment

Each arm requires knowledge of a set of target locations (e.g. rack containers, cuvette cells, clean / rinse stations), and each location is defined by X and Y axis coordinate positions as well as 3 Z axis coordinate positions (Zmax, Zsearch, Zposition). Originally, the coordinate positions are obtained from the CAD model of the instrument; however, due to mechanical tolerances, the physical geometry of each instrument is dif-ferent from the one defined by the CAD model due to manufacturing and assembly tolerances, as well as from mishandling, for example, a bent probe.

It requires 3 reference points to provide the 3-D transformation from the CAD coordinates to the coordinates of the specific instrument. By knowing how 3 reference points have moved, it can be calculated how all other points have moved. The system starts with a 3-D CAD model of the ACL-TOP system that is the “golden” model and provides the coordinates of all reference points and targets, referred to as “master reference coordinates” and “master target coordinates”. These “master coordinates” serve as the basis for all proce-dures performed on the AM.

The “Probe Alignment” procedure consists of measuring the position of a set of reference points using the probe Liquid Level Detection (LLD) capability.

J9J8J5

J2

J4J3

J1



The “Coordinates Adjustment” procedure is a method used by the software to adjust the CAD coordinates of all positions reachable by the arms to account for variances in the actual instrument geometry. (The flow-chart of the “Coordinate Adjustment” procedure is included in the "Probe and Arm Initialization Flow-charts" section of this chapter.)

The coordinate adjustment starts by locating reference points, using the master reference coordinates from the CAD model, and establishing correlations, or offsets, to those reference points for the instrument. The correlation calculation results in a “transform matrix”, that, once established, is used to calculate actual coor-dinates of all targets and the difference for any specific point. The actual reference point coordinates are saved in a file, to enable the instrument to adjust the coordinates at every startup without measuring refer-ence points every time.

To minimize the number of points required to adjust the coordinates, target locations are grouped together into modules. A module is defined as a set of mechanical components that maintain their 3-D relationship throughout the system’s lifetime, from assembly to years of operation. For example, the clean, waste, and rinse wells are built into a single mold. ORUs 1 to 4 share the same base. A module is characterized in 3-D by 3 reference points.

Reference Point Positions

The diagrams in this section show the reference point positions for each configuration of the TOP Instru-ment.

Figure 8-43 "Reference Point Positions for Base TOP Instruments (Cavro Arms)" shows the reference point positions for Base TOP Instruments with Cavro Arms.

Figure 8-44 "Reference Point Positions for CTS Instruments" shows the reference point positions for CTS Instruments.



Figure 8-43 Reference Point Positions for Base TOP Instruments (Cavro Arms)

Figure 8-44 Reference Point Positions for CTS Instruments

Shuttle Mechanism Zone

S6 S9 D1

1

2

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D2

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R6

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910

S2

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910

S3

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S4

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S5

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910

S7

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S8

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S10

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S12

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910

Cuvette Load

Cuvette Pivot Arm

Slot#10

Slot#9

Slot#8

Slot#7

Slot#6

Slot#5

Slot#4

Slot#3

Slot#2

Slot#1

Cuvette Indexer INCUBATOR #1

Slot#2

Slot#3

Slot#4

Slot#1

Slot#6

Slot#7

Slot#8

Slot#5 ORU #2 ORU #3 ORU #4

INCUBATOR #2

Slot#2

Slot#3

Slot#4

Slot#1

Slot#6

Slot#7

Slot#8

Slot#5

CTS Hold Area

Slot#2

Slot#3

Slot#4

Slot#1

Slot#6

Slot#7

Slot#8

Slot#5

Slot#9

Slot#10

ORU #1

1234

1234

1234

1234

Reagent Arm #1Zone- Logical

Arm #2

Sample Arm Zone - Logical Arm #1

10

7

8

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8

D3

1

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910

Reagent Arm #2 Zone -Logical Arm #3

Slot#11

Slot#12

Slot#13

Barcode Reader Module ( BC ) Zone

BC-HOME

Slot#14

CUVETTE

WASTE

ShuttleHome

R

R R R

R

R R

R

R

RR

R

R

R R

R

R R

R

RR

R

R

R Reference point

Clean Waste Rinse

PC1

PW1

Sample Station

PR1 RR

R

PC2

PW2

Reagent#1 Station

PR2 RR

R

Clean Waste Rinse Clean Waste Rinse

PC3

PW3

Reagent#2 Station

PR3 RR

R

Shuttle Mechanism Zone

S6 S9 D1

1

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D2

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S2

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S3

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S12

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910

Cuvette Load

Cuvette Pivot Arm

Slot#10

Slot#9

Slot#8

Slot#7

Slot#6

Slot#5

Slot#4

Slot#3

Slot#2

Slot#1

Cuvette Indexer INCUBATOR #1

Slot#2

Slot#3

Slot#4

Slot#1

Slot#6

Slot#7

Slot#8

Slot#5 ORU #2 ORU #3 ORU #4

INCUBATOR #2

Slot#2

Slot#3

Slot#4

Slot#1

Slot#6

Slot#7

Slot#8

Slot#5

CTS Hold Area

Slot#2

Slot#3

Slot#4

Slot#1

Slot#6

Slot#7

Slot#8

Slot#5

Slot#9

Slot#10

ORU #1

1234

1234

1234

1234

Reagent Arm #1Zone- Logical

Arm #2

Sample Arm Zone - Logical Arm #1

10

7

8

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8

D3

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910

Reagent Arm #2 Zone -Logical Arm #3

Slot#11

Slot#12

Slot#13

Barcode Reader Module ( BC ) Zone

BC-HOME

Slot#14

CUVETTE

WASTE

ShuttleHome

R

R R R

R

R R

R

R

RR

R

R

R R

R

R R

R

RR

R

R

R Reference point

Clean Waste Rinse

PC3

PW3

Reagent#2 Station

PR3 RR

R

PC2

PW2

Reagent#1 Station

PR2 RR

R

Clean Waste Rinse

wastewash

Sample Station

PC1 R

R

R

Clean



Reference Point Search

The adjustment operates on the premise that reference screws are, by definition, circular. The probe diam-eter is slightly narrower at the tip than the base and may come in contact from the side and cause a false detection. Also, the probe is not necessarily perfectly aligned vertically or, a droplet may lie at the tip of the probe. To alleviate these differences, 2 consecutive contacts are made for each point searched. If there is a substantial height difference between the two contacts, the first contact is rejected. If a droplet is present, it is dissipated on the first contact and cause the second contact to fail, and the scan resumes as if no con-tact was made.

Figure 8-45 Reference Screw Detection

Measurement of the Reference Screw Position

The nominal position of reference screws is the center of the screw head. The probe has to measure the position of three points on the external circumference of the head and calculate the coordinates of the cen-ter. Because the edges of the screw head are not vertical, to measure the Z coordinate of the screw head, the probe has to touch the highest part of the head after the X and Y coordinates of the center have been calculated.

The following describes the procedure used to measure the coordinates of a reference screw.

1. Set the start position

a. For the first screw in the module, the start searching position is set as follows:

XStartSearch: Xcad – ScrewRadius / 2YStartSearch: Ycad

(We don't start at the coordinates of the center of the screw head to avoid the hole)

b. The LLD start and end position for the first screws are set as follows:

ZStartLld = 9.75mm above Zcad

ZEndLld = 2.75mm above Zcad

These values are very conservative to avoid hitting the rack area plate.

c. For the second and third screws of each module, the start position is adjusted taking into account themeasured position of the first screw; in this way the instrument is able to touch the second and thirdscrew at the first attempt

2. Touch the screw head

a. The probe performs LLDs until the screw is touched. The size of searching area is 20.88mm on X and 11mm on Y.

12



b. If the screw is not found, the instrument performs another attempt updating the LLD start and endposition as follows:

ZStartLld = 6.5mm above Zcad

ZEndLld = 3.25mm below Zcad

c. If the screw is not found, the instrument performs another attempt updating the LLD start and endposition as follows:

ZStartLld = 4.25mm above ZcadZEndLld = 5.5mm below Zcad

If the screw is not found, the procedure is aborted and an error condition is reported.

3. Measure the X and Y coordinates of the screw center.

a. Starting from the position where the screw was touched the first time, the probe measures the posi-tion of three points on the external circumference of the screw head.

b. The X and Y coordinates of the center are calculated based on the three measured points.

4. Measure Z coordinate

a. Once the X and Y coordinates of the center are known, the probe scans the screw head to measure the screw height, keeping track of the highest point touched.

b. To achieve the maximum accuracy and avoid outliers, the height of the screw is measured threetimes, and the lowest result is used as measured screw height.

NOTE:The third screw in the incubator, ORU and holding area modules are too close to the indexer assemblies for running the entire measurement procedure. For these screws, only the Z coordinate is measured.

Z and Y coordinates are calculated as follows:

XLastScrewmeas XFirstScrewmeas + (XLastScrewcad - XFirstScrewcad)YLastScrewmeas YFirstScrewmeas + (YLastScrewcad - YFirstScrewcad)

Waste stations – Reagent and Cavro Arm Sample Probes

Three reference points are measured on the metallic contour of the waste station: two reference points at the extremities of the X-axis and one reference point on the extremity of the Y-axis. For each reference point, X, Y, and Z coordinates are recorded. Each Z coordinate is found by lowering the probe until it meets the contour surface of the station. As with screws, for each of the 3 points, 2 successive contacts must be made to determine a point.

Due to the unconventional shape of the waste station, it is considered a rectangle when searching. There-fore, the locating procedure starts by moving the probe to the center of the station, and then moving along the Y-axis (1) until the top edge is found. This is the largest linear edge of the station and reduces the pos-sibility of hitting the circular edge. Knowing the dimension of the station, the probe can be positioned at the center (relative to the Y axis) of the station and then moved along the X-axis to find both edges (2 & 3).

Only Y and Z coordinates can be measured for the first reference point, while only X and Z can be measured for second and third point. The non-measured coordinates are calculated as follows:



X1measured = (X2measured + X3measured) / 2Y2measured = Y1measured + (Y2cad - Y1cad)Y3measured = Y2meas

Figure 8-46 Well Area Cutout Reference Points for Non-CTS Probes

Waste Stations – CTS Sample Arm Sample Probes

The sample area waste station reference points on CTS Sample Arm instruments are in different positions, because the “sneeze guard” makes the left edge unreachable. Also, the sample probe could have the CTS piercer, and the system must be sure to touch the reference surface with the sample probe tip rather than with the piercer. Therefore, the process starts by moving the probe along the Y-axis until the bottom edge (1) and the top edge (2) are found. Knowing the dimension of the station, the probe can be positioned at the center (relative to the Y axis) of the station and then moved along the X-axis to find the right edge (3).

Only Y and Z coordinates are measured for the first two reference points, while only X and Z are measured for the third point. The non-measured coordinates are calculated as follows:

X1measured = X3measured + (X1cad - X3cad)X2measured = X1measured

Y3measured = (Y1measured + Y2measured) / 2

Figure 8-47 Well Area Cutout Reference Points for CTS Probes

Air gaps

To reduce the formation of droplets below the probe tip, at the beginning of the alignment procedure, the syringe is initialized and a 250 milliliter air gap is aspirated. The air gap is removed and aspirated again when the probe moves to the next module; to avoid the formation of air bubbles, before removing the air gap the probe is filled with rinse liquid by running the rinse pump.

Coordinates File

When the probe alignment procedure is successfully completed (i.e., the probe has measured all reference points) the measured coordinates are saved in a file.

X

Y

1

RR

R 2

RR

R 3

RR

R

X

Y 1

R

R

R

2

R

R

R

3

R

R

R



The file name and path are: C:\Program Files\IL\ACL-TOP\AMSw\FTPBoot\Coordinates\XX-XX-XX-XX-XX-XX-coor.dat where XX-XX-XX-XX-XX-XX is the MAC address of the master PCB Ethernet network adapter.

The file has a header section and a data section.

The header section contains the:

• Cyclic Redundancy Check (CRC) of the data section, to detect data corruption

• File version, to be sure that the file is compatible with the software running on the instrument.

The data section contains the measured coordinates of the reference points for all probes.

The file is read at startup and after each “recovery” operation after an emergency stop. If the file is not present, or the file version doesn't match with the software running on the instrument, or no data is written for one or more probes, an alarm is reported and the instrument status is set to error.

Coordinate Calculation and Check

After power up, the coordinates of each target location are calculated, to adjust the CAD coordinates based on the latest measurement. This calculation does not require any mechanical movement, but requires access to the “measured” coordinates of each reference point, as well as the CAD reference point coordi-nates. The measured coordinates are read from the coordinates file and the CAD coordinates are hard coded in the software running on the master PCB.

With this information, the transform matrix for each module is calculated, and all target location coordinates are adjusted according to the transform matrix. After all target coordinates are adjusted, an alignment check is performed to ensure that the last coordinates adjustment is still accurate. The alignment check involves measuring the coordinates of reference points in the waste module and comparing these coordinates with the last measured coordinates read from the coordinate file. If the expected and measured coordinates are not within tolerance, then the alignment check fails, and the probe must be re-aligned. The instrument can-not run jobs until the probe alignment is performed.

CTS Instruments – Alignment of Piercer Probe Foot to the Wash Station

CTS instruments must be able to insert the foot into the wash station during wash and priming operations. The mechanical tolerances between sample probe and external surface of the foot make collisions between the foot and edge of wash station possible even if the probe is aligned. For this reason, the piercing probe has to align the foot inside the wash station, overwriting the adjusted X and Y coordinates of the wash sta-tion with the coordinates measured during the foot alignment.

Since both wash station edge and foot are made by non-conductive materials, the instrument uses the cap detection mechanism instead of the liquid level detection.

The foot alignment is executed:

• During the probe mechanical initialization (at startup and via diagnostics)

• After the arm homing performing the Maintenance Routine Clean

• At the end of the probe alignment procedure

The foot alignment procedure is not executed if the measured coordinates of the wash station reference points are not available.

The following list describes the alignment procedure:



1. Set start and cap detection positions.

XStartSearch: Adjusted X coordinate of the wash stationYStartSearch: Adjusted Y coordinate of the wash station

The cap detection start and end position are defined as follows:

zStart: the bottom face of the foot 6mm is above the measured Z coordinate of the wash referencepointszEnd: the bottom face of the foot 3mm below the measured Z coordinate of the wash referencepoints

2. Insert the foot inside the wash station.

The probe performs cap detections until no surface is detected below the foot. The size of searching area is ±5mm on both X and Y axes.

3. Measure position of the left and right edges.

a. The probe moves on the X axis to detect the wash station edge on the left and on the right of the position found by the previous step.

b. The probe is then moved – on the X axis – to the middle position between the two edges. (Note: Thisposition maybe still be inaccurate, because the start search position could be far from the center onboth axes.)

4. Measure the position of the top and bottom edges.

a. The probe moves on the Y axis to detect the wash station edge and on the bottom of the position found by the previous step.

b. The probe is then moved – on the Y axis – to the middle position between the two edges.

5. Measure the position of left and right edges.

a. The probe moves on the X axis to detect the wash station edge on the left and on the right of the position found by the previous step.

b. The probe is then moved – on the X axis – to the middle position between the two edges.

6. Update the coordinates.

a. The position of the probe at the end of the previous step defines the “measured X-Y position” of the wash station.

b. The X and Y adjusted coordinates of the wash station are replaced by the X and Y coordinate of thecurrent position of the probe.

The foot alignment procedure fails if any of the following conditions exist:

• The measured coordinates of the wash station reference points are not available.

• The foot cannot be inserted into the wash station (the cap detection always reports “surface found”).

• The edges are not found (Moving toward the edges, the cap detection never reports “surfacefound”).

When the procedure fails, the instrument reports the alarm “Coordinates check failure”.

The following probe errors are corrected by the foot alignment procedure:

• Probe not accurately inserted into the Probe body

• Probe Bent



The following arm errors are corrected by the foot alignment procedure:

• The circuit PCB with the home flag has a high tolerance due to large fixing holes.

• The home flag is bent.

• The arms have a certain weight that can cause them to tilt around the X axis, towards the racks.

The following errors are not correctable by the foot alignment procedure:

• Mechanical assembly errors

• Component does not meet the size and assembly specifications (Transform matrix corruption, adjustment failure).

• Improper installation of the component to the chassis.

• Probe pipetter not accurately inserted into probe body (Probe cannot reach the reference point).

• Reference screw is not completely tightened.

• Reference screw is not grounded.

• Arm motor slippage that may go unnoticed by the Cavro software. (Note: The CTS Sample armcontroller monitors the motor slippage but a small amount of slippage is tolerated.)

• LLD is not functional. This will generate software exception when the arm slowly makes contact withthe reference point: Steps loss on Z axis - cavro error 22 (cavro arms), Slippage on Z Axis (CTSSample Arms).

• LLD falsely triggers. (Transform matrix corruption or alignment procedure failure.)

• Mechanical modules not grounded (alignment procedure failure).

• Arms not at 90 degrees.



Probe and Arm Initialization Flowcharts

This section contains flowcharts of the Probe and Arm initialization procedures.

Probe and Arm Initialization on CTS Sample and/or IL Double Arm

Figure 8-48 "CTS Sample and/or IL Double Arm Initialization" is the flowchart for CTS Sample and/or IL Double Arm initialization.

Figure 8-48 CTS Sample and/or IL Double Arm Initialization

Figure 8-49 "Probe Initialization for CTS Sample Arms" is the flowchart for the initialization of probes on CTS Sample Arms.



Figure 8-49 Probe Initialization for CTS Sample Arms



Probe and Arm Initialization on CTS Sample Arms

Figure 8-50 "Probe Initialization for CTS Sample Arms" is the flowchart for the initialization of probes on CTS Sample Arms.

Figure 8-50 Probe Initialization for CTS Sample Arms



IL Double Arm Homing Procedure Flowchart

Figure 8-51 "IL Double Arm Homing Procedure" contains the flowchart for the IL Double Arm Homing Procedure. Note that the Home sensor referenced in the procedure is the travel limit sensor for the direction in which the arm home position is located.

Figure 8-51 IL Double Arm Homing Procedure



Probe and Arm Initialization on Cavro Arms

Figure 8-52 "Probe Initialization for Cavro Arms" is the flowchart for the initialization of probes on Cavro Arms.

Figure 8-52 Probe Initialization for Cavro Arms



Coordinates Checking Procedure Flowchart

Figure 8-53 "Coordinates Checking Procedure" contains the flowchart for the Coordinates Checking Procedure.

Figure 8-53 Coordinates Checking Procedure



Tube Release Procedure Flowchart

Figure 8-54 "Tube Release Procedure" contains the flowchart for the Tube Release Procedure.

Figure 8-54 Tube Release Procedure




Verifying a CTS Arm or a Universal Dual Arm

1. Initialize all arms on the Instrument. Refer to "Diagnostics" for details.

2. Upon successful initialization of the arms, perform a coordinates adjustment for each arm on the instru-ment. Refer to "Coordinate Adjust".

3. Perform an LLD check for all arms. See "Probe LLD Error Troubleshooting".

Alidum Resistance Check

1. Disconnect the coaxial cable from the arm.

2. Measure the resistance between the center pin and the outside case of the coaxial cable.

3. The proper resistance is 7500 ohms +/- 1000 ohms.

4. If the resistance is more than expected or infinite, the Alidum assembly should be replaced.

8-6 Diagnostics

Probes Tab of Diagnostic Screen

The diagnostics for the XYZ Robotic Arms are on the Probes tab as shown on Figure 8-55 "The Probes Tab". The Probes tab contains five main areas: the Temperature log area, the LLD area, the Rinse area, the Clean area, and the Move area. In addition to the five main areas, the Probes tab contains six high-level functions for the XYZ Robotic Arms. The six functions are “

• "Initialize All Arms"

• "Home All Arms"

• "Disable Sample Arm"

• "Disable Reagent Arms"

• "Coordinate Adjust"

• "Set Valve"




Ch

Figure 8-55 The Probes Tab


Initialize All Arms

The “Initialize All Arms” button consists of homing the arm, moving it to the wash/clean station, priming the rinse, and priming the clean. The arms cannot be initialized individually due to the risk of collisions and leak-age.

The Arm Status field shows the initialization state for the arms. The possible values in this field are Unknown, Not initialized, Initialization in progress, Busy, Error, and Ready.

In the event of an error, the possible causes are displayed in the Alarms section. With the exception of the “Initialize All Arms” command, commands involving arm movements sent to an arm that is not initialized are ignored to avoid generation of error conditions.

Home All Arms

The “Home All Arms” button sends all arms to their home positions. Selecting this button causes the arms to go to their home positions without initializing them. Refer to "Arm Initialization" for a detailed description of the home position for each Robotic Arm.

Disable Sample Arm

The “Disable Sample Arm” button disables, i.e., powers off, the Sample Arm. When the Sample Arm is dis-abled, it can be moved by hand. This allows access to the left (Sample) side of the instrument.

Disable Reagent Arms

The “Disable Reagent Arms” button disables, i.e., powers off, the Reagent Arm. When the Reagent Arm is disabled, it can be moved by hand. This allows access to the right (Reagent) side of the instrument.

Coordinate Adjust

The “Coordinate Adjust” button initiates a complete probe coordinates adjustment. The probe to be adjusted is selected from the Probe pull-down list.

NOTE: Before the Coordinate Adjustment is performed, all interior covers must be removed from the Sample and Reagent modules. See “Sample Area Interior Skins Removal” in Chapter 4 and “Reagent Area Interior Skins Removal” in Chapter 4 for instructions on removing the covers.

The Coordinate Adjust is typically performed when the probe needs to be adjusted for the first time, or after a mechanical repair. If there are racks in the modules, or the bar code reader is not home, the Coordinate Adjust cannot be performed and the operator is notified. During the adjustment, the bar code reader cannot be moved by either the Analytical Module or Control Module track buttons until the operation is finished.

When a probe is selected from the Probe pull-down list, the screen displays the steps lost on the Arm since the last initialization and the steps lost since the Instrument Startup. This information is shown for the X, Y, and A axes.It is possible that a high number of Z steps will show as being lost (typical error values are 40-44 step lost). The number of steps lost during a positive calibration test is 1 or 2 maximum.



Set Valve

The “Set Valve” button sets the pump valve for the selected Probe to Input, Output, or Bypass based on the corresponding radio button. The probe to be used is selected from the Probe pull-down list. This button is used to test the valve to ensure it switched positions correctly.

LLD Area

The LLD area of the Probes tab, as shown on Figure 8-56 "LLD Area of Probes Tab", is used to investi-gate problems with Liquid Level Detection and as an alternative method for performing alignment checks. When the “Start” button in this area is clicked, the system performs an LLD on the container (Bottle type) that is in the location specified by the Module, Slot, and Position pull-downs in the LLD area.

Figure 8-56 LLD Area of Probes Tab

The Mode pull-down selections specify the conditions for stopping the LLD. The modes and when they cause a stop are:

• Stop on failure - The LLD stops upon detection of any failure.

• Stop always - The LLD stops after one cycle.

• Don’t stop - The LLD stops upon completion of the number of cycles specified in the #cycles box.

The number of LLD cycles is determined by the #Cycles entry. If Stop always is selected as the mode, the number of cycles is set to one.

The “Stop” button is used to stop an LLD in progress.

The number of successful LLDs is displayed in the Passes field; the number of failed LLDs is displayed in the Failures field. Table 8-8 "LLD Module, Slot, and Position Settings" shows the Module, Slot, and Posi-tion values that are available for each Arm.

Table 8-8 LLD Module, Slot, and Position Settings

Arm Module Track/Slot Position

Sample Sample Rack S1-S12 1-10

Diluent Rack D1-D2 1-8

CTS 2-14 1-4

Incubator 1 1-8 1-4



Rinse Area

The Rinse area of the Probes diagnostic screen, as shown on Figure 8-57 "The Rinse Area", is used to start and stop a probe rinse and to specify the duration of a probe rinse. The virtual LED labeled “Pump” turns green when the rinse pump is running and the rinse is in progress.

Figure 8-57 The Rinse Area

The “Duration” field specifies the length of time (in seconds) of the rinse cycle. Select the “Start” button to start the pump rinse; select the “Stop” button to stop a pump rinse cycle in progress.

The Flow Rate Test is used to determine if the rinse pumps are functioning properly and to detect any kinks in the tubing between the rinse pumps and the probes. The Start button control the start of the test. The Stop button can be used to stop a test in progress.

When the test is started, the selected probe is moved to a predefined XY position and to the maximum height to allow the placement of a graduated container beneath the probe. The positions XY where each probe shall be moved are the following:

Clean 1 1

Reagent Arm 1 Diluent Rack D3 1-8

Reagent Rack R1-R4 1-6

Incubator 2 1-8 1-4

Clean 1 1

Reagent Arm 2 Reagent Rack R3-R6 1-6

ORU 1-4 1-4

Clean 1 1

Table 8-8 LLD Module, Slot, and Position Settings




Sample ArmSample Track 6, Position 5

Reagent Arm 1Reagent Track 3, Position 3

Reagent Arm 2Reagent Track 3, Position 3

If there is another probe in the same area it will be homed.

Once the container has been placed beneath the probe, the “Start” button in the Rinse area is clicked to run the rinse pump for the specified duration. When the Flow Rate Test is performed, the Rinse Test runs the rinse pump without moving the probe to the rinse station. The “Stop” button is clicked on to discontinue the test. The volume mean must be 5.10mL (-0.3mL /=0.5mL). The flow rate mean must be 1.03 mL/ sec(-.06mL // =0.10mL). Measurements should be taken using a graduated container.

Clean Area

The Clean portion of the Probe diagnostic screen, as shown on Figure 8-58 "The Clean Area", causes the system a to run a Probe Clean cycle. A Probe Clean cycle consists of

• filling the Clean Cup

• aspirating the Clean-A fluid

• dispensing the Clean-A Fluid into the Waste Fluid Accumulator

• and rinsing the Probe.

Figure 8-58 The Clean Area

When the “Start” button is clicked on, the system performs a Clean Cycle in the specified location for the selected Arm. (The location is specified with the Module, Slot, and Position pull-downs.) Table 8-9 "Select-able Cleaning Locations" lists the Modules, slots, and positions that can be selected for each arm.



The following fields can be used to specify additional parameters for the Clean Cycle:

• Hold Time – The Clean Hold duration in seconds.

• Volume – The Clean Volume in uL.

• Enable agitation – Click this box to enable Clean Agitation.

• Air gap – The first air gap in uL.

• Transport Air gap – The Transport air gap in uL.

The “Stop” button stops a Clean Cycle in progress.

Move Area

The Move area, as shown on Figure 8-59 "The Move Area", is used to move material from one position to another.

The Source and Target locations for the material are selected from the respective pull-down lists (Module, Slot, and Position). The #Cycle field is used to specify the number of repetitions for the move activity. The Start button initiates the movement of material. The Stop button stops the movement after the current move cycle is completed.

NOTE: The Emergency Stop button stops the current movement.

Table 8-9 Selectable Cleaning Locations

Arm Module Slot Position

Sample Diluent Rack D1-D2 1-8

Clean 1 1


Clean 1 1


Clean 1 1



Figure 8-59 The Move Area

Table 8-10 "Allowable Source and Destination Positions" shows the allowable source and destination positions for each arm.

Use the following fields to specify additional parameters for moves:

• Volume – The Volume of material to be moved (in uL).

• Air gap – The first air gap in uL.

Table 8-10 Allowable Source and Destination Positions


Sample Arm Sample Rack S1-S12 1-10

Diluent Rack D1-D2 1-8

Predilution Area 2-14 1-4

Incubator 1 1-8 1-4

Reagent Arm 1 Diluent Rack D3 1-8

Reagent Rack R1-r4 1-6

Incubator 2 1-8 1-4


ORU 1-4



• Transport Air gap – The Transport air gap in uL.

• Head – The Head Volume (in uL) for the material move.

Probe Troubleshooting

The flowchart in Figure 8-60 "Probe Troubleshooting Flowchart" is to be used for performing functional tests after replacing, or repairing, a Probe component.

NOTE: If repairs are made to a specific component, follow the maintenance guidelines for the component. After a repair, leave the instrument initialized and in the READY state.



Figure 8-60 Probe Troubleshooting Flowchart



Probe LLD Error Troubleshooting

This procedure is to investigate major problem with the LLD system. In the case of minor problems with the LLD system, such as liquid level detection errors in specific areas or specific containers, it's recommended to use the specific LLD test in the service program (see Figure 8-61 "LLD Diagnostics") to reproduce the error conditions.

Figure 8-61 LLD Diagnostics

Cavro Probe Troubleshooting

The first check has to be done using a digital multi-meter device (DVM) set on the Ohm measurement.

1. Connect the DVM probe on the test point as shown in Figure 8-62 "DVM Probe Connections" (GND / SIGNAL). These are the 2 test points of the LLD coaxial cable that connect the probe to the LLD board inside the arm movement assembly.

Figure 8-62 DVM Probe Connections

2. A value in the range 5KOhm to 8KOhm is in the working range. A lower value (typically 200-300 Ohm), indicates a problem in the probe, coaxial cable or the assembly.

3. Check the following (see Figure 8-63 "Probe Visual Inspection"):

• The tubing connector bar must be straight. If the tubing connector bar (at signal level) is bent, once the probe is assembled, the bar touches the Z-rod assembly (at GND level). This causes a short cir-cuit in the LLD system.

Signal

Ground



• The hole in the probe assembly that is the housing for the Z-rod assembly must be dry. Any liquid drop, however small, may generate random or persistent short circuits between the Z-rod assembly (at GND level) and the tubing connector bar (at signal level).

Figure 8-63 Probe Visual Inspection

Universal Arm Diagnostic Screen

The diagnostics for the CTS Sample and/or IL Double Arms are on the Universal Arm tab as shown on Fig-ure 8-64 "Diagnostic Screen - Universal Arm". The Probes tab contains four main areas: the "Sensors Area", the "Intermediate Arm Area" area, the "Start Arm Area" area, and the "ZDAC Check" area. Each of these areas are described following the figure.

TubingConnectorBar

Housing forZ-RodAssembly




Ch

Figure 8-64 Diagnostic Screen - Universal Arm


Sample Arm Area

The Sample Area of the Universal Arm Dignostic screen consists of a Sensors, Encoder Limits, Encoder, and LLD Frequency Area. Each of these area are described below.

Sensors Area

The sensors area includes virtual LEDs for five sensors, as listed and described below.

X Home - When red, this virtual LED indicates the Arm is in the home position on the X Axis, to the far right of the Sample area, and has caused the Home sensor to be interupted. The LED is green when the limit switch is not interrupted.

Y Home - When red, this virtual LED indicates the Arm is in the home position on the Y Axis, to the extreme rear of the Sample area, and has caused the Home sensor to be interupted. The LED is green when the limit switch is not interrupted.

Y Limit -When red, this virtual LED indicates the Arm is at the limit of the Y Axis, the extreme front of the Sample area, and has caused the limit sensor to be interupted. The LED is green when the limit switch is not interrupted.

Z Home - When red, this virtual LED indicates the Arm is at the Home position on the Z Axis, all the way up, as indicated by the encoder value.

Encoder Limits

There are encoder limits that can be set for the X, Y, and Z Motors using the UP and DOWN arrows to the right of the entry box. These limits determine the amount of slippage the arm is permitted during one oper-ation, before causing an error. Any number between 1 and 9999 can be entered; however, the suggested settings are: X Motor: 4, Y Motor: 4, Z Motor: 30. The Set button at the bottom of the area causes the limits that have been entered in the input boxes to be stored in the system for use in error checking.

Encoder

The Encoder area displays the current encoder counts for the X, Y, and Z Arms. These counts indicate the location of the arm and should be at maximum value when the arm is at its limits. Typical values for each are are as follow:

X: Arm all the way to the right: approx. -500, Arm all the way to the left: approx. 16500.

Y: Arm all the way to the front: approx. 14200, Arm all the way to the back:approx. 0.

Z: Arm all the way to the top:approx. -7500, Arm all the way to the bottom: approx. 23400.

LLD Frequency

The LLD Frequency displays the frequency count of the Liquid Level Detection circuit. The LLD frequency can be used to check the LLD circuit. With no contact, the Sample Arm should be about 900 counts when the probe is not in contact with anything and 0 when touching a coordinate screw.



Intermediate Arm Area

The Intermediate Arm Area of the Universal Arm Dignostic screen consists of a Sensors, Encoder Limits, Encoder, and LLD Frequency Area. Each of these area are described below.

Sensors Area


X Home - When red, this virtual LED indicates the Arm is in the home position on the X Axis, to the far left of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit switch is not interrupted.

Y Home - When red, this virtual LED indicates the Arm is in the home position on the Y Axis, to the extreme rear of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit switch is not interrupted.

Y Limit -When red, this virtual LED indicates the Arm is at the limit of the Y Axis, the extreme front of the Reagent area, and has caused the limit sensor to be interupted.The LED is green when the limit switch is not interrupted.


Encoder Limits


Encoder





LLD Frequency

The LLD Frequency displays the frequency count of the Liquid Level Detection circuit. The LLD frequency can be used to check the LLD circuit. The Intermediate Arm should be about 900 counts when the probe is not in contact with anything and 0 when touching a coordinate screw.



Start Arm Area

The Start Arm area of the Universal Arm Dignostic screen consists of a Sensors, Encoder Limits, Encoder, and LLD Frequency Area. Each of these area are described below.

Sensors Area


X Home - When red, this virtual LED indicates the Arm is in the home position on the X Axis, to the far right of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit switch is not interrupted.

Y Home - When red, this virtual LED indicates the Arm is in the home position on the Y Axis, to the extreme rear of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit switch is not interrupted.

Y Limit -When red, this virtual LED indicates the Arm is at the limit of the Y Axis, the extreme front of the Reagent area, and has caused the limit switch to be interupted. The LED is green when the limit switch is not interrupted.


Encoder Limits


Encoder





LLD Frequency

The LLD Frequency displays the frequency count of the Liquid Level Detection circuit. The LLD frequency can be used to check the LLD circuit. The Start Arm should be about 900 counts when the probe is not in contact with anything and 0 when touching a coordinate screw.

ZDAC Check

The ZDAC (Z Digital to Analog Converter) portion of the screen is not used at present..



8-7 Removal/Replacement Procedures

CTS Arm (283777-00) Removal/Replacement

Closed Tube Sample (CTS) Arm Removal

CAUTION: Ensure that the instrument is powered OFF before you perform the following procedure.

1. Remove the Top Skin, Center Skin, Upper Skin (sample side), Inner Left Skin, and the interior Sample Skins as described in Chapter 4 “Enclosure/Chassis”.

2. Remove the Telescoping CTS Assembly as described in “Piercer Probe Removal/Installation” in Chapter 15.

3. Disconnect the rinse bottle coupling from the Fluidic I/O panel.(This should be done prior to any servic-ing of the fluid system. It prevents leaks and siphoning.)

4. Disconnect the fluid pump sensor cable from the 6-pin connector on the side of Bulk Fluidic Assembly. (See Figure 8-65 "CTS Bulk Fluid Connections".)

5. Disconnect the rinse input and output fittings from the CTS Bulk Fluidic Assembly as shown on Figure 8-65 "CTS Bulk Fluid Connections"

Figure 8-65 CTS Bulk Fluid Connections

Rinse Input &OutputConnectors

Sensor Cable6 Pin Connector



6. Disconnect the following cables from the X Axis Driver PCB. (See Figure 8-66 "Sample CTS X Axis Driver Cable Connections").

• 4-pin cable (286526-00) on J7 to the syringe pump

• 6-pin cable on J11 from the bulk fluid assembly

• 4-pin cable (286519-02) on J3 to the PC104 Board

• 14-pin power distribution cable (286539-01) on J9 from the fuse board.

• 5-pin cable (286514-00) on J13 from the air pump sensor.

Figure 8-66 Sample CTS X Axis Driver Cable Connections

7. Unscrew and remove the precision (probe) tubing from the Syringe Pump Valve (see Figure 8-67 "Syringe Pump Tubing"). (Fluid will drain from the probe.)

8. Carefully pull the Rinse tubing from the barbed fitting (see Figure 8-67 "Syringe Pump Tubing").


Front of Board

J7

J5

J11

J3

LEDLED

J13

J9



Figure 8-67 Syringe Pump Tubing

9. Using a tubing cutter, trim the rinse line by 1/4”. (This removes the part of the line that was stretched over the barbed fitting.) Move the rinse line from the interior of the Bulk Fluidics Assembly to enable the removal of the assembly.

10. Loosen the three captive mounting screws securing the syringe pump and Bulk Fluidics Assembly to the Sample Arm and slide the module out as shown on Figure 8-68 "CTS Fluidics Mounting".

Figure 8-68 CTS Fluidics Mounting

Precision(Probe)TubingRinse Tubing

MountingScrews



11. Remove the syringe pump cable from the 15 pin electrical connector on back of syringe pump as shown on Figure 8-69 "Syringe Pump Cable".

Figure 8-69 Syringe Pump Cable

12. Remove the end of the polyurethane tubing coming from the top of tube guide to the right angle fitting on the air Sample arm valve assembly. Pull the tubing through the grommet on the top of the air valve bracket as shown on Figure 8-70 "Air Tubing to Arm".

Figure 8-70 Air Tubing to Arm

13. Using a 5mm Allen wrench, remove the four mounting screws as shown on for the CTS Arm Assembly and lift and remove the CTS Arm Assembly from the left and center pylons.

Rear of Syringe Pump

Syringe Pump Cable

Air ValveBracketGrommet

Air LineConnection



Figure 8-71 CTS Arm Assembly Mounting Screws

Closed Tube Sample (CTS) Arm Installation


1. Mount CTS arm assembly on the left and center pylons. Ensure the arm assembly is aligned with the alignment pins on the pylon.

Mounting Screws



2. Insert and secure the four mounting screws securing the assembly using a 5mm Allen wrench as shown on Figure 8-72 "CTS Arm Assembly Mounting Screws"

Figure 8-72 CTS Arm Assembly Mounting Screws

3. Connect the following cables to the X Axis Driver PCB (see Figure 8-73 "CTS X Axis Driver PCB Cable Connections":

NOTE: All cables connected to the x-axis driver PCB should be routed toward the rear of the PCB to allow room for tubing connections to the bulk fluidics module.

• 5-pin cable (286514-00) from the fluid pressure sensor to J13

• 4-pin cable (286526-00) from the syringe pump to J7

• 6-pin cable (286547-00) from the bulkhead and air pressure pump to J11

• 4-pin cable (286519-01) from the PC104 board to J3

• 14-pin power distribution cable (286539-02) from the fuse board to J9.

Mounting Screws



Figure 8-73 CTS X Axis Driver PCB Cable Connections

4. Ensure the pump address on the Syringe Pump Housing is set to “1” as described in “Syringe Pump Addressing and Jumpers” in Chapter 7.

5. Attach the Syringe Pump Cable (286525-00) to the back of the Syringe Pump as shown on Figure 8-74 "Syringe Pump Cable" and secure the pump with the two 4-40 x 1/4” screws and flat washers.


6. Install the Sample Syringe Pump on the CTS Bulk Fluids Module. Refer to “CTS Sample Cavro Syringe Pump Installation” in Chapter 7 or “CTS Sample Hamilton Syringe Pump Installation” in Chapter 7. Do not fully tighten the screws yet. Tubing routing must be done before securing the Pump to the module.

(Front of Board)

LEDs

J3J13

J7

J11


Syringe Pump Cable



7. Mount the CTS Fluidics Module to the Arm Assembly using the three screws as shown on Figure 8-75 "CTS Fluidics Module Mounting".

Figure 8-75 CTS Fluidics Module Mounting

8. See Figure 8-76 "Syringe Pump Tubing". Attach the precision tubing to the sample syringe pump valve (upper right port).Route the rinse supply tube through the Bulk Fluidic assembly as shown on the above figure and attach it to the sample syringe pump valve (upper left port) by carefully pressing it onto the barbed fitting.Tighten the two screws securing the syringe pump.

Figure 8-76 Syringe Pump Tubing

MountingScrewsMountingScrews

Precision(Probe)TubingRinse Tubing



9. Install the CTS rinse input and rinse output fittings to the top of the CTS Bulk Fluidics Module as shown on Figure 8-77 "Rinse Input/Output Fittings".

Figure 8-77 Rinse Input/Output Fittings

10. Connect the rinse bottle coupling to the Fluidic I/O panel.

11. Connect air pump sensor cable ((286547-00)) to the connector on the side of Bulk Fluidic Assembly (see Figure 8-77 "Rinse Input/Output Fittings".

12. Pull the polyurethane tubing through the grommet on the top of the air valve bracket as shown on Fig-ure 8-78 "Connecting the Air Tubing to the Arm". Connect the end of the tubing to the right angle fitting on the air Sample arm valve assembly.

Figure 8-78 Connecting the Air Tubing to the Arm

13. Install the Telescoping CTS Assembly as described in “Telescoping CTS Assembly Installation” in Chapter 15.

14. Verify the CTS Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is run as part of the verification.

15. Reinstall the instrument skins.

Rinse Input &OutputConnectors

Sensor CableConnector

Air ValveBracketGrommet

Air LineConnection



Reagent IL Double Arm Removal/Replacement

Reagent IL Double Arm Removal


1. Remove the Top Skin, Center Skin, Inner Right Skin, and the Reagent area inner skins as described in “Removal/Replacement Procedures” in Chapter 8.

2. Move both reagent probes over the Rinse Cups. (This ensures that any fluid that drips out of the Probes drips into the Rinse Cup.)

3. Disconnect the rinse bottle coupling from the Fluidic I/O panel.(This should be done prior to any servic-ing of the fluid system. It prevents leaks and siphoning.)

CAUTION: When removing Reagent Syringe Pumps, ensure the tubes connected to Pump R1 and the tubes connected to Pump R2 are identified. This can be done by placing a small mark on the tubes for one Syringe Pump (R1 or R2). (It is recommended that the mark be made with a soft-tip marking pen.) When re-connecting the tubes, ensure the tubes are connected to the proper pumps.

4. Unscrew and remove the probe tubing from the Syringe Pump Valves (see Figure 8-79 "Reagent Syringe Pumps"). (Fluid will drain from the probe.)

5. Carefully pull the Rinse tubing from the barbed fitting on each valve (see Figure 8-79 "Reagent Syringe Pumps").




Figure 8-79 Reagent Syringe Pumps

6. Using a tubing cutter, trim the rinse line by 1/4”. (This removes the part of the line that was stretched over the barbed fitting.)

7. Disconnect the Fluidic Dispense cable between the syringe pump for Reagent Arm 2 and the ORU.

8. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probes and remove the probe from the Z-rack on each arm.

9. Remove the flex cable from the Probe PCB on each arm.

10. Remove the purple fittings of the probe tubing from the stainless steel fittings at the top of the probes Support the stainless steel support tube while disconnecting the tubing to ensure it doesn’t bend.

11. Disconnect the following cables from the X-axis driver PCB. (See Figure 8-80 "Reagent IL Double Arms X Axis Driver PCB Cabling"

• 4-pin cable (286525-00) on J7 to the Right Arm syringe pump

• 4-pin cable (286525-00) on J8 to the Left Arm syringe pump

• 5-pin cable (286535-00) on J5 to the Right Arm X Axis Stepper Motor Encoder

• 5-pin cable (286535-00) on J6 to the Left Arm X Axis Stepper Motor Encoder

• 4-pin cable (286519-01) on J3 to the PC104 Board

Rinse TubingConnectors

PrecisionTubingConnection



Figure 8-80 Reagent IL Double Arms X Axis Driver PCB Cabling

12. For each of the two heated probes (IL P/N 283950-00):

a. Lift the Sample Probe cover from the probe housing.

b. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probe andremove the Probe from the Z-rack.

c. Remove the flex cable from the Probe PCB.

13. Using a 5mm Allen wrench, remove the four mounting screws as shown on Figure 8-81 "Reagent IL Double Arm Assembly Mounting Screws" for the Reagent IL Double Arm Assembly and lift and remove the assembly from the right and center pylons.

Front of Board

J7

J14

J5J6

J3

LEDLED



Figure 8-81 Reagent IL Double Arm Assembly Mounting Screws

Reagent IL Double Arm Installation


1. Mount the Reagent Arm Assembly on the right and center pylons. Ensure the arm assembly is aligned with the alignment pins on the pylon.

2. Insert and secure the four screws securing the assembly using a 5mm Allen wrench as shown on Fig-ure 8-72 "CTS Arm Assembly Mounting Screws"

Figure 8-82 Reagent IL Double Arm Assembly Mounting Screws

3. Connect the following cables to the X-axis driver PCB.(See Figure 8-83 "Reagent IL Double Arms X Axis Driver PCB Cabling")

Mounting Screws

Mounting Screws



• 4-pin cable (286525-00) on J7 from the Right Arm syringe pump

• 4-pin cable (286525-00) on J8 from the Left Arm syringe pump

• 5-pin cable (286535-00) on J5 from the Right Arm X Axis Stepper Motor Encoder

• 5-pin cable (286535-00) on J6 from the Left Arm X Axis Stepper Motor Encoder

• 4-pin cable (286519-01) on J3 from the PC104 Board

Figure 8-83 Reagent IL Double Arms X Axis Driver PCB Cabling

4. Attach the Syringe Pump Cable (286525-00) to the back of the Syringe Pumps as shown on Figure 8-84 "Syringe Pump Cable" and secure the pump with the two 4-40 x 1/4” screws and flat washers.

CAUTION: Ensure the 15-pin connector with two extra wires (black twisted with blue) is connected to the R2 Syringe Pump.

Front of BoardLED LED

J5J6

J3

J8 J7




5. Mount the syringe pump assembly on the arm as shown on Figure 8-85 "Reagent Arm Pump Assem-bly Mounting". Do not tighten screws yet. Tubing routing must be done prior to securing the pump to the arm.

Figure 8-85 Reagent Arm Pump Assembly Mounting

6. See Figure 8-76 "Syringe Pump Tubing". Attach the precision tubing to both syringe pump valves (upper right port).Route the rinse supply tubes through the mounting bracket as shown on the figure and attach it to the syringe pump valves (upper left port) by carefully pressing it onto the barbed fitting. Ensure it is fully seated on the fitting.

7. Tighten the two screws securing the syringe pump.


Syringe Pump Cable

Mounting Screws



Figure 8-86 Reagent Syringe Pump Tubing

8. Connect the fluidic dispense cable between the syringe pump for reagent arm 2 and the ORU.

9. Connect the rinse bottle coupling to the Fluidic I/O panel.

10. For each of the two heated probes (IL P/N 283950-00):

a. Lift the Probe cover from the probe housing.

b. Insert the Probe on the Z-rack.

c. Use a 1.5mm Allen wrench to tighten the screws on the rear and upper left side of the probe.

d. Connect the flex cable to the Probe PCB.

11. Screw the purple fitting of probe tubing to the stainless steel fitting at the top of the probe as shown on Figure 8-97 "Probe Top". Hand tighten and then tighten one quarter turn with pliers. Support the stain-less steel support tube while connecting the tubing to ensure it doesn’t bend.

Figure 8-87 Probe Top

12. Verify the Reagent Arms as described in "Adjustments and Verifications". Ensure coordinate adjust is run as part of the verification.


Rinse Tubing


Probe Tubing FittingStainless Steel



Cavro Sample Arm Removal/Replacement

Cavro Sample Arm Removal


1. Remove the Top Skin, Center Skin, Upper Skin (sample side), Inner Left Skin, and the Sample Area interior skins as described in “Removal/Replacement Procedures” in Chapter 8.

2. Lift the Sample Probe cover from the probe housing.

3. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probe and remove the Sample Probe from the Z-rack.

4. Remove the flex cable from the Sample Probe PCB.

5. Use a Phillips head screwdriver to loosen the cable clamp holding the LLD coaxial cable to the Sample Arm as shown on Figure 8-88 "Cable Clamp on Arm"

Figure 8-88 Cable Clamp on Arm

6. Detach the end of the LLD coaxial cable from its connection in the arm and remove the cable from the cable clamp.

7. Remove the purple fitting of the probe tubing from the stainless steel fitting at the top of the probe as shown on Figure 8-89 "Probe Top". Support the stainless steel support tube while disconnecting the tubing to ensure it doesn’t bend.




8. Disconnect the following cables to the CCU-9000 PCB. (See Figure 8-90 "CCU Connections"):

• P15 from connector J15 (RS232 cable).

• P1 from connector J1 (Cable from the syringe pump).

• P2 from connector J2 (Cavro power cable).)

Figure 8-90 CCU Connections

9. Remove the Sample flex cable from the DC Driver PCB as shown on Figure 8-91 "DC Driver PCB Connections".


J1(Pump)

J2(Fuse Board) J15

(ControlBoard-RS232)

(Front of Board)



Figure 8-91 DC Driver PCB Connections

10. Using a 5mm Allen wrench, remove the front left mounting screw and the 277588-00 cable (GND) as shown on Figure 8-92 "Ground Cable Connection".

Figure 8-92 Ground Cable Connection

11. Using a 5mm Allen wrench, remove the rear left mounting screw and the two mounting screws on the right end of the Cavro Sample Arm Assembly.

12. Lift and remove the Cavro Sample Arm Assembly from the pylons.

Cavro Sample Arm Installation


1. If not mounted on the arm assembly, install the Sample Syringe Pump on the arm before mounting the arm. Refer to “Cavro Syringe Pump Assembly Removal/Replacement” in Chapter 7.

2. Mount the Cavro Sample Arm Assembly on the vibration isolators atop the left and center pylon assem-blies.

3. Using a 5mm Allen Wrench, insert and tighten the two right and the rear left mounting screws for the assembly. (The left mounting screws are shown on Figure 8-93 "Ground Wire and Mounting Screw".)

4. Attach the end of the ground cable to the front left mounting screw as shown in Figure 8-93 "Ground Wire and Mounting Screw" with a star washer above and below the ground connector.

SampleArm Cable

MountingScrew

GroundCable



Figure 8-93 Ground Wire and Mounting Screw

5. Connect the following cables to the CCU 9000 PCB. (See Figure 8-94 "CCU Connections".)

• P15 of the 277583-00 Cable Assembly (RS232) to J15

• P1 from the syringe pump to J1

• P2 of the Cavro power cable to J2


6. Connect the Sample Arm flex cable to the sample-side probe connector of the DC Driver PCB as shown in Figure 8-95 "DC Driver PCB Connections".

MountingScrews

GroundWire

J1(Pump)

J2(Fuse Board) J15


(Front of Board)




7. Insert the Sample probe onto the arm by sliding it on the Z Drive Rack. Orient the PCB of the Sample probe so that if faces to the right side of the Instrument as shown on Figure 8-96 "Heater Probe PCB and Heater Cable Routing".

CAUTION: Always hold the Probe by the Upper Housing. To prevent Thermistor damage, never handle the Probe by the black tube.

8. Attach the flex cable to the probe as shown in Figure 8-96 "Heater Probe PCB and Heater Cable Routing" so it will come out of the bottom of the probe cover.

Figure 8-96 Heater Probe PCB and Heater Cable Routing

9. Slide the probe tubing (with the purple tip) through the top of the probe cover.

SampleArmCable



10. Screw the purple fitting of probe tubing to the stainless steel fitting at the top of the probe as shown on Figure 8-97 "Probe Top". Hand tighten and then tighten one quarter turn with pliers. Support the stain-less steel support tube while connecting the tubing to ensure it doesn’t bend.


11. Loosen the screw holding the cable clamp on the side of the arm as shown in Figure 8-98 "Coax Cable Connection to Arm". Place the coaxial cable through the clamp cable and through the hole in the arm cover.

Figure 8-98 Coax Cable Connection to Arm

12. Slide the cable along the arm in the channel just above the bottom of the arm cover and attach it to the connector of the co-axial cable from the alidum.

13. Remove any slack in the portion of the cable in the arm cover and tighten the cable clamp to hold the cable in place on the arm.

14. Pull the excess probe tubing from above the arm while lightly pushing the probe onto the Z-rack until it bottoms out. Use a 1.5mm Allen wrench to remove the two set screws (one at the rear and one in upper left side of the probe housing) and apply a small amount of thread lock (P/N C311-0132-001) on at least four of the threads. Re-insert and tighten both set screws to secure the probe to the Z Drive Rack.

15. Slide the probe cover over the probe housing. Ensure the green wire on the probe is positioned in the notch located on the top front surface of the housing. Ensure the flex cable leading to the probe PCB is folded and exits from the bottom of the probe cover and the cable routing is as shown on Figure 8-99 "Flex Cable to Probe Assembly".




Figure 8-99 Flex Cable to Probe Assembly

16. Verify the Sample Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is run as part of the verification.


Cavro Reagent Arm Assembly Removal/Replacement

Cavro Reagent Arm Assembly Removal


1. Remove the Top Skin, Center Skin, Upper Skin (Reagent side), Inner Right Skin, and the interior Reagent Module skins as described in “Removal/Replacement Procedures” in Chapter 4.

2. Lift the probe cover from the probe housings on both arms.

3. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probe and remove the Sample Probe from the Z-rack.

4. Remove the flex cable from the Sample Probe PCB.

5. Use a Phillips head screwdriver to loosen the cable clamp holding the LLD coaxial cable to the Sample Arm as shown on Figure 8-88 "Cable Clamp on Arm"

Probe CableRouting



Figure 8-100 Cable Clamps

6. Detach the end of the LLD coaxial cables from their connection in the arms and remove the cable from the cable clamp.

7. Remove the purple fittings of the probe tubing from the stainless steel fittings at the top of the probes.

8. Remove the flex cable from the probes.

9. Disconnect the following cables to the CCU-9000 PCB. (See Figure 8-101 "CCU Connections"):

• P15 from connector J15 (RS232 cable.)

• P1 from connector J1 (Cable from the syringe pump.)

• P2 from connector J2 (Cavro power cable.)


10. Remove both Reagent flex cables from the DC Driver PCB as shown on Figure 8-102 "DC Driver PCB Connections".

Left Reagent Arm (R1) Clamp Right Reagent Arm (R2) Clamp

J1(Pump)

J2(Fuse Board) J15


(Front of Board)




11. Using a 5mm Allen wrench, remove the front right mounting screw and the 277588-00 cable (GND).

Figure 8-103 Ground Cable Connection

12. Using a 5mm Allen wrench, remove the rear left mounting screw and the two mounting screws on the left end of the Cavro Reagent Arm Assembly.

13. Lift and remove the Reagent arm assembly from the pylons.

Cavro Reagent Arm Assembly Installation


1. If not mounted on the arm assembly, install the Reagent Syringe Pumps on the arm before mounting the arm. Refer to “Reagent Cavro Syringe Pump Installation” in Chapter 7 or “Reagent Hamilton Syringe Pump Installation” in Chapter 7.

2. Mount the Cavro Reagent Arm assembly to the right and center pylon assemblies atop the vibration iso-lators.

ReagentArm 1

ReagentArm 2

MountingScrew

GroundCable

MountingScrew

Rear

Front



3. Using a 5mm Allen Wrench, insert and tighten the two right and the rear right mounting screws for the assembly. (Right mounting screws are shown on Figure 8-104 "Cavro Reagent Ground Wire, Mount-ing Screws".

4. Attach the end of the ground cable to the front left mounting screw as shown in Figure 8-104 "Cavro Reagent Ground Wire, Mounting Screws" with a star washer above and below the ground connector.

Figure 8-104 Cavro Reagent Ground Wire, Mounting Screws

5. Connect the following cables to the CCU 9000 PCB (see Figure 8-105 "CCU Connections"):

• Connect P15 of the 277583-00 Cable Assembly (RS232) to J15

• Attach P1 from the syringe pumps to J1

• Connect P2 of the 277511-00 Cavro Power Cable to J2

Reagent Ground Wire MountingScrews




6. Connect the reagent flex cables to the reagent probe connector of the DC Driver PCB as shown in Fig-ure 8-106 "DC Driver PCB Connections".

NOTE: Do not cross the cables. This means the R1 cable goes on the board connector labeled R2 and vice versa.


J1(Pump)

J2(Fuse Board) J15


(Front of Board)

ReagentArm 1

ReagentArm 2

SampleArm



CAUTION: Always hold the Probe by the Upper Housing. To Prevent Thermistor damage, never handle the Probe by the black tube.

7. Insert the Reagent probes on each of the arms by sliding it on to the Z Drive Rack. Orient the PCB of the probe so that if faces to the right side of the Instrument as shown on Figure 8-107 "Probe Orienta-tion".

Figure 8-107 Probe Orientation

8. For the right arm:

• Insert the probe tubing through the top of the probe cover. Support the stainless steel support tube while connecting the tubing to ensure it doesn’t bend.

• Screw the purple fitting of the probe tubing to the stainless steel fitting at the top of the probe as shown on Figure 8-97 "Probe Top". Hand tighten and then tighten with pliers one quarter turn.

Figure 8-108 Probe Top Connections

LLD

Clamp Screw

Cable Clamp

Probe Tubing Fitting

Sensing Cable



• Connect the flex cable to the probe as shown in Figure 8-96 "Heater Probe PCB and Heater Cable Routing" so it will exit the bottom of the probe housing.

Figure 8-109 R2 Heater Probe PCB and Cable Routing

• Remove the screw holding the cable clamp on the side of the arm as shown in Figure 8-110 "Coax Cable Connection to R2". Place the coaxial cable through the clamp cable and through the hole in the arm cover.

Figure 8-110 Coax Cable Connection to R2

• Slide the cable along the arm in the channel just above the bottom of the arm cover and attach it to the connector of the co-axial cable from the alidum.

• Tighten the cable clamp to hold the cable in place on the arm.

• Pull the excess probe tubing from above the arm while lightly pushing the probe into the Z-rack until it bottoms out. Use a 1.5mm Allen wrench to remove the two set screws (one at the rear and one in upper left side of the probe housing) and apply a small amount of thread lock (P/N C311-0132-001) on at least four of the threads. Tighten both set screws to secure the probe to the Z Drive Rack.

• Slide the probe cover over the probe housing. Ensure the green wire on the probe is positioned in the notch located on the top front surface of the housing. Ensure the flex cable leading to the probe PCB is folded and exits from the bottom of the probe cover and the cable routing is as shown on Fig-ure 8-111 "R2 Flex Cable to Probe Assembly".



Figure 8-111 R2 Flex Cable to Probe Assembly

For the left arm:

• Insert the probe tubing through the top of the probe cover. Support the stainless steel support tube while connecting the tubing to ensure it doesn’t bend.

• Screw the purple fitting of probe tubing to the stainless steel fitting at the top of the probe as shown on Figure 8-112 "Probe Top". Hand tighten and then tighten with pliers one quarter turn.


• Feed the flex cable through the cable guide on top of the probe cover, over the top of the probe heater board as shown on Figure 8-113 "Flex Cable Routing for Left Reagent Arm", and connect it to the probe heater board. Slide the probe cover over the probe housing. Ensure the green wire on the probe is positioned in the notch located on the top front surface of the housing. The resulting cable routing should look as shown on Figure 8-114 "Left Reagent Arm Flex Cable".

Flex Cable ExitsFrom Bottom ofProbe Cover

Fitting for Probe Tubing



Figure 8-113 Flex Cable Routing for Left Reagent Arm

Figure 8-114 Left Reagent Arm Flex Cable

• Remove the screw holding the cable bracket on the top of the probe as shown on Figure 8-115 "Cable Bracket Screw".

Figure 8-115 Cable Bracket Screw

• Place the LLD coaxial cable in the bracket channel so that it exits the under the bracket as shown in Figure 8-116 "Reagent Left Arm LLD Cable". Reinsert and tighten the cable bracket screw.

Cable Guide

Cable Bracket Screw

Cable Bracket



Figure 8-116 Reagent Left Arm LLD Cable

• Remove the screw holding the cable clamp on the side of the arm as shown in Figure 8-98 "Coax Cable Connection to Arm". Place the coaxial cable through the clamp and through the hole in the arm cover.

Figure 8-117 Coax Cable Connection to Left Reagent Arm

• Slide the cable along the arm in the channel just above the bottom of the arm cover and attach it to the connector of the co-axial cable from the alidum.

• Remove any excess cable in the channel of the arm cover and tighten the cable clamp to hold the cable in place on the arm.

• Pull the excess probe tubing from above the arm while lightly pushing the probe into the Z-rack until it bottoms out. Use a 1.5mm Allen wrench to remove the two set screws (one at the rear and one in upper left side of the probe housing) and apply a small amount of thread lock (P/N C311-0132-001) on at least four of the threads. Re-insert and tighten both set screws to secure the probe to the Z Drive Rack.

9. Verify the Reagent Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is run as part of the verification.


Cable ClampLLD CoaxialCable



Individual Cavro Arm Removal/Replacement

CAUTION: Ensure the instrument is powered OFF before performing the following procedure.

To access the individual Cavro arms follow steps 1-7 of "Cavro Sample Arm Removal" for the Sample side or steps 1-8 of "Cavro Reagent Arm Assembly Removal" for the Reagent side.

Individual Cavro Arm Removal

1. Remove the Z rack, insulation block and Probe assembly.

2. Remove the ADRI-9 board. (See "ADRI-9 Board Removal".)

3. Remove the front ADRI-9 bracket by removing the two 2.5mm Front Bracket screws. (See Figure 8-118 "Removing the Arm".)

Figure 8-118 Removing the Arm

4. Remove the three hex screws holding the arm on to the X-slide. Remove the arm.

Individual Cavro Arm Installation

1. Install the new arm by following these directions in reverse order (Step 5 through Step 1).

2. follow steps 6-17 of "Cavro Sample Arm Installation" for the Sample side or steps 6-10 of "Cavro Reagent Arm Assembly Installation" for the Reagent side.

Hex ScrewsFront Bracket Screws



Cavro Arm Insulation Block/Cable Assembly Removal/Replacement


Insulation Block/Cable Assembly Removal

1. Remove the plastic cable binder underneath the arm(s) holding the coax cable.

NOTE: Use a small wire cutter to remove the plastic cable binder. A new cable binder is included with each replacement insulation block assembly.

2. Push the coax cable through the back-end of the arm(s) until the gold connector is visible, as shown in Figure 8-119 "ALIDUM Coax Cable", to locate the coax cable connector.

Figure 8-119 ALIDUM Coax Cable

3. Disconnect the coax cable by gently sliding back the releasing cover on the insulation block side of the gold connector. This will release the cable from the ALIDUM cable.

4. To remove the insulation block assembly, carefully pull the coax cable forward through the arm.

Insulation Block/Cable Assembly

1. Install the new insulation block and feed the cable from the front of the arm through the hole in the arm mounting block.

2. Attach the gold connector to the matching connector on the coax cable. Be sure that the connector is firmly seated.

3. Adjust the ALIDUM coax cable until all of the slack is removed from behind the arm(s).

Gold Coax Connector



CAUTION: Ensure the Alidum coax cable is not twisted or kinked.

4. Fasten the coax cable to the arm using a new plastic cable binder.

Cavro Arm Flex Cable Removal/Replacement


Cavro Arm Flex Cable Removal

1. Remove the ADRI-9 board cover.

2. Disconnect the flex cable from the ADRI-9 board by holding the connector at its ends and gently pull straight upward.

3. Open the flex cable clamp located underneath the flex cable guide (located just right of the CCU-9000).

4. Remove the four screws which hold the CCU-9000 board in place.

5. Lower the CCU-9000 board approximately 2 cm.

6. Disconnect the flex cable from the CCU-9000 board.

Cavro Arm Flex Cable Installation

1. Remove old cable noting how it is routed over and under the flex cable supports.

2. Inspect the new flex cable ensuring that the foam protective strip is attached to the ADRI-9 end of the cable. (See Figure 8-120 "Installing the Flex Cable".)

Figure 8-120 Installing the Flex Cable

ADRI-9 Board

Protective Strip

Flex Cable Channel

Flex Cable Connector



3. Connect the end of the flex cable with the foam protective strip to the ADRI-9 board. (See Figure 2.)

4. Run the flex cable through the flex cable channel and flex cable clamp.

5. Carefully push the connector of the flex cable onto its appropriate base on the CCU-9000 board.

6. Reattach the CCU 9000 board to the X-frame using all four allen screws.

7. Close the flex cable clamp.

CAUTION: Ensure the flex cable is not twisted or kinked and is lying flat in the flex cable channel.

8. Reattach the ADRI-9 board cover.

Cavro Arm Y- and Z-axis Optical Sensor Removal/Replacement


Y- and Z-axis Optical Sensor Removal


2. Remove the screw holding the Y-/Z-axis slotted optical sensor in place. (See Figure 8-121 "Slotted Optical Sensors".)

Figure 8-121 Slotted Optical Sensors

3. Using wire cutters, cut the plastic cable binders holding the optical sensor wires in place.

Z-Axis Slotted Optical Sensor

Encoder Wheel

Z-Axis Slotted Optical Sensor

Z-Axis Mounting Screws

Y-Axis Mounting Screws



4. Loosen the ALIDUM bracket.

5. Disconnect the slotted optical sensor connector from its base on the ADRI-9 board.

Y- and Z-axis Optical Sensor Installation

1. Run the wires of the new slotted optical sensor under the ALIDUM bracket.

2. Attach the connector of the new slotted optical sensor to its base on the ADRI-9 board.

3. Tighten the ALIDUM bracket.

4. Attach the new slotted optical sensor.

5. Replace all three cable binders ensuring that all the cables are bound together. Space the cable binders approximately 2 cm apart.

6. Reattach the ADRI-9 board cover.

Cavro Arm X-Axis Optical (SLD) Sensor Removal/Replacement


X-Axis Optical (SLD) Sensor Removal

1. Move the arm(s) to the center.

2. Remove the allen screw from the optical sensor block that is to be replaced. (See Figure 8-122 "Opti-cal Switch Block".)

Figure 8-122 Optical Switch Block

3. Remove the four screws that hold the CCU-9000 board in place.

4. Cut the plastic cable binders (using small wire cutters) that hold the slotted optical sensor wires in place.

Optical Switch Block

Slotted Optical Switches



5. Unplug the slotted optical sensor connector from its base on the CCU-9000 board.

6. Pull the optical sensor block and the slotted optical sensor away from the X-frame.

7. Remove the allen screw holding the slotted optical sensor to the optical sensor block.

X-Axis Optical (SLD) Sensor Installation

1. Attach the new slotted optical sensor to the optical sensor block.

2. Feed the wires of the slotted optical sensor through the hole in the top of the X-frame. (Located by the X-axis motors.)

3. Guide the optical sensor block back into its original position.

4. Attach the optical sensor connector into the appropriate connection on the CCU- 9000 board.

5. Secure the loose wires of the optical sensor (using the plastic wire binders included) with the other wires underneath the X-frame.

6. Reinstall the CCU-9000 board.

CAUTION: Ensure no wires or cables leading to the Cavro Arm unit are creased or twisted. Ensure the slotted optical sensor is not touching the encoder wheel.

7. Reinstall the optical sensor block.

Cavro Arm ALIDUM Removal/Replacement


ALIDUM Removal


2. Remove the ALIDUM bracket.

NOTE: Notice how the optical sensor wires run underneath the ALIDUM bracket.

3. Carefully unseat the ALIDUM from the ADRI-9 board.

NOTE: Only Lift up on the ALIDUM until the pins are free from the ADRI-9 board.

4. Trace the coax wire from the ALIDUM to the gold connector.



5. Disconnect the ALIDUM from the coax cable by separating the gold connectors. (See Figure 8-123 "ALIDUM Coax Cable".)

Figure 8-123 ALIDUM Coax Cable

6. Discard the old ALIDUM.

ALIDUM Installation

Install the ALIDUM by following the "ALIDUM Removal" directions in reverse order (Step 5 through Step 1).

Gold Coax Connector



Cavro Arm ADRI-9 Board Removal/Replacement


ADRI-9 Board Removal


2. Disconnect all cables from the ADRI-9 board (See Figure 8-124 "Diagram of the ADRI-9 Board").

NOTE: Document where the cables connect to the ADRI-9 board. Remember to disconnect the ALIDUM cable.

Figure 8-124 Diagram of the ADRI-9 Board

3. Remove the four hexagon spacers from the ADRI-9 board.

4. Remove the ADRI-9 board.

NOTE: Do not try to lift the ADRI-9 board straight up. Turn the board a little to the left or right and then lift.



ADRI-9 Board Installation

1. Install the new ADRI-9 board by following the "ADRI-9 Board Removal" directions in reverse order (Step 4 through Step 1).

CAUTION: Ensure the red SW 1-4 switches on the new ADRI-9 board are set in the same positions as on the ADRI-9 board that was removed. The arms will not function properly if the switches are set in the wrong position. (See Figure 8-125 "SW Switches".)

Figure 8-125 SW Switches

CCU-9000 Board Removal/Replacement


CCU-9000 Board Removal

1. Remove the four screws holding the CCU-9000 board to the X-frame. Unplug all wires connected to the CCU-9000 board.

NOTE: Document where the connectors plug into the CCU-9000 board. (See Figure 8-126 "CCU-9000 Board Diagram").

2. Remove the old CCU-9000 board.

3. Place the new CCU-9000 board and reinstall the four mounting screws. Connect all wires to their appro-priate connections.



Figure 8-126 CCU-9000 Board Diagram



CAVRO Arm Belt Removal/Replacement

CAVRO Arm X-Axis Belt Removal

1. Loosen the Tensioner screw (as shown in Figure 8-127 "Tensioner Screw Location"), of the belt that is to be removed, until it is allowed to slack. These screws are located on the underside of the X-Axis chassis on the right-hand side, near the Pylon mounts.

Figure 8-127 Tensioner Screw Location

2. Remove the Z rack, insulation block and Probe assembly.

3. Remove the ADRI-9 board. (See Replacing the ADRI-9 Board on Page 8.)

4. Remove the front ADRI-9 bracket by removing its two 2.5mm screws. (See Figure 8.)

Tensioner Screws



5. Remove the two belt bracket screws (connecting the belt bracket to the Y-Axis carriage) as shown in Figure 8-128 "Belt Bracket Screw Location".

Figure 8-128 Belt Bracket Screw Location

6. Pull the bracket clear of the carriage and loosen the screw on the belt clamp to release the belt.

CAVRO Arm X-Axis Belt Installation

1. Feed the drive belt over the pulleys of the tensioner and motor pulley.

2. Ensure the belt is inserted straight in the belt clamp and close the belt by tightening clamp screws.

3. Secure the belt bracket to the carriage by replacing the two belt bracket screws as shown in Figure 8-128 "Belt Bracket Screw Location".

4. Verify that both belt tensioners' hold down screws are finger tight at this time and that all excess belt slack is removed by adjusting the tensioning screws. Do not over tighten the belt!

5. Tension the belt by pulling the pulley toward the end plate and tightening the tensioning screw until slack is entirely removed from belt. Tighten screw with torque driver to 20 in/lbs.

Belt Bracket Screws



CAVRO Arm Y-Axis Belt Removal

NOTE: A mirror may be helpful for Y-Axis arm servicing.

1. Loosen the tensioning screw (as shown in Figure 8-129 "Y-Axis Tensioning Screws") until the belt is slack.

Figure 8-129 Y-Axis Tensioning Screws

2. Remove the screw on the belt clamp (as shown in Figure 8-130 "Y-Axis Belt Clamp") to release the belt.

Figure 8-130 Y-Axis Belt Clamp

3. Remove the belt from the tensioner and motor pulleys.

CAVRO Arm Y-Axis Belt Installation

1. Feed drive belt, through the tensioner and motor pulley.

2. Ensure the belt is inserted straight in the belt clamp and close the belt by tightening the belt clamp screw as shown in Figure 8-129 "Y-Axis Tensioning Screws".

3. Tension the belt by pushing the pulley toward the end plate. Do not over tighten the belt!

4. Tighten tensioning screw.

Tensioning Screws

Belt ClampScrew


Chapter 9 – Cuvette Handling System 9 - 1

Chapter 9 –Cuvette Handling System

9-1 Overview

The Cuvette Handling System transports and handles four-well cuvettes within the ACL-TOP Instrument for blood chemistry analysis.

The Cuvette Handling System consists of six basic sub-modules:

• The Cuvette Loader Assembly

• The Cuvette Shuttle Assembly

• The Hold/Incubator #2 Assembly

• The Incubator #1 Assembly

• The Optical Reading Unit (ORU) Assembly

A four-well cuvette is moved sequentially from the Cuvette Loader to either the CTS Hold/Incubator #2 (depending on the type of analysis). Then the cuvette may be moved to Incubator #1 (again, depending on the type of analysis). From the Hold or Incubator, the cuvette is moved to the ORU, where the analysis takes place. When analysis is complete, the cuvette is moved to the Waste Shelf for disposal. Movement of the cuvettes to the various stations is accomplished by the Cuvette Shuttle Assembly.


– Cuvette Handling System 9 - 2


9

Fig

CUVETTE WASTE SHELF ASSY

Chapter 9

-2 Physical Layout

ure 9-1 "Layout of the Cuvette Handling System" shows the physical layout of the Cuvette Handling System.

Figure 9-1 Layout of the Cuvette Handling System

SHUTTLE ASSY

LOADER ASSY

CTS HOLD/INCUBATOR #2 ASSY

CHS CONTROLLER CARDLEFT POSITION

INCUBATOR #1 ASSY

OPTICAL READ UNIT ASSY



9

Fig ette Handling System.

Chapter 9


ure 9-2 "Interconnect Diagram for the Cuvette Handling System" contains the Interconnect Diagram for the Cuv

Figure 9-2 Interconnect Diagram for the Cuvette Handling System

9 - 4 Chapter 9 – Cuvette Handling System


Cuvette Shuttle Assembly

The Cuvette Shuttle Assembly transports one four-well cuvette at a time to the various submodules of the Cuvette Handling System. Figure 9-3 "The Cuvette Shuttle Assembly" shows the Cuvette Shuttle Assembly.

Figure 9-3 The Cuvette Shuttle Assembly

Cuvette Shuttle Assembly



The Cuvette Shuttle Assembly consists of several subassemblies, including the following: the Gripper Assembly, the Solenoid Assembly and the Shuttle Pivot Assembly.

Gripper Assembly

The Gripper Assembly is the mechanism that grabs and releases a single cuvette within the Cuvette Shuttle Assembly. The Gripper slides front to back within the Cuvette Shuttle Assembly via a DC stepper motor. The movement of the Gripper Assembly is limit controlled by front and rear slotted sensors. The rear sensor is a static location (end stop) and is located inside the Cuvette Shuttle Assembly (not visible from the outside); the front sensor is an adjustable position. (Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replace-ment" for information on making adjustments.) Figure 9-4 "The Gripper Assembly" shows the Gripper Assembly.

Figure 9-4 The Gripper Assembly

Solenoid Assembly

The Solenoid Assembly works in conjunction with the Gripper Assembly to allow the Gripper Arm (part of the Gripper Assembly) to grab and release a cuvette. The Solenoid Assembly is non-adjustable and con-sists of a wheel that slides on a linear rail, allowing the Gripper Assembly (when fully extended forward) to be "open" and release a cuvette. Conversely, when the Gripper Assembly is fully extended forward, and the solenoid is fired (also extended forward), the Gripper Arm returns to its default position of "closed", and grabs a cuvette. Figure 9-5 "The Solenoid Assembly" shows the Solenoid Assembly.

When the solenoid is in the default position, and the Gripper Assembly is forward of the solenoid wheel (fully extended), the Gripper is open. When the solenoid is in the default position, and the Gripper Assembly is behind the solenoid wheel (not extended), the Gripper is closed.

Gripper Assembly



Note: The default position for the solenoid is not extended (i.e., solenoid not fired). Figure 9-5 "The Solenoid Assembly" shows the solenoid in the default position.

Figure 9-5 The Solenoid Assembly

Shuttle Pivot Assembly

The Shuttle Pivot Assembly is used in coordination with the Shuttle Alignment Tool to adjust the Cuvette Handling Plane. The Cuvette Handling Plane is an imaginary horizontal plane which is defined by the bottom surface of the cuvette and extends from the Loader to the Cuvette Waste Assembly. The Cuvette Handling Plane must be adjusted to allow the Shuttle Assembly to pick and place cuvettes accurately.

Figure 9-6 "The Shuttle Pivot Assembly and the Shuttle Alignment Tool" shows the Shuttle Pivot Assembly and the Shuttle Alignment Tool.

The Shuttle Pivot Assembly consists of two adjustment (set) screws as shown in Figure 9-6 "The Shuttle Pivot Assembly and the Shuttle Alignment Tool". These set screws are used to adjust the tilt and "Z" height of the Shuttle Assembly. Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replacement" for infor-mation on using the Shuttle Pivot Assembly to adjust the Cuvette Handling Plane.

Linear RailSolenoid

Wheel

Solenoid Assembly

Shuttle Pivot Assembly



Note: The "X" and "Y" axes must also be adjusted to allow the Gripper Assembly to pick and place cuvettes accurately. Refer to "X Adjustment" to adjust the "X" axis and to "Y Adjustment" to adjust the "Y" axis.

Figure 9-6 The Shuttle Pivot Assembly and the Shuttle Alignment Tool

In addition to the three main subassemblies, the Shuttle Assembly has thermal control. For more informa-tion on thermal control in the Shuttle Assembly, refer to Chapter 12 (“Thermal Control”).

Cuvette Loader Assembly

The Cuvette Loader Assembly is made up of two main subassemblies: the Transport Deck Assembly and the Indexer Assembly. Using the two Transport Belts, the Transport Deck Assembly moves cuvette clips forward to the Indexer Assembly. The Indexer Assembly then aligns a clip of cuvettes to the number one position of the Indexer. When a cuvette clip is aligned, the Gripper Assembly grabs the individual cuvette in the number one position of the Indexer. Figure 9-7 "The Cuvette Loader Assembly" shows the Cuvette Loader Assembly.

Adjustment Screws

Shuttle Align-ment Tool



Figure 9-7 The Cuvette Loader Assembly

Transport Deck Assembly

The Transport Deck Assembly consists of a parallel belt system, which is actuated by a DC gear head motor combination that uses a drive belt. The DC motor works in conjunction with the following reflective sensors, which are shown in Figure 9-8 "The Transport Deck Sensors":

• The forward sensor is used as the load position to the Indexer Assembly. This sensor recognizesthe presence of a cuvette clip so that the Indexer Rotating Platform may be prepared with a new clipevery ten cuvettes.

• The reflective sensor at the number three cuvette clip position is used to generate a User warningwhen only two cuvette clips (20 cuvettes) remain in the Cuvette Loader Assembly. When this con-dition occurs, the operator must load more cuvette clips before the Instrument goes into a "con-trolled stop" (standy mode). (Refer to the Operator’s Manual for more information on controlledstops.)

Indexer Assembly

Transport Deck Assembly

Loader Shown in Number One Position of the Indexer

Transport Belts



Figure 9-8 The Transport Deck Sensors

Indexer Assembly

The Indexer Assembly is comprised of a Lead Screw Assembly that works in conjunction with a rotating plat-form. Within the Lead Screw Assembly, a Cuvette Pusher Assembly aids in indexing individual cuvettes to the number one position (pick-up position) of the Loader Assembly.

Figure 9-9 The Indexer Assembly

Front Sensor (#1 cuvette clip position)

Rear Sensor (#3 cuvette clip position)

RotatingPlatform

PusherAssembly

Pick-up Position for Cuvettes

Components of the Lead Screw Assembly



Pusher Assembly

The Pusher Assembly (Figure 9-9 "The Indexer Assembly") utilizes a compression spring and a slotted sensor to index, or push, the cuvettes in the "X" direction, so that the rightmost cuvette is always pushed against the inside right surface of the Indexer. The spring within the Pusher Assembly ensures that there is enough force against the cuvette so that it is in the correct position for the Gripper to grab. The sensor mounted within the Pusher Assembly indicates whether the Pusher Assembly should engage the Lead Screw to apply pressure to the cuvette (i.e., index the cuvettes to the pickup position).

The Lead Screw/Pusher Assembly also utilizes limit sensors at either end of the Lead Screw Assembly. Both limit sensors are of the slotted sensor type that control the beginning and end travel of the Lead Screw/Pusher Assembly. All movement of the Lead Screw Assembly is created using a DC gear head motor com-bination that also uses a drive belt. (All movement of the Lead Screw Assembly is in the 'X' direction.)

The other component that works in conjunction with the Lead Screw Assembly is the Cuvette Rotating Plat-form (Figure 9-10 "The Cuvette Rotating Platform (in Horizontal Down Position)"). This platform is the method by which cuvette clips are transferred from the vertical position (transport deck position) to the hor-izontal position (Indexer position).

Figure 9-10 The Cuvette Rotating Platform (in Horizontal Down Position)

The Cuvette Rotating Platform is actuated by a DC gear head motor combination via a flexible O-ring belt. The Cuvette Rotating Platform has two limit switches of the slotted sensor type. These sensors are used to indicate the two positions of the Cuvette Rotating Platform (vertical and horizontal):

• Vertical upright position – The position in which the Cuvette Rotating Platform picks up a cuvetteclip from the Transport Deck.

• Horizontal down position – This position allows horizontal cuvette indexing by the Lead ScrewAssembly.

Flexible O-ring Belt



CTS Hold and Incubator #2 Assembly

The CTS Hold/Incubator #2 Assembly is a 14-slot unheated incubator that is used to hold cuvettes during dilution. Figure 9-11 "The Incubators and the Cuvette Indexer Assemblies" shows the CTS Hold Incu-bator #2 Assembly.

The Cuvette Indexer Assemblies are mounted on top of the CTS Hold/Incubator #2 Assembly. Each Cuvette Indexer Assembly is an alignment mechanism that is used to accurately and consistently position cuvettes within the CTS Hold/Incubator #2. Figure 9-11 "The Incubators and the Cuvette Indexer Assemblies" shows the Cuvette Indexer Assembly for the CTS Hold/Incubator #2.

Figure 9-11 The Incubators and the Cuvette Indexer Assemblies

CTS Incubator #1 Assembly

The CTS Incubator #1 Assembly (PN 288168-00) is an 8-slot heated incubator. Figure 9-11 "The Incuba-tors and the Cuvette Indexer Assemblies" shows the CTS Incubator #1 Assembly.

The CTS Incubator #1 is thermal controlled. For more information on thermal control in the CTS Incubator #1, refer to Chapter 12 (“Thermal Control”).

As with the CTS Hold/Incubator #2, the Cuvette Indexer Assemblies are mounted on top of the CTS Incu-bator #1 Assembly. The Cuvette Indexer Assembly is an alignment mechanism that is used to accurately and consistently position cuvettes within the CTS Incubator #1. Figure 9-11 "The Incubators and the Cuvette Indexer Assemblies" shows the Cuvette Indexer Assembly for the CTS Incubator #1.

Optical Read Unit (ORU) Assembly

The ORU assembly is the analytical module of the Instrument, where chemical reactions take place and are analyzed for patient results. The ORU is made up of four Reader Head Subassemblies, an Emitter Subas-sembly, an Emitter Board, and a Fiber Bundle Subassembly. Figure 9-12 "The ORU Assembly" shows the ORU Assembly.

CTS Hold/Incubator #2 Assembly

Cuvette Indexer Assembly

Incubator #1 Assembly

Cuvette Indexer Assembly



Figure 9-12 The ORU Assembly

Each Reader Head has a Cuvette Indexer Assembly mounted to the top of it. The Cuvette Indexer Assem-bly performs the same function for each Reader Head that it performs for the incubators: it accurately locates and retains each cuvette within each Reader Assembly for repeatable Cuvette Shuttle picking and placing.

Each ORU includes an Emitter Subassembly, a Fiber Bundle Subassembly, and four Reader Head Subassemblies. Figure 9-13 "ORU Subassemblies" shows all of the subassemblies of the ORU.

Figure 9-13 ORU Subassemblies

Reader Head Subassemblies

Each Reader Head Subassembly is thermal controlled. For more information on thermal control in the Reader Head Subassemblies, refer to Chapter 12 (“Thermal Control”).

Each Reader Head Subassembly has a detector PCB that uses 4 detector diodes to capture reactions over time. Each detector PCB has four channels (diodes), one for each well of the cuvette.

Reader Head Assemblies

Cuvette Indexer Assemblies

EmitterSubassembly

Emitter BoardFiber Subassembly

Reader Head Subassemblies



Emitter Subassembly and Fiber Bundle Subassembly

The Emitter Assembly is mounted at the bottom of the ORU as shown in Figure 9-13 "ORU Subassem-blies". This subassembly produces the 405nm and 660nm light sources that are used to analyze the reac-tion.

The Fiber Bundle Subassembly is the mechanism that transfers both light sources to all four channels in each Reader Head Assembly. Through the use of plastic fiber optic cable, the 405nm and 660nm wave-lengths are generated at the Emitter and passed through an integrating rod located within the Fiber Bundle Subassembly, thus creating uniform light. The light source is then passed through each Reader Head Sub-assembly.

Within each Reader Head Subassembly, the light source is collimated in each of the four channels (via a collimating lens). The light source is then passed through each of the four windows of the cuvette, where the reaction takes place. Once passed through the optical window of the cuvette, each of the four detector diodes senses the reaction and reports the data back to the master controller for processing.

Sensors in the Cuvette Handling System

Cuvette Loader Sensors and How They Work

When there is no cuvette in the pick-up position for cuvettes, and there is no cuvette clip on the Loader Plat-form, the pivot table moves into the vertical position and gets the cuvette strip in the number one cuvette clip position on the Transport Deck. The Pivot Arm Down Sensor is a slotted sensor that detects when the pivot table is in the horizontal position. When the pivot table is in the horizontal position, and there is no cuvette in the pick-up position for cuvettes, the TOP software directs the pivot table to become vertical and get a cuvette clip from the number one cuvette clip position.

Note: The Front Sensor on the Transport Deck detects when the pivot table is in the horizontal position (see"Transport Deck Assembly"). The Cuvette in-slot sensor detects the presence of a cuvette in thepick-up position for cuvettes (see "Cuvette In Slot Sensor").

Cuvette Shuttle Sensors and How They Work

Shuttle Limit Sensors

The shuttle limits sensors are located on pylons at each end of the shuttle travel. The sensors are T type slotted sensors; the shuttle has a flag that enters each slot. Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replacement" for information on making adjustments.



Figure 9-14 The Left and Right End-of-limit Sensors

Gripper Limit Sensors

The gripper front and back T type sensors are enabled as the gripper moves forward (front sensor) and back (back sensor). Only the Gripper Front sensor (also known as the Cuvette Y-Axis Front Sensor) is adjustable. Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replacement" for information on making adjustments. Figure 9-15 "Sensors on the Front of the Cuvette Shuttle" shows the location of the gripper front sensor. (Note: The Gripper Back sensor, also known as the Cuvette Y-Axis Rear Sensor, is located on the back side of the Cuvette Shuttle Assembly and is shown in Figure 9-16 "Sensors on the Rear of the Cuvette Shut-tle".)

Figure 9-15 Sensors on the Front of the Cuvette Shuttle

Left End-of-Limit Sensor (on left side of chassis)

Right End-of-Limit Sensor (on right side of chassis)

Gripper Front Sensor

Shuttle Position Sensor

Cuvette In Slot Sensor



Figure 9-16 Sensors on the Rear of the Cuvette Shuttle

Cuvette In Slot Sensor

The cuvette in slot sensor is a reflective type sensor that is triggered when a cuvette in a slot is detected as the shuttle passes in front of that slot. Figure 9-15 "Sensors on the Front of the Cuvette Shuttle" shows the location of the Cuvette in Slot Sensor.

Shuttle Position Sensor

The Shuttle Position Sensor (also known as the Shuttle Position X-Axis Sensor) is a slotted sensor that detects the X-Axis alignment of cuvette slots relative to the Cuvette Shuttle. In order to move a cuvette into a slot, it is critical that the slot be properly aligned to the Cuvette Shuttle. Figure 9-15 "Sensors on the Front of the Cuvette Shuttle" shows the location of the Shuttle Position Sensor. Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replacement" for information on making adjustments to sensors.

Refer to Diagnostics later in this section for additional information on the Cuvette Shuttle sensors and their associated virtual LEDs.

Cuvette in Shuttle Sensor

The cuvette in shuttle sensor is a reflective sensor that is enabled when a cuvette is detected in the shuttle. This sensor is located on the Cuvette Shuttle PCB about half of the way back.

Board Descriptions

This section provides high-level descriptions of the PCBs in the Cuvette Handling System.

Gripper Back Sensor



Cuvette Loader PCB

• Located on the underside of the Cuvette Loader.

• Provides ability to transport cuvettes to pivot arm and to the Cuvette Shuttle.

• Interfaces to the Controller board to Provides the Drive capability to operate DC motors.

• Interfaces to optical sensors for positional feedback.

• Provides interface to reflective sensors for cuvette sensing.

Cuvette Shuttle Y-Axis PCB

• Located on the side of the Shuttle Assembly, under the Y-Axis PCB Cover.

• Provides the electrical interface to the mechanical shuttle assembly; enables the capability to trans-port cuvette strips from the Loading location to Incubator, ORU and Waste locations within the ACLTOP system.

• Interfaces the controller signals to drive a Stepper motor, fire a solenoid, and power a heater.

• Provides sensor signals to the controller from optical and reflective sensors (i.e., Gripper forwardsensor, Gripper Reverse Sensor, Module Position Sensor, Cuvette in Module Sensor and Cuvettein Shuttle Sensor).

• Includes a 12-bit Analog-to-Digital converter for thermal measurements; sends serial SPI Data tothe controller.

Cuvette Handling/Rack Handling X-Axis PCB

• Located on the floor of the chassis on the right hand side, under the plastic shield.

• Provides the electrical interface to the mechanical shuttle assembly; enables the capability to trans-port cuvette strips from the Loading location to Incubator, ORU and Waste locations within the ACLTOP system.

• Provides the ability to move the Rack Barcode Scanner Assembly to sample and reagent positionsfor Rack loading.

• Offers re-buffering of digital signals that feed through the board to, and from, the Cuvette HandlingY-Axis PCB and the Remote Traveling Interface PCB (RS-232 feed through only).

• Includes Inputs for end-of-travel optical sensors for both Cuvette Handling and Rack Handling Sub-systems,

• Supports a quadrature motor encoder interface used by the Rack handling Subsystem.

ORU Interface PCB

• Located on the bottom of the ORU Cradle Assembly.

• Interfaces with the ORU Controller board to interconnect with four detector boards and provide ther-mal regulation for each of the ORU heads.



• Accepts four 30HZ pulse width modulated signals from the controller to proportionally control theheating element on each ORU head utilizing FET drivers.

• A multiplexer on-board selects which ORU Head temperature is to be read.

• An on-board 12-bit ADC is used to convert the temperature signal from the thermistor to digital datawhich is interpreted by the ORU controller.

• Serves as a pass through for the Digital signals that interconnect the four detector boards.

ORU Detector PCB

• Located inside each ORU.

• Measures the amount of light that is emitted through patient samples during chemical reactions.

• Has four channels for analytical purposes and a reference channel that measures the raw lightsource.

• Utilizes a 16-bit ADC to provide analytical data to the ORU controller with high accuracy.

• For stability and noise immunity, voltages are re-regulated and filtered on-board.

• For signal integrity, digital signals are buffered entering and leaving the board.

ORU Emitter PCB

• The ORU Emitter PCB is a part of the Emitter Assy, located on the ORU Cradle Assy.

• Generates the 405 and 660 wavelengths that are emitted through the samples.

• Has a programmable DAC which is used to regulate the power in the LED and maintain consistentpower output on each LED (Closed Loop Control).

• Includes a hardware timer circuit as a safety device. (In the unlikely event of a software failure, theLED's are shut off to prevent burnout.)


The operation of the Cuvette Handling System can is verified by successfully moving cuvettes from the Cuvette Loader to every position in the system (i.e., CTS Hold/Incubator #2, Incubator #1, ORU, and Cuvette Waste Container). To do this, use the following steps:

1. Ensure that at least two cuvette strips are in the Transport Deck.

2. Click on the Cuvettes tab in Diagnostics.

3. Use the "Move Cuvettes" function to move 11 cuvettes from the Cuvette Loader to every position in the system (i.e., CTS Hold/Incubator #2, Incubator #1, ORU, and Cuvette Waste Container). (Note: Enter 11 in the “Number of cuvettes” field.

The "Move Cuvettes" function is in the Move Cuvette(s) Area of the Cuvettes Diagnostics tab. Refer to "Move" for information on using the "Move Cuvettes" function.




9

Th : the Shuttle area, the Waste area, and the Lo

Chapter 9

-6 Diagnostics

e diagnostics for the Cuvette Handling System are on the Cuvettes tab. The Cuvettes tab contains three main areasader area. Figure 9-17 "The Cuvettes Tab" shows the Cuvettes tab.

Figure 9-17 The Cuvettes Tab


Shuttle Area

Figure 9-18 "The Shuttle Area" shows the Shuttle area.

Figure 9-18 The Shuttle Area

Disable Shuttle Motors Button

The Shuttle motors are disabled by selecting the "Disable Shuttle Motors" button. When the Shuttle motors are disabled, the "Move Cuvettes" and "Clear All Cuvettes" functions are disabled. The Shuttle motors must be disabled when the Cuvette Shuttle is to be moved by hand to check the shuttle sensors or to remove jammed cuvettes. The "Initialize Shuttle" button re-enables the Shuttle motors.

Initialize Shuttle Button

The Cuvette Shuttle is initialized by selecting the "Initialize Shuttle" button. Initialization enables the Shuttle motors, checks the location of the cuvette slot positions, scans the slots for cuvettes, and positions the Shut-tle to pick up a new cuvette from the Cuvette Loader. The shuttle status is displayed and includes the follow-ing: Unknown (during system initialization), Ready, Not Initialized, Initializing, Error, and Busy. Initialization must be performed after clearing jammed cuvettes.

Note: The Shuttle motors cannot be disabled during Shuttle Initialization.



Cuvette Shuttle Temperature Area

The Cuvette shuttle temperature Area displays the current temperature of the Cuvette Shuttle in the Current value field and the lower, and upper, temperature limits in the Lower limit and Upper limit fields.

Move Cuvette(s) Area

The functions in the Move Cuvette(s) area may be used to move, extend, grab, or pull back cuvettes. The functions in this area are useful for fixing problems related to cuvette jamming. After clearing and repairing a cuvette jam, the positions that caused the jam should be exorcized. The Start button initiates all of these cuvette operations.

Move

The user can move cuvettes through any and all slots on the instrument. Both the direction and reuse of the same cuvette are options.

The requested operation is not executed if the Shuttle is not initialized, the Gripper is extended, or the num-ber of cuvettes to be moved is greater than zero and there is a cuvette in the shuttle.

The user can select the module(s), and position in the modules, to which the cuvette is moved. The user can select multiple positions, or all positions, in each module.

The selectable modules and positions are as follows:

If the Cuvette Waste module is not selected, the cuvette is moved through each selected position and stop at the last selected module and position, and the number of cuvettes can be set to any value from 1 through 99.

If the Cuvette Loader module is not selected, the number of cuvettes field can be set to any value from 1 through 99.

Note: Shuttle motors can not be disabled when a move is in progress.

Extend

The Extend operation moves the gripper on the cuvette shuttle into the position where it can pick up the cuvette in the slot.

Table 9-1 Selectable Modules and Positions

Module Position

Loader Not Applicable

Hold Area Positions 1-14

Incubator 2 Positions 1-8


ORU Positions 1-4

Waste Not Applicable



Note: This operation is not executed if a cuvette is present in the cuvette shuttle and the shuttle is at theCuvette Pick-up position, or there is a cuvette in the slot in front of the shuttle.

Note: It is not necessary for there to be a cuvette in the slot that is specified for this command. If the extendoperation is started, the gripper extends to its pick-up cuvette position and then retract into theCuvette Shuttle.

Grab

The Grab operation extends the gripper and closes the gripper's jaws. A cuvette is not required in the selected grab position. If the grab operation is started and the gripper is already extended, the jaws are just closed. If the grab operation is started and the gripper is not extended, the gripper is extended and then the jaws are closed.

Pullback

In the Pullback operation, the Gripper is extended, the jaws are closed, and the Gripper pulls back to move the cuvette into the Shuttle. It is recommended (but not required) that there be a cuvette in the slot that has been selected for the Pullback operation. If the pullback operation is started, the Extend and Grab opera-tions is performed, and then the Gripper pulls the cuvette into the shuttle. If the shuttle is in the Waste posi-tion, the cuvette is released when the Pullback operation is executed.

Clear All Cuvettes

Selecting the "Clear all Cuvettes" button transfers all cuvettes in CTS Hold/Incubator #2, all cuvettes in Incu-bator #1, and all cuvettes in the ORU to the Cuvette Waste Assembly.

Sensors Area

The Sensors Area contains virtual LEDs for all of the sensors in the Cuvette Handling System. When the sensor is enabled, the corresponding virtual LED turns green.

The state of each of the following sensors is shown in the Sensor Area of the Cuvettes tab:

• Shuttle left limit and Shuttle right limit – These sensors are mounted on the Right and Left OuterPylons at each end of the Shuttle Travel. The virtual LEDs for these sensors turn green when theCuvette Shuttle reaches its left or right limit.

• Gripper front and Gripper back – The Gripper Front sensor is enabled as the Gripper moves for-ward. The Gripper Back sensor is enabled as the Gripper moves backward. The virtual LED's forthe gripper front and gripper back sensors turn green when the front or back limit is reached.

• Cuvette in slot – The Cuvette in slot sensor is enabled when a cuvette placed into a slot is detectedas the shuttle passes in front of that slot. The virtual LED for the cuvette in slot sensor turns greenwhen a cuvette is detected in a slot.

• Cuvette in shuttle – The Cuvette in shuttle sensor is enabled when a cuvette is detected inside theShuttle. The virtual LED for the Cuvette in shuttle sensor turns green when a cuvette is detectedinside the shuttle.

• Shuttle position – The shuttle position sensor is a slot sensor that detects if a slot is correctlyaligned to allow a cuvette to be moved into the slot. The virtual LED for the Shuttle position sensorturns green when a correctly aligned slot is detected.



Waste Area

The Waste Area contains buttons that control the operation of the Waste Shelf (Accumulator), virtual LEDs that indicate the status of the Waste Assembly, and Sensors for the Waste Assembly. Figure 9-19 "The Waste Area" shows the Waste area.

Figure 9-19 The Waste Area

Start, Stop, and Clear Accumulator Buttons

Select the Stop button to turn off the Ultrasonic sensor for the Waste Shelf. The Ultrasonic sensor is turned off to make adjustments or to pull out the Waste Drawer, etc.

Select the Start button to turn on the Ultrasonic sensor for the Waste Shelf. This makes the Waste Shelf resume its normal operation (i.e., dumping waste cuvettes into the Waste Drawer).

Select the Clear Accumulator button to rotate the Waste Shelf to the "down" position. When the Waste Shelf is in the "down" position, the shelf is tilted to allow any cuvettes on the shelf to drop into the Waste Con-tainer.

Virtual LEDs

The upper-left portion of the Waste Area contains virtual LEDs for all of the sensors in the Waste Assembly. When the sensor is enabled, the virtual LED turns green.

The state of each of the following sensors is shown in the Waste Area of the Cuvettes tab:

• Cuvette waste inserted – This sensor indicates whether the Waste Container is inserted orremoved. The virtual LED for this sensor turns green when the Waste Container is inserted and redwhen the Waste Container is removed.

• Cuvette waste door – This sensor indicates whether the Waste Door is open or closed. The virtualLED for this sensor turns green when the Waste Door is opened.

• Accumulator up – This sensor indicates when the Accumulator is in the "up" position. (When theAccumulator is in the "up" position, the shelf is horizontal and can hold cuvettes. When the Accu-mulator is in the "down" position, the shelf is tilted down and any cuvettes on the shelf are dumpedinto the Waste Container.)



Other Sensors in the Waste Area

The Cuvette waste level field indicates the height of the waste cuvettes in the Waste Container. The Waste full limit field indicates the maximum allowable height of waste cuvettes in the Waste Container. When the waste cuvettes reach the height specified in the Waste warning limit field, a user warning is sent to the computer screen. When the waste cuvettes reach the height specified in the Waste full limit field, the Instrument goes into a “controlled stop” (standby mode). Refer to the Operator’s Manual for more informa-tion on controlled stops.

Loader Area

Figure 9-20 "The Loader Area" shows the Loader area.

Figure 9-20 The Loader Area

Initialize Loader

The Loader is initialized by clicking the “Initialize Loader” button. Loader initialization consists of the follow-ing:

1. The Transport Deck Belts are turned on until cuvette clips are transferred to the Index Pickup Position (i.e., frontmost position on the Transport Deck).

2. The Pivot Table moves from vertical to horizontal (i.e., rotates one cuvette clip to the Index position).

3. The Indexer Assembly pushes the cuvette clip against Shuttle Pick-up Position Number One.

When the Loader has finished initializing, the status message “Ready” displays as shown in Figure 9-20 "The Loader Area".

Move Indexer (Left)

Move the Indexer Assembly (in the Cuvette Loader Assembly) all the way to the left by clicking the “Move Indexer (Left)” button.



Move Indexer (Right)

Move the Indexer Assembly (in the Cuvette Loader Assembly) all the way to the right by clicking the “Move Indexer (Right)” button. If there is a cuvette strip on the Loader, it is indexed to the Number One position, where it can be picked up by the Cuvette Shuttle.

Up Pivot Arm

Move the Pivot Arm (for the Pivot Table) into the vertical position by clicking the “Up Pivot Arm” button.

Down Pivot Arm

Move the Pivot Arm (for the Pivot Table) into the horizontal position by clicking the “Down Pivot Arm” button.

Virtual LEDs in the Loader Area

The Loader Area contains virtual LEDs for all of the sensors in the Loader Assembly. When the sensor is enabled, the corresponding virtual LED turns green.

The state of each of the following sensors is shown in the Loader Area of the Cuvettes tab:

• Push cuvette – The Push Cuvette sensor is located in the Pusher Assembly. The virtual LED forthis sensor turns green when the Pusher Assembly is engaged (i.e., pushing a cuvette strip).

• Low – This is the rear sensor on the Transport Deck (see Figure 9-8 "The Transport Deck Sen-sors"). The virtual LED for this sensor turns green when the Loader is low on cuvette strips (i.e.,when three, or fewer, cuvette strips are left on the Transport Deck).

• Empty – This is the front sensor on the Transport Deck (see Figure 9-8 "The Transport Deck Sen-sors"). The virtual LED for this sensor turns red when there are no cuvette strips remaining in theLoader.

• Pivot arm up – This sensor is located in the Pivot Table. The virtual LED for this sensor turns greenwhen the Pivot Table is in the vertical position.

• Pivot arm down – This sensor is located in the Pivot Table. The virtual LED for this sensor turnsgreen when the Pivot Table is in the horizontal position.

• Indexer left limit – The virtual LED for this sensor turns green when the Indexer is in its leftmostposition. (This occurs when the Loader is full.)

• Indexer right limit – The virtual LED for this sensor turns green when the Indexer is in its rightmostposition. (This occurs when the Loader is empty.)



Cuvette Shuttle and Loader Functional Checks

Use the flowchart in Figure 9-21 "Cuvette Shuttle and Loader Troubleshooting Flowchart" for perform-ing functional tests after a component in the Cuvette Handling System is replaced or repaired. Aside from mechanical errors, Shuttle errors can occur as a result of the following:

• Improper placement of cuvettes by the Loader

• Obstructions in the cuvette path

• Faulty index bars

• Faulty cuvette clips

NOTE: If repairs are made to a specific component, follow the maintenance guidelines for the component. After a repair, leave the instrument initialized and in the READY state.

Figure 9-21 Cuvette Shuttle and Loader Troubleshooting Flowchart




Cuvette Loader Assembly Removal/Replacement

Cuvette Loader Removal

Refer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Loader Assembly the following covers must be removed: Left Skin, Inner Left Skin, Upper Skin (Sample Side), Sample Syringe Cover, Sample/Accumulator Wash/Rinse Cover, Top Skin, Front Panel, and Sample Side Robotic Arm Cover.

After the covers have been removed, do the following to remove the Loader Assembly:

1. Remove the cable J1 from P1 of the Loader PCB.

2. Remove the four screws shown in Figure 9-22 "The Cuvette Loader Assembly (seen from above and behind)", and remove the module from the Instrument. Please remember that the Loader mounting hardware is NOT captive.

Figure 9-22 The Cuvette Loader Assembly (seen from above and behind)

Loader Assembly Installation

1. Position the Loader Assembly using the alignment pin to ensure proper location.

2. Reinstall the mounting hardware previously removed.

3. Reconnect the cable J1 to P1 of the Loader PCB.

CTS Hold/Incubator #2 Removal/Replacement

NOTE:There is an error in the software that misidentifies the Incubators. Incubator 1 in the SW refers to Incubator 2 hardware. Incubator 2 in the SW refers to Incubator 1 hardware.

Screw Locations



CTS Hold/Incubator #2 Removal

Refer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the CTS Hold/Incubator #2 Assembly, the following covers must be removed: Sample Syringe Cover, Sample Accumulator/Wash Rinse Cover, and the Sample Module Cover.

After the covers have been removed, do the following to remove the CTS Hold/Incubator #2:

1. Loosen the four captive screws shown and remove the CTS Hold/Incubator #2 from the Instrument. (Note: The Captive screws are painted orange as shown in Figure 9-23 "Captive Screws on the CTS Hold/Incubator #2".)

2. Remove the cable P1 from J1 of the Incubator Heating PCB.

Figure 9-23 Captive Screws on the CTS Hold/Incubator #2

CTS Hold/Incubator #2 Installation

1. Reconnect cable P1 to J1 of the Heating PCB.

2. Position the assembly using the alignment pin to ensure proper location. (Note: The alignment pin is on the chassis.)

3. Tighten the four captive screws.

4. Refer to “Inputting Thermal Coefficients using ThermalCal” in Chapter 12 to enter the coefficients of the replacement unit.

Incubator #1 Removal/Replacement

NOTE:There is an error in the software that misidentifies the Incubators. Incubator 1 in the SW refers to Incubator 2 hardware. Incubator 2 in the SW refers to Incubator 1 hardware.

Incubator #1 Removal

Refer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Incubator #1 Assem-bly, the following covers must be removed: Reagent Syringe Cover, Reagent Accumulator/Wash Rinse Cover, Reagent Module Cover, and Peristaltic Pump Cover.

After the covers have been removed, do the following to remove the Incubator #1 Assembly:

Screw Locations



1. Loosen the four captive screws shown and remove the assembly from the unit.

2. Remove the cable P1 from J1 of the Incubator Heating PCB.

Incubator #1 Installation

1. Reconnect the cable P1 to J1 of the Incubator Heating PCB.

2. Position the assembly using the alignment pin to ensure proper location. (Note: The alignment pin is on the chassis.)

3. Tighten the four captive screws. (Note: The Captive screws are painted orange as shown in Figure 9-24 "Captive Screws on the Incubator #1".)

4. Refer to “Inputting Thermal Coefficients using ThermalCal” in Chapter 12 to enter the coefficients of the replacement unit.

Figure 9-24 Captive Screws on the Incubator #1

Optical Reading Units Cradle Assembly

Refer to “Removing the ORU Assembly” in Chapter 10 for details and instructions on ORU removal.

Cuvette Shuttle Assembly Removal/Replacement

Cuvette Shuttle Assembly Removal

Refer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Cuvette Shuttle Assembly, the following covers must be removed: Sample Syringe Cover and Sample Accumulator/Wash Rinse Cover.

Screw Locations



CAUTION: Ensure that the Instrument is powered OFF before performing the following procedure.

After the covers have been removed, do the following to remove the Cuvette Shuttle Assembly:

1. Position the Cuvette Shuttle Assembly so that it is between the Loader Assembly and the CTS Hold/Incubator #2. (Note: Ensure that the X-Axis sensor (i.e., position sensor) is not between a position flag.)

2. Remove the mounting screw, flat washer, and lock washer from the Mounting Bracket (see Figure 9-25 "The Mounting Bracket").

Figure 9-25 The Mounting Bracket

3. Carefully remove the Cuvette Shuttle Assembly from the mounting bracket so not to damage the posi-tion sensor. (It is recommended to slide the Cuvette Shuttle Assembly to the left before pulling it out of the Instrument.)

4. Remove the Shuttle Lower Strain Relief Bracket (see Figure 9-26 "The Y-Axis Adjustment and Lock-ing Screws").

5. Remove the cable from connector J6 (see Figure 9-26 "The Y-Axis Adjustment and Locking Screws").

Mounting Screw

Mounting Bracket



Figure 9-26 The Y-Axis Adjustment and Locking Screws

Cuvette Shuttle Assembly Installation

1. Connect cable P6 to connector J6 of the X-axis PCB.

2. Replace the Shuttle Lower Strain Relief Bracket.

3. Carefully position the Cuvette Shuttle Assembly on the bracket using the alignment pins taking care so as not to damage the position sensor.

4. Replace and tighten the mounting screw, flat washer, and lock washer on the Mounting Bracket.

5. Align the Cuvette Shuttle as described in "Cuvette Shuttle Y-Axis Motor Removal/Replacement".

6. Verify the operation of the Cuvette Shuttle by moving 11 cuvettes from the Cuvette Loader to every posi-tion in the system (i.e., CTS Hold Incubator #2, Incubator #1, ORU, and Cuvette Waste Container). Refer to "Adjustments/Verification" for information on how to do this.


Cuvette Shuttle Y-Axis Motor Removal/Replacement


Y-Axis Motor Removal

1. Remove the Shuttle Assembly from the ACL-TOP instrument as described in "Cuvette Shuttle Assem-bly Removal".

The Orange Thumbscrews

J6 Connector




2. Remove the Y-Axis PCB Cover by removing the four cover screws as shown in Figure 9-27 "Y-Axis PCB Cover".

Figure 9-27 Y-Axis PCB Cover

3. Disconnect all cables from the Y-Axis PCB.

4. Remove the four standoffs and remove the Y-Axis PCB. (See Figure 9-28 "Y-Axis PCB").

Figure 9-28 Y-Axis PCB

5. Remove the Motor and Shuttle Heater cables from the cable clamp on the bottom of the shuttle assem-bly, as shown on Figure 9-29 "Cables and Cable Clamp", and remove the cable ties.

Cover Y-Axis PCB

Cover screws

Y-Axis PCB

Standoffs



Figure 9-29 Cables and Cable Clamp

6. Move the Shuttle Heater cable back through the motor bracket and clear of the assembly.

7. Loosen the two socket head bracket mounting screws as shown on Figure 9-30 "Motor Bracket Mounting Screws".

8. Decrease the tension in the belt until it is slack by loosening the two adjustment screws on the Y-Axis Motor Bracket, as shown on Figure 9-30 "Motor Bracket Mounting Screws".

9. Remove the two Bracket Mounting screws and remove the Y-Axis Motor/Pulley Assy.

Figure 9-30 Motor Bracket Mounting Screws

Y-Axis Motor Installation

1. Place the new Y-Axis Motor/Pulley Assy (P/N 281855-00) on the Shuttle Assembly and finger-tighten the bracket mounting screws as shown in Figure 9-30 "Motor Bracket Mounting Screws".

Shuttle Heater Cable

Motor Cable Cable Clamp

Drive Belt

Bracket Mounting Screws

Tension Adjustment Set Screws



2. Place the drive belt on the motor pulley and turn the tension adjustment set screws until their top is even with the "ears" on the motor bracket.

3. Route the motor and heater cables through the cable clamp on the bottom of the Shuttle Assembly (See Figure 9-31 "Cables and Cable Clamp").

Figure 9-31 Cables and Cable Clamp

4. Route the Shuttle Heater cable through the opening in the motor bracket (See Figure 9-31 "Cables and Cable Clamp").

5. Ensure the cables are positioned as shown in Figure 9-32 "Cable Routing" before installing the Y-Axis Shuttle PCB.

Figure 9-32 Cable Routing

Shuttle Heater Cable

Motor Cable Cable Clamp

Drive Belt



6. Place the new Y-Axis PCB (P/N 276140-00) on the four standoffs and plug all cables into the PCB as shown on Figure 9-28 "Y-Axis PCB".

Figure 9-33 Y-Axis PCB

7. Secure the motor cable and the Shuttle Heater cable with cable ties as shown on Figure 9-34 "Com-pleted Assembly".

8. Secure the Y-Axis PCB Cover by re-installing the four cover screws as shown on Figure 9-34 "Com-pleted Assembly".

Figure 9-34 Completed Assembly

9. Install and align the Cuvette Shuttle as described in "Cuvette Shuttle Y-Axis Motor Removal/Replacement".

10. Verify the operation of the Cuvette Shuttle as described in "Cuvette Shuttle and Loader Functional Checks".

Cuvette Shuttle Solenoid Removal/Replacement

1. Remove the Shuttle Assembly from the ACL-TOP instrument as described in "Cuvette Shuttle Assem-bly Removal"

2.

Y-Axis PCB

Standoffs

Cable Ties

Cover Screws



3.

Aligning the Cuvette Shuttle

The Cuvette Shuttle must be aligned after it is removed or replaced. This section describes how to align the Cuvette Shuttle.

1. "Cuvette Shuttle Alignment Check"

2. "Z Height and Tilt Check"

3. "Y Adjustment"

4. "X Adjustment"

NOTE:A Cuvette Shuttle Alignment Check must be performed before any of the other tasks.

Cuvette Shuttle Alignment Check

1. With the Instrument powered on, select the Cuvettes tab in Diagnostics.

2. Select the “Disable Shuttle Motors” button.

3. Do the following to check the Left Limit Sensor of the Cuvette Shuttle Assembly: a) Manually move the Cuvette Shuttle Assembly all the way to the leftmost end of the Shuttle Travel.

(When the Cuvette Shuttle reaches the leftmost end of the Shuttle Travel, the virtual LED for “Shuttle Left Limit” should turn green.)

b) If the virtual LED for “Shuttle Left Limit” does not turn green, adjust the sensor bracket up or down.c) Repeat steps a and b (above) until the virtual LED for “Shuttle Left Limit” turns green.

4. Repeat steps a through c (above) for the Right Limit Sensor of the Cuvette Shuttle Assembly.

Figure 9-35 The Left and Right End-of-limit Sensors

5. Do the following to check the Shuttle Alignment Tool:

Left End-of-Limit Sensor (on left side of chassis)

Right End-of-Limit Sensor (on right side of chassis)



a) Position the Cuvette Shuttle Assembly in front of the Shuttle Alignment Tool. (The location of the Shuttle Alignment Tool is shown in Figure 9-36 "Location of the Shuttle Alignment Tool".)

b) Loosen the orange thumbscrews on the Shuttle Alignment Tool and insert the Shuttle Alignment Tool into the Cuvette Shuttle Assembly.

c) If the Shuttle Alignment Tool can not be smoothly inserted into the Cuvette Shuttle Assembly, per-form the Z Height and Tilt Check (see "Z Height and Tilt Check").

Figure 9-36 Location of the Shuttle Alignment Tool

Z Height and Tilt Check

1. Power off the Instrument.

2. Orient the Cuvette Shuttle Assembly so that the front face of the Shuttle is directly in front of the Align-ment Tool shown in Figure 9-36 "Location of the Shuttle Alignment Tool".

3. Loosen the orange thumbscrews on the Alignment Tool and attempt to insert the dowel pin (located in the center of the Alignment Tool) into the front face of the Shuttle Assembly.

4. If the dowel pin does not fit smoothly into the front face of the Shuttle Assembly, do the following:a) Loosen the Z Height and Tilt Locking Screws (see Figure 9-36 "Location of the Shuttle Align-

ment Tool").b) Adjust the Z Height and tilt by turning the Z Height and Tilt Adjustment Screws (see Figure 9-36

"Location of the Shuttle Alignment Tool"). The alignment is correct when 1) the dowel fits smoothly into the front face of the Shuttle Assembly and 2) the front face of the Alignment Tool is completely flush (perpendicular) with the mating face on the front of the Cuvette Shuttle Assembly.

c) Tighten the Z Height and Tilt Locking Screws to secure the adjustment.

5. With the Z Height and Tilt Locking Screws tightened, re-check the adjustment as follows1) The dowel should fit smoothly into the front face of the Shuttle Assembly.2) The front face of the Alignment Tool should be completely flush (perpendicular) with the mating

face on the front of the Cuvette Shuttle Assembly. (The Alignment Tool surface should not be tilted against the front surface of the Cuvette Shuttle.)

6. If the adjustment is not correct, repeat step 4 and step 5.

Shuttle Alignment Tool

Orange Thumbscrews

Z Height and Tilt Adjustment Screws

Z height and Tilt Locking Screws



NOTE:Ensure that each Z Height and Tilt Locking Screw has a lock washer, and a flat washer, assembled to it.

Figure 9-37 The Z Height and Tilt Adjustments

Y Adjustment

NOTE:The following procedure should be performed with the Instrument powered on.

1. Orient the Cuvette Shuttle Assembly so that the front face of the Shuttle is directly in front of the Cuvette Pick-up position on the Loader.

2. Loosen the Y-Axis Sensor Adjustment screw (see Figure 9-39 "The Y-Axis Adjustment and Locking Screws").

3. Turn the Turning Wheel until the front face of the Gripper Assembly is flush with the front face of a cuvette located at the Cuvette Pick-up position on the Loader Assembly. (The Turning Wheel is shown in Figure 9-38 "The Y-Axis LED and the Turning Wheel".)

4. Turn the Y-Axis Sensor Adjustment screw until the Y-Axis LED comes on with the Gripper Assembly just touching the front face of the Cuvette at the Cuvette Pick-up position. (The Y-Axis Sensor Adjustment screw is shown in Figure 9-39 "The Y-Axis Adjustment and Locking Screws". The Y-Axis LED is shown in Figure 9-38 "The Y-Axis LED and the Turning Wheel".)

Note:Turning the Y-Axis Sensor Adjustment screw in a counterclockwise direction moves theY-Axis Sensor towards the front of the Instrument.

5. After the alignment of the Y-Axis Sensor has been set, tighten the Y-Axis Adjustment Locking screw to secure the adjustment. (The Y-Axis Adjustment Locking screw is shown in Figure 9-39 "The Y-Axis Adjustment and Locking Screws".)

NOTE:Ensure that the Y-Axis Sensor Adjustment Screw has a lock washer, and a flat washer, assembled to it.

Z Height and Tilt Locking Screws

Z Height and Tilt Adjustment Screws



6. When the Y-Axis Sensor is properly adjusted, slight turns of the Y-Axis Sensor Adjustment screw makes the LED go on and off. If the adjustment is not correct, repeat step 4 and step 5.

Figure 9-38 The Y-Axis LED and the Turning Wheel

Figure 9-39 The Y-Axis Adjustment and Locking Screws

X Adjustment

NOTE:The following procedure should be performed with the Instrument powered on.

1. Place a cuvette into the first slot of CTS Hold/Incubator #2.

2. Orient the Cuvette Shuttle so that the Gripper Assembly is directly in front of the cuvette in the first slot of CTS Hold/Incubator #2.

3. Align the center of the Gripper Assembly to the center of the cuvette in the first slot of CTS Hold/Incuba-tor #2.

Y-Axis LED Turning Wheel

Y-Axis Adjustment Locking Screw

Y-Axis Sensor Adjustment Screw



4. Extend the Gripper Assembly until its front surface touches the front surface of the cuvette.

5. Do the following to establish where the X-Axis Sensor LED illuminates with respect to the Gripper Assembly:

a) Turn the X-Axis Sensor Adjustment Screw clockwise, or counterclockwise, until the X-Axis LED goes on. (The X-Axis Adjustment Screw is shown in Figure 9-40 "The X-Axis Adjustment and Locking Screws"; the X-Axis LED is shown in Figure 9-41 "LEDs on the Cuvette Shuttle Assembly".)

b) When the X-Axis LED goes on, note how far off center the Gripper Assembly is to the center of the cuvette. (Turning the X-Axis Adjustment Screw clockwise moves the Sensor towards the right; turning the X-Axis Adjustment Screw counterclockwise moves the Sensor towards the left.)

NOTE:Because the sensor is seeing two edges of a slot, the LED only stays on when in the zone of the slot. This means that if the shuttle moves in the “X” direction, from one side of the Instrument to the other, the LED illuminates for a certain distance and then shut off. This is because the sensor is off until it sees the first edge, then illuminates for the width of the slot (.50 mm), then shuts off after it sees the other edge. Knowing this, we need to establish where the other edge of the slot turns off the LED, and then note how far off center the Gripper Assembly is in relation to the center of the cuvette. These two distances need to be equal.

6. Turn the X-Axis Sensor Adjustment Screw until the two distances (see above NOTE) appear to be equal.

7. When an equal spacing has been established, tighten the X-Axis Adjustment Screw.

NOTE:Ensure that the X-Axis Adjustment Screw has a lock washer, and a flat washer, assembled to it.



Figure 9-40 The X-Axis Adjustment and Locking Screws

Figure 9-41 LEDs on the Cuvette Shuttle Assembly

After the X-Axis Sensor Adjustment is performed, do the following to verify proper alignment of both the X- and Y-Axis adjustments:

1. Power on the Instrument and select the Cuvettes tab from the Diagnostics menu.

2. Initialize the Cuvette Shuttle by clicking on the “Initialize Shuttle” button on the Cuvettes tab.

3. Fill the Transport Deck with at least three cuvette clips.

4. Using the “Move Cuvettes” function, move 25 cuvettes in the following fashion:

a) From the Loader to the respective first slots of the CTS Hold Area, Incubator #2, Incubator #1, and the ORU.

b) From the first slot of the ORU to Waste.

X-Axis Adjustment Locking Screw

X-Axis Sensor Adjustment Screw (Located behind the Locking Screw)

X-Axis LED

Y-Axis LED

Cuvette In-slot Sensor LED




NOTE:When the Cuvette Shuttle picks and places the cuvette, note where the Gripper Arm is placed within the cuvette well. The Gripper Arm should be in the center. The Gripper Arm should not hit the right inner side wall of the cuvette. If the Gripper Arm hits the right inner side wall of the cuvette, it is not be able to properly pick and place the cuvettes.

5. If the Gripper Arm does not pick cuvettes at all, or if it fails to pick and place smoothly within the cuvette well, re-adjust the X-Axis alignment.

6. If the Gripper Arm appears to be in the center but still does not pick cuvettes, re-adjust the Y-Axis align-ment.

7. If there is a gap between the cuvette front face and the Gripper front face, re-adjust the Y-Axis align-ment.


Chapter 10 – Reaction Detection 10 - 1

Chapter 10 –Reaction Detection

10-1 Overview

The ACL-TOP Reaction Detection subsystem measures turbidity (opaqueness) of the cuvette well during a clotting reaction. The Emitter PCB produces light that travels from the Emitter PCB via the Optical paths, through the cuvette wells, and onto the detector chips on the Detector PCB. At power up, electrical currents through the red and the blue LEDs are automatically adjusted so that the reference detector (on the Detector PCB) sees a pre-determined amount of light energy from each LED. These two light levels are maintained by automatic adjustment of the Emitter PCB by the Optical Reading Unit (ORU) Controller.

When a reaction occurs in a cuvette well, the cuvette well becomes more cloudy and less light is allowed to reach the detector chip.


The Reaction Detection subsystem consists of five functional components:

• ORU controller

• Emitter PCB

• Optical Paths

• Detector PCB

• Thermal regulation

NOTE: Please refer to “Physical Layout” in Chapter 9 for the physical layout aspects of reaction detection and to “Theory of Operation/Block Diagram” in Chapter 5 for informa-tion on the Level II CPU, controller PCBs, and their associated software.

ORU Controller PCB

The ORU Controller has four primary functions:

• It pulses the two light sources on the Emitter PCB at 40 Hertz, with the blue light having a 10% duty cycle and the red light having a 25% duty cycle.

• It retrieves data from the Detector PCB.

• It provides thermal regulation to the ORU heads.

• It monitors the 12V supply on the Emitter PCB.


10 - 2 Chapter 10 – Reaction Detection

The ORU Controller PCB is located in the card cage in the middle front of the instrument between the Sam-ple and Reagent modules. It is the rightmost PCB of the three PCBs in the module.

Emitter PCB

The Emitter PCB powers the red and blue LEDs that are the light source for reaction detection. The Emitter PCB also sends an analog signal back to the ORU Controller for monitoring purposes. Upon power up, there is a beam of magenta light (combination of red and blue) passing across each cuvette channel of each ORU head.

The Emitter PCB is located on the right end of the ORU Assembly.

Optical paths

There are two parts to the ACL-TOP optical path, the optical fiber path and the reference path. The optical fibers, or fiber assembly, consists of two collecting rods, one integrating rod, and 19 individual fibers of var-ious lengths. The two collecting rods gather light from the red and blue sources while the integrating rod combines the two wavelengths. The 19 individual fibers distribute the combined light to all channels of the ORU heads, the reference channel, and two spares. Obstructions, pinching, and tight bends of the fibers impede the light propagation.

The Reference path is an acrylic rod that directs light from the reference optical fiber to the reference detec-tor chip on the Detector PCB. The output of the reference path is used for automatic adjustment of the Emit-ter PCB by the Optical Reading Controller.

Detector PCB

Light passing through the reaction cuvette well enters the detector chips on the Detector PCB. The corre-sponding signals are conditioned and converted to digital format for the controller to process. Each ORU head has a detector PCB mounted within the head.

ORU Light Generation, Flow and Sensing

Figure 10-1 "ORU Light Path" shows a simplified version of the generation and flow of the light in the ORU that is used to sense reactions in the cuvettes. Note that the description does not include the reference channel, the optical and voltage feedbacks and various checking circuits that are used to ensure the accu-racy of the ORU. As shown in the figure, the generation of the light for the ORU begins with the Emitter PCB supplying voltage to the LEDs in the Emitter Block. (There are four LEDs for each of the two light sources in the Emitter Block. Each set of four LEDS are enclosed as a single light source.) The LED light outputs are filtered and focused within the Emitter Block and enter the large and small fiber bundles as red and blue light, i.e., wavelength of 405, and 671nm respectively). The large fiber bundle is used to transmit the Blue light while the small fiber bundle is used to transmit the red light. The two colored light sources enter a col-lecting rod and are combined into a magenta light in an integrating rod. From the integrating rod, the light separates into the fibers for each ORU head and is delivered through the optical fibers to the ORU head where it is used to detect reactions. After passing through the cuvette wells in the ORU head, the light is focused by lenses on the other side of the head and sensed by a sensor within the head. The output of the sensor is converted to a proportionate voltage output and used by the detector PCB to determine the reac-tion.



Figure 10-1 ORU Light Path



Thermal Regulation

Logic signals from the ORU Controller enable/disable the Field Effect Transistors (FETs) to turn on or off power to the heating pads in the ORU heads. The FETs are located on the ORU Interface PCB. Also, there is a thermal cut-off switch mounted on each ORU head to prevent run-away temperatures. Refer to “Optical Reading Unit (ORU) Cradle Thermal Regulation” in Chapter 12 for a description of thermal elements.

Interconnect Diagram

Figure 10-2 "Reaction Detection Block Diagram/Interconnections" shows the data flow throughout the components of the Optical reading Unit.



Figure 10-2 Reaction Detection Block Diagram/Interconnections



10-3 Adjustments/Verifications

Verification of the ORU assembly is accomplished through use of the verification procedures described in the following pages. The procedures are based on and use the diagnostic capabilities built into the ACL-TOP instrument.

Adjustments to the ORU assembly are included within the verification procedures that follow.

Verifying the ORU

Following is the procedure to test/verify the ORU with references to the other, more detailed procedures for testing/verifying individual ORU areas. Figure 10-3 "Overall ORU Verification" shows the overall flow of the procedure. There are two symbols used in the flowcharts to aid in navigation. The symbols and their meaning are as follow:

...Indicates a link to another flowchart

Indicates an entry from one or more other flowcharts

NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following the flowchart includes all actions required.



Figure 10-3 Overall ORU Verification

1. Open the General Log File for the instrument to verify the ORU error. (Click on System -> General Log List.

2. Power up the instrument and place it in Diagnostic mode. (Click on System Diagnostics.


ter 10 – Reaction Detection 10 - 8


3.

er

Chap

Open the Voltage tab in the diagnostics window as shown in Figure 10-4 "Voltage Tab in Diagnostics Window".

Figure 10-4 Voltage Tab in Diagnostics Window

ORU Controll

Emitter Voltages

ORU Voltages

Voltages


4. Check the ORU Controller, Emitter and ORU voltages as shown in Figure 10-4 "Voltage Tab in Diag-nostics Window" and verify that they are all within the limits shown on the screen. (Out of Limit read-ings are displayed in red.)

5. If any voltage is not within limits, refer to "Testing/Correcting Voltage Errors".

6. Open the ORU tab in the diagnostics window as shown on Figure 10-5 "ORU Tab of Diagnostic Screen".




Chap

Figure 10-5 ORU Tab of Diagnostic Screen


7. Verify that ORUs 1-4 are enabled (Green LED) as indicated on Figure 10-6 "ORUs Enabled Indica-tors Portion of Diagnostic Screen".

Figure 10-6 ORUs Enabled Indicators Portion of Diagnostic Screen

8. If all four LEDs are not lit, refer to "Enabling ORUs".

9. Ensure all ACL-TOP covers are installed and the sample and reagent doors are closed.

10. Within the Dark Readings area of the screen as shown on Figure 10-7 "Dark Readings Portion of Diagnostic Screen", click on the Start button to test the ORU dark readings and, after approximately one minute, click on the Stop button to end the test. Ensure the test is stopped before proceeding with any other tests. Verify the dark readings on each channel of each ORU are below the limit indicated on the screen. If any readings are not below the limit, refer to "Testing/Correcting Dark Readings".

Figure 10-7 Dark Readings Portion of Diagnostic Screen

11. Click on the Start button in the Reference Reading portion of the diagnostic screen as shown on Figure 10-8 "Reference Readings Portion of Diagnostic Screen". Check Min. /Max. Reference readings and ensure that they are within the limits specified on the screen. Most important, check Min. DAC and Max. DAC readings for both blue and red and verify that they are between 35 -235. Click on the Stop button before proceeding with the next test. If any readings are not within the limits, refer to "Tuning ORU Optics".

Figure 10-8 Reference Readings Portion of Diagnostic Screen

Limit(Maximum Value)



12. Using the ORU selection buttons as shown on Figure 10-9 "Optical Readings Portion of Diagnostic Screen", select each ORU individually, press the Start button, and check the value of the mean air opti-cal blanking (“Air “column) and ensure that they are within the limits specified on the screen. (The Air reading indicates the values when there is nothing in the cuvette well - except “air”. Ensure readings for Red - 671 and Blue - 405 on all 4 ORU heads are checked. Press the Stop button before proceeding with each ORU test. If any readings are not within limits, refer to "Testing/Correcting Optical Blank-ing Errors".

Figure 10-9 Optical Readings Portion of Diagnostic Screen

13. Check all cables and cable connections to the ORU and verify they have not been damaged or subject to spillage. If they have been damaged in any way, replace them.

NOTE: If the cables are to be replaced, be sure to check the board connectors to ensure they are not damaged or have spillage affecting their operation.

14. Check that the temperature readings of all four ORUs are within the upper and lower limits as specified in the temperature portion of the diagnostic screen (see Figure 10-10 "Temperature Portion of Diag-nostic Screen"). At this time, temperature controls are not replaceable items. Therefore, if the readings are not within specifications, replace the ORU as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

Figure 10-10 Temperature Portion of Diagnostic Screen



15. Clean the ORU heads, using a dry cotton swab, and wipe the channel of the ORU head from the front of the instrument to the back. Continue cleaning with clean swabs until the swab being used comes out completely clean.

16. Perform a coordinate adjust as described in “Diagnostics” in Chapter 8.17. At this point, all diagnostic tests on the ORU have passed. Perform the Air Blanking for all ORUs to

reset the reference point as stated in the following steps.

18. Click on the Start Air Blanking for all ORUs button, in the Optical readings portion of the diagnostic screen as shown in Figure 10-11 "Air Blanking of All ORUs".

Figure 10-11 Air Blanking of All ORUs

19. Upon completion of the Air Blanking (approximately 5 minutes), a message box is displayed showing the readings for each channel. Verify all readings are between 500000 and 1200000. If not, replace the ORU as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assem-bly".

20. Click on the Start Factor Diluent Blanking for all ORUs button, in the Optical readings portion of the diagnostic screen as shown in Figure 10-12 "Factor Diluent Blanking for all ORUs".

NOTE: A prompt is displayed to place a vial in position 1 of Rack R5 filled with 10mL of Factor Diluent to perform the Factor Diluent Blanking.

Air Blanking forall ORUs button



Figure 10-12 Factor Diluent Blanking for all ORUs

21. Upon completion of the Factor Diluent Blanking (approximately 30 minutes), a message box is dis-played showing the readings for each channel. Verify all readings are between 500000 and 1200000. If so, the ORU is working properly. Verify the system operation by monitoring the customer application.

22. If the Factor Diluent Blanking is not within the limits, once again clean the ORU heads with a clean dry cotton swab and wipe the channel of the ORU heads from the front of the instrument to the back. Con-tinue cleaning with clean swabs until the swab being used comes out completely clean.

23. Inspect the probe and, if necessary, clean or replace the probe.

24. Perform a coordinate adjust as described in “Diagnostics” in Chapter 8.

25. Perform the Factor Diluent Blanking again and verify all readings are between 500000 and 1200000. If so, verify the system operation by monitoring the customer application.

26. If not, replace the ORU as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

Testing/Correcting Voltage Errors

Figure 10-13 "Testing/Correcting Voltage Errors" shows the overall flow of the procedure for testing/cor-recting voltage errors.


Factor Diluent Blankingfor all ORUs button



Figure 10-13 Testing/Correcting Voltage Errors



NNOTE:Ensure voltages are checked in the following order because voltages being incorrect in one area could cause voltages to be incorrect in the following area.

1. Check the ORU controller voltages on the Voltage tab of the diagnostic screen as shown in Figure 10-14 "ORU Controller Voltages".

Figure 10-14 ORU Controller Voltages

2. Are the voltages within limits? If not, continue with step 3. If the voltages are within limits, go to step 8.

3. Check the voltages on the Fuse PCB, using a meter.

4. If the voltages are okay on the fuse board, replace the ORU controller PCB (as part of the ORU Assem-bly) as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assem-bly".

5. If the voltages on the Fuse PCB are not correct, check the power supply output voltages using a meter.

6. If the power supply output voltages are okay, replace the Fuse PCB as described in “Fuse Board Removal/Replacement” in Chapter 6.

7. If the power supply voltages are NOT okay, replace the power supply as described in “Non-adjustable Power Supply Removal/Replacement” in Chapter 6.”

8. Check the Emitter voltage on the Voltage tab of the diagnostic screen as shown in Figure 10-15 "Emit-ter Voltage Display".

Figure 10-15 Emitter Voltage Display

9. If the Emitter voltages are within limits, go to step 11.

10. If the Emitter voltages are not within limits, replace the ORU Assembly as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

11. Check the cabling and cable seating to the ORU, specifically the cabling to the Emitter Board.

12. If the cabling is okay and all cables are properly seated, replace the Emitter Assembly as described in "Removing/Installing the Emitter Assembly".

13. If the cabling is not okay, reseat any cables that need seating and/or replace all ORU cables.

14. Go to the procedure "Verifying the ORU" to verify the ORU operation as described in that procedure.



Enabling ORUs

The overall flow of the procedure for enabling ORUs is shown in Figure 10-16 "Enabling ORUs Flow-chart".




Figure 10-16 Enabling ORUs Flowchart

1. If all four ORU Enabled LEDs are not lit, click on any box without a check mark as shown in Figure 10-17 "ORU Enabling Portion of Diagnostic Screen" and click on the Save button. Verify that the green LED light indicating the ORU is enabled becomes lit.

2. If all ORUs cannot be enabled, check the log file in an attempt to determine what disabled the ORU, verify the items in the Testing/Verifying the ORU procedure and correct as necessary, recognizing that an ORU can be disabled by problems with the temperature, reference output, dark readings, voltages, or air readings. If checking and correcting any problem in these areas does not allow the ORU to be enabled, replace the ORU Assembly as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

Enabling ORUs

B

Re-enable ORU in Diagnostic mode.

Can ORU be re-enabled

Change to Operating Mode

Yes

Replace ORU

No

I

Review Error log, check for

extraordinary light. Clean head.

Change to Operating Mode

Reinitialize OK?

I

Yes

Verify System

Yes

Reinitialization OK?

No

Replace ORU

NoVerify ORU



Figure 10-17 ORU Enabling Portion of Diagnostic Screen

3. If all ORUs can be enabled, place the instrument in user mode by clicking on one of the three buttons (Sample, Reagent, and Diluent) in the upper right of the window as shown in Figure 10-18 "Sample, Reagent, Diluent Buttons".

Figure 10-18 Sample, Reagent, Diluent Buttons

4. Was an error displayed? (During conversion to user mode, the instrument is re-initialized and checks are made to ensure it is in proper operating condition.)

5. If an error was detected, review the error log to determine what error was detected and use the proce-dures in "Verifying the ORU" to analyze the error. Also, check the unit to ensure there is not excessive light on the instrument (if so, move the instrument or shield it from the light), and clean the heads by using a dry cotton swab and wiping the channel of the ORU head from the front of the instrument to the back. Continue cleaning with clean swabs until the swab being used comes out completely clean.

6. Place the instrument in diagnostic mode and then back in user mode by clicking on one of the three but-tons (Sample, Reagent, and Diluent) in the upper right of the window as shown in Figure 10-18 "Sam-ple, Reagent, Diluent Buttons" to re-initialize it.

7. Was an error displayed? If not, return to the "Verifying the ORU" and check the remaining diagnostic readings bearing in mind that the ORU was disabled by the system by one of the following:

• Air reading went below the low limit.

• Air reading went above the high limit.

• The difference between the current air reading and the stored air reading was higher than the limit.

• A detector voltage error was detected by the ORU.

8. If an error was displayed, replace the ORU Assembly as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

Testing/Correcting Dark Readings

Figure 10-19 "Testing/Correcting Dark Readings Flowchart" shows the overall flow of the procedure for Testing/Correcting Dark Readings.




Figure 10-19 Testing/Correcting Dark Readings Flowchart

1. Check the environment for excessive light, for example, bright sunlight shining directly on the unit.

2. If the light is excessive, either move the unit or shield the unit from the excessive light. Repeat the test-ing by clicking on the Start button to test the ORU dark readings and, after approximately one minute, click on the Stop button to end the test. Ensure the test is stopped before proceeding with any other tests.

3. If all dark readings on each channel of each ORU, as shown on Figure 10-20 "Dark Readings Portion of Diagnostic Screen", are now below the limit, the problem has been corrected and all steps of "Ver-ifying the ORU" should be performed to verify the ORU operation. If any reading is not below the limit, continue to step 4.

Testing/Correcting Dark Readings

C

Does instrument have extraordinary

light?Move equipment out of the light or shield it from light.

Yes

Problem resolved?

I

Check remainder of ORU diagnostic readings.

Correct as necessary.

Verify operation

No

Yes Replace ORU

No

Good grounding connections on ORU

heads?

Verify ground connections.

Yes

No



Figure 10-20 Dark Readings Portion of Diagnostic Screen

4. Remove the ORU as described in "Removing/Replacing the ORU Assembly".

5. Check the grounding on each of the four ORU heads by using a digital multimeter to measure the resis-tance between the ground wire as shown in Figure 10-21 "ORU Head Ground Connections" and anywhere on the ORU chassis plate. Resistance should be less than 0.5 ohms.

Figure 10-21 ORU Head Ground Connections

6. If any ground readings are higher than 0.5 ohms, tighten the ground screws and verify the connection until the resistance is within limits.

7. Check the remainder of the ORU diagnostic screen readings as described in "Verifying the ORU" and follow the procedure for correcting the problem.

8. If all other readings are within specification and the ground connections were the proper resistance, replace the ORU as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

9. Verify the operation of the instrument by monitoring the user application.

Ground connections for ORU headsORU Chassis Plate



Testing/Correcting Optical Blanking Errors

Figure 10-22 "Testing/Correcting Optical Blanking Errors" shows the overall flow of the procedure.


Figure 10-22 Testing/Correcting Optical Blanking Errors

1. Using a dry cotton swab, clean the ORU heads by wiping the channel of the ORU head from the front of the instrument to the back. Continue cleaning with clean swabs until the swab being used comes out completely clean.

2. Recheck the value of the mean air optical blanking as described in the Optical blankings portion of "Verifying the ORU".

Testing /Correcting Optical Blanking Errors

E

Clean ORU heads

Problem Corrected?

I

Yes

Verify ORU

Connect the ORU via the extended cables.

Remove the ORU

Inspect unit cables for damage, dirt and spills .

Damage, dirt, or spill?

Clean or Replace cables as needed.

Yes

No

Power up instrument in Diagnostic Mode.

Remove/check and, if necessary, clean Fiber

Bundle Ends (at ORU end).

Are they cracked, scratched, damaged? Spillage?

Yes

G

No

No

Tune ORU Optics.

Readings Okay Now?

Replace Emitter Block Assembly .

INo

Min./Max. Reference

Readings Okay Now?

YesG

Yes

Verify ORU.

IVerify ORU.

Replace ORU.

Replace ORU.

No



3. If the readings are now within specifications, the problem has been corrected and all steps of the "Veri-fying the ORU" procedure should be performed to verify the ORU operation.

4. If the readings are still not within specifications, the ORU should be removed as described in "Remov-ing/Replacing the ORU Assembly" and the optics should be tuned as described in the “"Tuning ORU Optics" procedure.

5. If the readings are now within specifications, the problem has been corrected and all steps of the "Veri-fying the ORU" should be performed to verify the ORU operation.

6. If the readings are still not within specification, the ORU assembly should be replaced as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

Temperature Troubleshooting

1. Check that the temperature readings for all four ORUs are within the upper and lower limits as specified in the temperature portion of the diagnostic screen Figure 10-23 "Temperature Portion of Diagnostic Screen"

Figure 10-23 Temperature Portion of Diagnostic Screen

2. At this time, temperature controls are not replaceable items. Therefore, if the readings are not within specifications, replace the failing unit as described in the procedure identified in the following table.

Table 10-1 Temperature Repair Procedures

Unit with Temperature outside range

Procedure

Incubator # 1 “Incubator #1 Removal/Replacement” in Chapter 9

Incubator # 2 “CTS Hold/Incubator #2 Removal/Replacement” in Chapter 9

ORU # 1 through # 4 "Removing/Replacing the ORU Assembly"



10-4 Diagnostics

ORU Diagnostics Tab

As shown on Figure 10-24 "ORU Diagnostic Tab", the ORU tab contains four main areas:

• The Optical Blanking area

• The Temperatures area

• The Reference Readings area

• The Dark Readings area.




Dark Readings Area

Temperature Area

Chap

Figure 10-24 ORU Diagnostic Tab

Optical Blanking Area

Reference Reading Area


Optical Blanking Area

The ORU optical blanking tests the output values of the ORU with air, i.e. an empty ORU, and with a cuvette containing Factor Diluent whose opacity is known. Using these outputs, the system measures and stores the results which are factored into measurements taken when the instrument is in non-diagnostic mode. As shown on Figure 10-25 "Optical Blanking Area of ORU Diagnostic Screen", the Optical Blanking area contains the following:

• ORU selection

• ORU status

• Optical blankings

Figure 10-25 Optical Blanking Area of ORU Diagnostic Screen

ORU Selection

The ORU Selection buttons enable the selection of an individual ORU for testing. Clicking one of the radio buttons, followed by the Start button to the right, initiates the optical blanking of the selected ORU. Clicking the Start Air Blanking button or Start Factor Diluent Blanking button causes Air or Factor Diluent blank-ing to be performed on the selected ORU

NOTE: Reference readings tests cannot be executed while performing the optical reading tests.

ORU Status

Each ORU can be enabled or disabled using the Enable buttons in the middle right of the diagnostic screen area.

The instrument automatically disables an ORU when one of the following conditions is detected for any of the ORU’s 4 channels:

• The current air reading is lower than the air reading low limit

ORU Selection

ORU Status



• The current air reading is higher than the air reading high limit

• The difference between the current air reading and the stored air reading is greater than the airreading drift limit

• A detector voltage error is reported by the ORU.

The air reading low limit is 500,000; the air reading high limit is 1,200,000; the air reading drift limit is 6%.

In normal operation, current air readings are automatically executed at the end of the cuvette shuttle mechanical initialization and every time a cuvette is removed from an ORU. Current air readings are not executed if the instrument status is DIAGNOSTICS, to avoid conflict with diagnostics tests. If the instrument status is BUSY or CONTROLLED STOP, automatic requests to disable ORU’s are processed when the RUN session is completed. Cuvettes still to be scheduled are not sent to ORU’s waiting to be disabled.

Results from ORU channels where the previous air reading was invalid (value out of range or drift detected) are flagged. When the instrument status is DIAGNOSTICS, ORU’s are not automatically disabled and an alarm is displayed.

If stored air readings are not available for an existing and enabled ORU (they have never been stored or the file cannot be read at startup), an alarm is displayed to ask the user to perform the Air Blanking and the instrument status is changed to ERROR to prevent the user from running any tests.

NOTE: Reference readings tests cannot be performed while performing blanking.

Optical Blanking

Optical blanking can be started and stopped for each wavelength and analytical channel for the selected ORU. If the ORU selection is changed, all displayed values are reset to zero. Once blanking is started, the values currently displayed on the screen are set to zero. The readings are based on 25 acquisitions or until the test is stopped.

For each wavelength (405, 671), and for each channel (1-4), the following data are displayed as shown on Figure 10-25 "Optical Blanking Area of ORU Diagnostic Screen":

• Mean (%T)

• CV (%CV)

• Absolute Absorbance (mAbs)

• Stored DiH20 Reading (Factor Diluent)

• Stored Air Reading (Air)

Lower and upper limits for air readings, which are valid for all ORU’s, channels, and wavelengths are dis-played for reference.

ORU Air Calibration

Air Blanking is performed on a selected ORU by clicking on the desired ORU radio button and clicking the “Start Air Blanking” button, or on all the ORU’s by clicking the “Start Air Blanking for all ORU's” button.

The instrument calculates the mean of 1000 readings for the ORU channel and wavelengths.

Each ORU generates eight Air Reading values, one for each wavelength and one for each of the four chan-nels.



The currently stored Air Readings values are shown in the Optical Blanking display. When the newly acquired Air Readings values are available, they can be accepted or not. If they are not accepted, the cur-rently stored Air Readings values continue to be used. If the new Air Readings values are accepted, they replace the currently stored values.

The air reading low limit is 500,000; the air reading high limit is 1,200,000; the air reading drift limit is 6%.

ORU Factor Diluent Calibration is performed on a selected ORU by enabling the desired ORU radio button (in the Optical Readings portion of the screen) and clicking the Start Factor Diluent Blanking button, or the Factor Diluent Blanking can be performed on all the ORU’s by clicking the Start Factor Diluent Blanking for all ORU's button. The instrument calculates the mean of the readings for each ORU, for all channels and wavelengths, using 10 cuvettes filled with Factor Diluent. For each head/channel/wavelength, after having calculated the mean of the replicates, the replicate having the maximum distance from the mean is dis-carded. The mean is then recalculated using the remaining 9 replicates.

When Factor Diluent Blanking has been initiated, a prompt is provided to the user to place a vial in position 1 of rack R5 filled with 10mL of Factor Diluent, and to Confirm (OK) or to Reject (Cancel) the start of the procedure. Each cuvette is automatically placed in the first selected ORU. Each cell of the cuvette is filled from the placed Factor Diluent using the following parameters.

To remove air bubbles in the cuvette, a 70% mix is performed after each dispensation. A 10 second delay is then enacted before starting ORU readings after the last dispensation and/or after moving a cuvette into the next ORU. Each ORU generates eight Factor Diluent reading values, one for each wavelength and one for each of the four channels. Each value is the mean of 100 readings. If the “All ORU’s” button was selected, the cuvette is then moved into each of the other selected ORU’s. When a cuvette has been used by all the selected ORU’s, it is moved to the cuvette waste and a new cuvette is loaded, until the proper number of cuvettes have been used.

For each ORU, channel, and wavelength, the instrument calculates the mean of the values read from each cuvette. These values are the new Factor Diluent Readings that can be accepted or rejected. If rejected, the currently stored Factor Diluent Readings values continue to be used. If accepted, the new Factor Diluent Readings values replace the currently stored values.

Temperatures Area

As shown on Figure 10-27 "Reference Readings Portion of Diagnostic Screen", the temperature, lower limit, and upper limit are displayed for each ORU head and both incubators. Refer to “Optical Reading Unit (ORU) Cradle Thermal Regulation” in Chapter 12 for detailed information on the thermal elements in the instrument.

Volume 200ml

Air gap 15ml

Transport Air gap 10ml



Figure 10-26 Temperature Area of ORU Diagnostic Screen

Reference Readings Area

The reference channel readings come from one ORU (ORU #1, the leftmost ORU). The reference readings are used with the analytical channels. The user has the ability to start and stop reference readings. For the Blue 405 wavelength, Red 671 wavelength, and for Dark, the following values are displayed after being ini-tialized when the Reference Reading test starts, as shown on Figure 10-27 "Reference Readings Portion of Diagnostic Screen".

• Minimum (Min.) reference reading

• Maximum (Max.) reference reading

• Lower Limit

• Upper Limit

Figure 10-27 Reference Readings Portion of Diagnostic Screen

For each wavelength, the following values are displayed for the DAC after being initialized when the Refer-ence Reading test starts.

• Minimum DAC value (Min. DAC)

• Maximum DAC value (Max. DAC)

NOTE: Blanking cannot be performed while performing reference readings tests.

NOTE: Blanking and reference reading tests are automatically stopped if the user starts the Fluid Precision Test.



Dark Readings

The Dark Reading is the reading of the analytical channel without the emitter and is displayed as shown on Figure 10-28 "Dark Readings.". This reading indicates the electronics (dark current) and stray light effect on the ORU light readings. Dark readings can be started and stopped for all enabled ORUs. When started, the maximum readings are reset to zero. The maximum dark reading are updated for each ORU and each channel until the test is stopped. The upper dark limit, valid for all the channels and all the ORU’s, and dis-played as “Limit”, is displayed for reference

Figure 10-28 Dark Readings.

Linearity Test Tab

The linearity diagnostic, as shown on Figure 10-29 "ORU Linearity Diagnostic" is being refined for field use and is currently only for Research and Development use.




Chap

Figure 10-29 ORU Linearity Diagnostic



Removing/Replacing the ORU Assembly

Removing the ORU Assembly

1. Turn off power to the ACL-TOP instrument.

2. To enable the removal the Optical Reading Units Cradle Assembly, remove the Reagent Syringe Cover, Reagent Accumulator/Wash Rinse Cover, Reagent Rack Cover, as described in “Removal/Replace-ment Procedures” in Chapter 4.

3. Place a table or cart that is approximately the same height as the Instrument base in front of the instru-ment.

4. Loosen the four captive retaining screws securing the ORU module as shown on Figure 10-30 "ORU Retaining Screws".

Figure 10-30 ORU Retaining Screws

NOTE: In the following steps that disconnect cables from the ORU, the cables are only to be disconnected from the ORU cradle assembly. They are not to be removed from the ACL-TOP instrument.

5. Lift the ORU module and disconnect the ribbon cables from J1 and J2 of the ORU Interface PCB as shown in Figure 10-31 "ORU Cable Connections".

ORU Retaining Screws



Figure 10-31 ORU Cable Connections

6. Remove the ribbon cable from J1 of the Emitter PCB as shown on Figure 10-31 "ORU Cable Connec-tions".

7. Remove the Power cable from J3 of the ORU Interface PCB as shown on Figure 10-31 "ORU Cable Connections".

8. Remove the ORU Assembly from the instrument and place it on the table or cart in front of the instru-ment.

9. If you are connecting the ORU to the extended cables for testing, perform the procedure “"Connecting the ORU for Testing".

Installing the ORU Assembly

1. If not previously checked, check the ORU cables for damage, dirt, and spills that may compromise their operation. If damaged, replace the cables.

2. If installing a new ORU, write down the ORU Thermal Coefficient figures from the calibration sticker on the bottom cover of the replacement ORU as shown on Figure 10-32 "Calibration Offsets".

NOTE: These figures are used in step 8 to enter the coefficients for the new ORU.

J1J2 J3

ORU Interface PCB Emitter PCB

J1



Figure 10-32 Calibration Offsets

3. If re-installing the ORU Assembly after tuning the ORU optics, remove the ORU extended cables and attach the original cables to the Backplane PCB as follow:

• Remove the extended cable from J17 of the ORU Interface PCB to J1 of the Emitter PCB.

• Remove the extended cable from J15 of the Backplane PCB to J1 of the ORU Interface PCB.

• Remove the extended cable from J16 of the Backplane PCB to J2 of the ORU Interface PCB.

• Remove the extended power cable connected to J3 of the ORU Interface PCB.

• Attach the original signal cable to J15 of the Backplane PCB

• Attach the original signal cable to J16 of the Backplane PCB

• Attach the original signal cable to J17 of the ORU Interface PCB

4. Place the ORU into the instrument while re-attaching the cables to the ORU, as shown on Figure 10-33 "ORU Backplane PCB Connections" and Figure 10-34 "ORU Cable Connections" as follow:

• Attach the signal cable from J15 of the Backplane PCB to J1 of the ORU Interface PCB

• Attach the signal cable from J16 of the Backplane PCB to J2 of the ORU Interface PCB

• Attach the signal cable from J17 of the ORU Interface PCB to J1 of the Emitter PCB

• Attach the power cable to J3 on the ORU Interface PCB



Figure 10-33 ORU Backplane PCB Connections


5. Tighten the four screws securing the ORU in the instrument as shown in Figure 10-34 "ORU Cable Connections".

J15 J16J17

ORU Interface PCB

J1

J3J2J1

Emitter PCB



Figure 10-35 ORU Retaining Screws

6. Re-install the instrument covers as described in “Removal/Replacement Procedures” in Chapter 4.

7. Apply power to the ACL-TOP instrument and enter the ORU diagnostics screen.

8. If a new ORU is being installed, enter the thermal coefficients for the ORU as described in “Inputting Thermal Coefficients using ThermalCal” in Chapter 12.

9. Verify the operation of the ORU by performing all checks in "Verifying the ORU".

10. Remove the inner covers of the Reagent area. (Reagent Syringe Cover, Reagent Accumulator/Wash Rinse Cover, and Reagent Rack Cover as described in “Removal/Replacement Procedures” in Chapter 4.)

11. Perform a coordinates check on both reagent arms as described in “Diagnostics” in Chapter 8.

12. Perform the air blankings and factor diluent blankings as described in "Verifying the ORU".

13. Re-install the inner covers of the Reagent area.

Removing/Installing the Emitter Assembly

Removing the Emitter Assembly

1. Turn off power to the ACL-TOP instrument.

2. Loosen the small fiber bundles set screw as shown in Figure 10-36 "Fiber Bundle Disconnect".

3. Remove the small fiber optic bundle from the emitter block.

CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.

4. Loosen the two large fiber bundle holder set screws as shown on Figure 10-36 "Fiber Bundle Discon-nect".

Figure 10-36 Fiber Bundle Disconnect

ORU Retaining Screws



5. Carefully pull to remove the large fiber bundle from the emitter block.


6. If this procedure was entered from the ORU test procedure, remove the extended cable connected to J1 of the Emitter PCB.

7. Using a 3mm Allen wrench, remove the two screws securing the emitter head assembly as shown on Figure 10-37 "Emitter Head Attachment Screws" and lift the emitter head from the ORU cradle assembly.

Large fiber bundleholder set screws

Small fiber bundleset screw



Figure 10-37 Emitter Head Attachment Screws

8. Using a 1.5mm Allen wrench, verify the set screw securing the small fiber bundle is in the new Emitter Assembly and loosen it to enable the insertion of the small fiber bundle.

9. Place the new Emitter Assembly and secure it using the two Allen screws. Do not fully tighten the Allen screws at this time.

10. Attach the extended cable to J1 of the Emitter PCB.

11. Insert both fiber bundles completely into the emitter head.

12. Tighten the two Allen screws on the Emitter Block assembly.


14. Slowly slide the large optic bundle out of the emitter head while watching the DAC readings being dis-played on the diagnostic screen. (Move the optic bundle in small increments and pause to allow the DAC readings to stabilize for each movement.)


15. Adjust the position of the large fiber bundle until the DAC readings are minimized. Adjust the small fiber bundle to further minimize the reading. Adjust until the DAC Readings are minimal but not below 35 (the signal is maximized). When the readings are at their lowest and acceptable (between 35 – 235), using a 1.5mm Allen wrench, secure the small fiber bundle with the fiber bundle set screw in the emitter head and the large fiber bundle with the two set screws in the fiber bundle holder.

16. Re-install the ORU as described in “"Installing the ORU Assembly" and perform all verifications as directed in that procedure.

Connecting the ORU for Testing

NOTE: All cable connectors are keyed.

Allen head screws securingemitter head.

Set screw securing small fiber bundle



Refer to Figure 10-38 "Backplane Connectors" and Figure 10-39 "ORU Cable Connections" for steps 1 through 3.

1. Remove the ORU emitter ribbon cable from J17 of backplane PCB,. Connect the extended ribbon cable (PN 277667-00) from the kit to J17 (note that the key for the cable is facing toward the front of the instrument) and connect the other end to J1 on the Emitter PCB.

2. Remove the ORU signal cable from J16 of backplane PCB. Connect the extended ribbon cable (PN 277668-01) from the kit to J16 and connect the other end to J2 on the ORU Interface PCB.

3. Remove the ORU signal cable from J15 of backplane PCB. Connect the extended ribbon cable (PN 277668-02) from the kit to J15 and connect the other end to J1 on the ORU Interface PCB.

Figure 10-38 Backplane Connectors

J15J16

J17




4. Connect the male end of the Power cable in the kit (PN 277666-00) to the power cable removed from J3 on the ORU Interface PCB as shown on Figure 10-40 "Power Cable Connection"

5. Connect the other end of the Power Cable to J3 on the ORU Interface PCB as shown on Figure 10-39 "ORU Cable Connections".

ORU Interface PCB

J1

J3J2J1

Emitter PCB



Figure 10-40 Power Cable Connection

6. Place the ORU upside down and on a stable surface as shown in Figure 10-41 "ORU Positioned For Testing".

Figure 10-41 ORU Positioned For Testing

7. Power up instrument in the diagnostics mode only. (It will automatically come up in diagnostic mode because the reagent door is open.)

CAUTION: Do not power unit up in the normal operating mode as damage to the instrument could result.

8. Refer to the procedure “"Tuning ORU Optics".

Extended power cable (male end)

Original ORU power cable



Tuning the ORU OpticsFigure 10-42 "Tuning ORU Optics" shows the overall flow of the procedure for tuning the ORU optics.


Figure 10-42 Tuning ORU Optics



Tuning ORU Optics

NOTE: It is assumed the ORU has been removed from the unit as described in the procedure "Removing/Replacing the ORU Assembly"and connected to the instrument with the extended cables as described in the procedure "Connecting the ORU for Testing". If not, perform these procedures before proceeding.

1. Ensure power to the system is OFF.

2. Check to determine if the serial number of the ACL-TOP instrument is below 05080387. If so, the instru-ment was not initially built with the bracket and cover that allows the optics to be tuned.

NOTE: This procedure assumes the new ORU fiber bundle bracket and bottom cover of the ORU has been installed (as shown in Figure 10-43 "Fiber Bundle Set Screws" and recog-nized by the fiber bundle holder for the large fiber bundle and the curved cover that allows adjustment). If not, perform the procedure "Installing the ORU Optics Alignment Kit (PN 280033-00)".

3. Using a 1.5mm Allen wrench, loosen the two set screws, as shown on Figure 10-43 "Fiber Bundle Set Screws", on the large fiber bundle holder securing the large fiber bundle.

Figure 10-43 Fiber Bundle Set Screws

4. Using a 1.5mm Allen wrench, loosen the set screw that locks the small fiber bundle in place as shown on Figure 10-44 "Fiber Bundle Disconnect".

Large fiber bundleholder set screws.

FiberBundleHolder




5. Carefully pull to remove the large and small fiber bundles from the emitter blocks.


6. Inspect the ends of the optic fiber bundles for damage (cracking, scratching, fluid leakage) dirt, dust and contaminants. If dirty or dusty, gently clean the ends of both the large and small fiber bundles, as shown in Figure 10-45 "Fiber Bundle Ends", with a clean, dry cotton swab. If the optics show damage or signs of leakage, replace the ORU as described in the procedure “"Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".

Figure 10-45 Fiber Bundle Ends

7. Insert both fiber bundles all the way into the emitter head.

Small fiberbundle

Large fiber bundle

Small Fiber Bundle

LargeFiberBundle





CAUTION: With power applied, there are potentially harmful voltages available in the ORU. Do not touch anything other than the fiber bundle.

9. Slowly slide the large optic bundle out of the emitter head while watching the DAC readings being dis-played on the diagnostic screen. (Move the optic bundle in small increments and pause to allow the DAC readings to stabilize for each movement.)


10. Adjust the position of the large fiber bundle until the DAC readings are minimized. Adjust the small fiber bundle to further minimize the reading. Adjust until the DAC Readings are minimal but not below 35 (the signal is maximized). When the readings are at their lowest and acceptable (between 35 – 235), using a 1.5mm Allen wrench, secure the small fiber bundle with the fiber bundle set screw in the emitter head and the large fiber bundle with the two set screws in the fiber bundle holder.

11. If the DAC readings are now acceptable, the adjusting and cleaning of the optical components has cor-rected the problem and the instrument should be powered off, the extended cables should be removed and the ORU re-installed as described in "Installing the ORU Assembly".

12. If the DAC readings are still too high (above 235), the adjusting and cleaning of the optical components has not corrected the problem, the instrument should be powered off, and the Emitter Assembly should be replaced as described in "Removing/Installing the Emitter Assembly".

Installing the ORU Optics Alignment Kit (PN 280033-00)

NOTE: The following assumes that the ORU has been removed from the instrument. If not, use the removal steps in “"Removing/Replacing the ORU Assembly" to remove the ORU from the instrument.

1. Remove the four screws securing the cover on the bottom of the ORU as shown in Figure 10-46 "ORU Cover Attachment Screws " and remove the cover.



Figure 10-46 ORU Cover Attachment Screws

2. Remove the set screw for the large fiber optic bundle as shown in Figure 10-47 "Fiber Bundle Discon-nect". (The new fiber bundle holder will be used to secure the large fiber bundle.)

3. Loosen the set screw for the small fiber bundle as shown in Figure 10-47 "Fiber Bundle Disconnect".


4. Carefully pull to remove the large and small fiber bundles from the emitter block.

CAUTION: Do not twist the fiber optic bundle as it may damage the fibers.

5. Remove the center cover standoff and the screw securing the ORU Interface PCB as shown in Figure Figure 10-48 "Cover Hardware Removal"

ORU CoverScrews

Large fiber bundle

Small fiber bundleSmall fiber bundle set screw.

Large fiber bundle set screw



Figure 10-48 Cover Hardware Removal

6. Using a 2.5mm Allen wrench, install the bracket, as shown in Figure 10-49 "Bracket Mounting", using the two M3x6 screws included in the kit.

Figure 10-49 Bracket Mounting

7. Insert the Large Fiber Bundle through the opening in the bracket and into the opening on the emitter block. Ensure all fiber optic cables are within the standoffs for the cover.

CAUTION: Do not twist the fiber optic bundle as it may damage the fibers.

CenterCover Standoff

ORU Interface Board Retaining Screw

Bracket Attachment Screws



8. Insert the Small Fiber Bundle into the Emitter Block.

9. Attach the new cover as shown in Figure 10-50 "New Cover Attachment".

Figure 10-50 New Cover Attachment

11. Return to the procedure “"Tuning ORU Optics" to properly adjust the focal lengths of the optical fiber

bundles.

Cover retaining screws


Chapter 11 – Rack Handling 11 - 1

Chapter 11 –Rack Handling

11-1 Overview

The Rack Handling System is responsible for recording, storing and handling of patient samples as well as recording, storing and handling of ACL-TOP Diluent and Reagent chemistries.


11 - 2 Chapter 11 – Rack Handling

11-2 Physical Layout

Figure 11-1 "Rack Handling System.", the Rack Handling System is made up of three modules/assem-blies, the Sample Module, the Reagent Module, and the Bar Code Reader assembly. The Sample Module is responsible for the storing and handling of patient samples and diluents and sensing the presence or absence of racks in the module. The Reagent Module is responsible for the storing and handling of reagents and diluents and sensing the presence or absence of racks in the module. The Bar Code Reader assembly is responsible for allowing access to only one sample or reagent rack at a time and reading the bar code labels on all racks/vials that are inserted or removed from either the sample or reagent modules.

Figure 11-1 Rack Handling System.




11

Fig k Handling System.


ure 11-2 "Rack Handling Interconnections" shows the interconnections between the various elements in the Rac

Figure 11-2 Rack Handling Interconnections



Sample Module Assembly

The Sample Module is responsible for the storing and handling of patient samples and diluents and sensing the presence or absence of racks in the module. The sample holding area accommodates a maximum of 12 sample racks and two diluent racks. Each sample rack accommodates 10 sample vials providing a total capacity of 120 samples. Each diluent rack accommodates eight diluent vials providing a total capacity of 16 diluents. Figure 11-3 "Sample Module (CTS)" shows a fully loaded sample module.

Figure 11-3 Sample Module (CTS)

Sample racks are inserted from the front of the instrument. As each rack is inserted (or removed) the bar code reader reads all bar code labels on the sample rack as explained in the Bar Code Reader Assembly section. Each rack has a protrusion on the rear that, when a rack is fully inserted, trips a sensor on a Sample Presence PCB located on the back of the sample module. Tripping the sensor on the Sample Presence PCB indicates to the system that a sample rack is present in the position and is indicated to the operator by the lighting of an LED on the keypad located below the sample rack location. The LEDs for the samples are labeled S1 through S12 corresponding to the 12 sample rack positions. The Sample PCB, along with the LED indications to the operator, is shown on Figure 11-5 "Sample Rack Sensing Indications (all posi-tions filled)".

NOTE:Special CTS racks are used for cap piercing; these rack are identified by labels having "CTS" in bold on the front of the rack.

Sample RacksDiluent Racks



Figure 11-4 Sample Racks

NOTE: Standard and CTS Sample Racks are not interchangeable.

Figure 11-5 Sample Rack Sensing Indications (all positions filled)

The diluent racks are physically different from the sample racks and accommodate 4ml, 8ml, 10ml, 15ml, 20ml, and 30ml vial sizes. The various sizes are accommodated by the addition of vial adapters. The diluent racks, like the sample racks, have a protrusion on the rear that is used to trip a sensor on the Sample PCB. Tripping the sensor indicates to the system that a diluent rack is present in the position and is indicated to the operator by the lighting of an LED on the keypad located below the sample rack location. The LEDs for the diluents are labeled D1 and D2 corresponding to the diluent rack positions.

Sample Presence PCB

The Sample Presence PCB is mounted on the rear of the Sample module and is used to sense, and indicate to the instrument and the operator, the presence of sample racks and diluent racks. The PCB contains 14 sensors, 12 for the sample racks and two for the diluent racks. The sensors for the sample racks are optical sensors whose beam is broken by the protrusion (flag) on the rear of the sample or diluent racks. The out-puts of the sensors are fed through a ribbon cable that goes to the backplane PCB and then to the Rack Controller PCB. Figure 11-6 "Sample Presence PCB" shows a Sample Presence PCB mounted on the rear of the Sample assembly.

CTS

NON CTS



ACL-T

Figure 11-6 Sample Presence PCB

Sample Flag

The sample module includes a sample flag for the bar code reader. This flag is a precisely machined cut piece of sheet metal, mounted with alignment pins, on the front underside of the sample plate as shown on Figure 11-7 "Sample Flag ". The flag has cutouts (slots) that coincide to each sample and diluent rack posi-tion. Using an optical sensor mounted on the RTI PCB on the bar code reader assembly, the slots in the flag allow the curtain opening and bar code reader to be positioned at the correct rack position. In this manner, the rack can be inserted and bar code reading can occur during loading and unloading of the sample or dilu-ent rack. Located at the bottom right corner of the Sample flag is an additional slot used for the Bar Code Reader to establish its home position when initializing or returning from a prompted task.

Figure 11-7 Sample Flag

Sample Presence PCB

Sample Flag

OP Service Manual


Reagent Module

The Reagent Module is responsible for the storing and handling of reagents and diluents and sensing the presence or absence of racks in the module. The reagent holding area accommodates a maximum of six reagent racks and one diluent rack labeled R1 through R6 and D3 respectively. The reagent rack accommo-dates six reagent vials providing a total capacity of 36 reagent vials. Each diluent rack accommodates eight diluent vials providing a total capacity of eight diluents. The reagent module accommodates stirring posi-tions in each reagent rack. Only stirring is available at position 1 and 2 (the two rear positions) of each rack. Figure 11-8 "Reagent Module" shows a fully loaded reagent module with the locations of the reagent racks and diluent rack identified.

Figure 11-8 Reagent Module

Reagent and diluent racks are inserted from the front of the instrument, similar to the sample and diluent racks. Each rack has a protrusion on the rear that, when a rack is fully inserted, trips a sensor on a Reagent Presence PCB located on the back of the reagent module. Tripping the sensor on the Reagent Presence PCB indicates to the system that a reagent rack is present in the position and is indicated to the operator by the lighting of an LED on the keypad located below the reagent rack location. The LEDs for the reagent racks are labeled D3, R1 through R6 corresponding to the diluent and six reagent rack positions. The Reagent PCB, along with the LED indications to the operator, is shown on Figure 11-9 "Reagent Rack Sensing Indicators". The Reagent Module is the same for CTS and non CTS models.

D3 R1 R2 R3 R4 R5 R6



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Figure 11-9 Reagent Rack Sensing Indicators

Reagent Presence PCB

The Reagent Presence PCB is mounted on the rear of the reagent module and is used to sense, and indi-cate to the instrument and the operator, the presence of reagent and diluent racks. The PCB contains seven sensors, six for the reagent racks and one for the diluent rack. The sensors for the reagent and diluent racks are optical sensors whose beam is broken by the protrusion (flag) on the rear of the reagent or diluent racks. The outputs of the switches are fed through a ribbon cable that goes to the backplane PCB and then to the Rack Controller PCB. Figure 11-10 "Reagent Presence PCB " shows a Reagent Presence PCB mounted on the rear of the Reagent assembly.

Figure 11-10 Reagent Presence PCB


OP Service Manual


Reagent Mounting Plate

The Reagent Module mounting plate provides stirring for the two rear positions in each reagent rack. In addi-tion, the Reagent Module mounting plate is cooled to maintain the temperature of the fluid inside the vials at 15 degrees C plus or minus 3 degrees C.

The stirring of the reagent positions is accomplished by “stirring transformers” on the Magnetic Stirrer Assembly on the bottom of the reagent module as shown on Figure 11-11 "Reagent Mounting Plate Stir-rers and Heat Sink". The transformers cause the metal stirrers in the vials to revolve and stir the fluid. In normal operation, the transformers are always supplied power. In normal operation, if a reagent container that does not require stirring is placed in these positions, the system indicates an Placement Error alarm to the operator or, in diagnostic mode, lights the stirring LED on the Fluids diagnostic tab.

Figure 11-11 Reagent Mounting Plate Stirrers and Heat Sink

Reagent Cooling with Fan Speed Controller PCB

Control of the Thermal Electric Coolers is performed by the Reagent Cooling with Fan Speed Controller PCB mounted on the right side of the reagent module as shown in Figure 11-12 "Reagent Cooling with Fan Speed Controller PCB". This PCB provides power to the Coolers when cooling is required as indi-cated by a thermal sensor (via a thermistor) located on the mounting plate. In addition to supplying power to the coolers when cooling is required, the PCB also controls the speed of the five reagent cooling fans based on input from the sensor. The PCB also monitors the temperature of the mounting plate and generates a sig-nal causing a System temperature ‘out-of-range’ indication if the temperature goes outside its range of 15 degrees C plus or minus 3 degrees C.

NOTE: Units below S/N 05070377 do not have speed control. Kit P/N 294113-00 can be used to upgrade.

NOTE: Thermistors are sealed. Units below S/N 05110442 do not have sealed thermistors. Kit P/N 277559-01 can be used to upgrade.

Stirrers

Heat Sink

Reagent Flag



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Figure 11-12 Reagent Cooling with Fan Speed Controller PCB

Reagent Flag

The reagent module includes a flag for the bar code reader. This flag, which consists of a precisely cut piece of sheet metal, is mounted, with alignment pins, on the front underside of the reagent plate as shown on Fig-ure 11-13 "Reagent Flag". The flag has precision cutouts (slots) that coincide to each sample and diluent rack position. Using an optical sensor mounted on the RTI PCB on the bar code reader assembly, the slots in the flag allow the curtain opening and bar code reader to position at the correct rack position for reagent loading and unloading.

Figure 11-13 Reagent Flag


Flag

OP Service Manual


Bar Code Reader Assembly

The Bar Code Reader assembly, as shown on Figure 11-14 "Bar Code Reader Assembly", allows access to only one sample or reagent rack at a time and reads the bar code labels on all racks that are inserted or removed from either the sample or reagent modules. The Bar Code Reader Assembly reads bar code labels on sample tubes and ACL-TOP reagent bottles when they are inserted into and removed from the ACL-TOP Sample, Reagent and Diluent racks. The ACL-TOP uses a traveling bar code reader that travels along the front of the instrument and aligns itself with the rack being inserted. By use of a curtain material that limits access to the rack where the bar code reader is positioned, the bar code reader also ensures access to one rack at a time and ensures system integrity and security.

Figure 11-14 Bar Code Reader Assembly

To provide its travel, the bar code reader is mounted on a carriage that slides within a rail across the front of the Sample and Reagent modules of the instrument. The movement is provided by the Bar Code Drive Motor and the Bar Code Drive Belt as described below. Upon being directed to a specific rack location, the bar code reader travels to that location where the curtain opening only allows access to the specific rack location selected. Included within the bar code reader assembly is an RTI PCB, as described below, con-taining the sensor for the racks.

Rack Insertion

1. A position is selected for the Bar Code Reader using either the Sample or Reagent Touch pads.

2. The Bar Code Reader moves to the selected position.

3. The Bar Code Reader reads all of the position labels and must read them all in order starting from position1. In between each position label there is a "0" label that informs the Analytical Module if that position is occupied. If the occupied position has a bar code label it is read at this time. If there is no bar code label a question mark is displayed on that position in the appropriate detail section. The last label read from the rack is the rack identifier label. Sample rack identifier labels also specify if the rack is a CTS rack.

4. The flag on the end of the rack interrupts a sensor on the presence printed circuit board. If any of these labels are not read or read out of sequence the TOP reports an alarm.



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Rack Removal

1. A position is selected for the Bar Code Reader using either the Sample or Reagent Touch pads.

2. Removing the rack from the instrument causes the flag to be removed from the sensor of the Presence printed circuit board.

3. The Analytical Module reads the identifier label and then all of the position labels from the highest posi-tion down. The rack must be completely removed from the unit.

Remote Travel Interface PCB

The rack sensor for the bar code reader is on the Remote Travel Interface (RTI) PCB. The RTI PCB is attached to the moving bar code reader as a traveling PCB that has a slotted, vertically mounted optical sen-sor mounted to it as shown on Figure 11-15 "RTI PCB". This sensor uses the slots on the Sample and Reagent Flags (sheet metal flags mounted to the bottom front of the Sample and Reagent modules) which is a slotted piece of sheet metal, previously discussed in the Sample Flag and Reagent Flag sections. This sensor optically senses each slot on both the sample and reagent flags as it passes by them. These slots, on both the sample and reagent flags, coincide with each rack location on the sample and reagent modules. Output from the sensor is provided to the X Axis PCB which drives the bar code reader motor.

Figure 11-15 RTI PCB

Bar Code Reader Travel Limit Sensors

Mounted to the curtain brackets at the left end of the sample module and the right end of the reagent module are vertically mounted sensors that establish the travel limits of the Bar Code Reader assembly. The tabs that are sensed by these sensors are shown on Figure 11-15 "RTI PCB" and are metal tabs that protrude from the RTI PCB mounting bracket. These tabs block the light source for the limit sensor mounted on the curtain bracket as shown on Figure 11-16 "Bar Code Reader Travel Limit Sensor", when the reader reaches the limit of its travel and stop the reader from moving any further in that direction. Output from the sensors is provided to the X Axis PCB which drives the bar code reader motor.

RTI PCB

OpticalSensor

Tabs for Travel Limit

OP Service Manual


Figure 11-16 Bar Code Reader Travel Limit Sensor

Bar Code Reader Drive Motor

The bar code reader drive motor is located on the right side of the bar code reader assembly and is attached to the support plate of the bar code reader. The motor is a quick start/stop two phase motor driven from the X Axis PCB. The motor moves the bar code reader via a drive belt that prevents slippage. Each end of the belt is attached to the bar code reader assembly via screws.

Bar Code Reader Encoder

The bar code reader encoder is located in the left side of the bar code reader assembly and is attached to the support plate of the bar code reader. It also acts as the left pulley for the bar code reader drive belt. The encoder functions as a “counter” and is used by the X Axis PCB to determine the slot location of the bar code reader at any given time.

Bar Code Reader Curtain

The curtain in front of the Sample and Reagent modules is mounted on two spring loaded spools at the right and left sides of the bar code reader assembly. The curtain is made up of two pieces, each piece being wrapped upon the left or right spool and is made of teflon coated fabric.


There are no adjustment procedures for the Rack Handling Assembly.

Upon completion of any replacement or modification to the instrument, the operation of the instrument should be completely verified. The extent of the verification depends on the severity, complexity, and/or fre-quency along with the individual situation. The minimum verification after servicing the Rack Handling sys-tem is to insert and remove sample, diluent, and reagent racks with barcoded tubes, cups, and vials and verify the system reads the labels correctly and the racks fit properly without interference.

Travel Limit Sensor



11-6 Diagnostics

Rack Handling Diagnostics

Figure 11-17 "SW, Covers, and Racks Diagnostic Screen" shows the diagnostic screen that includes the Rack Handling Diagnostic area. The area specific to Rack handling is identified and broken out in the follow-ing paragraphs to describe the area.




k Handling

Figure 11-17 SW, Covers, and Racks Diagnostic Screen

RacArea


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Racks area

The Left Travel and virtual LEDs, as shown on Figure 11-18 "Racks Area of Diagnostic Screen", turn green when the bar code reader is moved to its leftmost position. The Right Travel virtual LED turns green when the bar code reader is moved to its rightmost position. To verify these sensors, click the Disable Bar Code Reader Motor button and manually move the bar code reader to it left and rightmost positions. As the reader is moved, the Track virtual LED turns green when the reader passes over a track position. Clicking the Initialize Bar Code Reader Motor button restarts the bar code reader motor and moves the reader back to its home position.

Figure 11-18 Racks Area of Diagnostic Screen

Encoder Value

The encoder value of the motor is displayed in the rack area. The encoder is zeroed when moved to the home position and changes value when the reader is moved to different rack positions.

When this screen is closed, if the reader motor was manually disabled it needs to be reinitialized.

Perform Loop Back Check

A serial port loop back check with a Pass/Fail status enables the communication to the bar code reader to be tested. To perform the check, remove the cover of the bar code reader, remove the cable to the reader, attach a serial port loopback connector, and click on the “Perform Loop Back Check” to initiate the check. A portable computer with a serial port and reader diagnostics software can also be used to check the reader.

OP Service Manual


Track Buttons

Track buttons do not have a diagnostic test. If the track buttons on the Analytical Module do not function, the user has the ability to move to the track positions using the virtual buttons on the Control Module. If the Con-trol Module buttons are operational, the track buttons on the AM have a failure.

Bar Code Label Reading and Rack Detection

Reading bar code labels and detecting rack insertions do not have a diagnostic test. The reading of labels and rack presence is a normal instrument operation. To test the reading of labels, a rack should be inserted into a slot while the appropriate rack detail screen is displayed. The rack should be displayed when the rack presence is detected.

Reagent temperatures

The reagent block actual temperature, lower limit, and upper limit are displayed as shown on Figure 11-19 "Reagent Temperature Area of Diagnostic Screen".

Figure 11-19 Reagent Temperature Area of Diagnostic Screen

Stirrers

The Stirrer status is accessible under the Fluids tab as shown on Figure 11-20 "Stirring Screen"

Figure 11-20 Stirring Screen



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The following provides removal/replacement procedures for the Sample and Reagent Module Assemblies as well as the Bar Code Reader Assembly. Each replaceable part within those assemblies is described in a removal /replacement procedure.

Sample Module Assembly Removal/Replacement

Sample Module Assembly Removal (Both CTS and non-CTS models)

Perform the following steps to remove the sample module assembly. (See Figure 11-21 "Sample Assem-bly Removal".

1. To remove the Sample Module Assembly, the sample area interior skins must be removed as described in “Sample Area Interior Skins Removal/Replacement” in Chapter 4.

2. It is suggested that the Front Panel Assembly be removed for easier access as described in “Front Panel Assembly Removal/Replacement” in Chapter 4.

3. Move the bar code reader to the far right of its travel.

NOTE: Failure to move the bar code reader to the far right of its travel can result in damage to the bar code reader assembly and the sample module flag.

4. Using an Allen wrench, loosen the four orange colored cap-head screws on the sides of the Sample Module Assembly. (The screws are captive and should not be removed.)

5. Remove the ribbon cable located on the top of the Sample Presence PCB at connector P1.

6. Lift and remove the Sample Assembly. Lift the left side of the assembly higher to help slide the sample flag out.

OP Service Manual


Figure 11-21 Sample Assembly Removal

Sample Module Assembly Installation

To replace the Sample Assembly, perform the preceding removal instructions then install the assembly by performing the removal in reverse order making sure that the sample module is correctly seated on the chassis alignment pins.

Sample Presence PCB Removal/Replacement

Sample Presence PCB Removal

Perform the following steps to remove the Sample PCB.

1. Remove the Sample Module Assembly as shown in the previous procedure.

2. Remove the eight Phillips Head screws and washers securing the Sample Presence PCB to the Sample Module as shown on Figure 11-22 "Sample Presence PCB".

3. Lift and remove the Sample PCB.

Sample ModuleMountingScrews

Sample ModuleMountingScrews

CTS

Non-CTS



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Figure 11-22 Sample Presence PCB

Sample Presence PCB Installation

To replace the Sample PCB, perform the preceding removal instructions then install the PCB by performing the removal in reverse order.

Sample Flag Removal/Replacement

Sample Flag Removal

Perform the following steps to remove the Sample Flag.

1. To remove the Sample Flag, the Sample Module must be removed as previously described.

2. Remove the four Phillips head screws holding the Sample Flag as shown in Figure 11-23 "Sample Flag". (Note the alignment pins on the Sample Module and their orientation with the alignment holes in the Sample Flag.)

3. Remove the Sample Flag.

Sample Presence PCB

OP Service Manual


Figure 11-23 Sample Flag

Sample Flag Installation

To replace the Sample Flag, perform the preceding removal instructions, ensuring the alignment pins are in their respective holes, then install the flag by performing the removal in reverse order. After installing the Sample Flag, manually move the barcode reader assembly to ensure the slotted sensor on the RTI PCB clears the Sample Flag.

Reagent Module Removal/Replacement

Reagent Module Removal

Perform the following steps to remove the Reagent Module Assembly.

1. Remove the reagent area interior skins as described in “Reagent Area Interior Skins Removal/Replacement” in Chapter 4.

2. Move the bar code reader to the far left of its travel.

NOTE: Failure to move the bar code reader to the far left of its travel can result in damage to the bar code reader assembly.

3. Loosen the four orange Phillips Head screws on the sides of the reagent module as shown onFigure 11-24 "Reagent Module Screws (Left Side)"and Figure 11-25 "Reagent Module Screws (Right Side)". (The screws are captive and should not be removed.)

4. Remove the cable (J1) located on the top rear of the reagent module (on the reagent presence PCB).

Alignment Pins

Attachment Screws



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Figure 11-24 Reagent Module Screws (Left Side)

Figure 11-25 Reagent Module Screws (Right Side)

5. Remove the cables for the fans in the lower right of the Reagent Cooling with Fan Speed Controller PCB (J4, J5, J6, J7, and J8) as shown on Figure 11-26 "Reagent Cooling with Fan Speed Controller PCB Mounting".

6. Disconnect the five ground wires that connect to chassis ground.

7. Disconnect J1 (as shown on Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB") on the Reagent Cooling with Fan Speed Controller PCB.

MountingScrews(Left Side)

MountingScrews(Right Side)

OP Service Manual


8. Disconnect the Power In cable (J3) (as shown on Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB") on the Reagent Cooling with Fan Speed Controller PCB.

Figure 11-26 Reagent Cooling with Fan Speed Controller PCB Mounting

9. Disconnect the fan outputs (J4, J5, J6, J7, J8) on the Reagent Cooling with Fan Speed Controller PCB as shown in Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB". (Note that the fan out-puts can be attached to any fan even though they are labeled as attaching to a specific fan.)


10. Remove the drain tube connecting the reagent module to the waste pump at the waste pump connec-tion. Tube can be removed by pulling while twisting.

11. Carefully lift and remove the reagent module.

Reagent Cooling with Fan Speed Controller PCB J1

J3 See below.

J3J2

J5J6 J7

J1

J4

J9J8



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Reagent Module Installation

To replace the reagent module, first write down the ORU Thermal Coefficient figures from the calibration sticker on the bottom cover of the replacement ORU. Then perform the preceding removal instructions and install the module by performing the removal in reverse order. Ensure all fan and ground connections are reconnected. Failure to do so results in overheating of the TEC. Perform the procedure “Inputting Thermal Coefficients using ThermalCal” in Chapter 12 to enter the coefficients of the replacement unit

Reagent Drain Tube Removal/Replacement

ACL-TOP Units with serial numbers above XXX use the new style drain tube. Instruemnts with SN below 06030563 were manufactured with the old style drain tube and should be upgraded.

Refer to "Reagent Module Removal/Replacement" for instructions on removing and installing the Reagent Module.

Reagent Module Tubing Removal

1. Remove the Reagent Module as specified in Reagent Module Removal/Replacement in Chapter 11 of the ACL TOP Service Manual.

2. Flip the Reagent module over to expose the tubing and remove each end from its barb fitting as shown in Figure 11-28 "Barb Fittings".

Figure 11-28 Barb Fittings

3. Pull the old tubing out of the clamps and discard it.

4. Remove the single cable clamp on the Reagent Flag side of the assembly.

NOTE: The screws holding the clamps to the coupler plate may be loosened to ease removal of the tubing.

Barb Fitting Barb Fitting

OP Service Manual


Reagent Module Tubing Installation

1. Replace the cable clamp on the Reagent Flag side of the assembly with a double clamp configuration as shown in Figure 11-29 "Double Clamp Assembly".

Figure 11-29 Double Clamp Assembly

2. Connect the center tube (the 19mm tube at the "Y" base) to the barb fitting on the Reagent Flag side of the assembly.

3. Run the longer end of the tubing through the bottom clamp on the Reagent Flag side of the assembly.

4. Run the tube through the two clamps on the Magnetic Stirrer Board.

5. Insert the longer tube end of the new drain tubing assembly into the barb fitting closest to the Magnetic Stirrer Board (see Figure 11-30 "Reagent Cooler").

Figure 11-30 Reagent Cooler

Top Clamp

Bottom Clamp

Short End

Long End

“Y” Base TEC Cable Short EndDouble Clamp

Long EndSingle ClampStirrer Board



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6. Run the shorter end of the tubing through the top of the double clamp

7. Attach one Cable Clamp as shown in Figure 11-31 "Secured Tubing" and route the tubing through it.

8. Attach two Tie Wraps around black wire and both loops of the TEC Cable as shown in Figure 11-31 "Secured Tubing".

Figure 11-31 Secured Tubing

9. Reinstall the Reagent Module as specified in Reagent Module Removal/Replacement in Chapter 11 of the ACL-TOP Service Manual.

Reagent Presence PCB Removal/Replacement

Reagent Presence PCB Removal

Perform the following steps to remove the Reagent Presence PCB.

1. Remove the Reagent Module as shown in the previous procedure.

2. Remove the eight Phillips head screws and washers securing the Reagent Presence PCB to the Reagent Module as shown on Figure 11-32 "Reagent Presence PCB".

3. Lift and remove the Reagent Presence PCB.

Figure 11-32 Reagent Presence PCB

Cable ClampTie WrapTie Wrap


OP Service Manual


Reagent Presence PCB Installation

To replace the reagent PCB, perform the preceding removal instructions then install the PCB by performing the removal in reverse order.

Reagent Cooling with Fan Speed Controller PCB Removal/Replacement

Reagent Cooling with Fan Speed Controller PCB Removal

Perform the following steps to remove the Reagent Cooling with Fan Speed Controller PCB.

1. Remove the Reagent Module as described in "Reagent Module Removal/Replacement".

2. Disconnect the remaining connectors on the PCB (TEC output (J2) and the reagent cooling thermistor (J9) connectors as shown on Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB").

3. Remove the four Phillips Head screws and washers securing the Reagent Cooling with Fan Speed Con-troller PCB to the Reagent Module as shown on Figure 11-33 "Reagent Cooling with Fan Speed Controller PCB".


4. Lift and remove the Reagent Cooling with Fan Speed Controller PCB.

Reagent Cooling with Fan Speed Controller PCB Installation

To replace the Reagent Cooling with Fan Speed Controller PCB, perform the preceding removal instructions then install the PCB by performing the removal in reverse order. (Note that the fan outputs (J4, J5, J6, J7, J8) can be attached to any fan even though they are labeled as attaching to a specific fan.)

Reagent Flag Removal/Replacement

Reagent Flag Removal

Perform the following steps to remove the Reagent Flag.

1. To remove the Reagent Flag, the Reagent Module must be removed as described in "Reagent Module Removal/Replacement".

Mounting Screws




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2. Using an Allen wrench, remove the five cap head screws holding the Reagent Flag as shown in Figure 11-34 "Reagent Flag".

NOTE: When disassembling the Reagent Flag, a flexible drip shield and backing plate also comes off. Note the orientation of these parts for reassembly.

3. Remove the Reagent Flag.

Figure 11-34 Reagent Flag

Reagent Flag Installation

To replace the Reagent Flag, perform the preceding removal instructions then install the flag by performing the removal in reverse order making sure the flag is aligned on the three flag alignment pins before inserting any screws.

Bar Code Reader Assembly Removal/Replacement

Bar Code Reader Assembly Removal

Perform the following steps to remove the Bar Code Reader Assembly.

1. Remove the top and front cover as described in Section 4, Enclosures/Chassis.

2. Remove the Sample and Reagent Area interior covers as previously described in this section.

NOTE: When removing/installing the bar code reader assembly, the bar code reader must be in its home position. The bar code reader home position is when the left edge of the bar code reader’s white cover is even with the left edge of the reagent module. In its home position, the slotted sensor on the RTI PCB assembly is positioned between the Sample and Reagent flags so the sensor is not damaged when removing the bar code reader assembly. Ensure the bar code reader is aligned as shown in Figure 11-35 "Bar Code Reader Home Position".

3. Move the bar code reader to its home position (left edge of the bar code reader aligned with the left edge of the reagent module) as shown in Figure 11-35 "Bar Code Reader Home Position".

Mounting Screws

Reagent Flag

OP Service Manual


Figure 11-35 Bar Code Reader Home Position

4. Using an Allen wrench, remove the nine cap head screws securing the bar code reader assembly as shown on Figure 11-36 "BCR Mounting Screws Location". Note that the screws are in three groups of three. Each group of three forms a triangle as shown in Figure 11-37 "Mounting Screws". (The fig-ure shows the screws at the left end of the bar code reader.)

Figure 11-36 BCR Mounting Screws Location

Reagent Module Left Edge

Bar CodeReaderLeft Edge

Bar CodeReader

Bar Code ReaderMounting Screw Locations



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Figure 11-37 Mounting Screws

5. Pull the bar code reader assembly forward to release it from the alignment pins on which it rests.

6. Remove one ribbon cable and one power cable attached to the bar code reader assembly from the backplane board.

7. Remove the bar code reader assembly from the instrument.

Bar Code Reader Assembly Installation

To replace the bar code reader assembly, perform the preceding removal instructions then install the assembly by performing the removal in reverse order.

NOTE: Position the RTI PCB sensor in the proper location before re-assembling the bar code reader assembly on the instrument. Failure to do this damages the RTI sensor.

Bar Code Reader Removal/Replacement


The new Microscan Reader units have a beam angle that is oriented 5º further downward to allow the unit to read a wider range of label placements. The new covers have a wider opening and are designed to cor-rect "Ghosting" errors. A Ghosting error is caused by a reflection from the cover interfering with the trans-mission of information to the reader

Bar Code Reader Removal

1. Remove two screws on the right and one screw on the left of the bar code reader cover.

2. Disconnect the cable from the red LED in the bar code reader cover and remove the cover.

MountingScrews

OP Service Manual


3. Unplug the Barcode Scanner Interface Board from the Microscan unit as shown in Figure 11-38 "Bar-code Scanner Interface Board".

Figure 11-38 Barcode Scanner Interface Board

4. Remove the two screws from the Barcode Reader Mounting Plate as shown in Figure 11-39 "Plate Mounting Screws".

Figure 11-39 Plate Mounting Screws

Barcode Scanner Interface Board

Plate Mounting Screws



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5. Tilt the unit forward to expose the cable clamp on the rear of the plate and free the cable from the assembly as shown in Figure 11-40 "Cable Clamp".

Figure 11-40 Cable Clamp

6. Remove the two screws holding the bar code reader bracket to the bar code reader as shown on Figure 11-41 "Bar Code Reader Mounting Screws".

Figure 11-41 Bar Code Reader Mounting Screws

Bar Code Reader Installation

1. Align the Microscan unit to the plate and reinstall its mounting screws (see Figure 11-41 "Bar Code Reader Mounting Screws").

2. Align the plate to its pins on the instrument and place the cable into the clamp on the back of the plate (see Figure 11-40 "Cable Clamp").

3. Reinstall the two screws to mount the plate to the instrument (see Figure 11-39 "Plate Mounting Screws").

4. Attach the Barcode Scanner Interface Board to the Microscan unit (see Figure 11-38 "Barcode Scan-ner Interface Board").

Cable Clamp

MountingScrews

OP Service Manual


5. Connect the indicator LED cable.

6. Place the cover and replace the three cover mounting screws.


RTI PCB Removal/Replacement

RTI PCB Removal

Perform the following steps to remove the RTI PCB. (Reference Figure 11-42 "RTI PCB" when performing this procedure.)

1. Remove the Bar Code Reader Assembly from the instrument as described in "Bar Code Reader Assembly Removal/Replacement".

1. Remove the ribbon cable on J1 connecting the RTI PCB to the X Axis PCB.

2. Remove the cable on J2 that connects the RTI PCB to the Bar Code Reader.

3. Remove the four screws holding the RTI PCB to the bar code reader bracket as shown on Figure 11-42 "RTI PCB". (Note the orientation of the RTI PCB and the order of the hardware being removed.)

Figure 11-42 RTI PCB

RTI PCB Installation

To replace the RTI PCB, perform the preceding removal instructions then install the assembly by performing the removal in reverse order.


J1

J2

RTI PCBMounting ScrewsX Axis PCB



X Axis PCB Removal/Replacement

X Axis PCB Removal

NOTE:Units with SN 04050149 and below had an earlier version X Axis PCB.

Perform the following steps to remove the X Axis PCB.

1. Remove the Bar Code Reader Assembly as previously described in this chapter.

2. Remove the following cables attached to the X Axis PCB as shown on Figure 11-43 "X Axis PCB".

•J1 – (Signal I/O) cable to Backplane PCB

•J2 – (Power) cable to power Backplane PCB

•J3 – (Encoder) cable to encoder

•J4 – (Left Limit) cable to bar code reader left limit sensor

•J5 – (Right Limit) cable to bar code reader right limit sensor

•J6 – Unused

•J7 - cable to RTI PCB.

•J8 – cable to bar code reader drive motor

•J9 – Unused



Figure 11-43 X Axis PCB

3. Remove the four screws holding the X Axis PCB to the X Axis mounting baracket.

4. Remove the X Axis PCB.

X Axis PCB Installation

To replace the X Axis PCB, perform the preceding removal instructions then install the assembly by per-forming the removal in reverse order.

Earlier version X Axis PCB Replacement

For replacement, please order IL part number 00027613010, which includes an X Axis PCB without DIP switch, jumper cable and instructions. This board requires jumper installation detailed below.

1. Remove Molex connector of barcode motor assy. from barcode X Axis PCB.

2. Insert and lock one jumper into positions p8-1 and p8-3 and the other jumper into positions p8-6 and p8-8 as shown in Figure 11-44 "Jumper Placement".

Note: be sure to maintain the proper orientation of the pin to the connector housing to insure pins locksecurely.

3. Check electrical continuity between pins p8-1 and p8-3, p8-6 and p8-8.

J6

J7

J8J4J2J1

J5J3J9



Figure 11-44 Jumper Placement

Encoder Removal/Replacement

Encoder Removal

Perform the following steps to remove the Encoder

1. Remove the top cover and front panel as described in “Top Skin Removal/Replacement” in Chapter 4 and “Front Panel Assembly Removal/Replacement” in Chapter 4.

2. As shown on Figure 11-45 "Encoder Assembly Location", the encoder has a positioning screw for locking and unlocking the encoder and a setscrew to tighten it on the shaft.

Figure 11-45 Encoder Assembly Location

3. The positioning screw is in the locked position as shown on Figure 11-46 "Encoder" with the slot in the positioning screw aligned with the single dot on the cover. To remove the encoder, using a flat blade screwdriver, turn the positioning screw to the unlocked position as shown in the figure. The slot in the positioning screw should be aligned with the single dot on the cover.)

P8-1/P8-3

NoteOrientation

P8-6/P8-8

Positioning Screw

Setscrew



Figure 11-46 Encoder

4. Use an Allen Wrench to loosen the set screw accessible through the opening in the upper right rear of the encoder as shown in Figure 11-46 "Encoder".

NOTE: The Encoder pulley must be rotated to locate the setscrew.

5. Pull the encoder, which snaps and unsnaps, to remove it from the shaft.

Encoder Installation

To replace the encoder, perform the preceding removal instructions then install the assembly by performing the removal in reverse order. Note that the set screw must be tightened with the encoder positioning switch in the unlocked position.

Curtain Removal/Replacement

The following procedures apply to both the left and right curtains. Where there is a difference in the proce-dure for the right and left curtain, it is clearly defined.

Curtain Removal

Perform the following steps to remove the Curtain.

1. Remove the Bar Code Reader Assembly as previously described. (See "Bar Code Reader Assembly Removal/Replacement").

2. Move the bar code reader next to the spool for the side of the curtain to be removed.

3. While holding the curtain material, remove the screws going through the curtain material and the mount-ing bracket securing the curtain to the Bar Code Reader as shown on Figure 11-47 "BCR Curtain Attachment".

Positioning screw inunlocked position

Positioning screw inlocked position

(Installed)(Uninstalled)



Figure 11-47 BCR Curtain Attachment

4. Release the tension in the curtain by slowly turning the spool until it stops on its own (9 turns).

5. Unwrap the curtain material from the spool until the mounting bracket is exposed as shown on Figure 11-48 "Curtain Spool Attachment".

Figure 11-48 Curtain Spool Attachment

6. Remove the three Phillips head screws that attach the mounting bracket and curtain to the spool and remove the mounting bracket and curtain from the spool.

Curtain Installation

To replace the curtain, perform the following steps to insert a new curtain.

1. Align the applicable curtain material (right or left) to the spool assembly (left or right) while noting the ori-entation of the curtain material.

2. Attach the curtain to the travelling Bar Code Reader using the mounting bracket and three screws that were removed. (Note: Do not tighten the screws at this time.)

3. Move the Bar Code Reader to the farthest position from the spool being replaced.

4. For the right curtain (as viewed from the front of the instrument), align the end of the curtain material to the spool in a manner that the material coming off the spool comes off the front of the spool as shown on

RightCurtain

Right Side MountingScrews

Left Curtain

Left SideMounting Screws

Curtain/SpoolAttachmentScrews



Figure 11-49 "Right Curtain Spool Attachment". Turn the spool clockwise (CW) nine turns (to pro-vide proper tension on the curtain material) and, while keeping tension on the spool, place the end of the curtain material under the mounting bracket and tighten the three screws that attach the mounting bracket and curtain to the spool.

Figure 11-49 Right Curtain Spool Attachment

5. For the left curtain, align the end of the curtain material to the spool in a manner that the material coming off the spool comes off the front of the spool as shown on Figure 11-50 "Left Curtain Spool Attach-ment". Turn the spool counter-clockwise (CCW) nine turns (to provide proper tension on the curtain material) and, while keeping tension on the spool, place the end of the curtain material in front of the spool and under the mounting bracket and tighten the three screws that attach the mounting bracket and curtain to the spool.

Figure 11-50 Left Curtain Spool Attachment

6. Slowly relieve the tension on the spool to allow it to turn and wind the curtain material on the spool.

7. Manually move the bar code reader from one end of its travel to the other (to properly align the material under the mounting bracket holding it to the bar code reader).

8. Tighten the screws attaching the curtain to the travelling bar code reader assembly.

Mounting Screws

RightCurtain

MountingBracket

Right Spool Assembly



Bar Code Reader Drive Belt Removal/Replacement

Bar Code Reader Drive Belt Removal

Perform the following steps to remove the Bar Code Reader Drive Belt.

1. Remove the bar code reader assembly from the instrument as previous described. (See "Bar Code Reader Assembly Removal/Replacement").

2. Using an Allen wrench, loosen the two screws that tension the drive belt as shown in Figure 11-51 "Bar Code Reader Drive Belt Tension Adjustment". This releases the drive belt tension.

Figure 11-51 Bar Code Reader Drive Belt Tension Adjustment

3. Using an Allen wrench, remove the two screws attaching the RTI PCB bracket to the bar code reader as shown on Figure 11-52 "Bar Code Reader Drive Belt Fastening" and remove the RTI PCB and bracket. (This must be removed to supply access to the belt clamps.)

NOTE: Removing the curtain material provides better access but is not required.

Tension AdjustmentScrews



Figure 11-52 Bar Code Reader Drive Belt Fastening

4. Using an Allen wrench, remove the four screws on the drive belt clamp on one side of the RTI PCB mounting bracket.

5. Using an Allen wrench, remove the four screws on the drive belt clamp on the other side of the RTI PCB mounting bracket.

6. Remove the belt.

Bar Code Reader Drive Belt Installation

To replace the Bar Code Drive Belt, install the assembly by performing the following steps.

1. Place one end of the belt in one of the drive belt clamps as shown in Figure 11-53 "Bar Code Reader Drive Belt Attachment".

Figure 11-53 Bar Code Reader Drive Belt Attachment

Drive Belt ClampScrews

RTIBracketScrews

Belt Bracket Screws

Ensure cogs in beltand clamp align.

Drive Belt Clamps



2. While holding the clamp together over the belt, ensuring the last cog on the belt fits within the indenta-tion at the bottom part of the clamp as shown on the figure, and the belt is between the four screw holes, insert and tighten the four screws in the belt clamp using an Allen wrench.

3. Wrap the belt around the encoder and pulley at the ends of the bar code reader assembly and ensure the belt is straight across the front of the bar code assembly as shown in as shown in Figure 11-54 "Bar Code Reader Drive Belt Tension".

Figure 11-54 Bar Code Reader Drive Belt Tension

4. Bring the end of the belt to the other side of the travelling bar code reader assembly and place the end of the belt in the drive belt clamp.

5. While holding the clamp together over the belt, ensuring the last cog on the belt fits within the indenta-tion at the bottom part of the clamp and the belt is between the four screw holes, insert and tighten the four screws in the belt clamp using an Allen wrench.

6. Verify the bar code reader assembly moves freely and the belt tracks properly over the pulleys.

NOTE: The belt is provided at the proper length and should require minor tension adjustment.

7. Adjust the belt tension so the belt is straight with no sag across the entire front of the bar code reader assembly and an 8 or 10ml vial adapter laid on the middle of the belt moves it 0.2 to 0.3cm. To adjust the tension, move the pulley to the left or right to increase or decrease the belt tension and tighten the screws when the tension is correct.

8. Reattach the two screws securing the RTI PCB bracket to the bar code reader as shown on Figure 11-52 "Bar Code Reader Drive Belt Fastening".

9. Reinstall the bar code reader assembly as described in "Bar Code Reader Assembly Removal/Replacement".

Bar Code Reader Drive Motor Removal/Replacement

Bar Code Reader Drive Motor Removal

Perform the following steps to remove the Bar Code Reader Drive Motor.

1. Remove the bar code reader assembly as previous described. (See "Bar Code Reader Assembly Removal/Replacement").

2. Using an Allen wrench, loosen the two screws that tension the drive belt and secure the drive belt motor bracket as shown in Figure 11-55 "Bar Code Reader Drive Motor". This releases the drive belt ten-sion.

3. Using an Allen wrench, remove the two screws and remove the motor bracket and motor from the bar code reader assembly.

Ensure Straight Across



4. Remove the four TORX screws securing the bar code reader drive motor as shown on Figure 11-55 "Bar Code Reader Drive Motor".

Figure 11-55 Bar Code Reader Drive Motor

5. Remove the bar code reader drive motor.

Bar Code Reader Drive Motor Installation

To replace the bar code reader drive motor, install the assembly by performing the removal in reverse order. After reinstalling the motor bracket and motor, perform the following steps to verify the drive belt tracking and tension.

1. Verify the bar code reader assembly moves freely and the belt tracks properly over the pulleys.

NOTE: The belt is provided at the proper length and should require minor tension adjustment.

2. Adjust the belt tension so the belt is straight with no sag across the entire front of the bar code reader assembly and an 8 or 10 ml vial adapter laid on the middle of the belt moves it 0.2 to 0.3cm. To adjust the tension, move the pulley to the left or right to increase or decrease the belt tension and tighten the screws when the tension is correct.

Torx ScrewsSecuringMotor

Drive Belt tension Adjustment


Chapter 12 – Thermal Control 12 - 1

Chapter 12 –Thermal Control

12-1 Overview

Temperature ControlCertain modules in the ACL-TOP instrument are thermally regulated to maintain specified temperatures. The following are the thermally controlled modules in the ACL-TOP instrument and the temperatures to which they are kept.

• Cuvette shuttle - 37° Centigrade

• Incubator #1 - 37° Centigrade

• Incubator #2 - 37° Centigrade

• ORU Cradle - 37° Centigrade

• Reagent Module - 15° Centigrade

• Reagent Probes for Cavro - 37° Centigrade

• Reagent Probes for Universal Arms - 37° Centigrade

• Sample probe - for Base Top - Cavro - 37° Centigrade (CTS Sample arm is not heated).

Note that the temperature display is provided on the ACL-TOP system display by clicking on System -> Instrument Status as shown on Figure 12-1 "System Temperature Display Selection".

Figure 12-1 System Temperature Display Selection

Clicking on the Temperatures tab in the resulting screen display shows the temperature of all thermal con-trolled elements as shown in Figure 12-2 "Temperature Tab of Instrument Status Display".


12 - 2 Chapter 12 – Thermal Control

Figure 12-2 Temperature Tab of Instrument Status Display


Physical layout for the thermal elements is included in the description of the module in which the element is contained.


Interconnect diagrams for the thermal elements are included in the description of the module in which the element is contained.




Thermal Sensing

Each thermal sensing circuit consists of a Thermistor, a conditioning circuit, may include a filter, and an ana-log to digital converter as shown on Figure 12-3 "Thermal Sensing Block Diagram". A thermistor is a tem-perature-sensitive resistor that changes its resistance dependent on the temperature. The thermistor resistance is sensed by the conditioning circuit that converts the thermistor resistance to a proportional ana-log voltage. Dependent on the individual circuit, the sensing circuit may provide filtering of the conditioning circuit analog output. The analog output of the conditioning circuit/filter is input to an analog to digital con-verter and produces a digital output proportional to the analog output of the conditioning circuit (and there-fore the resistance of the Thermistor). The output of the analog to digital converter is input to the controller of the thermal element and used to determine if the element requires power to heat or cool the element.

Figure 12-3 Thermal Sensing Block Diagram

Thermal Control

Each thermal control circuit consists of a Thermal Control Circuit, a Power Switch, may include coils and capacitors, and a thermal element as shown on Figure 12-4 "Thermal Control Block Diagram". The Probe Integrated Controller is the controller for probe thermal regulation. All other thermal controllers are the corresponding controller boards. The controller does the recognition of the heating or cooling and turns on the power switch to effect the change. The coils and capacitors (specific to the Reagent Plate and the Probes) are used to eliminate spurious electrical signals into other areas of the instrument. The thermal ele-ment actually performs the heating or cooling of the area.

Figure 12-4 Thermal Control Block Diagram

Thermistor ConditioningCircuit

Filter(Optional)

Analog toDigitalConverter

To ThermalControl Circuit

Thermal ControlCircuit

PowerSwitch

Coils andCapacitors forFluctuations(Optional)

ThermalElement



Cuvette Shuttle Thermal Regulation

The Cuvette Shuttle is kept at 37° Centigrade. The heater is a heating pad and is located as shown on Fig-ure 12-5 "Cuvette Shuttle Heater". The thermistor for the cuvette shuttle is on the other side of the assem-bly from the heater as shown on Figure 12-6 "Cuvette Shuttle Thermistor" (the white wires go to the thermistor). The overload protection is a thermal switch that disables current flow to the heating element when the temperature reaches the cut-off point of the circuit. The thermal switch is in series with the heating element. Normal function is restored only when the temperature goes below a 2nd thermal point of the cir-cuit, that is lower than the cut-off temperature. The cuvette thermal control is provided by the Cuvette Con-troller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power switch.

Figure 12-5 Cuvette Shuttle Heater

OverloadProtection

HeaterElement



Figure 12-6 Cuvette Shuttle Thermistor

Incubator #1 Thermal Regulation

NOTE: The hardware drawings, PN’s, etc. and this document refer to Incubator #1 being on the Sample side of the instrument. The ACL-TOP software refers to Incubator #1 being on the Reagent side of the instrument (not the ThermalCal software). Bear this in mind when trou-bleshooting, etc. the instrument.

Incubator #1 is kept at 37° Centigrade. The heater is a heating pad and is located as shown on Figure 12-7 "Incubator 1". The thermal control for Incubator #1 is provided by the ORU Controller PCB using a Pro-portional Integral Derivative loop for control and a Field Effect Transistor as a power switch. The overload protection is a thermal switch that disables current flow to the heating element when the temperature reaches the cut-off point of the circuit. The thermal switch is in series with the heating element. Normal func-tion is restored only when the temperature goes below the 2nd thermal point, which is lower than the cut-off temperature.

CuvetteShuttleThermistor



Figure 12-7 Incubator 1

Incubator #2 Thermal Regulation

NOTE: The hardware drawings, PN’s, etc. and this document refer to Incubator #2 being on the Reagent side of the instrument. The ThermalCal software refers to Incubator #2 being on the Sample side of the instrument. Be aware of this when troubleshooting, etc. the instrument.

Incubator #2 is kept at 37° Centigrade. The heater is a heating pad and is located as shown on Figure 12-8 "Incubator 2 Thermal Regulation". The thermal control for Incubator #2 is provided by the ORU Controller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power switch. The overload protection is a thermal switch that disables current flow to the heating element when the temperature reaches the cut-off point of the circuit. The thermal switch is in series with the heating element. Normal function is restored only when the temperature goes below the 2nd thermal point, which is lower than the cut-off temperature.

Figure 12-8 Incubator 2 Thermal Regulation

ThermistorOverloadProtection

Heater Element

OverloadThermistor Protection

Heater Element



Optical Reading Unit (ORU) Cradle Thermal Regulation

The ORU Cradle is kept at 37° Centigrade. Heating is performed by a heating pad and temperature control is performed by a thermistor. There is one heating pad and thermistor mounted on each of the four ORU sta-tions as shown on Figure 12-9 "Optical Reading Unit Thermal Regulation". The thermal control for the ORU Cradle is provided by the ORU Controller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power switch. The overload protection is a thermal switch that disables current flow to the heating element when the temperature reaches the cut-off point of the circuit. The thermal switch is in series with the heating element. Normal function is restored only when the temperature goes below the 2nd thermal point, which is lower than the cut-off temperature.

Figure 12-9 Optical Reading Unit Thermal Regulation

Reagent Module Thermal Regulation

The cooling of the reagent mounting plate is performed by three Thermal Electric Coolers mounted on the mounting plate below a large heat sink as shown in Figure 11-9. The heat sink dissipates the heat generated by the coolers and in turn is cooled by air flow from an inlet duct from on the middle lower edge of the front panel assembly. This duct is the fresh air inlet to the reagent module and allows cool air to be blown across the heat sink of the Reagent module. The air is exhausted out the rear of the instrument, using the integrated channels in the base skin as duct work, as shown on Figure 12-10 "Cooling Fan Ductwork".

Overload Protection

Thermistors

Heater Element



Figure 12-10 Cooling Fan Ductwork

Mounted to the chassis base, between the reagent module and the base skin is a fan assembly, as shown on Figure 12-11 "Fan Assembly", comprised of five fans mounted side-by-side in a single row. The middle three fans provide inlet air to the Reagent module. These three fans are positioned below the center of the heat sink to allow air to be blown directly at the heat sink (air is directed at the heat sink fins as opposed to across the fins). The two outside fans of the fan assembly act as exhaust fans and exhaust air beneath the base skin of the instrument. They create air flow away from the Reagent module as shown on Figure 12-11 "Fan Assembly".

Figure 12-11 Fan Assembly

If the air inlet vent located on the middle lower edge of the front panel assembly is blocked or the air flow impeded (i.e. lab papers sitting on countertop, etc.) system temperature ‘out-of-range’ warnings and errors can occur.

Air Filter

ExhaustDuct

Exhaust Duct Intake Duct

Air Inlet Vent

Exhaust Fans

Inlet Fans



Reagent Cooling with Fan Speed Controller PCB.

Control of the Thermal Electric Coolers is performed by the Reagent Cooling with Fan Speed Controller PCB mounted on the right side of the reagent module as shown in Figure 12-12 "Reagent Cooling with Fan Speed Controller PCB". This PCB provides power to the Coolers when cooling is required as indi-cated by a thermal sensor located on the mounting plate. The Reagent Cooling with Fan Speed Controller PCB controls the speed of the three reagent cooling fans based on the heat sink temperature as indicated by the sensor. The Reagent Rack Presence PCB also monitors the temperature of the mounting plate and generates a signal causing a System temperature ‘out-of-range’ indication if the temperature goes outside its range of 15° Centigrade plus or minus 3° Centigrade.

Units below serial number 05070377 do not have the fan control PCB but can be upgraded using IL part number 00029411300.


Reagent Probes for Cavro Thermal Regulation

The reagent probes for Cavro units are kept at 37° Centigrade. There are two heaters and thermistors mounted within the probe as shown on Figure 12-13 "Cavro Reagent Probe". The thermal control for the Reagent Probe is provided by the Probe Integrated Controller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power switch. Over load protection for the probe is pro-vided by a fuse in the Probe Integrated Controller PCB.


Reagent Rack PresencePCB



Figure 12-13 Cavro Reagent Probe

Reagent Probes for Universal Arms Thermal Regulation

The reagent probes for Universal Arms are kept at 37° Centigrade. There are two heaters and two ther-mistors mounted within the probe as shown on Figure 12-14 "Universal Arms Reagent Probe". The Reagent Probe thermal control is provided by the Probe Integrated Controller PCB using a Proportional Inte-gral Derivative loop for control and a Field Effect Transistor as a power switch. Over load protection for the probe is provided by a fuse in the Probe Integrated Controller PCB.

Figure 12-14 Universal Arms Reagent Probe

Probe Heaters andThermistors(within probe)

Probe IntegratedControllerPCB

Probe Heaters and Thermistors(within probe)

Probe IntegratedController PCB



Cavro Sample Probe Thermal Regulation

The sample probes for Cavro units are kept at 37° Centigrade. There are two heaters and two thermistors mounted within the probe as shown on Figure 12-15 "Cavro Sample Probe". The Sample Probe thermal control is provided by the Probe Integrated Controller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power switch. Over load protection for the probe is provided by a fuse in the Probe Integrated Controller PCB.

Figure 12-15 Cavro Sample Probe

CTS Sample Probe Thermal Regulation

The CTS Sample probe is not thermally controlled.


Adjustments

Mechanical adjustments and verification for the thermally controlled modules are covered in the Rack Han-dling, Cuvette Handling and Robotics XYZ chapters of this manual.

Probe Heaters andThermistors(within probe)

Probe IntegratedControllerPCB



ThermalCal Description

The following describes the requirements, use, and user interface of the Thermal Calibration Software (also known as ThermalCal). The Thermal Calibration software enables the calibration of several thermally con-trolled modules within the instrument. ThermalCal use is intended for Instrumentation Laboratory personnel and authorized Service Personnel trained to support the ACL TOP.

NOTE: ThermalCal does NOT address the thermal calibration of the probes within the instru-ment which are required to be calibrated by the manufacturer. Nor does it cover the calibra-tion of the cuvette shuttle, which does not need calibration.

The software is a Windows 2000 application and is distributed with a required DLL called the “Console DLL”. This DLL is required to support the communication with the TOP AM.

References

The following equipment is required to perform the calibration of the TOP AM:

• Rack Thermistor Mount, IL Part Number 285211-00

• Thermistor Probe Assembly, IL Part number 189960-00

• Futura Thermal Test Fixture, IL Part number 189937-00

NOTE: Automatic mode is not intended for field use and is not included in the following description and procedures.

User Interface

The User’s Interface is a single dialog box as shown in Figure 12-16 "ThermalCal Dialog Initial State". During operation, message boxes are used for additional interaction such as warnings and confirmations. As shown in the figure, ThermalCal is initiated in automatic mode and, for field use, must be placed in man-ual mode by clicking on the “Go To Manual Mode” button at the top left of the window.



Figure 12-16 ThermalCal Dialog Initial State

Once entering Manual Mode, the main dialog box is divided into several sections as shown in Figure 12-17 "Thermal Dialog after Changing to Manual Mode".

The User Interface screen is divided into four sections as follow:

• The Mode Selection and Current Mode is indicated at the top.

• Meter Connection and Status section (automatic mode) or the Temperature Entry section (manualmode) is in the upper section

• TOP AM Connection and Status section is in the middle

• Calibration Status and Control section is at the bottom

The various buttons and controls have tool tips to simplify their use. Tool tips pop up whenever the mouse is left over a control for more than a few seconds. The mouse needs to be an arrow cursor for the tool tip to pop up. The following paragraphs describe each of these sections and provide information on their usage during the calibration process.



Figure 12-17 Thermal Dialog after Changing to Manual Mode

Mode Selection and Display

At the top of the dialog box is a mode selection button and a message indicating the current mode.

NOTE: Automatic mode is not intended for field use and is not included in the following descriptions and procedures.

Temperature Entry

The temperature data entry section is used to enter the temperature as measured by the probe and the Futura tester. Clicking the Submit temperature button causes the system to record the temperature, display the Entered Temperature, the Target temperature, and the Temperature difference in the lower part of the screen. The software also submits the temperature to the system so it can calculate offsets/coefficients to compensate for any differences between the measured temperature and the system controlled temperature.

ACL-TOP Connection and Status

The connection to the Analytical Module is performed through this portion of the ThermalCal screen. The proper sequence for connecting to the AM is to have the CM Computer and the touch screen monitor ON, the CM Software NOT running and the Analytical Module OFF. The CM is connected (normally) to the Ana-lytical Module and is running the ThermalCal application. Once this is in place:

Temperature Entry

CalibrationStatus andControl

Mode selection and display

ACL-Top AnalyticalModule Connect-ion and Status



• The Analytical Module must be turned on.

• Wait 2 minutes for the TOP Analytical Module to start. Since the CM is not running, there is no visual indication that the Analytical Module is operational.

• Click the “Connect to TOP” button of the ThermalCal application.

The application connects automatically and updates the “TOP Status” to “AM Connected” as shown on Fig-ure 12-18 "Screen after connecting to the TOP AM. (Manual Mode)".

The Display Coefficients button is used to display the coefficients presently stored in the TOP AM. An exam-ple of the resulting display is shown in Figure 12-24 "Display Coefficient Settings".

Figure 12-18 Screen after connecting to the TOP AM. (Manual Mode)

Calibration Status and Control

The Calibration Status and Control portion of the ThermalCal screen is used to control the actual calibration process. The process of calibrating each module is the same. This process is depicted in the flow chart in Figure 12-19 "Calibration Process for a Single Module". This process is repeated for each module that needs to be calibrated.



Figure 12-19 Calibration Process for a Single Module

The first step of calibrating any module is to select the module to be calibrated. The module is selected by clicking on the module selection button with the name of the module on it. After the module is selected (or before), the Thermistor Probe Assembly must be placed in the correct location for that module. The list below gives the location of the thermistor when the module is being calibrated. When the module is selected, a message box pops up reminding the user to check that the Thermistor Probe Assembly is in the correct location.

• RACK – Reagent Rack – Position 2 (from the rear of the instrument) of a Reagent Rack in locationR3.

• ICU 1 – Incubator 1 – The fourth slot (from the left) of the incubator on the sample side of the TOPAM.

• ICU 2 – Incubator 2 – The fourth slot (from the left) of the incubator on the reagent side of TOP AM.

• ORU 1 – Optical Reading Unit 1 – The slot of the leftmost Optical Reading Unit.

• ORU 2 – Optical Reading Unit 2 – The slot of the Optical Reading Unit second from the left.

• ORU 3 – Optical Reading Unit 3 – The slot of the Optical Reading Unit third from the left.

• ORU 4 – Optical Reading Unit 4 – The slot of the rightmost Optical Reading Unit.



After the module is selected, a soaking period is started to ensure that the temperature of the TOP AM and the thermistor have reached their true steady state values. During this period, the remaining soaking time is displayed on the application’s main screen. (See Figure 12-20 "Display of the Soaking Time Remain-ing".)

Figure 12-20 Display of the Soaking Time Remaining

NNOTE:When the first module is selected, if the TOP AM was not turned off prior to connecting with ThermalCal, the message shown in Figure 12-21 "Time-out Message" is displayed. When this occurs, the TOP AM must be shutdown, ThermalCal must be exited, and the process restarted.

Figure 12-21 Time-out Message

Soak Time Remaining



When the temperature reading is stable, the wording “Temp Stable” is displayed as shown on Figure 12-22 "Temperature Stable Display". The screen then returns to the idle state waiting for another module to be selected.

Figure 12-22 Temperature Stable Display

Once the temperature is stable, the temperature reading from the Futura Thermal Test Fixture is entered in the “Enter Temperature Here” box and the “Submit Temp” button is clicked. The ThermalCal software cal-culate the temperature error from the target temperature versus the entered temperature. The entered tem-perature, target temperature, and the temperature difference are displayed in the lower left part of the ThermalCal dialog box.

If the “Temp Difference” is NOT within +/- 0.2 degrees, the “Update Coefficients” button is clicked for the system to recalculate and store new coefficients. In this case, the software calculates new coefficients and they are sent to the TOP AM. A new waiting period is then initiated and the check is repeated to validate the calibration with the new coefficients.

If the “Temp Difference” is within 0.2 degrees of the target temperature, the “Done” button is clicked to end the calibration of that module. When the temperature reading is stable and the “Done” button is clicked, a message box is displayed for the user to confirm his choice. After clicking OK, a second message box is dis-played showing the calibration offset that is saved in the TOP AM as shown in Figure 12-23 "Screen show-ing Offset (Coefficient)". This value should be recorded as a record of the calibration. The screen then returns to the idle state waiting for a new site to be selected. Note that after a site is calibrated and saved, the button associated with that site displays “Done”.

Temp StableIndication



Figure 12-23 Screen showing Offset (Coefficient)

The preceding process is be repeated for each module that requires calibration. When all modules are com-pleted, the “EXIT” button in the upper right corner of the window is clicked. This displays a confirmation dia-log box. Selecting OK in this dialog box exits the ThermalCal software.

Display Coefficients Screen

After ThermalCal is connected to an ACL-TOP and if a calibration is not being performed, a Display Coeffi-cients dialog box is available. This dialog is displayed when the “Display Coefficients” button is clicked on. The dialog lists the “Offset” coefficient for each module that can be calibrated. This allows for single screen review of the calibration parameters of the ACL-TOP. The screen is shown in Figure 12-24 "Display Coef-ficient Settings".

Figure 12-24 Display Coefficient Settings

The Calibration Settings window also provides for the entry of coefficients. Coefficients need to be entered into the system whenever a thermal module or a controller card is replaced (the controller cards are used to store the coefficients). In the case of the controller card, the coefficients are displayed before replacing the card and are re-entered after the new card is inserted. For the thermal modules, the coefficients (as docu-mented on the thermal module) are entered into the system when replacing the unit. It is recommended that the calibration of each thermal module be performed after their replacement.

NOTE: To prevent faulty entries, the software only allows the offset to be adjusted by 200 at a time.



Other Handled Events

There are several other events that are handled by the software.

1. If the user selected the wrong module or needs to abort the current calibration for some reason, the user can click the “Stop” button. This will display the confirmation message box shown in Figure 12-25 "Message Box Confirming a Stop Calibration Request". If “Yes” is selected, the calibration will be aborted and the previously saved calibration will be restored to the TOP AM.

Figure 12-25 Message Box Confirming a Stop Calibration Request

2. If a additional module is selected while a module is being calibrated, a warning is displayed as shown in Figure 12-26 "Message Warning that a Second Module cannot be Selected " and the request is ignored.

Figure 12-26 Message Warning that a Second Module cannot be Selected

3. If the “EXIT” button that exits the software is selected during a calibration, the following message is displayed (see Figure 12-27 "Complete Calibration before Exiting message") and the request is ignored.

Figure 12-27 Complete Calibration before Exiting message



ThermalCal Instructions for Adjusting Coefficients/Offsets

Load the ThermalCal Program

NOTE: ThermalCal must be performed with all ACL-TOP covers closed.

1. If the ThermalCal software is installed on the CM computer, double click on the ThermalCal icon on the desktop, as shown on Figure 12-28 "ThermalCal Icon", to open the program.

Figure 12-28 ThermalCal Icon

NNOTE:The most recent versions of ACL-TOP have the ThermalCal software pre-installed on the CM. Verify it is not installed by clicking on Start —> Programs to display the list of installed programs and use the installed version if available.

2. If the ThermalCal software is not loaded on the CM computer, load the software by performing the following steps.

STEP 1: Insert the distribution CD-ROM into the computer.

STEP 2: Double click the “My Computer” icon on the desktop.

STEP 3: Double click the icon of the CD-ROM drive to open it.

STEP 4: Drag the ThermalCal folder onto the computer desktop.

STEP 5: Double click on the ThermalCal folder.

STEP 6: Double click on the ThermalCal icon.

3. Click on the “Go To Manual Mode” button as shown on Figure 12-29 "ThermalCal Screen" to place the software in manual mode.



Figure 12-29 ThermalCal Screen

4. Verify the following:

•The CM Computer and the touch screen monitor are ON.

•The CM Software is NOT running.

•The Analytical Module is OFF (power is off to the instrument).

•The CM is connected (normally) to the Analytical Module and running ThermalCal.

5. Turn on the Analytical Module. (Power up the instrument.).

NOTE: Do not remove any of the instrument covers. ThermalCal; should be run with all cov-ers in place.

6. Wait 2 minutes for the Analytical Module to start. (Because the CM software is not running, there is no visual indication that the Analytical Module is operational.)

7. Click the “Connect to TOP AM” button of the ThermalCal application as shown on Figure 12-30 "Connecting ThermalCal Application to the AM".



Figure 12-30 Connecting ThermalCal Application to the AM

Test the Thermal Modules

8. Once the TOP AM Status: displays “Connected”, as shown in Figure 12-32 "AM Connected", select the module to be tested by clicking on the module selection button with the name of the mod-ule on it.

NNOTE:When the first module is selected, if the TOP AM was not turned off prior to connecting with ThermalCal, the message shown in Figure 12-31 "Time-out Message" is displayed. If this occurs, the TOP AM must be powered down, ThermalCal must be exited, and the procedure restarted.

Figure 12-31 Time-out Message

Connection Button



Figure 12-32 AM Connected

9. Place the thermistor depending on the module to be calibrated. Ensure the thermistor is laying flat and is all the way to the front of the slot. The locations are:

• RACK – Reagent Rack – Position 2 (from the rear of the instrument) in location R3 of the Reagent Rack.

• ICU 1 – Incubator 1 – The fourth slot (from the left) of the incubator on the sample side of the TOP AM as shown on Figure 12-33 "ICU1 Thermistor Placement".

Figure 12-33 ICU1 Thermistor Placement

• ICU 2 – Incubator 2 – The fourth slot (from the left) of the incubator on the reagent side of TOP AM as shown on Figure 12-34 "ICU2 Thermistor Placement".

Selection ofModule To Be Tested

Connected Status

ICU1 ThermistorPlacement



Figure 12-34 ICU2 Thermistor Placement

See Figure 12-35 "ORU Thermistor Placement" for thermistor placement for the ORU heads.

• ORU 1 – Optical Reading Unit 1 – The slot of the left most Optical Reading Unit.

• ORU 2 – Optical Reading Unit 2 – The slot of the Optical Reading Unit second from the left.

• ORU 3 – Optical Reading Unit 3 – The slot of the Optical Reading Unit third from the left.

• ORU 4 – Optical Reading Unit 4 – The slot of the right most Optical Reading Unit.

Figure 12-35 ORU Thermistor Placement

ICU2 ThermistorPlacement

ORU 1 ORU 2 ORU 3ORU 4



10. Use the Thermistor Probe Assembly, IL PN 189960-00 as shown in Figure 12-36 "Thermistors and Futura Test Fixture" for measuring the temperature in all but the Reagent Module. (The probe is inserted in the back of the thermal module and slid to the front in the same manner a cuvette is loaded.) Use the Rack Thermistor Mount, IL PN 285211-00, for the Reagent Rack by placing the Probe Assembly into the mount, locking it into position and placing it in Position 2, loca-tion R3, of the reagent rack.

11. Connect the other end of the thermal test probe into the Futura Thermal Test Fixture as shown in Figure 12-36 "Thermistors and Futura Test Fixture".

Figure 12-36 Thermistors and Futura Test Fixture

12. When the pop-up screen is displayed asking to verify the placement of the thermistor, verify the thermistor placement and click the OK button to initiate the calibration. The instrument enters a soaking period to ensure the temperature and thermistor have reached steady state values and displays the soaking time remaining as shown on Figure 12-37 "Soak Time Remaining".

Rack Thermistor MountThermistor Probe Assembly

Futura Connection

Futura Test Fixture

(IL PN 189960-00) (IL PN 285211-00)

(IL PN 189937-00)



Figure 12-37 Soak Time Remaining

13. After the soaking period ends and “Temp Stable” is displayed as shown on Figure 12-38 "Tem-perature Input", enter the temperature displayed on the Futura Thermal Test Fixture into the “Enter Temperature Here” box on the ThermalCal screen and click on the “Submit Temperature” button.

Figure 12-38 Temperature Input

Soak TimeRemaining

Temperature StableIndication

TemperatureSubmission



14. If the “Temperature Difference (Deg C):”, as shown in Figure 12-39 "Temperature Difference", is more than 0.2 degrees, click the “Update Coefficients” button to store the coefficients gener-ated as part of the ThermalCal procedure, initiate a new soaking period, and initiate a new calibra-tion check using the new coefficients.

Figure 12-39 Temperature Difference

15. If the “Temperature Difference (Deg C)”, as shown in Figure 12-39 "Temperature Difference", is less than 0.2 degrees, click on the “Done” button. The system displays a message box on which the “Yes” button should be clicked, as shown on Figure 12-40 "Save Calibration", to confirm the calibration of the module is complete.

Figure 12-40 Save Calibration

16. A second message box is displayed showing the final calibrated offset that is saved in the TOP AM as shown on Figure 12-41 "Calibration Offset".

Figure 12-41 Calibration Offset

Temperature Difference



17. Verify that the button for the module tested states “Done” as shown in Figure 12-42 "Done Indi-cation". If so, select the next module by returning to "Test the Thermal Modules".

Figure 12-42 Done Indication

Save the Coefficients

18. If all modules to be calibrated are complete, click the “Display Coefficients” button in the Ther-malCal window as shown on Figure 12-43 "Display Coefficients".

Done Indication



Figure 12-43 Display Coefficients

19. With the coefficients being displayed as shown on Figure 12-44 "Calibration Settings", click on ALT + Print Screen to capture the screen content.

Figure 12-44 Calibration Settings

20. Click on the OK button in the Calibration Settings window to store the new coefficients and close the window.

21. If the WordPad icon is not on the desktop, generate a shortcut to WordPad for storing of the Screen content:

• Double click on “My Computer”.

• Select C: —> Document and Settings —> Administrator —> Start Menu —> Program —> Accessories.

Display Coefficients Button



• Right click on the WordPad icon and select “Create Shortcut”.

• Click on the WordPad icon and drag it to the desktop.

22. Close the Accessories window and return to the desktop.

23. Click on the WordPad icon to open the application.

24. Click on Edit —> Paste to paste the screen capture into the file.

25. Click on File —> Save As and save the file as “C:\Thermal Coefficients”. (If the file already exists, replace it.)

26. Exit the WordPad application by clicking on File —>Exit.

27. Exit the ThermalCal application by clicking on the “Exit” button in the upper right corner of the screen.

Inputting Thermal Coefficients using ThermalCal

This procedure is used whenever one of the thermally controlled modules or a controller board is replaced. When a thermal module is replaced, the coefficients, as written on the module, must be entered into the sys-tem to ensure the proper temperature is maintained in the new module. When a controller board is replaced, the coefficients that were stored in the previous controller board must be entered into the new controller board.

NOTE: ThermalCal must be performed with all ACL-TOP covers closed.

1. If the ThermalCal software is installed on the CM computer, double click on the ThermalCal icon on the desktop, as shown on Figure 12-28 "ThermalCal Icon", to open the program.


NNOTE:The most recent versions of ACL-TOP have the ThermalCal software pre-installed on the CM. Verify it is not installed by clicking on Start —> Programs to display the list of installed programs and use the installed version if available.


• Insert the distribution CD-ROM into the computer.

• Double click the “My Computer” icon on the desktop.

• Double click the icon of the CD-ROM drive to open it.

• Drag the ThermalCal folder onto the computer desktop.

• Open the ThermalCal application by double clicking on the ThermalCal icon.



3. Click on the “Go To Manual Mode” button as shown on Figure 12-46 "ThermalCal Screen" to place the software in manual mode.



• The CM Computer and the touch screen monitor are ON.

• The CM Software is NOT running.

• The Analytical Module is OFF (power is off to the instrument).

• The CM is connected (normally) to the Analytical Module and running the thermal application.

5. Turn on the Analytical Module. (Power up the instrument.).

6. Wait 2 minutes for the TOP Analytical Module to start. (Since the CM software is not running, there is no visual indication that the Analytical Module is operational.)

Mode Button



7. Click the “Connect to TOP AM” button of the ThermalCal application as shown on Figure 12-47 "Connecting ThermalCal to the AM".

Figure 12-47 Connecting ThermalCal to the AM

8. Once the TOP AM Status displays “Connected”, as shown in Figure 12-48 "Connection Status", click on the “Display Coefficients” button to display the stored coefficients of the system.

ConnectionButton

Connection Status



Figure 12-48 Connection Status

9. Highlight the correct entry and enter the coefficient(s) for the new unit(s), as written from the calibra-tion tag during the installation steps, into the box as shown in Figure 12-49 "Thermal Coefficient Display".

Figure 12-49 Thermal Coefficient Display

10. Click on the OK button to store the new coefficients.

ConnectionStatus

Display Coefficients Button



11. With the coefficients being displayed, click on ALT + Print Screen to capture the screen content.

12. Click on the OK button in the Calibration Settings window to store the new coefficients and close the window.

13. Minimize the ThermalCal application.

14. If the WordPad icon is not on the desktop, generate a shortcut to WordPad for storing of the Screen content:

• Click on “My Computer”.

• Select C:—> Document and Settings ——> Administrator —> Start Menu —> Program —> Accessories.

• Click on WordPad.

• Right click and select Create Shortcut.

• Click on the WordPad (2) icon and drag it to the desktop.

15. Close all Windows and return to the desktop.


17. Click on Edit —> Paste to paste the screen capture into the application.

18. Click on File —> Save As and save the file as C:\Thermal Coefficients. (If the file already exists, replace it.)

19. Exit the WordPad application by clicking on File —>Exit.

20. Maximize and then exit the ThermalCal application by clicking on the “Exit” button in the upper right corner of the screen.

12-6 Diagnostics

The reagent block actual temperature, reagent block lower limit, and reagent block upper limit are displayed on the Controllers, Covers, and Racks Diagnostic Screen as shown in Figure 12-50 "Controllers, Covers and Racks Diagnostic Screen".


apter 12 – Thermal Control 12 - 36


t Temperature Area

Ch

Figure 12-50 Controllers, Covers and Racks Diagnostic Screen

Reagen


As shown on Figure 12-51 "Reagent Temperature Area of Diagnostic Screen", the screen displays the current, lower limit and upper limit temperatures.

Figure 12-51 Reagent Temperature Area of Diagnostic Screen

Temperature Troubleshooting

1. Open the ORU tab in the diagnostics window as shown in Figure 12-52 "ORU Tab of Diagnostic Screen".


apter 12 – Thermal Control 12 - 38


Ch

Figure 12-52 ORU Tab of Diagnostic Screen

Temperature Area


2. Check that the temperature readings for all four ORUs and the two incubators are within the upper and lower limits as specified in the temperature portion of the screen as shown on Figure 12-53 "Temperature Portion of ORU Diagnostic Screen"

Figure 12-53 Temperature Portion of ORU Diagnostic Screen

3. Click on the Controllers, Covers and Racks tab of the Diagnostic screen. Check that the temperature readings for the Reagent Block are within the upper and lower limits as specified in the temperature portion of the diagnostic screen as shown on Figure 12-54 "Software, Covers and Racks Diagnos-tic Screen".



Figure 12-54 Software, Covers and Racks Diagnostic Screen

4. Figure 12-55 "Reagent Block Temperature" provides a better depiction of the Block Temperature area of the screen.

Figure 12-55 Reagent Block Temperature

Rea



5. At this time, temperature controls are not replaceable items. Therefore, if the readings are not within specifications, replace the failing unit as described in the procedure identified in the following table.


None of the heaters or thermistors in the ACL-TOP instrument are replaceable at this time. Refer to Rack Handling, Cuvette Handling and Robotics XYZ for removal/replacement procedures. Table 12-2 "Thermal Control Module/Assembly, Driver, Controller" lists the thermal elements, the PCBs containing the driv-ers for the thermal elements and the controller for the thermal elements.

Table 12-2 Thermal Control Module/Assembly, Driver, Controller

Table 12-1 Procedures for Replacing Thermal Elements

Unit with Temperature outside range

Procedure

Incubator # 1 “Incubator #1 Removal/Replacement” in Chapter 9

Incubator # 2 “CTS Hold/Incubator #2 Removal/Replacement” in Chapter 9

ORU # 1 through # 4 “Removing/Replacing the ORU Assembly” in Chapter 10

Module Module/Assembly containing thermal element

Module/Assembly Removal/Replacement Procedure

Driver for thermal element

Controller for thermal element

Cuvette shuttle Cuvette Shuttle Assembly

“Cuvette Shuttle Assembly Removal/Replacement” in Chapter 9

Cuvette Shut-tle Y-Axis Board

Cuvette CPU

Incubators Cuvette Handling Assembly

“CTS Hold/Incu-bator #2 Removal/Replacement” in Chapter 9

“Incubator #1 Removal/Replacement” in Chapter 9

Incubator Heater Board

ORU CPU



ORU heads Optical Reading Unit

“Removing/Replacing the ORU Assembly” in Chapter 10

ORU Interface Board

ORU CPU

Reagent plate Reagent Assem-bly

“Reagent Mod-ule Removal/Replacement” in Chapter 11

Reagent Cool-ing PCB

Rack CPU

Probes FET/Coil/Cap “Probe Trouble-shooting” in Chapter 8

Probe Inte-grated Control-ler PCB

Probe Integrated Controller PCB


Chapter 13 – Waste Management System 13 - 1

Chapter 13 –Waste Management System

13-1 Overview

The Waste Management System consists of the Bulk Fluid Waste Management Subsystem and the Cuvette Waste Management Subsystem. The Bulk Fluid Waste Subsystem includes those components that are involved in disposing of the HemosIL Rinse Fluid Waste, and the Clean A Fluid Waste, that are by-products of rinse and clean operations. The Cuvette Waste Subsystem includes those components that are involved in disposing of cuvette waste.

The Bulk Fluid Waste Management consists of the Sample Accumulator, Reagent Accumulator, Waste Fluid Presence Sensor, Peristaltic Waste Pump and Waste Bottle.


Waste Management System 13 - 2


1

Fig . The Sample Accumulator is shown in red, the hown in magenta and the Waste Bottle is sh

te Waste Drawer

Cuvette Waste Shelf

Waste Bottle

Chapter 13 –

3-2 Physical Layout

ure 13-1 "Layout of the Waste Management System" shows the physical layout of the Waste Management System Reagent Accumulator is shown in green, the Cuvette Waste Shelf is shown in cyan, the Cuvette Waste Drawer is s

own in yellow. The location of the Waste Pump is indicated in blue.

Figure 13-1 Layout of the Waste Management System

Sample Accumulator Reagent Accumulator

Peristaltic Waste Pump Cuvet



The Interconnect Diagram for the Bulk Fluid Waste Management System is included in the Interconnect Dia-gram for the Fluid Handling System (see “Interconnect Diagrams” in Chapter 7).

The Interconnect Diagram for the Cuvette Waste Management System is included in the Interconnect Dia-gram for the Cuvette Handling System (see “Interconnect Diagrams” in Chapter 9).


Bulk Fluid Waste Management Subsystem

The Bulk Fluid Waste Management consists of the following components:

• Sample Accumulator

• Reagent Accumulator

• Waste Fluid Presence Sensor

• Peristaltic Waste Pump

• Waste Bottle

Sample and Reagent Accumulators

Each ACL TOP Instrument is equipped with two Fluid Accumulators that contain both a Waste Fluid Collec-tion Tank and a Rinse/clean Station to support each probe. All ACL TOP Instruments utilize the same Reagent Side Accumulator. Instruments equipped with Cavro arms have a different Sample Side Accumu-lator than instruments equipped with IL arms and CTS.


13 - 4 Chapter 13 – Waste Management System

Figure 13-2 The Sample and Reagent Accumulators

Reagent Side Accumulator

The Reagent Side Accumulator is identical on all ACL TOP instrument configurations. The Reagent Side Accumulator contains two Rinse/clean stations, a Clean Pump, two Clean Valves, a Fluid Level Sensor, and a reservoir to hold excess rinse and other waste fluids. The Waste Fluid Reservoir is a solvent-bonded assembly made of PVC. The front of the reservoir is clear to allow operators to observe the fluid level during Diagnostics. The two center stacks in the Accumulator are vent tubes to equalize the pressure within the Waste Reservoir. Fluid is removed by the Waste Pump via the 1/8-27 NPT barb fitting at the bottom of the reservoir.

Figure 13-3 The Reagent Side Accumulator

Sample Accumulator Reagent Accumulator

CTS Accumulator

Reagent Accumulator



The Reagent Side Accumulator has a Rinse cup and a Clean cup for each Reagent Arm. The Clean Cups are filled by the Clean Pump. Each Clean Cup has a 24V DC solenoid valve which energizes when Clean A Fluid is required. The valves are normally closed (N/C), but they are opened to allow Clean A Fluid to pass when requested by the ACL TOP software. Clean A Fluid is moved by the Clean Pump as described in Chapter 7 “Fluid Movement”.

The metal bracket on the Accumulator is made of a chemically resistant material to protect the finish from the Hydrochloric Acid in the Clean A Fluid. The metal surface around the Rinse/clean Stations should be wiped clean on a regular basis with an isopropyl alcohol pad.

Sample Side Accumulator

ACL TOP Instruments with Cavro Arms use the Sample Side Accumulator shown in Figure 13-2 "The Sam-ple and Reagent Accumulators". Instruments with the CTS Sample Arm use the Sample Side Accumula-tor shown in Figure 13-4 "The Sample Side Accumulator (CTS)".

Sample Side Accumulators for ACL TOP Instruments with Cavro Arms

The Sample Side Accumulator on an ACL TOP with Cavro Arms contains two Rinse/clean Stations, a Clean Pump, two Clean Valves, a Fluid Level Sensor, and a reservoir to hold excess rinse and other waste fluids. The Waste Fluid Reservoir is a solvent-bonded assembly made of PVC. The front of the reservoir is clear to allow operators to observe the fluid level during Diagnostics. The two center stacks in the Accumulator are vent tubes to equalize the pressure within the Waste Reservoir. Fluid is removed by the Waste Pump via the 1/8-27 NPT barb fitting at the bottom of the reservoir.

Sample Side Accumulators for ACL TOP Instruments with CTS Sample Arms

The Sample Side Accumulator on an ACL TOP with CTS Sample Arms contains one Rinse/clean Stations, a Clean Pump, two Clean Valves, a Fluid Level Sensor, and a reservoir to hold excess rinse and other waste fluids (see Figure 13-4 "The Sample Side Accumulator (CTS)"). The Waste Fluid Reservoir is a solvent-bonded assembly made of PVC. The front of the reservoir is clear to allow operators to observe the fluid level during Diagnostics. There are two vent ports on the top of the reservoir to equalize the pressure within the Waste Reservoir. The Waste Reservoir has a larger capacity to hold the additional Rinse fluid generated by the CTS external wash function. Fluid is removed by the Waste Pump via the 1/8-27 NPT barb fitting at the bottom of the reservoir.

Figure 13-4 The Sample Side Accumulator (CTS)



This accumulator has one clean/rinse station on the right side of the assembly. The clean/rinse station is unique to this accumulator. In addition to the clean cup and a standard rinse location, this clean/rinse station also holds an external wash station with filter for use in CTS equipped instruments. When equipped with CTS, rinse fluid is supplied to the external rinse location by a dedicated diaphragm pump located in the CTS Bulk fluidics module. The clean cup can hold the same volume as the base top accumulator (250uL) and is filled by the clean pump. The clean pump is a 24V DC solenoid driven with a 2 Hz pulse. No solenoid valves are used on this accumulator assembly because the clean pump is self-checking. Clean fluid is moved by the clean pump as described in Chapter 7 “Fluid Movement”.

The metal bracket on the Accumulator is made of a chemically resistant material to protect the finish from the Hydrochloric Acid in the Clean A Fluid. The metal surface around the Rinse/clean Stations should be wiped clean on a regular basis with an isopropyl alcohol pad. Holder for filter changer is located on CTS accumulator.

Waste Fluid Removal in the Accumulator

Fluid level in all accumulators is monitored by a capacitance sensor mounted on the back side of the accu-mulator. The sensor sees through the plastic wall of the accumulator and detects waste fluid when it reaches the height of the sensor. The sensor has an amber LED which illuminates when the sensor is trig-gered. The sensitivity of the sensor is fixed an cannot be adjusted by the operator or by service personnel.

The sensor is positioned to trigger when fluid in the accumulator reaches approximately 80% of the total capacity. When the sensor triggers, the ACL TOP system turns on the Waste Pump. The Waste Pump is left running for a length of time that is sufficient to drain most of the fluid in the accumulator. After the Waste Pump turns off, a small volume of fluid is left in the accumulator to increase the efficiency of the Waste Pump the next time it is used.

The Waste Pump

The Waste Pump is located above the Rinse Pump Box and to the right of the Reagent Module. The Waste Pump has a peristaltic design and it consists of a pump head with four rollers and three waste tubes. The back tube is connected to the Sample Side Accumulator, the center tube to the Reagent Side Accumulator, and the front tube to the Reagent Area Cold Plate (refer to Figure 13-5 "The Parts of the Waste Pump"). The pump head is turned by a 24V DC motor. The motor terminates at a bulkhead-mounted connector on the Waste Pump assembly. An interconnect cable ties the Waste Pump motor to the fluidic connector PCB located in the lower center of the ACL TOP.

Figure 13-5 The Parts of the Waste Pump

Tube to Reagent Accumulator

Tube to Sample Accumulator

Debubbler



The Waste Pump tubes are molded to a specific length from a rubber formulation developed by Instrumen-tation Laboratory. The end of each tube has a molded hub reinforced by an aluminum ring. (The aluminum ring acts as a bearing surface when it is installed.) Proper tension of the Waste Pump tubes is critical to effi-cient operation of the pump.

When the Waste Pump head turns, the rollers spin with the head. The movement of the rollers along the waste tubing creates a peristaltic action very similar to the act of swallowing food. This operation draws fluid out of the accumulators and reagent area and into the waste bottle, or floor drain, located below the ACL TOP. The rollers are independent of each other; to decrease friction and wear, the rollers spin freely when they are drawn across the waste tubing.

The Waste Pump is controlled by the ACL TOP system software. It can also be controlled within the Fluidic Diagnostics Menu. The pump is operated each time one of the two accumulator fluid height sensors is trig-gered and every 20 minutes to drain condensation from the reagent area cold plate. The duration of oper-ation is controlled by software timing. Operation is timed to leave a small volume of fluid in the accumulator. The waste pump is capable of dry priming the waste lines, but functions most efficiently when primed by a head volume. If full drainage of both accumulators is desired for service, the pump can be operated from the Fluidic Diagnostics Menu. Prior to shipment of the instrument, the shipping preparation routine should be run to fully purge the accumulators of waste fluid.

Waste pump tubes should be replaced by service personnel on a scheduled basis. Prior to replacement of the tubes, the Waste Accumulators and lines should be fully drained by running the Waste Pump from the Fluidic Diagnostics Menu.

If the ACL TOP has not been used for several weeks, it is possible for the tubes to take a set. If this hap-pens, unhook the tubes from the bracket and roll them between two fingers to reestablish the tube cross section.

Cuvette Waste Management Subsystem

The Cuvette Waste Shelf Assembly collects the cuvette waste for the Instrument. After a cuvette has been used for analysis, the Cuvette Shuttle leaves the cuvette on the Waste Shelf. Figure 13-6 "The Waste Shelf Assembly" shows the Waste Shelf Assembly and the Waste Container.

Figure 13-6 The Waste Shelf Assembly

Waste Shelf

WasteContainer

Sonic Sensor



The Waste Shelf accommodates up to six cuvettes before dumping them into the Waste Container. The Waste Shelf continues to dump cuvettes into the Waste Container until a sonic sensor senses that the pile of waste cuvettes has reached a maximum height. The maximum height is usually reached when there are about 200 cuvettes in the Waste Container. Figure 13-6 "The Waste Shelf Assembly" shows the location of the sonic sensor on the Waste Shelf.

Note: The sonic sensor height is not adjustable. It is a fixed height built into the Waste Shelf Assembly.

When the pile of waste cuvettes has reached the maximum height, the user is notified via an onboard LED panel and by a message to the computer screen.

The horizontal tilt of the Waste Shelf can be changed with the horizontal tilt adjustment (m3 cap screw) shown in Figure 13-7 "Tilt Adjustment and Positional Sensor". The horizontal tilt of the Waste Shelf is set at the time when the Instrument is assembled. However, the horizontal tilt adjustment can be used to make a field adjustment of the horizontal tilt of the Waste Shelf. If it is necessary to make a field adjustment, the Waste Shelf should be adjusted so that it becomes horizontal to the table surface. Verification that the Waste Shelf is horizontal is done by performing a series of successful Cuvette Shuttle drop-offs. (Verify the drop-offs of the cuvettes with the Cuvette Shuttle under the Diagnostics screen.)

The Waste Shelf Platform also uses a slotted sensor to sense the up and down positions of the shelf (shown in Figure 13-7 "Tilt Adjustment and Positional Sensor"). A linear plunge solenoid is the mechanism that creates the rotation of the Waste Shelf itself (i.e., the solenoid tilts the Waste Shelf to the dump position). An extension spring is used as the return mechanism (i.e., returns the shelf back to the horizontal position).

Figure 13-7 Tilt Adjustment and Positional Sensor

Tilt Adjustment Screw and Sensor Location

Sensor Adjustment Screw



Board Descriptions

This section provides high-level descriptions of the PCBs in the Waste Management System.

Fluidics Connector/Controller Board

• Located between the Sample side and Reagent side incubators below the metal cover.

• Interfaces to the Fluidic controller board to provide control of all fluidic pumps and solenoid valves.

• Provides sensor inputs for Liquid sensors, Rinse, Clean, and liquid waste in the internal accumu-lators and external liquid waste bottle.

• Provides solenoid power to cover interlocks, Sample and Reagent front cover sensors, and emer-gency stop button.

Fluidic LED Board

• Located on the front of the instrument on the right hand side.

• Provides a visual indication of the liquid level status of Clean, Rinse and liquid waste.

• Provides Visual indication of waste cuvette height.

Cuvette Waste Interface Board

• Located on the cuvette waste shelf.

• Provides the electrical interface to the mechanical waste shelf in order to perform the function ofdumping cuvettes into a waste container.

• Features a buffered feed through connection that supports a distance ranging module to gauge thecuvette waste height.

• Interfaces the controller signals to fire a solenoid, and to communicate with the ranging module.

• Provides return sensor signals to the controller from the optical door open/close sensor andmechanical drawer presence sensor.




This section contains verification procedures for the Bulk Fluid Waste Management Subsystem and the Cuvette Waste Management Subsystem.

Verification of the Bulk Fluid Waste Management Subsystem

Verification of the operation of the Bulk Fluid Waste Management Subsystem is done by filling the Sample (or Reagent) Accumulator and then pumping the Accumulator contents into the Bulk Fluid Waste Container. To do this, use the following steps:

1. Go the Fluids tab in Diagnostics and slowly fill the Sample Accumulator until the virtual LED for the Sam-ple Accumulator turns green. At the same time, visually inspect for leaks around the Sample Accumula-tor.

2. From the Fluids tab, run the Waste Pump for 90 seconds or until the virtual LED for the Sample Accumu-lator turns off.

3. Repeat for Reagent Accumulator.

Verification of the Cuvette Waste Management Subsystem

Verification of the operation of the Cuvette Waste Management Subsystem is done by successfully moving cuvettes from the Cuvette Loader to the Cuvette Waste Container. To do this, use the following steps:

1. Ensure that there are at least two cuvette strips in the Transport Deck.

2. Click on the Cuvettes tab in Diagnostics.

3. Use the "Move Cuvettes" function to move 11 cuvettes from the Cuvette Loader to the Cuvette Waste Container. (Note: Enter 11 in the “Number of cuvettes” field.)




13-6 Diagnostics

This section describes the Diagnostics for the Waste Management Subsystem. The following section describes the Diagnostics for the Bulk Fluid Waste Management Subsystem. Refer to "Diagnostics for the Cuvette Waste Management Subsystem" for information on Diagnostics for the Cuvette Waste Manage-ment Subsystem.

Bulk Fluid Waste Management Subsystem

The diagnostics for the Bulk Fluid Waste Management Subsystem are in the Waste sensors area and the Waste pump Area of the Fluids tab. Figure 13-8 "The Fluids Tab" shows the Fluids tab.




Chapter 13 –

Figure 13-8 The Fluids Tab


Waste Sensors Area

The Waste Sensors Area contains virtual LEDs that indicate the status of the Sample Accumulator, the Reagent Accumulator, and the Bulk Waste Fluid Container. Figure 13-9 "The Waste Sensors Area" shows the Waste area.

Figure 13-9 The Waste Sensors Area

The virtual LED “Sample waste fluid full” turns red when the Sample Accumulator is full.

The virtual LED “Reagent waste fluid full” turns red when the Reagent Accumulator is full.

The virtual LED “Waste container” turns red when the Bulk Waste Fluid Container is full.

Waste Pump Area

The Waste Pump Area contains the “Waste pump on” virtual LED, which turns green when the Waste pump is running. The Waste Pump Area also contains a utility for running the Waste pump. Figure 13-10 "The Waste Pump Area" shows the Waste area.

Figure 13-10 The Waste Pump Area

Enter in the Duration box the length of time (in seconds) to run the Waste pump.

Click the Start button to run the Waste pump. If the Stop button is not clicked before the end of the specified duration, the Waste pump runs for the selected duration. If the Stop button is clicked before the end of the specified duration, the Waste pump stops immediately.




D

Th of the Cuvettes tab. Figure 13-11 "The Cu

Chapter 13 –

iagnostics for the Cuvette Waste Management Subsystem

e diagnostics for the Cuvette Waste Management Subsystem are in the Move cuvette(s) area and the Waste Area vettes Tab" shows the Cuvettes tab.

Figure 13-11 The Cuvettes Tab


Move Cuvette(s) Area

Figure 13-12 "The Move Cuvette(s) Area" shows the Move Cuvette(s) area. The Move Cuvette(s) area may be used to move cuvettes to the Waste Container and thereby test the functioning of the Cuvette Waste Management Subsystem. The Start button initiates the Move cuvette(s) function.

Figure 13-12 The Move Cuvette(s) Area

Move

The user can move cuvettes through the slots on the instrument. Both the direction and reuse of the same cuvette are options.

The requested operation is not executed if the Shuttle is not initialized, the Gripper is extended, or the num-ber of cuvettes to be moved is not greater than zero or there is a cuvette in the shuttle.

The module(s), and position in the modules, to which the cuvette is be moved can be selected. Multiple posi-tions, or all positions, in each module may be selected.

The selectable modules and positions are as follows:

Table 13-1 Selectable Modules and Positions

Module Position

Loader Not Applicable

Hold Area Positions 1-14



ORU Positions 1-4

Waste Not Applicable



If the Cuvette Waste module is not selected, the cuvette moves through each selected position and stop at the last selected module and position, and the number of cuvettes can be set to any value from 1 through 99.

If the Cuvette Loader module is not selected, the number of cuvettes field can be set to any value from 1 through 99.

Note: Shuttle motors can not be disabled when a move is in progress.

Clear All Cuvettes

Selecting the "Clear all Cuvettes" button transfers all cuvettes in CTS Hold/Incubator #2, all cuvettes in Incu-bator #1, and all cuvettes in the ORU to the Cuvette Waste Assembly.

Waste Area

The Waste Area contains buttons that control the operation of the Waste Shelf (Accumulator), virtual LEDs that indicate the status of the Waste Assembly, and Sensors for the Waste Assembly. Figure 13-13 "The Waste Area" shows the Waste area.

Figure 13-13 The Waste Area

Start, Stop, and Clear Accumulator Buttons

Select the Stop button to turn off the Ultrasonic sensor for the Waste Shelf. The Ultrasonic sensor is turned off to make adjustments or to pull out the Waste Drawer, etc.

Select the Start button to turn on the Ultrasonic sensor for the Waste Shelf. This is done when it is desired to have the Waste Shelf resume its normal operation (i.e., during dumping waste cuvettes into the Waste Drawer).

Select the Clear Accumulator button to rotate the Waste Shelf to the "down" position. When the Waste Shelf is in the "down" position, the shelf is tilted to allow any cuvettes on the shelf to drop into the Waste Con-tainer.



Virtual LEDs

The upper-left portion of the Waste Area contains virtual LEDs for all of the sensors in the Waste Assembly. When the sensor is enabled, the virtual LED turns green.

The state of each of the following sensors is shown in the Waste Area of the Cuvettes tab:

• Cuvette waste inserted – This sensor indicates whether the Waste Container is inserted orremoved. The virtual LED for this sensor turns green when the Waste Container is inserted and redwhen the Waste Container is removed.

• Cuvette waste door – This sensor indicates whether the Waste Door is open or closed. The virtualLED for this sensor turns green when the Waste Door is opened.

• Accumulator up – This sensor indicates when the Accumulator is in the "up" position. (When theAccumulator is in the "up" position, the shelf is horizontal and can hold cuvettes. When the Accu-mulator is in the "down" position, the shelf is tilted down and any cuvettes on the shelf are dumpedinto the Waste Container.)

Other Sensors in the Waste Area

The Cuvette waste level field indicates the height of the waste cuvettes in the Waste Container. The Waste full limit field indicates the maximum allowable height of waste cuvettes in the Waste Container. When the waste cuvettes reach the height specified in the Waste warning limit field, a user warning is sent to the computer screen. When the waste cuvettes reach the height specified in the Waste full limit field, the Instrument goes into a “controlled stop” (standby mode). Refer to the Operator’s Manual for more infor-mation on controlled stops.


Waste Shelf Assembly Removal/Replacement

Waste Shelf Assembly Removal

Refer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Waste Shelf Assem-bly, the following covers must be removed: Reagent Syringe Cover, Reagent Accumulator/Wash Rinse Cover, Reagent Module Cover, Top Skin, Front Panel, Peristaltic Pump Cover, Upper Skin (Reagent Side), and Right Inner Skin.

After the covers have been removed, do the following to remove the Waste Shelf Assembly:

1. Remove cables P1, P2, and P6 from connectors J1, J2, and J6 from the Cuvette Waste PCB (see Fig-ure 13-14 "Connectors on the Cuvette Waste PCB").

2. Remove cables from connectors J1, J2, J3, J4, and J5 on Front Panel Disconnect PCB Assembly (see Figure 13-15 "Three Captive Screws").

Note: Connectors J3, J4, and J5 are on the front of Front Panel Disconnect PCB; connectors J1 andJ2 are on the rear of Front Panel Disconnect PCB.



3. Loosen the three captive screws shown in Figure 13-15 "Three Captive Screws" and remove the Waste Shelf Assembly.

Figure 13-14 Connectors on the Cuvette Waste PCB

Figure 13-15 Three Captive Screws

J6 Connector

J2 Connector

J1 Connector

Captive ScrewCuvette Waste Door SwitchPCB Assembly



Waste Shelf Assembly Installation1. Position the module for correct location and tighten the three captive screws.

2. Connect cables P1, P2, and P6 to connectors J1, J2, and J6 on the Cuvette Waste PCB.

3. Connect cables to connectors J1, J2, J3, J4, and J5 on PCB Assembly 275030-00 (see Figure 13-15 "Three Captive Screws").

Note: Connectors J3, J4, and J5 are on the front of PCB Assembly 275030-00; connectors J1 and J2are on the rear of PCB Assembly 275030-00.

4. Verify the operation of the Waste Assembly by moving 11 cuvettes from the Cuvette Loader to every position in the system (i.e., CTS Hold Incubator #2, Incubator #1, ORU, and Cuvette Waste Container). Refer to "Verification of the Cuvette Waste Management Subsystem" for information on how to do this.




r/r

Sample Accumulator Removal/Replacement

Sample Accumulator RemovalRefer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Sample Accumula-tor, all of the inside covers on the sample and on the reagent side must be removed.

After the covers have been removed, do the following to remove the Sample Accumulator:

1. Go the Fluids tab in Diagnostics and run the Waste Pump for 90 seconds with three repetitions. This ensures that the Accumulator is empty.

CAUTION: Ensure that the Instrument is powered OFF before the following steps are performed.

2. Remove the cover over the Fluidic Connector/Controller PCB by loosening the two captive screws (see Figure 13-16 "The Fluidic Connector/Controller PCB"). (Note: The captive screws fasten into Incu-bator #1 and Incubator #2.)

3. Remove Connector J2 from the Fluidic Connector/Controller PCB (see Figure 13-16 "The Fluidic Con-nector/Controller PCB").

Figure 13-16 The Fluidic Connector/Controller PCB

4. Loosen the two captive screws on either end of the Sample Accumulator (see Figure 13-17 "The Sam-ple Accumulator (with the Sample Module Removed)").

5. Lift the Accumulator up and remove the Clean Line from the Clean Pump and the Waste tubing from the bottom of the Accumulator (see Figure 13-17 "The Sample Accumulator (with the Sample Module Removed)"). As the Accumulator is lifted, guide the attached cable away from the Instrument.

Captive Screws for the Fluidic ConnectoController PCB Cove

Connector J2

Connector J9



Figure 13-17 The Sample Accumulator (with the Sample Module Removed)

Sample Accumulator Installation

1. Connect the Waste tubing to the bottom of the Accumulator.

2. Connect Clean Line to the Clean Pump.

3. Carefully guide the Accumulator into the Instrument. Ensure that the captive hardware is aligned.

4. Attach Connector J2 to the Fluidic Connector/Controller PCB.

5. Tighten the two captive hardware screws on the Accumulator.

6. Go the Fluids tab in Diagnostics and slowly fill the Sample Accumulator until the virtual LED for the Sam-ple Accumulator turns green. At the same time, visually inspect for leaks around the Sample Accumula-tor.


8. Repeat steps 6 and 7.

Captive Screws

Waste Tubing



r/r

CTS Accumulator Removal/Replacement

CTS Accumulator RemovalRefer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the CTS Accumulator, all of the inside covers on the sample and on the reagent side must be removed.

Note: The CTS Accumulator is mounted to the instrument in the same way as the Sample Accumulator.

After the covers have been removed, do the following to remove the CTS Accumulator:






4. Loosen the two captive screws on either end of the CTS Accumulator (see Figure 13-19 "CTS Accu-mulator").

5. Lift the Accumulator up and remove the Clean Line from the Clean Pump and the Waste tubing from the bottom of the Accumulator. As the Accumulator is lifted, guide the attached cable away from the Instru-ment.


Connector J2

Connector J9



Figure 13-19 CTS Accumulator

CTS Accumulator Installation






6. Go the Fluids tab in Diagnostics and slowly fill the CTS Accumulator until the virtual LED for the Sample Accumulator turns green. At the same time, visually inspect for leaks around the Sample Accumulator.



Reagent Accumulator Removal/Replacement

Reagent Accumulator RemovalRefer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Reagent Accumula-tor, all of the inside covers on the sample side and on the reagent side must be removed.

After the covers have been removed, do the following to remove the Reagent Accumulator:




Captive Screws



r/r



4. Loosen the two captive screws on either end of the Reagent Accumulator (see Figure 13-21 "The Reagent Accumulator (with the Reagent Module Removed)").

5. Lift the Accumulator up and remove the Clean Line from the Clean Pump and the Waste tubing from the bottom of the Accumulator (see Figure 13-21 "The Reagent Accumulator (with the Reagent Module Removed)"). As the Accumulator is lifted, guide the attached cable away from the Instrument.

Figure 13-21 The Reagent Accumulator (with the Reagent Module Removed)

Note: The Waste Tubing for the Reagent Accumulator is beneath the module and is not shown in Figure13-21 "The Reagent Accumulator (with the Reagent Module Removed)".


Connector J2

Connector J9

Captive Screws



Reagent Accumulator Installation






6. Go the Fluids tab in Diagnostics and slowly fill the Reagent Accumulator until the virtual LED for the Reagent Accumulator turns green. At the same time, visually inspect for leaks around the Reagent Accumulator.

7. From the Fluids tab, run the Waste Pump for 90 seconds or until the virtual LED for the Reagent Accu-mulator turns off.


Waste Pump Removal/Replacement

Waste Pump Removal

Refer to Chapter 4 “Enclosure/Chassis” for details on cover removal. To remove the Waste Pump, all of the inside covers on the sample side and on the reagent side must be removed.

After the covers have been removed, do the following to remove the Waste Pump:

9. Remove the four screws on top of the Waste Pump cover, as shown onFigure 13-22 "Waste Pump Cover Screws". Lift and remove the cover.

Figure 13-22 Waste Pump Cover Screws

10. Disconnect the Waste Pump motor cable.

11. Loosen the Waste Output Tube bracket as shown on Figure 13-23 "Waste Pump Removal"

Cover Screws Screws



Figure 13-23 Waste Pump Removal

12. Disconnect the Waste Output tube from the bottom of the debubbler.

13. Disconnect the output tubes from the EP20 Waste Tubing to the debubbler as shown on Figure 13-23 "Waste Pump Removal".

14. Disconnect the input tubes to the EP20 Waste Tubing.

15. Remove the four cap head screws securing the Waste Pump as indicated on Figure 13-23 "Waste Pump Removal".

16. Lift and remove the Waste Pump from the instrument.

Waste Pump Installation

1. Place the Waste Pump on top of the Waste Pump Bracket and attach it to the bracket using the four socket head cap screws as shown on Figure 13-24 "Waste Pump Mounting".

Cap Head Screws

Waste OutputTube Bracket

Output Tubes from EP20 Waste Tubing



Figure 13-24 Waste Pump Mounting

2. Connect the three tubes from the top of the debubbler to the ends of the EP-20 waste pump tubing as shown on Figure 13-24 "Waste Pump Mounting".

3. Connect the Waste Pump motor cable.

4. Place the Waste Tube in the Waste Tube Clamp (as shown on Figure 13-24 "Waste Pump Mounting") and connect the waste tube to the bottom of the debubbler.

NOTE: Ensure there are no kinks in the tubing.

5. Install the new Waste Pump cover using the four captive screws as shown in Figure 13-25 "Assembly with Waste Pump Cover".

Figure 13-25 Assembly with Waste Pump Cover

Waste TubeClamp

MountingScrews

Tubes fromDebubbler

CoverScrews


Chapter 14 – Preventive Maintenance 14 - 1

Chapter 14 –Preventive Maintenance

The recommended preventive maintenance procedures contained within are based on the unit processing500 tests per day and having those tests spread evenly throughout the day. These recommended sched-ules should be adapted for those units processing different volumes.

There are two ACL-TOP maintenance procedures, a primary procedure, and a secondary procedure. Theprimary procedure is performed on an annual basis (with the first occurance taking place one year after theinstallation). The secondary procedure is not as comprehensive as the primary and is also performed on anannual basis, six months after the primary procedure (with the first occurance taking place six months afterthe installation). In this manner, the ACL-TOP receives either a primary or secondary maintenance everysix months. The steps required in each procedure are identified in the checklist on the following page. Thesucceeding pages contain the detailed steps required for both the primary and secondary procedures andclearly identify what step is associated with each procedure.

Parts RequiredFor the primary PM, the ACL-TOP Primary PM Kit, P/N 00029412000, is required. This kit contains all partsthat are required during the maintenance activity.

For the secondary PM, new syringes/tips are required that must be obtained prior to the maintenance activ-ity. Prior to performing the PM, the FSE performing the PM should verify the syringe pumps installed in theinstrument (there are currently Hamilton and Cavro/Tecan syringe pumps in the ACL-TOP) and ensurethey have the correct syringes for the installed pumps.

14-1 Base TOP Preventive Maintenance

The following pages provide a printable checklist that should be completed and signed for each Preventive Maintenance activity as well as instructions for each ot the actions to be performed. Note that the following is for the Base TOP system and is to be done in conjunction with the maintenance for the CTS portion of the system as described in if the system being PM’d is CTS.


14 - 2 Chapter 14 – Preventive Maintenance

ACL TOP Preventive Maintenance Checklist

ACCOUNT: _____________________ DATE: _______________

Address: ______________________________ ______________________________Model: ____________________Serial No.: ___________

Customer Name: __________________Service Engineer Name: __________________

Signature: _______________________Signature: _______________________

PM Activities Primary Secondary Service Manual Refer-ences

Complete

1. Rinse Waste Accumulators with DH2O X Ch. 7 – Fluid Movement

2. Inspect Fluidic System for Leakage and Damage X X Ch. 7 – Fluid Movement

3. Replace All Syringes/Tips X X Ch. 7 – Fluid Movement4. Perform Disk Defragmenter X X Ch. 2 - Installation5. Replace Air Filters X X Ch. 12 - Thermal Control6. Replace Bulkhead Connectors X Ch. 7 – Fluid Movement7. Replace Pump to Probe Tubing on All

Arms X Ch. 7 – Fluid Movement

8. Replace Waste Tubing on Peristaltic Pump X Ch. 13 Waste Management

9. Clean Cavro/Tecan Arms X X Ch. 8 – Robotic XYZ Arms10. Clean ORU X X Ch. 10 – Reaction Detection11. Perform Air and Factor Diluent

Blanking X X Ch. 10 – Reaction Detection

12. Verify Cuvette Shuttle Alignment and All Indexers X X Ch. 9 – Cuvette Handling

13. Perform Coordinate Adjustment X Ch. 8 – Robotic XYZ Arms14. Perform Flow Rate Test for all Arms X X Ch. 8 – Robotic XYZ Arms

15. Check Stirrer Bar Rotation X Ch. 10 – Reaction DetectionCh. 7 – Fluid Movement

16. Check Instrument Software Versions X X Ch. 2 - Installation

17. Verify Touch Screen Calibration X Ch. 2 - Installation18. Check Instrument Temperatures X Ch. 12 - Thermal Control19. Perform Wipe down and Cleaning X X Ch. 2 - Installation20. Verify a “Ghost Image” of the hard

drive exists X X` Ch. 2 - Installation



ACL-TOP Maintenance

1. Rinse Waste Accumulators with DH2O. (Primary PM Only)1. Open the Fluids tab in the Diagnostics screen.

2. Remove the Sample and Reagent area interior covers of the instrument as described in Chapter 4 of the ACL-TOP Service Manual.

3. Using a syringe with tubing attached, carefully add distilled water to fill each accumulator until the appropriate virtual LED on the Fluids tab indicates the accumulator is full.

4. Run the waste pump until the accumulators are empty; visually verify that the accumulator is empty and the LEDs on the Fluids tab are off.

5. Repeat steps c and d two more times.

2. Inspect the Fluidic System for Leakage and/or Damage(Primary and Secondary PM)1. Ensure the ACL-TOP instrument is in the “Ready” state.

2. Power down the instrument using the Power On/Off switch on the right rear of the instrument.

3. Inspect all components of the fluidic system, especially the components not normally replaced, such as pumps and valves.

4. If the Rinse tubing is found to be in need of replacement, perform the following steps to replace it.

a. Remove the Rinse Tubing that attaches to the Sample Syringe Pump.

NOTE: Do not unscrew the barbed fitting on the Rinse tubing line of the Syringe Pump Valve. The barbed fitting is torqued to a precise specification. If the torque is changed, it could cause imprecision.

If this is a Primary PM:

1. Remove the precision tubing to one of the arms as stated in PM Activity 7 to use in this procedure.

15. Cut off the fittings on the ends of the precision tubing.16. Insert one end of the precision tubing into the end of the New Rinse tubing removed from

the Syringe Pump, as shown on Figure 14-1 "Use of Precision Tubing as Threader for Rinse Tubing". (Ensure it is inserted far enough into the Rinse tubing to provide a tight fit.)

Figure 14-1 Use of Precision Tubing as Threader for Rinse Tubing

Rinse TubingPrecision Tubing



17. Using the precision tubing as a threader, feed, and pull the new Rinse tubing through the tubing guide and use it to pull the tubing through to the rinse box and remove the threader.

NOTE: Feed the new Rinse tubing along the same path to the Rinse Box as the old tubing.

If this is a secondary PM, tape the new tubing to the end of the old tubing and carefully feed and pullthe new tubing through the guide tube to the Rinse Pump.

b. Mark the tubing in indelible ink or with a stick-on tag to identify it and connect it to the RinsePump.

c. Cut and connect the other end of the rinse tubing to the Syringe pump.

d. Repeat the above steps for the rinse tubing on the other syringe pumps.5. If the Waste Outlet or Rinse Input tubing is found to be in need of replacement, perform the follow-

ing steps to replace it.

1. Remove sample module, reagent module, ORU cradle, and the Right Skin of the instrument (along with the prerequisite top skin, front panel assembly, and inner right skin) as described in Chapter 4 of the ACL-TOP Service Manual.

18. Remove the four (4) screws attaching the I/O Fluidics Panel to the unit. Then remove the center screw above the "Clean" coupling that attaches the panel to the back fluidics cover. (See Figure 14-2 "I/O Fluidics Panel Screws".)

Figure 14-2 I/O Fluidics Panel Screws

19. See Figure 14-3 "I/O Fluidic Panel Removal". To replace the Rinse Input Tubing, carefully pull the panel forward. Detach the Tygon Tubing from the back of the Rinse coupling, run the new Tygon tubing to the Rinse Pump box area and cut the tubing ensuring there will be enough tubing to connect to the Rinse Input connection on the Rinse Box.

Corner Screws Corner Screws

Center Screw



Figure 14-3 I/O Fluidic Panel Removal

20. See Figure 14-3 "I/O Fluidic Panel Removal". To replace the Waste Outlet Tubing, carefully pull the panel forward. Detach the Tygon Tubing from the back of the Waste coupling, run the new Tygon tubing to the Waste Pump box area and cut the tubing ensuring there will be enough tubing to connect to the bottom of the debubbler next to the Waste Pump.

NOTE: Ensure the Tygon tubes are connected to the correct couplings.

21. Connect the tubing to the Rinse Pump connector or to the debubbler.22. If this is a minor PM, re-assemble the bulkhead portion of the instrument . If it is a major

PM, do not re-assemble the bulkhead as it is removed to replace the bulkhead connectors in step 6 of the major PM.

6. If the CTS, Sample, or Reagent Accumulator tubing is found to be in need of replacement, perform the following steps to replace it.

1. Remove the Sample or Reagent Accumulator as described in“Removal/Replacement” in Chapter 13.

23. Replace the tubing with the harness (tubing with tees and connectors) as supplied in the PM kit and described in the ACL-TOP Service Manual.

3. Replace all Syringes/Tips (IL PN 00287839801).(Primary and Secondary PM)1. Refer to the Online Help for Syringe Replacement.

2. Enter Maintenance Mode and select the appropriate syringe.

3. Follow the on screen prompts to replace the syringe (including the syringe tip).

4. Perform the Disk Defragmenter on the “C” Drive(Primary and Secondary PM)1. Exit the ACL-TOP Application.

2. Power down the Analytical Module by turning off the AC Main switch on the right, rear side of the instrument.

3. Click on Start --> Programs --> Accessories --> System Tools --> Disk Defragmenter.

4. Select Actions and then Defragment. The defragmenter may take a half hour or more to run.

5. While the defragmenter program is running, perform the following PM activities with the power to the Analytical Module OFF.

5. Replace the Main Air Filter (IL PN 0028617300) and Power Supply Air Filter (IL PN 0028454300)(Primary and Secondary PM)

Clean Line

Rinse Input Line

Waste Outlet Line



1. The main air filter is located under the front of the instrument, directly beneath the reagent module. To remove the filter, slide the filter toward the front of the unit.

2. The 24-volt power supply has a filter that is located under the left rear of the unit. To remove the fil-ter, slide it to the left.

6. Replace the Bulk Head Connectors(Primary PM Only)1. Ensure power has been turned OFF to the instrument.

2. Remove the Right Skin of the instrument (along with the prerequisite top skin, front panel assembly, and inner right skin) as described in the ACL-TOP Service Manual.

3. Remove the four (4) screws attaching the I/O Fluidics Panel to the unit. Then remove the center screw above the “Clean” coupling that attaches the panel to the back fluidics cover. (See Figure 14-4 "Fluidics Panel Screws".

Figure 14-4 Fluidics Panel Screws

4. Pull the panel forward. Tag the Tygon Tubing Lines as “Clean”, “Rinse”, and “Waste” as shown on Figure 14-5 "I/O Fluidics Panel Removal". Detach the Tygon Tubing from the back of the fluidic couplings and discard the fluidic panel. Attach Tygon Tubing lines to the new Fluidics Panel Assembly - P/N 286069-01.

NOTE: Ensure the Tygon tubes are connected to the correct couplingsI

Four Corner ScrewsCenter Screw



Figure 14-5 I/O Fluidics Panel Removal

5) Re-assemble the bulkhead portion of the instrument in reverse order.

7. Replace Pump to Probe Precision Tubing on all Arms (IL PN 0028741600). (Primary PM Only)1. Remove the tubing clamp from the top of the arm.

2. Slide the probe cover off the probe.

3. Loosen the two setscrews that hold the probe on the z shaft.

4. Unscrew the minstack fitting.

5. Unscrew the right hand fitting on the syringe pump and pull the tubing from the tubing guide.

6. Save the used tubing for use as a threader if replacing the Rinse Tubing.

7. Replace the tubing, retighten the screws, and re-install the tubing clamp.

8. Replace Three Waste Pump Winding Tubing on Peristaltic Pump (IL PN 0028760501).(Primary and Secondary PM)1. Remove one of the Waste Pump Winding tubes (see Figure 14-6 "Waste Pump Windings") by

sliding the end to the side to disengage it from the pump housing.

CLEAN Line

Rinse Line

Waste Line



Figure 14-6 Waste Pump Windings

2. Disconnect the waste tubing from the end of the tube, connect it to the new tube, and engage the lip of the new tube under the indentation in the pump housing.

3. Repeat steps 1 and 2 for the other end of the tube.

4. Repeat the above steps for the other Waste Pump Windings.

9. Clean the ORU Cradle.(Primary and Secondary PM)1. Using clean, dry cotton applicators, carefully wipe an ORU cuvette slot from the front to the rear,

inspect the applicator for dirt or foreign substances, and repeat until the applicator is clean.

2. Repeat for each ORU.

10. Cavro/Tecan Arms Cleaning(Primary and Secondary PM)

Z-Rack Assembly

NOTE: Do not use alcohol or solvents when cleaning the Z-rack.

1. Ensure power to the instrument has been turned OFF.

2. With a lint-free cloth, wipe the Z-rack thoroughly. If necessary, use a toothbrush to remove dust or dirt from the Z-rack teeth.

Cleaning X-frame, flex-cable channel, square shaft pinion, armsThe Cavro/Tecan arms must be cleaned every six months. However, if the instrument is operated in adusty or humid environment, it must be cleaned more often. Follow the instructions below to preventdamage to the instrument.


2. Remove the arm end caps and covers.

3. Wipe the arm(s) using a lint-free cloth dampened with isopropyl alcohol to remove any residual dust.

Waste Pump Winding Tubes



NOTE: Use only isopropyl alcohol and a lint-free cloth to clean the Cavro/Tecan arms. Other cleaning agents may affect the performance of the instrument.

4. Wipe the inside of the flex cable channel (see Figure 14-7 "Flex Cable Channel"”) using a lint-free cloth dampened with isopropyl alcohol.

Figure 14-7 Flex Cable Channel

Flex Cable Channel



5. Wipe the inside of the X-frame with a lint-free cloth dampened with isopropyl alcohol, ensuring that the lubricant on the X-axis guide rails is not removed. See Figure 14-8 "X Frame and Rails".

Figure 14-8 X Frame and Rails

6. Wipe the square shaft pinion located underneath the arm(s) (see Figure 14-9 "Y Frame and Rails") using a lint-free cloth dampened with isopropyl alcohol.

NOTE: When cleaning the square shaft pinion, ensure alcohol does not enter the Z-bearing or wiped on the Y-axis guide rails.

Figure 14-9 Y Frame and Rails

X or Y-axis Guide Rails Lubrication (ONLY as necessary)Do not wipe the X or Y-axis guide rails. The guide rails are lubricated with grease that does not requireremoval unless they are "extremely" dirty. If extremely dirty or if the factory applied lubricant is wipedaway, they should be cleaned ONLY using the following procedure.

NOTE: Never clean the X or Y-axis guide rails with alcohol or solvents. Serious damage to the instrument may occur.


X FrameX-Axis Guide Rails

Y-Axis Guide Rails

Square Shaft PinionZ Bearing




2. Move the arm(s) to the far right side of the X-frame.

3. Apply a thin film of Food Grade Lubricant to the rails.

• Lubricant should not be visible or collect during operation.

• If lubricant is visible or collects when the element is moved, wipe the lubricated area with a dry lint-free cloth to remove the excess lubricant.

11. Perform Air and Factor Diluent Blankings(Primary and Secondary PM)1. Apply power to the instrument by pressing the power switch on the right rear of the instrument.

2. Access the Diagnostic screen.

3. Select the ORU tab on the Diagnostics screen.

4. Verify that ORUs 1-4 are enabled (Green LED) as indicated on Figure 14-10 ".ORUs Enabled"

Figure 14-10 .ORUs Enabled

5. If all four ORU Enabled LEDs are not lit, click on any box without a check mark as shown in Figure 14-11 "ORU Enabling Portion of Diagnostic Screen" and click on the “Save” button. Verify that the green LED light, indicating the ORU is enabled, is lit.

Figure 14-11 ORU Enabling Portion of Diagnostic Screen



6. Click on the ”Start Air Blanking for all ORUs” button, in the Optical Blankings portion of the diag-nostic screen as shown in Figure 14-12 "Air Blanking of All ORUs"

Figure 14-12 Air Blanking of All ORUs

7. Upon completion of the Air Blanking (approximately 5 minutes), a message box is displayed show-ing the readings for each channel as shown on Figure 14-13 "Air Blanking Value Reading" Ver-ify all readings are between 500000 and 1200000 and the drift is less than 6% (< 6.0). If all readings are within specifications, select the radio button marked “Overwrite” for the instrument to use the new readings. If all readings are not within specification, troubleshoot the problem.

Figure 14-13 Air Blanking Value Reading

for All ORUs ButtonStart Air Blanking



8. Click on the “Start Factor Diluent Blanking for all ORUs” button, in the Optical Blankings portion of the diagnostic screen as shown in Figure 14-14 "Factor Diluent Blanking for all ORUs".

Figure 14-14 Factor Diluent Blanking for all ORUs

9. Ensure Factor Diluent is available in the instrument as requested by the message box.

NOTE: All mechanical assemblies (Arms, Loader, Shuttle, and Bar Code Reader) must be initialized (using the radio buttons in diagnostics) or the blanking will immediately fail. In addition, Cuvettes, Rinse, and Clean A must be available in the instrument.

10. Upon completion of the Factor Diluent Blanking (approximately 30 minutes), a message box is dis-played showing the readings for each channel as shown on Figure 14-15 "Factor Diluent Blank-ing Readings". Factor Diluent Blanking Readings. Verify all readings are between 500000 and 1200000 and the drift is less than 6% (< 6.0). If all readings are within specifications, select the radio button marked “Overwrite”. If all readings are not within specification, select the radio button marked “Cancel” and troubleshoot the problem.

Figure 14-15 Factor Diluent Blanking Readings

Factor Diluent Blanking for All ORUs Button



12. Verify Cuvette Shuttle Alignment(Primary and Secondary PM)End of Limit Sensor Check1. If not already done, remove the Sample and Reagent Area Interior Covers.

2. With the instrument powered on, select the Cuvettes tab on the Diagnostics screen.

3. Click on the “Disable Shuttle Motors” button.

4. Perform the following steps to check the Left Limit Sensor of the Cuvette Shuttle Assembly as shown on Figure 14-16 "Left and Right End-of-Limit Sensors".

Figure 14-16 Left and Right End-of-Limit Sensors

a. Manually move the Cuvette Shuttle Assembly all the way to the left most end of the Shuttle Travel. (When the Cuvette Shuttle reaches the lifetimes end of the Shuttle Travel, the virtual LED for “Shuttle Left Limit” should turn green.)

b. If the virtual LED for “Shuttle Left Limit” does not turn green, adjust the sensor bracket up or down.

c. Repeat steps a and b (above) until you can make the virtual LED for “Shuttle Left Limit” turn green.

d. Repeat steps a through c (above) for the Right Limit Sensor of the Cuvette Shuttle Assembly.

Cuvette Shuttle Verification/Alignment Verifying and aligning the Cuvette Shuttle consists of three discrete tasks:

Z Height and Tilt Check and AdjustmentY Check and AdjustmentX Check and AdjustmentThese tasks are described in the following paragraphs.

Z Height and Tilt Check and Adjustment1. Disable the Cuvette Shuttle by clicking the “Disable Shuttle Motors” button in the Shuttle area of

the Cuvettes Diagnostics Tab.

2. Orient the Cuvette Shuttle Assembly so the front face of the Shuttle is directly in front of the Align-ment Tool, as shown in Figure 14-17 "Shuttle Alignment Tool".



Figure 14-17 Shuttle Alignment Tool

3. Loosen the orange thumbscrews on the Alignment Tool and attempt to insert the dowel pin (located in the center of the Alignment Tool) into the front face of the Shuttle Assembly.

4. If the dowel pin fits smoothly, the shuttle height and tilt is correct and proceed to the Y Check and Adjustment below. If the dowel pin does not fit smoothly into the front face of the Shuttle Assembly, perform the following steps:

a. Using a 2.5mm Allen wrench, loosen the Z Height and Tilt Locking Screws (see Figure 14-17"Shuttle Alignment Tool"

b. Using a 1.5mm Allen wrench, adjust the Z height and tilt by turning the Z Height and Tilt Adjust-ment Screws (see Figure 14-18 "Z Height and Tilt Adjustments"). (Note: Turning the screwsclockwise lowers the shuttle; turning the screws counterclockwise raises the shuttle.) The align-ment is correct when 1) the dowel fits smoothly into the front face of the Shuttle Assembly and 2)the front face of the Alignment Tool is completely flush (perpendicular) with the mating face on thefront of the Cuvette Shuttle Assembly.

Figure 14-18 Z Height and Tilt Adjustments



c. Tighten the Z Height and Tilt Locking Screws to secure the adjustment.5. With the Z Height and Tilt Locking Screws tightened, re-check the adjustment as follows:

• The dowel should fit smoothly into the front face of the Shuttle Assembly.

• The front face of the Alignment Tool should be completely flush (perpendicular) with the mating face on the front of the Cuvette Shuttle Assembly. (The Alignment Tool surface should not be tilted against the front surface of the Cuvette Shuttle.)

6. If the adjustment is not correct, repeat step 4 above.

Y Check and Adjustment1. Orient the Cuvette Shuttle Assembly so the front face of the Shuttle is directly in front of the cuvette

pick-up position on the Loader.

2. To check the Y adjustment, slowly turn the Turning Wheel to move the gripper assembly toward the cuvette until the Y-axis LED comes on. (The Turning Wheel and Y-axis LED are shown in Figure 14-19 "Y Axis LED and Turning Wheel".) Check that the front face of the Gripper is flush with the front face of the cuvette. If it is flush, the adjustment is correct. Proceed to the "X Check and Adjust-ment". If the Gripper is not flush, proceed with step 3.

Figure 14-19 Y Axis LED and Turning Wheel

3. Using a 2.5mm Allen wrench, loosen the Y-Axis Sensor lock down screw (see Figure 14-20 "Y-Axis Adjustment and Locking Screws").

Figure 14-20 Y-Axis Adjustment and Locking Screws



4. Turn the Turning Wheel until the front face of the Gripper Assembly is flush with the front face of a cuvette located at the Cuvette Pick-up position on the Loader Assembly. (The Turning Wheel is shown in Figure 14-19 "Y Axis LED and Turning Wheel".)

5. Using a 2.5mm Allen wrench, turn the Y-Axis Sensor Adjustment screw until the Y-Axis LED comes on with the Gripper Assembly just touching the front face of the Cuvette at the Cuvette Pick-up position. (The Y-Axis Sensor Adjustment screw is shown in Figure 14-20 "Y-Axis Adjustment and Locking Screws". The Y-Axis LED is shown in Figure 14-19 "Y Axis LED and Turning Wheel".)

NOTE: Turning the Y-Axis Sensor Adjustment screw in a counterclockwise direc-tion will move the Y-Axis (and Gripper) Sensor towards the front of the Instrument.

6. After the alignment of the Y-Axis Sensor has been set, tighten the Y-Axis Adjustment Locking screw to secure the adjustment. (The Y-Axis Adjustment Locking screw is shown in Figure 14-20 "Y-Axis Adjustment and Locking Screws".)

7. When the Y-Axis Sensor is properly adjusted, slight turns of the Y-Axis Sensor Adjustment screw make the LED go on and off. If the adjustment is not correct, repeat steps 5 and 6.

X Check and Adjustment

NOTE: Ensure the Instrument is powered ON. Before starting this adjustment, clean the Shuttle alignment rails on the back of each assembly, using a paper towel, and clean the X-Axis sensor using a dry cotton swab.

1. Initialize the Cuvette Shuttle by clicking the “Initialize Shuttle” button in the Shuttle area of the Cuvettes Diagnostics Tab.

2. In the Move Cuvette section, move one cuvette into the first Hold Area position by performing the following steps.

a. Click on the “Loader” box.

b. Click on the “Hold Area” radio button and click on the first box in the Hold area.

c. In Number of Cuvettes, enter “1”.

d. Click on the “Move” radio button and click on the “Start” button.3. Perform the following steps to move one cuvette into the first Hold area position:

• Click on the “Extend” radio button and click on the “Start” button.

• Click on the “Grab” radio button and click on the “Start” button.

4. As the Gripper grabs the cuvette, visually check whether the gripper is centered inside the cuvette. If it is centered, the X-Axis alignment is correct. If it is not centered, proceed with the next step to perform the X adjustment.

5. Click on the “Disable Shuttle” button.

6. Using a 2.5mm Allen wrench, loosen the X-Axis lock down screw. (See Figure 14-21 "X-Axis Adjustment and Locking Screws"). Turn the X-Axis adjustment screw clockwise to move the Gripper to the left, or counterclockwise to move it to the right. Tighten down the locking screw.



Figure 14-21 X-Axis Adjustment and Locking Screws

7. Click on the “Initialize Shuttle” button and repeat steps 2 and 3 to check for proper centering of the Gripper inside the cuvette. Repeat steps 2 through 6 until proper alignment is achieved.

8. Using steps 2 and 3 above, check the alignment in other areas by selecting that position in the Move Cuvette section.

9. The shuttle alignment is complete.

13. Coordinate Adjustment(Primary PM Only)1. Before the Coordinate Adjustment is performed, verify that ALL interior instrument covers are

removed.

2. Clean all probe tips and probe alignment positions, including the Rinse cup, using an alcohol prep pad.

3. Open the Probes tab in the Diagnostic screen.

4. Disable all Arms.

5. Open the Controllers, Covers, Racks tab in the Diagnostic screen.

6. Click on the “Initialize the Bar Code Reader Motor” button.

7. Open the Probes tab in the Diagnostic screen.





9. Click on the “Coordinate Adjust” button on the Probes tab as shown on the figure.

10. After the arm’s coordinate adjustment is complete, repeat steps 8 and 9 for each arm.

14. Perform Flow Rate Test for All Arms(Primary and Secondary PM)The Flow Rate Test is used to determine if the rinse fluidics are functioning properly.1. Open the Probes tab of the Diagnostic screen.



3. Click on the Flow Rate Test button in the Rinse portion of the screen (lower left) as shown in Fig-ure 14-24 "Flow Rate Test Buttons".

Figure 14-24 Flow Rate Test Buttons

Arm Selection Coordinate Adjust

Arm Selection



4. Based on the arm selected, the system displays a message stating where to place a graduated con-tainer. The locations are:

Sample Arm: Sample Track 6, Position 5

Reagent Arm 1: Reagent Track 3, Position 3

Reagent Arm 2: Reagent Track 3, Position 3 5. Place the graduated container in the indicated position.

6. Select the number of seconds for the pump to run (5 seconds) in the Duration: box in the Rinse portion of the screen as shown on Figure 14-24 "Flow Rate Test Buttons".

7. NOTE: If necessary, the “Stop” button can be clicked on to discontinue the test.

8. Click the Start button Rinse area of the screen.

9. After the probe has dispensed Rinse solution into the graduated container for the set length of time, measure the volume of solution in the graduated beaker. The flow rate must be as shown in Table 14-1. Rate Flow Measurements.

Table 14-1 Rate Flow Measurements

10. If the flow rate is too low, i.e., not enough Rinse is deposited in the beaker; check the fluidic rinse tubes for any restrictions and the rinse pump for proper operation. If the flow rate is too high, check the rinse pump and check valves.

15. Check Stirrer Bar Rotation.(Secondary PM Only)1. Insert a stirrer bar into two reagent vials and insert the vials into the first (rearmost) two positions in

a reagent rack.

2. Verify the bars spin when the rack is inserted in each reagent slot.

16. Check Instrument Software Version.(Primary and Secondary PM)1. Click on System --> Instrument Status as shown on Figure 14-25 "System Software Versions-

Display Selection".

Figure 14-25 System Software VersionsDisplay Selection

2. Click on the SW-Version tab tab in the resulting screen to display the software revisions and verify the software is at the latest revision, as shown in Figure 14-26 "Software Revisions Display" .

Base Top CTSVolume After 5 Seconds Flow Rate Volume After 5 Seconds Flow Rate

5.15±0.5ml (4.65 to 5.65ml) 1.03ml/sec (±0.10ml)

5.58±1.04ml (4.54 to 6.61ml) 1.12 ml/sec ± (0.20ml)



(Refer to the ACL-TOP Information Notifications for the current mandatory and recommended soft-ware revisions.)

Figure 14-26 Software Revisions Display

17. Check the Touch Screen Calibration.(Secondary PM Only)

• The first method is to click on the Elo shortcut on the Windows desktop, select "Align”, and fol-low the prompts.

• The second method, if the short cut is missing, is Start -->Settings -->Control Panel -->Select Elo, click on Align, and follow the prompts.

18. Check Instrument Temperatures. (Secondary PM Only)1. Click on System --> Instrument Status as shown on Figure 14-27 "System Temperature Dis-

play Selection".

Figure 14-27 System Temperature Display Selection

2. Click on the Temperatures tab in the resulting screen to display the temperature of all thermal con-trolled elements as shown in Figure 14-28 "Temperature Tab of Instrument Status Display".



Figure 14-28 Temperature Tab of Instrument Status Display

3. Record the coefficients as stored in the instrument using the ThermalCal program as described below.

NOTE: ThermalCal must be run with all covers closed.

ThermalCal Operating Procedure for Storing Coefficients

Inputting Thermal Coefficients using ThermalCal1. If any CM software is running, close the applications.

2. If the ThermalCal software is installed on the CM computer, double click on the ThermalCal icon on the desktop, as shown on Figure 14-29 "ThermalCal Icon" to open the program.


NOTE: The most recent versions of ACL-TOP have the ThermalCal software pre-loaded on the CM. Verify it is not loading by clicking on Start ¯> Programs to dis-play the list of installed programs.


a. Insert the distribution CD-ROM into the computer.



b. Double click the “My Computer” icon on the desktop.

c. Double click the icon of the CD-ROM drive to open it.

d. Drag the ThermalCal folder onto the computer desktop.

e. Open the ThermalCal application by double clicking on the ThermalCal icon.4. ThermalCal boots into the “Automatic” mode. Click on the “Go to Manual Mode” button as shown

on Figure 14-30 "ThermalCal Screen".



•The CM Computer and the touch screen monitor are ON.

•The CM Software is NOT running.

•The Analytical Module is OFF (power is off to the instrument).

6. Turn on the Analytical Module. (Power up the instrument.)

7. Wait 4 minutes for the TOP Analytical Module to start. (Since the CM software is not running, there is no visual indication that the Analytical Module is operational.)



8. Click the “Connect to TOP AM” button of the ThermalCal application as shown on Figure 14-31 "Connecting ThermalCal to the AM".

Figure 14-31 Connecting ThermalCal to the AM

9. Wait until the TOP AM Status displays “Connected”, as shown in Figure 14-32 "Connection Sta-tus - Connected".

Figure 14-32 Connection Status - Connected

Connection Button

Connection Status



10. Once the TOP AM Status: displays “Connected”, click on the “Display Coefficients” button to display the stored coefficients of the system as shown in Figure 14-33 "Thermal Coefficient Dis-play".

Figure 14-33 Thermal Coefficient Display

11. With the coefficients being displayed, click on ALT + Print Screen to capture the screen content.

12. Minimize the ThermalCal application.

13. If there is not a WordPad icon on the desktop, generate a shortcut to WordPad for storing of the Screen content:

• Click on "My Computer".

• Select C:/ --> Document and Settings --> Administrator --> Start Menu --> Program --> Accessories.

• Click on “WordPad”.

• Right click and select “Create Shortcut”.

• Click on the WordPad icon and drag it to the desktop.

• Close all Windows and return to the desktop.


15. Click on Edit --> Paste to paste the screen capture into the application.

16. Click on File --> Save As and save the file as C:\Thermal Coefficients.

17. Exit the WordPad application by clicking on File --> Exit.

18. Maximize and then exit the ThermalCal application by clicking on the “Exit” button in the upper right corner of the screen.

19. Perform a General Wipe Down of the Instrument(Primary and Secondary PM)



• Perform a wipe down of the exterior and interior of the instrument using a moistened lint free cloth.

20. Verify there is a “Ghost Image of the CM Hard Drive(Primary and Secondary PM)The “Ghost Image” procedure creates an image of the entire Control Module hard drive content includ-ing Windows 2000 and all ACL-Top application software. This image must be created any time there isa major system upgrade or during PM and can be used to restore the CM computer to its condition atthe time of the “ghost Image” generation.

To determine if a ghost image needs to be created, check with the Lab Supervisor.

NOTE: It is highly recommended that Medical Grade Media be used to store the image created by this procedure. Always store the media according to manufac-tures specifications.

Per the Symantec Ghost license agreement, this tool may only be used on ONE CM PC for each CMRecovery Kit obtained from IL.

NOTE: Read through this entire process before beginning. Be sure to read each step fully before executing.

1. Click on Start -> Shutdown ->Shutdown -> OK to power off the computer (if it is not already shut-down).

2. Turn on the CM computer and immediately insert the Symantec Ghost Boot CD into the CD/DVD Drive.

3. Select “OK” in the Ghost message box.

4. In the Ghost application, select Local Partition To Image

5. When the “Select local source drive by clicking on the drive number” window is displayed, select the correct drive (only one should be available), and select “OK”.

6. When the “Select source partition(s) from Basic drive: 1” window is displayed, select the correct partition (only one should be available), and select “OK”.

7. The “File name to copy image to” window is displayed.

8. Insert a blank CD-R into the CD Drive.

NOTE: If the CM has a DVD R/RW Drive, the door of the drive will have “DVD R/RW” label, then a DVD-R may be used to create the image.

9. Select the CD/DVD Drive (@CD-R1…. DVD Drive) from the “Look in:” dropdown list, and then select Save

10. A message box is displayed asking to compress the image. Select High.

11. A message box is displayed asking to copy a bootable floppy to the CD/DVD disc. Select “NO”.

12. A message box is displayed asking to proceed. It also provides an estimate of the number of CD’s or DVD’s that are needed to store the image, although the estimate is usually very high. Select “Yes”.

13. A warning message about spanned NTFS images is displayed. Select “Yes”.

14. The image starts to be created, and a progress bar is displayed indicating how long it will take the image to be created.



15. If more than one CD/DVD is necessary to save the image file, a prompt is displayed requiring another blank CD/DVD to be inserted.

16. Label each CD/DVD with the name of the CM computer, the number of the CD/DVD used, and the date.

17. After completion of the Ghost image, it must be verified for correct content. In the Ghost applica-tion, select Local Check Image File.

18. Insert the Ghost image CD/DVD (Disk 1 if there are multiple discs) into the CD/DVD Drive.

19. Select the CD/DVD Drive (@CD-R1…) from the “Look In” dropdown menu, and click on “Open”.

20. A message box is displayed asking to proceed with the image file integrity check. Select “Yes” and the verification process begins. A progress indicator is displayed showing what percentage of the validation has been completed.

NOTE: If more than one CD/DVD is required to store the image file, a prompt is displayed to insert the next CD/DVD at the appropriate time.

21. When the validation has completed successfully, a message box is displayed, “Image file passed integrity check”. Click on “Continue”.

22. If the integrity check fails, the Ghost Image procedure must be re initiated using high-quality media. If it fails again, contact technical support.

23. Exit Ghost by selecting “Quit” from the menu, remove the CD/DVD, and restart the computer.

24. Provide the CD/DVD(s), labeled as stated in step 16, to the Lab Supervisor for proper storage.

14-1 CTS PreventiveMaintenance

For CTS, the following checklist is to be completed in addition to the Base TOP Preventive Maintenance. Each of these ites are specific to the CTS portion/aspect of the system.



ACL TOP CTS Preventive Maintenance Checklist

ACCOUNT: _____________________ DATE: _______________

Address: ______________________________ ______________________________Model: ____________________Serial No.: ___________

Customer Name: _____________________Service Engineer Name: _____________________

Signature: __________________________Signature: __________________________

PM Activities Primary Secondary Service Manual Refer-ences

Complete

1. Replace Piercer Tip X Ch. 15 – CTS Piercer2. Replace the Probe and Seal

Assembly. X X Ch. 15 – CTS Piercer

3. Replace the piercer probe. X X Ch. 15 – CTS Piercer4. Replace all pneumatic Tygon tubings X Ch. 7 - Fluid Movement5. Clean the belt residue inside the

frame near the belt tensioning assembly for the X axis for all arms.

X Ch. 8 – Robotic XYZ Arms

6. Clean belt residue on cable tray ( X axis) for all arms. X Ch. 8 – Robotic XYZ Arms

7. Wipe down the X axes on top of the bearing rails on each arm. X Ch. 8 – Robotic XYZ Arms

8. Verify the belt tension and adjustment for the X axis of each arm. X Ch. 8 – Robotic XYZ Arms

9. Remove the covers and clean the Y axis of each arm. X Ch. 8 – Robotic XYZ Arms

10. Clean the cable residue and dust on contact surface of cable guides of the Y axe on each arm.


11. Wipe down the bearing rails on the Y axes for each arm. X Ch. 8 – Robotic XYZ Arms

12. Wipe down the rack shafts for the Z axis on each arm. X Ch. 8 – Robotic XYZ Arms

13. Check for backlash, looseness, etc. for all parts on the Z axis of each arm.



Chapter 15 – CTS Piercer 15 - 1

Chapter 15 –CTS Piercer

WARNING: Piercing Hazard. Do not put hand inside Instrument while it is in motion.

BIOHAZARD: The Sample probe and Piercer probe should be treated as a biohazard item and laboratory precautions for biohazard material should be taken in its handling and disposal.

15-1 Overview

The Closed Tube Sample (CTS) Piercer provides piercing and sampling of capped/uncapped Sample Tubes for the ACL-TOP instrument. The piercer is a part of the Sample Robotic Arm and is a separate arm assembly from non-CTS instruments. As shown in Figure 15-1 "CTS Piercer Components", the CTS Piercer is comprised of 3 components:

• Telescoping CTS Assembly

• Sample Probe-n-Seal Assembly

• CTS Piercer Probe

The Telescoping CTS Assembly and its components are not customer replacable parts while the Probe-n-Seal Assembly and CTS Piercer Probe are both replacable on an as needed basis by customers and/or dur-ing scheduled service by service personnel.


15 - 2 Chapter 15 – CTS Piercer

Figure 15-1 CTS Piercer Components

The piercer probe consists of the probe that pierces the cap of a sample tube, as well as a sample probe (located in the center of the piercer probe) that aspirates or dispenses a sample. The sample probe is inside the Piercer Probe that protects the sample probe during piercing. The Sample Probe-n-Seal Assembly, in turn, is mounted within the Telescoping CTS Assembly.

The ACL-TOP instrument uses HemosIL Rinse solution for cleaning the sample tube and as a working fluid. As a working fluid, the solution is used to ensure displacements created in the Syringe Pump are precisely replicated at the probe tip when samples are aspirated or dispensed. The HemosIL Rinse solution accom-plishes this by limiting the compressibility of the system. Refer to Chapter 7 “Fluid Movement” for detailed information on how the instrument uses the HemosIL Rinse solution and conducts fluid movement.


Figure 15-2 "CTS Piercer Location" shows the physical location of the CTS Piercer. As shown, the CTS Piercer is located within the Sample Arm.

PiercerProbe

SampleProbe-n-SealAssembly

TelescopingCTSAssembly




Figure 15-2 CTS Piercer Location

Sample Arm

CTS Piercer Probe



Figure 15-3 "CTS Piercer Interconnect Diagram" contains the Interconnect Diagram for the CTS Sample Arm.

Figure 15-3 CTS Piercer Interconnect Diagram

CTS Piercer

J1

J9

J4

J6

J3

J5

J2

J8

J5

J4

J1

J3J

2

J6

J5

J8

J4

J2

J1

J3

J4

J7

J2

J6

J5

J1

J3

J6

J5

J3J1

1

J13J10J12

J16

J15J2

J1

J8

J7

J14

J4

J9

J7

PIERCERLLD

J6

COAXIAL

28654100



The following paragraphs list the functions of the PCBs and their functions relative to the Sample Arm Assembly with the CTS Piercer.

Board Descriptions

CTS X Axis Board

• Provides the electrical interface to the mechanical arm assembly.

• Drives the stepper motor that moves the arm in the X direction to coordinate positions.

• Power distribution point to/from the fuse PCB and the controllers through ribbon cables.

• Provides the drive circuitry for the X-Axis Motor.

• Drives the interface circuitry for the X-Axis encoder.

• Provides the drive circuitry for the Air Pump, Fluid Pump, and the Air Pressure Sensor input inter-face.

• Provides pass through connections for RS-232 signals to the syringe pumps and the FET switchcontrolling power to the syringe pump.

• Provides a CAN bus feed through to the controller for the master computer communications.

CTS Controller Interface Board

Subsystem controller that controls XYZ Motion.

• Provides communications with master controller through the CAN Bus.

• Interfaces with Controller Interface to decode data and an address for Digital I/O.

• Provides an Analog to Digital Converter for Power Supply Voltage Monitoring.

• Includes encoder counters for the X, Y, and Z motors.

• Dip Switch selectable for SMP, IRP,. and STP, configurations.

• Communications to Probe heater board PIC, through SPI communications.

CTS Y Driver Board


• Drives the stepper motor, which moves the arm in the Y direction to coordinate positions.

• Provides drive circuitry for the Y-Axis Motor.

• Provides interface circuitry for the Y-Axis encoder.

• Supports three probes, with two heating elements per probe.

• Converts PWM to a variable DC Voltage for the two probe heaters.

• Converts a 30kHz PWM signal from the probe microcontroller and converts it to a DC voltage. (TheDC voltage minimizes the switching surges on the power supply, and the noise impact on the instru-ment. It also reduces interference with the LLD circuitry.)



• Provides two optical slot sensor interfaces that provide limit sensing for X-Axis travel.

• Provides two optical slot sensor interfaces that provide limit sensing for Y-Axis travel.

CTS Z Driver Board


• Drives the stepper motor, which moves the probe to coordinate positions in the Z direction.

• Contains an integrated controller/driver IC that drives the motor in full, half, quarter, and eighth stepmovements.

• Provides interface circuitry for the Z-Drive motor encoder in the Universal Arm.

• Provides the interfaces drive circuitry for the piercer lock solenoid and the rack lock solenoid.

• Includes an optical switch interface for travel limit measurements.

• Includes pass through connections for the Heated Probe and CTS probe PCBs.

CTS Travelling Signal Interconnect)

The Travelling Signal Interconnect PCB is specific to the CTS version of the ACL-TOP instrument. As such, it contains all circuitry that controls the piercer aspect of the probe. This includes:

• The interface circuitry for the CTS mechanism.

• A solenoid driver for the Lock Solenoid that switches the probe between Piercer and Sample mode.

• Provides optical slot sensor interfaces that provide limit sensing for

• cap sensing,

• piercer lock sensing, and

• piercer position sensing.

• a Liquid Level Detection (LLD) circuit to control the sample probe LLD.

15-4 CTS Piercer Theory of Operation

Piercer and Sample Mode

The CTS Piercer has two operating modes, Sample and Piercer. When the piercer probe is in the down position to pierce the cap of a sample tube, it is in piercer mode. When the sample probe is extended and ready to aspirate or dispense a sample, it is in sample mode.



Figure 15-4 "Piercer Probe in Piercer and Sample Mode" shows the CTS Piercer Probe in piercer and sample mode. As depicted on the left side of the figure, when in piercer mode, the Piercer Probe is locked in the “down” position, entirely covers the sample probe, and is able to pierce the cap of a sample tube. As depicted on the right side of the figure, when the CTS Piercer is in sample mode, the CTS Piercer Probe is locked in the “up” position, the sample probe is exposed and ready to aspirate or dispense a sample. Note that the foot is shown covering the probe. The foot moves up and down with the Piercer Probe until the foot encounters the cap of a closed top sample.

Figure 15-4 Piercer Probe in Piercer and Sample Mode

Probe Status LEDs

The CTS Piercer Probe has one red and one green status LED, located on the Telescoping CTS Assembly (as shown on Figure 15-5 "Status LEDs"). When the Probe is in piercer mode, both status LEDs (green and red) are off. When the Probe is in sample mode, the green status LED is on and the red status LED is off. As shown in the table,

• the red LED is only on when the probe is changing modes

• the green LED is on in Sample mode and off in Piercer mode.

Table 15-1 "Status LEDs" shows the on/off state of the LEDs in each of the three operating modes of the CTS Piercer Probe

NOTE: The green status LED indicates the position of the CTS Piercer Probe when the Tele-scoping CTS Assembly is home in the Z-axis. (Home is considered to be when it is traveling between the tube, bottle, incubator, or wash/clean positions.) When sampling or dispensing, the software does not assess the state of the piercer probe.

Table 15-1 Status LEDs

Operating Mode Green LED Red LED

Piercer Mode OFF OFF

Sample Mode ON OFF

Changing Mode ON/OFF ON

Piercer Mode Sample Mode

Sample ProbeExtended

PierceProbe

FootFoot



Figure 15-5 Status LEDs

Sample and Piercer LLD

The Sample and Piercer Liquid Level Detection (LLD) sensing is driven by a capacitance differential circuit. The sensor output uses a coaxial cable that connects the probes to the electronics to enable Liquid Level Detection (LLD) in tubes, bottles, or the cuvette. The sample LLD senses the liquid while the piercer LLD prevents intermittent LLD signals from affecting the detection. During the LLD operation, the brake rack is locked and the electrical connection between the brake rack and retraction shaft is broken, thereby breaking the ground path for the Piercer LLD circuit. By using the Piercer as part of the circuit, false indications are eliminated when the pressures exerted by cap piercing causes the sample and piercer probe to touch. The Sample and Piercer LLD cable are connected as shown in Figure 15-6 "LLD Cables".

Note: LLD is also used to perform the coordinate adjustment for the CTS Piercer Probe. This is accom-plished by having the probe contact the edges of specified locations within the sample rack and usingthe capacitance differential circuit to sense that contact.

Figure 15-6 LLD Cables

Probe Foot

Except when in a tube, the foot moves with the CTS Piercer Probe. The foot protects the probe from dam-age, the user from potential injury, and has an attached air line used to remove any droplets left on the piercer probe after a Deep Wash. Refer to Chapter 7 (“Fluid Movement”) for more information about Deep Washing.

Green Status LED

Red Status LED

Piercer LLDCable

Sample LLDCable



Piercer Lock/Lock Solenoid/Sensor

Figure 15-7 "Piercer Lock Components" shows the components of the Piercer Lock Assembly, the piercer probe, and the piercer “lock” with the elongated hole and the hole through which the lock optical sen-sor determines the position of the lock. The Piercer Lock consists of a plate with an elongated hole through which the piercer probe extends that is used to “lock” hold the probe in position. Note that the Piercer Lock Solenoid is a bit of a misnomer because when energized, it unlocks the probe. When the Piercer Lock Sole-noid is not engaged, i.e., the probe is locked in position, the narrow part of the elongated hole fits into the indentations in the probe and locks it in place (either for Sample or Piercer mode). When the Piercer Lock Solenoid is energized, it retracts the CTS Piercer Lock and the large part of the elongated hole allows the piercer probe to move. The solenoid is only energized long enough for the probe to move out of the locked position, thereby changing modes. Power being applied to the Piercer Lock Solenoid is indicated by the red status LED (indicating a mode change). When the CTS Lock is disengaged, the CTS Piercer Probe moves along with the sample probe.

The Piercer Lock Sensor, shown in dotted lines on the figure, consists of an optical sensor that sees light through a hole in the lock as long as the solenoid is not energized (and the probe is locked). When the Piercer Lock Solenoid is supplied power, it retracts the Piercer Lock and the hole is moved, blocking the light path of the sensor. This change in the sensor output is used to indicate to the instrument that the lock is being released and the probe is changing modes.

Figure 15-7 Piercer Lock Components

Piercer Lock Sensor

Elongated hole in Piercer Lock

Piercer Lock

Piercer Lock Solenoid

Probe Indentations

Pierce ModeLock Position

Sample ModeLock Position

Piercer Probe

SensorHole

Solenoid Shaft

PiercerLock



Cap Detect Sensor

As shown on Figure 15-8 "Cap Detect Sensor", the Cap Detect Sensor is an optical sensor. It detects the CTS Piercer encountering a sample tube cap by the hold down flag, which is attached to the Brake Rack, breaking its beam. When a cap is encountered by the foot, which is attached to the Brake Rack, the foot stops its travel while the CTS Piercer Assembly continues its travel. This action drives the hold down flag up until the Cap Detect optical sensor is no longer blocked indicating to the system the cap has been detected. The changing of the Cap Detect Sensor output causes the system to lock the foot (also known as the CTS Hold-Down) on the CTS Piercer via a brake in the Universal Arm. The locking of the foot enables the system to hold the sample tube in place during piercing and aspiration.

Figure 15-8 Cap Detect Sensor

Piercer Position Sensor

The Piercer Position Sensor is an optical sensor used to determine whether the CTS Piercer is in sample mode or piercer mode. It does this by detecting the position of the hold down flag attached to the Brake Rack. Figure 15-9 "Piercer Position Sensor" shows the Piercer Position Sensor and the hold down flag. When in Sample mode (and in home position on the Z-axis, which is when the software checks it), the flag blocks the Piercer Position optical sensor and indicates to the system the probe is in Sample mode.

The Retraction Shaft and Retraction Shaft Contact are used to change from Piercer to Sample mode as described in "Operation of the CTS Piercer Probe".

Figure 15-9 Piercer Position Sensor

Cap Detect Sensor

Hold Down Flag

Brake Rack

Hold Down FlagBrake Rack

Piercer PositionSensor

Retraction Shaft

Retraction ShaftContact



Operation of the CTS Piercer Probe

As shown in Figure 15-10 "Z-Drive Rack and Brake Rack", the Telescoping CTS Assembly is attached to the Z-Drive Rack used to provide vertical (Z-Axis) movement to the assembly in the same manner it supplies vertical movement to a non-CTS probe assembly. In contrast, the Brake Rack is part of the CTS Piercer Probe and is used to provide the vertical (Z-Axis) movement to the CTS Piercer Probe.

Figure 15-10 Z-Drive Rack and Brake Rack

The Telescoping CTS Assembly is attached to the Z-Drive Rack that provides vertical (Z-Axis) movement to the entire Telescoping CTS Assembly. Internal to the Telescoping CTS Assembly, the Brake Rack is used to provide the vertical (Z-Axis) movement to the Piercer Probe. To go to Piercer Mode, the software locks the Brake Rack in position, energizes the Piercer Lock Solenoid (unlocking the piercer probe), and drives the Z-Drive Rack up. The Piercer Lock Solenoid is only energized long enough for the Brake rack to move enough that the lock no longer enters the detent on the brake rack. With the Telescoping CTS Assembly being driven up via the Z-Axis motor in the Arm, and the brake rack locked, the Retraction Shaft Contact pushes down the Piercer Retraction Shaft (and the Piercer Support Bracket attached to its bottom) as shown on Figure 15-9 "Piercer Position Sensor". With the Piercer Lock Solenoid no longer energized, the lock (which is spring loaded) latches into the upper detent of the piercer probe, locking the probe in the piercer position. If either the lock fails to pull back, or fails to latch into the detent, the lock sensor is used to sense the failure and an error condition is indicated and an Emergency Stop is initiated.

Note that the Retraction shaft has a spring on it that is used to raise the Brake Rack (and the piercer probe) when the Piercer Lock Solenoid is energized allowing the CTS Piercer to change from Piercer to Sample mode.

Z-driveRack

Brake Rack



Figure 15-11 Retraction Shaft and Contact

The following provides a step-by-step sequence of the CTS assembly from being in pierce mode, piercing the cap of the sample tube and aspirating of the sample, dispensing of the sample, washing of the probes, and back to the pierce mode.

1. The CTS Telescoping Assembly is in Pierce Mode with the Pierce Probe locked in the down position ready to pierce.

2. The sample arm is moved to a position above a test tube by moving in both X (left to right) & Y axes (front to back).

3. The CTS Telescoping Assembly is driven down (Z-axis) via the Z-axis stepper motor and the Z-Drive Rack until the Cap Detect Sensor is triggered by the Hold-Down Flag attached to the Brake Rack.

4. When the Cap Detect Sensor is triggered, the Brake is energized, locking the Brake Rack in place. The Foot (also known as the CTS Hold-Down) that is attached to the bottom of the Brake Rack, keeps the test tube in-place during piercing and aspiration. The location of the encoder (attached to back of Z-axis stepper motor) is stored to allow the CTS Telescoping Assembly to return to the same position after aspirating a sample from the test tube.

5. The CTS Telescoping Assembly is driven down (Z-axis - via the Z-axis stepper motor and the Z-Drive Rack) piercing the cap and then retracted slightly to relieve the CTS Lock from any external forces created from the cap piercing.

6. The Travelling Signal Interconnect Board applies power to the Piercer Lock Solenoid unlocking the CTS Piercer Lock and the CTS Telescoping Assembly is driven down to allow the piercer to be locked in Sample Mode (up position) once the Piercer Lock Solenoid has power removed.

7. The CTS Telescoping Assembly is driven up to ensure the Sample Probe is not in sample and an LLD baseline is taken. The LLD baseline value allows the CTS Telescoping Assembly to sense a change in capacitance when fluid is contacted by the Sample Probe.

8. The CTS Telescoping Assembly is moved down until sample is contacted (as determined by the LLD) and submerged in the sample.

Retraction Shaft Contact

Retraction Shaft

Piercer Support Bracket



9. The sample is aspirated from the test tube, the CTS Telescoping Assembly is moved up slightly and air is aspirated and an air gap created to ensure the volume of sample is protected inside the sample probe.

10. The CTS Telescoping Assembly is driven out of the cap back to the original location where the Foot was locked on top of the cap.

11. The CTS Telescoping Assembly is left in Sample Mode and dispenses in the Incubator area and then continues to the Wash Cup.

12. After the Sample Probe and Piercer are washed, the Brake Rack is locked in place and the CTS Piercer is driven up, forcing the Retraction Shaft Contact to push the Piercer Retraction Shaft Down and forcing the CTS Pierce probe down into Pierce Mode.

13. With the Piercer Lock Solenoid no longer energized, the lock (which is spring loaded) latches into the detent in the brake shaft locking the probe in the piercer position.

14. The Piercer Lock Sensor senses the Piercer Lock motion and ensures the Piercer Lock is fully engaged on the Piercer shaft.

15. The CTS Telescoping Assembly is in Pierce Mode and is ready to pierce the next capped test tube.


Adjustments and verifications for the CTS Piercer consist of Initializing the Arms and Adjusting the Coordi-nates. Initializing Arms and Adjusting Coordinates are both performed from the Probes tab of the ACL-TOP Diagnostic screen as shown on Figure 15-12 "Probes Tab of Diagnostic Screen".




inate Adjust Button

Figure 15-12 Probes Tab of Diagnostic Screen

Probes Tab

Coord

Disable SampleArm Button

Probe Pull Down List

Initialize All Arms Button


Initialize Arms

Perform the following steps to initialize the Robotic Arms:

1. Click the “Initialize All Arms” button on the Probes Diagnostics Screen. This starts the Arms Initial-ization process. (This process can take 4 - 5 minutes.)

2. After the Arms Initialization process has completed, click on the CTS tab to display the CTS Diagnos-tics Screen (see Figure 15-13 "CTS Tab of Diagnostic Screen").

3. At the CTS Diagnostics Screen,

• In the Piercer Loop Test portion of the screen enter “50” in Loop Count

CAUTION: Running the Loop Count beyond 50 cycles may cause the solenoid to overheat and result in injury or equipment damage.

• Click on the Start button

• Verify that the Status changes to Pass

4. When the system passes the Piercer Loop Test, the Arms are re-initialized and the instrument is ready for use.

Adjust Coordinates

To adjust the Robotic Arm Coordinates, perform the following steps (see Figure Figure 15-12 "Probes Tab of Diagnostic Screen":

1. Open the Diagnostics window by clicking on System --> Diagnostics.

2. Click on the Probes tab in the diagnostics window.

3. Click on the “Disable Sample Arm” button.

4. Select “Sample Arm” from the Probe pull-down list.

5. Click the “Coordinates Adjust” button. This starts the Coordinates Adjustment process.

The Coordinates Adjust process takes 20 - 30 minutes during which time the Sample probe will touch vari-ous portions of the Sample module, take coordinate readings and calculate the proper coordinates for future probe movements.

15-6 Diagnostics

CTS Piercer diagnostics are on the CTS tab. The CTS tab contains five areas: the Piercer loop test area, the Fluid test area, the Foot test area, the Sensors area, the Air pressure valve area, and the Air accu-mulator valve area. Figure 15-13 "CTS Tab of Diagnostic Screen" shows the CTS tab.




Figure 15-13 CTS Tab of Diagnostic Screen


Disable CTS Operation

This button disables the CTS operation (in the Diagnostic Mode). Upon exiting Diagnostics and re-initializing the ACL-TOP, the system reverts to CTS operation. While CTS operation is disabled the system does not pierce caps and runs in “non-pierce” mode. This mode will provide higher throughput if the samples do not have caps.

Piercer Loop Test Area

Figure 15-14 "Piercer Loop Test Area" shows the Piercer Loop Test Area.

Figure 15-14 Piercer Loop Test Area

This test causes the piercer to switch from piercer mode to sample mode and back to piercer mode. The number of repetitions can be selected in the “Loop Count” field. Click the “Start” button to start the Piercer Loop Test. Click the “Stop” button to stop a Piercer Loop Test in progress. At the end of the test the “Sta-tus:” display shows the result.

CAUTION: Running the Loop Count beyond 50 cycles may cause the solenoid to overheat and result in injury or equipment damage.

Foot Test Area

This test checks for slippage of the foot when the brake in the arm is engaged. The status of pass or fail is displayed at the end of the test. Click the “Start” button to start the Foot Test and the “Stop” button to stop a Foot Test in progress. Basically, in this test the foot brake is locked and the Z-drive rack is moved against the brake. The foot should not move up (since it is locked) and Z-slippage values are checked to verify they are within the anticipated move distance (with some tolerance). This ensure the brake doesn't slip, i.e., the foot should stay at the same height on the Z-drive rack’s move up.

Sensors Area

Figure 15-15 "Sensors Area" shows the Sensors Area. Each of the LEDs in the Sensor area can display red or green to indicate the condition of the item. Following the figure is the list of sensors with an explana-tion of what their indications mean.



Figure 15-15 Sensors Area

Virtual LEDs are supplied for the following sensors:

• Air Pressure - The LED is green when the air pressure is above 26psi (where it should be) and redwhen the pressure is below 26psi.

• Piercer Lock Solenoid - The LED is green when the Piercer Lock Solenoid is not engaged (thepiercer probe is locked) and red when the Piercer Lock Solenoid is not engaged (the piercer probeis unlocked).

• Piercer Position - The LED is green when the probe is in Pierce Mode and red when it is in SampleMode.

• Tube Cap - The LED is green when the Tube Cap Sensor is not blocked by the flag and red whenit is blocked by the flag.

• Fluid Pump - The LED is green when the pump is off and red when the pump is on.

Air Controls

Air Pressure Valve

This Air Pressure Valve buttons, as shown on Figure 15-16 "Air Valve, Pressure Release Buttons" allows the user to open and close the air pressure valve. The LED being green indicates the valve is open and red indicates it is closed. If working properly, the valve should be able to be heard as air is released and the air pump turns on.



Figure 15-16 Air Valve, Pressure Release Buttons

Air Accumulator Valve

This Air Accumulator buttons, as shown on Figure 15-16 "Air Valve, Pressure Release Buttons" allow the user to open and close the air accumulator valve. The LED being green indicates the valve is open and red indicates it is closed. If working properly, the valve should be able to be heard as air is released and the air valve turns is activated.

Air Pressure

This Air Pressure buttons, as shown on Figure 15-16 "Air Valve, Pressure Release Buttons" allow the air pressure to be released from, or restored to, the CTS Piercer. If working properly, the valve should be able to be heard as air is released and the air pressure LED should light after the pressure is restored using the Restore button.


Probe-n-Seal Assembly Removal/Installation

NOTE: It is not necessary to remove any of the instrument covers to perform this procedure.

Probe-n-Seal Assembly Removal

1. Click on System -->Diagnostics then select the “Controllers, Covers and Racks” tab from the Diag-nostics Screen.

2. Click the “Unlock Sample Cover” button on the “Controllers, Covers and Racks” tab.

3. Open the Sample Cover on the instrument.

4. Power off the instrument by turning off the main power switch.

5. Manually move the CTS Piercer Arm into the sample area. Ensure that the piercer probe, and the sample probe, stay above the skins as the arm is moved.

6. Using Figure 15-17 "Probe-n-Seal Assembly Connections." as a reference,



• Disconnect the 1/4” air line from the front of the Probe-n-Seal Assembly

• Loosen the Tube Support Bracket screw by turning it counter-clockwise until the bracket can beremoved.

• Remove the fluid line from the top of the Probe-n-Seal Assembly by sliding the sleeve back over thetubing, then removing the tubing.

Figure 15-17 Probe-n-Seal Assembly Connections.

7. Remove, by gently pulling on the connector, the Sampling Probe LLD cable from the front of the CTS Telescoping Assembly (see Figure 15-18 "Sampling Probe LLD Cable").

Figure 15-18 Sampling Probe LLD Cable

8. Push the Z-drive rack down so that it is just above the Sample Plate. (This is done by pushing down on the top of the Z-drive rack.)

9. Loosen the thumbscrew on the side of the Telescoping CTS Assembly (see Figure 15-19 "CTS Assembly Thumbscrew") by turning it counter-clockwise. The thumbscrew is spring loaded and will pop outward when loosened it all the way. The Piercer Probe Hold Down Bracket that is attached to the thumbscrew should also pop outward enabling the removal of the Probe-n-Seal assembly.

New Figure

Fluid Line

Tube SupportBracket Screw

1/4” Air Line

Sample Probe LLD Cable



Figure 15-19 CTS Assembly Thumbscrew

10. Carefully pull the Probe-n-Seal assembly, as shown on Figure 15-20 "Probe-n-Seal Assembly" up and out of its mounting. Do not bend the sample probe as the probe is pulled out of its mounting. (The Probe-n-Seal Assembly can be loosened by gently rocking it.)

NNOTE:To remove the sample probe without bending it, the Z-drive must first be pushed down as far as possible. With the Z-drive in this position, the Robotic Arm is cleared when pulling the sample probe out of its mounting.

Figure 15-20 Probe-n-Seal Assembly

Probe-n-Seal Assembly Installation

1. Ensure that the main power switch for the instrument is turned off.

Thumbscrew



2. Push the Z-drive rack down so that it is just above the Sample Plate. (This is done by pushing down on the top of the Z-drive rack.)

NNOTE:The Z-drive Rack must be down to insert the Probe-n-Seal Assembly without bending it.

3. Ensure the Probe-n-Seal Hold Down Bracket is not blocking the hole as shown on Figure 15-21 "Probe-n-Seal Hold Down Bracket".

Figure 15-21 Probe-n-Seal Hold Down Bracket

4. Insert the Probe-n-Seal Assembly in its mounting, as shown on Figure 15-22 "Inserting the Probe-n-Seal Assembly", and gently push down on the Assembly until its seats and the Probe-n-Seal Hold Down Bracket can be slid over its lip.

NNOTE:Make sure the Telescoping CTS Assembly is held to prevent motion of the Assembly as the Probe-n-Seal Assembly is seated. Otherwise, damage the CTS Piercer Probe may occur.

Probe-n-Seal HoldDown Bracket



Figure 15-22 Inserting the Probe-n-Seal Assembly

5. Push the Piercer Probe Hold Down Bracket over the top lip of the Probe-n-Seal Assembly.

6. Tighten the thumbscrew as shown on Figure 15-23 "CTS Thumbscrew" on the side of the Telescop-ing CTS Assembly by turning it clockwise. (Make the thumbscrew finger-tight.)

Figure 15-23 CTS Thumbscrew

7. Connect the Sampling Probe LLD cable to the front of the Telescoping CTS Assembly as shown on Figure 15-24 "Sampling Probe LLD Cable".

Thumbscrew



Figure 15-24 Sampling Probe LLD Cable

8. Using Figure 15-25 "Probe-n-Seal Assembly Connections." as a reference,

• Install the fluid line to the top of the Probe-n-Seal Assembly by sliding the fluid line over the steeltube and sliding the sleeve over the end of the tubing.

• Reinstall the Tube Support Bracket and tighten the screw by turning it clockwise until the bracket istight.

• Connect the 1/4” air line to the front of the Probe-n-Seal Assembly.

Figure 15-25 Probe-n-Seal Assembly Connections.

9. It is recommended the system be powered up and the Piercer loop test be executed with a count of 50 as described in "Piercer Loop Test Area".

10. Initialize the arms, remove the sample area interior skins as described in "Sample Area Interior Skins Removal".

11. Adjust the coordinates as described in “Coordinate Adjust” in Chapter 8 and reinstall the sample area interior skins.

Piercer Probe Removal/Installation

NOTE: It is not necessary to remove any of the instrument covers to perform this procedure.

Sample Probe LLD Cable

New Figure

Fluid Line

Tube SupportBracket Screw

1/4” Air Line



Piercer Probe Removal


2. Click the “Unlock Sample Cover” button on the “Controllers, Covers and Racks” tab.



5. Remove the Probe-n-Seal Assembly as described in "Probe-n-Seal Assembly Removal".

6. Raise the Telescoping CTS Assembly as high as necessary to access the knurled nut on the bottom of the Piercer (see Figure 15-26 "Piercer Probe Knurled Nut").

Figure 15-26 Piercer Probe Knurled Nut

7. Loosen the knurled nut by turning it counter-clockwise. (Pliers may be needed to do this.) Loosen the nut until it falls into the foot.

8. Push the Z-drive rack down until the Foot is just above the Sample Plate. (This is done by pushing down on the top of the Z-drive rack.)

9. Push, and hold in, the CTS Piercer Lock on the right-hand side of the Telescoping CTS Assembly as shown on Figure 15-26 "Piercer Probe Knurled Nut" to release pressure on the piercer probe.

10. While holding the CTS Piercer Lock in, remove the piercer probe by pulling up on the probe top. Do not use tools to pull out the piercer probe. It may be necessary to twist and move the probe back and forth to remove it.

WARNING: Piercing Hazard. Do not put hand inside Instrument while it is in motion.

Knurled Nut

CTS Piercer Lock



Figure 15-27 CTS Piercer Probe Removal/Insertion

Piercer Probe Installation

1. Ensure the main power switch for the instrument is turned off.

2. Push in the CTS Piercer Lock on the side of the Telescoping CTS Assembly, and hold it all the way in (see Figure 15-27 "CTS Piercer Probe Removal/Insertion").

3. While holding in the CTS Piercer Lock, guide the piercer probe into its mounting.

NNOTE:As the piercer probe is inserted into its mounting, the flat side of the piercer probe threads must face the front of the instrument. This is required for proper seating of the probe.

4. Push down on the piercer probe until it locks into the “down” position.

5. Apply a drop of Loctite #222 (Low Strength) to the thread on the top of the piercer probe.

6. Re-fasten the piercer probe knurled nut (see Figure 15-26 "Piercer Probe Knurled Nut") ensuring the nut is tight.

7. Install the Probe-n-Seal Assembly as described in "Probe-n-Seal Assembly Installation".

8. Power up the system and execute the Piercer loop test with a count of 50 as described in "Piercer Loop Test Area".



CTS Piercer Lock

CTS Piercer Probe



Telescoping CTS Assembly Removal/Installation

NOTE: it is not necessary to remove any instrument covers to perform this procedure.

CAUTION: Do not remove the Telescoping CTS Assembly without first removing the sample probe (see "Probe-n-Seal Assembly Removal") and the piercer probe (see "Piercer Probe Removal"). Serious injury and equipment damage can result from removing these items in any sequence other than described in the following procedure.

Telescoping CTS Assembly Removal


2. Click the “Unlock Sample Cover” button on the “Controller, Covers and Racks” tab.



5. Remove the sample probe as described in "Probe-n-Seal Assembly Removal".

6. Remove the piercer probe as described in "Piercer Probe Removal".

7. Referencing Figure 15-28 "Removal of Telescoping CTS Assembly", perform the following steps:

• Disconnect the air line from the Foot.

• Remove, and discard, the tie wrap from the air line.

• Loosen, but do not remove, the hose clamp screw

• Slide the ribbon cable to the left to remove it from the flange to which the hose clamp is mounted.

• Remove the piercer probe LLD cable.

• Using an Allen wrench, remove the Telescoping CTS Assembly’s four cover screws.

• Lift the Telescoping CTS Assembly’s cover off.

NOTE: Save the screws and hardware removed from the top of the Telescoping CTS Assem-bly. They are required to re-assemble the Telescoping CTS Assembly.



Figure 15-28 Removal of Telescoping CTS Assembly

8. Pull up on the front of the ribbon cable connector to remove the flexible cable from the PCB (see Fig-ure 15-29 "CTS Piercer Board").

NNOTE:To open the Ribbon Cable Connector, pull up the front of the Connector Tab. Push the front of the two-piece connector down to secure the ribbon cable connection.

Figure 15-29 CTS Piercer Board

9. Raise the Telescoping CTS Assembly all the way.

Cover Screws

Air Line

Tie Wrap

Hose ClampScrew

Piercer Probe LLD Cable

RibbonCable

Cover

Ribbon CableConnector



10. Using a 2.5mm Allen wrench, remove the screw and hardware from the top of the Brake Rack (see Figure 15-30 "Brake Rack Screw"). (Note: Save the screw and hardware; they are required to reas-semble the Telescoping CTS assembly.)

Figure 15-30 Brake Rack Screw

11. Insert a 1.5mm Allen wrench through the set screw access hole as shown on Figure 15-31 "Tele-scoping CTS Assembly Set Screw", and loosen, but do not remove, the set screw securing the Telescoping CTS Assembly to the Z-drive rack). (Note: Loosen the set screw only to the extent that the head of the screw can be seen when looking from the top of the assembly.)

Figure 15-31 Telescoping CTS Assembly Set Screw

12. While holding the Telescoping CTS Assembly to keep it from falling, use a 2.5mm Allen wrench to remove the screw at the bottom of the Z-drive rack (see Figure 15-31 "Telescoping CTS Assembly Set Screw"). (Note: The Telescoping CTS Assembly becomes free when the screw is removed. Do not allow the assembly to drop.)

Brake Rack Screw

SetScrewAccess

Set ScrewLocation



Figure 15-32 Z-Drive Rack Screw

13. Slide the Telescoping CTS Assembly off the arm and remove it from the instrument.

14. Save the screw removed in step 12, along with the lock washer and star washer. They are used when installing the Telescoping CTS Assembly.

Telescoping CTS Assembly Installation


2. Using a 2.5mm Allen wrench to hold the Z-drive rack screw in place in the bottom of the Telescoping CTS Assembly (along with the lock washer and star washer) as shown on Figure 15-33 "Z-Drive Rack Screw (Bottom View of Assembly)", slide the Brake Rack up through the Spline Bearing in the arm.

Figure 15-33 Z-Drive Rack Screw (Bottom View of Assembly)

Brake Rack

Z-driveRack Screw

Brake Rack

Z-driveRack Screw



NNOTE:Steps 3 through 7 must be performed in the sequence stated to ensure proper alignment of the Brake Shaft and the Z-drive shaft. If the Brake Shaft and the Z-drive Shaft are not properly aligned, the two shafts may bind, resulting in improper operation of the CTS Piercer Assembly.

3. Tighten the Z-drive Rack screw as shown in Figure 15-33 "Z-Drive Rack Screw (Bottom View of Assembly)" until it is finger tight, then loosen (turn the screw counter clockwise) 1/2 to one full turn. Ensure the star washer is on the bottom and the lock washer is between the star washer and the screw head.

4. Use a 2.5mm Allen wrench to fasten the Brake Rack screw as shown in Figure 15-34 "Brake Rack Screw" to the top of the Brake Rack.

Figure 15-34 Brake Rack Screw

5. Push the Telescoping CTS Assembly all the way up.

6. Insert a 1.5mm Allen wrench through the set screw access hole as shown on Figure 15-31 "Tele-scoping CTS Assembly Set Screw", and tighten the set screw that secures the Telescoping CTS Assembly to the Z-drive rack.

Brake Rack Screw



Figure 15-35 Telescoping CTS Assembly Set Screw

7. Using a 2.5mm Allen wrench, tighten the Z-drive Rack screw that was finger tightened in step 3.

8. Re-connect the ribbon cable as shown in Figure 15-29 "CTS Piercer Board". The black side of the cable-end must face the front of the instrument as shown in Figure 15-29 "CTS Piercer Board".

NNOTE:To open the Ribbon Cable Connector, pull up the front of the Connector Tab. Push the front of the two-piece connector down to secure the ribbon cable connection.

Figure 15-36 CTS Piercer Board

SetScrewAccess

Set ScrewLocation

Ribbon CableConnector



9. In addition, the cable-end must be fully seated and level in the connector and the cable routed as shown on the right side of Figure 15-37 "Ribbon Cable Routing/Connection". Ensure the cable is “folded” with a clearly defined right turn leading to the PCB and under the mounting bracket.

Figure 15-37 Ribbon Cable Routing/Connection

10. Fasten the cover screws, lock washers, and flat washers to the cover of the of the Telescoping CTS Assembly. Ensure that the front/right screw location has the screw, lock washer, and star washer (in that order) fastened through the cover.

11. Using Figure 15-38 "Connection of Telescoping CTS Assembly" as a reference:

• Connect the LLD Cable for the piercer probe.

• Place the Ribbon Cable between the Flange and the Telescoping CTS Assembly.

• Feed the smaller of the two air tubes (1/16” Tygon tube) through the hose clamp in the directionshown in the figure. Leave a service loop in the tube as shown in Figure 15-39 "Connecting AirTube to the Foot".

• Verify:

• the hose clamp is in a straight, vertical position

• the ribbon cable hangs down straight from the Ribbon Cable Connector

• the horizontal portion of the ribbon cable is even and level

• the ribbon cable rises up straight behind the flange secured by the hose clamp

• there is an adequate service loop in the portion of the ribbon cable above the flange

Note: Ensure the service loop is long enough that the Ribbon Cable does not impede the Z-axis movementof the Telescoping CTS Assembly.

• Secure the ribbon cable between the Flange and the Telescoping CTS Assembly by tightening thehose clamp screw.

Correct Cable Routing/Connection

Incorrect Cable Routing/Connection



Figure 15-38 Connection of Telescoping CTS Assembly

12. Connect the air line from the Telescoping CTS Assembly to the Foot as shown in Figure 15-39 "Con-necting Air Tube to the Foot". Note that this figure clearly displays the service loop in the air tube as mentioned in the previous step.

13. Secure the air tube to the steel tube on the Foot with a tie wrap ensuring the head of the tie wrap faces the front of the instrument, as shown in the figure. This prevents the head of the tie wrap from hitting the back wall of the Sample Module.

Figure 15-39 Connecting Air Tube to the Foot

14. Cut any excess length from the end of the tie wrap.

Cover Screws

Air Line

Hose ClampScrew

Piercer Probe LLD Cable

RibbonCable

Cover

Small Air Tube

Service Loop

Tie Wrap



15. Replace the piercer probe as described in "Piercer Probe Installation".

16. Replace the Probe-n-Seal Assembly as described in "Probe-n-Seal Assembly Installation".

17. Power up the instrument.




Chapter 16 – Schematics 16 - 1

Chapter 16 –Schematics

16-1 Overview:

This section contains the schematics for the TOP Instrument.

16-2 Schematics

The schematics in this chapter are listed in ascending order by drawing number.

The following schematics are applicable to the Base TOP:

• 27501100 – Figure 16-1 "Power Interconnect Fuse PCB (Drawing # 27501100)"

• 27502100 – Figure 16-2 "Back Plane PCB (Drawing # 27502100, Sheet 1 of 6)"

• 27503100 – Figure 16-8 "Front Panel Disconnect PCB (Drawing # 27503100)"

• 27504100 – Figure 16-9 "PC104 Can Bus PCB (Drawing # 27504100, Sheet 1 of 4)"

• 27505100 – Figure 16-13 "Fluidics Controller PCB (Drawing # 27505100, Sheet 1 of 5)"

• 27506100 – Figure 16-18 "Fluidics Connector PCB (Drawing # 27506100, Sheet 1 of 4)"

• 27507100 – Figure 16-22 "Fluidics LED PCB (Drawing # 27507100)"

• 27552100 – Figure 16-23 "ORU Detector PCB (Drawing # 27552100, Sheet 1 of 3)"

• 27554100 – Figure 16-26 "ORU Interface PCB (Drawing # 27554100, Sheet 1 of 3)"

• 27555100 – Figure 16-29 "Incubator Heater PCB (Drawing # 27555100)"

• 27556100 – Figure 16-30 "Emitter PCB (Drawing # 27556100)"

• 27600100 – Figure 16-31 "Y-Axis PCB (Drawing # 27600100, Sheet 1 of 2)"

• 27601100 – Figure 16-33 "Shuttle/Barcode X-Axis PCB (Drawing # 27601100)"

• 27602100 – Figure 16-34 "Cuvette Loader Interface PCB (Drawing # 27602100)"

• 27604100 – Figure 16-35 "Cuvette Sensor PCB (Drawing # 27604100)"

• 27605100 – Figure 16-36 "Cuvette Waste Interface PCB (Drawing # 27605100)"

• 27607100 – Figure 16-37 "Heated Probe PCB (Drawing # 27607100)"

• 27608100 – Figure 16-38 "Probe DC Driver PCB (Drawing # 27608100, Sheet 1 of 2)"

• 27609100 – Figure 16-40 "Probe Interconnect PCB (Drawing # 27609100)"

• 27611100 – Figure 16-41 "Cuvette Loader Flex Cable PCB (Drawing # 27611100)"


16 - 2 Chapter 16 – Schematics

• 27700100 – Figure 16-42 "Sample Rack Presence PCB (Drawing # 27700100)"

• 27701100 – Figure 16-43 "Reagent Rack Presence PCB (Drawing # 27701100, Sheet 1 of 2)"

• 27702100 – Figure 16-45 "Reagent KeyBoard PCB (Drawing # 27702100)"

• 27703100 – Figure 16-46 "Reagent Cooling PCB (Drawing # 27703100)"

• 27704100 – Figure 16-47 "Magnetic Stirring PCB (Drawing # 27704100, Sheet 1 of 2)"

• 27705100 – Figure 16-49 "Sample Key Board PCB (Drawing # 27705100, Sheet 1 of 2)"

• 27710100 – Figure 16-51 "Remote Travel Interface PCB (Drawing # 27710100)"

• 27800100 – Figure 16-52 "Rack Controller CPU PCB (Drawing # 27800100, Sheet 1 of 3)"

• 27810100 – Figure 16-55 "Rack Controller Interface PCB (Drawing # 27810100, Sheet 1 of 7)"

The following schematics are applicable to the CTS TOP:

• 27605100 – Figure 16-62 "Cuvette Waste Interface PCB (Drawing # 27605100)"

• 27613100 – Figure 16-63 "X Motion Control PCB W/ out Dip (Drawing # 27613100)"

• 28630100 – Figure 16-64 "CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 of 9)"

• 28631100 – Figure 16-73 "Y Axis U Arm PCB (Drawing # 28631100, 1 of 2)"

• 28633100 – Figure 16-75 "Z Driver PCB (Drawing # 28633100, Sheet 1 of 3)"

• 28634100 – Figure 16-78 "CTS Traveling Interconnect PCB (Drawing # 28634100)"

• 28641100 – Figure 16-79 "U Arm Fuse Board PCB (Drawing # 28641100)"




Figure 16-1 Power Interconnect Fuse PCB (Drawing # 27501100)



Figure 16-2 Back Plane PCB (Drawing # 27502100, Sheet 1 of 6)



Figure 16-8 Front Panel Disconnect PCB (Drawing # 27503100)



Figure 16-9 PC104 Can Bus PCB (Drawing # 27504100, Sheet 1 of 4)


Figure 16-13 Fluidics Controller PCB (Drawing # 27505100, Sheet 1 of 5)


Figure 16-18 Fluidics Connector PCB (Drawing # 27506100, Sheet 1 of 4)



Figure 16-22 Fluidics LED PCB (Drawing # 27507100)



Figure 16-23 ORU Detector PCB (Drawing # 27552100, Sheet 1 of 3)



Figure 16-26 ORU Interface PCB (Drawing # 27554100, Sheet 1 of 3)



Figure 16-29 Incubator Heater PCB (Drawing # 27555100)



Figure 16-30 Emitter PCB (Drawing # 27556100)



Figure 16-31 Y-Axis PCB (Drawing # 27600100, Sheet 1 of 2)



Figure 16-32 Y-Axis PCB (Drawing # 27600100, Sheet 2 of 2)



Figure 16-33 Shuttle/Barcode X-Axis PCB (Drawing # 27601100)



Figure 16-34 Cuvette Loader Interface PCB (Drawing # 27602100)



Figure 16-35 Cuvette Sensor PCB (Drawing # 27604100)



Figure 16-36 Cuvette Waste Interface PCB (Drawing # 27605100)



Figure 16-37 Heated Probe PCB (Drawing # 27607100)



A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED

DSIZE DWG. NO. REV. SHEET

SCALE

REVISIONS

Title

113 HARTWELL AVENUE, LEXINGTON MASS. 02421

Instrumentation Laboratory

REV CHECKED APPROVED DATEBYDESCRIPTION

+24V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244A

P

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244A

04/17/02

04/17/02

N/A

10_WATT_WIRE_WOUND

Current Limit Resistor

for Probe protection

Probe DC Driver Board

REAGENT 2 PROBE

INTERCONNECT

1 of 2276081_00

0

1

ORIGINATED PER ECO# 15203 G.JAMIOLS.RATTA D.VO 4/17/02

23SEP03CONNECTORS CHANGES PER CO L16763 D.COX D.VO C.BERGERON

2 D.COXRESTORE ORIG CONNECTORS PER CO L17655 28SEP04

2

Saverio Ratta

D.VO

G.JAMIOL

04/17/02

B_RGT2_SPI_CLK

B_RGT2_PROBE_CS

B_RGT2_PROBE_PIC_RESET

RGT2_PROBE_CS B_RGT2_PROBE_CS

SPI_DATA_OUT


30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1J5

R24

S_RGT2_PROBE_PIC_RESET

B_S_RGT2_PROBE_PIC_RESETS_RGT2_PROBE_PIC_RESET

RGT2_PROBE_PIC_RESET

8

18

16

12

14

2

4

6

1

U5

RGT2_PWM_HEAT_1

RGT2_DC_HEAT2

RGT2_DC_HEAT1

RGT2_PWM_HEAT_2

B_RGT2_SPI_DATA_IN

RGT2_PROBE_IRQ

RGT2_DC_HEAT1

RGT2_DC_HEAT1

RGT2_DC_HEAT2

RGT2_DC_HEAT2

19

15

13

11

5

3

7

9

17

U5

SPI_DATA_IN

SPI_CLK

B_RGT2_SPI_DATA_IN

B_RGT2_SPI_CLK

R22 0

Figure 16-38 Probe DC Driver PCB (Drawing # 27608100, Sheet 1 of 2)

+24V

1 2 3 4 5 6

1 2 3 4 5 6

+5V

+5V+5V

P

+5V+24V

+5V+5V +5V

+5V

+24V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244A

SN74ACT32

SN74ACT32

P

P

+5V

SN74ACT00A

SN74ACT00A

SN74ACT32

SN74ACT32

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244A

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244A

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244A

+5V

P

+24V+5V

P

+5V

SN74ACT00ASN74ACT00A

SN74ACT08

SN74ACT08

+5V

+5V

+DC_LOAD

+_CONTROL

-DC_LOAD

-_CONTROL

SOLID STATE RELAY

+5V

+24V

+24V

INTERCONNECT

for Probe protectionfor Probe protection


10_WATT_WIRE_WOUND10_WATT_WIRE_WOUND

TO BACKPLANE


REAGENT 1 PROBESAMPLE PROBE

INTERCONNECT

PWR_IN

D7

FR301

PWR_IN 1

3

2

4

RELAY1

4

1

2

3

J1

B_RGT1_SPI_CLK

0

R21R20 0

B_SMPLE_SPI_CLK

4.75K

R5

0.1UF

C30.1UF

C2

C80.1UF0.1UF

C40.1UF

C7

C15

1000UF1000UF

C14C13

1000UF

1 TP17

1 TP16

B_SMPLE_SPI_DATA_IN

1 TP15

1 TP1

R422.1K

13

2

U7

56

4U7

12

1311

U1

810

9U1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

J4

B_RGT1_PROBE_CSB_SMPLE_PROBE_CS

RGT2_PROBE_CS

RGT1_PROBE_CS

SMPLE_PROBE_CS

B_SMPLE_PROBE_CS

RGT1_PROBE_CSSMPLE_PROBE_CS


B_RGT1_PROBE_CS

B_RGT2_PROBE_CS

B_RGT1_PROBE_CSB_SMPLE_PROBE_CS

B_SMPLE_PROBE_PIC_RESET

B_S_RGT1_PROBE_PIC_RESET

B_S_SMPLE_PROBE_PIC_RESETSPI_DATA_OUT

SPI_DATA_OUTSPI_DATA_OUT

SMPLE_PROBE_IRQ

B_RGT1_PROBE_PIC_RESETB_SMPLE_PROBE_PIC_RESET

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1J3

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

J2

1 TP31 TP2

B_S_SMPLE_PROBE_PIC_RESET

C50.1UF

C60.1UF

C10.1UF

2

1

LED1

3.32K

R3

R64

4

R1

B_RGT1_SPI_DATA_IN

S_SMPLE_PROBE_PIC_RESETS_RGT1_PROBE_PIC_RESET


19

15

13

11

5

3

7

9

17

U4RGT1_PROBE_PIC_RESET

B_SMPLE_SPI_CLK

SMPLE_PROBE_PIC_RESET








B_PROBE_RESET_IRQ


8

18

16

12

14

2

4

6

1

U6

1

6

4

2

14

12

16

18

8

U4

9

108

U3

1

23

U3

65

4U1

1

23

U1

RGT2_PROBE_IRQ

RGT1_PROBE_IRQ

SPI_DATA_IN

B_SPI_DATA_OUT

SPI_CLK

RGT1_PROBE_IRQ

RGT1_PWM_HEAT_1

RGT1_DC_HEAT2

RGT1_DC_HEAT1

B_RGT1_SPI_CLK

B_RGT1_SPI_DATA_INSPI_DATA_IN

SPI_CLK

RGT1_PWM_HEAT_2

RGT1_DC_HEAT1

RGT1_DC_HEAT1

RGT1_DC_HEAT2

RGT1_DC_HEAT2

SMPLE_DC_HEAT1

SMPLE_DC_HEAT1

SMPLE_DC_HEAT1

SMPLE_DC_HEAT2

SMPLE_DC_HEAT2

SMPLE_DC_HEAT2

SMPLE_PWM_HEAT_1

SMPLE_PWM_HEAT_2

B_SMPLE_SPI_DATA_IN

65

4U3

1113

12U3

19

15

13

11

5

3

7

9

17

U6

PROBE_RESET_IRQ

SMPLE_PROBE_IRQ

1

2

LED2

1 TP4

S_SMPLE_PROBE_PIC_RESET

4.75K

R7 ALL_PROBE_CS

B_SPI_DATA_OUT

SPI_DATA_IN

1 TP18

SPI_CLK



A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




P

D

S

N

+24V

04/17/02

04/17/02

Probe DC Driver Board

2 of 2276081_00

N/A

SEE SHEET 1

2

Saverio Ratta

G.JAMIOL

D.VO

04/17/02

100UF

C22

1 TP19

1 TP8

RGT2_DC_HEAT2

1 TP12

100U

C18

C20

100U

3

2

FET5

C9

100UF

100U

C11

C12

100U

L1

550UH

L3

550UH

L6

550UH

D6

SMPLE_DC_HEAT2

RGT1_DC_HEAT2

Figure 16-39 Probe DC Driver PCB (Drawing # 27608100, Sheet 2 of 2)

1 2 3 4 5 6

1 2 3 4 5 6

+5V

+24V

Y1

Y2

Y3

Y4A4

A3

A2

A1

G

SN74ACT240

Y1

Y2

Y3

Y4A4

A3

A2

A1

G

SN74ACT240

PP

P

P

P

G

D

S

IRLR024N

G

IRLR024

G

D

S

IRLR024N

G

D

S

IRLR024N

G

D

S

IRLR024NG

D

S

IRLR024N

SN74ACT08

SN74ACT08

SN74ACT08

SN74ACT08

SN74ACT08

SN74ACT08

+24V

+24V

+24V

+24V

+5V

SAMPLE PROBE

REAGENT PROBE 2

REAGENT PROBE 1

1K

R26R231K

R1322.1K

10.0K

R14

R822.1K

100UF

C23

C10

100UF

1 TP11

1 TP7

98

10

U7

1 TP5

1 TP6

1 TP9

1 TP13

1 TP20

98

10

U8

1311

12U7

1311

12U8

56

4U8

13

2

U8

B_SMPLE_PWM_HEAT_2

1 TP10

100UF

C19

C17

100U100U

C16

C21

100UF

3

2

1

FET3

1

2

3FET4

1

2

3FET1 3

2

1

FET2

11

2

3FET6

L4

550UH

L2

550UH

L5

550UH

D5

D4

D3

D2D1

18

16

14

128

6

4

2

1

U2

9

7

5

317

15

13

11

19

U2

B_SMPLE_PWM_HEAT_1

PROBE_RESET_IRQ B_PROBE_RESET_IRQ

B_RGT2_PWM_HEAT_2

B_RGT2_PWM_HEAT_1

B_RGT1_PWM_HEAT_2

B_RGT1_PWM_HEAT_1

B_SMPLE_PWM_HEAT_2

SMPLE_DC_HEAT1

RGT1_DC_HEAT1

B_SMPLE_PWM_HEAT_1

B_RGT1_PWM_HEAT_1

B_RGT1_PWM_HEAT_2

B_RGT2_PWM_HEAT_1B_RGT2_PWM_HEAT_2

1 TP14

RGT2_DC_HEAT1

1

2

LED3

R922.1K

1

2

LED4

R1022.1K

1

2

LED5

R1122.1K

1

2

LED6

R1222.1K

1

2

LED7

1

2

LED8



R1510.0K


R1610.0K


10.0K

R17

10.0K

R18


10.0K

R19


SMPLE_PWM_HEAT_1

SMPLE_PWM_HEAT_2

RGT1_PWM_HEAT_1

RGT1_PWM_HEAT_2

1K

R24 R251K

R271K1K

R28

RGT2_PWM_HEAT_2

RGT2_PWM_HEAT_1



Figure 16-40 Probe Interconnect PCB (Drawing # 27609100)



Figure 16-41 Cuvette Loader Flex Cable PCB (Drawing # 27611100)



Figure 16-42 Sample Rack Presence PCB (Drawing # 27700100)



2)
Figure 16-43 Reagent Rack Presence PCB (Drawing # 27701100, Sheet 1 of



2)
Figure 16-44 Reagent Rack Presence PCB (Drawing # 27701100, Sheet 2 of



Figure 16-45 Reagent KeyBoard PCB (Drawing # 27702100)



Figure 16-46 Reagent Cooling PCB (Drawing # 27703100)


Figure 16-47 Magnetic Stirring PCB (Drawing # 27704100, Sheet 1 of 2)


Figure 16-48 Magnetic Stirring PCB (Drawing # 27704100, Sheet 2 of 2)


Figure 16-49 Sample Key Board PCB (Drawing # 27705100, Sheet 1 of 2)


Figure 16-50 Sample Key Board PCB (Drawing # 27705100, Sheet 2 of 2)



Figure 16-51 Remote Travel Interface PCB (Drawing # 27710100)



)
Figure 16-52 Rack Controller CPU PCB (Drawing # 27800100, Sheet 1 of 3



)



f 7)
Figure 16-55 Rack Controller Interface PCB (Drawing # 27810100, Sheet 1 o



f 7)



A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




+5V

MC74ACT86

MC74ACT86

MC74ACT86

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

IN1

GND

IN2

OUT1

VCC

OUT2

MAX6817

Cuvette Waste Interface Board

Hardware Debaounce Implementation

Drawer Removal Switch

WHITE

1 of 1276051-00 0

Saverio Ratta

N/A

Spares Gates

ORIGINATED PER ECO # 150790 S.RATTA

02/28/01

1

2

3

6

5

4

U4

19

15

13

11

5

3

7

9

17

U2

1112

13

U3

89

10

U3

64

5

U3

DRAWER_OPEN

TP10

Figure 16-62 Cuvette Waste Interface PCB (Drawing # 27605100)

+5V

+5V

+5V

1 2 3 4 5 6

1 2 3 4 5 6

P

+5V

P

+24V

+5V

P

+24V

IRLR024N

G

D

S

+24V

P

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

IRL510

D

G

S

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

+5V

MC74ACT86

WHITE

BLACK

ANODE 1

U4

1 ANODE

3 OUTPUT

4 CATHODE

5 N/C

6 DET.GND

1 GND

2 N/C

3 N/C

4 INIT

5 N/C

6 N/C

7 ECHO

8 BINH

2 N/C

COMMON 1

NORNALLY OPEN 2

N/C 3

1 RED

3 BLK

TO ULTRASONIC WASTE

SENSOR

TO ACCUM DUMP SOLENOID

2 +5V

9 +5V

SOL_FLAG SENSOR

TO CUV_WASTE_ACC_

TO MICROSWITCH

Accumulator Dump

OUTPUT 3

+5V 2

CATHODE 4

To Waste Door

Sensor

DET.GND 5

SOLENOID ACTIVE

P_GND

BLACK

+24V

+5V

WHITE

WHITE

WHITE

WHITE

+5V

SONSORS ON

RED

RED

FOR U2FOR U1 FOR U3 FOR U4D_GND

POWER GROUNDDIGITAL GROUND

Green

Green Green+24V

GREEN LED

LED3

LED4

LED2LED1

R1

3.0K

R2

22.0K

B_CH_WASTE_DOOR_OPEN_CLOSE

TP8

ULTRASONIC_ECHO

TP6

4.7K

R15

CH_WASTE_DOOR_OPEN_CLOSE

TP9

TP11

TP3

B_CH_ACCUM_SOL_ENABLE

31

2

U3

1

2

3

4

5

6

7

8

9

J5

2

3

4

5

6

1

J4

180

R14

2

3

4

5

1J2

C8470UF

R4

3.0K

SWITCH_CONTROL

CH_WASTE_DOOR_OPEN_CLOSEB_CH_WASTE_DOOR_OPEN_CLOSE

B_ULTRASONIC_ECHO_INIT

TP4

1

6

4

2

14

12

16

18

8

U2

2

1

3

Q2

19

15

13

11

5

3

7

9

17

U1

1

6

4

2

14

12

16

18

8

U1

4.7KR6 R5

22.0K

2

3

1

J3

CUV_WASTE_ACC_SOL_FLAG

TP5

1

2

3Q1

TP2

4.7KR3

DRAWER_OPEN

CUV_WASTE_ULTRASONIC_BINH

CH_CUV_WASTE_ACC_SOL_FLAG

CH_DRAWER_OPEN

CH_ULTRASONIC_ECHO_INIT

B_CH_LED_CONTROL

4.7KR13

4.7KR12

4.7KR11

4.7KR10

B_CH_ULTRASONIC_BINH

B_CH_ULTRASONIC_INIT

CUV_WASTE_ACC_SOL_FLAG

10

4

5

6

7

8

9

18

17

16

15

12

3

1

2

11

13

14

19

20

24

23

22

21

26

25

J1

B_CH_LED_CONTROL

C6

10UF

C7

0.1UF0.1UF

C3 C4

0.1UF

C5

0.1UF

C2

0.1UFTP1

C1

10UF

CH_ACCUM_SOL_ENABLE

CH_LED_CONTROL

CH_ULTRASONIC_INIT

D5

MBRS340T3

TP7

4.7KR9

R8

180

R7

4.7K

1

2

J6

B_CH_ULTRASONIC_BINH

B_CH_ULTRASONIC_INIT

SWITCH_CONTROL

SWITCH_CONTROL



A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




SN74ACT02 SN74ACT02

+5V

A

+15V

+5V

P

+24V

4ACT244

D

G

S

LR024N

P

+24V

12may04

FET1 17A Logic D-Pack

U7

Stepper Motor

Connector

Plated Mounting Holes

Interface

To Y-Axis Board

Board

Saverio Ratta

1 of 1

N/A

0

1

To Back Cover Fan

Dual Row

276131-00

05/12/04

ORIGINATED PER ECO # L17382 S.RATTA

X Motion Control bd.

without DIP

Schematic,

HOLD_CURRENT_R

HOLD_CURRENT

VREF_L297_R

VREF_L297

R270

B_SHUTTLE_ADC_CS

G1

TH1

1

10

11

12

13

14

15

16

17

18

19

2

20

21

22

23

24

25

26

27

28

29

3

30

31

32

33

34

35

36

37

38

39

4

40

5

6

7

8

9

J6

2

1

3

FET1

9

7

3

5

8

7

6

5

4

3

2

1J8

1

2

J9

G2

10

4

5

6

7

8

9

20

19

18

17

16

15

12

3

1

2

11

13

14

J7

R154.75K

B_CHY_CUV_IN_GRIP

B_CHY_GRIPPER_REV

B_CHY_GRIPPER_FOW

B_CH_CUV_IN_MOD

B_CH_GRIP_SOL_ENABLE

B_HEAT_CON_SH

1311

12

U10

9

810

U10

ENS_2

C17

0.22UF

C14

10NF

C13

10NF

SENSE2

R22

1.8

R23

1.8

B_BAR_SEN_LED_CTRL

B_CH_LED_CONTROL

SW_LED_CON

B_CH_MOD_POS

0.1UF

C7

1

TP161

TP17

CH_MOD_POS

B_CH_Y_MOT_RESET

B_CH_Y_MOT_HALF/FULL

B_CH_LED_CONTROL

B_CH_Y_MOT_ENABLE

SPI_DATA_OUT

B_SM2_CLK

B_CH_Y_MOT_CW/CCW

B_CH_GRIP_SOL_ENABLE

B_SHUTTLE_ADC_CS

B_Y_MOT_HOLD_CURRENT

B_HEAT_CON_SH

CH_CUV_IN_MOD

CHY_GRIPPER_FOW

CHY_GRIPPER_REV

CHY_CUV_IN_GRIP

B_SPI_CLK

Figure 16-63 X Motion Control PCB W/ out Dip (Drawing # 27613100)

+5V

P

+5V

P

+24V

+24V

+5V

+5V

P

+24V

P

A P

+15V +24V +5V

P

P

+5V

1 2 3 4 5 6

1 2 3 4 5 6

BOOT1

BOOT2

ENABLE

GND1

GND2

GND3

GND4

IN1

IN2 OUT1

OUT2

SENSE

VREF

L6201P_A

VS_1

3 TEMP

VIN2

GND

VOUT

TRIM

1

N/C

N/CN/C

+5V

+5V

P

P

P

P

+15V

A

P

+15V

BOOT1

BOOT2

ENABLE

GND1

GND2

GND3

GND4

IN1

IN2 OUT1

OUT2

SENSE

VREF

L6201P_A

VS_1

+5V

P

+5V

D

GND

IN

N/C

S

V-

VL

DG417

V+

+24V

P

P

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

SN74ACT02

SN74ACT02

+24V

P

+24V

+5V

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

CON6L

L297

A

B

C

D

INH1

INH2

P10

P11

P17

P18

P19

P20 SEN1

SEN2

SYNC

HOME

OSC

VREF

+5V

A

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN7

P

+24V

P

+24V

+5V

+5V

+5V

+24V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

P

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

Tantalum Cap size A 35V

U5

U6

U3

U2

U10

U1

Single Row

Dual Row

X

X

ONOFF

OFFOFFOFF

Sub System

Right Limit Sensor

Left Limit Sensor

21khz

SW1 SW2 SW3 SW4

Cuvette Hand

Rack HandON

ENCODER

INPUT SIGNALPOWER

Bar Code Reader

Single Row

Buffering for Signals to the Y-Axis

U4

ALL 33UF capacitors are 35V Aluminum E ALL 0.1UF and 0.01UF capacitors are 50V Ceramic 0805


Ground GuardVREF and HoldCurrent SignalsTo connector J8

VREF_L297VREF_L297_R

HOLD_CURRENT_R

13.3K

R8

HOLD_CURRENT

B_SHUTTLE_ADC_CS

17

9

7

3

5

11

13

15

19

U11R11

3.0K

SHUTTLE_ADC_CS

CH_GRIP_SOL_ENABLE

CH_MOD_POS

CHY_GRIPPER_FOW

CH_CUV_IN_MOD

HEAT_CON_SH

1

6

4

2

14

12

16

18

8

U11

510

98763 421

4.7K

R28

1 2 43 6 7 8 9

10 5

R25

4.7K

SPI_DATA_OUT B_SPI_DATA_OUT

SM2_CLK

CH_Y_MOT_RESET

17

9

7

3

5

11

13

15

19

U6

G3

X_MOT_HOLD_CURRENT

1 2 43 6 7 8 9

10 5

4.7K

R26

510

98763 421

R24

4.7K

C32

33UF

1

TP11

33UF

C31 C30

33UF 33UF

C29

1 TP131 TP4

1 TP121 TP3

C26

33UF

0.1UF

C8

X_MOT_HOLD_CURRENT

Y_MOT_HOLD_CURRENT

CH_Y_MOT_CW/CCW

CH_X_MOT_CW/CCW

1

TP2

CH_X_MOT_HALF/FULL

R19

10K

1

TP7

1

TP10

1

TP8

X_MOT_HOLD_CURRENT

Y_MOT_HOLD_CURRENT

CH_Y_MOT_CW/CCW

CH_X_MOT_CW/CCW

LED1

2.87K

R10

17

11

13

15

19

U7

CH_Y_MOT_HALF/FULL

TRANS_SMPL

1

TP15

1

TP14

1

TP9

Y_MOT_HOLD_CURRENT

1

TP1

CH_X_MOT_CW/CCW

CH_X_MOT_ENABLE

LED2

C10.1UF

4

6

7

9

5

8

10

11

17

18

19

20 14

13

1

3

16

15

U1

6

5

4

3

2

1

J2

C60.1UF

0.1UF

C3

B_X_MOT_HOLD_CURRENT

B_X_MOT_HOLD_CURRENT

B_CHY_GRIPPER_REV

B_CHY_GRIPPER_FOW

CH_Y_MOT_RESET

SHUTTLE_ADC_CS

SM3_ENC_B

SM3_ENC_A

SM3_ENC_B

SM3_ENC_A

BCX_R_LIMIT

BCX_L_LIMIT

4.75K

R14

R24.75K

TRANS_RGT_B

TRANS_SMPL_B

TRANS_RGT_B

TRANS_SMPL_B

TRANS_RGT

TRANS_SMPL

1

6

4

2

14

12

16

18

8

U7

B_CW/CCW

B_SPI_CLK

B_CH_Y_MOT_HALF/FULL

B_CH_Y_MOT_ENABLE

B_CH_Y_MOT_CW/CCW

1

6

4

2

14

12

16

18

8

U6

17

9

7

3

5

11

13

15

19

U4

12

3

U10

6

54

U10

1

TP5

1

TP6

B_CH_LED_CONTROL

B_BAR_SEN_LED_CTRLBAR_SEN_LED_CTRL

CH_LED_CONTROL

CH_LED_CONTROL

VREF_L297

OSC_L297

B_/CLOCK

17

9

7

3

5

11

13

15

19

U5

1

6

4

2

14

12

16

18

8

U5

1

6

4

2

14

12

16

18

8

U4

0.01UF

C15

C20

0.1UF

59

58

57

56

55

54

53

52

51

50

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

60

49

48

J1

8

3

6

2

1

7

5

4

U9

R16

10K

7

14

17

8

13 6

4

16

15

U3

C27

10UF

C210.1UF

21.5K

R12

SENS_1

S

C220.1UF

R913.3K

SW_LED_CON

1W_R_SENSE1

R21

0.22

10NF

C12

R18

100K

R5121 R6

2.7K

2

3

4

5

1

J3

5.11KR7

10UF

C25C11

0.22UF

1

2

3

4

5

6

J5

4

8

7

6

5

U8

7

14

17

8

13 6

4

16

15

U2

0.01UF

C16

C24

10NF0.1UF

C19

R17

5.11K

2.7K

R3121

R4

R20

0.22

1W_R_

C90.1UF

C18

0.01UF

C23

6.8NF

R14.75K

LED3LED4

R13

13.3K

BCX_R_LIMIT

BCX_L_LIMIT

X_MOT_HOLD_CURRENT

SM1/SM3_CLK

TX0

RX0

CTS0

RTS0

SPI_CLK

B_SPI_DATA_OUT

B_CH_CUV_IN_MOD

B_CHY_CUV_IN_GRIP

B_CH_MOD_POS

CH_Y_MOT_ENABLE

CH_Y_MOT_HALF/FULL

CH_Y_MOT_CW/CCW

HEAT_CON_SH

SM2_CLK

SENS_2

SENS_1

B_CW/CCW

/B_RESET

B_ENABLE

B_HALF/FULL

L_LIMIT

R_LIMIT

C100.1UF

0.1UF

C2

0.1UF

C5B_SM2_CLK

B_CH_Y_MOT_RESET


CH_GRIP_SOL_ENABLE

RTS0

CTS0

TX0

RX0

0.1UF

C4

BAR_SEN_LED_CTRL

CH_X_MOT_RESET

CH_X_MOT_HALF/FULL

SW_LED_CON

1

2

3

4

5

6

J4TRANS_RGT

SPI_CLK

CH_Y_MOT_ENABLE

CH_X_MOT_RESET

CH_X_MOT_ENABLE

SM1/SM3_CLK

C28

0.1UF

CHY_CUV_IN_GRIP

CHY_GRIPPER_REV

CONTROL



f 9)

GND

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




SN74LS09

MC74ACT04

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74LS09

SN74LS09

GND

5/27/05

5/27/05

G.DAVIDS.RATTA

N/A

286301-00

Brian Walker 7/06/04

1 of 9

UNIVERSAL ARM

CONTROLLER BOARD

Mounting holes for the

on the board.

Note:

board are to be plated andattached to the CGND net

0 Released per co L18255 DRC 26MAY05

S.RATTA

G.DAVID

1SEP05

1

0C CHANGED C99, +24V,PGND PLANE PER CO L18579 DRC

1 CHANGED MOTOR/ENCODER RESET WIRING BJW

DO NOT POPULATE

R684.02K

32

1U4

9

108

U4

SPARE5

15

14

13

12

11

10

98765

10K RP1

19

15

13

11

5

3

7

9

17

U53

1213

U2

12

1311

U4

SPARE4

Figure 16-64 CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 o

GND

VDD

GND

VDD

VDD

GND

GND

1 2 3 4 5 6

1 2 3 4 5 6

+24VVDD +15VVDD

GND

GND

VDD

VDD

+24V

PA

P

GND

A

VDD +15V +24V

VDD

GND

PA

+15V

U50

U26 U26

U1U1U1U1U1U1U1U1U1U1

BLACK RED BLACK RED BLACK

VDD

GREEN

+15V

GREEN

+24V

GREEN

RED

U1 U1 U1 U2 U3

U4 U5 U6 U6 U7 U7 U9

U26

U11 U12 U13 U14 U15 U16 U17 U18

U19 U20 U21 U22 U23 U24 U25 OSC1 U26 U26 U26 U26

U26 U27 U28 U29 U30 U31 U32 U33 U34 U35 U36 U37 U38 U39 U40

U41 U42 U43 U44 U45 U46 U47 U48 U49 U51

2.00V 3.48V

U52 U53 U54 U55

4.02V

20.0K

R8

4.02K

R11LED3

+24V_MON

C510.1UF

C970.1UF

16

4321

LED1 LED2

+15V_MON+5V_MON

TP1 TP6TP5TP4TP3

R712.1K3.01K

R6

TP2

0.1UFC15C14

0.1UFC120.1UF0.1UF

C11C90.1UF

0.1UFC25

0.1UFC31C28

0.1UFC260.1UF

C240.1UF

C180.1UF

C100.1UF 0.1UF

C13 C160.1UF 0.1UF

C170.1UFC19

0.1UFC27

0.1UFC29 C30

0.1UFC320.1UF 0.1UF

C33 C340.1UF

C200.1UF 0.1UF

C21 C220.1UF 0.1UF

C23

C350.1UF 0.1UF

C36 C370.1UF 0.1UF

C38

C147UF

C247UF

C347UF

C40.1UF 22UF

C5

2.00K

R9 R103.65K

0.1UFC6 C8

0.1UFC7

10UF

R23.01K 13.3K

R3 R422.1K

C680.1UF0.1UF

C67C660.1UF0.1UF

C65

C530.1UF0.1UF

C520.1UFC50

0.1UFC64C63

0.1UF0.1UFC62

0.1UFC60C59

0.1UFC570.1UF

C490.1UF

C470.1UF0.1UF

C46C430.1UF0.1UF

C400.1UFC48

0.1UFC54

0.1UFC56

0.1UFC58 C61

0.1UFC550.1UF

0.1UFC39 C41

0.1UF 0.1UFC42

0.1UFC44 C45

0.1UF

C780.1UF0.1UF

C770.1UFC75C74

0.1UFC720.1UF0.1UF

C690.1UFC71

0.1UFC73 C76

0.1UFC700.1UF 0.1UF

C79 C950.1UF 0.1UF

C960.1UFC98



f 9)

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




N/A

286301-00

Brian Walker 7/06/04 UNIVERSAL ARM

CONTROLLER BOARD

2 of 9

REFER TO PAGE 1

1

*/DSO

/A21

H*/DSI

E

/BKPT


VDD

GND SN74LS09

GND

1 2 3 4 5 6

1 2 3 4 5 6

VDD

GND

VDD

VDD

A1

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A2

A20

A5

A6

A8

A9

A3

A4

A7

IN

GND

GND

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

A2

A1

A4

A5

A3

IN

VDDVDD

VDD

MC74ACT04

MC74ACT04ADM705

MR

PFI

WDI

RESET

PFO

WDO

GND

GND

MC68332

IRQ6*/PF6

VSSE10

VSSE9

RXD

D0

D1

D2

D3

D4

D5

D6

D7

D15

D14

D13

D12

D11

D10

D9

D8

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

BR*/CS0*

BG*/CS1*

BGACK*/CS2*

PC0/FC0/CS3*

PC1/FC1/CS4*

PC2/FC2/CS5*

PC3/A19/CS6*

PC4/A20/CS7*

PC5/A21/CS8*

PC6/A22/CS9*

IFETCH*/DSI

IPIPE*/DSO

PQS0/MISO

PQS1/MOSI

PQS2/SCK

PQS3/PCSO*/SS*

PQS4/PCS1*

PQS5/PCS2*

PQS6/PCS3*

PQS7/TXD

TPUCH15

TPUCH14

TPUCH13

TPUCH12

TPUCH11

TPUCH10

TPUCH9

TPUCH8

TPUCH7

TPUCH6

TPUCH5

TPUCH4

TPUCH3

TPUCH2

TPUCH1

R/W*

CLKOUT

BERR*

HALT*

TPUCH0

A23/CS10*

DSACK0*/PE0

DSACK1*/PE1

AVEC*/PE2

RMC*/PE3

SIZ0/PE6

SIZ1/PE7

MODCLK/PF0

IRQ1*/PF1

IRQ2*/PF2

IRQ3*/PF3

IRQ4*/PF4

IRQ5*/PF5

IRQ7*/PF7

VDDI1

VDDI2

VDDSYN

XFC

CSBOOT*

VSSE1

SHLDPAD

VSSE2

VSSE3

VSSE4

VSSE5

VSSE7

VSSE8

VSSE11

VSSE6

VSTBY

VDDE1

VSSI2

VDDE2

VDDE3

VDDE4

VDDE5

VDDE6

VDDE9

VDDE7

VDDE8

VDDE10

VDDE11

VSSI1

VSSI3

VSSI4

TSC

RESET*

XTAL

EXTAL

T2CLK

FREEZE

DSCLK/BKPT

DS*/PE4

AS*/PE5

132 PQFP

GND

MC74ACT04

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

40.000KHZ

X1

X2

68K BDM Connector

Fsys = 16Mhz, Y = 49, W = 1, X = 0

Fsys = 40kHz (4*(Y+1)*2^((2*W) + X))

40.0 KHZ Crystal

EEPROM_PUP

1

4

X1

C8410PF

16

15

14

13

12

11

10

987654321

DNP RP3

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15PQS1/MOSI

PCS03

PQS1/MOSI

CPU_MISO

MODCLK/PF0

PQS2/SCK

PQS2/SCK

IPIPE

3 4

U2

IRQ4*/PF4

DATA[00:15]

CS7_EXT/A20

0

R54

CS4_IO_8BIT

CS1_CAN

CS3_RAMLR55

0

CS2_UART1

R52

0

SIZ0/PE6

0

R36

PCS02

PCS01

PCS00

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16 RP410K

DS*/PE4R34

0

0

R35AS*/PE5

R37

0

33

R38

R39

33

HALT

RD/WR*

BERR

CS10_EXT/A23

CS9_EXT/A22

CS8_IO_16BIT

CS6_EXT/A19

CS5_UART2

DSACK1*/PE1

SYSCLK

RD/WR*_INV RD

33

R40

72

117

106

53

111

110

109

108

105

104

103

102

91

92

93

94

97

98

99

100

90

20

21

22

23

24

25

26

27

30

31

32

33

35

36

37

38

41

42

113

114

115

118

119

120

121

122

123

124

55

54

43

44

45

46

47

48

49

52

129

130

131

132

3

4

5

6

9

10

11

12

13

14

15

79

66

70

69

16

125

89

88

87

86

85

82

81

80

78

77

76

75

74

73

71

1

63

61

64

112

8

17

29

40

51

83

95

12767

19

7

34

18

28

39

50

65

107

84

96

116

126

2

59

101

57

68

60

62

128

58

56133

U1

R13

332K

R1410M

SER_IRQ

1

4

6

7

5

8

U3

RESET

65

U2

21

U2

34

12

SW1

10

1

2

3

4

5

6

7

8

9

J1

C830.01UF

IPIPE*/DSO

RESET

IFETCH*/DSI

FREEZE

DSCLK/BKPT

DS*/PE4

BERR

RESET

0

2

3

1

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

C800.01UF 0.1UF

C81 C820.1UF

R1217.8K

C8510PF

18

17

16

15

14

13

12

0

1

2

3

4

5

6

7

8

9

10

11

RESET_IN

825R15

RESET

IFETC

FREEZ

IRQ1*/PF1

IRQ2*/PF2

IRQ3*/PF3

IRQ4*/PF4

CAN_IRQ

IRQ6*/PF6

IRQ7*/PF7

TPUCH[00:15]

ADDR[00:18]

PCS[00:03]

RESET_PUP

4

56

U4

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16 RP210K

DSACK0*/PE0

CPU_SCK

CPU_MOSI

DSCLK

RESET_PUP

RESET_IN

RMC*/PE3

SIZ1/PE7

CSBT_FLASH

CS0_RAMH



f 9)

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




REFER TO PAGE 1

N/A

286301-00


CONTROLLER BOARD

3 of 91

3

1

8

RD/WR*_CAN

RD/WR*_INV

4

2

5

6

7

RD/WR*_FLASH

RD/WR*_SRAM

RD/WR*_245

RD/WR*_PLD

RD_FLASH

RD_SRAM


GND

VDD

GND

GND

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

1 2 3 4 5 6

1 2 3 4 5 6

+15V

VDDVDDVDDVDDVDDVDDVDD

GND GND GND GND GND GND

VDD

GNDGND

VDD

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

GND

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

HOLD

WP

SCK

SI

CS

SO

A1

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A2

A20

A5

A6

A8

A9

A3

A4

A7

IN A1

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A2

A20

A5

A6

A8

A9

A3

A4

A7

IN

A1

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A2

A20

A5

A6

A8

A9

A3

A4

A7

IN29F200A

A0

A1

A10

A11

A12

A13

A14

A15

A16

A2

A3

A4

A5

A6

A7

A8

A9

DQ1

DQ10

DQ11

DQ12

DQ13

DQ14

DQ15/A-1

DQ2

DQ3

DQ4

DQ5

DQ6

DQ7

DQ8

DQ9

RY/BY*

BYTE

CE

OE

RESET

WE

DQ0

N/C

N/C

A6

A7

A10

A11

A12

A13

A14

A15

A16

I/O1

I/O3

I/O4

I/O5

I/O6

I/O8

I/O7

A0

A1

A2

A3

A4

A5

A8

A9

A17

I/O9

I/O10

I/O11

I/O12

I/O13

I/O14

I/O15

I/O16

I/O2

CS

WE

OE

UB

LB

K6X4016C3F

TSOP

A6

A7

A10

A11

A12

A13

A14

A15

A16

I/O1

I/O3

I/O4

I/O5

I/O6

I/O8

I/O7

A0

A1

A2

A3

A4

A5

A8

A9

A17

I/O9

I/O10

I/O11

I/O12

I/O13

I/O14

I/O15

I/O16

I/O2

CS

WE

OE

UB

LB

K6X4016C3F

TSOP

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

LTC1296

CH0

CH1

CH2

CH3

CH4

CH5

CH6

CH7

DIN

REF-

REF+

CS

CLK

VCC

V-

SSO

COM

AGND

DGND

DOUT

REF02

VIN

TEMP

GND

TRIM

VOUT

A

GND

A

GND

GND

D1 thru D17 are all MBR0520LT1

512K x 16 flash

Connected for

512 x 8 EEPROM

256K x 16 SRAM256K x 16 SRAM

SYSTEM SRAM128K x 16 Flash

DEBUG SRAMPROGRAM FLASH

For use with debugger only.

and vice versa.

Remove U4 when U6 is installed

+C99

4.7UF

16V

47UFC87

CS0_RAMH

CS3_RAML

EXT2_MON

RD_SRAM

RD/WR*_SRAM

0

R53

R4

33

RAM_CS

FLASH_PUP

10K

R64

R4

33

0

R59

R4

33

R1

0

CPU_MISO

CPU_SCK

CPU_MISO

4

3 5

2 6U10

1

2

3

4

5

6

7

8

15

13

14

17

18

20

11

19

9

12

10

16

U8

CPU_MOSI

CPU_SCK

RD/WR*_FLASH

RD_FLASH

CSBT_FLASH

CSBT_FLASH

RD/WR*_FLASH

RD_FLASH

RD/WR*

RD

33

R4

33

R4

8

18

16

12

14

2

4

6

1

U52

D17

D16

D3

39

40

41

17

6

8

38

37

36

35

32

31

30

29

18

26

27

44

1

2

3

4

5

15

16

14

13

10

9

7

19

20

21

22

23

24

25

42

43

U7

43

42

25

24

23

22

21

20

19

7

9

10

13

14

16

15

5

4

3

2

1

44

27

26

18

29

30

31

32

35

36

37

38

8

6

17

41

40

39

U6

25

24

6

5

4

3

2

1

48

23

22

21

20

19

18

8

7

31

34

36

39

41

43

45

33

35

38

40

42

44

30

32

15

47

26

28

12

11

17

16

29

U5

D8D1

8

9

10

11

12

13

14

15

16

17

0

18

3

4

6

7

1

2

55

2

1

7

6

4

3

18

0

17

16

15

14

13

12

11

10

9

88

9

10

11

12

13

14

15

16

17

0

18

3

4

6

7

1

2

5

ADDR[00:18]

DATA[00:15]

7

3

6

5

1

2U9

AT25040

CPU_MOSI

EEPROM_CS

CPU_ADC_CS

EXT5_MON

B_RESET

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

EEPROM_PUP

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

CS6_EXT/A19

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

C880.1UF

C860.1UF

EXT4_MON

+15V_MON

+5V_MON

PRESSURE_VACUMM_PUMP_SENSE

D2 D4 D5 D6 D7

D9 D10 D11 D12 D13 D14 D15

19

15

13

11

5

3

7

9

17

U52

33

R4

R4

33

33

R4

+24V_MON



f 9)

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




GND

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

A1

A2

A4

A5

A6

A8

A9

A10

A11

A12

A13

A7

A3

IN

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT245

G

A1

A2

A3

A4

A5

A6

A7

A8

B7

B8

B6

B5

B4

B3

B2

B1

DIR

MC74ACT245

G

A1

A2

A3

A4

A5

A6

A7

A8

B7

B8

B6

B5

B4

B3

B2

B1

DIR

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

REFER TO PAGE 1

N/A

286301-00


CONTROLLER BOARD

4 of 91

8

18

16

12

14

2

4

6

1

U17

B_ADDR[00:11]

1

18

17

16

15

14

13

11

12

9

8

7

6

5

4

3

2

19

U14

19

2

3

4

5

6

7

8

9

12

11

13

14

15

16

17

18

1

U13

17

9

7

3

5

11

13

15

19

U18

1

6

4

2

14

12

16

18

8

U18

19

15

13

11

5

3

7

9

17

U170

2

3

4

6

7

8

9

10

11

5

1

0

3

4

6

7

8

9

10

11

12

13

14

15

1

5

2

BDIR_DATA[00:15]

B_RESET

B_RESET

Figure 16-67 CTS Controller Interface PCB (Drawing # 28630100, Sheet 4 o1 2 3 4 5 6

1 2 3 4 5 6

A1

A2

A4

A5

A6

A8

A9

A10

A11

A12

A13

A7

A3

IN

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

GND

A1

A2

A5

A6

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A3

A7

A4

IN

GND

VDD

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

VDD

From PLD

OR'ED INPUT

OR'ED INPUT

X_MOT_IRQ_TPU_01

Y_MOT_IRQ_TPU_03

Z_MOT_IRQ_TPU_05

UNIVERSAL ARM TPU CONFIGURATION

Z_MOT_CLK

10KR67

TPUCH04

R6610K10K

R65

TPUCH00

4.99KR16

SPARE5

SPARE4

RESET

RD/WR*_245

17

9

7

3

5

11

13

15

19

U11

ADDR[00:18]

B_DATA[00:15]

1

6

4

2

14

12

16

18

8

U16

TPUCH08

17

9

7

3

5

11

13

15

19

U16

1

6

4

2

14

12

16

18

8

U15

17

9

7

3

5

11

13

15

19

U15

17

9

7

3

5

11

13

15

19

U12

1

6

4

2

14

12

16

18

8

U12

1

6

4

2

14

12

16

18

8

U11

INTF_DATA_ENA

Y_MOT_CLK TPUCH03

X_MOT_CLK

TPUCH15

TPUCH14

TPUCH13

TPUCH12

TPUCH09

TPUCH06

TPUCH07

GEN_CONT_STOP_IRQ

CAP_SENSE_TUBE_RELEASE

Z_MOTOR_STEP_SIZE_SYNC

AIR_BUBBLE_DETECT

Z_MOT_HOME_SENSE

TPUCH10

X_MOT_CLK

Y_MOT_CLK

Z_MOT_CLK

TPUCH05

X-LIMITS_COLLISION_AVOID

Y_EOT_LIMITS

TPUCH01

TPUCH11

0

3

4

6

7

8

9

10

11

12

13

14

15

1

5

2

DATA[00:15]

0

3

4

6

7

8

9

10

11

12

13

14

15

1

5

2

DATA[00:15]

0

3

4

6

7

8

9

10

11

12

13

14

15

1

5

2

0

2

3

4

6

7

8

9

10

11

5

1

RESET

TPUCH02

10KR63

B_TPU_IN6

LLD_IRQ



f 9)

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




VDD

GND

VDD

GND

VDD

GND

GND

VDD

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

N/A

286301-00


CONTROLLER BOARD

5 of 9

REFER TO PAGE 1

1

LLD_FREQUENCY_IN

B_SPI_CLK

MOSI

MISO

SPI_CLK_DIF_A

SPI_CLK_DIF_B

8

5

6

7

2

1

3

4

REFDES=U24

4

3

1

2

7

6

5

8

REFDES=U23

8

5

6

7

2

1

3

4

REFDES=U22

8

5

6

7

2

1

3

4

REFDES=U21

121R22

R21121

121R20

PROBE_LLD_FREQ_DIF_A

PROBE_LLD_FREQ_DIF_B

SPI_DATA_OUT_DIF_B

SPI_DATA_IN_DIF_B

SPI_DATA_IN_DIF_A

SPI_DATA_OUT_DIF_A

R23121


GND

VDD

1 2 3 4 5 6

1 2 3 4 5 6

GND

VDD

GND

ENA

GND

VDD

OUT

VDD

GND

VDD

GND

GND

GND

GND

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

VDD

GND

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

GND

XTAL1

XTAL2

RX0

RX1

TX1

TX0

CLOCKOUT

RDY/MISO

RESET

MODE1

P1.6/AD14

P1.5/AD13

P1.4/AD12

P1.3/AD11

P1.2/AD10

P1.1/AD9

P1.0/AD8

AD7

AD6/SCK

AD5

AD4/MOSI

AD3

MODE0

AD2

AD1

AD0

ALE/AS

RD*/E

P2.1

AGND

DNGD

RD/WR*

CS

DSACK0

P2.7/WRH*

P2.6/INT*

P2.5

P2.4

P2.3

P2.2

P2.0

INT*/VCC/2

AS82527

P1.7/AD15VCC

VREF

TXD

RXD CANL

CANH

RS

PCA82C250

A0

A1

A2

CS0

CS1

D0

D1

D2

D3

D4

D5

D6

D7

DDIS

INTRPT

MR

NC

NC0

NC1

NC2

NC3

NC4

NC6

RCLK

RD2

SIN

SOUT

VCC

VSS

WR2XIN

XOUT

ADSBAUDOUT

CS2

CTS

DCD

DSR

DTR

OUT1

OUT2

RD1

RI

RTS

RXRDY

TXRDY

WR1

NC5

16C550PQFP

C1+

C1-

C2+

C2-

T1IN

T2IN

R2IN

R1IN

VCC

MAX232A

V+

V-

GND

T1OUT

R1OUT

T2OUT

R2OUTR2

T2

T1

R1

VDD

GND

8 or 16 MHZ Crystal

Mode3, non Intel, non mux'ed

WHITEWHITE

GREEN

CAN

Serial Port 1

0R24

LED5

ADDR[00:07]

UART_IOR

1

3

4

5

11

10

8

13

16

2

6

15

14

12

7

9

REFDES=U26

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16 RP610K

28

27

26

9

10

43

44

45

46

47

2

3

4

22

30

35

25

21

1

13

36

37

48

5

20

7

8

42

18

17

14

15

24

12

11

38

40

39

33

34

31

19

41

32

29

23

16

6

U25

5

1

4 6

7

8

U20

1

TP8

12

13

16

15

19

20

21

22

23

24

26

27

28

29

30

31

32

33

34

35

36

37

38

40

41

42

43

44

10

14

17

1

2

3

4

5

6

7

8

9

11

18

2539

REFDES=U19

1

TP7

R173.01K

CTS

RTS

SIN

SOUT

RTS

SIN

SOUT

0.1UFC94C93

0.1UF0.1UFC92

C8922PF

B_RESET

B_RESET

SER_CS

UART_IOW

SER_CS

CTS

B_ADDR00

9

11

12

13

14

15

10

8

UART_IOW

CS1_CAN

C9022PF

X2

16MHZ

7

6

5

4

3

2

1

0

R191.82K

2.74K

R18

8

9

10

11

12

13

14

15

CAN_IRQ

1

2

4

3

OSC1

1.8432MHZ

B_ADDR02

B_ADDR01

UART_IOR

BDIR_DATA[00:15]

0.1UFC91

R564.99K

SER_IRQ



f 9)

GND

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




VDD

GNDGND

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

N/A

286301-00


CONTROLLER BOARD

PLD ISP connector

6 of 9

REFER TO PAGE 1

1

R261.00K

TCK

8

18

16

12

14

2

4

6

1

U53

SYSCLK_DIV2_XR49

33

SYSCLK_DIV2_Y

SYSCLK_DIV2_ZR51

33

SYSCLK_DIV2

R271.00K

TDI

10

1

2

3

4

5

6

7

8

9

J2

R251.00K

TDO

TMS

33

R50


1 2 3 4 5 6

GND

GND

GND

A2

A1

A4

A5

A3

IN

A1

A2

A4

A5

A6

A8

A9

A10

A11

A12

A13

A7

A3

IN

GND

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

EPM7128SQC100-15

IO56

IO55

IO22

IO23

IO24

IO25

IO26

IO27

IO28

IO29

IO40

IO41

IO45

IO46

IO47

IO48

IO50

IO51

IO52

IO53

IO59

IO60

IO61

IO62

IO63

IO64

IO66

IO68

IO69

IO70

IO71

IO72

IO73

IO74

IO75

IO76

IO3

IO12

IO18IO20

IO37

IO39

IO42

IO43

IO44

IO54

INPUT/GCLK1

INPUT/GCLRN

IO1

IO2

IO4

IO5

IO6

IO7

IO8

IO9

IO10

IO11

IO13

IO14

IO15

IO16

IO17

IO19

TDI

IO21

TMS

IO30

IO31

IO32

IO33

IO34

IO35

IO36

IO38

IO49

IO57

TCK

IO58

IO65

IO67

TDO

INPUT/OE1

INPUT/OE2/GCLK2

LAB A

LAB C LAB D

LAB GLAB H

LAB B

LAB E

LAB F

GNDIO;13,28,45,61,76,97

GNDINT;40,88

VCCIO;5,20,36,53,68,84

VCCINT;41,93

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

Y_FOW_LIMIT

Y_REV_LIMIT

X_RIGHT_LIMIT

X_LEFT_LIMIT

TUBE_RELEASE_SENSE

TUBE_CAP_SENSE

GENERAL_CONTROLLED_STOP_IRQ1

GENERAL_CONTROLLED_STOP_IRQ2 Y END OF TRAVEL LIMITS

LLD_LATCH

8B_REG8_CS

LLD_CNTR_CLR

LLD_IRQ

LLD_HIGH_BYTE

LLD_LOW_BYTE

SER_CS

8B_REG3_CS

Y_EOT_LIMITS

B_SPARE_VALVE_CONTROL

B_SYRINGE_PUMP_POWER_ENABLE

B_LLD_ON_OFF

AS*/PE5

R533

1

6

4

2

14

12

16

18

8

U30

OR28

62

60

25

24

23

22

21

19

18

39

43

44

49

50

51

52

55

56

57

58

66

67

69

70

71

72

74

78

79

80

81

82

83

85

86

87

2

15

827

30

42

46

47

48

59

89

91

4

3

1

100

99

98

96

95

94

16

14

12

11

10

9

7

6

26

17

38

37

35

34

33

32

31

54

63

64

65

73

77

75

90

92

29

U27

B_ADDR[00:11]

PCS[00:03]

CS2_UART1

CS8_IO_16BIT/A21

CS4_IO_8BIT

B_PRESSURE_VAC_SOL_CONTROL

B_PIERCER_LOCK_SOLENOID_CONTROL

B_RACK_LOCK_BRAKE_CONTROL

17

9

7

3

5

11

13

15

19

U30

17

9

7

3

5

11

13

15

19

U29

1

6

4

2

14

12

16

18

8

U29

17

9

7

3

5

11

13

15

19

U28

1

6

4

2

14

12

16

18

8

U28

8B_REG7_CS

B_RESET

SYSCLK

B_Z_DAC_CS

B_Z_ADC_CS

B_SPI_CS7

B_SPI_CLK

MOSI

B_PROBE_CS

B_SPI_CS6

B_PROBE_TYPE_SPI_CS

PROBE_CS

PROBE_TYPE_SPI_CS

SPI_CS7

SPI_CS6

Z_ADC_CS

Z_DAC_CS

PROBE_CS

PROBE_TYPE_SPI_CS

SPI_CS7

SPI_CS6

Z_ADC_CS

Z_DAC_CS

BIT_ADDR_BIT3

BIT_ADDR_BIT0

BIT_ADDR_BIT10

B_DATA08

SPI_ENA

EEPROM_CS

CPU_ADC_CS

X_MOT_ENC_CS

8B_REG1_CS

UART_IOW

UART_IOR

8B_REG5_CS

8B_REG4_CS

GEN_CONT_STOP_IRQ

8B_REG2_CS

0

2

3

4

6

7

8

9

10

11

5

1

0

2

3

1

BIT_ADDR_BIT10

B_VENT_SOLENOID_CONTROL

B_CTS_FLUID_PUMP_CONTROL

B_CTS_VACUUM_PUMP_CONTROL

B_CTS_PRESSURE_PUMP_CONTROL

BIT_ADDR_BIT8

BIT_ADDR_BIT9

BIT_ADDR_BIT7

BIT_ADDR_BIT5

BIT_ADDR_BIT6

BIT_ADDR_BIT4

BIT_ADDR_BIT1

BIT_ADDR_BIT2

BIT_ADDR_BIT0

BIT_ADDR_BIT1

BIT_ADDR_BIT2

BIT_ADDR_BIT3

BIT_ADDR_BIT4

BIT_ADDR_BIT5

BIT_ADDR_BIT6

BIT_ADDR_BIT7

BIT_ADDR_BIT8

BIT_ADDR_REG_CS

BIT_ADDR_BIT9

8B_REG6_CS

B_8B_REG7_IN7

B_8B_REG7_IN6

B_8B_REG6_IN1

B_8B_REG6_IN0

B_8B_REG5_IN5

B_8B_REG5_IN4

B_8B_REG5_IN3

B_8B_REG5_IN2

TDO

TCK

TMS

TDI

INTF_DATA_ENA

Y_MOT_ENC_CS

SPI_ENA

MISO

SYSCLK_DIV2

Z_MOT_ENC_CS



f 9)

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




GND

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

GND

VDD

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

GND

VDD

VDD

GND

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

D3

D4

D5

D6

D7

CLK

CHB

SEL

OE

VDDD0

RST

CHA

VSS

D2

D1

PLCC-20

HCTL2016

D3

D4

D5

D6

D7

CLK

CHB

SEL

OE

VDDD0

RST

CHA

VSS

D2

D1

PLCC-20

HCTL2016

D3

D4

D5

D6

D7

CLK

CHB

SEL

OE

VDDD0

RST

CHA

VSS

D2

D1

PLCC-20

HCTL2016

N/A

286301-00


CONTROLLER BOARD

Interface Address

Interface Address

Interface Address

Low Byte 41 High Byte 42

Low Byte 47 High Byte 48

Low Byte 4D High Byte 4E

7 of 9

REFER TO PAGE 1

X-Motor Encoder Counter

Y-Motor Encoder Counter

Z-Motor Encoder Counter

1

8B_REG1_OUT4

B_X_MOT_ENC_B

SYSCLK_DIV2_Z

SYSCLK_DIV2_Y

SYSCLK_DIV2_X

SP_BUF2

SP_BUF1

Z_MOT_ENC_B

BDIR_DATA[00:15]

BDIR_DATA[00:15]

BDIR_DATA[00:15]

17

14

13

12

11

2

8

3

4

201

7

9

10

18

19

U33

19

18

10

9

7

1 20

4

3

8

2

11

12

13

14

17

U36

17

14

13

12

11

2

8

3

4

201

7

9

10

18

19

U39

1

6

4

2

14

12

16

18

8

U41

17

9

7

3

5

11

13

15

19

U41

B_Z_MOT_ENC_B

B_Y_MOT_ENC_B

B_Y_MOT_ENC_A

B_X_MOT_ENC_B

B_X_MOT_ENC_A

Y_MOT_ENC_B

Y_MOT_ENC_A

Z_MOT_ENC_A

Y_MOT_ENC_CS

B_ADDR00

B_ADDR00

B_Y_MOT_ENC_B

B_Y_MOT_ENC_A

B_X_MOT_ENC_A

9

11

12

13

14

15

10

8

9

11

12

13

14

15

10

8

8

10

15

14

13

12

11

9

X_MOT_ENC_CS

8B_REG2_OUT4

B_Z_MOT_ENC_A

Z_MOT_ENC_CS

B_ADDR00

8B_REG3_OUT4

B_Z_MOT_ENC_B

B_Z_MOT_ENC_A


VDD

1 2 3 4 5 6

1 2 3 4 5 6

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

VDD VDD

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT373

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

G

OC

MC74ACT373

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

G

OC

MC74ACT373

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

G

OC

MC74ACT373

8Q

7Q

6Q

5Q

4Q

3Q

2Q

1Q

8D

7D

6D

5D

4D

3D

2D

1D

G

OC

ABCD

GND

GND

WHITE TEST POINTS

3 2 18765

4

REFDES=SW2

BDIR_DATA[00:15]

X_LEFT_LIMIT_SENSE

X_RIGHT_LIMIT_SENSE

8B_REG5_CS

8B_REG6_CS

8B_REG8_CS

8B_REG7_CS

Y_REV_LIMIT_SENSE

TP12TP11TP10TP9

1

11

3

4

7

8

13

14

17

18

2

5

6

9

12

15

16

19

U40

19

16

15

12

9

6

5

2

18

17

14

13

8

7

4

3

11

1

U38

1

11

3

4

7

8

13

14

17

18

2

5

6

9

12

15

16

19

U35

19

16

15

12

9

6

5

2

18

17

14

13

8

7

4

3

11

1

U32

19

15

13

11

5

3

7

9

17

U37

1

6

4

2

14

12

16

18

8

U37

1

6

4

2

14

12

16

18

8

U34

17

9

7

3

5

11

13

15

19

U34

17

9

7

3

5

11

13

15

19

U31

8

18

16

12

14

2

4

6

1

U31

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16 RP910K

16

15

14

13

12

11

10

987654321

10K RP8

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16 RP710K

SP_BUF2



FLUID_PUMP_SENSE

VENT_SOLENOID_SENSE

TUBE_RELEASE_SENSE

PIERCE_SOL_LOCK_SENSE

AIR_BUBBLE_DETECT

PROBE_PIC_RESET

RACK_LOCK_SOLENOID_SENSE

Y_FWD_LIMIT_SENSE

TUBE_CAP_SENSE

Z_MOT_HOME_SENSE

8B_REG8_CS

8B_REG7_CS

9

11

12

13

14

15

10

8

8B_REG6_CS

8B_REG5_CS

9

11

12

13

14

15

10

8

B_8B_REG7_IN2

B_8B_REG7_IN6

B_8B_REG7_IN5

B_8B_REG7_IN4

B_8B_REG7_IN0

B_8B_REG7_IN1

B_8B_REG6_IN4

B_8B_REG7_IN3

B_8B_REG6_IN0

B_8B_REG6_IN1

B_8B_REG6_IN2

B_8B_REG6_IN3

B_8B_REG6_IN5

B_8B_REG6_IN6

B_8B_REG6_IN7

B_8B_REG5_IN7

B_8B_REG5_IN6

B_8B_REG5_IN5

B_8B_REG5_IN1

B_8B_REG5_IN2

B_8B_REG5_IN4

B_8B_REG5_IN3

9

11

12

13

14

15

10

8B_8B_REG5_IN0

B_8B_REG7_IN7

8

10

15

14

13

12

11

9

SP_BUF1



f 9)

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

VDD

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




GND

GND

ADP

CDP

AA

AFAB

AC

AD

AE

AG

CC

VDD

Y6

Y7

CLR

Y5

Y4

Y3

Y2

Y1

Y0

74LV8154

BEN

RCOA

RCLK

GBU

GBL

GAU

GAL

CLKB

CLKA

VDD

D

C

B

A AA

AB

AC

AD

AE

AF

AGLE

BI

LT

CD4511BNSR

N/A

286301-00


CONTROLLER BOARD

8 of 9

REFER TO PAGE 1

1

7 13

12

11

10

9

15

14

1

2

6

4

5

3

U54

10

12346789

5

RP11

4.7K

13

12

11

14

15

16

17

18

19

9

8

7

6

5

4

3

2

1

U55

LLD_CNTR_CLR

4.99KR57

HEARTBEAT_LED

7

6

1 2

10 8 5 4 3

9 LED4

1 2 43 5 6 7

891011121314RP10

470 R58475

9

11

12

13

14

15

10

8

BDIR_DATA[00:15]


1 2 3 4 5 6

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

MC74ACT04

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

MC74ACT04

A3

A5

A6

A7

A8

A9

A4

A1

A2

IN

MC74ACT273

CLR

6Q

5Q

2Q

1Q

3Q

4Q

7Q

8Q

1D

2D

3D

4D

5D

6D

7D

8DCLK

MC74ACT273

CLR

6Q

5Q

2Q

1Q

3Q

4Q

7Q

8Q

1D

2D

3D

4D

5D

6D

7D

8DCLK

MC74ACT273

CLR

6Q

5Q

2Q

1Q

3Q

4Q

7Q

8Q

1D

2D

3D

4D

5D

6D

7D

8DCLK

MC74ACT273

CLR

6Q

5Q

2Q

1Q

3Q

4Q

7Q

8Q

1D

2D

3D

4D

5D

6D

7D

8DCLK

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

VDD

G

MC74ACT259

D

S0

S1

S2

CLRQ7

Q5

Q4

Q2

Q1

Q0

Q3

Q6

GND

L297 & ON BOARD ENCODER 1 /RESET

L297 & ON BOARD ENCODER 2 /RESET

ON BOARD ENCODER 3 /RESET

RED GREEN GREENGREEN

HEARTBEAT ERROR TEST1 TEST2

Inverter on motor enable signalallows for active low enablesignal on the driver board.

B_RESET

B_RESET

B_RESET

8B_REG3_OUT4

8B_REG2_OUT4

8B_REG1_OUT4

B_RESET

LLD_LATCH

13

4

5

6

7

9

10

11

12

1

2

3

15

14

U50

TESTPOINT1

ERROR_LED

HEARTBEAT_LED

B_RESET

8B_REG1_CS

LED_DISPLAY_D

8B_REG3_CS

LED_DISPLAY_A

LED_DISPLAY_B

LED_DISPLAY_C

LED_DISPLAY_D

LED_DISPLAY_C

LED_DISPLAY_B

LED_DISPLAY_A

R323.01K

LED8LED7LED6

B_DATA[00:15]

8

18

16

12

14

2

4

6

1

U49

17

9

7

3

5

11

13

15

19

U49

19

15

13

11

5

3

7

9

17

U47

1

6

4

2

14

12

16

18

8

U47

19

15

13

11

5

3

7

9

17

U45

8

18

16

12

14

2

4

6

1

U45

19

15

13

11

5

3

7

9

17

U43

8

18

16

12

14

2

4

6

1

U43

11

18

17

14

13

8

7

4

3

19

16

9

6

2

5

12

15

1

U48

1

15

12

5

2

6

9

16

19

3

4

7

8

13

14

17

18

11

U46

11

18

17

14

13

8

7

4

3

19

16

9

6

2

5

12

15

1

U44

1

15

12

5

2

6

9

16

19

3

4

7

8

13

14

17

18

11

U42

Z_MOT_CW/CCW

PROBE_PIC_RESET_CONTROL

Z_MICRO_CONT_2

Z_MOT_ENABLE

Z_MOT_SLEEP

Z_MOT_RESET

Y_MOT_CW/CCW

Y_MOT_ENABLE

TESTPOINT2

R313.01K

R303.01K

R293.01K

8B_REG4_CS

BIT_ADDR_REG_CS

B_ADDR02

B_ADDR01

B_ADDR00

1

3

4

5

6

7

2

0

Y_MOT_HOLD_CURRENT

Y_MOT_RESET

Y_MOT_HALF/FULL

X_MOT_ENABLE

X_MOT_HALF/FULL

X_MOT_CW/CCW

11 10

U2

1

3

4

5

6

7

2

0

1

3

4

5

6

7

2

0

89

U2

8B_REG2_OUT[0:7]

1

3

4

5

6

7

2

0

8

1

3

4

5

6

7

2

0

1

3

4

5

6

7

2

0

1

3

4

5

6

7

2

0

9

11

12

13

14

15

10

8

9

11

12

13

14

15

10

8

1

3

4

5

6

7

2

0

9

11

12

13

14

15

10

8

9

11

12

13

14

15

10

8

8B_REG4_OUT[0:7]

8B_REG2_CS

8B_REG3_OUT[0:7]

8B_REG1_OUT[0:7]

X_MOT_HOLD_CURRENT

X_MOT_RESET

LED9

Z_MICRO_CONT_1

LLD_FREQUENCY_IN

LLD_LOW_BYTE

LLD_HIGH_BYTE



f 9)

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




VDD +24V

GND

P CGND

N/A

286301-00


CONTROLLER BOARD

9 of 9

To Z Motor Driver Board

REFER TO PAGE 1

1

1

B_Z_ADC_CS

B_Z_DAC_CS

B_PIERCER_LOCK_SOLENOID_CONTROL

B_RACK_LOCK_BRAKE_CONTROL

TUBE_RELEASE_SENSE


RACK_LOCK_SOLENOID_SENSE

SPI_CLK_DIF_B

Z_MOTOR_STEP_SIZE_SYNC

Z_MOT_SLEEP

Z_MOT_RESET

B_PROBE_TYPE_SPI_CS

Z_MOT_ENABLE

TUBE_CAP_SENSE

Z_MOT_CW/CCW


Z_MOT_CLK

B_PROBE_CS

Z_MICRO_CONT_1

Z_MICRO_CONT_2

PROBE_PIC_RESET_CONTROL



SPI_DATA_IN_DIF_A

SPI_DATA_IN_DIF_B

Z_MOT_HOME_SENSE

Z_MOT_ENC_A

SPI_DATA_OUT_DIF_A

Z_MOT_ENC_B

SPI_DATA_OUT_DIF_B

PROBE_DC_HEATER_2

PROBE_DC_HEATER_2

PROBE_DC_HEATER_1

PROBE_DC_HEATER_1

PROBE_PWM_HEAT_2

PROBE_PWM_HEAT_1

SPI_CLK_DIF_A



GND

1 2 3 4 5 6

1 2 3 4 5 6

GND

P

VDD

+15V

+24V

A

P

GND

CGND

CGND

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

VDD

MC74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

GND

VDD

VDD

Debug CAN

To Y Motor Driver Board

To X Motor Driver Board

To Y Motor Driver Board

10

4

5

6

7

8

9

20

19

18

17

16

15

12

3

1

2

11

13

14

J6

HEARTBEAT_LED

10KR62

PROBE_PIC_RESET

SPARE1

SPARE3

1

6

4

2

14

12

16

18

8

U51

PROBE_PWM_HEAT_2

PROBE_PWM_HEAT_1

R33DNP

B_SYRINGE_PUMP_POWER_ENABLE

B_ERROR_LED

B_HEARTBEAT_LED

B_HEARTBEAT_LED

CAN_H

ERROR_LED

B_ERROR_LED

B_PROBE_PIC_RESET

B_PROBE_PWM_HEAT_2

B_PROBE_PWM_HEAT_1

17

9

7

3

5

11

13

15

19

U51

1

1

Y_INDEX

Y_FWD_LIMIT_SENSE

PROBE_DC_HEATER_2

PRESSURE_VACUMM_PUMP_SENSE

FLUID_PUMP_SENSE

B_PRESSURE_VAC_SOL_CONTROL

B_CTS_PRESSURE_PUMP_CONTROL



B_CTS_VACUUM_PUMP_CONTROL

X_MOT_RESET

RS232_RX

RS232_TX

X_RIGHT_LIMIT_SENSE

X_LEFT_LIMIT_SENSE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

J5

CAN_L

CAN_H

4

1

2

3

J3

Y_MOT_ENC_A

Y_MOT_ENC_B

Y_MOT_CLK

Y_MOT_ENABLE

Y_MOT_HALF/FULL

Y_MOT_RESET

Y_MOT_HOLD_CURRENT

Y_REV_LIMIT_SENSE

PROBE_DC_HEATER_1

+24V

PROBE_DC_HEATER_1

PROBE_DC_HEATER_1

PROBE_DC_HEATER_1

PROBE_DC_HEATER_2

PROBE_DC_HEATER_2

PROBE_DC_HEATER_2

B_PROBE_PWM_HEAT_1

B_PROBE_PWM_HEAT_2

10

4

5

6

7

8

9

18

16

15

12

3

1

2

11

13

14

19

20

22

23

25

17

21

24

26

27

28

29

30

31

32

33

34

35

36

37

39

38

42

41

40

44

43

45

46

47

48

49

50

J4

X_MOT_HOLD_CURRENT

X_MOT_ENC_B

X_MOT_CLK

X_MOT_ENC_A

X_MOT_ENABLE

X_MOT_HALF/FULL

X_MOT_CW/CCW

CAN_L

B_CTS_FLUID_PUMP_CONTROL

Y_MOT_CW/CCW

48

49

60

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

50

51

52

53

54

55

56

57

58

59

J7

B_PROBE_PIC_RESET

R6010K

SPARE2

10KR61



P

P

+24V

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




BOOT1

BOOT2

ENABLE

GND1

GND2

GND3

GND4

IN1

IN2 OUT1

OUT2

SENSE

VREF

L6201P_A

VS_1

P

P

CON8L

15MAR050



N/A

Saverio Ratta

To Y Axis Motor

onic Type PRX2W2.22CT

Panasonic Type PRX2W2.22CT

1 of 2

01/10/05

0

SCHEMATIC,

D.COX

Y DRIVER BD,

UNIVERSAL ARM

286311-00

RELEASED PER CO L18074

8

7

6

5

4

3

2

1

J2

7

14

7

8

3 6

4

16

15

0

0

1

U3

R4

1.8

C11

10NF

10NF

C15

C27

0.22UF

C26

0.22UF

0.01UF

C14

C13

10NF

C12

10NF

R5

0.22

R3

1.8

C9

0.01UF

SENS_2

C210.1UF

Figure 16-73 Y Axis U Arm PCB (Drawing # 28631100, 1 of 2)

P

PP

+24V

+24V

BOOT1

BOOT2

ENABLE

GND1

GND2

GND3

GND4

IN1

IN2 OUT1

OUT2

SENSE

VREF

L6201P_A

VS_1

TEMP

VIN

GND

VOUT

TRIM

N/C

N/CN/C

+5V

D

GND

IN

N/C

S

V-

VL

DG417

V+

+24V

1 2 3 4 5 6

1 2 3 4 5 6

+5V

+5V

+24V

+5V

+5V

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

P

P

+24V

+24V

+5V

P

P

P

P

P

P

P

P

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

L297

A

B

C

D

INH1

INH2

P10

P11

P17

P18

P19

P20 SEN1

SEN2

SYNC

HOME

OSC

VREF

To Interface Connector Board

21khz

Panas

Test Equipment Connector Header

To ARM Controller Interface Board

Running Power ~ 1.73AVref L297 ~ 0..381V

Vref L297 ~ 0.114VHolding Power ~ 0.517A

14

13

11

2

1

3

12

15

16

17

18

19

20

9

8

7

6

5

4

10

J6

4

6

7

9

5

8

10

11

17

18

19

20 14

13

1

3

16

15

U4

8

18

16

12

14

2

4

6

1

U5

B_PROBE_PIC_RESET

B_INDEX


B_HALF/FULL

INDEX

B_INDEX

PROBE_PIC_RESET

VDD

1

1

TH1

SYNC

SYNC

VREF

VREF

VREF_L297

2

3

4

5

1

J7

1

1

5

2

1

1

1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

J5

B_Y_HOME_REV_LIMIT

B_X_RIGHT_LIMIT

B_X_LEFT_LIMIT

B_Y_FOW_END_TRAVEL

VREF_L297

OSC_L297

Y_MOT_HOLD_CURRENT

68UF

C30

8.25KR7

C37

47UF 10UF

C28

PROBE_PIC_RESET

Y_MOT_HALF/FULL

R9

0.22SENS_2

SENS_1

C160.1UF

1

TP3

1 TP5 1 TP6

1

TP1

1 2 43 6 7 8 9

10 5

4.7K

R20

19

15

13

11

5

3

7

9

17

U5

PRESSURE_PUMP_SENSE

PROBE_PWM_HEAT_1

PROBE_PWM_HEAT_2

B_Y_MOT_ENABLE

Y_MOT_ENABLE

B_Y_ENC_B

B_Y_ENC_A

Y_MOT_RESET

Y_MOT_CW/CCW

C170.1UF

R10

10K

Y_ENC_B

Y_ENC_A

B_Y_ENC_B

B_Y_ENC_A

Y_MOT_CW/CCW

+24V

R8

100K

CONTROL

R11

10KB_Y_MOT_RESET

B_Y_MOT_CW/CCW

0.1UF

C10

B_Y_MOT_CLK

C33

100UF 100UF

C32 C31

100UF

C29

68UF

0.1UF

C20

1

TP7

C190.1UF

0.01UF

C18

8

3

6

2

1

7

5

4

U7

1

3

2

4

8

7

6

5

U6

7

14

17

8

13 6

4

16

155

20

10

1

11

U2

R6

3.24K

C8

6.8NF

0.1UF

C6

C5

0.1UF

VREF_L297

SENS_1


B_Y_MOT_RESET

Y_MOT_HOLD_CURRENT

Y_MOT_RESET

Y_MOT_HALF/FULL

Y_MOT_CLK

B_Y_MOT_CW/CCW

C230.1UF

PROBE_HEATER_1

PROBE_HEATER_2

47UF

C38C39

47UF

100UF

C34 C35

100UF100UF

C36

1

TH2



G

D

S

IRLR024N

G

D

S

IRLR024N

P

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




P

SEE SHEET 1

N/A

Saverio Ratta

2 of 2

12/10/04

0

SCHEMATIC,

UNIVERSAL ARM

Y DRIVER BD,

286311-00

D1

D2

1

TP2

1

TP4

L2

560UH

L1

560UH

3

2

1

FET2

+24V

+24V

100UF

C3

100UF

C2

C1

100UF

1

2

3FET1

C4

100UF

D1

PROBE_HEATER_1

PROBE_HEATER_2

Figure 16-74 Y Axis U Arm PCB (Drawing # 28631100, 2of 2)

P

P

CON6L

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

+5V

+5V

+5V

SN74ACT08

Y1

Y2

Y3

Y4A4

A3

A2

A1

G

SN74ACT240

Y1

Y2

Y3

Y4A4

A3

A2

A1

G

SN74ACT240

SN74ACT08

VOUT

GND

A

K

VCC

VREF

GND

VDD

GNDGND

VOUT

GND

A

K

VCC

VREF

VDD

GND

GND

VDD

+5V

+5V

+5V

+5V

+24V+5V

P

1 2 3 4 5 6

1 2 3 4 5 6

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

+5V

CON6L

SN74ACT08

SN74ACT08

1/2 Watt

/Hold Power LED

Full Power

To Y Motor Encoder

To Y- Reverse HOME Limit Sensor

Y Foward End of Travel Connector

TO PRESSURE PUMP SENSOR

RIGHT_LIMIT_OPTICAL SENSORLEFT_LIMIT_OPTICAL SENSOR

1/2 Watt

X_LEFT_LIMIT X_RIGHT_LIMIT

1211

13

U8

108

9U8

INDEX6

5

4

3

2

1

J1

2.2K

R25

R222.1K

1 2 43 6 7 8 9

10 5

4.7K

R23

B_Y_HOME_REV_LIMIT

B_Y_FOW_END_TRAVEL

B_X_LEFT_LIMIT

B_X_RIGHT_LIMIT

PRESSURE_PUMP_SENSE

X_LEFT_LIMIT

X_RIGHT_LIMIT

Y_FOW_END_TRAVEL

Y_HOME_REV_LIMIT

Y_HOME_REV_LIMIT

510

98763 421

R21

4.7K

8

18

16

12

14

2

4

6

1

U9

R18

120

2.87KR16

1

2

LED4

2

1

LED3

R17

22.1K

0.1UF

C22

1

2

3

4

5

J3

1

5

4

3

2

J4

120

R22

R14

121

4

5

1

2

3OPT1

121

R12

4

5

1

2

3OPT2

Y_FOW_END_TRAVEL

Y_ENC_B

Y_ENC_A

PS_OFFSET_ADJ

1

2

LED5

13

2

U8

9

7

5

317

15

13

11

19

U1

1

2

4

6

8 12

14

16

18

U1

56

4U8

R122.1K

1

2

LE

1

2

LED2

0.1UF

C24

R19

2.87K

Y_MOT_HOLD_CURRENT

B_Y_MOT_ENABLEY_MOT_ENABLE

Y_MOT_CLK

B_PWM_HEAT_1

B_Y_MOT_CLK

B_PROBE_PIC_RESET

B_PWM_HEAT_1

B_PWM_HEAT_2PROBE_PWM_HEAT_2

PROBE_PWM_HEAT_1

B_PROBE_PIC_RESET

B_PWM_HEAT_2

0.1UF

C25

C70.1UF

19

15

13

11

5

3

7

9

17

U9

1

2

3

4

5

6

J8

510

98763 421

R24

4.7K

R262.2K



V

+5V

+24V

+24V

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




+5V

P

ADDED VREF TO ADC CIRCUITRY (PROTOTYPE)

26MAY05D.COX

Not used Probe reset

Z Driver Board

CTS / Universal Arm

1 of 3

To Heated Probe Board

286331-00

Vent Solenoid Connector

Rack Lock Brake Connector

+24V


0 RELEASED PER CO L18255

0A

0A

10

4

5

6

7

8

9

18

17

16

15

12

3

2

11

13

14

19

20

1

24

23

22

21

J3

4

3

2

1

J9

2

1

J8

SPARE_SOLENOID_PWR

1

TP5

B_SPI_CLK

RACK_LOCK_BRAKE_PWR

1

10

11

12

13

14

15

16

17

18

19

2

20

21

22

23

24

25

26

27

28

29

3

30

31

32

33

34

35

36

37

38

39

4

40

5

6

7

8

9

J1

B_SPI_DATA_IN

PROBE_DC_HEATER_1

PROBE_DC_HEATER_2

PRB+24V

PROBE_PWM_HEAT_1

B_SPI_DATA_OUT

PROBE_PIC_RESET

PROBE_PWM_HEAT_2

PROBE_LLD_FREQ

PROBE_DC_HEATER_2

PROBE_DC_HEATER_2

PROBE_DC_HEATER_2

PROBE_DC_HEATER_1

PROBE_DC_HEATER_1

PROBE_DC_HEATER_1

R183.01K

2

1

LED2

B_PROBE_CS

VENT_SOLENOID_PWR

Figure 16-75 Z Driver PCB (Drawing # 28633100, Sheet 1 of 3)

+24V

+24

P

+5V

+5V

+5V

+5V

1 2 3 4 5 6

1 2 3 4 5 6

+5V +24V

P

+24V

+5V

VDD

CGND

CGND P

P

1 Watt 1 Watt 1 Watt 1 Watt

1 Watt1 Watt1 Watt1 Watt

To CTS Controller Interface Board

U7 U7 U7U7

U7 U12 U4 U8 U9 U3 U11

Z_HOME_SENSOR

MOTOR ENCODER

To CTS Probe / Sensor Board

Note:

board are to be plated

and attached to the

CGND net on the board.

Mounting holes for the

U2

U5 U13

U10 U1

F1

3.0A

1

TP1

0.1UF

C23

0.1UFC22

48

49

60

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

50

51

52

53

54

55

56

57

58

59

J2

C290.1UF

PIERCER_LOCK_SOLENOID_CONT

B_SPI_DATA_OUT

B_SPI_DATA_IN

B_SPI_CLK

TUBE_CAP_SENSE

PIERCER_POSITION_SENSE


B_PROBE_TYPE_SPI_CS

PROBE_LLD_FREQ

1

TP6

1

2

3

4

5

1

J4



1

SPARE_VALVE_CONTROL

Z_ADC_CS

Z_MOT_HOME_SENSETUBE_CAP_SENSE

Z_DAC_CS

Z_ADC_CS

PROBE_PWM_HEAT_1

RACK_LOCK_BRAKE_CONT

PROBE_DC_HEATER_1

PROBE_DC_HEATER_2

PROBE_DC_HEATER_2

PROBE_PWM_HEAT_2

PROBE_DC_HEATER_1

PIERCER_LOCK_SOLENOID_CONT

B_Z_MOT_ENC_B

SPI_DATA_OUT_DIF_B

B_Z_MOT_ENC_A

SPI_DATA_OUT_DIF_A

B_STEP_SIZE_CHANGE_SYNC

SPI_CLK_DIF_B

SPI_CLK_DIF_A

B_Z_MOT_HOME_SENSE

SPI_DATA_IN_DIF_B

Z_DAC_CS

SPI_DATA_IN_DIF_A

B_TUBE_RELEASE_SENSE



VENT_SOLENOID_CONTROL


Z_MICRO_CONT_2

PROBE_PIC_RESET

Z_MICRO_CONT_1

PROBE_CS

Z_MOT_CLK

Z_MOT_CW/CCW


TUBE_CAP_SENSE

Z_MOT_ENABLE

Z_MOT_RESET

PROBE_TYPE_SPI_CS

Z_MOT_SLEEP

2

1

LED3

1 2 43 6 7 8 9

10 5

4.7K

RP5

PROBE_PWM_HEAT_2

PROBE_PWM_HEAT_1

PRB+24V

C190.1UF47UF

C21C2047UF

C270.1UF

C250.1UF0.1UF

C12

2

3

4

5

6

1

J5

Z_MOT_ENC_A

Z_MOT_ENC_B

120

R28

R88.2

8.2

R12

8.2

R7

R118.2

33UF

C1 C160.1UF 0.1UF

C170.1UFC26

0.1UFC28

C233UF 33UF

C3 C433UF 33UF

C50.1UF

C6

8.2

R13

R98.2

R148.2

8.2

R10

+24V

1

TP2

R1922.1K

0.1UFC30

C310.1UF

1

TP4

1

TP3



P

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




SEE SHEET 1

Z Driver Board

CTS / Universal Arm

Assist in decreasing

Optional Diodes

To Z Motor

8 Pin Dual Row

2 of 3

Dissipation of Driver Device

286331-00

river is allowed to run fullng of a cap in microstep mode.ower inorder to facilitate

ull step mode, the attached over-heat, ruining the motor.t a design issue but rather a the potential in case it was

er design allows for 2.5A


0A

1

2

D7

2

1

D8

2

1

D4

2

1

D6

8

7

6

5

4

3

2

1J6

+24V

1

2

D5

1

2

D3

2

1

D2

1

2

D1


+24V

+5V

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

1 2 3 4 5 6

1 2 3 4 5 6

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

+5V

P

P

VOUT

REF

DIN

CS

VDDCLK

DOUT GND

LTC1451

+5V

AGND

CP1

CP2

DIRHOME

LOAD_SUPPLY1

LOAD_SUPPLY2

LOGIC_SUPPLY

MS1

MS2

OUT1B

OUT2B

PFD

PGND

RC1

REF

SENSE1

SENSE_2

SR

STEP

VCP

VREG

SLEEP

A3977TSSOPENABLE

RESET

OUT1A

RC2

OUT2A

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

P

P

P

MCP3201

CLK

DOUT

IN+

IN-

VDDVREF

VSS CS

TEMP

VIN

GND

VOUT

TRIM

N/C

N/CN/C

+24V

1 Watt 5%

1 Watt 5%

1.4 Microseconds

Blanking Time set to

1 Watt 5%

Current setting 1.85A per Phase

When Vref = 3.478V

1 Watt 5%

If motor dthe peirciworth of p

power in fmotor willThis is nowarning toto happen.

Motor driv

Note:Populate to activateSynchronous Rectification(No Diodes Installed)

If disabled insure extenalDiodes are used with motor

U6

+5V_REF

+5V_REF

0.1UFC183

2

4

6

5

1 8

7

U13

7

6

2

3

81

4 5

U6

Z-MOT_B

Z_MOT_/A

Z_MOT_/B

30.1KR30

R2930.1K 0.001UF

C9

R20

4.75K

Z_DAC_CS

Z_ADC_CS

SPI_DATA_IN

Z_ADC_CS

17

9

7

3

5

11

13

15

19

U12

1

6

4

2

14

12

16

18

8

U12

7 23

24

32

28

15

10

13

12

25

18

5

21

6

8

1

14

16

19

22

20

27

26

17

4

9

11

U7

B_Z_DAC_CS

B_SPI_DATA_IN

B_SPI_CLK7

6

2

3

81

4 5

U4

SPI_DATA_OUT

SPI_DATA_OUT B_SPI_DATA_OUT

B_Z_ADC_CS

B_SPI_CLK

0.22UF

C140.39

R2R10.39

+24V

C70.22UF

C100.001UF

SPI_CLK

10

1 2 3 4 6 7 8 9

5

4.7K

RP1

Z_MOT_CLK

0.22UF

C11

C130.22UF

19

15

13

11

5

3

7

9

17

U2

R64.75K

0

R5

8

18

16

12

14

2

4

6

1

U2B_Z_MOT_CLK

B_Z_MOT_CW/CCW

B_Z_MICRO_CONT_1

B_Z_MICRO_CONT_2

B_STEP_SIZE_CHANGE_SYNC

B_Z_MOT_ENABLE

B_Z_MOT_RESET

B_Z_MOT_SLEEP

Z_MOT_CW/CCW

Z_MICRO_CONT_1

Z_MICRO_CONT_2

STEP_SIZE_CHANGE_SYNC

Z_MOT_ENABLE

Z_MOT_RESET

Z_MOT_SLEEP

B_Z_MOT_CLK

B_Z_MOT_CW/CCW

B_Z_MOT_SLEEP

B_Z_MOT_ENABLE

B_Z_MOT_RESET

B_Z_MICRO_CONT_1

B_Z_MICRO_CONT_2

STEP_SIZE_CHANGE_SYNC

0.22UF

C150.39

R4R30.39

B_Z_ADC_CS

B_SPI_CLK

B_SPI_DATA_IN

B_Z_DAC_CS

1

TP7

R310

Z-MOT_A



P

P

P

IRF7103

S

D

G

D2

IRF7103

S

D

G

D2

IRF7103

S

D

G

D2

IRF7103

S

D

G

D2

+24V

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




+24V

+24V

P

SEE SHEET 1

Z Driver Board

CTS / Universal Arm

286331-003 of 3


0A

SPARE_SOLENOID_PWR

RACK_LOCK_BRAKE_PWR

VENT_SOLENOID_PWR


2

1

D11

1

2

D10

B_RACK_LOCK_BRAKE_CONT


1

2

D12

B_FET_CONTROL

6

5

4

3

Q1

6

5

4

3

Q2

8

7

2

1

Q2

8

7

2

1

Q1


+5V

+5V

+5V

+5V

1 2 3 4 5 6

1 2 3 4 5 6

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

LTC485

VCC

GND

A

B

RE

RO

DE

DI

R

D

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

+5V

+5V

+5V

Y1

Y2

Y3

Y4A4

A3

A2

A1

G

SN74ACT240

Y1

Y2

Y3

Y4A4

A3

A2

A1

G

SN74ACT240

RACK_LOCK_BRAKE_CONT

R174.75K

RS485_PUP4

RS485_PUP4

RS485_PUP3




B_FET_CONTROL

B_FET_CONTROL



SPARE_VALVE_CONTROL


SPI_CLK_DIF_B

SPI_CLK_DIF_A

SPI_DATA_IN_DIF_B

SPI_DATA_OUT_DIF_A

B_Z_MOT_ENC_A

B_Z_MOT_ENC_B

B_TUBE_RELEASE_SENSETUBE_RELEASE_SENSE

Z_MOT_HOME_SENSE

B_PROBE_CSPROBE_CS

PROBE_TYPE_SPI_CS

Z_MOT_ENC_B

Z_MOT_ENC_A

B_PROBE_TYPE_SPI_CS

SPI_CLK

B_SPI_DATA_OUT

SPI_DATA_IN

VENT_SOLENOID_CONTROL

19

11

13

15

17 3

5

7

9

U1

18

16

14

128

6

4

2

1

U1

B_Z_MOT_HOME_SENSE

1 2 43 6 7 8 9

10 5

4.7K

RP2

R21121

19

15

13

11

5

3

7

9

17

U3

8

18

16

12

14

2

4

6

1

U3

4

3

1

2

7

6

5

8

U11

8

5

6

7

2

1

3

4

U10

8

5

6

7

2

1

3

4

U9

4

3

1

2

7

6

5

8

U8

1 2 43 6 7 8 9

10 5

4.7K

RP3

121

R26

R22121

121

R25

SPI_DATA_OUT_DIF_B

RS485_PUP2

RS485_PUP3

RS485_PUP4

RS485_PUP1

SPI_DATA_IN_DIF_A

RS485_PUP1

RS485_PUP2

RS485_PUP3

PROBE_LLD_FREQ



510

98763 421RP4

4.7K



+5V

TC4S584

+24V

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




CON2L

+5V

+24V

RED GRN

+5V

DRV101

P

14APR05D.COXRELEASED PER CO L0

100ms Delay 50% Duty Cycle

CTS Traveling Signal

286340-00

Piercer Lock Solenoid

1 of 1


Interconnect Board

0

1

2 3

4

5

6

7

U6

1

2

D2

LED4

4

1

2

3

LED2

280R8 R9

280

2

1

J1

PIERCER_LOCK_SOL_PWR

R123.01K

0.1UF

C10

28.7K

R13

PIERCER_LOCK_SOL_PWR3

5

42

U7

CONT

Figure 16-78 CTS Traveling Interconnect PCB (Drawing # 28634100)

VDD

P

+24V

1 2 3 4 5 6

1 2 3 4 5 6

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

+5V

+5V

TEMP

VIN

GND

VOUT

TRIM

N/C

N/CN/C

CON10L

HOLD

WP

SCK

SI

CS

SO

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

G

A3

A2

A1

Y3

Y4

Y2

Y1

A4

SN74ACT244

+5V

CGND

+5V +24V

+24V

+24V

TC4S584

P

P

+5V

COAX CONN

LLD Detection

FFC Type Connecetor

U5

U1 U2

U3

In From Z-Axis Board

Piercer Position Sensor

Piercer Lock and Tube Cap Sensors

Note:Mounting Holes for the board

are to be plated and attached

to the CGND net on the board.

U4 U6 U7

LLD Detection

COAX CONN

10

1 2 3 4 6 7 8 9

5

RP1

4.7K

SPARE1

SPARE3

PIERCER_LOCK_SOL_CONT

VREF_LLD

SPARE2

2

3

4

5

1

J5

SPARE1

SPARE1

SPARE2

SPARE3

B_PIERCE_SOL_LOCK_SENSE

0.1UF

C6

2 4

5

3

U3

WP


B_PIERCER_POSITION_SENSE

B_PROBE_LLD_FREQ


SPI_DATA_IN

PROBE_TYPE_SPI_CS

1


LED1CTS_PROBE_LLD

B_PROBE_LLD_FREQ

1

TP1

2

3

4

5

1J4

R533.2K

B_SPI_DATA_OUT

SPI_CLK

B_TUBE_CAP_SENSE

B_PIERCE_SOL_LOCK_SENSE

B_PIERCER_POSITION_SENSE

19

15

13

11

5

3

7

9

17

U2

1

6

4

2

14

12

16

18

8

U2

1

6

4

2

14

12

16

18

8

U1

CTS_PROBE_LLD

TUBE_CAP_SENSE


R44.75K4.75K

R2

C2

0.1UF

D1

BZV55C10V

2

1

5

6

3

7

AT25040AN-10SI-2_7

U4

10

1

2

3

4

5

6

7

8

9

J3

10

4

5

6

7

8

9

18

17

16

15

12

3

2

11

13

14

19

20

24

23

22

21

1J2

R74.75K120

R6

0.1UF

C3

3

2

4

6

5

1 8

7

U5

120

R3R1120

C110UF

0.1UF

C4 C50.1UF

C80.1UF

17

9

7

3

5

11

13

15

19

U1B_SPI_DATA_OUT

PROBE_LLD_FREQ


TUBE_CAP_SENSE B_TUBE_CAP_SENSE

WP

HOLD

SPI_DATA_IN

SPI_CLK

B_PROBE_TYPE_SPI_CS

B_PROBE_TYPE_SPI_CS

3.01KR10

1

TP2

1

TP3

PROBE_LLD_FREQ

1

TP5

LED3

R1122.1K

1

TP4

1

TP6

C90.1UF

33UF

C7


B_PIERCER_LOCK_SOL_CONT

B_PIERCER_LOCK_SOL_

C110.1UF

HOLD

PROBE_TYPE_SPI_CS

CTS_PROBE_LLD1

5

4

3

2

J6



MECCA

A

H

G

F

E

D

C

B

H

G

F

E

D

C

B

7 8

7 8

DRAWN

CHECKED

DATEAPPROVALS

A

APPROVED


SCALE

REVISIONS

Title




+DC_LOAD

+_CONTROL

-DC_LOAD

-_CONTROL

OLID STATE RELAY

MECCA

+DC_LOAD

+_CONTROL

-DC_LOAD

-_CONTROL

OLID STATE RELAY

CON12

MECCA

MECCA

MECCA

MECCA

Saverio Ratta

SPARE FUSES

1 of 1

N/A

USING #16 GUAGE WIRE

TO BACK PANEL FAN1

FUSE BOARDPower Interconnect

Universal Arm

TO BACKPLANE USING

286411-00

TO BACKPLANE

TO DC DRIVER BOARD

#16 GUAGE WIRE

TO CAVRO ARMS

CAN BUS

DUAL ROW

08/18/04

D

2

1

J2

1

G2

1

G1

SE

D1FR301

12.5A

F16

+24V_DC_DRIVER

21

JP2

1 2

JP1

F15

2A

F9

4A

F10

4A

4A

F13

F11

2A

F12

8A

1

2

3

4

5

6

7

8

9

10

11

12

J4

EAGENT_CAVRO_PWR

AMPLE_CAVRO_PWR

AY1

FR301D2

CAVRO_RESET_2

CAVRO_RESET_1

AY2

10

4

5

6

7

8

9

18

17

16

15

12

3

2

11

13

14

19

20

24

23

22

21

1

J9

+5V_BP_CONTROLLERS

+5V_BACKPLANE

+15V_BACKPLANE

-15V_BACKPLANE

-15V_BACKPLANE

+15V_BACKPLANE

+5V_BP_CONTROLLERS

+5V_BACKPLANE

+28V_COOLING_BD

+28V_COOLING_BD

+28V_COOLING_BD

+24V_BACKPLANE

+24V_BACKPLANE

1

2

J6

4

1

2

3

J3

+24V_BACKPLANE

+15V_BACKPLANE

+5V_BACKPLANE

+5V_BP_CONTROLLERS

8

7

6

5

4

3

2

1J5

8A

F14

BP_FANS_FUSE

Figure 16-79 U Arm Fuse Board PCB (Drawing # 28641100)

MECCAMECCA

MECCA MECCA

MECCA

MECCA

MECCA

MECCA

1 2 3 4 5 6

1 2 3 4 5 6

MECCA

MECCAMECCA

S

MECCA

MECCA

S

MECCAMECCA

MECCA MECCA

MECCA

MECCA

MECCA

MECCA

MECCA

MECCA

MECCA

MECCA

1 Watt 5%

Diffused

Green

0.5 WATT

Diode

3.0V Zener

0.5 WATT

1 Watt 5%

1 Watt 5%

Diffused

Green

TIME DELAY

Green

Diffused

Green

Diffused

Green

Diffused

Diffused

GreenGreen

FUSE SIZE 4A

TIME DELAYFUSE SIZE 4A

TIME DELAY

+24V_SYSTEM_GND

SAMPLE SIDE

REAGENT SIDE

35V

+5V_GND

+15V_GND

-15V_GND

+28V_COOLING_GND

USING #10 GUAGE WIRE

Barrier Terminal Black

CAVRO ARM POWER CONTROL RELAYS

0.5 WATT

1 Watt 5%

1 Watt 5%

TIME DELAY

FUSE SIZE 4A

Board +5V FUSE +15V

SLOW BLOW

Board +28V

FUSE SIZE 8.0A

TIME DELAY

FUSE +24V

FUSE SIZE 2A

FANS +24V

TIME DELAY

FUSE SIZE 2A

FUSE SIZE 8.0A

TIME DELAY

Diffused

Green

Diffused

Green

FUSE SIZE 8.0A

TIME DELAY

REAGENT COOLINGDC Driver

Board +24V

CAVRO ARM UNITSFUSE -15V

Green

Diffused

1 Watt 5%

FROM POWER SUPPLIES

BACKPLANE SYSTEMBACKPLANE SYSTEMBOARDS +5V

Level III CPULevel II CPU

Diffused

Green

Diffused Diffused

Green Green

Diffused

Green

Diffused

Green

Diffused

Green

Diffused

TO LEVEL II CPU BOARD

TO BACK PANEL FAN2

Universal Arm Set 2

Universal Arm Set 1

BACKPLANE SYSTEMFUSE +5V

1 Watt 5%

1 Watt 5%

Diode

3.0V Zener

Diode

0.5 WATT

FUSE SIZE 12.5A

BACK PANEL

TO SIDE PANEL

#20 GUAGE WIRE

#20 GUAGE WIRE

13.0V Zener

0.5 WATT

BACKPLANE SYSTEM

40.2

R17 R16

40.2

LED9

R15

40.2

D3

1N52251N5243

D41N5225

D5

F3

4A

+5V_POWER

F18

2A

-15V_POWER

F2

12.5A

+28V_COOLING_BD

+28V_COOLING

LED4

F5

4A

+5V_BACKPLANE

+5V_POWER

F8

4A

+5V_LEVEL_II_CPU

+5V_POWER

F1

2A

BP_FANS_FUSE

+24V_SYSTEM

F7

8A

+24V_DC_DRIVER

+24V_SYSTEM

F6

8A

+24V_CAVRO

+24V_SYSTEM

C11000U

14

12

11

2

1

9

8

7

6

5

4

3

10

13

J10

13

10

3

4

5

6

7

8

9

1

2

11

12

14

J11

REAGENT_CAVRO_PWR

SAMPLE_CAVRO_PWR

+24V_SYSTEM_F_UA1

CAN_BUS_FU

CAN_BUS_FUSE

LED12

F25

2A

+24V_SYSTEM

LED7

8A

F20

1.1K

R9

R111.1K

240

R12

R51.8K

R13240

F24

4A

+15V_POWER

+5V_POWER_F_UA1+5V_POWER

LED14

F19

8A

R11.8K

R6240

+24V_SYSTEM

F4

8A

+24V_SYSTEM

F17

4A

+15V_BACKPLANE

+24V_SYSTEM_F_UA2

+5V_POWER

R81.8K

LED1LED2

R101.1K

R71.8KR4

2.2K

2

1

J7

R

S

-15V_POWER

+28V_COOLING

1

2

3

4

REL

LED5

LED10

LED8

LED6 LED3

4

3

2

1

REL

2

3

4

5

6

1

J8

10

1

2

3

4

5

6

7

8

9

J1

BP_FANS_FUSE

+5V_LEVEL_II_CPU

+15V_POWER

+24V_BACKPLANE

+24V_CAVRO

CAVRO_RESET_1

CAVRO_RESET_2

+24V_CAVRO

R21.8K

LED11

1.8K

R3

+24V_SYSTEM +15V_POWER_F_UA1

F22

2A

LED13

2A

F21

4A

F23

LED15

LED16

+15V_POWER

+24V_SYSTEM_F_UA1

+15V_POWER+5V_POWER_F_UA2+5V_POWER +15V_POWER_F_UA2+24V_SYSTEM +24V_SYSTEM_F_UA2

R141.8K

LED17

+15V_POWER_F_UA1

+5V_POWER_F_UA1

+15V_POWER_F_UA2

+5V_POWER_F_UA2

-15V_BACKPLANE

+5V_BP_CONTROLLERS

16 - 82 Chapter 16 – Schematics



Chapter 17 – Assembly Drawings/Part Numbers 17 - 1

Chapter 17 –Assembly Drawings/Part

Numbers

17-1 Saleable Parts List

The following lists the parts that are saleable by Instrumentation Laboratory.

Table 17-1 Saleable Parts/ Modules

9746606 MAGNETIC, STIR BARS, ACL 6/PK18794301 SYRINGE INSTALL TOOL27501001 FUSE BOARD27503001 PCB FRONT PANEL27540400 ASSY WASTE BOTTLE FAKEOUT PLUG CIRC LOCK27554001 ORU INTERFACE27555001 ASSY INCUBATOR HEATING27555001 ASSY INCUBATOR HEATING27602001 PCB LOADER27604001 PCB CUVETTE SENSOR27605001 PCB CUVETTE WASTE27610001 ASSY POLAROID RANGING BD TESTED27612001 S/S BCR SCANNER INT LED ASSY27613010 PCB ASSY X-MOT CONT BD W/OUT DIP REPLAC27700001 PCB SAMPLE PRESENCE27701001 PCB RACK PRESENCE27703001 PCB REAGENT COOLING27704001 PCB STIRRER27707001 PCB ASSY SAMPLE KEYPAD TESTED27707101 PCB ASSY REAGENT KEYPAD TESTED27707201 FLUIDICS LED PANEL27710001 PCB REMOTE TRAVEL INTERFACE BD27711001 PCB ASSY, REAGENT COOLING BD W/FAN SPEED27753801 S/S HEATER STRIP W/PROTECTION27753901 S/S INCUBATOR 1 & 2 THERMISTOR27754501 S/S LOADER PIVOT TABLE SENSORS27755711 FAN DUCT ASSY W/9" CABLE27755712 FAN DUCT ASSY W/15" CABLE27755713 FAN DUCT ASSY W/18" CABLE27755901 MODIF. THERMISTOR BLOC REACTIFS ACL TOP27757012 FAN CHASSIS ASSY W/12" CABLE27757013 FAN CHASSIS ASSY W/42" CABLE27760001 S/S EMERGENCY STOP SWITCH27765500 REPLACEMENT KIT SAMPLE DOOR OPTL SENSOR


17 - 2 Chapter 17 – Assembly Drawings/Part Numbers

27765601 SOLENOID ASSY SAMPLE SHIELD LOCK KIT27994801 FUSE, 2A 63V REMOVABLE QTY 1027999000 FLOPPY DRIVE MODEL FD-235 HF28110001 S/S ASSY CUVETTE WASTE SHELF28116301 WASTE DRAWER28116401 WASTE DOOR28137101 PULLEY BELT DRIVE28141701 S/S, CUVETTE LOADER ASSY28161601 S/S SHUTTLE X MOTOR ASSY28162101 S/S SHUTTLE BCR LINEAR BEARING28162701 S/S SHUTTLE X IDLER PULLEY ASSY28165001 S/S ASSY SHUTTLE ASSY28166900 MANUAL SERVICE ACL TOP CD VERSION28182801 SHUTTLE SENSOR ASSY28183101 MOUNT, ADJ 'X' AXIS SENSOR28185001 SHUTTLE SOLENOID28185601 S/S APERTURE, CUVETTE PRESENCE SENSOR28201501 S/S BCR X MOTOR ASSY28204801 BAR, ALIGNMENT SAMPLE28204901 S/S REAGENT GUIDE28205201 S/S SAMPLE HEEL ASSY28205801 S/S REAGENT HEEL ASSY28208601 SUPPORT, DILUENT28209001 ASSY, MONITOR/KEYBOARD SUPPORT28210500 KIT, 2D BARCODE UPGRADE28211101 BARCODE SCANNER LINEAR28211301 KIT BCR COVER UPGRADE ASSY28211401 BCR, LINEAR, 6 DEGREE TILT, SALEABLE28254900 CURTAIN, RIGHT28255300 CURTAIN, LEFT28300301 CAVRO, 2 ARM28300501 CAVRO, 1 ARM28300601 S/S CAVRO, Z RACK28302001 LLD SENSOR, ACL TOP SALEABLE28302701 CAVRO CCU 9000 PCB28302801 S/S FLAG, CAVRO28302901 S/S PCB,TECAN SYSTEMS ARM BD W/O ALIDUM28304601 S/S FUSE KIT, (1.6A, 2.0A, 3.15A)28304701 S/S CABLE, FLEXIBLE ARM COMMON28304801 S/S BRACKET, Y-IDLER PULLEY28304901 S/S SINGLE ARM X BELT28305001 S/S LEFT DUAL ARM BELT28305101 S/S RIGHT DUAL ARM BELT28305201 S/S Y TRAVEL BELT28305301 S/S Z DRIVE BELT28305401 S/S GREASE28305501 S/S Y-ARM ASSY L340 IL TOP28305601 S/S Y-ARM ASSY R340 IL TOP




28305701 S/S ASSY, Y-IDLER PULLEY28307901 S/S SENSOR, OPTICAL, RSP900028320901 ASSY, ARM SINGLE, CTS28321001 ASSY, ARM DOUBLE28356801 S/S DIDVIDER WALL RIGHT28386300 ASSY, FILTER CHANGER, CTS28401101 KIT CABLE ASSY RESTRAINT28420001 S/S BCR OPTICAL ENCODER28444701 PLUNGER, LATCH, SOLENOID, SAMPLE S/S28445001 S/S SAMPLE DOOR ASSY28445900 WINDOW, REAGENT DOOR28446001 ASSY REAGENT DOOR28447501 S/S POWER ENTRY MODULE28448301 S/S DOOR STUD28448401 S/S DOOR STUD28451901 S/S SENSOR ULTRASONIC28453102 S/S BATTERY 3.6 LITHIUM W/CABLE28453701 POWER SUPPLY 24V28454001 POWER SUPPLY 5/15V28454301 FILTER POWER SUPPLY28470201 SENSOR FLAG S/S28512501 S/S ASSY REAGENT RACK ASSY28519301 S/S REAGENT MODULE FLAG28519701 DUCT ASSY28521100 ASSY, RACK RACK MOUNT THERMISTOR28578601 S/S ASSY SAMPLE RACK ASSY28579301 S/S SAMPLE HOUSING SENSOR FLAG28608101 BACKPLANE ASSY28608201 COMPUTER HOUSING28608301 DC DRIVER ASSY28612701 SNAP DETENT28613501 SOLENOID SHIELD LOCK28614101 DOOR LOCK ASSY28617301 FILTER REAGENT COOLING28621201 PCB CUVETTE CONTROLLER28621301 PCB RACK CONTROLLER28621401 PCB ORU CONTROLLER ACL TOP28622801 COMPUTER MONITOR 17" TOUCH SCREEN ACLTOP28622911 ASSY ACL TOP CM PC28623500 KIT START-UP,ACL TOP28640001 PC/104 CAN BUS PCB28702301 CONN / CONT FLUIDS PCB ASSY28712401 RINSE TUBING, ACL TOP28712501 WASTE TUBING, ACL TOP28713200 ASSY, CLEAN ASPIRATOR, ACL TOP28713400 ASSY, 4L RINSE, ASPIRATOR, ACL TOP28713600 VALVE, CHECK, 1/8 BARB, 5 PSI28735500 PUMP XP 3.000




28739801 SYRINGE28740300 FITTING, 1/4-28 THD TO 1/16 BARB28741600 ASSY, PUMP/PROBE TUBE28745501 S/S PUMP,PRECISION,PSD4-IL W/SYRINGE/VAL28749801 ASSY,SYRINGE,250 UL FOR PSD4 PUMP W/INST28749901 S/S ASSY, VALVE HV3-2-Y, PSD4-IL28750001 S/S SEAL (TIP) 250UL SYRINGE, HAMILTON28758701 S/S CLEAN / RINCE CUP ASSY28759501 S/S SAMPLE ACCUMULATOR ASSY28759601 S/S REAGENT ACCUMULATOR ASSY28760501 PUMP TUBING, ACL TOP28761601 ASSY, WASTE PUMP, SALEABLE28771801 ASSY WASTE BOTTLE PRESENCE SENSOR28775901 ASSY ACL TOP PROBE HOUSING28816801 S/S ASSY, INCUBATOR #128817201 S/S ASSY, INCUBATOR #228819201 TOOL, CUVETTE ALIGNMENT28820401 BRACKET, INDEXER ASSY MTG28825001 S/S ASSY ORU CRADLE ASSY28829501 CLIP, ORU CUVETTE SPRING28911601 SYRINGE TIP, 250uL 6/PK ACL TOP28912801 O-RING PIVOT TABLE28913601 BELT 6MM WIDE28916401 S/S SHUTTLE TIMING BELT28919201 S/S LOADER CUVETTE PUSHER MOTOR BELT28919401 S/S LOADER X PORT MOTOR BELT28940600 COUPLING, INSERT, 1/8 FLOW28940700 COUPLING, PANEL, 1/8 FLOW, HC-V28940800 COUPLING, INSERT, 1/4 FLOW, HC-V28940900 COUPLING, PANEL, 1/4 FLOW, HC-V29225301 CD-R, BLANK29225401 DVD-R, BLANK29226604 CD ON-LINE HELP V2.2 ACL TOP29228402 CD,ACL TOP THERMAL CAL SW V1.529401100 CUVETTE WASTE LINER 10 PK, ACL TOP29404000 HARD DRIVE, BLANK

Table 17-2 Saleable Kits

27754001 KIT LEVEL 2 CPU POWER CABLE UPGRADE ASSY28321100 ASSY, PNEU UPGRADE, CTS28321800 KIT, CTS LAUNCH CONFIG. UPGRADE28321900 KIT, ARM UPGRADE, CTS28533201 KIT REAGENT DRAIN TUBE UPGRADE ASSY28850001 KIT EMITTER ASSEMBLY29227403 KIT,ACL TOP AM SW UPD RACK V2.0929236905 KIT,ACL TOP TEST DEF LIB P4.8 (NON-BCI)29236906 KIT TEST DEF LIBRARY P5.0 ACL TOP




29239801 KIT,ACL TOP V2.1/P4.8 SW UPGRADE (BCI)29239901 KIT,ACL TOP V2.1/P4.8 SW UPGDE(NON-BCI)29240923 KIT, MAIN SYS SW INSTALL ACL TOP V2.7.729241602 KIT,ACL TOP P4.8 TEST DEF LIBRARY (BCI)29242300 KIT, ACL TOP LANGUAGE TRASLATION29404900 KIT,WASTE SHELF INTERLOCK SWITCH UPGD29405200 KIT, BUNDLED UPGRADE, A29405300 KIT, BUNDLED UPGRADE, B29405800 KIT, TOP CM PC RECOVERY29410000 KIT, FLOOR DRAIN, ACL TOP29411000 KIT UPGRADE LIQUID WASTE FULL/PRESENCE29411300 UPGRADE KIT, FAN NOISE ACL TOP29411500 KIT ORU CABLES29411600 KIT OPTICS ADJUSTMENT ORU

Table 17-3 Saleable Cables

27750001 S/S CB POWER SWITCH TO 5/15 PWR SUPPLY27750401 S/S CB FLUIDCS CTRL P13 TO VALVES/SENSOR27750501 CABLE ASSY BARCODE X-AXIS TO L LIMIT27750601 CABLE ASSY BARCODE X-AXIS TO R LIMIT27750703 S/S CB BACK PIN P30 TO BCR X-AXIS BD P227750704 S/S CB BACK PIN P29 TO SHTL X-AXIS BD P227750801 S/S CB BACK PIN P38 TO BCR X-AXIS BD P127751101 S/S CB BACK PIN P34 TO CAVRO ARMS27751201 S/S CB CUV WASTE INTF BD P3 TO ACCUM SOL27751401 CUVETTE WASTE TO DOOR OPEN SENSOR27751401 CUVETTE WASTE TO DOOR OPEN SENSOR27751501 S/S CB BACK PIN P40 TO CUV LOADER BD P127751601 S/S CB BACK PIN P20 TO EMITTER BD P127751701 CUV WASTE TO DRAWER OPEN SWITCH27751801 S/S FLUIDICS LED27751901 S/S CB BACK PIN P32 TO FLUIDCS CTLR P127753601 S/S CB BACK PIN P36 TO FLUIDCS CTLR P727753703 S/S CB INCB HTG BD 2 P1 TO BACK PIN P1227753704 S/S CB INCB HTG BD 1 P1 TO BACK PIN P327754601 S/S CB EMITTER BD P1 TO BACK PIN P1727754701 S/S CB BACK PIN P26 TO ORU INTFC BD P1527754803 S/S CB ORU INTFC BD P2 TO BACK PIN P1627754804 S/S CB ORU INTFC BD P1 TO BACK PIN P1527755101 S/S CB CANBUS P3 TO BACK PIN P2527755201 S/S CB CANBUS P4 TO FLUIDCS CTLR P127755301 S/S CB PROBE DC BD P2 TO BACK PIN P227755401 S/S CB FUSE BD P3 TO PROBE DC DRVR BD P127755501 S/S CB BACK PIN P28 TO RGT COOLNG BD P327755601 S/S CB BACK PIN P18 TO RGT COOLING BD P127756001 S/S CB CAVRO RGT SYRG PMP TO CCU P127756201 S/S CB RGT RACK BD P2 TO RGT STRRG BD P1

Table 17-2 Saleable Kits



27756301 S/S CB BACK PIN P13 TO RGT RACK P127756501 S/S CB CAVRO SMPL SYRG PMP TO CCU P127756701 S/S CB SMPL RACK BD P1 TO BACK PIN P127756901 S/S CB BACK PIN P23 TO SHTL X-AXIS BD P127757004 S/S CB FUSE BD P9 W/ FAN27757101 S/S CB SHTL X-AXIS BD J4 W/LFTLMT SNSR27757201 S/S CB SHTL X-AXIS BD P5 W/RTTLM SNSR27757301 S/S CB SHTL X-AXIS BD P8 W/SHTL MTR27758201 S/S CB FS BD P8.CPU P3 TO FLOPPY DR27758901 S/S CB BCR X-AXIS BD P7 TO RMT TRVL P127759101 FLEX CABLES, PROBE DC DRIVER27759501 FLEX CABLE27759601 S/S CB SHTL X-AXIS BD P6 TO Y-AXIS BD P127759801 S/S CB FLUIDCS CTRL P3 TO DR SENSORS27760101 S/S CB FRONT PNL BD P5 TO RGT KYPD BD P127760301 S/S REAGENT ACCUM FLUIDIC HARNESS27760401 S/S CB FLUIDICS CTLR P2 TO SMPL PUMP/VAL27760601 S/S CB FLUIDCS CTRL P6 WASTE SNSR BD P327760701 S/S CB FLUIDS CTLR P6 TO RINSE PUMP P127761101 S/S CB INCUBATOR TO GROUND27761301 S/S CB FUSE BD P4 TO BACK PIN P2727761401 S/S CB 5V PWR SPPLY TO FUSE BD P127761501 S/S CB 24V PWR SPPLY TO FUSE BD P127761601 S/S CB FUSE BD J9 TO BACK PIN BD J2127761701 S/S CB 277606 CB P1/J1 TO RNS CLN WASTE27761801 S/S CB +15V PWR SPPLY TO FUSE BD P127761901 S/S CB -15V PWR SPPLY TO FUSE BD P127762101 S/S CB FLUIDCS CTRL P8 TO FRONT BD P127762201 S/S CB BACK PIN P22 TO FRONT PANL BD P227762301 S/S CB FRONT PNL BD P4 TO SMP KYPD BD P127762501 S/S CB CPU BD P2 W/SPEAKER27762601 S/S CB BACK PIN P14 TO SIDE PANEL P127762801 S/S CB PROBE DC DRVR BD P12 TO SIDE PANL27763001 S/S CB X-AXIS MTR TO GRND27763205 S/S CB REAGENT GROUND STRAP CB 55027763206 S/S CB REAGENT GROUND STRAP CB 10027763207 S/S CB REAGENT GROUND STRAP CB 22027764601 S/S CB RMT TRVL BD P2 TO BCR SCNNR P327764701 S/S CB CUV LOADR BD P6 TO SENSORS27764800 CABLE ASSY, REAGENT COOLING TO THERMIST27769001 S/S CB SAMPLE GRND TO REAGENT GRND28651401 S/S CB U-ARM X-AXIS BD P13 TO BLK FLD P128652101 S/S CB U-ARM X-AXIS BD P2 TO BLK FLD P228652501 S/S CB R1 SYRNG PUMP TO CCU P528652601 S/S CB SMPL SYRNG PUMP TO CCU P728653501 S/S CB FLUIDCS CONN P2 TO VALVES/SENSOR28653701 S/S CB R2 SYRNG PUMP TO CCU P728654201 S/S CB BACK PIN P31 TO SYRNG PUMP P2

Table 17-3 Saleable Cables



Table 17-4 Saleable Adapters

28520500 ADAPTER FOR 4 ML VIAL ACL TOP28520900 ADAPTER 10 ML VIAL, ACL TOP28525300 ADAPTER, ALIQUOT TUBES, 5 PCS28525400 ADAPTER, PEDIATRIC TUBES, 5 PCS28526001 ADAPTER, DILUENT, 4ML, ACL-TOP, 2PCS28526101 ADAPTER, DILUENT, 10ML, ACL-TOP, 2PCS28526201 ADAPTER, DILUENT, 20ML, ACL-TOP, 2PCS28529300 ADAPTER SET MICRO TUBE

Table 17-5 Saleable Rack Sets

28780001 TRAY 12 SAMPLE RACKS ACL TOP 1 PCS28780201 TRAY 6 SAMPLE RACKS ACL TOP 1 PCS29400501 SAMPLE RACK SET 01-12, ACL TOP29400502 SAMPLE RACK SET 13-24, ACL TOP29400503 SAMPLE RACK SET 25-36, ACL TOP29400504 SAMPLE RACK SET 37-48, ACL TOP29400505 SAMPLE RACK SET 49-60, ACL TOP29400506 SAMPLE RACK SET 61-72, ACL TOP29400507 SAMPLE RACK SET 73-84, ACL TOP29400508 SAMPLE RACK SET 85-96, ACL TOP29400601 RACK SET REAGENT, RA-RF ACL TOP29400602 RACK SET REAGENT, RG-RM ACL TOP29400711 ACL TOP DILUENT RACK SET DA-DC29400712 RACK SET, DILUENT DD-DF, ACL TOP



17-2 Assembly Drawings

The following pages include the Assembly Drawings for ACL-TOP along with the Bill of Material that applies to the drawing.

Part No. Description

28111001 Figure 17-1 "2811001, ASSY, WASTE SHELF"

28116301 Figure 17-2 "28116301 ASSY, WASTE DRAWER"

28116401 Figure 17-3 "28116401 ASSY, WASTE DOOR"

28141701 Figure 17-4 "28141701 ASSY, LOADER"

28161601 Figure 17-5 "28161601 X-MOTOR ASSEMBLY"

28165001 Figure 17-6 "28165001 ASSY CUVETTE SHUTTLE"

28200001 Figure 17-7 "28200001 ASSY, BARCODE MODULE"

28201501 Figure 17-8 "28201501 MOTOR ASSY"

28209001 Figure 17-9 "28209001 ASSY, MONITOR/KEYBOARD SUPPORT"

28200300 Figure 17-10 "28200300 ASSY, 2-ARM RIGHT CAVRO"

28300500 Figure 17-11 "28300500 ASSY, 1-ARM, LEFT CAVRO"

28321001 Figure 17-12 "28321001 ASSEMBLY, ARM, DOUBLE"

28366901 Figure 17-54 "28366901 CTS Accumulator"

28320901 Figure 17-13 "28320901 ASSEMBLY, ARM, CTS"

28383001 Figure 17-55 "28383001 Assy CTS Bulk Fluidics"

28395001 Figure 17-14 "28395001 PROBE, HEATED, ACL-TOP"

28445001 Figure 17-15 "28445001 ASSY SAMPLE DOOR"

28446001 Figure 17-16 "28446001 ASSY REAGENT DOOR"

28512501 Figure 17-17 "28512501 ASSY, REAGENT TOP"

28519700 Figure 17-18 "28519700 DUCT ASSY, REAGENT COOLING"

28578601 Figure 17-19 "28578601 ASSY, SAMPLE HOUSING"

28578621 Figure 17-20 "28578621 ASSY, CTS SAMPLE HOUSING"

28602701 Figure 17-21 "28602701 ASSY, COMPUTER"

28608000 Figure 17-22 "28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY)"

Figure 17-23 "28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY)"

28608101 Figure 17-24 "28608101 ASSY, BACKPLANE"

28608201 Figure 17-25 "28608201 ASSY, COMPUTER HOUSING"



28608301 Figure 17-26 "28608301 DC DRIVER ASSY"

28612000 Figure 17-27 "28612000 ASSY, FRONT, TOP SKIN"

28612700 Figure 17-28 "28612701 SNAP DETENT"

28621201 Figure 17-29 "28621201 PCB, CUVETTE ASSY."

28621301 Figure 17-30 "28621301 PCB, RACK ASSY."

28621401 Figure 17-31 "28621401 PCB, ORU ASSY."

28660002 Figure 17-32 "28660002 ASSY, TELESCOPE CTS"

29403701 Figure 17-33 "29403701 CRU, SAMPLE PROBE N SEAL"

29403601 Figure 17-34 "29403601 PIERCER PROBE, CTS"

28712020 Figure 17-35 "28715801 ASSY, RINSE PUMP, BASE TOP"

28715821 Figure 17-36 "28715821 ASSY, RINSE PUMP, CTS"

28735500 Figure 17-37 "28735500 ASSY, PUMP SINGLE XP3000"

28759500 Figure 17-38 "28759501 ASSY, CWR STATION, SAMPLE"

28759601 Figure 17-39 "28759601 ASSY, CWR STATION, REAGENT"

28761600 Figure 17-40 "28774601 ASSY, WASTE PUMP"

28775900 Figure 17-41 "28775900 ASSY, ACL TOP PROBE HOUSING"

28816801 Figure 17-42 "28816801 ASSY, INCUBATOR #1 (REAGENT SIDE)"

28817201 Figure 17-43 "28817201 ASSY, INCUBATOR #2 (SAMPLE SIDE)"

28820501 Figure 17-44 "28820501 8 POS INC INDEXER ASSY"

28821501 Figure 17-45 "28821501 7 POS INC INDEXER ASSY"

28825000 Figure 17-46 "28825000 ASSY, ORU CRADLE"

PCB Assemblies

27501001 Figure 17-47 "27501001 ASSY, FUSE BOARD"

27503001 Figure 17-48 "27503001 PCB ASSY FRONT PANEL DISCONNECT"

27605001 Figure 17-49 "27605001 PCB CUVETTE WASTE INTERFACE"

27613010 Figure 17-50 "27613010 PCB ASSY X-MOTION CONTROL BD W/OUT DIP"

27700001 Figure 17-51 "27700001 PCB SAMPLE RACK PRESENCE"

27707001 Figure 17-52 "27707001 SAMPLE KEYPAD ASSEMBLY"

27707101 Figure 17-53 "27707101 REAGENT KEYPAD ASSEMBLY"

28641001 Figure 17-56 "28641001 CTS Sample & IL Double Arm Fuse Board"


bly Drawings/Part Numbers 17 - 10


TE

00025703001PCB FRONT PANEL

Chapter 17 – Assem

Figure 17-1 2811001, ASSY, WASTE SHELF

00027610001ASSY POLAROID RANGING BOARD

00027605001PCB CUVETTE WAS




Figure 17-2 28116301 ASSY, WASTE DRAWER




Figure 17-3 28116401 ASSY, WASTE DOOR



RIVE

00027604001PCB ASSY CUVETTESENSOR BOARD

0002919201CUVETTE PUSHERBELT


Figure 17-4 28141701 ASSY, LOADER

00027602001PCB LOADER

00028913601BELT 6mm WIDE

00028912801O-RING, PIVOT TABLE

00028137101PULLEY, BELT D




Figure 17-5 28161601 X-MOTOR ASSEMBLY



0P

00028185601APERATURE CUVETTEPRESENCE SENSOR

00028182801SHUTTLE SENSOR ASSY


Figure 17-6 28165001 ASSY CUVETTE SHUTTLE

0027604001CB CUVETTE SENSOR

0002818500SHUTTLE SOLENOID



01EEL

00028204801BAR, ALIGNMENT SAMPLE

0IGHT

(8x)

00028205801REAGENT HEEL


Figure 17-7 28200001 ASSY, BARCODE MODULE

000282052SAMPLE H

00028204901BAR, ALIGNMENT REAGENT

0002825490CURTAIN, R

00027613010PCB X MOTION CONTROL

00027710001PCB REMOTE TRAVELINTERFACE (13x)

00028255300CURTAIN, LEFT

00028162101BCR LINEAR BEARING

00028208601BAR, ALIGNMENT DILUENT(3x)




Figure 17-8 28201501 MOTOR ASSY




Figure 17-9 28209001 ASSY, MONITOR/KEYBOARD SUPPORT




Figure 17-10 28200300 ASSY, 2-ARM RIGHT CAVRO




Figure 17-11 28300500 ASSY, 1-ARM, LEFT CAVRO




Figure 17-12 28321001 ASSEMBLY, ARM, DOUBLE




Figure 17-13 28320901 ASSEMBLY, ARM, CTS


Figure 17-14 28395001 PROBE, HEATED, ACL-TOP





Figure 17-15 28445001 ASSY SAMPLE DOOR




Figure 17-16 28446001 ASSY REAGENT DOOR



11001SY REAGENT COOLING W/ FAN SPEED


Figure 17-17 28512501 ASSY, REAGENT TOP

00027704001PCB STIRRER

00028519301REAGENT MODULE FLAG

00027701001PCB RACK PRESENCE

000277PCB ASBOARD



00027755713FAN W/18” CABLE


Figure 17-18 28519700 DUCT ASSY, REAGENT COOLING

00027755711FAN W/9” CABLE

00027755712FAN W/15” CABLE

00027762901DOUBLE FAN



579301LE HOUSING SENSOR FLAG


Figure 17-19 28578601 ASSY, SAMPLE HOUSING

00027700001PCB SAMPLE PRESENCE

00028SAMP



NCE


Figure 17-20 28578621 ASSY, CTS SAMPLE HOUSING

00028579301SAMPLE HOUSING SENSOR FLAG

00027700001PCB SAMPLE PRESE



00027999000FLOPPY DRIVEMODEL FD-235 HF


Figure 17-21 28602701 ASSY, COMPUTER

00028640001PCB PC-104



Y)


Figure 17-22 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONL



Y)


Figure 17-23 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONL




Figure 17-24 28608101 ASSY, BACKPLANE




Figure 17-25 28608201 ASSY, COMPUTER HOUSING

00028602701ASSY, COMPUTOR

00028456102BATTERY, 3.6 LITHIUM W/CABLE




Figure 17-26 28608301 DC DRIVER ASSY



00027760001EMERGENCY STOP SWITCH

844601GENT DOOR

0002848401DOOR STUD

00028448301DOOR STUD


Figure 17-27 28612000 ASSY, FRONT, TOP SKIN

00028445900WINDOW, REAGENT DOOR

00027707101REAGENT KEYPAD

00027707001SAMPLE KEYPAD

0002844501SAMPLE DOOR

0002REA

00028444701PLUNGER LATCH SOLENOID


Figure 17-28 28612701 SNAP DETENT

NOTE: FOR USE WITH 00028618700BACK WALL ASSY (LEFT) AND00028618800 BACK WALL ASSY (RIGHT)





Figure 17-29 28621201 PCB, CUVETTE ASSY.




Figure 17-30 28621301 PCB, RACK ASSY.




Figure 17-31 28621401 PCB, ORU ASSY.


Figure 17-32 28660002 ASSY, TELESCOPE CTS



Figure 17-33 29403701 CRU, SAMPLE PROBE N SEAL



Figure 17-34 29403601 PIERCER PROBE, CTS



Figure 17-35 28715801 ASSY, RINSE PUMP, BASE TOP



Figure 17-36 28715821 ASSY, RINSE PUMP, CTS





Figure 17-37 28735500 ASSY, PUMP SINGLE XP3000

00028739801SYRINGE



NESS


Figure 17-38 28759501 ASSY, CWR STATION, SAMPLE

00027760401FLUIDIC HAR

00028758701CLEAN RINSE CUP



FLUIDIC HARNESS

8701INSE CUP


Figure 17-39 28759601 ASSY, CWR STATION, REAGENT

00027760301S/S REAGENT ACCUM

0002875WASH R




Figure 17-40 28774601 ASSY, WASTE PUMP

00028760501PUMP TUBING, ACL TOP




Figure 17-41 28775900 ASSY, ACL TOP PROBE HOUSING

00027994801FUSE 2A 6.3V REMOVABLE



CTION

G


Figure 17-42 28816801 ASSY, INCUBATOR #1 (REAGENT SIDE)

00027753901INCUBATOR 1 & 2 THERMISTER

00027753801S/S HEATER STRIP W/ PROTE

00027755001ASSY INCUBATOR HEATIN




Figure 17-43 28817201 ASSY, INCUBATOR #2 (SAMPLE SIDE)

00027753901INCUBATOR 1 & 2 THERMISTER

0002755501ASSY INCUBATOR HEATING

00027753801HEATER STRIP W/ PROTECTION

00028819201TOOL, CUVETTE ALIGNMENT




Figure 17-44 28820501 8 POS INC INDEXER ASSY




Figure 17-45 28821501 7 POS INC INDEXER ASSY



0002885001EMITTER ASSY


Figure 17-46 28825000 ASSY, ORU CRADLE

00027554001PCB ORU INTERFACE




Figure 17-47 27501001 ASSY, FUSE BOARD




Figure 17-48 27503001 PCB ASSY FRONT PANEL DISCONNECT




Figure 17-49 27605001 PCB CUVETTE WASTE INTERFACE




Figure 17-50 27613010 PCB ASSY X-MOTION CONTROL BD W/OUT DIP




Figure 17-51 27700001 PCB SAMPLE RACK PRESENCE




Figure 17-52 27707001 SAMPLE KEYPAD ASSEMBLY




Figure 17-53 27707101 REAGENT KEYPAD ASSEMBLY




Figure 17-54 28366901 CTS Accumulator




Figure 17-55 28383001 Assy CTS Bulk Fluidics




Figure 17-56 28641001 CTS Sample & IL Double Arm Fuse Board