ACL-TOP
Service Manual
October, 2006
PN 28166900 Rev 03
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL TOP Pre - Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 14
2 - 16
2 - 17
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitor Control Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitor Control Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitor Control Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Area Interior Skins Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Area Interior Skins Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Area Interior Skins Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Left Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Left Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Left Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Area Interior Skins Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Area Interior Skins Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Area Interior Skins Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Right Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Right Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Right Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Back Wall Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Back Wall (Power Supply Assembly) Removal/Replacement . . . . . . . . . . . . . . . . . . . . .
4 - 15
4 - 15
4 - 16
4 - 16
4 - 16
4 - 19
4 - 19
4 - 19
4 - 20
4 - 20
4 - 20
4 - 22
4 - 22
4 - 22
4 - 23
4 - 23
4 - 23
4 - 24
4 - 24
4 - 24
4 - 26
4 - 26
4 - 26
4 - 27
4 - 28
4 - 28
4 - 29
4 - 29
4 - 29
4 - 30
4 - 30
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
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6-2
6-3
6-4
6-4
3
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
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ACL-TOP Service Manual
Contents
Air Pump/Air Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCB Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluidic Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluidics Driver/Connector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluidic LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluidics Diagrams for the TOP Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Syringe Pump Addressing and Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Rinse System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Clean System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing the Rinse Flow Rate Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verifying the Fluidics after Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the CTS Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Select Pull-down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Set Valve Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Duration Selection Field and the Start and Stop Buttons . . . . . . . . . . . . . . . . . . . . . . .
Stirring Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping Preparation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Precision Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Pump Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Sample Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Sample Cavro Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base TOP Sample Arm Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base TOP Cavro Sample Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Cavro Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Tip Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Valve Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Syringe Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Pump Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Sample Hamilton Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Sample Hamilton Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base TOP Hamilton Sample Arm Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base TOP Hamilton Sample Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Hamilton Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Hamilton Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Tip Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Valve Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hamilton Syringe Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rinse Pump Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
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Contents
Rinse Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rinse Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precision Tubing Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precision Tubing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precision Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 - 80
7 - 81
7 - 82
7 - 82
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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
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ACL-TOP Service Manual
Contents
Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verifying a CTS Arm or a Universal Dual Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alidum Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probes Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initialize All Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home All Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disable Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disable Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coordinate Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LLD Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rinse Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probe Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probe LLD Error Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Probe Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Arm Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZDAC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Arm (283777-00) Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closed Tube Sample (CTS) Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closed Tube Sample (CTS) Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent IL Double Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent IL Double Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent IL Double Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Sample Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Sample Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Sample Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Reagent Arm Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Reagent Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Reagent Arm Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cavro Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cavro Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cavro Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavro Arm Insulation Block/Cable Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . .
Insulation Block/Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulation Block/Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
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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
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ACL-TOP Service Manual
Contents
Cuvette Handling/Rack Handling X-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORU Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORU Detector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORU Emitter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disable Shuttle Motors Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initialize Shuttle Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Temperature Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear All Cuvettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start, Stop, and Clear Accumulator Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Virtual LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Sensors in the Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initialize Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Indexer (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Move Indexer (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Up Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Down Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Virtual LEDs in the Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle and Loader Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Loader Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Loader Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Hold/Incubator #2 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Hold/Incubator #2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTS Hold/Incubator #2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incubator #1 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incubator #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incubator #1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optical Reading Units Cradle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Y-Axis Motor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Y-Axis Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Y-Axis Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Solenoid Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cuvette Shuttle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Z Height and Tilt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Y Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
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9 - 16
9 - 17
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9 - 20
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents
Reagent Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Travel Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Travel Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Handling Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Racks area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Perform Loop Back Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Label Reading and Rack Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stirrers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Module Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Module Assembly Removal (Both CTS and non-CTS models) . . . . . . . . . . . . . . . . . .
Sample Module Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Presence PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Presence PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Presence PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Flag Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Flag Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Module Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Drain Tube Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Module Tubing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Module Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Presence PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Presence PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Presence PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Cooling with Fan Speed Controller PCB Removal/Replacement . . . . . . . . . . . . . . . . . .
Reagent Cooling with Fan Speed Controller PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Cooling with Fan Speed Controller PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Flag Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reagent Flag Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTI PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTI PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTI PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Axis PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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X Axis PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X Axis PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Earlier version X Axis PCB Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curtain Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curtain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Curtain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Belt Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Motor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Reader Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
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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
ACL-TOP Service Manual
13
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
14
ACL-TOP Service Manual
List of Illustrations
Chapter 1 Instrument Overview
Figure 1-1. ACL TOP Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Figure 1-2. Analytical Module with Open Safety Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Figure 1-3. Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Figure 1-4. Cuvette Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Figure 1-5. Cuvette Strip being picked up by Cuvette Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Figure 1-6. Bar Code Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Figure 1-7. Sample Area with Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Figure 1-8. Sample Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Figure 1-9. Sample Arm CTS probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Figure 1-10. CTS Cap Piercing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Figure 1-11. CTS Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Figure 1-12. Diluent Area with Sample Probe (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Figure 1-13. Diluent Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Figure 1-14. Reagent Area Showing Intermediate (left) and Start (right) Reagent Arms . . . . . . . . . . . . 1 - 12
Figure 1-15. Reagent Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Figure 1-16. Probe (in foreground) and Syringe (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Figure 1-17. Sample Probe and Incubator Slots (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Figure 1-18. Rinse (left) and Clean Bottles on ACL TOP with Fluid Waste Container Underneath . . . . 1 - 16
Figure 1-19. Cuvette Waste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Figure 1-20. Cuvette Waste Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Chapter 2 Pre-Installation and Installation
Figure 2-1. Duch Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Figure 2-2. Shipping Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Figure 2-3. Reagent Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Figure 2-4. Reagent Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Figure 2-5. Sample/Reagent Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Figure 2-6. Probe/Arm Tie Wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Figure 2-7. TOP Sample Arm Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Figure 2-8. CTS Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Figure 2-9. CTS Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Figure 2-10. CTS Assy. tie wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Figure 2-11. Shuttle tie wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Figure 2-12. Monitor Arm Mounting Studs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Figure 2-13. Computer/Monitor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
Figure 2-14. System Software Versions Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Figure 2-15. Software Version Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Chapter 3 Troubleshooting
Figure 3-1. Maintenance Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-2. The Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-3. General Log List Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-4. General Log List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-5. General Log Entry Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-6. Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-7. Temperature Tab on Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
3-3
3-4
3-5
3-6
3-7
3-8
3-9
1
Figure 3-8. SW Versions on Instrument Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-9. Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-10. Status Tab on Statistics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-11. Alarms Tab on Statistics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 10
3 - 11
3 - 12
3 - 13
Chapter 4 Enclosure/Chassis
Figure 4-1. ACL-TOP Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Figure 4-2. ACL-TOP Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Figure 4-3. Diagnostics Screen, Controllers, Covers and Racks Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Figure 4-4. Cover Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Figure 4-5. Sample Door Lower Right Sensor (upgradable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Figure 4-6. Sample Door Upper Right Sensor (current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Figure 4-7. Reagent Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Figure 4-8. Sample Door Hinge Attaching Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Figure 4-9. Sample Door ground Wire/Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Figure 4-10. Sample Door Hinge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Figure 4-11. Flag/Ground Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Figure 4-12. Reagent Door Left Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Figure 4-13. Reagent Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Figure 4-14. Reagent Door Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Figure 4-15. Top Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Figure 4-16. Front Panel Lower Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
Figure 4-17. Front Panel Upper Right Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
Figure 4-18. Front Panel Center Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
Figure 4-19. ACL-TOP Enclosure Upper Left Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
Figure 4-20. Front Panel Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Figure 4-21. Monitor Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Figure 4-22. Sample Module Interior Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
Figure 4-23. Interior Skin Ground Lug/Snap Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
Figure 4-24. Brackets for Snap Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Figure 4-25. Sample Side Upper Skin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Figure 4-26. Inner Left Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
Figure 4-27. Left Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Figure 4-28. Reagent Area Inner Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
Figure 4-29. Interior Skin Ground Lug/Snap Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
Figure 4-30. Brackets for Snap Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Figure 4-31. Upper Skin Above the Reagent Side Robotic Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Figure 4-32. Inner Right Skin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Figure 4-33. Right Skin Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
Figure 4-34. Right Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
Figure 4-35. Center Skin Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
Chapter 5 Processor / Software
Figure 5-1. System Software Version Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Figure 5-2. Software Version Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Figure 5-3. Software Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Figure 5-4. Processor Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Figure 5-5. Software, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
Figure 5-6. Controller Status Area of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
Figure 5-7. Software Version Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
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ACL-TOP Service Manual
Chapter 6 Power Management
Figure 6-1. Layout of the Power Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Figure 6-2. Interconnect Diagram for Power Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
Figure 6-3. The Power Entry Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Figure 6-4. The Power Supply Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Figure 6-5. The +5V/+15V/-15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Figure 6-6. The +24V/+28V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Figure 6-7. Fuse Diagram for the ACL TOP/Cavro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Figure 6-8. Fuse Diagram for the CTS TOP Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Figure 6-9. Power Supply Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13
Figure 6-10. +5/+15/-15V Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13
Figure 6-11. The Voltages Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14
Figure 6-12. The ORU Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15
Figure 6-13. The Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
Figure 6-14. The Arm Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
Figure 6-15. Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Figure 6-16. Non-Adjustable Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19
Figure 6-17. Wire Terminals on a +5/+15/-15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Figure 6-18. The Power Supply Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Figure 6-19. The Fuse Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
Chapter 7 Fluid Movement
Figure 7-1. Layout of the Fluid Movement System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Figure 7-2. Fluid Movement System Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
Figure 7-3. Cavro XP3000 Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Figure 7-4. Hamilton PSD4 Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Figure 7-5. Cavro Syringe Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-6. Hamilton Syringe Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-7. Syringe Pump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-8. Syringe Valve Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-9. Cavro Syringe Pump Communication/Valve Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Figure 7-10. Cavro Syringe Pump Lower Jumpers and Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
Figure 7-11. Hamilton Syringe Pump Jumpers/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
Figure 7-12. The Probe for the non-CTS instrument with Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
Figure 7-13. The Onboard Rinse Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14
Figure 7-14. Rinse, Clean Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
Figure 7-15. Rinse Pump Box Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16
Figure 7-16. Cavro Sample/Reagent Rinse/Clean Cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
Figure 7-17. CTS Sample Rinse/Clean Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
Figure 7-18. CTS Reagent Rinse/Clean Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
Figure 7-19. The Clean Fluid Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20
Figure 7-20. Clean Fluid Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20
Figure 7-21. Clean Fluid LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Figure 7-22. Clean Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Figure 7-23. CTS Sample Clean Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22
Figure 7-24. CTS Bulk Fluids Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
Figure 7-25. CTS Air Pump/Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
Figure 7-26. Air Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24
Figure 7-27. Location of Fluidics Controller/Connector PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25
Figure 7-28. Fluidic LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
Figure 7-29. CTS ACL-TOP Fluidic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
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Figure 7-30. Non-CTS Fluidic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-31. Maintenance Screen Run Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-32. Maintenance Screen Run Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-33. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-34. Flow Rate Test Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-35. Flowchart for Fluidic Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-36. Sensor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-37. Fluids Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-38. Clean Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-39. Clean Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-40. Stirring Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-41. Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-42. Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-43. Shipping Preparation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-44. Fluid Precision Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-45. Sample Cavro Syringe Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-46. CTS Fluidics Mounting (Cavro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-47. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-48. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-49. Cavro Syringe Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-50. Cavro Sample Arm Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-51. Cavro Sample Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-52. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-53. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-54. Sample Arm Cavro Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-55. Sample Arm Cavro Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-56. Reagent Cavro Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-57. Reagent Arm Cavro Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-58. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-59. Cavro Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-60. Reagent Arm Cavro Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-61. Reagent Cavro Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-62. Removing the Cavro Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-63. Cavro Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-64. Cavro Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-65. Cavro Syringe Valve Assembly/Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-66. Cavro Syringe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-67. Cavro Syringe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-68. Hamilton CTS Sample Syringe Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-69. CTS Fluidics Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-70. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-71. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-72. Hamilton Syringe Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-73. Hamilton Sample Arm Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-74. Hamilton Sample Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-75. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-76. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-77. Hamilton Sample Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-78. Hamilton Sample Arm Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-79. Hamilton Reagent Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-80. Reagent Arm Hamilton Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-81. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-82. Hamilton Syringe Pump Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-83. Reagent Arm Hamilton Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 7-84. Reagent Hamilton Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-85. Removing the Hamilton Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-86. Hamilton Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-87. Hamilton Syringe Tip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-88. Hamilton Syringe Valve Assembly/Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-89. Hamilton Pump Syringe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-90. Hamilton Syringe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-91. Rinse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-92. Rinse Pump Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-93. Rinse Pump Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-94. The Probe Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 7-99. 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 8 Robotic XYZ Arms
Figure 8-1. XYZ Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
Figure 8-2. Layout of the Robotic XYZ Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2
Figure 8-3. Interconnect Diagram - CTS/IL Double Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
Figure 8-4. Interconnect Diagram - CTS/IL Double Reagent Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
Figure 8-5. Interconnect Diagram - Sample-side Cavro Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Figure 8-6. Interconnect Diagram - Reagent-side Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Figure 8-7. ACL-TOP with Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
Figure 8-8. X Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
Figure 8-9. Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
Figure 8-10. X Axis Rollers and Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
Figure 8-11. Motor, drive belt and encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
Figure 8-12. X Axis Motors - Reagent Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
Figure 8-13. X Axis Belts - Reagent Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Figure 8-14. Y Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Figure 8-15. Y Axis Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Figure 8-16. Z Axis Motor, Pulley and Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Figure 8-17. Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
Figure 8-18. X Limit Flags and Travel Limit Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13
Figure 8-19. Y Limit Flag and Travel Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
Figure 8-20. Central Control Unit (CCU) for Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
Figure 8-21. ADRI-9 PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
Figure 8-22. ADRI 9 Dip Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
Figure 8-23. Heater Probe PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Figure 8-24. ACL-TOP CTS with CTS Sample and IL Double Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Figure 8-25. X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
Figure 8-26. X Axis Drive Belt (Sample Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
Figure 8-27. X Axis Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
Figure 8-28. Reagent Side Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
Figure 8-29. Reagent Side X Axis Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
Figure 8-30. Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
Figure 8-31. Y Axis Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22
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Figure 8-32. Y Axis Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-33. Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-34. CTS Piercer Z-Axis Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-35. Z Axis Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-36. CTS Sample and/or IL Double Arm X Flag and Travel Limit Sensors . . . . . . . . . . . . . . . .
Figure 8-37. Flags and Sensors Between Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-38. CTS Sample and/or IL Double Arm Y Flags and End of Limit Sensors . . . . . . . . . . . . . . .
Figure 8-39. CTS Sample and/or IL Double Arm PCB Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-40. XYZ Controller Interface PCB, Y-Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-41. X Axis Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-42. Z-Axis Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-43. Reference Point Positions for Base TOP Instruments (Cavro Arms) . . . . . . . . . . . . . . . . .
Figure 8-44. Reference Point Positions for CTS Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-45. Reference Screw Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-46. Well Area Cutout Reference Points for Non-CTS Probes. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-47. Well Area Cutout Reference Points for CTS Probes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-48. CTS Sample and/or IL Double Arm Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-49. Probe Initialization for CTS Sample Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-50. Probe Initialization for CTS Sample Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-51. IL Double Arm Homing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-52. Probe Initialization for Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-53. Coordinates Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-54. Tube Release Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-55. The Probes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-56. LLD Area of Probes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-57. The Rinse Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-58. The Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-59. The Move Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-60. Probe Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-61. LLD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-62. DVM Probe Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-63. Probe Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-64. Diagnostic Screen - Universal Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-65. CTS Bulk Fluid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-66. Sample CTS X Axis Driver Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-67. Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-68. CTS Fluidics Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-69. Syringe Pump Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-70. Air Tubing to Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-71. CTS Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-72. CTS Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-73. CTS X Axis Driver PCB Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-74. Syringe Pump Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-75. CTS Fluidics Module Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-76. Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-77. Rinse Input/Output Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-78. Connecting the Air Tubing to the Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-79. Reagent Syringe Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-80. Reagent IL Double Arms X Axis Driver PCB Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-81. Reagent IL Double Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-82. Reagent IL Double Arm Assembly Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-83. Reagent IL Double Arms X Axis Driver PCB Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-84. Syringe Pump Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-85. Reagent Arm Pump Assembly Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 8-86. Reagent Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 78
Figure 8-87. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 78
Figure 8-88. Cable Clamp on Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
Figure 8-89. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
Figure 8-90. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
Figure 8-91. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
Figure 8-92. Ground Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
Figure 8-93. Ground Wire and Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 82
Figure 8-94. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 82
Figure 8-95. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 83
Figure 8-96. Heater Probe PCB and Heater Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 83
Figure 8-97. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
Figure 8-98. Coax Cable Connection to Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
Figure 8-99. Flex Cable to Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85
Figure 8-100. Cable Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86
Figure 8-101. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86
Figure 8-102. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87
Figure 8-103. Ground Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87
Figure 8-104. Cavro Reagent Ground Wire, Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 88
Figure 8-105. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 89
Figure 8-106. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 89
Figure 8-107. Probe Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 90
Figure 8-108. Probe Top Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 90
Figure 8-109. R2 Heater Probe PCB and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 91
Figure 8-110. Coax Cable Connection to R2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 91
Figure 8-111. R2 Flex Cable to Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 92
Figure 8-112. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 92
Figure 8-113. Flex Cable Routing for Left Reagent Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93
Figure 8-114. Left Reagent Arm Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93
Figure 8-115. Cable Bracket Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93
Figure 8-116. Reagent Left Arm LLD Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 94
Figure 8-117. Coax Cable Connection to Left Reagent Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 94
Figure 8-118. Removing the Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95
Figure 8-119. ALIDUM Coax Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96
Figure 8-120. Installing the Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97
Figure 8-121. Slotted Optical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98
Figure 8-122. Optical Switch Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99
Figure 8-123. ALIDUM Coax Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 101
Figure 8-124. Diagram of the ADRI-9 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102
Figure 8-125. SW Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103
Figure 8-126. CCU-9000 Board Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 104
Figure 8-127. Tensioner Screw Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105
Figure 8-128. Belt Bracket Screw Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 106
Figure 8-129. Y-Axis Tensioning Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107
Figure 8-130. Y-Axis Belt Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107
Chapter 9 Cuvette Handling System
Figure 9-1. Layout of the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-2. Interconnect Diagram for the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-3. The Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-4. The Gripper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-5. The Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 9-6. The Shuttle Pivot Assembly and the Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7
Figure 9-7. The Cuvette Loader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8
Figure 9-8. The Transport Deck Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9
Figure 9-9. The Indexer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9
Figure 9-10. The Cuvette Rotating Platform (in Horizontal Down Position) . . . . . . . . . . . . . . . . . . . . . . 9 - 10
Figure 9-11. The Incubators and the Cuvette Indexer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11
Figure 9-12. The ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12
Figure 9-13. ORU Subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12
Figure 9-14. The Left and Right End-of-limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14
Figure 9-15. Sensors on the Front of the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14
Figure 9-16. Sensors on the Rear of the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
Figure 9-17. The Cuvettes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18
Figure 9-18. The Shuttle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19
Figure 9-19. The Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22
Figure 9-20. The Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23
Figure 9-21. Cuvette Shuttle and Loader Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25
Figure 9-22. The Cuvette Loader Assembly (seen from above and behind). . . . . . . . . . . . . . . . . . . . . . 9 - 26
Figure 9-23. Captive Screws on the CTS Hold/Incubator #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
Figure 9-24. Captive Screws on the Incubator #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
Figure 9-25. The Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 29
Figure 9-26. The Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30
Figure 9-27. Y-Axis PCB Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31
Figure 9-28. Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31
Figure 9-29. Cables and Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
Figure 9-30. Motor Bracket Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
Figure 9-31. Cables and Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
Figure 9-32. Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
Figure 9-33. Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34
Figure 9-34. Completed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34
Figure 9-35. The Left and Right End-of-limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35
Figure 9-36. Location of the Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 36
Figure 9-37. The Z Height and Tilt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37
Figure 9-38. The Y-Axis LED and the Turning Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38
Figure 9-39. The Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38
Figure 9-40. The X-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 40
Figure 9-41. LEDs on the Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 40
Chapter 10 Reaction Detection
Figure 10-1. ORU Light Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3
Figure 10-2. Reaction Detection Block Diagram/Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
Figure 10-3. Overall ORU Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
Figure 10-4. Voltage Tab in Diagnostics Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
Figure 10-5. ORU Tab of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
Figure 10-6. ORUs Enabled Indicators Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
Figure 10-7. Dark Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
Figure 10-8. Reference Readings Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
Figure 10-9. Optical Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Figure 10-10. Temperature Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Figure 10-11. Air Blanking of All ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13
Figure 10-12. Factor Diluent Blanking for all ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14
Figure 10-13. Testing/Correcting Voltage Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15
Figure 10-14. ORU Controller Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17
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Figure 10-15. Emitter Voltage Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-16. Enabling ORUs Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-17. ORU Enabling Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-18. Sample, Reagent, Diluent Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-19. Testing/Correcting Dark Readings Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-20. Dark Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-21. ORU Head Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-22. Testing/Correcting Optical Blanking Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-23. Temperature Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-24. ORU Diagnostic Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-25. Optical Blanking Area of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-26. Temperature Area of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-27. Reference Readings Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-28. Dark Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-29. ORU Linearity Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-30. ORU Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-31. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-32. Calibration Offsets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-33. ORU Backplane PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-34. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-35. ORU Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-36. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-37. Emitter Head Attachment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-38. Backplane Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-39. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-40. Power Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-41. ORU Positioned For Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-42. Tuning ORU Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-43. Fiber Bundle Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-44. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-45. Fiber Bundle Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-46. ORU Cover Attachment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-47. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-48. Cover Hardware Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-49. Bracket Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-50. New Cover Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 11 Rack Handling
Figure 11-1. Rack Handling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2
Figure 11-2. Rack Handling Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
Figure 11-3. Sample Module (CTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4
Figure 11-4. Sample Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
Figure 11-5. Sample Rack Sensing Indications (all positions filled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
Figure 11-6. Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6
Figure 11-7. Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6
Figure 11-8. Reagent Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7
Figure 11-9. Reagent Rack Sensing Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8
Figure 11-10. Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8
Figure 11-11. Reagent Mounting Plate Stirrers and Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9
Figure 11-12. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
Figure 11-13. Reagent Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
Figure 11-14. Bar Code Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11
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Figure 11-15. RTI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-16. Bar Code Reader Travel Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-17. SW, Covers, and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-18. Racks Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-19. Reagent Temperature Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-20. Stirring Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-21. Sample Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-22. Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-23. Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-24. Reagent Module Screws (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-25. Reagent Module Screws (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-26. Reagent Cooling with Fan Speed Controller PCB Mounting. . . . . . . . . . . . . . . . . . . . . .
Figure 11-27. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-28. Barb Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-29. Double Clamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-30. Reagent Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-31. Secured Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-32. Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-33. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-34. Reagent Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-35. Bar Code Reader Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-36. BCR Mounting Screws Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-37. Mounting Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-38. Barcode Scanner Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-39. Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-40. Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-41. Bar Code Reader Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-42. RTI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-43. X Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-44. Jumper Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-45. Encoder Assembly Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-46. Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-47. BCR Curtain Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-48. Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-49. Right Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-50. Left Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-51. Bar Code Reader Drive Belt Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-52. Bar Code Reader Drive Belt Fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-53. Bar Code Reader Drive Belt Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-54. Bar Code Reader Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-55. Bar Code Reader Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 12 Thermal Control
Figure 12-1. System Temperature Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-2. Temperature Tab of Instrument Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-3. Thermal Sensing Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-4. Thermal Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-5. Cuvette Shuttle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-6. Cuvette Shuttle Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-7. Incubator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-8. Incubator 2 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12-9. Optical Reading Unit Thermal Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 12-10. Cooling Fan Ductwork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
Figure 12-11. Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
Figure 12-12. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9
Figure 12-13. Cavro Reagent Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10
Figure 12-14. Universal Arms Reagent Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10
Figure 12-15. Cavro Sample Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
Figure 12-16. ThermalCal Dialog Initial State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13
Figure 12-17. Thermal Dialog after Changing to Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
Figure 12-18. Screen after connecting to the TOP AM. (Manual Mode) . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15
Figure 12-19. Calibration Process for a Single Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 16
Figure 12-20. Display of the Soaking Time Remaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17
Figure 12-21. Time-out Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17
Figure 12-22. Temperature Stable Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 18
Figure 12-23. Screen showing Offset (Coefficient) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
Figure 12-24. Display Coefficient Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
Figure 12-25. Message Box Confirming a Stop Calibration Request . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
Figure 12-26. Message Warning that a Second Module cannot be Selected . . . . . . . . . . . . . . . . . . . 12 - 20
Figure 12-27. Complete Calibration before Exiting message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
Figure 12-28. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21
Figure 12-29. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 22
Figure 12-30. Connecting ThermalCal Application to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23
Figure 12-31. Time-out Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23
Figure 12-32. AM Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24
Figure 12-33. ICU1 Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24
Figure 12-34. ICU2 Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25
Figure 12-35. ORU Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25
Figure 12-36. Thermistors and Futura Test Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 26
Figure 12-37. Soak Time Remaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27
Figure 12-38. Temperature Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27
Figure 12-39. Temperature Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28
Figure 12-40. Save Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28
Figure 12-41. Calibration Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28
Figure 12-42. Done Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 29
Figure 12-43. Display Coefficients. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 30
Figure 12-44. Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 30
Figure 12-45. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 31
Figure 12-46. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 32
Figure 12-47. Connecting ThermalCal to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 33
Figure 12-48. Connection Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 34
Figure 12-49. Thermal Coefficient Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 34
Figure 12-50. Controllers, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 36
Figure 12-51. Reagent Temperature Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 37
Figure 12-52. ORU Tab of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 38
Figure 12-53. Temperature Portion of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 39
Figure 12-54. Software, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 40
Figure 12-55. Reagent Block Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 40
Chapter 13 Waste Management System
Figure 13-1. Layout of the Waste Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-2. The Sample and Reagent Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-3. The Reagent Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-4. The Sample Side Accumulator (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 13-5. The Parts of the Waste Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 6
Figure 13-6. The Waste Shelf Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7
Figure 13-7. Tilt Adjustment and Positional Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 8
Figure 13-8. The Fluids Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 12
Figure 13-9. The Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
Figure 13-10. The Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
Figure 13-11. The Cuvettes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14
Figure 13-12. The Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15
Figure 13-13. The Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16
Figure 13-14. Connectors on the Cuvette Waste PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 18
Figure 13-15. Three Captive Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 18
Figure 13-16. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 20
Figure 13-17. The Sample Accumulator (with the Sample Module Removed) . . . . . . . . . . . . . . . . . . . 13 - 21
Figure 13-18. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 22
Figure 13-19. CTS Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23
Figure 13-20. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 24
Figure 13-21. The Reagent Accumulator (with the Reagent Module Removed). . . . . . . . . . . . . . . . . . 13 - 24
Figure 13-22. Waste Pump Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25
Figure 13-23. Waste Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 26
Figure 13-24. Waste Pump Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 27
Figure 13-25. Assembly with Waste Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 27
Chapter 14 Preventive Maintenance
Figure 14-1. Use of Precision Tubing as Threader for Rinse Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 3
Figure 14-2. I/O Fluidics Panel Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 4
Figure 14-3. I/O Fluidic Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 5
Figure 14-4. Fluidics Panel Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 6
Figure 14-5. I/O Fluidics Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 7
Figure 14-6. Waste Pump Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 8
Figure 14-7. Flex Cable Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 9
Figure 14-8. X Frame and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 10
Figure 14-9. Y Frame and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 10
Figure 14-10. .ORUs Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 11
Figure 14-11. ORU Enabling Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 11
Figure 14-12. Air Blanking of All ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 12
Figure 14-13. Air Blanking Value Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 12
Figure 14-14. Factor Diluent Blanking for all ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13
Figure 14-15. Factor Diluent Blanking Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13
Figure 14-16. Left and Right End-of-Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 14
Figure 14-17. Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15
Figure 14-18. Z Height and Tilt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15
Figure 14-19. Y Axis LED and Turning Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16
Figure 14-20. Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16
Figure 14-21. X-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 18
Figure 14-22. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
Figure 14-23. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
Figure 14-24. Flow Rate Test Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
Figure 14-25. System Software VersionsDisplay Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 20
Figure 14-26. Software Revisions Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21
Figure 14-27. System Temperature Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21
Figure 14-28. Temperature Tab of Instrument Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 22
Figure 14-29. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 22
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Figure 14-30. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-31. Connecting ThermalCal to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-32. Connection Status - Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-33. Thermal Coefficient Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 - 23
14 - 24
14 - 24
14 - 25
Chapter 15 CTS Piercer
Figure 15-1. CTS Piercer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 2
Figure 15-2. CTS Piercer Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 3
Figure 15-3. CTS Piercer Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4
Figure 15-4. Piercer Probe in Piercer and Sample Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7
Figure 15-5. Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8
Figure 15-6. LLD Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8
Figure 15-7. Piercer Lock Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 9
Figure 15-8. Cap Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10
Figure 15-9. Piercer Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10
Figure 15-10. Z-Drive Rack and Brake Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 11
Figure 15-11. Retraction Shaft and Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 12
Figure 15-12. Probes Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 14
Figure 15-13. CTS Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 16
Figure 15-14. Piercer Loop Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
Figure 15-15. Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18
Figure 15-16. Air Valve, Pressure Release Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
Figure 15-17. Probe-n-Seal Assembly Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20
Figure 15-18. Sampling Probe LLD Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20
Figure 15-19. CTS Assembly Thumbscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21
Figure 15-20. Probe-n-Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21
Figure 15-21. Probe-n-Seal Hold Down Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 22
Figure 15-22. Inserting the Probe-n-Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 23
Figure 15-23. CTS Thumbscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 23
Figure 15-24. Sampling Probe LLD Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24
Figure 15-25. Probe-n-Seal Assembly Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24
Figure 15-26. Piercer Probe Knurled Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 25
Figure 15-27. CTS Piercer Probe Removal/Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 26
Figure 15-28. Removal of Telescoping CTS Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28
Figure 15-29. CTS Piercer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28
Figure 15-30. Brake Rack Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29
Figure 15-31. Telescoping CTS Assembly Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29
Figure 15-32. Z-Drive Rack Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30
Figure 15-33. Z-Drive Rack Screw (Bottom View of Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30
Figure 15-34. Brake Rack Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 31
Figure 15-35. Telescoping CTS Assembly Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 32
Figure 15-36. CTS Piercer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 32
Figure 15-37. Ribbon Cable Routing/Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 33
Figure 15-38. Connection of Telescoping CTS Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 34
Figure 15-39. Connecting Air Tube to the Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 34
Chapter 16 Schematics
Figure 16-1. Power Interconnect Fuse PCB (Drawing # 27501100) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-2. Back Plane PCB (Drawing # 27502100, Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-3. Back Plane PCB (Drawing # 27502100, Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-4. Back Plane PCB (Drawing # 27502100, Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
16 - 3
16 - 4
16 - 5
16 - 6
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Figure 16-5. Back Plane PCB (Drawing # 27502100, Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 7
Figure 16-6. Back Plane PCB (Drawing # 27502100, Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 8
Figure 16-7. Back Plane PCB (Drawing # 27502100, Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 9
Figure 16-8. Front Panel Disconnect PCB (Drawing # 27503100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 10
Figure 16-9. PC104 Can Bus PCB (Drawing # 27504100, Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . 16 - 11
Figure 16-10. PC104 Can Bus PCB (Drawing # 27504100, Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . 16 - 12
Figure 16-11. PC104 Can Bus PCB (Drawing # 27504100, Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . 16 - 13
Figure 16-12. PC104 Can Bus PCB (Drawing # 27504100, Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . 16 - 14
Figure 16-13. Fluidics Controller PCB (Drawing # 27505100, Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 15
Figure 16-14. Fluidics Controller PCB (Drawing # 27505100, Sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 16
Figure 16-15. Fluidics Controller PCB (Drawing # 27505100, Sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 17
Figure 16-16. Fluidics Controller PCB (Drawing # 27505100, Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 18
Figure 16-17. Fluidics Controller PCB (Drawing # 27505100, Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . 16 - 19
Figure 16-18. Fluidics Connector PCB (Drawing # 27506100, Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 20
Figure 16-19. Fluidics Connector PCB (Drawing # 27506100, Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 21
Figure 16-20. Fluidics Connector PCB (Drawing # 27506100, Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 22
Figure 16-21. Fluidics Connector PCB (Drawing # 27506100, Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . 16 - 23
Figure 16-22. Fluidics LED PCB (Drawing # 27507100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 24
Figure 16-23. ORU Detector PCB (Drawing # 27552100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 25
Figure 16-24. ORU Detector PCB (Drawing # 27552100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 26
Figure 16-25. ORU Detector PCB (Drawing # 27552100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . 16 - 27
Figure 16-26. ORU Interface PCB (Drawing # 27554100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 28
Figure 16-27. ORU Interface PCB (Drawing # 27554100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 29
Figure 16-28. ORU Interface PCB (Drawing # 27554100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . 16 - 30
Figure 16-29. Incubator Heater PCB (Drawing # 27555100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 31
Figure 16-30. Emitter PCB (Drawing # 27556100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 32
Figure 16-31. Y-Axis PCB (Drawing # 27600100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 33
Figure 16-32. Y-Axis PCB (Drawing # 27600100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 34
Figure 16-33. Shuttle/Barcode X-Axis PCB (Drawing # 27601100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 35
Figure 16-34. Cuvette Loader Interface PCB (Drawing # 27602100) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 36
Figure 16-35. Cuvette Sensor PCB (Drawing # 27604100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 37
Figure 16-36. Cuvette Waste Interface PCB (Drawing # 27605100) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 38
Figure 16-37. Heated Probe PCB (Drawing # 27607100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 39
Figure 16-38. Probe DC Driver PCB (Drawing # 27608100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 40
Figure 16-39. Probe DC Driver PCB (Drawing # 27608100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 41
Figure 16-40. Probe Interconnect PCB (Drawing # 27609100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 42
Figure 16-41. Cuvette Loader Flex Cable PCB (Drawing # 27611100) . . . . . . . . . . . . . . . . . . . . . . . . 16 - 43
Figure 16-42. Sample Rack Presence PCB (Drawing # 27700100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 44
Figure 16-43. Reagent Rack Presence PCB (Drawing # 27701100, Sheet 1 of 2) . . . . . . . . . . . . . . . 16 - 45
Figure 16-44. Reagent Rack Presence PCB (Drawing # 27701100, Sheet 2 of 2) . . . . . . . . . . . . . . . 16 - 46
Figure 16-45. Reagent KeyBoard PCB (Drawing # 27702100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 47
Figure 16-46. Reagent Cooling PCB (Drawing # 27703100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 48
Figure 16-47. Magnetic Stirring PCB (Drawing # 27704100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 49
Figure 16-48. Magnetic Stirring PCB (Drawing # 27704100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 16 - 50
Figure 16-49. Sample Key Board PCB (Drawing # 27705100, Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 16 - 51
Figure 16-50. Sample Key Board PCB (Drawing # 27705100, Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . 16 - 52
Figure 16-51. Remote Travel Interface PCB (Drawing # 27710100) . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 53
Figure 16-52. Rack Controller CPU PCB (Drawing # 27800100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . 16 - 54
Figure 16-53. Rack Controller CPU PCB (Drawing # 27800100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . 16 - 55
Figure 16-54. Rack Controller CPU PCB (Drawing # 27800100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . 16 - 56
Figure 16-55. Rack Controller Interface PCB (Drawing # 27810100, Sheet 1 of 7) . . . . . . . . . . . . . . . 16 - 57
Figure 16-56. Rack Controller Interface PCB (Drawing # 27810100, Sheet 2 of 7) . . . . . . . . . . . . . . . 16 - 58
Figure 16-57. Rack Controller Interface PCB (Drawing # 27810100, Sheet 3 of 7) . . . . . . . . . . . . . . . 16 - 59
Figure 16-58. Rack Controller Interface PCB (Drawing # 27810100, Sheet 4 of 7) . . . . . . . . . . . . . . . 16 - 60
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Figure 16-59. Rack Controller Interface PCB (Drawing # 27810100, Sheet 5 of 7) . . . . . . . . . . . . . . .
Figure 16-60. Rack Controller Interface PCB (Drawing # 27810100, Sheet 6 of 7) . . . . . . . . . . . . . . .
Figure 16-61. Rack Controller Interface PCB (Drawing # 27810100, Sheet 7 of 7) . . . . . . . . . . . . . . .
Figure 16-62. Cuvette Waste Interface PCB (Drawing # 27605100). . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-63. X Motion Control PCB W/ out Dip (Drawing # 27613100). . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-64. CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 of 9) . . . . . . . . . . . . . . . .
Figure 16-65. CTS Controller Interface PCB (Drawing # 28630100, Sheet 2 of 9) . . . . . . . . . . . . . . . .
Figure 16-66. CTS Controller Interface PCB (Drawing # 28630100, Sheet 3 of 9) . . . . . . . . . . . . . . . .
Figure 16-67. CTS Controller Interface PCB (Drawing # 28630100, Sheet 4 of 9) . . . . . . . . . . . . . . . .
Figure 16-68. CTS Controller Interface PCB (Drawing # 28630100, Sheet 5 of 9) . . . . . . . . . . . . . . . .
Figure 16-69. CTS Controller Interface PCB (Drawing # 28630100, Sheet 6 of 9) . . . . . . . . . . . . . . . .
Figure 16-70. CTS Controller Interface PCB (Drawing # 28630100, Sheet 7 of 9) . . . . . . . . . . . . . . . .
Figure 16-71. CTS Controller Interface PCB (Drawing # 28630100, Sheet 8 of 9) . . . . . . . . . . . . . . . .
Figure 16-72. CTS Controller Interface PCB (Drawing # 28630100, Sheet 9 of 9) . . . . . . . . . . . . . . . .
Figure 16-73. Y Axis U Arm PCB (Drawing # 28631100, 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-74. Y Axis U Arm PCB (Drawing # 28631100, 2of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-75. Z Driver PCB (Drawing # 28633100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-76. Z Driver PCB (Drawing # 28633100, Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-77. Z Driver PCB (Drawing # 28633100, Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-78. CTS Traveling Interconnect PCB (Drawing # 28634100) . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16-79. U Arm Fuse Board PCB (Drawing # 28641100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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16 - 69
16 - 70
16 - 71
16 - 72
16 - 73
16 - 74
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16 - 76
16 - 77
16 - 78
16 - 79
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Chapter 17 Assembly Drawings/Part Numbers
Figure 17-1. 2811001, ASSY, WASTE SHELF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-2. 28116301 ASSY, WASTE DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-3. 28116401 ASSY, WASTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-4. 28141701 ASSY, LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-5. 28161601 X-MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-6. 28165001 ASSY CUVETTE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-7. 28200001 ASSY, BARCODE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-17. 28512501 ASSY, REAGENT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-18. 28519700 DUCT ASSY, REAGENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-19. 28578601 ASSY, SAMPLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-20. 28578621 ASSY, CTS SAMPLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-21. 28602701 ASSY, COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-22. 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY). . . . . . . . . . . . . . . .
Figure 17-23. 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY). . . . . . . . . . . . . . . .
Figure 17-24. 28608101 ASSY, BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-25. 28608201 ASSY, COMPUTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-26. 28608301 DC DRIVER ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-27. 28612000 ASSY, FRONT, TOP SKIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-28. 28612701 SNAP DETENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-29. 28621201 PCB, CUVETTE ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACL-TOP Service Manual
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17 - 12
17 - 13
17 - 14
17 - 15
17 - 16
17 - 17
17 - 18
17 - 19
17 - 20
17 - 21
17 - 22
17 - 23
17 - 24
17 - 25
17 - 26
17 - 27
17 - 28
17 - 29
17 - 30
17 - 31
17 - 32
17 - 33
17 - 34
17 - 35
17 - 36
17 - 37
17 - 38
15
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-38. 28759501 ASSY, CWR STATION, SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-39. 28759601 ASSY, CWR STATION, REAGENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-40. 28774601 ASSY, WASTE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-41. 28775900 ASSY, ACL TOP PROBE HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-42. 28816801 ASSY, INCUBATOR #1 (REAGENT SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-43. 28817201 ASSY, INCUBATOR #2 (SAMPLE SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-44. 28820501 8 POS INC INDEXER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-45. 28821501 7 POS INC INDEXER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17-46. 28825000 ASSY, ORU CRADLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . .
16
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ACL-TOP Service Manual
1
Safety and Compliance
This section describes the Safety and Compliance Requirements for the ACL TOP, including Site Requirements, Environmental Requirements, Reagent Specifications, Limitations, Important Symbols, and Certifications.
Site Requirements
Only 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 Warranty
Instrumentation 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 or
repairs.
•
The electrical installation of the room complies with the local, state, or national requirements (including 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 Requirements
The 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:
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
The maximum external dimensions for the monitor are:
Height
43.1 cm
17 inches
Width:
35.5 cm
14 inches
Depth:
7.6 cm
3 inches
Environmental Conditions
The instrument will function correctly in an ambient temperature of 15°C to 32°C (59°F to 89°F) with a relative humidity of 5% to 85% (non-condensing).
In accordance with the IEC regulations, no instrument failures will occur in the presence of short-term ambient 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 Specifications
Reagent 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.
ACL-TOP Service Manual
3
Limitations
Instrumentation Laboratory, Co. (IL) is responsible for the safety and electrical performance of this equipment if and only if:
•
Assembly operations, extensions, adjustments, modifications or repairs are carried out by persons
authorized by IL.
•
The electrical installation of the room complies with the local, state or national requirements (including 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 Symbols
Only 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", "CAUTION", "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 personal injury hazards and product damage hazards.
ACL-TOP Service Manual
4
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.
Label Symbols
The following symbols appear on the labels of ACL TOP components.
Symbol
Description
CE Mark
Temperature Limitation
Use by
Manufacturer
Batch Code
Biological Risk
Attention: See Instructions for Use
ACL-TOP Service Manual
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)
ACL-TOP Service Manual
6
Bar Code Reader Hazard
Stop Action – Instrument will stop all moving parts
immediately
Warning: Personal Injury
Certification
CE 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.
ACL-TOP Service Manual
7
European regulation on data protection, concerning:
§ Luxembourg
§ Ireland
§ Greece
§ United Kingdom
§ Belgium
§ Portugal
§ Austria
§ Germany
§ Italy
§ Denmark
§ France
§ Netherlands
§ Sweden
§ Finland
§ Spain
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.
ACL-TOP Service Manual
8
CAUTION: Do not bypass safety switches. The moving CTS Pierce Probe
can cause serious personal injury.
AM Safety Covers
The 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.
ACL-TOP Service Manual
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 monitor, 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
ACL-TOP Service Manual
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.
ACL-TOP Service Manual
Chapter 1 – Instrument Overview
1-3
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.
ACL-TOP Service Manual
1 - 4 Chapter 1 – Instrument Overview
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 operational 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.
ACL-TOP Service Manual
Chapter 1 – Instrument Overview
1-5
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 instrument 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 running.
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.
ACL-TOP Service Manual
1 - 6 Chapter 1 – Instrument Overview
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 clicking 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.
N
ACL-TOP Service Manual
NOTE: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.
Chapter 1 – Instrument Overview
1-7
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.
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1 - 8 Chapter 1 – Instrument Overview
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.
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Chapter 1 – Instrument Overview
1-9
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
1
2
CAUTION: Due to the force of the piercing, glass sample tubes may break.
To avoid this potential breakage please use plastic tubes where possible.
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1 - 10 Chapter 1 – Instrument Overview
Following aspiration the CTS/Sample arm moves to the wash station and performs a deep wash. Pressurized 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 instrument 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.
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Chapter 1 – Instrument Overview
1 - 11
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
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1 - 12 Chapter 1 – Instrument Overview
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 intermediate reagent is one that when mixed with sample activates certain constituents of the sample but is not
enough to bring the reaction to completion.)
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Chapter 1 – Instrument Overview
1 - 13
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 interest. 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 station 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.
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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 temperature 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 the
reagent incubator where start reagents such as APTT CaCl2 are dispensed into the cuvette cells to start the
reaction. 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.
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Chapter 1 – Instrument Overview
1 - 15
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, displacing 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 contains 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 contaminants 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.
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1 - 16 Chapter 1 – Instrument Overview
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.
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Chapter 1 – Instrument Overview
1 - 17
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 container 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 finished, 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
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1 - 18 Chapter 1 – Instrument Overview
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 photodetector, 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.
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Chapter 1 – Instrument Overview
1 - 19
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 antigenantibody 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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ACL-TOP Service Manual
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 accommodate 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 suitable 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 importance. 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.
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2 - 2 Chapter 2 – Pre-Installation and Installation
Table 2-1 Table One Pre-Installation Check List
Item to be Checked Acceptable
Unacceptable Construction
In Progress
Comments
Reception Area
Transportation
Pathway
Working Area
Environment
Direct Waste Drain
Electrical Power
Requirements
DMS / LIS Interface
Functional
Customer Training
Complete
Supplies on Order
The physical dimensions for the shipping crate are as follows:
Table 2-2 Crated Instrument Size/Weight Specifications
ACL-TOP Service Manual
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)
Chapter 2 – Pre-Installation and Installation
2-3
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
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.)
The maximum external dimensions for the Monitor are:
Table 2-4 Monitor Size Specifications
Total height
43.1 cm (17 inches)
Width
35.5 cm (14 inches)
Depth
7.6 cm (3 inches)
The maximum external dimensions for the Analytical Module on the shipping table are:
Table 2-5 Analytical Module Size Specifications
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)
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2 - 4 Chapter 2 – Pre-Installation and Installation
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 following 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
Value of supply voltage for normal
function
Value as shown on the label
230 Vac ± 10%
230 Vac
115 Vac ± 10%
100-115 Vac
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.
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Chapter 2 – Pre-Installation and Installation
2-5
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
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2 - 6 Chapter 2 – Pre-Installation and Installation
•
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
Polystyrene
Foam
Retaining
Boards
•
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.
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Chapter 2 – Pre-Installation and Installation
2-7
•
Open the sample and reagent door covers. Note: The sample and reagent cover may be locked for
shipping. To unlock the reagent cover, remove the waste drawer and manually release the solenoid
door lock located under the lower right hand corner of the reagent cover. With the reagent door open
it is possible to unlock the sample door. The sample door solenoid is located under the lower left
hand 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
Cardboard
Support Box
Figure 2-4 Reagent Internal Packing Material
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2 - 8 Chapter 2 – Pre-Installation and Installation
•
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
Shipping
Bracket
•
Carefully remove the tie wraps around the probes and arms. (See Figure 2-6 "Probe/Arm Tie
Wraps".)
Figure 2-6 Probe/Arm Tie Wraps
Tie Wraps
•
For non CTS units, remove the cardboard boxes under the sample arm. (See Figure 2-7 "TOP
Sample 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 Arm
Packing".)
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Chapter 2 – Pre-Installation and Installation
2-9
Figure 2-7 TOP Sample Arm Packing
Tie Wrap
Shipping
Bracket
Cardboard
Support for
Arm
•
For TOP CTS units remove the cardboard support boxes under the CTS arm (See.Figure 2-8 "CTS
Internal Packing Material")
Figure 2-8 CTS Internal Packing Material
Cardboard
Support Boxes
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2 - 10 Chapter 2 – Pre-Installation and Installation
•
Carefully remove the tie wraps around the CTS Piercer/Probe assembly. (See Figure 2-9 "CTS
Assy. tie wraps")
Figure 2-9 CTS Assy. tie wraps
Shipping
Bracket
Tie Wrap
Tie Wrap
•
Remove the shipping bracket from the CTS arm. (See Figure 2-10 "CTS Shipping Brackets")
Figure 2-10 CTS Shipping Brackets
Shipping
Bracket
•
Remove the interior covers.
ACL-TOP Service Manual
Chapter 2 – Pre-Installation and Installation
•
2 - 11
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 storage 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 Arm
Mounting Studs
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2 - 12 Chapter 2 – Pre-Installation and Installation
•
Connect the monitor, keyboard and mouse as shown on Figure 2-13 "Computer/Monitor Connections".
Figure 2-13 Computer/Monitor Connections
Keyboard
Power
Sound
Touchscreen
Touchscreen
Monitor
Mouse
Sound
Monitor
•
Install the correct fuses ( 2 required) into the fuse holder (5 Amp for 220VAC and 10 Amp for 110
VAC).
•
Install the waste presence sensor assembly (00028762900) onto the waste bottle. Connect the
waste 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 system and connect the bulkhead connector.
•
Insert the rinse bottle aspirator (00028713400) into the clean bottle. Place the bottle on to the system and connect the bulkhead connector.
•
Close both sample and reagent doors, boot up the Command module and power up the Analytical
module. Log in using the password provided at training session. The instrument initializes and goes
to 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 “Initialize Loader” in Chapter 9).
•
Check and adjust the Cuvette shuttle alignments (see “Cuvette Shuttle Alignment Check” in
Chapter 9).
•
Reinstall and close all of the covers and blank the Optical Reading Unit (ORU) with air and factor
diluent (PN 9757600). Refer to “Optical Blanking” in Chapter 10 for specific instructions on how
to 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.
ACL-TOP Service Manual
Chapter 2 – Pre-Installation and Installation
2 - 13
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
ACL-TOP Service Manual
2 - 14 Chapter 2 – Pre-Installation and Installation
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 manufactures specifications.
Per the Symantec Ghost license agreement, this tool may only be used on ONE CM PC for each CM
Recovery 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 Æ Partition Æ 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”.
ACL-TOP Service Manual
Chapter 2 – Pre-Installation and Installation
2 - 15
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 Æ Check Æ 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.
ACL-TOP Service Manual
2 - 16 Chapter 2 – Pre-Installation and Installation
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 Service Manual
Chapter 2 – Pre-Installation and Installation
2 - 17
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
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
Pass/Adjust/ Check
ACL-TOP Service Manual
2 - 18 Chapter 2 – Pre-Installation and Installation
2-6 Start Up Kit Contents
28623500
Component
5575100
9746606
28713400
28713200
18902000
9831704
9832700
14871705
14871713
14871708
14871711
29400100
28739800
28911600
18924100
18924104
19006300
29400501
29400711
29400601
20009700
28520500
28520900
18794300
28741600
27764900
14871709
14871702
27540300
19725500
29401100
28525200
28771800
18901300
14871712
19085463
28525100
28766600
29240902
9757600
28780200
28526000
28526100
28526200
KIT START-UP,ACL TOP
Description
CUP SAMPLE 2 ML, 1000/PK
MAGNETIC, STIR BARS, ACL 6/PK
ASSY, 4L RINSE, ASPIRATOR, ACL TOP
ASSY, CLEAN ASPIRATOR, ACL TOP
BOTTLE, PLASTIC 30ML W/ CAP, FUTURA/ADVANCE
CLEANING AGENT, ACL, 4X500 ML
Critical Care/HemosIL CLEANING AGENT80ML
FUSE, 2.0AMP 250 VOLT, 682
FUSE 12.5A 250V 5x20MM TLAG
FUSE 4A 250V 5x20MM TLAG
FUSE 8A 250V 5x20MM TLAG
CUVETTES, ACL TOP, 6X100X4
SYRINGE, 250UL FOR XP3000 PUMP
SEAL (TIP), 250 UL SYRINGE
BOTTLE, GLASS, 10/PK, ACL FUTURA/ADVANCE
BOTTLE KIT, 10X4 ML
TOOL, STYLET, ACL FUTURA/ADVANCE
SAMPLE RACK SET 01-12, ACL TOP
ACL TOP DILUENT RACK SET DA-DC
RACK SET REAGENT, RA-RF ACL TOP
HEMOSIL RINSE SOLUTION, 4 LITER
ADAPTER FOR 4 ML VIAL ACL TOP
ADAPTER 10 ML VIAL, ACL TOP
TOOL, SYRINGE TIP INSTALLATION, ACL FUTURA/ADVANCE
ASSY, PUMP/PROBE TUBE
CABLE ASSY CAT5E CROSSOVER
FUSE 5A 250V 682
FUSE 1.25A 250V 5x20MM TLAG
CORD, POWER 115VAC, 15A SHIELDED
VDE APPROVED LINE CORD 220V
CUVETTE WASTE LINER 10 PK, ACL TOP
BARCODE SHEET, SOLUTIONS ACL TOP
ASSY WASTE BOTTLE PRESENCE SENSOR
BOTTLE, WASTE 10L, ACL FUTURA
FUSE 10A 250V 5x20MM TLAG
VIAL GLASS 8-PK 20ML
START-UP, ALIQUOT SET
CONTAINER, 10L WASTE BOTTLE
KIT SOFTWARE ACL V2.1/P4.6 INSTALL
DILUENT, FACTOR, 1X100ML
TRAY 6 SAMPLE RACKS ACL TOP 1 PCS
ADAPTER, DILUENT, 4ML, ACL-TOP
ADAPTER, DILUENT, 10ML, ACL-TOP
ADAPTER, DILUENT, 20ML, ACL-TOP
ACL-TOP Service Manual
Quantity
1
1
1
1
1
0.25
1
5
5
5
5
1
3
6
1
1
1
1
1
1
1
12
12
1
3
1
5
5
3
3
1
1
1
1
5
1
1
1
1
1
1
6
6
6
Chapter 2 – Pre-Installation and Installation
28760500
29411100
28470400
28001500
28210900
29242300
28119500
28623520
Component
5575100
9746606
28713400
28713200
18902000
9831704
9832700
14871705
14871713
14871708
14871711
29400100
28739800
28911600
18924100
18924104
19006300
29400501
29400711
29400601
20009700
28520500
28520900
18794300
27764900
14871709
14871702
27540300
19725500
29401100
28525200
28771800
18901300
14871712
19085463
28525100
28766600
9757600
TUBE, WASTE PUMP ASSY, WASTE
CUSTOMER NOTICE WASTE CONT DECONTAMINATE
L-KEY WRENCH SET, METRIC 1.5MM TO 5.0MM
DOC., ACL TOP PHASE 1 VALUE ASSIGNMANT
KIT, 2D BARCODE ACL TOP
KIT, ACL TOP LANGUAGE TRANSLATION
SPEC. PRECISION PERFORMANCE REQUIREMENT ACL TOP
KIT START-UP,ACL TOP CTS
Description
CUP SAMPLE 2 ML, 1000/PK
MAGNETIC, STIR BARS, ACL 6/PK
ASSY, 4L RINSE, ASPIRATOR, ACL TOP
ASSY, CLEAN ASPIRATOR, ACL TOP
BOTTLE, PLASTIC 30ML W/ CAP, FUTURA/ADVANCE
CLEANING AGENT, ACL, 4X500 ML
Critical Care/HemosIL CLEANING AGENT80ML
FUSE, 2.0AMP 250 VOLT, 682
FUSE 12.5A 250V 5x20MM TLAG
FUSE 4A 250V 5x20MM TLAG
FUSE 8A 250V 5x20MM TLAG
CUVETTES, ACL TOP, 6X100X4
SYRINGE, 250UL FOR XP3000 PUMP
SEAL (TIP), 250 UL SYRINGE
BOTTLE, GLASS, 10/PK, ACL FUTURA/ADVANCE
BOTTLE KIT, 10X4 ML
TOOL, STYLET, ACL FUTURA/ADVANCE
SAMPLE RACK SET 01-12, ACL TOP
ACL TOP DILUENT RACK SET DA-DC
RACK SET REAGENT, RA-RF ACL TOP
HEMOSIL RINSE SOLUTION, 4 LITER
ADAPTER FOR 4 ML VIAL ACL TOP
ADAPTER 10 ML VIAL, ACL TOP
TOOL, SYRINGE TIP INSTALLATION,FUTURA /ADVANCE
CABLE ASSY CAT5E CROSSOVER
FUSE 5A 250V 682
FUSE 1.25A 250V 5x20MM TLAG
CORD, POWER 115VAC, 15A SHIELDED
VDE APPROVED LINE CORD 220V
CUVETTE WASTE LINER 10 PK, ACL TOP
BARCODE SHEET, SOLUTIONS ACL TOP
ASSY WASTE BOTTLE PRESENCE SENSOR
BOTTLE, WASTE 10L, ACL FUTURA
FUSE 10A 250V 5x20MM TLAG
VIAL GLASS 8-PK 20ML
START-UP, ALIQUOT SET
CONTAINER, 10L WASTE BOTTLE
DILUENT, FACTOR, 1X100ML
2 - 19
3
1
1
1
1
1
1
Quantity
1
1
1
1
1
0.25
1
5
5
5
5
1
3
6
1
1
1
1
1
1
1
12
12
1
1
5
5
3
3
1
1
1
1
5
1
1
1
1
ACL-TOP Service Manual
2 - 20 Chapter 2 – Pre-Installation and Installation
28780200
28526000
28526100
28526200
28760500
28366800
28666400
28660102
28470400
29315200
29400901
28386300
28529400
28210900
29411100
29240920
TRAY 6 SAMPLE RACKS ACL TOP 1 PCS
ADAPTER, DILUENT, 4ML, ACL-TOP
ADAPTER, DILUENT, 10ML, ACL-TOP
ADAPTER, DILUENT, 20ML, ACL-TOP
TUBE, WASTE PUMP ASSY, WASTE
FILTER, MOLDED
PIERCER PROBE, CTS
CRU, SAMPLE PROBE N SEAL
L-KEY WRENCH SET, METRIC 1.5MM TO 5.0MM
TUBE ASSY, PRECISION, UNIV.
SAMPLE RACK SET 01-12, ACL CTS
ASSY, FILTER CHANGER, CTS
ASSY, CTS TUBE ADAPTER
KIT, 2D BARCODE ACL TOP
CUSTOMER NOTICE WASTE CONTAINER DECONTAMINATION
KIT, ACL TOP V2.5.5 MAIN SYSTEM SOFTWARE INSTALLATION
ACL-TOP Service Manual
1
6
6
6
3
12
1
1
1
3
1
1
1
1
1
1
Chapter 3 – Troubleshooting
3-1
Chapter 3 –
Troubleshooting
3-1 Overview
The troubleshooting chapter provides information on troubleshooting resources the ACL TOP software provides 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 operator 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 perform 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 open
that 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:
ACL-TOP Service Manual
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.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3-3
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".
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3-4
Figure 3-2 The Maintenance Screen
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3-5
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".
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3-6
Figure 3-4 General Log List
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3-7
Double clicking on an error brings up the General Log Detail pop up screen. This pop up screen contains tabs with detailed descriptions, causes, and operator actions
to correct the error as well as a tab for the end user to leave comments. See Figure 3-5 "General Log Entry Details".
Note: On occasion, additional information on a particular error is requested. In that event the Error code, File name and Line Number should be sent to the Software
Department of Instrumentation Laboratory per normal procedures.
Figure 3-5 General Log Entry Details
ACL-TOP Service Manual
3 - 8 Chapter 3 – Troubleshooting
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
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3-9
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
ACL-TOP Service Manual
3 - 10 Chapter 3 – Troubleshooting
SW Version Tab
The SW Version tab lists all of the software versions in the TOP (see Figure 3-8 "SW Versions on Instrument Status."). This tab can be printed.
Figure 3-8 SW Versions on Instrument Status.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3 - 11
Statistics
Selecting Statistics from the pull down brings up another two tab screen Status and Alarms.(see Figure 39 "Statistics").
Figure 3-9 Statistics
ACL-TOP Service Manual
3 - 12 Chapter 3 – Troubleshooting
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
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
3 - 13
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.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
DB down
Alarm Description
Code
The database service
is down and it is not
accessible.
0
Message
Cause
An unrecoverable
data base exception has occurred.
The database service got disconnected.
Analyzer / Control
Module loss of
communication.
Communication
cable disconnection. Software or
electronic failure.
AM-CM
Communication
Error
A non-recoverable
error occurred in the
CM/AM Communications Manager (e.g.
loss of connection).
Program
Integrity
(Failure):
master
Failure of LRC or CRC
check.
0005 Master controller
failure.
Master controller
board malfunction.
(Processor) Initialization
(Failure):
Sample
Arm
(Processor) Initialization
(Failure):
Intermediate
Reagent
Arm
One of the AM processors failed to initialize,
due to an Invalid Controller ID.
0008 Sample Arm controller initialization
failure.
Sample Arm controller board did not
pass initialization
tests.
One of the AM processors failed to initialize,
due to an Invalid Controller ID.
0009 Intermediate
Reagent Arm controller initialization
failure.
Intermediate
Reagent Arm controller board did not
pass initialization
tests.
3 - 14
System
Service
Response
Manual
Section
Processor/ Perform an
Start SQL service. 1) Start SQL Server,
Software emergency stop
Start CM applica- 2) Restart CM
and shutdown
tion.
the application.
Check communica- Check cross over cable, Processor/ - Notify the
bulk head connector,
Software alarm via the UI
tion cable.
and Level II CPU PCB.
- Perform an
Power off and
emergency stop
restart the instrument.
If the problem persists, call Service.
Check level II CPU, PC Processor/ - Notify the
Power off and
Software alarm via the UI
restart the instru- 104 and all computor
housing connections.
- Perform an
ment.
emergency stop
If the problem persists, call Service.
Power off and
This is a software defect. Processor/ - Notify the
restart the instru- Please obtain the log
Software alarm via the UI
(if possible)
files / backups and subment.
- Do not go to
If the problem per- mit a complaint into the
READY state
sists, call Service. complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Power off and
Software alarm via the UI
restart the instru- Please obtain the log
(if possible)
files / backups and subment.
- Do not go to
If the problem per- mit a complaint into the
READY state
sists, call Service. complaint system for
immediate attention.
Operator Action
Where
raised
Service Action
CM
AM Master
CM
AM Master
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
(Processor) Initialization
(Failure):
Start
Reagent
Arm
(Processor) Initialization
(Failure):
cuvette
Alarm Description
One of the AM processors failed to initialize,
due to an Invalid Controller ID.
One of the AM processors failed to initialize,
due to an Invalid Controller ID.
(Processor) Initialization
(Failure):
rack
One of the AM processors failed to initialize,
due to an Invalid Controller ID.
(Processor) Initialization
(Failure):
ORU
One of the AM processors failed to initialize,
due to an Invalid Controller ID.
Invalid
Invalid parameter proParamevided in a function call,
ter: master message queue or
inter-task communication mechanism.
3 - 15
System
Where
Service
Response
raised
Manual
Section
AM ConThis is a software defect. Processor/ - Notify the
0010 Start Reagent Arm Start Reagent Arm Power off and
Software alarm via the UI trollers
controller initializa- controller board did restart the instru- Please obtain the log
(if possible)
files / backups and subnot pass initializa- ment.
tion failure.
- Do not go to
If the problem per- mit a complaint into the
tion tests.
READY state
sists, call Service. complaint system for
immediate attention.
Code
Message
Cause
Operator Action
Service Action
This is a software defect.
Please obtain the log
files / backups and submit a complaint into the
complaint system for
immediate attention.
This is a software defect.
0012 Racks controller ini- Racks controller
Power off and
tialization failure.
board did not pass restart the instru- Please obtain the log
files / backups and subinitialization tests. ment.
If the problem per- mit a complaint into the
sists, call Service. complaint system for
immediate attention.
This is a software defect.
Power off and
0013 Optical Reading
Optical Reading
restart the instru- Please obtain the log
Units controller ini- Units controller
files / backups and subtialization failure.
board did not pass ment.
initialization tests. If the problem per- mit a complaint into the
sists, call Service. complaint system for
immediate attention.
This is a software defect.
Power off and
0015 Master Controller Built-in checks in
restart the instru- Please obtain the log
software error.
the software
files / backups and subdetected an unre- ment.
If the problem per- mit a complaint into the
coverable error.
sists, call Service. complaint system for
immediate attention.
0011 Cuvettes controller Cuvettes controller Power off and
initialization failure. board did not pass restart the instruinitialization tests. ment.
If the problem persists, call Service.
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
(if possible)
- Do not go to
READY state
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
(if possible)
- Do not go to
READY state
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
(if possible)
- Do not go to
READY state
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
Invalid parameter pro- 0016 Cuvettes ControlInvalid
ler software error.
vided in a function call,
Parameter: cuvette message queue or
inter-task communication mechanism.
Cause
Operator Action
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
Parameter: rack
Invalid parameter provided in a function call,
message queue or
inter-task communication mechanism.
0017 Racks Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
Parameter: ORU
Invalid parameter provided in a function call,
message queue or
inter-task communication mechanism.
0018 Optical Reading
Units Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
Parameter: Sample
Arm
Invalid parameter provided in a function call,
message queue or
inter-task communication mechanism.
0019 Sample Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
CTRL
Comm
Error
0020 Analyzer internal
A non-recoverable
communication
error occurred in the
error.
Controller Communications Manager or the
low level CAN bus
driver (master or controller side).
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
3 - 16
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Processor/ - Notify the
Check Level II CPU,
Software alarm via the UI
PC104, ALL controller
- Perform an
PCBs and all software
emergency stop
revisions.
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Invalid
Parameter: Intermediate
Reagent
Arm
Invalid
Parameter: Start
Reagent
Arm
Alarm Description
Code
Message
Cause
Operator Action
Invalid parameter provided in a function call,
message queue or
inter-task communication mechanism.
0021 Intermediate
Reagent Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid parameter provided in a function call,
message queue or
inter-task communication mechanism.
0022 Start Reagent Arm Built-in checks in
Controller software the software
detected an unreerror.
coverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Memory allocation
failed or stack usage
exceeds limit.
0025 Master Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
OS (Fail- Error detected when
ure): mas- calling kernel facilities.
ter
0030 Master Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Error detected when
calling kernel facilities.
0031 Cuvettes Controller software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Memory
Allocation
(Failure):
master
OS (Failure):
cuvette
3 - 17
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
OS (Failure): rack
Alarm Description
Code
Message
Cause
Operator Action
Error detected when
calling kernel facilities.
0032 Racks Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
OS (Fail- Error detected when
ure): ORU calling kernel facilities.
0033 Optical Reading
Units Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Software
Logic (Failure): master
Software logic error
such as an invalid path
in a switch statement
or if else branch.
0035 Master Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Software
Logic (Failure):
cuvette
Software logic error
such as an invalid path
in a switch statement
or if else branch.
0036 Cuvettes Controller software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
0037 Racks Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Software Software logic error
Logic (Fail- such as an invalid path
ure): rack in a switch statement
or if else branch.
3 - 18
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
0038 Optical Reading
Software Software logic error
Units Controller
Logic (Fail- such as an invalid path
software error.
ure): ORU in a switch statement
or if else branch.
Cause
Operator Action
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid state for an
Invalid
State: mas- event, function call,
message, etc.
ter
0040 Master Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid state for an
event, function call,
message, etc.
0041 Cuvettes Controller software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
Invalid state for an
State: rack event, function call,
message, etc.
0042 Racks Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
Invalid state for an
State: ORU event, function call,
message, etc.
0043 Optical Reading
Units Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
State:
cuvette
3 - 19
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
0045 Master Controller
Stack Low: It was detected that
software error.
master
there is a potential for a
stack problem.
Cause
Operator Action
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Stack Low: It was detected that
cuvette
there is a potential for a
stack problem.
0046 Cuvettes Controller software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Stack Low: It was detected that
rack
there is a potential for a
stack problem.
0047 Racks Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Stack Low: It was detected that
ORU
there is a potential for a
stack problem.
0048 Optical Reading
Units Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
0050 Master Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Unknown
Command:
master
The command
received is not supported.
3 - 20
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Please obtain the log
Software alarm via the UI
files / backups and sub- Perform an
mit a complaint into the
emergency stop
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Where
raised
Service Action
AM Controllers
AM Controllers
AM Controllers
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Unknown
Command:
cuvette
Alarm Description
Code
Message
Cause
Operator Action
0051 Cuvettes Controller software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Unknown The command
received is not supCommand: rack ported.
0052 Racks Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
The command
received is not supported.
0053 Optical Reading
Units Controller
software error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
0056 Interrupted communication between
the Analyzer and
the Control Module.
Communication
cable disconnected. Analyzer
powered off. Other
hardware/software
communication
problems.
Check communication cable connection. Verify that the
Analyzer is powered on. Restart the
system (both Analyzer and Control
Module); if the
problem persist call
Service.
Unknown
Command:
ORU
The command
received is not supported.
AM DisThe CM has lost the
connection connection with the AM
module.
3 - 21
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Processor/ - Notify the user
Check Level II CPU,
Software as appropriate.
cross over cable, CM
- The AM on its
and connections.
side performs
an emergency
stop
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
CM
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Controller
Upgrade
Failed
Alarm Description
Controller Upgrade has
failed since downloaded SW version
does not match SW
version actually used.
OS (Fail- Error detected when
ure): Sam- calling kernel facilities.
ple Arm
OS (Fail- Error detected when
ure): Inter- calling kernel facilities.
mediate
Reagent
Arm
Code
Message
0058 Downloaded controller Software version (<Downloaded
File Name>) is different than Software version
actually used by
AM (<Used File
Name>).
0061 Sample Arm Controller software
error.
0062 Intermediate
Reagent Arm Controller software
error.
Cause
Operator Action
Controller Upgrade Call Service.
has failed.
Built-in checks in
the software
detected an unrecoverable error.
Built-in checks in
the software
detected an unrecoverable error.
OS (Failure): Start
Reagent
Arm
Error detected when
calling kernel facilities.
0063 Start Reagent Arm Built-in checks in
Controller software the software
detected an unreerror.
coverable error.
Software
Logic (Failure): Sample Arm
Software logic error
such as an invalid path
in a switch statement
or if else branch.
0066 Sample Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
System
Where
Service
Response
raised
Manual
Section
CM
Verify software versions Processor/ - Notify user
and controller card flash Software through alarms
area.
version. Controller flash
version may not be compatible.
Service Action
This is a software defect.
Please obtain the log
files / backups and submit a complaint into the
complaint system for
immediate attention.
This is a software defect.
Power off and
restart the instru- Please obtain the log
files / backups and subment.
If the problem per- mit a complaint into the
sists, call Service. complaint system for
immediate attention.
Power off and
This is a software defect.
restart the instru- Please obtain the log
ment.
files / backups and subIf the problem per- mit a complaint into the
sists, call Service. complaint system for
immediate attention.
This is a software defect.
Power off and
restart the instru- Please obtain the log
files / backups and subment.
If the problem per- mit a complaint into the
sists, call Service. complaint system for
immediate attention.
Power off and
restart the instrument.
If the problem persists, call Service.
3 - 22
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
AM Master
AM Controllers
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
AM Master
AM Controllers
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
AM Master
AM Controllers
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Software
Logic (Failure): Intermediate
Reagent
Arm
Software
Logic (Failure): Start
Reagent
Arm
Alarm Description
Code
Message
Cause
Operator Action
Software logic error
such as an invalid path
in a switch statement
or if else branch.
0067 Intermediate
Reagent Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Software logic error
such as an invalid path
in a switch statement
or if else branch.
0068 Start Reagent Arm Built-in checks in
Controller software the software
detected an unreerror.
coverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
State:
Sample
Arm
Invalid state for an
event, function call,
message, etc.
0071 Sample Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid
State:
Intermediate
Reagent
Arm
Invalid
State: Start
Reagent
Arm
Invalid state for an
event, function call,
message, etc.
0072 Intermediate
Reagent Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Invalid state for an
event, function call,
message, etc.
0073 Start Reagent Arm Built-in checks in
Controller software the software
detected an unreerror.
coverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
3 - 23
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
0076 Sample Arm ConStack Low: It was detected that
troller software
there is a potential for a
Sample
error.
stack problem.
Arm
Cause
Operator Action
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Stack Low: It was detected that
Intermedi- there is a potential for a
stack problem.
ate
Reagent
Arm
0077 Intermediate
Reagent Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Stack Low: It was detected that
there is a potential for a
Start
stack problem.
Reagent
Arm
0078 Start Reagent Arm Built-in checks in
Controller software the software
detected an unreerror.
coverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
0081 Sample Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
0082 Intermediate
Reagent Arm Controller software
error.
Built-in checks in
the software
detected an unrecoverable error.
Power off and
restart the instrument.
If the problem persists, call Service.
Unknown
Command:
Sample
Arm
The command
received is not supported.
Unknown The command
received is not supComported.
mand:
Intermediate
Reagent
Arm
3 - 24
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
This is a software defect. Processor/ - Notify the
Software alarm via the UI
Please obtain the log
- Perform an
files / backups and subemergency stop
mit a complaint into the
complaint system for
immediate attention.
Where
raised
Service Action
AM Controllers
AM Controllers
AM Controllers
AM Master
AM Controllers
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Unknown
Command:
Start
Reagent
Arm
Arm
(Device
Fault) ERR 1
Alarm Description
Code
Message
The command
received is not supported.
0083 Start Reagent Arm
Controller software
error.
The CAVRO arm is
inoperable
1001 <Arm> Arm failure.
Arm
(Device
Fault) ERR 2
The CAVRO arm is
inoperable
1002 <Arm> Arm failure.
Arm
(Device
Fault) ERR 3
The CAVRO arm is
inoperable
1003 <Arm> Arm failure.
3 - 25
System
Service
Response
Manual
Section
This is a software defect. Processor/ - Notify the
Power off and
Built-in checks in
Software alarm via the UI
restart the instru- Please obtain the log
the software
- Perform an
files / backups and subdetected an unre- ment.
emergency stop
If the problem per- mit a complaint into the
coverable error.
sists, call Service. complaint system for
immediate attention.
- Notify the
Check all cabling in the Robotic
The system perSoftware or
alarm via the UI
Cavro System, CCU 900 XYZ
mechanical error. formed an Emer- Perform an
and all sensors.
Initialization error. gency stop:
emergency stop
perform a Recovery.
If the problem persists call Service.
Check all cabling in the Robotic
- Notify the
Software or
The system perCavro System, CCU
XYZ
alarm via the UI
mechanical error. formed an Emer9000 and all sensors
- Perform an
Invalid Command. gency stop:
emergency stop
perform a Recovery.
If the problem persists call Service.
Suspect CCU 9000.
Robotic
- Notify the
Software or
The system perXYZ
mechanical error. formed an Emeralarm via the UI
Invalid Operand.
gency stop:
- Perform an
perform a Recovemergency stop
ery.
If the problem persists call Service.
Cause
Operator Action
Where
raised
Service Action
AM Master
AM Controllers
AM Master
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm
(Device
Fault) ERR 4
Alarm Description
The CAVRO arm is
inoperable
Code
Message
Cause
1004 <Arm> Arm failure. Software or
mechanical error.
Invalid command
sequence.
Arm
(Device
Fault) ERR 5
The CAVRO arm is
inoperable
1005
<Arm> Arm failure. Software or
mechanical error.
Device not implemented.
Arm
(Device
Fault) ERR 6
The CAVRO arm is
inoperable
1006
<Arm> Arm failure. Software or
mechanical error.
Timeout error.
Arm
(Device
Fault) ERR 7
The CAVRO arm is
inoperable
1007
<Arm> Arm failure. Software or
mechanical error.
Device not initialized.
Operator Action
Service Action
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
Suspect CCU 9000.
Service
Manual
Section
Robotic
XYZ
3 - 26
System
Response
Where
raised
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Check for loose connec- Robotic
tions at the cables and XYZ
sensors. A malfunctioning syringe module may
also cause this error.
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Inspect the CCU 9000
PCB and cabling to it.
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Suspect CCU 9000.
Robotic
XYZ
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm
(Device
Fault) ERR 8
Alarm Description
Code
The CAVRO arm is
inoperable
1008
Arm
(Device
Fault) ERR 9
The CAVRO arm is
inoperable
1009
Arm
(Device
Fault) ERR 10
The CAVRO arm is
inoperable
1010
Arm
(Device
Fault) ERR 11
The CAVRO arm is
inoperable
1011
Message
Cause
Operator Action
Service Action
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerNo liquid detected gency stop:
with ZX command. perform a Recovery.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerEntered move for gency stop:
Z-axis out of range. perform a Recovery.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerNot enough liquid gency stop:
perform a Recovdetected with ZX
ery.
command.
If the problem persists call Service.
Suspect CCU 9000.
<Arm> Arm failure. Software or
mechanical error.
Command overflow.
Service
Manual
Section
Robotic
XYZ
3 - 27
System
Response
Where
raised
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Error may be caused by Robotic
CCU 900 or more likely XYZ
the DRI PCB.
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Suspect CCU 9000.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Error may be caused by Robotic
CCU 900 or, more likely, XYZ
the DRI PCB.
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm
(Device
Fault) ERR 12
Alarm Description
Code
The CAVRO arm is
inoperable
1012
Arm
(Device
Fault) ERR 13
The CAVRO arm is
inoperable
1013
Arm
(Device
Fault) ERR 17
The CAVRO arm is
inoperable
1017
Arm
(Device
Fault) ERR 20
The CAVRO arm is
inoperable
1020
Message
Cause
Operator Action
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerNot enough liquid gency stop:
perform a Recovdetected with ZZ
ery.
command.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an Emergency stop:
Arm collision
perform a Recovavoided.
ery.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerStep loss on X axis. gency stop:
perform a Recovery.
If the problem persists call Service.
<Arm> Arm failure. Software or
mechanical error.
No liquid detected
with ZZ command.
Service Action
Service
Manual
Section
Error may be caused by Robotic
CCU 900 or, more likely, XYZ
the DRI PCB.
3 - 28
System
Response
Where
raised
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Error may be caused by Robotic
CCU 900 or, more likely, XYZ
the DRI PCB.
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Check Arm Sensors.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Check for binding and
obstructions.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm
(Device
Fault) ERR 21
Alarm Description
Code
The CAVRO arm is
inoperable
1021
Arm
(Device
Fault) ERR 22
The CAVRO arm is
inoperable
1022
Arm
(Device
Fault) ERR 23
The CAVRO arm is
inoperable
1023
Arm
(Device
Fault) ERR 24
The CAVRO arm is
inoperable
1024
Message
Cause
Operator Action
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerStep loss on Y axis. gency stop:
perform a Recovery.
If the problem persists call Service.
<Arm> Arm failure. Software or
The system permechanical error. formed an EmerStep loss on Z axis. gency stop:
perform a Recovery.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerStep loss detected gency stop:
on X-axis of oppos- perform a Recovery.
ing arm.
If the problem persists call Service.
The system per<Arm> Arm failure. Software or
mechanical error. formed an EmerALDIUM pulse time gency stop:
perform a Recovout.
ery.
If the problem persists call Service.
Service Action
3 - 29
System
Response
Where
raised
Check for binding and
obstructions.
Service
Manual
Section
Robotic
XYZ
Check for binding and
obstructions.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Check for binding and
obstructions.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Suspect the aldium or
DRI PCB.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm
(Device
Fault) ERR 25
Alarm Description
Code
Message
Cause
The CAVRO arm is
inoperable
1025
<Arm> Arm failure. Software or
mechanical error.
Tip not fetched.
Arm
(Device
Fault) ERR 26
The CAVRO arm is
inoperable
1026
<Arm> Arm failure. Software or
mechanical error.
Tip crash.
Arm
(Device
Fault) ERR 27
The CAVRO arm is
inoperable
1027
<Arm> Arm failure. Software or
mechanical error.
Tip not clean.
Arm
(Device
Fault) ERR
UNDEF
The CAVRO arm is
inoperable
1028
<Arm> Arm failure. Software or
mechanical error.
Undefined error
code reported.
Operator Action
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
Service Action
3 - 30
System
Response
Where
raised
Clean probe and check
all LLD connections.
Service
Manual
Section
Robotic
XYZ
Clean probe and check
all LLD connections.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Clean probe and check
all LLD connections.
Robotic
XYZ
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
Check all cabling in the Robotic
Cavro System, CCU 900 XYZ
and all sensors.
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
The CAVRO arm is
Arm
inoperable
(Device
Fault) TIME OUT
Code
Message
Cause
1029
<Arm> Arm failure. Software or
mechanical error.
Communication
timeout.
Syringe
Pump
(Fault) ERR 1
The pump used to
aspirate/dispense fluids is inoperable.
1031
<Syringe> Syringe Software or
failure.
mechanical error.
Initialization error.
Syringe
Pump
(Fault) ERR 2
The pump used to
aspirate/dispense fluids is inoperable.
1032
<Syringe> Syringe Software or
failure.
mechanical error.
Invalid command.
Operator Action
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Robotic
Check for loose cable
and sensor connections. XYZ
A malfunctioning sryinge
module may also cause
this error.
Initialization error. This
error occurs when the
pump fails to initialize.
Check for blockages and
loose connections
before attempting to
reinitialize. The pump
will not accept commands until it has been
successfully initialized.
This error can only be
cleared by successfully
initializing the probe.
Invalid command. This
error occurs when an
unrecognized command
is issued.
Either Software defect or
communication error.
3 - 31
System
Response
Where
raised
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
AM MasFluid
- Notify the
Movement alarm via the UI ter
- Perform an
emergency stop
AM MasFluid
- Notify the
Movement alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Syringe
Pump
(Fault) ERR 3
Syringe
Pump
(Fault) ERR 4
Alarm Description
Code
Message
Cause
The pump used to
aspirate/dispense fluids is inoperable.
1033
<Syringe> Syringe Software or
failure.
mechanical error.
Invalid operand.
The pump used to
aspirate/dispense fluids is inoperable.
1034
<Syringe> Syringe Software or
failure.
mechanical error.
Invalid command
sequence.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
3 - 32
System
Service
Response
Manual
Section
Fluid
- Notify the
Invalid operand. This
Movement alarm via the UI
error occurs when an
- Perform an
invalid parameter (<n>)
emergency stop
is given with a command.
Either Software defect or
communication error.
Fluid
- Notify the
Invalid command
Movement alarm via the UI
sequence. This error
- Perform an
occurs when the comemergency stop
mand structure or communication protocol is
incorrect.
Either Software defect or
communication error.
Where
raised
Service Action
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Syringe
Pump
(Fault) ERR 5
Syringe
Pump
(Fault) ERR 6
Alarm Description
Code
Message
Cause
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Fluid Detection Error. 1035
This error occurs when
the sensor board
detects fluid, which is
caused by leaking out
the back of the valve.
<Syringe> Syringe The sensor board
failure.
detects fluid, which
is caused by leaking out the back of
the valve.
EEPROM Failure. This 1036
error occurs when the
EEPROM is faulty.
<Syringe> Syringe EEPROM is faulty. The system perfailure.
formed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
3 - 33
System
Service
Response
Manual
Section
Fluid
- Notify the
Fluid detection. This
Movement alarm via the UI
error occurs when the
- Perform an
sensor board detects
emergency stop
fluid, which is caused by
fluid leaking out of the
back of the valve.
To clear the error:
1. Power off the pump
2. Remove the valve
3. Wipe up any detectable fluid on sensor
board using a cotton
swab. You can insert the
swab through the valve
opening on the front
panel, and gently wipe
the circuit.
4. Assuming the valve is
leaking fluid, put a new
valve on the pump.
5. Reinitialize the pump
- Notify the
EEPROM Failure. This Fluid
Movement alarm via the UI
error occurs when the
- Perform an
EEPROM is faulty.
emergency stop
Where
raised
Service Action
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Syringe
Pump
(Fault) ERR 7
Alarm Description
Code
Message
Cause
Operator Action
The pump used to
aspirate/dispense fluids is inoperable.
1037
<Syringe> Syringe Software or
failure.
mechanical error.
Device not initialized.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The pump used to
aspirate/dispense fluids is inoperable.
1039
<Syringe> Syringe Software or
failure.
mechanical error.
Undefined error
code reported.
The pump used to
Syringe
aspirate/dispense fluPump
ids is inoperable.
(Fault) TIME OUT
1040
<Syringe> Syringe Software or
failure.
mechanical error.
Communication
timeout.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
ORU Disabled Cause 2
1042
The Optical Read- The ORU has been Call Service.
ing Unit <ORU ID> disabled. Air readhas been disabled. ing out of range
(low).
Syringe
Pump
(Fault) ERR
UNDEFINED
The ORU Head has
been disabled due to
low air limit.
3 - 34
System
Service
Response
Manual
Section
Fluid
- Notify the
Device not initialized.
This error occurs when Movement alarm via the UI
- Perform an
the pump is not initialemergency stop
ized or when a command
is sent to the syringe
when the syringe is in
error status.
To clear the error, reinitialize the syringe.
- Notify the
Unrecognized error code Fluid
has been reported by the Movement alarm via the UI
- Perform an
syringe.
emergency stop
The cause can be a
communication error, a
problem in the syringe or
a defect in software.
- Notify the
Communication timeout Fluid
Movement alarm via the UI
expired.
- Perform an
This failure can be
emergency stop
caused by:
1. a previous error condition
2. a communication failure between master
board and cavro module
3. A defect in the syringe
that slows down the
syringe operations
See code 1295
Reaction - Notify the
Detection alarm via the UI.
Where
raised
Service Action
AM Master
AM Master
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Alarm/
Error
Name
ORU Disabled Cause 3
The ORU Head has
been disabled due to
due to a high air limit.
1043
ORU Disabled Cause 4
The ORU Head has
been disabled due to
air drift low limit.
1044
ORU Disabled Cause 5
The ORU Head has
been disabled due to
air drift high limit.
1045
ORU Disabled Cause 6
1046
The ORU Head has
been disabled due to
an ORU voltage problem.
Plunger Overload. This 1047
error occurs when
movement of the
syringe plunger is
blocked by excessive
pressure.
Syringe
Pump
(Fault) ERR 9
Message
Cause
The Optical Read- The ORU has been
ing Unit <ORU ID> disabled. Air readhas been disabled. ing out of range
(high).
The Optical Read- The ORU has been
ing Unit <ORU ID> disabled. Air readhas been disabled. ing drift (low)
detected.
The Optical Read- The ORU has been
ing Unit <ORU ID> disabled. Air readhas been disabled. ing drift (high)
detected.
The Optical Read- The ORU has been
ing Unit <ORU ID> disabled. Detector
has been disabled. voltage error
detected.
<Syringe> Syringe Movement of the
failure.
syringe plunger
was blocked by
excessive pressure.
Operator Action
Service Action
3 - 35
System
Response
Where
raised
Service
Manual
Section
Reaction
Detection
- Notify the
AM Masalarm via the UI. ter
Call Service.
See code 1295
Call Service.
See code 1295
Reaction
Detection
- Notify the
AM Masalarm via the UI. ter
Call Service.
See code 1295
Reaction
Detection
- Notify the
AM Masalarm via the UI. ter
Call Service.
Check power cables,
fuses, and power supply.
If power looks correct,
replace ORU module.
Plunger overload. THis
error occurs when movement of the syringe
plunger is blocked by
excessive back pressure. The pump must be
reinitialized before normal operation can
resume.
Reaction
Detection
- Notify the
AM Masalarm via the UI. ter
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
AM MasFluid
- Notify the
Movement alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Syringe
Pump
(Fault) ERR 10
Alarm Description
Code
Valve Overload. This 1048
error occurs when the
valve drive loses steps
by blockage or excess
back pressure. Continual valve overload
errors are an indication
the valve should be
replaced.
Message
Cause
Operator Action
Service Action
<Syringe> Syringe Valve drive loses
failure.
steps by blockage
or excess back
pressure.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Valve Overload. This
error occurs when the
valve drive loses steps
by blockage or excess
back pressure. The
valve must be reinitialized before normal operation can resume.
Continual valve overload
errors are an indication
the valve should be
replaced.
Plunger Move Not
Allowed. When the valve
is in bypass or throughput position plunger
movement commands
are not allowed.
This error can be caused
by a previous error condition of by a defect in
software.
Command Overflow.
This error occurs when
the command buffer contains too many characters.
This error can be caused
by a previous error condition, a defect in software or communication
error.
Syringe
Pump
(Fault) ERR 11
Plunger Move Not
Allowed. When the
valve is in bypass or
throughput position
plunger movement
commands are not
allowed.
1049
<Syringe> Syringe Plunger Move Not
failure.
Allowed. When the
valve is in bypass
or throughput position plunger movement commands
are not allowed.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Syringe
Pump
(Fault) ERR 15
Command Overflow. 1050
This error occurs when
the command buffer
contains too many
characters.
<Syringe> Syringe Command Overfailure.
flow. This error
occurs when the
command buffer
contains too many
characters.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
3 - 36
System
Service
Response
Manual
Section
Fluid
- Notify the
Movement alarm via the UI
- Perform an
emergency stop
Where
raised
AM Master
AM MasFluid
- Notify the
Movement alarm via the UI ter
- Perform an
emergency stop
AM MasFluid
- Notify the
Movement alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
CAVRO
Comm
Error
1105
RS232 communications error with CAVRO
arms
Arm communication error.
Incubator
Temperature Error
(Incubator
#1)
Incubator temperature 1110
defined to be out of
range for a period
exceeding the fatal
error limits.
Cuvettes incubator Temperature out of Call Service.
No. 1 temperature range in cuvette
incubator.
control failure.
Software or Hardware failure.
Call Service.
3 - 37
System
Service
Response
Manual
Section
If consistent, then check Processor/ - Notify the
both cabling and power Software alarm via the UI
- Execute an
to the CAVRO control
emergency stop
unit board. If the problem
is intermittent, then
report a complaint to
record the incidence as
this is a documented
CAVRO problem.
- Notify the
The heating wire could Thermal
alarm via the UI
be broken, the thermistor Control
- Turn off power
could be shorted, or the
to affected
module could require
heater.
calibration. To help trou- Perform Conbleshoot, use Diagnostrolled Stop
tics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
Where
raised
Service Action
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Incubator
Temperature Error
(Incubator
#2)
Alarm Description
Code
Incubator temperature 1111
defined to be out of
range for a period
exceeding the fatal
error limits.
Message
Cause
Operator Action
Cuvettes incubator Temperature out of Call Service.
No. 2 temperature range in cuvette
incubator.
control failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 38
System
Response
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform Controlled Stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
ORU Temperature
Error (ORU
#1)
Alarm Description
ORU temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
Code
1115
Message
Cause
Operator Action
Optical reading unit Temperature out of Call Service.
No. 1 temperature range in optical
reading unit.
control failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 39
System
Response
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform Controlled Stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
ORU Temperature
Error (ORU
#2)
Alarm Description
ORU temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
Code
1116
Message
Cause
Operator Action
Optical reading unit Temperature out of Call Service.
No. 2 temperature range in optical
reading unit.
control failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 40
System
Response
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform Controlled Stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
ORU Temperature
Error (ORU
#3)
Alarm Description
ORU temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
Code
1117
Message
Cause
Operator Action
Optical reading unit Temperature out of Call Service.
No. 3 temperature range in optical
reading unit.
control failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 41
System
Response
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform Controlled Stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
ORU Temperature
Error (ORU
#4)
Alarm Description
ORU temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
Code
1118
Message
Cause
Operator Action
Optical reading unit Temperature out of Call Service.
No. 4 temperature range in optical
reading unit.
control failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 42
System
Response
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform Controlled Stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Alarm/
Error
Name
Cuvette shuttle
Cuvette Shuttle tem- 1120 Cuvette shuttle
Cuvette
temperature control temperature out of
perature defined to be
Shuttle
range.
failure.
Temp Error out of range for a
period exceeding the
fatal error limits.
Operator Action
The system performed a controlled
stop: the run has to
be re-started. If the
problem persists
call Service.
Reagent Area temper- 1125
Reagent
Temp Error ature defined to be out
of range for a period
exceeding the fatal
error limits.
Reagent area tem- Reagent area tem- The system performed a controlled
perature out of
perature control
stop: the run has to
range.
failure.
be re-started. If the
problem persists
call Service.
Data
Detector interface fault, 1130
Acquisition e.g. conversion did not
(Fault)
complete, emitter light
source not correct.
CRC Error detected in 1132
CRC
writing to or reading
(Error):
from a permanent storSample
age device (e.g.
Arm
EEPROM)
Optical reading
Built-in checks
units data acquisi- detected an error.
tion control failure.
Call Service.
Sample Arm controller failure.
Call Service.
Sample Arm controller board malfunction.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > Cuvettes Tab. If
the temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
Check the Thermistor for Thermal
open or short. If temp is Control
out high, check the fans
for proper operation and
bloackage.
3 - 43
System
Response
Where
raised
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform an
controlled stop
- Notify the
alarm via the UI
- Turn off power
to affected
heater.
- Perform a controlled stop
If error is persistent, then Reaction - Notify the
replace the ORU mod- Detection alarm via the UI
- Perform an
ule. If infrequent, report a
emergency stop
complaint.
Replace the universal
Processor/ - Notify the
sample arm controller. Software alarm via the UI
- Perform an
emergency stop
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
CRC
(Error):
Intermediate
Reagent
Arm
CRC
(Error):
Start
Reagent
Arm
CRC
(Error):
cuvette
CRC
(Error):
rack
CRC
(Error):
ORU
Storage
Write
(Fault):
cuvette
Storage
Write
(Fault):
rack
Alarm Description
Code
Message
Cause
Operator Action
Service Action
3 - 44
System
Service
Response
Manual
Section
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
Where
raised
AM Controllers
CRC Error detected in 1133
writing to or reading
from a permanent storage device (e.g.
EEPROM)
Call Service.
Intermediate
Intermediate
Reagent Arm con- Reagent Arm controller board maltroller failure.
function.
Replace the universal
intermediate reagent
arm controller.
1134
Start Reagent Arm Start Reagent Arm Call Service.
controller failure.
controller board
malfunction.
Replace the universal
start reagent arm controller.
1135
Cuvettes controller Cuvettes controller Call Service.
failure.
board malfunction.
AM ConReplace the cuvette con- Processor/ - Notify the
troller. Execute thermal Software alarm via the UI trollers
- Perform an
calibration for the
emergency stop
cuvette areas.
1136
Racks controller
failure.
AM ConReplace the rack control- Processor/ - Notify the
ler. Execute thermal cali- Software alarm via the UI trollers
- Perform an
bration for the cuvette
emergency stop
areas.
1137
Call Service.
Optical Reading
Optical Reading
Units controller fail- Units controller
board malfunction.
ure.
Replace the ORU controller. Execute thermal
calibration for the
cuvette areas.
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
- Perform an
emergency stop
1140
Cuvettes controller Cuvettes controller Call Service.
failure.
board malfunction.
Refer to 1135.
1141
Racks controller
failure.
Refer to 1136.
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
CRC Error detected in
writing to or reading
from a permanent storage device (e.g.
EEPROM)
CRC Error detected in
writing to or reading
from a permanent storage device (e.g.
EEPROM)
CRC Error detected in
writing to or reading
from a permanent storage device (e.g.
EEPROM)
CRC Error detected in
writing to or reading
from a permanent storage device (e.g.
EEPROM)
Error detected in
updating data on a permanent storage device
(e.g. EEPROM)
Error detected in
updating data on a permanent storage device
(e.g. EEPROM)
Racks controller
Call Service.
board malfunction.
Racks controller
Call Service.
board malfunction.
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
- Perform an
emergency stop
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Storage
Write
(Fault):
ORU
Storage
Write
(Fault):
Sample
Arm
Storage
Write
(Fault):
Intermediate
Reagent
Arm
Storage
Write
(Fault):
Start
Reagent
Arm
Alarm Description
Code
Message
Cause
Operator Action
Service Action
3 - 45
System
Service
Response
Manual
Section
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
Processor/ - Notify the
Software alarm via the UI
- Perform an
emergency stop
Where
raised
AM Controllers
Call Service.
Optical Reading
Optical Reading
Units controller fail- Units controller
board malfunction.
ure.
Refer to 1137.
Sample Arm controller failure.
Call Service.
Refer to 1132.
1145
Error detected in
updating data on a permanent storage device
(e.g. EEPROM)
Call Service.
Intermediate
Intermediate
Reagent Arm con- Reagent Arm controller board maltroller failure.
function.
Refer to 1133.
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
- Perform an
emergency stop
1146
Error detected in
updating data on a permanent storage device
(e.g. EEPROM)
Start Reagent Arm Start Reagent Arm Call Service.
controller failure.
controller board
malfunction.
Refer to 1134.
AM ConProcessor/ - Notify the
Software alarm via the UI trollers
- Perform an
emergency stop
1142
Error detected in
updating data on a permanent storage device
(e.g. EEPROM)
1144
Error detected in
updating data on a permanent storage device
(e.g. EEPROM)
Sample Arm controller board malfunction.
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Voltage
Monitor
(Fault):
Sample
Arm
Alarm Description
Code
1152
Voltage out-of-range
fault detected on a controller.
Voltage out-of-range
1153
Voltage
fault detected on a conMonitor
troller.
(Fault):
Intermediate
Reagent
Arm
Message
Cause
Sample Arm con- Sample Arm controller voltage out of troller board malfunction.
range.
Intermediate
Reagent Arm controller voltage out of
range.
Operator Action
Call Service.
Call Service.
Intermediate
Reagent Arm controller board malfunction.
Service Action
Service
Manual
Section
Power
Management
The problem could be
with the fuse, cabling,
power supply, or the
controller board itself.
Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to examine the voltages of the
controllers against their
limits. If a voltage is marginally out of limits,
replace the supply.
Power
The problem could be
Managewith the fuse, cabling,
ment
power supply, or the
controller board itself.
Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to examine the voltages of the
controllers against their
limits. If a voltage is marginally out of limits,
replace the supply.
3 - 46
System
Response
Where
raised
AM Con- Notify the
alarm via the UI trollers
- Perform an
emergency stop
AM Con- Notify the
alarm via the UI trollers
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Voltage
Monitor
(Fault):
Start
Reagent
Arm
Voltage
Monitor
(Fault):
cuvette
Alarm Description
Code
Message
Cause
Operator Action
1154
Voltage out-of-range
fault detected on a controller.
Start Reagent Arm Start Reagent Arm Call Service.
controller voltage controller board
malfunction.
out of range.
Voltage out-of-range
1155
fault detected on a controller.
Cuvettes controller Cuvettes controller Call Service.
voltage out of
board malfunction.
range.
Service Action
Service
Manual
Section
Power
Management
The problem could be
with the fuse, cabling,
power supply, or the
controller board itself.
Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to examine the voltages of the
controllers against their
limits. If a voltage is marginally out of limits,
replace the supply.
Power
The problem could be
Managewith the fuse, cabling,
ment
power supply, or the
controller board itself.
Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to examine the voltages of the
controllers against their
limits. If a voltage is marginally out of limits,
replace the supply.
3 - 47
System
Response
Where
raised
AM Con- Notify the
alarm via the UI trollers
- Perform an
emergency stop
AM Con- Notify the
alarm via the UI trollers
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Voltage
Monitor
(Fault):
rack
Voltage
Monitor
(Fault):
ORU
Alarm Description
Code
Message
Cause
Operator Action
1156
Voltage out-of-range
fault detected on a controller.
Racks controller
voltage out of
range.
Racks controller
Call Service.
board malfunction.
Voltage out-of-range
1157
fault detected on a controller.
Optical Reading
Units controller
voltage out of
range.
Optical Reading
Call Service.
Units controller
board malfunction.
Service Action
Service
Manual
Section
Power
Management
The problem could be
with the fuse, cabling,
power supply, or the
controller board itself.
Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to examine the voltages of the
controllers against their
limits. If a voltage is marginally out of limits,
replace the supply.
Power
The problem could be
Managewith the fuse, cabling,
ment
power supply, or the
controller board itself.
Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to examine the voltages of the
controllers against their
limits. If a voltage is marginally out of limits,
replace the supply.
3 - 48
System
Response
Where
raised
AM Con- Notify the
alarm via the UI trollers
- Perform an
emergency stop
AM Con- Notify the
alarm via the UI trollers
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Alarm/
Error
Name
Automatic coordinates 1160
FMov
Coor(dinat check failure
es)
Maint(enan
ce)
Autocheck
Fail
FMov
Coor(dinat
es) not
adjusted
AM coordinates have 1165
never been adjusted
using the "Coordinate
adjustment" procedure.
(ORU)
Invalid
Configuration
Invalid emitter, detec- 1170
tion, or incubator module configuration
detected, or reference
channel not on
installed detection
module.
Message
Cause
Operator Action
Service Action
Service
Manual
Section
Robotic
XYZ
The coordinates check
fails.
- Clean the metallic edge
of the rinse/clean station
and try to reinitialize
again
- Clean all reference
points, go to diagnostics
and perform the "Coordinate Adjustment" routine
Robotic
Use the diagnostics
Arm <Arm> coordi- Coordinate adjust- Service or Lab
XYZ
nate adjust
ment procedure not Administrator to run mode to run a coordinates adjustment of the
required.
executed or failed. the Coordinate
Adjust procedure. instrument.
Arm <Arm> coordi- Arm coordinates
nates error or CTS mismatch.
foot coordinates
error.
Invalid system con- System detected a
figuration.
hardware configuration that cannot
support the current
system configuration settings: missing or inactive
optical reading
unit(s), cuvettes
incubator or CTS
module.
The arm cannot initialize.
Perform a probe
alignment.
If the problem persists call Service.
Check system configuration settings.
Power off and
restart the instrument.
If the problem persists, call Service.
Check that the incuba- Reaction
tors and ORU heads are Detection
installed. Make sure
ORU and incubator
cables to the backplane
are secured. Otherwise,
replace ORU module
and/or incubators.
3 - 49
System
Response
Where
raised
- Notify the
AM Masalarm via the UI ter
- Notify the
alarm via the UI
- Impossible to
start jobs, therefore the instrument cannot go
to ready
- Notify the
alarm via the UI
- Impossible to
start jobs, therefore the instrument cannot go
to ready
AM Master
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Sample
Probe
Pre(Heater)
Temperature Error
Alarm Description
Code
Message
Cause
Operator Action
Service Action
Service
Manual
Section
Thermal
Control
Probe Pre-Heater tem- 1175
perature defined to be
out of range for a
period exceeding the
fatal error limits.
Sample probe pre- Probe pre-heating
heater temperature system malfunction.
control failure.
Check fuse on probe,
The system performed a controlled replace probe.
stop. Call Service.
Reagent 1
Probe
Pre(Heater)
Temperature Error
Probe Pre-Heater tem- 1176
perature defined to be
out of range for a
period exceeding the
fatal error limits.
Probe pre-heating
Reagent 1 probe
pre-heater temper- system malfunction.
ature control failure.
The system perCheck fuse on probe,
formed a controlled replace probe.
stop. Call Service.
Thermal
Control
Reagent 2
Probe
Pre(Heater)
Temperature Error
Probe Pre-Heater tem- 1177
perature defined to be
out of range for a
period exceeding the
fatal error limits.
Probe pre-heating
Reagent 2 probe
pre-heater temper- system malfunction.
ature control failure.
The system perCheck fuse on probe,
formed a controlled replace probe.
stop. Call Service.
Thermal
Control
CTS sample Probe
Pre(Heater)
Temperature Error
Probe Pre-Heater tem- 1178
perature defined to be
out of range for a
period exceeding the
fatal error limits.
CTS sample probe Probe pre-heating
pre-heater temper- system malfuncature control failtion.
ure.
CTS Sample probe is not Thermal
The system performed a controlled heated, this error will not Control
stop. Call Service. occur under normal conditions. Contact IL if error
occurs.
3 - 50
System
Response
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
LAS sample Probe
Pre(Heater)
Temperature Error
Alarm Description
Code
Probe Pre-Heater tem- 1179
perature defined to be
out of range for a
period exceeding the
fatal error limits.
Message
Cause
LAS sample probe Probe pre-heating
pre-heater temper- system malfunction.
ature control failure.
Operator Action
Service Action
Error Code Reserved.
The system performed a controlled
stop. Call Service.
Service
Manual
Section
Thermal
Control
Sample
Probe
Temperature Error
Probe temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
1180
Sample probe tem- Probe heating sys- The system perThis Sample probe is not Thermal
perature control
tem malfunction.
formed a controlled heated, this error will not Control
failure.
stop. Call Service. occur under normal conditions. Contact IL if error
occurs.
Reagent 1
Probe
Temperature Error
Probe temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
1181
Reagent 1 probe
Probe heating sys- The system perCheck fuse on probe,
temperature control tem malfunction.
formed a controlled replace probe.
failure.
stop. Call Service.
Thermal
Control
Reagent 2
Probe
Temperature Error
Probe temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
1182
Check fuse on probe,
Probe heating sys- The system perReagent 2 probe
formed a controlled replace probe.
temperature control tem malfunction.
stop. Call Service.
failure.
Thermal
Control
3 - 51
System
Response
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
CTS Sample Probe
Temperature Error
Alarm Description
Code
Probe temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
1183
LAS Sample Probe
Temperature Error
Probe temperature
defined to be out of
range for a period
exceeding the fatal
error limits.
1184
Clean Fluid
Valve (in
Incorrect
State):
Sample
Arm
Valve commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1185
Clean Fluid
Valve (in
Incorrect
State):
Reagent
Arm 1
Valve commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1186
Message
Cause
Operator Action
Service Action
Service
Manual
Section
CTS Sample probe is not Thermal
CTS sample probe Probe heating sys- The system performed a controlled heated, this error will not Control
temperature control tem malfunction.
stop. Call Service. occur under normal confailure.
ditions. Contact IL if error
occurs.
3 - 52
System
Response
- Notify the
alarm via the UI
- Turn Power off
to the affected
heater
- Perform a controlled stop
LAS sample probe Probe heating sys- The system perError Code Reserved.
Thermal
- Notify the
temperature control tem malfunction.
formed a controlled
Control
alarm via the UI
failure.
stop. Call Service.
- Turn Power off
to the affected
heater
- Perform a controlled stop
- Notify the
Perform the diagnostics Fluid
Sample arm clean Clean fluid valve
The system perMovement alarm via the UI
clean valve test.
fluid valve failure. not responding.
formed an Emer- Perform an
If the error is reproducgency stop:
emergency stop
perform a Recov- ible, verify if the valve
ery. If the problem moves (in this case the
sensor is not working) or
persists call Sernot (in this case the
vice.
valve is not working).
Reagent arm 1
Clean fluid valve
- Notify the
Perform the diagnostics Fluid
The system perclean fluid valve
Movement alarm via the UI
clean valve test.
not responding.
formed an Emerfailure.
- Perform an
If the error is reproducgency stop:
emergency stop
perform a Recov- ible, verify if the valve
ery. If the problem moves (in this case the
sensor is not working) or
persists call Sernot (in this case the
vice.
valve is not working).
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Clean Fluid
Valve (in
Incorrect
State):
Reagent
Arm 2
Alarm Description
Code
Message
Cause
Operator Action
Valve commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1187
Reagent arm 2
clean fluid valve
failure.
Clean fluid valve
not responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Clean
Pump (in
Incorrect
State):
Sample
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1190
Sample clean
pump failure.
Clean pump not
responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Clean
Pump (in
Incorrect
State):
Reagent
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1191
Reagent clean
pump failure.
Clean pump not
responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Sample
Rinse
Pump (in
Incorrect
State)
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1200
Sample rinse pump Rinse pump not
failure.
responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
3 - 53
System
Where
Service
Response
raised
Manual
Section
- Notify the
Perform the diagnostics Fluid
Movement alarm via the UI
clean valve test.
- Perform an
If the error is reproducemergency stop
ible, verify if the valve
moves (in this case the
sensor is not working) or
not (in this case the
valve is not working).
- Notify the
Perform the diagnostics Fluid
Movement alarm via the UI
clean pump test.
- Perform an
If the error is reproducemergency stop
ible, verify if the pump
runs (in this case the
sensor is not working) or
not (in this case the
pump is not working).
- Notify the
Perform the diagnostics Fluid
Movement alarm via the UI
clean pump test.
- Perform an
If the error is reproducemergency stop
ible, verify if the pump
runs (in this case the
sensor is not working) or
not (in this case the
pump is not working).
- Notify the
Perform the diagnostics Fluid
Movement alarm via the UI
rinse test.
- Perform an
If the error is reproducemergency stop
ible, verify if the rinse
pump runs (in this case
the sensor is not working) or not (in this case
the pump is not working).
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Reagent 1
Rinse
Pump (in
Incorrect
State)
Alarm Description
Code
Message
Cause
Operator Action
3 - 54
System
Where
Service
Response
raised
Manual
Section
- Notify the
Perform the diagnostics Fluid
Movement alarm via the UI
rinse test.
- Perform an
If the error is reproducemergency stop
ible, verify if the rinse
pump runs (in this case
the sensor is not working) or not (in this case
the pump is not working).
Service Action
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1201
Reagent arm 1
Rinse pump not
rinse pump failure. responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Reagent 2
Rinse
Pump (in
Incorrect
State)
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1202
Reagent arm 2
Rinse pump not
rinse pump failure. responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Perform the diagnostics Fluid
Movement
rinse test.
If the error is reproducible, verify if the rinse
pump runs (in this case
the sensor is not working) or not (in this case
the pump is not working).
- Notify the
alarm via the UI
- Perform an
emergency stop
LAS Sample Rinse
Pump (in
Incorrect
State)
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1204
LAS sample arm
Rinse pump not
rinse pump failure. responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Error Code Reserved
- Notify the
alarm via the UI
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Waste
Pump (in
Incorrect
State)
Alarm Description
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
Code
1205
Message
Waste pump failure.
Cause
Waste pump not
responding.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Either the waste pump is Waste
not functional or the sen- Managesors to check the state of ment
the waste pump are not
functional. Enter Diagnostics > Fluids tab to
check the waste pump.
In the Waste pump section, enter a duration of
10 seconds and press
the Start button. After the
Start button is pressed,
the operator should be
able to hear the waste
pump operating. If the
pump cannot be heard,
then remove the covers
to expose the waste
pump and repeat the
test. If the pump continues to fail, then check
both cabling and power.
If the pump is moving,
then the failure is probably in the detection sensor. Make sure the
Waste pump on virtual
LED changes state
whether the pump is On
or Off.
3 - 55
System
Response
Where
raised
AM Mas- Notify the
alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
Failure saving coordi- 1206 Coordinate File
CoordiSaving Failure.
nates File nates file on the FTP
Write Fail- server
ure
Cause
Operator Action
Invalid FTP server Call Service.
configuration, AM/
CM connection network not working.
ORU
Stored
Reading
File Write
Failure
Failure saving ORU
stored reading file on
the FTP server
1207
ORU Stored Read- Invalid FTP server Call Service.
ing File Saving Fail- configuration, AM/
CM connection neture.
work not working.
CTS Sample Air
Pump (in
Incorrect
State)
Pump commanded
ON(OFF) but sensor
did not indicate
ON(OFF) state.
1208
CTS sample arm
air pump failure.
Air pump not
responding.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Robotic
Check network cables
and connections are reli- XYZ
able.
Ensure FTP server is
running.
Check that the software
versions are correct for
the release and that the
FTP service is running
on the personal computer. Fix all incorrect
versions. Re-boot the
personal computer as an
attempt to restart the
FTP service.
If the vacuum pump is on
too long; the instrument
assumes it is not pressurizing the accumulator.
Go to the CTS Diagnostics screen and open the
CTS air valves.
If the CTS air pumps
runs, the problem is in
the air accumulator sensor; if the pump doesn't
run, the problem is the
pump.
Reaction
Detection
3 - 56
System
Response
Where
raised
- Notify the
AM Masalarm via the UI ter
- Notify the
AM Masalarm via the UI ter
AM MasFluid
- Notify the
Movement alarm via the UI ter
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
CTS Failed
to Enter
Deep
Wash
Alarm Description
Code
The foot hit the wash 1209
station edge when the
CTS probe was
inserted inside the
wash station. This
would have caused a
probe mode switch failure at the end of the
wash cycle.
Cuvette
Cuvette Waste Level 1210
Level Sen- Sensor Not Respondsor (Error) ing.
Message
Cause
Operator Action
Service Action
System
Service
Response
Manual
Section
Fluid
- Notify the
Movement alarm via the UI
- Perform an
emergency stop
- Verify that the foot is
properly connected to
the sample arm/probe
- Verify the position of
the sample wash station
- Perform Coordinates
Adjustment procedure
for sample arm
- Verify cap detection
sensors
Cuvette
The feedback signal
Cuvette waste level Cuvette waste level The system perMovement
sensor failure.
sensor not
formed a controlled from the ultrasonic
responding.
stop: the run has to cuvette level was not
be re-started. If the detected. Ensure that all
cables are connected
problem persists
and the board has
call Service.
power. Use diagnostics
(Cuvettes Tab > Waste >
Cuvette Waste Level) to
check if the level
changes with different
amount of cuvettes in the
drawer.
CTS Failed to Enter The foot hit the
Deep Wash.
wash station edge
when the CTS
probe was inserted
inside the wash station.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
3 - 57
Where
raised
AM Master
AM Con- Notify the
alarm via the UI trollers
- Perform a controlled stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Waste
(Accumulator Full
Sensor)
Stuck
Alarm Description
Code
1215
Waste Accumulator
Full Sensor remains in
ON state despite
cycling of Waste
Pump.
Message
Cause
Operator Action
Call Service.
Peristaltic pump
Unable to empty
internal waste res- failure.
Waste drain path
ervoir.
obstruction.
Liquid sensor malfunction.
Service Action
Service
Manual
Section
If the waste accumulator Waste
is full, waste container is Managepresent and full, then this ment
alarm occurs. Or if the
waste accumulator is full
after an attempt to empty
it. Or if the waste accumulator is full and the
container is not present.
In these cases, the
waste fluid sensors and
the tubing need to be
checked.
Enter Diag>Fluids tab to
check the Waste sensors and accumulator
draining. If the accumulator is empty, but the
LED on the sensor is
active, then there is a
problem with the sensor
or an object in front of
the sensor. If the accumulator is full, set the
Waste pump duration
such as 60 seconds.
Start the pump. Ensure
that fluid is flowing
through the tube to the
waste container. If the
sensors are working and
the tubing is good, test
the waste container
presence sensor.
3 - 58
System
Response
Where
raised
AM Mas- Notify the
alarm via the UI ter
- Perform Emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
System
Service
Response
Manual
Section
Call Service.
The sensor that monitors Rack Han- - Notify the
Reagent stirring
alarm via the UI
the power to all the stir- dling
system malfunc- Disable all stirring detected a failure.
tion.
ring positions in
Either the sensor is bad
diagnostics
or the stirring circuitry
screen.
has failed. To check,
place vials with stir bars
into all of the stir locations. If all the positions
are stirring properly, then
the sensor is malfunctioning. If any of the stir
positions are not stirring,
then check the reagent
stirring circuitry.
Call Service.
Product under develop- Rack Han- - Notify the
Reagent stirring
Reagent stirring
alarm via the UI
ment - Not needed in the dling
failure in position system malfunc- Disable that
service manual
tion.
<rack
stirring position
position #>, track #
in diagnostics
<rack track #>.
screen.
- Notify the
Check for obstructions Cuvette
Cuvette Loader fail- Cuvette loader mal- The system performed a controlled that would prevent the Movement alarm via the UI
ure.
function. The
- Perform a concuvette clip may not stop: the run has to cuvette clip from droptrolled stop
have fallen flat for be re-started. If the ping flat in the loader.
- Deschedule
Also use diagnostics to
pickup by the shut- problem persists
and cancel jobs
verify that the cuvette
call Service.
tle. The cuvette
requiring new
clip presence sensor is
strips on the clip
cuvettes
functioning. When the
may not be aligned
clip is moved into pickup
evenly or there may
position, the sensor is
be debris on the
read to verify that the clip
pivot arm.
is ready.
Alarm Description
Code
Message
Alarm/
Error
Name
Stir Power A check on the power 1220 Reagent stirring
failure.
Bad
required for stirring
returned an error
Stir Power A check on the power 1221
required for stirring
Bad: by
position returned an
Position
error
(Cuvette)
Indexing
Failure
Failure during cuvette 1239
indexing detected.
3 - 59
Cause
Operator Action
Where
raised
Service Action
AM Controllers
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
Clean Well Validate LLD height in 1240 Cleaning solution
low in clean well.
Not Full
Clean well. If too low,
short sipping may
occur.
Cuvette
Shuttle
Motor Cause 3
The motor did not com- 1245
plete the requested
move.
Cuvettes shuttle
movement failure.
Cuvette
Shuttle
Motor Cause 4
The motor did not com- 1246
plete the requested
move.
Cuvettes shuttle
movement failure.
Cuvette
Shuttle
Motor Cause 5
The motor did not com- 1247
plete the requested
move.
Cuvettes shuttle
movement failure.
3 - 60
System
Service
Response
Manual
Section
- Notify the
- Perform Clean pump Fluid
Air bubbles in the Perform a Clean
clean solution line. prime cycle (Main- diagnostics test and ver- Movement alarm on UI
ify that clean well are
Undetected clean tenance). If the
filled with clean solution
solution shortage. problem persists
- Perform LLD test in
Clean pump mal- call Service.
clean cup and verify that
function.
liquid is detected
- Remove the clean bottle and verify that the
instrument report the
proper alarm.
- Turn off power
Use diagnostics to verify Cuvette
The motor moved The system perthat the cuvette position Movement to stepper
to the left limit then formed an Emermotor.
sensor is operational
to the home posi- gency stop:
- Notify the
perform a Recov- (color when in slot). If
tion at the loader
alarm via the UI
and the home posi- ery. If the problem sensor is functional, per- Perform an
form cuvette shuttle align
tion was not found. persists call Seremergency stop
procedure.
vice.
- Turn off power
A slot is dirty or the shut- Cuvette
Incorrect # slots
The system pertle in position slot sensor Movement to stepper
found.
formed an Emermotor.
is dirty. Clean either slots
gency stop:
- Notify the
perform a Recov- on the incubators or the
alarm via the UI
ery. If the problem shuttle in position slot
- Perform an
sensor. Use diagnostics
persists call Seremergency stop
to verify that all cuvette
vice.
slots can be detected.
This is a software defect Processor/ - Turn off power
Home Required. A The system perthat should be submitted Software to stepper
formed an Emercuvette shuttle
motor.
to software developgency stop:
operation was
- Notify the
requested before perform a Recov- ment.
alarm via the UI
the shuttle was ini- ery. If the problem
- Perform an
persists call Sertialized into a
emergency stop
vice.
known state.
Cause
Operator Action
Where
raised
Service Action
AM Master
AM Controllers
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Cuvette
Shuttle
Motor Cause 6
Alarm Description
Code
Message
The motor did not com- 1248
plete the requested
move.
Cuvettes shuttle
movement failure.
Cuvette
Shuttle
Motor Cause 7
The motor did not com- 1249
plete the requested
move.
Cuvettes shuttle
movement failure.
Cuvette
Shuttle
Motor Cause 8
The motor did not com- 1250
plete the requested
move.
Cuvettes shuttle
movement failure.
Cuvette
Shuttle
Motor Cause 11
The motor did not com- 1253
plete the requested
move.
Cuvettes shuttle
movement failure.
Cause
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Cuvettes shuttle
The system permovement hit unex- formed an Emerpected travel limit. gency stop:
perform a Recovery. If the problem
persists call Service.
The system perCuvettes shuttle
movement timeout. formed an EmerGripper move fail- gency stop:
perform a Recovure.
ery. If the problem
persists call Service.
Cuvettes shuttle
movement timeout.
Move Timeout. This
occurs if the software does not complete the move
profile.
Cuvettes shuttle
movement stalled.
3 - 61
System
Service
Response
Manual
Section
Either the processor or Processor/ - Turn off power
software has a malfunc- Software to stepper
motor.
tion. Replace the cuvette
- Notify the
controller board and
alarm via the UI
repeat the failure sce- Perform an
nario.
emergency stop
This alarm is not
Cuvette
- Turn off power
enabled.
Movement to stepper
motor.
- Notify the
alarm via the UI
- Perform an
emergency stop
This could be a problem Cuvette
- Turn off power
with either the motor
Movement to stepper
step size or direction.
motor.
- Notify the
alarm via the UI
- Perform an
emergency stop
Cuvette
- Turn off power
General alarm to alert
there was a gripper fail- Movement to stepper
motor.
ure. Should be accom- Notify the
panied with a detailed
alarm via the UI
alarm.
- Perform an
emergency stop
Where
raised
Service Action
AM Controllers
AM Controllers
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Bar Code
Reader
Motor Cause 1
Alarm Description
Code
The motor did not com- 1255
plete the requested
move prior to a motor
move time out (bar
code).
Message
Barcode reader
movement failure.
3 - 62
System
Where
Service
Response
raised
Manual
Section
Clear obstruction This is a high level alarm Rack Han- - Turn off power AM ConBarcode reader
trollers
dling
to stepper
that alerts that somemovement timeout. and wait for barmotor.
Home Not Found. code reader time- thing in the reader home
- Notify the
operation was not comout to occur
alarm via the UI
pleted successfully.
(homing of barWatch the reader to see
code). If problem
persists disable the where the failure occurs.
barcode reader in Listen for hitting an
Global Definitions obstruction. In Diagnostics > Racks section, use
and call Service.
the Disable Bar Code
Reader Motor button to
disable the power to the
motor. With the power
disabled, move the
reader by hand to look
for rough spots. While
checking for rough
spots, make sure that
the Track, Left Travel,
and Right Travel virtual
LEDs change state at
the appropriate time.
Cause
Operator Action
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Bar Code
Reader
Motor Cause 2
Alarm Description
Code
The motor did not com- 1256
plete the requested
move prior to a motor
move time out (bar
code).
Message
Barcode reader
movement failure.
3 - 63
System
Where
Service
Response
raised
Manual
Section
Clear obstruction When moving to a posi- Rack Han- - Turn off power AM ConBarcode reader
trollers
to stepper
tion the exact number of dling
movement timeout. and wait for barmotor.
code reader time- slots were not detected.
Incorrect Slots
- Notify the
The alarm reports the
out to occur
Found.
alarm via the UI
number of slots
(homing of bardetected. If the number
code). If problem
persists disable the of slots was less than
barcode reader in expected, then the motor
Global Definitions either stalled or hit an
obstruction. If the numand call Service.
ber of slots is a large
number, then false trips
may have been
detected. The false trips
can come from a bad
sensor, intermittent
cabling, or sensor to slot
alignment. In Diagnostics > Racks section, use
the Disable Bar Code
Reader Motor button to
disable the power to the
motor. With power disabled, move the reader
by hand to look for rough
spots. While checking for
rough spots, ensure the
Track, Left Travel, and
Right Travel virtual LEDs
change state at the
appropriate time. Also,
see if the Track LED
flickers when on a slot
location.
Cause
Operator Action
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Bar Code
Reader
Motor Cause 3
Bar Code
Reader
Motor Cause 4
Alarm Description
Code
Message
The motor did not com- 1257
plete the requested
move prior to a motor
move time out (bar
code).
Barcode reader
movement failure.
The motor did not com- 1258
plete the requested
move prior to a motor
move time out (bar
code).
Barcode reader
movement failure.
3 - 64
System
Where
Service
Response
raised
Manual
Section
Clear obstruction This alarm is produced Rack Han- - Turn off power AM ConBarcode reader
trollers
dling
to stepper
when a command is
movement timeout. and wait for barmotor.
code reader time- given to move the reader
Home Required.
- Notify the
to a rack position prior to
out to occur
alarm via the UI
it being homed. This sce(homing of barnario is rare. If this
code). If problem
persists disable the occurs, it should be
barcode reader in entered as a complaint.
Global Definitions
and call Service.
Rack Han- - Turn off power AM ConBarcode reader
Clear obstruction This alarm has a very
trollers
dling
to stepper
low probability. Either
movement timeout. and wait for barmotor.
Move Timeout.
code reader time- the hardware that
- Notify the
changes the ramp speed
out to occur
alarm via the UI
has a circuitry problem
(homing of baror there is a software
code). If problem
persists disable the logic error that is loading
barcode reader in an incorrect ramp profile.
Global Definitions A solution would be to
replace the rack controland call Service.
ler card since this will fix
either of the problems.
Cause
Operator Action
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Bar Code
Reader
Motor Cause 5
Alarm Description
Code
The motor did not com- 1259
plete the requested
move prior to a motor
move time out (bar
code).
Message
Barcode reader
movement failure.
3 - 65
System
Where
Service
Response
raised
Manual
Section
Rack Han- - Turn off power AM ConClear obstruction The alarm is reported
Barcode reader
trollers
to stepper
when the reader hits an dling
movement timeout. and wait for barmotor.
code reader time- object. It is detected by
Stalled.
- Notify the
monitoring the encoder
out to occur
alarm via the UI
during the move opera(homing of bartion. The problem is
code). If problem
persists disable the either with hitting an
barcode reader in object or the encoder
Global Definitions feedback. In Diagnostics
> Racks section, use the
and call Service.
Disable Bar Code
Reader Motor button to
disable the power to the
motor. With the power
disabled, move the
reader by hand to look
for rough spots. While
checking for rough
spots, make sure that
the Track, Left Travel,
and Right Travel virtual
LEDs change state at
the appropriate time.
Also, watch to verify that
the Encoder value
changes when the
reader is moved.
Cause
Operator Action
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Bar Code
Reader
Motor Cause 6
All ORUs
Disabled
Alarm Description
Code
Message
The motor did not com- 1260
plete the requested
move prior to a motor
move time out (bar
code).
Barcode reader
movement failure.
All the ORU have been 1261
disabled, either manually or automatically.
The instrument cannot
perform any tests.
All the Optical
Reading Units are
disabled. Analysis
cannot be performed.
Cause
Operator Action
Clear obstruction
and wait for barcode reader timeout to occur
(homing of barcode). If problem
persists disable the
barcode reader in
Global Definitions
and call Service.
All the ORUs have If the ORUs have
been automatically
been disabled,
disabled, call Sereither automatically or manually. vice.
When all the ORUs
- Automatically:
are disabled the
ORU real-time
system cannot percheck failed
- Manually: opera- form analysis.
tor disabled ORU If this occurs during
through Diagnos- a run, the system
performs an Emertics
gency Stop.
Barcode reader
movement timeout.
Unexpected Travel
Limit.
3 - 66
System
Where
Service
Response
raised
Manual
Section
Rack Han- - Turn off power AM ConThis alarm should be
trollers
dling
to stepper
rare in the field. The
motor.
most probable cause is
- Notify the
that the motor direction
alarm via the UI
wiring is reversed hence
sending the motor in the
opposite direction than
requested. If this problem occurs, check the
wiring.
AM MasReaction - Notify the
Use ORU Diagnostic
Detection alarm via the UI ter
screen to attempt to
- Enter the Error
manually enable ORUs.
Status
Check cabling to ORU
- If there are
from backplane. Replace
active jobs, perthe ORU module.
form an Emergency Stop
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Cuvette
Waste
accumulator stuck
Alarm Description
Code
The accumulator does 1263
not return to the up
position within 2 seconds of being emptied.
Message
Cause
Operator Action
Cuvettes accumu- Cuvettes accumu- The system performed an Emerlator failure.
lator movement
gency stop:
timeout.
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Waste
Check to see if the
cuvette waste accumula- Managetor is stuck in the down ment
position. If may has got
caught and cannot return
to the level position to
gather more cuvettes. In
order to check the sensor, enter Diagnostics >
Cuvettes tab. In the
Waste section of the tab
there is a sensor named
Accumulator Up.
Remove the cuvette
waste drawer and check
that the sensor changes
state by moving the
cuvette waste accumulator up and down. Also, in
Diagnostics, use the
Clear Accumulator button to verify the dump
operation of the accumulator.
3 - 67
System
Response
Where
raised
AM Con- Notify the
alarm via the UI trollers
- Disable the
accumulator
solenoid
- Perform an
Emergency
Stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
1264 Optical reading unit Temperature out of Call Service.
ORU Tem- Temperature out of
range in a reading unit
No. 1 temperature range in optical
perature
reading unit.
control failure.
Warning
(ORU #1)
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 68
System
Response
- Notify the
alarm on UI
Where
raised
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
1265 Optical reading unit Temperature out of Call Service.
ORU Tem- Temperature out of
range in a reading unit
No. 2 temperature range in optical
perature
reading unit.
control failure.
Warning
(ORU #2)
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 69
System
Response
- Notify the
alarm on UI
Where
raised
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
1266 Optical reading unit Temperature out of Call Service.
ORU Tem- Temperature out of
range in a reading unit
No. 3 temperature range in optical
perature
reading unit.
control failure.
Warning
(ORU #3)
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 70
System
Response
- Notify the
alarm on UI
Where
raised
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
1267 Optical reading unit Temperature out of Call Service.
ORU Tem- Temperature out of
range in a reading unit
No. 4 temperature range in optical
perature
reading unit.
control failure.
Warning
(ORU #4)
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 71
System
Response
- Notify the
alarm on UI
Where
raised
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
Incubator Temperature out of
Tempera- range in an incubator
ture Warning
(incubator
#1)
Code
1268
Message
Cause
Operator Action
Cuvettes incubator Temperature out of Call Service.
No. 1 temperature range in cuvettes
incubator.
control failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
3 - 72
System
Response
- Notify the
alarm on UI
Where
raised
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
Incubator Temperature out of
Tempera- range in an incubator
ture Warning
(incubator
#2)
Probe
Temperature Warning
(Sample)
Probe
Temperature Warning
(Reagent
1)
Code
Message
Cause
Operator Action
1269
Cuvettes incubator Temperature out of Call Service.
No. 2 temperature range in cuvettes
incubator.
control failure.
Probe temperature or 1270
dispense temperature
defined to be out of
warning range but
within failure range.
Probe temperature dis- 1271
pense temperature
defined to be out of
warning range but
within failure range.
Sample probe tem- Probe heating sys- Call Service.
tem malfunction.
perature or dispense temperature
out of range.
Probe heating sys- Call Service.
Reagent arm 1
probe temperature tem malfunction.
or dispense temperature out of
range.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > ORU Tab. If the
temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
Verify what test(s) error Thermal
occurs. Check test vol- Control
umes especially if not an
IL test. Consult with
Applications
Verify what test(s) error Thermal
occurs. Check test vol- Control
umes especially if not an
IL test. Consult with
Applications
3 - 73
System
Response
- Notify the
alarm on UI
Where
raised
AM Controllers
- Notify the
alarm on UI
- Notify the
alarm on UI
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Probe
Temperature Warning
(Reagent
2)
Pre(Heater)
Probe
Temperature Warning
Pre(Heater)
Probe
Temperature Warning
Pre(Heater)
Probe
Temperature Warning
Reagent
Temp
Warning
Alarm Description
Code
Message
Cause
Operator Action
Service Action
Service
Manual
Section
Thermal
Verify on what test(s)
error occurs. Check test Control
volumes especially if not
an IL test. Consult with
Applications.
3 - 74
System
Response
- Notify the
alarm on UI
Probe temperature dis- 1272
pense temperature
defined to be out of
warning range but
within failure range.
Probe heating sys- Call Service.
Reagent arm 2
probe temperature tem malfunction.
or dispense temperature out of
range.
Probe Pre-Heater tem- 1273
perature defined to be
out of warning range
but within failure range
Sample probe pre- Probe pre-heating
heater temperature system malfunction.
out of range.
Call Service.
Thermal
Verify on what test(s)
error occurs. Check test Control
volumes especially if not
an IL test. Consult with
Applications.
- Notify the
alarm on UI
Probe Pre-Heater tem- 1274
perature defined to be
out of warning range
but within failure range
Probe pre-heating
Reagent arm 1
system malfuncprobe pre-heater
temperature out of tion.
range.
Call Service.
Thermal
Verify on what test(s)
error occurs. Check test Control
volumes especially if not
an IL test. Consult with
Applications.
- Notify the
alarm on UI
Probe Pre-Heater tem- 1275
perature defined to be
out of warning range
but within failure range
Probe pre-heating
Reagent arm 2
system malfuncprobe pre-heater
temperature out of tion.
range.
Call Service.
Thermal
Verify on what test(s)
error occurs. Check test Control
volumes especially if not
an IL test. Consult with
Applications.
- Notify the
alarm on UI
Reagent area tempera- 1276
ture defined to be out
of warning range but
within failure range.
Reagent area tem- Reagent cooling
system malfuncperature out of
range.
tion.
Call Service.
Thermal
Verify on what test(s)
error occurs. Check test Control
volumes especially if not
an IL test. Consult with
Applications.
- Notify the
alarm on UI
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Cuvette
Shuttle
Temp
Warning
Alarm Description
Code
1277
Cuvette shuttle temperature defined to be
out of warning range
but within failure range.
Message
Cause
Cuvette shuttle
Cuvette shuttle
temperature out of heating system
malfunction.
range.
LED or electronic
failure.
Operator Action
Call Service.
Call Service.
1278
(ORU) Ref Optical Reference
readings not within
High or
expected range, possiLow
bly due to LED aging or
failure.
Optical reading
units reference
readings out of
range for ORU
<ORU ID>.
(ORU)
ORU dark readings are 1279
High Dark too high, possibly indicating excessive stray
light.
Optical reading unit Stray light interfer- Call Service.
<ORU ID> dark
ence or electronic
readings too high. failure.
Service Action
Service
Manual
Section
The heating wire could Thermal
be broken, the thermistor Control
could be shorted, or the
module could require
calibration. To help troubleshoot, use Diagnostics > Cuvettes Tab. If
the temperature is fluctuating and barely out of
specification, then recalibrate. If the temperature is stuck solid then
the heating wires could
be not connected or broken. If the temperature is
fluctuating, then the thermistor wires are probably okay.
Replace the ORU mod- Reaction
ule if: when the Start but- Detection
ton is pressed in
Diagnostics > ORU tab >
Reference Readings
section, the DAC value is
greater than 240.
Reaction
Check for missing or
Detection
damaged covers that
would allow light into the
system. Look for possible sources of light into
the system. If covers
have integrity, then
replace ORU module.
3 - 75
System
Response
Where
raised
- Notify the
alarm on UI
- Notify the
alarm on UI
AM Controllers
AM Con- Notify the
trollers
alarm on UI
- Remove the
associated ORU
module from the
scheduling process????
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
(ORU) A/D Optical readings too
noisy, possibly due to
readings
too noisy LED aging or failure.
(ORU) A/D ORU amplifier and/or
Saturated A/D converter saturated
(ORU)
Math
Code
1280
1281
Math exception error 1283
(e.g. attempt to divide
by zero, overflow,
result not reasonable).
Message
Optical reading
units readings too
noisy for ORU
<ORU ID>.
Cause
LED or electronic
failure.
Operator Action
Call Service.
Optical reading unit ORU LED or elec- Call Service.
<ORU ID> readings tronic failure.
out of range.
Amplifier and/or A/
D converter saturated.
Optical reading unit
If the problem perraw data calculasists call Service.
tion error.
Service Action
Service
Manual
Section
Replace the ORU mod- Reaction
ule.
Detection
Replace the ORU mod- Reaction
ule.
Detection
Report problem into the Reaction
complaint system. This Detection
is a software defect that
cannot be addressed by
the field. If possible,
monitor the operator
workflow and make suggestions to change the
workflow which could
avoid the software path.
3 - 76
System
Response
Where
raised
- Notify the
alarm on UI
AM Controllers
- Create Log
Entry.
- Notify the
alarm on UI
- Create Log
Entry.
AM Controllers
- Notify the
AM Conalarms through trollers
the UI.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Liquid
Level
Detection
Alarm Description
Code
1285
LLD error occurred
during pipetting operation.
Message
Cause
Operator Action
Service Action
Service
Manual
Section
Robotic
Check probe condi- Try to determine if the
This alarm is
Probe <probe
tions. If the problem failure is caused by liquid XYZ
name> Liquid Level reported by the
not detected or by a false
persists call SerDetection error in analyzer when,
positive LLD.
rack position <X>, aspirating a liquid vice.
Problems detecting liqfrom a rack contrack <YY>.
uid can be investigated
tainer, one of the
performing diagnostics
following conditions
LLD test into rack conis detected.
tainers, cuvettes and
- Liquid not found
clean cups.
- LLD monitor failFalse positive LLDs can
ure
be detected performing
diagnostics LLD test
selecting as target location "Reference point".
3 - 77
System
Response
Where
raised
AM Mas- Notify the
alarm through ter
the UI
- Complete current job as
failed, with no
results if all
determinations
are failed. Also,
if on a measurement check,
another measurement is performed.
If an LLD failure
is during aspirating any sample or material,
1. If the aspirate/dispense
step is a dilution
step, the job is
descheduled
and canceled:
(continued)
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
LLD error occurred
Liquid
during pipetting operaLevel
Detection tion. (continued)
(continued)
Code
1285
(continued)
Message
Cause
Operator Action
Service Action
Service
Manual
Section
3 - 78
System
Response
(all replicates for
the current concentration are
affected)
marked as
'failed', the job is
descheduled
and canceled. 2.
If the aspirate/
dispense step is
a predilution
step or a sample/reagent
step, the current
determination is
marked as
'failed' and its
results are
flagged.
3. If all replicate
of one concentration are In
case there is not
enough liquid in
the dispense
location to perform the
requested mix,
the same rules
1, 2 and 3 apply.
ACL-TOP Service Manual
Where
raised
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Dispense
error
Liquid
Level
Detection
(Cuvette)
Alarm Description
Code
Message
Cause
Operator Action
Dispense error
1286
Probe <probe
name> Dispense
error.
Dispense error.
Check probe conditions. If the problem
persists call Service.
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 failure
Check probe conditions. If the problem
persists call Service.
3 - 79
System
Service
Response
Manual
Section
Fluid
- Notify the
The system has
detected a missing post Movement alarm through
the UI
dispense rinse/clean
- Do the same
operation.
like an LLD
This is not an hardware
- Create Log
problem.
Entry
Robotic
- Notify the
Try to determine if the
alarm through
failure is caused by liquid XYZ
the UI
not detected or by a false
- Complete the
positive LLD.
current job as
Problems detecting liqfailed, with no
uid can be investigated
results if all
performing diagnostics
determinations
LLD test into cuvettes.
are failed.
False positive LLDs can
be detected performing
diagnostics LLD test
selecting as target location "Reference point".
Where
raised
Service Action
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Liquid
Level
Detection
(Clean/
Rinse)
Air Read
Failure Out Of
Range
Alarm Description
LLD error in well
Code
1294
Current air read for this 1295
wavelength, read head
and read channel is out
of range
Message
Cause
Service
Manual
Section
Robotic
Check probe condi- Try to determine if the
This alarm is
Probe <Probe
tions. If the problem failure is caused by liquid XYZ
name> Liquid Level reported by the
not detected or by a false
persists call SerDetection error in analyzer when,
positive LLD.
well position <well aspirating a liquid vice.
Problems detecting liqfrom a well, one of
pos>.
uid can be investigated
the following condiperforming diagnostics
tions is detected.
LLD test into the clean
- Liquid not found
cup.
- LLD monitor failFalse positive LLDs can
ure
be detected performing
diagnostics LLD test
selecting as target location "Reference point".
ORU air reading
Air read out of
out of range.
range for ORU#
<ORU ID> Channel# <CHAN ID>
Wavelength#
<WAVE ID> Reading: <ORU READING>
Operator Action
Call Service.
Service Action
Look for foreign obstruc- Reaction
tion in the ORU head. If Detection
ORU cuvette slot is
clear, then insert a piece
of white paper. The
paper should have 4
dots of purple light. If red
only, then the blue light
is missing. If blue only,
then the red light is missing. Replace ORU module if obstruction was not
detected.
3 - 80
System
Response
Where
raised
- 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 performs an emergency stop.
- Notify the
alarms through
the UI
- Disable the
ORU head
when the instrument status is
not BUSY
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Invalid
Transmit
Message
Format
Reader
Transmit
Hardware
Alarm Description
Code
Invalid transmit mes- 1296
sage format for the bar
code reader.
Communications trans- 1297
mission hardware is
not functional.
Cuvette not A request was made to 1318
present to drop off a cuvette, but
drop off
no cuvette is detected
in the shuttle.
Cuvette
source
empty
The source position for 1323
picking up a cuvette is
empty.
Message
Cause
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The system perRS232 transmit
The serial port
formed an Emerhardware error.
hardware is not
gency stop:
functioning propperform a Recoverly.
ery. If the problem
persists call Service.
No cuvette strip in Either a cuvette is The system pershuttle to drop off. really not present, formed an Emerthe presence sen- gency stop:
sor is not function- perform a Recovery. If the problem
ing properly (ex.
persists call Serdirty), or a cable
vice.
has come
unplugged.
Cuvette not present Either a scheduler The system perto pickup.
error or operator
formed an Emererror in diagnostics. gency stop:
perform a Recovery. If the problem
persists call Service.
Bar code reader
invalid message
format.
Service Action
Service
Manual
Section
Bar code label format not Reaction
Detection
supported by the ACL
TOP.
3 - 81
System
Response
Where
raised
Notify the alarm AM Convia the UI. Per- trollers
form an emergency stop.
Repair / replace serial
Reaction
port on Command Mod- Detection
ule.
Notify the alarm AM Convia the UI. Per- trollers
form an emergency stop.
Cuvette
Use diagnostics
Movement
(Cuvettes Tab > Move
cuvettes section) to
move cuvettes and verify
that the Cuvette in shuttle sensor changes state.
- Turn off power AM Controllers
to stepper
motor.
- Notify the
alarm via the UI
- Perform an
emergency stop
This is a software defect. Cuvette
Movement
Ask the operator or
watch the operator for
how they load and program the system. After
determining how the
instrument is operated,
suggest a different order
to avoid following the
same logic path in software.
- Turn off power AM Controllers
to stepper
motor.
- Notify the
alarm via the UI
- Perform an
emergency stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
The destination posiCuvette
destination tion for placing a
cuvette is occupied.
full
Code
1324
The number of cuvette 1328
Invalid
number of slots detected is not a
valid configuration
cuvette
slots
The number of
Cuvette
slots found required slots was
too early. detected too early in
move distance.
1329
Message
Cuvette destination position full.
Cause
Operator Action
Either a scheduler The system performed an Emererror or operator
error in diagnostics. gency stop:
perform a Recovery. If the problem
persists call Service.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Cuvette slot found Either there are too The system pertoo early.
many mechanical formed an Emerslots or the sensor gency stop:
perform a Recovhas picked up
ery. If the problem
noise.
persists call Service.
Invalid number of
cuvette slots.
Either a module is
incorrect or the
configuration dip
switch is set incorrectly.
3 - 82
System
Service
Response
Manual
Section
- Turn off power
This is a software defect. Cuvette
Movement to stepper
Ask the operator or
motor.
watch the operator for
- Notify the
how they load and proalarm via the UI
gram the system. After
- Perform an
determining how the
emergency stop
instrument is operated,
suggest a different order
to avoid following the
same logic path in software.
Cuvette
- Turn off power
Ensure the PC104 dip
switches are set to the Movement to stepper
motor.
proper instrument con- Notify the
figuration.
alarm via the UI
- Perform an
emergency stop
Cuvette
- Turn off power
Check cable connections to make sure sen- Movement to stepper
motor.
sor is not noisy. In this
- Notify the
case, the move comalarm via the UI
pleted in finding the cor- Perform an
rect number of slots, but
emergency stop
the distance traveled
was too short.
Where
raised
Service Action
AM Controllers
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Gripper
back sensor On
Gripper
back sensor not
found
Alarm Description
Code
Message
Cause
Operator Action
1330
During initialization
(home), the gripper
attempts to move off
the back sensor, but
the sensor is still
detected or extend
gripper operation performed, but the back
sensor is still detected.
Gripper back sensor still active.
Either a sensor fail- The system perure, cabling failure, formed an Emergency stop:
or motor stall.
perform a Recovery. If the problem
persists call Service.
1331
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.
Gripper back sensor not found.
Either a sensor fail- The system perure, cabling failure, formed an Emeror motor stall.
gency stop:
perform a Recovery. If the problem
persists call Service.
3 - 83
System
Service
Response
Manual
Section
Cuvette
- Turn off power
Use Diagnostics
(Cuvettes Tab) to check Movement to stepper
motor.
the Gripper Back sensor.
- Notify the
Press the Disable Shutalarm via the UI
tle Motors button to
- Perform an
move the shuttle freely.
emergency stop
On the side of the shuttle, turn the motor wheel
to move the gripper in
and out. Move the gripper all the way to the
back and verify that the
Gripper back sensor
changes state.
Cuvette
- Turn off power
Use Diagnostics
(Cuvettes Tab) to check Movement to stepper
motor.
the Gripper Back sensor.
- Notify the
Press the Disable Shutalarm via the UI
tle Motors button to
- Perform an
move the shuttle freely.
emergency stop
On the side of the shuttle, turn the motor wheel
to move the gripper in
and out. Move the gripper all the way to the
back and verify that the
Gripper back sensor
changes state.
Where
raised
Service Action
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
1332 Gripper forward
Gripper for- After the gripper has
sensor still active.
ward sen- completed a retract
move the forward sensor On
sor is still detected.
Gripper for- Extend gripper opera- 1333
ward sen- tion did not detect the
front sensor.
sor not
found
Gripper forward
sensor not found.
Cause
Operator Action
Either a sensor fail- The system perure, cabling failure, formed an Emergency stop:
or motor stall.
perform a Recovery. If the problem
persists call Service.
Either a sensor fail- The system perure, cabling failure, formed an Emeror motor stall.
gency stop:
perform a Recovery. If the problem
persists call Service.
3 - 84
System
Service
Response
Manual
Section
Cuvette
- Turn off power
Use Diagnostics
(Cuvettes Tab) to check Movement to stepper
motor.
the Gripper Front sen- Notify the
sor. Press the Disable
alarm via the UI
Shuttle Motors button to
- Perform an
move the shuttle freely.
emergency stop
On the side of the shuttle, turn the motor wheel
to move the gripper in
and out. Move the gripper all the way out and
verify that the Gripper
front sensor changes
state.
Cuvette
- Turn off power
Use Diagnostics
(Cuvettes Tab) to check Movement to stepper
motor.
the Gripper Front sen- Notify the
sor. Press the Disable
alarm via the UI
Shuttle Motors button to
- Perform an
move the shuttle freely.
emergency stop
On the side of the shuttle, turn the motor wheel
to move the gripper in
and out. Move the gripper all the way out and
verify that the Gripper
front sensor changes
state. If the sensor is
functional, then re-align
the shuttle as it may not
be extending far enough
to trip the sensor.
Where
raised
Service Action
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Cuvette
Tray Not
Down
Cuvette
Tray Not
Up
Alarm Description
Code
Message
Cause
Operator Action
1334
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 position. Allowed 250 ms to
move.
Cuvette waste tray Tray mechanically The system performed an Emerdid not dump.
stuck or solenoid
gency stop:
malfunction.
perform a Recovery. If the problem
persists call Service.
1335
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.
Cuvette waste tray Tray mechanically The system performed an Emernot ready to receive stuck or solenoid
gency stop:
malfunction.
cuvettes.
perform a Recovery. If the problem
persists call Service.
3 - 85
System
Service
Response
Manual
Section
- Notify the
Check for obstructions in Cuvette
the cuvette waste drawer Movement alarm via the UI
- Disable the
that would prevent the
accumulator
tray from moving. Use
solenoid
Diagnostics (Cuvettes
- Perform an
Tab > Waste section) to
Emergency
move the tray with the
Stop
Clear Accumulator button.
- Notify the
Check for obstructions in Cuvette
the cuvette waste drawer Movement alarm via the UI
- Disable the
that would prevent the
accumulator
tray from moving. Use
solenoid
Diagnostics (Cuvettes
- Perform an
Tab > Waste section) to
Emergency
move the tray with the
Stop
Clear Accumulator button.
Where
raised
Service Action
AM Controllers
AM Controllers
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
Arm Failure 1
X Axis - Invalid Profile 1341
Parameter
X Axis - Invalid Pro- The universal arm
file Parameter
controller reporting
the alarm was sent
a velocity profile
parameter(s) for
the X axis motor
that exceeded maximum/minimum criteria or was
incompatible with
other profile parameters.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Arm Failure 2
Y Axis - Invalid Profile 1342
Parameter
Y Axis - Invalid Pro- The universal arm
file Parameter
controller reporting
the alarm was sent
a velocity profile
parameter(s) for
the Y axis motor
that exceeded maximum/minimum criteria or was
incompatible with
other profile parameters.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 86
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 3
Arm Failure 4
Alarm Description
Code
Message
Cause
Operator Action
Z Axis - Invalid Profile 1343
Parameter
Z Axis - Invalid Pro- The universal arm
file Parameter
controller reporting
the alarm was sent
a velocity profile
parameter(s) for
the Z axis motor
that exceeded maximum/minimum criteria or was
incompatible with
other profile parameters.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
X Axis - Speed
1344
Exceeds Profile Maximum
X Axis - Speed
Exceeds Profile
Maximum
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
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.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 87
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 5
Arm Failure 6
Alarm Description
Code
Message
Cause
Operator Action
1345
Y Axis - Speed
Exceeds Profile Maximum
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Z Axis - Speed
1346
Exceeds Profile Maximum
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 88
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
Arm Failure 7
X Axis - Cannot Process 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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Arm Failure 8
Y Axis - Cannot Process 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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 89
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Alarm/
Error
Name
Arm Failure 9
Z Axis - Cannot Process Steps Required
Arm Failure 10
X Axis - Selected Pro- 1350
file Is Invalid
1349
Message
Cause
Operator Action
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
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 profile does not exist.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 90
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
Arm Failure 11
Y Axis - Selected Pro- 1351
file Is Invalid
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 profile does not exist.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Arm Failure 12
Z Axis - Selected Pro- 1352
file Is Invalid
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 profile does not exist.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 91
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 13
Alarm Description
Code
X Axis - Move Took
1353
Too Long To Complete
Message
Cause
X Axis - Move Took The universal arm
Too Long To Com- controller reporting
the alarm has
plete
detected that the an
X axis move is taking longer than
expected to complete.
Possible causes:
1. The universal
arm controller
receives a verification pulse from the
X axis motor circuitry for each step
pulse. The controller assumes that an
X axis move is
complete when the
number of verification pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step verification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complications.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that connections Robotic
and circuitry related to XYZ
the X axis step pulse are
functioning.
3 - 92
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that connections
and circuitry related to
the X axis verification
pulse are functioning.
Suspect defect in software.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 14
Alarm Description
Code
Y Axis - Move Took To 1354
Long To Complete
Message
Cause
Y Axis - Move Took The universal arm
Too Long To Com- controller reporting
the alarm has
plete
detected that the an
Y axis move is taking longer than
expected to complete.
Possible causes:
1. The universal
arm controller
receives a verification pulse from the
Y axis motor circuitry for each step
pulse. The controller assumes that an
Y axis move is
complete when the
number of verification pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step verification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complications.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that connections Robotic
and circuitry related to XYZ
the Y axis step pulse are
functioning.
3 - 93
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that connections
and circuitry related to
the Y axis verification
pulse are functioning.
Suspect defect in software.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 15
Alarm Description
Code
Z Axis - Move Took
1355
Too Long To Complete
Message
Cause
Z Axis - Move Took The universal arm
Too Long To Com- controller reporting
the alarm has
plete
detected that the an
Z axis move is taking longer than
expected to complete.
Possible causes:
1. The universal
arm controller
receives a verification pulse from the
Z axis motor circuitry for each step
pulse. The controller assumes that an
Z axis move is complete when the
number of verification pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step verification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complications.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that connections Robotic
and circuitry related to XYZ
the Z axis step pulse are
functioning.
3 - 94
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that connections
and circuitry related to
the Z axis verification
pulse are functioning.
Suspect defect in software.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 16
Alarm Description
X Axis - Movement
Generates Too Many
Steps
Code
1356
Message
Cause
X Axis - Movement The universal arm
controller reporting
Generates Too
the alarm was sent
Many Steps
a command to
move the X axis
motor to a position
which would
require exceeding
the number of steps
that can be processed.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 95
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 17
Alarm Description
Y Axis - Movement
Generates Too Many
Steps
Code
1357
Message
Cause
Y Axis - Movement The universal arm
controller reporting
Generates Too
the alarm was sent
Many Steps
a command to
move the Y axis
motor to a position
which would
require exceeding
the number of steps
that can be processed.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
3 - 96
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 18
Arm Failure 19
Alarm Description
Code
Message
Cause
Operator Action
Z Axis - Movement
Generates Too Many
Steps
1358
Z Axis - Movement The universal arm
controller reporting
Generates Too
the alarm was sent
Many Steps
a command to
move the Z axis
motor to a position
which would
require exceeding
the number of steps
that can be processed.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
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 initialize 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 malfunctioning or misplaced limit
sensor(s).
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Ensure
that the FTP service is
running on the personal
computer. Fix any incorrect versions. Re-boot
the personal computer in
an attempt to restart the
FTP service and allow
the CM to initiate reprogramming of the controllers.
Check X axis limit sen- Robotic
sors for proper operation XYZ
and placement.
3 - 97
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for blockages or
other causes of slippage
in the X axis - especially
during arm initialization.
Possible software
defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 20
Arm Failure 21
Alarm Description
Y Axis - Invalid Limit
State While Homing
Z Axis - Invalid Limit
State While Homing
Code
1360
1361
Message
Y Axis - Invalid
Limit State While
Homing
Z Axis - Invalid
Limit State While
Homing
Cause
The universal arm
control reporting
the alarm was
attempting to initialize 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 malfunctioning or misplaced limit
sensor(s).
The universal arm
control reporting
the alarm was
attempting to initialize 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 malfunctioning or misplaced limit
sensor(s).
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check Y axis limit sen- Robotic
sors for proper operation XYZ
and placement.
3 - 98
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for blockages or
other causes of slippage
in the Y axis - especially
during arm initialization.
Possible software
defect.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check Z axis limit sen- Robotic
sors for proper operation XYZ
and placement.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for blockages or
other causes of slippage
in the Z axis - especially
during arm initialization.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 22
Arm Failure 23
Alarm Description
Code
X Axis - Limit Detected 1362
During Move
Y Axis - Limit Detected 1363
During Move
Message
X Axis - Limit
Detected During
Move
Y Axis - Limit
Detected During
Move
Cause
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 defect
3. malfunctioning or
misplaced limit sensor(s)
4. X axis Encoder
malfunction.
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 defect
3. malfunctioning or
misplaced limit sensor(s)
4. Y axis Encoder
malfunction.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check X axis limit sen- Robotic
sors for proper operation XYZ
and placement.
3 - 99
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for blockages or
other causes of slippage
in the X axis - especially
during arm initialization.
Check for malfunctioning
X axis position encoder
and support circuits.
Suspect software defect.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check Y axis limit sen- Robotic
sors for proper operation XYZ
and placement.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for blockages or
other causes of slippage
in the Y axis - especially
during arm initialization.
Check for malfunctioning
Y axis position encoder
and support circuits.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 24
Alarm Description
Code
Z Axis - Limit Detected 1364
During Move
Message
Z Axis - Limit
Detected During
Move
Cause
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 defect
3. malfunctioning or
misplaced limit sensor(s)
4. Z axis Encoder
malfunction.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Check Z axis limit sen- Robotic
sors for proper operation XYZ
and placement.
3 - 100
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for blockages or
other causes of slippage
in the Z axis - especially
during arm initialization.
Check for malfunctioning
Z axis position encoder
and support circuits.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 25
Alarm Description
X Axis - Slippage
Detected
Code
1365
Message
X Axis - Slippage
Detected
Cause
The universal arm
control reporting
the alarm has
detected that the X
axis motor did not
reach the expected
position at the completion of a move.
Could be caused
by:
1. Blockage or
restricted movement in the X axis.
2. Faulty X axis
position encoder.
3. X axis velocity
profile parameters
are incompatible
with current system.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check for X axis blockages or restrictions.
Check X axis position
encoder and supporting
circuitry for malfunction.
Service
Manual
Section
Robotic
XYZ
3 - 101
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that current versions of master and universal arm controllers
are compatible with the
current revision of the
instrument.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 26
Alarm Description
Y Axis - Slippage
Detected
Code
1366
Message
Y Axis - Slippage
Detected
Cause
The universal arm
control reporting
the alarm has
detected that the Y
axis motor did not
reach the expected
position at the completion of a move.
Could be caused
by:
1. Blockage or
restricted movement in the Y axis.
2. Faulty Y axis
position encoder.
3. Y axis velocity
profile parameters
are incompatible
with current system.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check for Y axis blockages or restrictions.
Check Y axis position
encoder and supporting
circuitry for malfunction.
Service
Manual
Section
Robotic
XYZ
3 - 102
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that current versions of master and universal arm controllers
are compatible with the
current revision of the
instrument.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 27
Arm Failure 28
Alarm Description
Z Axis - Slippage
Detected
Code
1367
X Axis - Cannot Store 1368
More Ramps
Message
Z Axis - Slippage
Detected
Cause
The universal arm
control reporting
the alarm has
detected that the Z
axis motor did not
reach the expected
position at the completion of a move.
Could be caused
by:
1. Blockage or
restricted movement in the Z axis.
2. Faulty Z axis
position encoder.
3. Z axis velocity
profile parameters
are incompatible
with current system.
X Axis - Cannot
The universal arm
Store More Ramps controller reporting
the alarm ran out of
memory allocated
for storage of
ramps for the X axis
motor.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check for Z axis blockages or restrictions.
Service
Manual
Section
Robotic
XYZ
Check Z axis position
encoder and supporting
circuitry for malfunction.
3 - 103
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that current versions of master and universal arm controllers
are compatible with the
current revision of the
instrument.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Reboot the personal computer in an attempt to
restart the FTP service
and allow the CM to initiate reprogramming of
the controllers.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Cause
Operator Action
Alarm/
Error
Name
Arm Failure 29
Y Axis - Cannot Store 1369
More Ramps
Y Axis - Cannot
The universal arm
Store More Ramps controller reporting
the alarm ran out of
memory allocated
for storage of
ramps for the Y axis
motor.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Arm Failure 30
Z Axis - Cannot Store
More Ramps
Z Axis - Cannot
The universal arm
Store More Ramps controller reporting
the alarm ran out of
memory allocated
for storage of
ramps for the Z axis
motor.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
1370
Service Action
Service
Manual
Section
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Reboot the personal computer in an attempt to
restart the FTP service
and allow the CM to initiate reprogramming of
the controllers.
Check that the software Robotic
versions are correct for XYZ
the release - in particular
the Master and Universal
Arm controller that produced the alarm. Reboot the personal computer in an attempt to
restart the FTP service
and allow the CM to initiate reprogramming of
the controllers.
3 - 104
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 31
Alarm Description
Code
X Axis - Motor Stalled 1371
Message
X Axis - Motor
Stalled
Cause
The universal arm
controller reporting
the alarm is reporting 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 movement in the X axis.
2. Faulty X axis
position encoder.
3. X axis velocity
profile parameters
are incompatible
with current system.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check for X axis blockages or restrictions.
Check X axis position
encoder and supporting
circuitry for malfunction.
Service
Manual
Section
Robotic
XYZ
3 - 105
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that current versions of master and universal arm controller
software are compatible
with the current revision
of the instrument.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 32
Alarm Description
Code
Y Axis - Motor Stalled 1372
Message
Y Axis - Motor
Stalled
Cause
The universal arm
controller reporting
the alarm is reporting 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 movement in the Y axis.
2. Faulty Y axis
position encoder.
3. Y axis velocity
profile parameters
are incompatible
with current system.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check for Y axis blockages or restrictions.
Check Y axis position
encoder and supporting
circuitry for malfunction.
Service
Manual
Section
Robotic
XYZ
3 - 106
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that current versions of master and universal arm controller
software are compatible
with the current revision
of the instrument.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 33
Alarm Description
Z Axis - Motor Stalled
Code
1373
Message
Z Axis - Motor
Stalled
Cause
The universal arm
controller reporting
the alarm is reporting 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 movement in the Z axis.
2. Faulty Z axis
position encoder.
3. Z axis velocity
profile parameters
are incompatible
with current system.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check for Z axis blockages or restrictions.
Check Z axis position
encoder and supporting
circuitry for malfunction.
Service
Manual
Section
Robotic
XYZ
3 - 107
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that current versions of master and universal arm controller
software are compatible
with the current revision
of the instrument.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 34
Alarm Description
Code
X Axis - Operation Tim- 1374
eout
Message
Cause
X Axis - Operation The universal arm
Timeout
controller reporting
the alarm has
detected that the X
axis motor is taking
too long to complete a move.
Possible causes:
1. The universal
arm controller
receives a verification pulse from the
X axis motor circuitry fro each step
pulse. The controller assumes that an
X axis move is
complete when the
number of verification pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step verification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complications.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that connections Robotic
and circuitry related to XYZ
the X axis step pulse are
functioning.
3 - 108
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that connections
and circuitry related to
the X axis verification
pulse are functioning.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 35
Alarm Description
Code
Y Axis - Operation Tim- 1375
eout
Message
Cause
Y Axis - Operation The universal arm
Timeout
controller reporting
the alarm has
detected that the Y
axis motor is taking
too long to complete a move.
Possible causes:
1. The universal
arm controller
receives a verification pulse from the
Y axis motor circuitry fro each step
pulse. The controller assumes that an
Y axis move is
complete when the
number of verification pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step verification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complications.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that connections Robotic
and circuitry related to XYZ
the Y axis step pulse are
functioning.
3 - 109
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that connections
and circuitry related to
the Y axis verification
pulse are functioning.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 36
Alarm Description
Code
Z Axis - Operation Tim- 1376
eout
Message
Cause
Z Axis - Operation The universal arm
Timeout
controller reporting
the alarm has
detected that the Z
axis motor is taking
too long to complete a move.
Possible causes:
1. The universal
arm controller
receives a verification pulse from the
Z axis motor circuitry fro each step
pulse. The controller assumes that an
Z axis move is complete when the
number of verification pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step verification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complications.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that connections Robotic
and circuitry related to XYZ
the Z axis step pulse are
functioning.
3 - 110
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Ensure that connections
and circuitry related to
the Z axis verification
pulse are functioning.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 37
Arm Failure 38
Arm Failure 39
Alarm Description
X Axis - Operation
Failed
Y Axis - Operation
Failed
Z Axis - Operation
Failed
Code
1377
1378
1379
Message
Cause
Operator Action
Service Action
X Axis - Operation This is an internal
Failed
software error.
Cause is always
software defect.
Incorrect message
was placed on a
queue.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
This is an internal software error
Y Axis - Operation This is an internal
Failed
software error.
Cause is always
software defect.
Incorrect message
was placed on a
queue.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
This is an internal software error
Z Axis - Operation This is an internal
Failed
software error.
Cause is always
software defect.
Incorrect message
was placed on a
queue.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
This is an internal software error
Service
Manual
Section
Robotic
XYZ
Suspect software defect.
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Robotic
XYZ
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Robotic
XYZ
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Suspect software defect.
Suspect software defect.
3 - 111
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 40
Alarm Description
Tube Release Procedure Failed
Code
1380
Message
Cause
Tube Release Pro- The controller has
detected in initialcedure Failed
ization the tube
(CTS Only)
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 sensors.
2. Restricted or
blocked movement
in the Z axis.
3. Piercer latch
solenoid.
4. Excessive friction between
piercer latch and
probe.
5. Excessive force
required to extract
the piercer from the
cap.
6. Software defect.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that Z axis move- Robotic
XYZ
ment is unrestricted.
Ensure CTS sensors are
functioning especially
cap detect, piercer lock,
piercer position, and
travel limit.
3 - 112
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for excessive friction between piercer
latch and probe.
Check for proper operation of piercer latch and
solenoid.
Ensure that (if the
piercer is in a cap) there
is not excessive force
required to extract the
piercer from the cap.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 41
Arm Failure 42
Alarm Description
Code
Sensor Or Motor Fail- 1381
ure Caused Latch Offset Measurement To
Fail
LLD Hardware Failure 1382
Message
Cause
The universal arm
controller reporting
the alarm has
detected that the
latch offset measurement operation failed.
This is only applicable to CTS instruments.
The failure can
have many causes:
1. Faulty cap, limit,
piercer position, or
piercer latch sensors.
2. Restricted or
blocked movement
in the Z axis.
3. Piercer latch
solenoid.
4. Excessive friction between
piercer latch and
probe.
5. Software defect.
LLD Hardware Fail- The universal arm
ure
controller reporting
the arm has
detected that the
LLD circuitry is not
interrupting the processor at the
required rate.
Sensor Or Motor
Failure Caused
Latch Offset Measurement To Fail
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Service
Manual
Section
Ensure that Z axis move- Robotic
XYZ
ment is unrestricted.
Ensure CTS sensors are
functioning especially
cap detect, piercer lock,
piercer position, and
travel limit.
3 - 113
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check for excessive friction between piercer
latch and probe.
Check for proper operation of piercer latch and
solenoid
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check all LLD circuitry Robotic
involved with liquid level XYZ
detection. In particular
ensure that the circuitry
responsible for interrupting the processor is functioning properly.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 43
Alarm Description
Code
Piercer Was Not In The 1383
Expected State
Message
Cause
Piercer Was Not In The universal arm
The Expected State controller reporting
the alarm was sent
a command to verify that the piercer
was in a particular
state (CTS or Sample). The verification failed.
i.e. There is a mismatch between the
state that the Master SW expects the
Piercer to be in and
the state that the
universal arm controller thinks the
piercer is in.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Check the piercer latch
solenoid for excessive
friction.
Service
Manual
Section
Robotic
XYZ
3 - 114
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check the piercer spring
for proper tension.
Check for proper operation of the latch solenoid
and drive circuitry.
Suspect software defect.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 44
Arm Failure 45
Alarm Description
Z Axis - Power DAC
failed
Code
1384
Syringe Is Always Busy 1385
Message
Cause
Operator Action
Z Axis - Power DAC The universal arm
failed
controller reporting
the alarm has
detected that DAC
controlling the
amount of power to
the Z axis motor is
not performing
within tolerances.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Syringe Is Always
Busy
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The universal arm
controller reporting
the alarm is waiting
for the CAVRO
syringe to complete
an operation but it
is taking too long.
Service Action
Service
Manual
Section
Check that supply volt- Robotic
ages are functioning and XYZ
are within specifications.
Ensure the reference
voltage to the Z axis
DAC is within specifications.
If possible, ensure that
the Z axis power DAC is
supplying the expected
output for the applied
input data.
Replace the Z axis DAC
or the board containing
the Z axis DAC if the
DAC is not functioning
properly.
Check serial connecRobotic
tions to the CAVRO
XYZ
syringe pump.
3 - 115
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
(unused)
Syringe Is Always Busy 1386
Syringe Is Always
Busy
Arm Failure 47
Syringe Took Too Long 1387
To Respond
Syringe Took Too
Long To Respond
Arm Failure 48
Syringe Could Not Be 1388
Initialized
Cause
Operator Action
Service Action
Service
Manual
Section
Robotic
XYZ
3 - 116
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check serial connections to the CAVRO
syringe pump.
The universal arm
controller reporting
the alarm is waiting
for the CAVRO
syringe to respond
to a previous command but it took too
long.
Syringe Could Not The universal arm
Be Initialized
controller reporting
the alarm could not
initialize the
CAVRO syringe
pump.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check serial connections to the CAVRO
syringe pump.
Robotic
XYZ
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check for blockages and Robotic
XYZ
loose connections
before attempting to
reinitialize. The pump
will not accept commands until it has been
successfully initialized.
This error can only be
cleared by successfully
initializing the probe.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 49
Alarm Description
Code
Message
Cause
Operator Action
Service Action
Service
Manual
Section
Either Software defect or Robotic
XYZ
communication error.
Check syringe serial
communications cables
for unreliable connections.
3 - 117
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
1389
Syringe Does Not
Understand The Command
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Arm Failure 50
Syringe Command
Parameter Is Invalid
Syringe Command The universal arm
Parameter Is
controller reporting
Invalid
the alarm received
an error message
from the CAVRO
syringe indicating
that the last command sent to it contained an invalid
parameter.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Either Software defect or Robotic
XYZ
communication error.
Check syringe serial
communications cables
for unreliable connections.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Arm Failure 51
Syringe Must Be Initial- 1391
ized
Syringe Must Be
Initialized
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Either Software defect or Robotic
XYZ
communication error.
Check syringe serial
communications cables
for unreliable connections.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
1390
The universal arm
controller reporting
the alarm received
an error message
from the CAVRO
syringe indicating
that it must be initialized before any
further commands
can be performed.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
Arm Failure 52
Syringe Plunger Is
Overloaded
Arm Failure 53
Arm Failure 54
Code
Message
Cause
Operator Action
Service Action
Service
Manual
Section
Robotic
XYZ
3 - 118
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Syringe Plunger Is The universal arm
Overloaded
controller reporting
the alarm received
an error message
from the CAVRO
syringe indicating
that the plunger is
overloaded.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check for blockages of
the syringe plunger or
excessive back pressure. The pump must be
reinitialized before normal operation can
resume.
Syringe Valve Is Over- 1393
loaded
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check for valve block- Robotic
age or excess back pres- XYZ
sure. The valve must be
reinitialized before normal operation can
resume.
Continual valve overload
errors are an indication
the valve should be
replaced.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Syringe Move Is Not
Permitted
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.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
This error can be caused Robotic
by a previous error con- XYZ
dition where the valve is
left in bypass or throughput position.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
1392
1394
Suspect defect in software.
Initialization of the
syringe via diagnostics
mode or recovery is
required.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 55
Alarm Description
Syringe Error With
Unknown Source
Code
1395
Message
Cause
Syringe Error With The universal arm
Unknown Source controller reporting
the alarm received
an error message
from the CAVRO
syringe but it is not
a recognized published error.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Service Action
Suspect communications error or software
version incompatibility.
Service
Manual
Section
Robotic
XYZ
3 - 119
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check CAVRO syringe
serial connections for
reliability.
Ensure that software
versions are correct for
the release - in particular
the master, and universal arm software as well
as CAVRO syringe revision.
Correct if required.
Arm Failure 56
Error Communicating
With The Syringe
1396
Error Communicat- The universal arm
ing With The
controller reporting
Syringe
the alarm is indicating that either 1. The buffer used
for receiving serial
data from the
CAVRO syringe
has overflowed.
2. The control signals used for coordinating serial data
transmission to the
syringe are not in
the correct state.
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Check CAVRO syringe
serial connections for
reliability.
Robotic
XYZ
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Software defect - possibly buffer must be
increased.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Alarm/
Error
Name
Arm Failure 57
Syringe Hardware Mal- 1397
function
Arm Failure 74
Cts piercer lock not
locked
1414
Message
Syringe Hardware
Malfunction
Cause
Not used.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
The system perCts piercer lock not The AM has
formed an Emerlocked
detected that the
piercer latch is not gency stop:
in one of it's detent perform a Recovery. If the problem
positions.
persists call Service.
Service Action
Replace Syringe Module.
Check CTS latch solenoid and drive circuitry
for proper operation.
Service
Manual
Section
Robotic
XYZ
Robotic
XYZ
3 - 120
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check piercer spring for
proper tension.
Check piercer latch for
excessive friction.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Arm Failure 75
Alarm Description
Code
Cts probe mode switch 1415
failure
1416
CTS Sole- The CTS hardware
noid Latch used to change the
Failure
probe between piercing mode and sample
mode failed to switch.
Message
Cts probe mode
switch failure
Cause
The AM attempted
to set the CTS
mode (sample or
CTS) but after verifying determined
that the piercer was
not in the expected
mode.
Operator Action
The system performed an Emergency stop:
perform a Recovery. If the problem
persists call Service.
Possible causes:
1. CTS spring tension too light.
2. Faulty CTS position,
or latch sensor
3. Faulty latch solenoid or circuitry.
Cannot switch CTS The sensor was not Perform a recovery.
between piercing seen after perform- If the problem perand sample mode. ing the CTS mode sists, call service.
switch operation.
Failure could be
sensor, spring,
solenoid, or software.
Service Action
Check CTS latch solenoid and drive circuitry
for proper operation.
Service
Manual
Section
Robotic
XYZ
3 - 121
System
Response
Where
raised
Notify the alarm AM Masvia the UI. Per- ter
form an emergency stop.
Check piercer spring for
proper tension.
Check piercer latch for
excessive friction.
Check CTS latch solenoid and drive circuitry
for proper operation.
Robotic
XYZ
Notify the alarm AM Convia the UI. Per- trollers
form an emergency stop.
Check piercer spring for
proper tension.
Check piercer latch for
excessive friction.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Code
Message
Alarm/
Error
Name
Vial Location Unreach- 1417 Location unreachLocation
able by <Probe>:
Unreach- able
track #
able (sam<Rack>,position
ple or
<Position>.
reagent)
(Cuvette)
Location
Unreachable
Cuvette Location
Unreachable
1418
UnexThe probe detects liq- 1419
pected Liq- uid but the measured
uid Level position of the liquid is
unexpected.
Unexpected Liquid Level
(Cuvette)
The probe detects liq- 1420
uid but the measured
position of the liquid is
unexpected.
Cause
Operator Action
Service Action
Service
Manual
Section
Instrument coordinates Robotic
Invalid arm homing Perform Coordiposition or coordi- nates Adjustment. are closely referenced to XYZ
If the problem per- the arm home position
nate adjustment
sists, call service. sensor.
failure.
1. Ensure that the home
sensor for the arm that
reports the alarm is in
the proper location.
2. From diagnostics run
coordinates adjustment.
Instrument coordinates Robotic
Location unreach- Invalid arm homing Perform Coordiable by <Probe>: position or coordi- nates Adjustment. are closely referenced to XYZ
If the problem per- the arm home position.
cuvette <Cuvette nate adjustment
sists, call service.
Slot ID>, well <well failure.
1. Ensure that the home
position>.
sensor for the arm that
reports the alarm is in
the proper location.
2. From diagnostics run
coordinates adjustment.
Probe <probe
name> unexpected
liquid level in rack
position <X>, track
<YY>.
Probe <probe
name> unexpected
liquid level in
cuvette position
<X>, slot <YY>.
The probe detects
liquid but the measured position of
the liquid is unexpected.
The probe detects
liquid but the measured position of
the liquid is unexpected.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
3 - 122
System
Response
- Notify the
alarm through
the UI
Where
raised
AM Master
- Notify the
AM Masalarm via the UI ter
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Unexpected Liquid Level
(Clean/
Rinse)
Pre Aspiration Baseline Check
Failure
Alarm Description
Code
Where
raised
Cause
Operator Action
The probe detects liq- 1421
uid but the measured
position of the liquid is
unexpected.
Probe <Probe
name> unexpected
liquid level in well
position <well pos>.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
Invalid liquid detection: 1422
difference in baseline
values read before and
after liquid detection is
too low.
Probe <probe
name> Pre Aspiration Baseline
Check Failure in
rack position <X>,
track <YY>.
Probe <probe
name> Pre Aspiration Baseline
Check Failure in
cuvette position
<X>, slot <YY>.
Probe <Probe
name> Pre Aspiration Baseline
Check Failure in
well position <well
pos>.
Probe <probe
name> aspiration
baseline check failure in rack position
<X>, track <YY>.
The probe detects
liquid but the measured position of
the liquid is unexpected.
Invalid liquid detection: difference in
baseline values
read before and
after liquid detection is too low.
Invalid liquid detection: difference in
baseline values
read before and
after liquid detection is too low.
Invalid liquid detection: difference in
baseline values
read before and
after liquid detection is too low.
Invalid liquid detection: difference in
baseline values
read before and
after aspiration is
too high.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
Invalid liquid detection: 1423
difference in baseline
values read before and
after liquid detection is
too low.
Pre Aspiration Baseline Check
Failure
(Clear/
Rinse)
Aspiration
Baseline
Check Failure (Position)
Invalid liquid detection: 1424
difference in baseline
values read before and
after liquid detection is
too low.
Invalid liquid detection: 1425
difference in baseline
values read before and
after aspiration is too
high.
Service
Manual
Section
System
Response
Message
Pre Aspiration Baseline Check
Failure
(Cuvette)
Service Action
3 - 123
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
AM Master
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Aspiration
Baseline
Check Failure
(Cuvette)
Alarm Description
Code
Invalid liquid detection: 1426
difference in baseline
values read before and
after aspiration is too
high.
Aspiration
Baseline
Check Failure (Well)
Invalid liquid detection: 1427
difference in baseline
values read before and
after aspiration is too
high.
Post Aspiration
Baseline
Check Failure (Position)
1428
Invalid liquid aspiration. LLD Baseline read
after liquid level detection and after liquid
aspiration is too high:
the probe did not stay
submerged.
Invalid liquid aspira1429
tion. LLD Baseline read
after liquid level detection and after liquid
aspiration is too high:
the probe did not stay
submerged.
1430
Invalid liquid aspiration. LLD Baseline read
after liquid level detection and after liquid
aspiration is too high:
the probe did not stay
submerged.
Post Aspiration
Baseline
Check Failure
(Cuvette)
Post Aspiration
Baseline
Check Failure (Well)
Message
Cause
Operator Action
Service Action
Service
Manual
Section
3 - 124
System
Response
Where
raised
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
The probe did not
Probe <probe
name> Post Aspira- stay submerged.
tion Baseline
Check Failure in
cuvette position
<X>, slot <YY>.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
The probe did not
Probe <Probe
name> Post Aspira- stay submerged.
tion Baseline
Check Failure in
well position <well
pos>.
Check probe conditions. If the problem
persists call Service.
Check LLD counts in
Diagnostics, check
probe, rerun coordinates.
- Notify alarm
through the UI
- Flag results
with
LLD_ERROR
AM Master
Invalid liquid detection: difference in
baseline values
read before and
after aspiration is
too high.
Invalid liquid detection: difference in
baseline values
read before and
after aspiration is
too high.
The probe did not
Probe <probe
name> Post Aspira- stay submerged.
tion Baseline
Check Failure in
rack position <X>,
track <YY>.
Probe <probe
name> aspiration
baseline check failure in cuvette position <X>, slot
<YY>.
Probe <Probe
name> aspiration
baseline check failure in well position
<well pos>.
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
(Cuvette)
Invalid
Move
Alarm Description
Code
The requested Cuvette 2040
move is not allowed
2075
(Cuvette) Insufficient Liquid
Insufficient detected when mixing
Liquid
is performed in a
cuvette.
Scheduling Time
Violation
The actual execution
did not meet a critical
scheduling time. The
job failed and it is not
possible to recover
2080
Message
Cause
Cuvettes strip posi- Invalid positioning
tioning failure.
command.
Operator Action
3 - 125
System
Service
Response
Manual
Section
Processor/ - Notify the
Report this alarm and
Software alarm through
backup log as a comthe UI
plaint. This is a software
- Perform an
defect that requires coremergency stop
rection.
Where
raised
Service Action
The system performed an Emergency stop:
perform a Recovery.
If the problem persists call Service.
Verify probe alignment;
Insufficient liquid in This error flag is set Call Service.
run Diagnostics "Coordicuvette <Cuvette by the analyzer
nates Adjustment" for
Slot ID> well <well when, aspirating
the probe that reported
from a rack cuvette
position>.
the alarm.
cell, liquid is not
found or the available liquid volume
is less than the volume to be aspirated.
Report this alarm and
Unrecoverable
Internal scheduling The system perbackup log as a comscheduling time
conflict.
formed an Emerplaint. This is a possible
violation.
gency stop:
perform a Recov- software defect that
requires correction. It
ery.
If the problem per- could also be the speed
sists call Service. of the hardware.
Observe both cuvette
and arm movement for
speed.
AM Controllers
Fluid
- Notify the
AM MasMovement alarm via the UI ter
AM MasProcessor/ - Notify the
Software alarm through ter
the UI
- Perform Emergency Stop
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
LIS Mes- The UDC storage is
sage Stor- almost full of messages waiting to be
age Full
sent to LIS.
Code
Message
3200
Storage of messages sent to LIS
<%> full.
LIS Message Storage
Overloaded
The UDC storage is
almost full of messages waiting to be
sent to LIS. No more
messages are
accepted.
3201
Storage of messages sent to LIS
overloaded. New
uploaded messages will be
rejected.
Upload
Message
Rejected
UDC Rejected
Uploaded Message
3202
Upload message
was rejected and
therefore not sent
to LIS.
3 - 126
System
Where
Service
Response
raised
Manual
Section
CM
Processor/ - Notify user
Check communica- Ensure LIS system is
Number of messages pending to tion status in both physically attached and Software through alarms
area.
be uploaded to LIS ends. If communi- powered on. If possible
- Create Log
is reaching capac- cations cannot be from the LIS, verify conEntry
nection status. Verify
restored disable
ity.
them and call ser- wiring configuration
according to the LIS venvice.
dor specification.
CM
Processor/ - Notify user
Check communica- Refer to 1130
Number of mesSoftware through alarms
sages pending to tion status in both
area.
be uploaded to LIS ends. If communi- Create Log
has reached stor- cations cannot be
Entry
restored disable
age limit.
them and call service.
CM
Processor/ - Notify user
Check communica- Refer to 1130
Communications
Software through alarms
tion status in both
are not properly
area.
configured or stor- ends. If communi- Create Log
age of messages cations cannot be
Entry
restored disable
sent to LIS overthem and call serloaded. No more
messages can be vice.
accepted.
Cause
Operator Action
Service Action
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm/
Error
Name
Auto Start
Failed
Alarm Description
Code
Auto Start could not be 3211
started.
Message
Auto Start failed.
Cause
Possible causes
are:
- The instrument
was in a status that
did not allow for the
auto start to be initiated.
- CTS Filter was not
detected (for CTS
configuration only).
- Enhanced clean
required.
- Temperatures are
out of range.
- There is a ORU
disabled.
Operator Action
Service Action
The system looks Recheck all actions
for an opportunity listed in Operator's
to auto start every 1 actions column, Check
LIS settings
minute. Certain
conditions might
change without
operator's intervention.
Identify the cause
among the following and resolve:
- Instrument status:
the auto start cannot be initiated
when the status is
Initializing, Warming Up, Error,
Emergency Stop,
Controlled Stop,
Maintenance or
Diagnostics.
- CTS Filter missing: install a new filter (Maintenance
activity).
Service
Manual
Section
3 - 127
System
Response
- Notify user
through UI.
- Retry Auto
Start after 1
minute.
Where
raised
CM
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
Auto Start Auto Start could not be
started. (continued)
Failed
(continued)
The rack button
Invalid
(Rack) But- pressed is not a valid
code.
ton
Code
3211
(continued)
4015
Message
Cause
Operator Action
Service Action
Service
Manual
Section
3 - 128
System
Response
Where
raised
(continued)
- Temperatures are
out of range: wait
until the temperatures stabilize
(depending from
the system and
ambient conditions, this might
take more than 30
minutes); if they do
not stabilize, call
Service.
- Enhanced Clean
required: perform
Enhanced Clean
for all probes
(Maintenance activity).
- ORU disabled:
call Service.
Rack HanRack button identi- Rack position key- Call Service.
Check that cabling is
dling
fication failure.
pad malfunction.
properly seated to the
rack LED status boards.
If cabling is correct,
replace the rack status
boards.
AM Con- Notify the
alarm through trollers
the UI
- trace the error
for debug purpose
ACL-TOP Service Manual
Chapter 3 – Troubleshooting
Alarm Description
Alarm/
Error
Name
Cannot communicate
Scanner
Communi- with the bar code
reader.
cations
Code
4020
Message
Cause
Operator Action
Call Service.
Cable disconBarcode reader
communication fail- nected. Barcode
reader malfunction.
ure.
Rack controller or
Reader Traveling
board malfunction.
3 - 129
System
Service
Response
Manual
Section
Ensure that the cables Rack Han- - Notify the
alarm through
are seated properly. To dling
the UI
determine if the wiring is
- work without
correct from the reader
positive id
to the computer, turn off
the instrument power,
remove the cover of the
reader, disconnect the
cable to the reader, and
attach the loopback connector. After the connector is attached, restart
the instrument and enter
diagnostics. On the SW,
Covers, Racks tab,
press the Perform Loop
Back Check. If the test
has a result of Pass,
then there could be a
problem with the reader
or power to the reader. If
the result is Fail, then
check all the cabling.
Where
raised
Service Action
AM Controllers
ACL-TOP Service Manual
3 - 130 Chapter 3 – Troubleshooting
3-4 Troubleshooting Procedures
Please refer to individual chapters for detailed troubleshooting procedures.
ACL-TOP Service Manual
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 instrument 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 instrument. On the front panel of the instrument are two assemblies, the Sample and the Reagent doors, that provide 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 Assemblies, 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.
ACL-TOP Service Manual
4 - 2 Chapter 4 – Enclosure/Chassis
4-2 Physical Layout
Figure 4-1 ACL-TOP Chassis
Pylons
Rear Walls
Chassis
Base Skin
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 modules 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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4-3
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 Chassis". 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.
ACL-TOP Service Manual
4 - 4 Chapter 4 – Enclosure/Chassis
Figure 4-2 ACL-TOP Enclosure
Top Skin
Inner Left Skin
Upper Skin
(Sample Side)
Center Skin
Left Skin
Sample
Door
Upper Skin
Reagent Side
Inner Right
Skin
Front Panel
Reagent
Door
Right
Skin
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 sensing 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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4-5
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.
ACL-TOP Service Manual
4 - 6 Chapter 4 – Enclosure/Chassis
Figure 4-3 Diagnostics Screen, Controllers, Covers and Racks Tab
Covers Area
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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4-7
Figure 4-4 Cover Status
Virtual LEDs
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 enclosure.
ACL-TOP Service Manual
4 - 8 Chapter 4 – Enclosure/Chassis
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 prerequisites 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)".
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4-9
Figure 4-5 Sample Door Lower Right Sensor (upgradable)
Sensor
Figure 4-6 Sample Door Upper Right Sensor (current)
Door Sensor
3. Unplug, at connector (J2/P2) under the reagent door, the two wires that lead from the back of the sensor.
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.
ACL-TOP Service Manual
4 - 10 Chapter 4 – Enclosure/Chassis
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
Sensor Mounting
Screws
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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 11
Sample Door Removal
Perform the following steps to remove the sample door.
1. Open 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
Holding 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".
ACL-TOP Service Manual
4 - 12 Chapter 4 – Enclosure/Chassis
Figure 4-9 Sample Door ground Wire/Flag
Ground Wire/Flag
Screw
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
Hinge Attachment
Screws
Lower Portion
of 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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 13
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
Ground Wire
Flag
Tab
Optical Sensor Cable
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".
ACL-TOP Service Manual
4 - 14 Chapter 4 – Enclosure/Chassis
Figure 4-12 Reagent Door Left Hinge
Holding Screw
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
Attachment
Screw
Removal
Pocket
4. Insert a flat tip screwdriver into the removal pocket (if necessary) to pry the hinge loose from the alignment 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".
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 15
Figure 4-14 Reagent Door Hinge Removal
Hinge Arm
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".
ACL-TOP Service Manual
4 - 16 Chapter 4 – Enclosure/Chassis
Figure 4-15 Top Skin
Top Skin Screws
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".
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 17
Figure 4-16 Front Panel Lower Screws
Front Panel 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
Attachment Screw
ACL-TOP Service Manual
4 - 18 Chapter 4 – Enclosure/Chassis
Figure 4-18 Front Panel Center Screw
Attachment Screw
Figure 4-19 ACL-TOP Enclosure Upper Left Screw
Attachment 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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 19
Figure 4-20 Front Panel Cable Connections
Front
Panel
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"
ACL-TOP Service Manual
4 - 20 Chapter 4 – Enclosure/Chassis
Figure 4-21 Monitor Control Arm
Attachment
Screws
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.
1. Open the sample door.
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.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 21
Figure 4-22 Sample Module Interior Skins
Sample Syringe
Pump Interior
Skin
Sample Accumulator/
Wash Station
Interior Skin
Sample Area
Module Cover
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
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.
ACL-TOP Service Manual
4 - 22 Chapter 4 – Enclosure/Chassis
9. Carefully remove the skin from the instrument using caution to avoid hitting the probe assembly.
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
Cover Holding Brackets
Inner Left Skin Removal/Replacement
Prerequisites: Prior to removing the Inner Left skin, the top panel and front panel must be removed as previously 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.
Attachment
Screws
Upper
Skin
Attachment
Screws
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".
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 23
Figure 4-26 Inner Left Skin
Inner Left Skin
Attachment Screws
Inner Left Skin
Attachment Screws
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 is
glued 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".
ACL-TOP Service Manual
4 - 24 Chapter 4 – Enclosure/Chassis
Figure 4-27 Left Skin
Attachment
Screws
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 Interior Skin.
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 25
6. Lift (straight up) and remove the peristactic pump interior skin.
Figure 4-28 Reagent Area Inner Skins
Reagent
Accumulator/
Wash Station
Interior Skin
Reagent Syringe
Pump Interior
Cover
Peristaltic
Pump
Interior
Skin
Reagent Module Assembly Cover
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
Ground Lug
Snap Detent
9. Carefully remove the skin from the instrument using caution to avoid hitting the probe assembly.
10. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Reagent Accumulator/Wash Station Interior Skin.
11. Carefully remove the skin from the instrument using caution to avoid hitting the probe assembly.
ACL-TOP Service Manual
4 - 26 Chapter 4 – Enclosure/Chassis
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
Cover Holding Brackets
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.
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. 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".
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 27
Figure 4-31 Upper Skin Above the Reagent Side Robotic Arms
Attachment
Screws
Attachment
Screws
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
Attachment
Screws
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 following the top skin.
ACL-TOP Service Manual
4 - 28 Chapter 4 – Enclosure/Chassis
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.
1. Power down the ACL-TOP instrument and remove the plug from the AC Main.
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
Connector
(J1/P1) for
sensors
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".
ACL-TOP Service Manual
Chapter 4 – Enclosure/Chassis
4 - 29
Figure 4-34 Right Skin
Attachment
Screws
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.
ACL-TOP Service Manual
4 - 30 Chapter 4 – Enclosure/Chassis
Figure 4-35 Center Skin Attachment
Attachment
Screws
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.
ACL-TOP Service Manual
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".
ACL-TOP Service Manual
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 produce results (patient, quality control, diagnostics, maintenance) as requested by the operator. Both the Control 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.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5-3
Figure 5-3 Software Components
Control Module
The control module resides in the personal computer and is composed of the following software components. The function of each component is also briefly described.
ACL-TOP Service Manual
5 - 4 Chapter 5 – Processor / Software
•
Job Ordering accepts patient, QC, and calibration requests from the operator or Laboratory Information 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 a
specific result.
•
Results Management provides access to lists of results of tests that are completed or pending
completion.
•
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 quality.
•
Maintenance provides a collection of actions that must be executed at different intervals to maintain
a healthy instrument.
•
Diagnostic Ordering enables the service engineer or customer to identify and correct an instrument malfunction.
•
Log Management records operator and instrument actions providing an audit history and assistance in troubleshooting any problems.
•
Alarm Management alerts the operator to an action that needs to be taken to keep the instrument
executing efficiently.
•
Test Definition enables a specialist to define the steps needed to perform a new test or to edit an
existing 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 Laboratory
Information System.
•
AM Interface provides communications between the TOP personal computer and the Analytical
Module (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 instrument (AM).
•
Job Processing controls job sorting and job submission.
•
Device Scheduling provides and coordinates the steps needed to have devices in the instrument
perform their function at the scheduled time.
•
Alarm Management supplies alarm information to the personal computer for user notification and
changes the instrument state based on the alarm.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5-5
•
Safety detects when a safety violation occurs and it places the instrument into a safe state if a violation 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 the
cuvette waste.
•
Fluid Movement conducts all tasks needed to move fluid from one point to another. These tasks
include 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 performed.
•
Maintenance executes maintenance routines as requested by the operator.
•
Waste Management monitors instrument waste and changing the instrument to the appropriate
state 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 to
ensure sample processing is collected at the necessary temperature.
•
Optical Reading is a device control component and performs data acquisition of different optical
wavelengths 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 interface 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.
ACL-TOP Service Manual
5 - 6 Chapter 5 – Processor / Software
Figure 5-4 Processor Architecture
The personal computer communicates to the master processor via an Ethernet connection. The master processor communicates to the sub-system controllers via a CAN Bus interface, which enables future expansion. 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.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5-7
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 processor
and software. They are the Controller Status and Software Version portions as shown in Figure 5-5 "Software, Covers and Racks Diagnostic Screen" and described below.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5-8
Figure 5-5 Software, Covers and Racks Diagnostic Screen
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5-9
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 controller 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 as
shown on Figure 5-7 "Software Version Area of Diagnostic Screen".
ACL-TOP Service Manual
5 - 10 Chapter 5 – Processor / Software
Figure 5-7 Software Version Area of Diagnostic Screen
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 11
5-4 LIS Specifications (ASTM E 1381-95 Protocol)
ASTM LLP CM STS
Revision History: (Printed: 01/Sep/2000 16:09)
Author
Berenguer Torelló
Berenguer Torelló
Date
September 1, 2000
February 5, 2001
Berenguer Torelló
Xavier Ramirez
Néstor Silveira
March 23, 2001
November 26, 2001
July 4, 2002
Xavier Ramirez
October 11, 2002
Version Comment
R0.1
Initial version
R0.1.1
Minor style changes added to change from SRS to
STS.
R0.1.2
Comments from Carolina Altafulla added.
R0.1.3
Some minor changes added after first implementation.
R0.1.4
Baud rate has been extended to match Window’s
configuration.
R 1.0
Updated diagram with a new state when the instrument
don’t accept the connection
Futura data removed and redirected to apendix A
where still needs to be added the futura required
changes
ACL-TOP Service Manual
5 - 12 Chapter 5 – Processor / Software
Xavier Ramirez
December 9, 2002
R 1.1
Xavier Ramirez
Xavier Ramirez
February 10, 2003
March 5, 2003
R 1.2
R 1.2.1
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
New socket physical layer added
Fixed two typos
TABLE OF CONTENTS
1. Overview..................................................................... 5 - 12
2. Physical layer .............................................................. 5 - 12
3. 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 (reference 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 implementation and the new implementation of the driver.
1.2
Ref
R1
R2
R3
REFERENCES
Description
ASTM 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
ISO 7498-1984 (E), Information Processing Systems – Open Systems Interconnection –
Basic Reference Model
ACL Futura Host Communication Message Protocol
ACL-TOP Service Manual
Chapter 5 – Processor / Software
ACL-Futura II Control Module Laboratory Information System (LIS) Interface Software
Requirements – ASTM Low Level Protocol (RS-232)
LIS Control Module Software Functional Specification (LIS CM SFS)
R4
R5
2.
5 - 13
PHYSICAL LAYER
TOP 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 Interconnection (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 sections: start bit, data bits, parity bit and stop bit(s).
The configurable bit sections are:
Bit sections
Data bits
Parity bit
Stop bit(s)
Parameter
Number of data bits coding a character
Parity type
Number of stop bits
Allowed values
8
No parity Odd
1
7
Even
Mark
Space
2
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:
Baud rate
300
57600
1200
115200
2400
4800
9600
19200
38400
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 connector (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.
Mnemonic
EIA/TIA
Name
CCITT
V.24
Signal
direction
DB-9
Pin
DB-25
Pin
Description
Used by the
Instrument
ACL-TOP Service Manual
5 - 14 Chapter 5 – Processor / Software
TD
RD
RTS
CTS
DSR
SG
DCD
DTR
RI
BA
BB
CA/CJ
CB
CC
AB
CF
CD
CE
103
104
105/133
106
107
102
109
108/1, /2
125
Out
In
Out
In
In
In
Out
In
3
2
7
8
6
5
1
4
9
2
3
4
5
6
7
8
20
22
Transmitted Data
Received Data
Request To Send
Clear To Send
Data Ready Set
Signal Ground
Carrier Detect
Data Terminal Ready
Ring Indicator
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
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 client 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 Reference 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 synchronizing, 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 receiving 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 returning 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 systems.
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 computer 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
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 15
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 establishment phase. It acts as a receiver, waiting for connections of the other system.
Sender
Receiver
[Idle state]: Monitor data link()
[Idle state]: Monitor data link()
[information_available AND data_link_in_neutral_state]: Send <ENQ>()
Set timer to 15 secs()
[ready_to_receive]: Send <ACK>()
[ready_to_receive]: Begin transfer phase()
[<ACK> received]: Begin transfer phase()
{OR}
{OR}
[Timeout]: Begin termination phase()
[unable_to_receive]: Send <NAK>()
Wait 10 seconds()
Enter Idle state()
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.
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Instrument (CLI)
LIS host
[...]: Send <ENQ>()
[...]: Send <ENQ>()
[Contention]: Set timer to 1 second()
[Contention]: Set timer to 20 seconds()
Monitor data link()
[...]: Send <ENQ>()
See details on how the process
continues after solving contention,
in the diagram above
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 Æ<STX> FN Text <ETB> C1 C2 <CR> <LF>
End frame Æ<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 consecutive messages without restarting the connection with an <ENQ>.
A brief description for every part of a frame is given in the table below.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
Frame part
<STX>
FN
Text
<ETB>
<ETX>
C1
C2
<CR>
<LF>
5 - 17
Frame part description
Start of Text transmission control character
Frame Number (single digit comprised in the range 0-7) – See details in section Frame Number
Data content of Message
End of Transmission Block transmission control character
End of Text transmission control character
Most significant character of checksum (belonging to {0-9, A-F}) – See details in section
Checksum
Least significant character of checksum (belonging to {0-9, A-F}) – See details in section
Checksum
Carriage Return ASCII character
Line Feed ASCII character
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 fashion.
3.3.4 CHECKSUM
The checksum permits the receiver to detect a defective frame. The checksum is encoded as two characters.
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 checksum is transmitted as the ASCII character 5 followed by the ASCII character B.
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Sender
Receiver
Set frame number to 1 .()
Set timer to 30 seconds()
Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0 .()
[valid_frame] : Send <ACK>()
Set timer to 30 seconds()
Increase frame number()
Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0 .()
[wrong_frame] : Send <NAK>()
Send frame()
Set timer to 30 seconds()
Set timer to 15 seconds()
Check frame validity()
Increase frame retransmissions()
[valid_frame] : Send <ACK>()
Set timer to 30 seconds()
The process continues until
all frames have been transmitted
[all_frames_transmitted] : Begin termination phase()
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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 to
receive 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 prepared
to receive the frame again.
•
A reply of <EOT> means the last frame was successfully received and the receiver is ready to
receive 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> until
the message is finished. Once the message is finished ACL-TOP will allow the other system to
retrieve the message.
Sender
Receiver
Set frame number to 1.()
Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0.()
[valid_frame AND receiver_interrupt_request] : Send <EOT>()
Set timer to 30 seconds()
Increase frame number()
[sender_not_attend_the_receiver_interrupt_request] : Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0.()
[valid_frame AND receiver_interrupt_re-request] : Send <EOT>()
Set timer to 30 seconds()
[sender_attend_the_receiver_interrupt_request] : Begin termination phase()
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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.
Sender
Receiver
Send <EOT>()
Enter idle state()
Enter idle 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…).
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•
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 different 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
Sender
Receiver
Set frame number to 1 .()
Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0 .()
[valid_frame] : Send <ACK>()
Set timer to 30 seconds()
Increase frame number()
Send frame()
Set timer to 15 seconds()
Set frame retransmissions to 0 .()
The receiver is unable
to communicate with the sender
[Timeout] : Begin termination phase()
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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.
Sender
Receiver
Set frame number to 1 .()
Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0 .()
[valid_frame] : Send <ACK>()
Set timer to 30 seconds()
[Timeout] : Discard incomplete message()
The sender is unable
to communicate with the receiver
[Timeout] : Enter idle state()
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 pending
to send an <EOT> is sent.
•If a <NAK> is received TOP assumes the connection is rejected by the LIS and retries every 10
seconds 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
•
3.7
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 sending
and <ENQ> and after receiving the response sends an <EOT> to finish the transmission.
RESTRICTED MESSAGE CHARACTERS
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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:
Transmission control characters
<SOH>, <STX>, <ETX>, <EOT>, <ENQ>,
<ACK>, <DLE>, <NAK>, <SYN>, <ETB>
Format effector control character Device control characters
<LF>
<DC1>, <DC2>, <DC3>,
<DC4>
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.
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State diagram for the Instrument
FrameReceived [good_new_frame AND data_to_send] / IncrementFrameNumber,Send<EOT>,SetTimerTo30
FrameReceived [good_repeat_frame AND data_to_send] / Send<EOT>,SetTimerTo30
FrameReceived [bad_frame] / Send<NAK>,SetTimerTo30
Receiving
Receive<EOT>
FrameReceived [good_repeat_frame AND no_data_to_send] / Send<ACK>,SetTimerTo30
FrameReceived [good_new_frame AND no_data_to_send] / IncrementFrameNumber,Send<ACK>,SetTimerTo30
/ Shutdown
Receive<ENQ> [instument don't accept connection] / Send<NAK>
/ Startup
Receive<ENQ> [instrument_ready] / SetFrameNumberTo1,Send<ACK>,SetTimerTo30
Timeout
Idle
Receive<NAK> / SetTimerTo10
Timeout / Send<EOT>
DataToSend / SetFrameNumberTo1,Send<ENQ>,SetTimerTo15
Connecting
Receive<ENQ> / SetTimerTo1
Sleeping
Receive<ACK> [pending_frames] / ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15
Receive<ACK> [no_pending_frames] / Send<EOT>
Timeout / Send<EOT>
<NAK> condition [RetryCount<6] / IncrementRetryCount,SendFrame,SetTimerTo15
Receive<EOT> [interrupt_ignored] / IncrementFrameNumber,ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15
Receive<EOT> [no_pending_frames] / Send<EOT>
Sending
Receive<ACK> [pending_frames] / IncrementFrameNumber,ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15
<NAK> condition [RetryCount=6] / Send<EOT>
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APPENDIX A – FUTURA COMPATIBILITY MODE
The low-level protocol implementation of TOP acting in Futura mode is fully compliant with the last implementation of the Futura device.
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ASTM HLP CM STS
ACL-TOP Service Manual
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Revision History: (Printed: 22/Jul/2004 12:06)
Author
Berenguer Torelló
Berenguer Torelló
Date
Version
October 10, 2000 R0.1
December 22,
R0.1.1
2000
Berenguer Torelló
Xavier Ramirez
Francesc Fernandez
February 5, 2001 R0.1.2
June 28, 2002
R 1.0
July 10, 2002
R1.1
Francesc Fernandez
Xavier Ramirez
July 29, 2002
July 31, 2002
R1.2
R 1.2.1
Francesc Fernandez
August 30, 2002
R 1.2.2
Maite Burrel
September 04,
2002
R 1.3
Xavier Ramirez
September 08,
R 1.4
2002
October 11, 2002 R 1.5
Xavier Ramirez
Xavier Ramirez
December 9,
2002
R 1.6
Xavier Ramirez
January 7, 2003
R 1.7
Xavier Ramirez
January 31, 2003 R 1.8
Xavier Ramirez
February 7, 2003 R 1.8.1
Comment
Initial version
· 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.
Minor style modifications to change from SRS to STS.
Document updated with TOP implementation
· Section Demographic Data updated.
· Section Sample Identification added.
· Table of contents updated.
Updated after NTE internal review.
Errors section updated. Some fields added to give at least the
same functionality delivered by Futura.
Describe logic for setting ordered date and time to current
date when ordered date and time received from the LIS is
empty.
Add changes in instrument test order autocancelation
message. Section 4.1.2
Update in Header Record specification the correct ASTM
version field max length to 7.
Added comments about the futura driver
Changes to note that error messages sent to the HOST can be
disabled
Field 012 removed in 4.5.1 – Instrument uploads test result
Removed an incorrect field in the sample in section 4.5.1
Added Patient laboratory ID in messages coming from the
LIS. This field is still not used in TOP, but may be used in the
future
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.
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.
Section 2.3.3 added
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Xavier Ramirez
March 5, 2003
R 1.8.2
Xavier Ramirez
April 8, 2003
R 1.8.3
Francesc Fernandez
June 17, 2003
R 1.8.4
Xavier Ramírez
June 27, 2003
R 1.8.5
Xavier Ramírez
Maite Burrel
July 2, 2003
July 2, 2003
R 1.8.6
R 1.8.7
Xavier Ramírez
July 15, 2003
R 1.8.8
Xavier Ramírez
November 26,
2003
R 1.9
Daniel Moncusí
January 27, 2004 R 1.10
Daniel Moncusí
July 22, 2004
ACL-TOP Service Manual
R 1.11
Updated 2.2.3 with the information of codepages
Updated 2.3.2 with allowed escape values and use of the local
escape delimiter
Updated 2.3.3 with the detail of the possible escaped
characters
Updated 2.3.4 with how local escape delimiter works
Section 6 added units mapping between TOP and Futura (still
not completed)
Section 3.3 added that the consistency among values in
different fields is not checked. Added information about the
tracing system
Section 4.5. Result unit max size have changed from 50 chars
to 15 chars
Section 6 has been updated with more differences between
TOP and Futura compatible driver and the final units mapping
from TOP to Futura.
Updated section 2.4 Patient Demographics for specifying that
Patient demographics are not updated from LIS unless
Samples are identified through Instrument Sample Id.
Appendix A: added restriction to reject messages with t
sample id bigger than 16 characters in Futura mode
Updated 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.
Appendix A: Futura does not support ‘V’ flag in R9
Appendix A: ERRORS Add the exemption of non-validation
of H14 date field.
Max length for Attending physician ID has changed from 30
to 14 as specified in TOP
Changed the way reruns are notified in section 4.5.1
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
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)
Added clarifying note to section 4.3.3
Changed diagrams of section 5
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5 - 29
TABLE OF CONTENTS
1. Overview ............................................................................1
2. Message structure and content..........................................30
3. Message transmission control...........................................35
4. Transmission scenarios.....................................................38
4.1
TOP REQUEST TEST ORDERS TO HOST ........................................................................................................39
4.2
LIS HOST INITIATED TEST ORDERS DELIVERY ............................................................................43
4.3
HOST QUERY PERFORMED BY THE INSTRUMENT .........................................................................44
4.4
INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST ..............................................................46
4.5
INSTRUMENT UPLOADS TEST RESULTS ........................................................................................................47
4.6
LIS HOST REQUEST RESULTS TO THE INSTRUMENT ......................................................................49
4.7
INSTRUMENT UPLOADS ERROR INFORMATION.............................................................................................51
5. Transmission scenarios relationships ...............................53
5.1
MANUAL OR AUTOMATIC JOB ORDERS DOWNLOADING ................................................................53
5.2
HOST-INITIATED JOB ORDERS DOWNLOADING ............................................................................................54
5.3
HOST QUERY ...............................................................................................................................................55
5.4
MANUAL OR AUTOMATIC JOB RESULTS UPLOADING ....................................................................56
6. Appendix A – Futura Compatibility mode .......................57
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1.
1.1
OVERVIEW
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 information 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 standard, 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
Ref
R1
REFERENCES
Description
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
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.
Level 0 records
Message Header (H)
Level 1 records
Comment (C)
Request Information (Q)
ACL-TOP Service Manual
Level 2 records
Level 3 records
Level 4 records
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Comment (C)
Patient Information (P)
Comment (C)
Test Order (O)
Comment (C)
Result (R)
Comment (C)
Message Terminator (L)
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 message
terminator 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 Terminator), 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
.
.
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(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 further 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 separated 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 values 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 different 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, 128-254
Disallowed 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.
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•
Record delimiter: It signals the end of any of the defined record types. It is fixed to carriage return
character Latin-1 (13) (ASCII 13).
•
Field delimiter: It is used to separate adjacent fields. It is configurable, and is specified in the message 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 of
equal 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 delimiter.
•
Component delimiter: It is used to separate data elements of fields of a hierarchical or qualifier
nature. It is configurable, and is specified in the message header record. It shall be a single character, excluding Latin-1 (13) (ASCII 13), the value used by the field delimiter and the value used by
the repeat delimiter.
•
Escape delimiter: Used within text fields to signify special case operations. It is configurable, and is
specified in the message header record. It has a complex structure, but mainly use a single character. The chosen character shall be different from Latin-1 (13) (ASCII 13) and the field, repeat, and
component 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)
•
Any value from ASCII (58) to ASCII (64)
•
Any value from ASCII (91) to ASCII (96)
•
Any value from ASCII (123) to ASCII (126)
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 corresponding 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.
ACL-TOP Service Manual
5 - 34 Chapter 5 – Processor / Software
•
\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 configured 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 character 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 represented 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.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 35
Thus, samples can be identified from the LIS host either through the Instrument Specimen Id or the Specimen Id + Sample Life.
2.5.1 SPECIMEN ID
Since the Specimen ID can be reused by the LIS host for different patients, the TOP uses the concept Sample 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 < Sample 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 ID
The 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 instruments.
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:
3.
•
Instrument Specimen ID is not reused and therefore test orders are always properly assigned to the
corresponding 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 it
always identifies univocally a sample.
MESSAGE TRANSMISSION CONTROL
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5 - 36 Chapter 5 – Processor / Software
3.1
ERROR RECOVERY
In order to ensure proper error logging and error recovery, the next rule is followed according to the standard.
Storage Rule: Since data content is structured in hierarchical fashion, any decreasing change in the hierarchical 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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Level
Message Header
Patient1
Order1
Result1
Order2
Order3
Patient2
Order1
Comment1
Result1
Comment1
Result2
Order2
Patient3
Order1
Result1
Message Terminator
(level variation) Storage action
L0
L1
L2
L3
L2
L2
L1
L2
L3
L3
L4
L3
L2
L1
L2
L3
L0
(0)
(+1)
(+1)
(+1)
(-1)
(0)
(-1)
(+1)
(+1)
(0)
(+1)
(-1)
(-1)
(-1)
(+1)
(+1)
(-3)
{Save 1 – 4}
{Save 5 – 6}
{Save 7 – 11}
{Save 12}
{Save 13}
{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 section 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
1
Message Header
L0
(0)
2
Patient1
L1
(+1)
3
Order1
L2
(+1)
4
Result1 L3
(+1)
5
Order2
L2
(-1)
6
Order3
L2
(0)
7
Patient2
L1
(-1)
8
Order1
L2
(+1)
9
Comment1
L3
(+1)
10
Result1
L3
(0)
ACL-TOP Service Manual
Retransmission of:
{Save 1 – 4}
{Save 5 – 6}
1
1, 2
1, 2, 3
1, 2, 3, 4
1, 2, 3, 4, 5
1, 2, 5, 6
1, 2, 5, 6, 7
1, 7, 8
1, 7, 8, 9
1, 7, 8, 9, 10
Chapter 5 – Processor / Software
11
12
13
14
15
16
17
Comment1
L4
Result2 L3
Order2
L2
Patient3
L1
Order1
L2
Result1 L3
Message Terminator
L0
3.2
(+1)
(-1)
(-1)
(-1)
(+1)
(+1)
(-3)
{Save 7 – 11}
{Save 12}
{Save 13}
‘
{Save 14 – 16}
‘
5 - 37
1, 7, 8, 9, 10, 11
1, 7, 8, 9, 10, 11, 12
1, 7, 8, 12, 13
1, 7, 13, 14
1, 14, 15
1, 14, 15, 16
1, 14, 15, 16, 17
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 delivered. 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 instrument. 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 specified 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. The
order is removed.
ACL-TOP Service Manual
5 - 38 Chapter 5 – Processor / Software
•
Invalid instrument sample id: The LIS host retrieved an invalid instrument sample id. The test is
removed.
•
Cancellation of pending test request could not be performed: The LIS host can cancel a previously
ordered test if this hasn’t been executed yet. This message specifies the test could not be cancelled
because 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 a
request 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 interpreting it as if no error existed. For extended error information for the skipped part, check the TOP communication 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 button in the communications configuration screen.
This are the more specific rules implemented by TOP to manage the storage of messages:
4.
•
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> providing information of the percentage of the storage that is full. This alarm is reported during start-up
as 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 no
more messages are accepted in the storage. This alarm will also be reported every time the communications are restored.
•
Once the storage is full (100% of its capacity) the upload of any new messages will be rejected and
TOP triggers the following two alarms < Upload Message Rejected> and < LIS Message Storage
Overloaded>
TRANSMISSION SCENARIOS
This section details all the possible scenarios to exchange data between TOP and a LIS host.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
4.1
5 - 39
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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Request information (Q)
Message terminator (L)
Message Header Record
Field
No.
1
2
3
5
10
12
13
14
Comp
Field Name Description
Max.
Allow
onent Data typeLengt Req Repeat Allowed values
h
1
String
1
Y N
H
Record Type Identifies the record
ID
Delimiter Defi- Define the delimiters to 1
nition
be used throughout the
subsequent records of
the message
Message ID Uniquely identifies the
1
message
Sender Name Name or ID of the sender 1
or ID
Receiver ID Name or ID of the
1
receiver
Processing ID Indicates how this mes- 1
sage is to be processed.
Version No. Version level of the cur- 1
rent ASTM version specification.
Date and time the mes- 1
Date and
Time of Mes- sage was generated
sage
String
4
Y
N
String
50
Y
N
String
14
Y
N
14
Y
N
String
1
Y
N
The value defined in TOP
configuration’s
The value defined in TOP
configuration’s
P (Production)
String
7
Y
N
1394-97
Y
N
ASTM
Date
See section Delimiters for
more information
Request Information Record
Field
No.
1
2
3
13
Field Name
Description
Record Type ID
Sequence
Number
Starting Range
ID Number
Request
Information
Status Codes
Identifies the record
Defines the i’th occurrence of the
associated record type
Comp
onent
Data type
1
1
String
String
3
String
1
String
Max.
Lengt
h
1
1
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
Q
1
Y
N
ALL
Y
Y
O (req. test order and demogs),
N (request new/edited results)
ACL-TOP Service Manual
5 - 40 Chapter 5 – Processor / Software
Message Terminator Record
Field
No.
1
2
3
Comp
Field Name
Description
Max.
Allow
onent Data typeLengt Req Repeat Allowed values
h
1
String
1
Y N
L
Record Type Identifies the record
ID
1
Sequence
Defines the i’th occurNumber
rence of the associated
record type
Termination Provides explanation of 1
Code
end of session
String
1
Y
N
1
String
1
Y
N
N (normal termination)
Example
H | @ ^ \ | <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 priority.
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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Request information (Q)
Comment (C)
Message terminator (L)
Message Header RecordField No.Request Information Record
Field
No.
1
2
13
Field Name
Description
Record Type ID
Sequence
Number
Request
Information
Status Codes
Identifies the record
Defines the i’th occurrence of the
associated record type
ACL-TOP Service Manual
Comp
onent
Data type
1
1
String
String
Max.
Lengt
h
1
1
1
String
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
Q
1
Y
N
A (abort last request)
Chapter 5 – Processor / Software
5 - 41
Comment Record
Field
No.
Field Name
Description
3
4
Record Type ID
Sequence
Number
Comment Source
Comment Text
5
Comment Type
Identifies the record
Defines the i’th occurrence of the
associated record type
Comment origination point
Comment id
Comment description
Comment type qualifier
1
2
Comp
onent
Data type
1
1
String
String
1
1
2
1
String
String
String
String
Max.
Lengt
h
1
1
50
500
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
C
1,2,3 … n
Y
N
N
Y
N
N
I
timeout
last request has been cancelled
P (information)
N
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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Patient Information (P)
Test Order (O)
…
…
Message terminator (L)
Message Header Record
Field
No.
Comp
onent
Data type
Identifies the record
Define the delimiters to be used
throughout the subsequent
records of the message
Uniquely identifies the message
Name or ID of the sender
1
1
1
1
Name or ID of the receiver
1
Indicates how this message is to
be processed.
Version level of the current
ASTM 1394-91 specification.
Date and time that the message
was generated
1
Field Name
Description
1
2
Record Type ID
Delimiter
Definition
3
5
10
Message ID
Sender Name or
ID
Receiver ID
12
Processing ID
13
Version No.
14
Date and Time of
Message
Req
Allow
Repeat
String
String
Max.
Lengt
h
1
4
Y
Y
N
N
String
String
50
14
N
Y
N
N
14
Y
N
String
1
Y
N
The value defined in TOP
configuration’s
The value defined in TOP
configuration’s
P (Production)
1
String
7
Y
N
1394-97
1
ASTM
Date
N
N
Allowed values
H
See section Delimiters for more
information
Patient Information Record
ACL-TOP Service Manual
5 - 42 Chapter 5 – Processor / Software
Field
No.
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
1
1
String
Numeric
Y
Y
N
N
P
1,2,3 … n
1
String
15
N
N
1
2
1
1
String
String
ASTM
Date
String
20
20
N
N
N
N
N
1
N
N
Id of the attending physician
1
String
14
N
N
Description
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
1
1
String
Numeric
Y
Y
N
N
O
1,2,3 … n
1
String
16
Y
N
1
String
30
N
N
4
1
1
Numeric
String
ASTM
Date
6
1
Y
N
N
Y
N
N
1
String
1
N
Y
Sample type
1
String
1
Y
N
0 - 999999
S (Stat), R (normal)
If empty, Requested/Ordered Date
and Time is set to current date and
Time.
A (Added in previous specimen
or creates a new specimen
following the rules of the sample
life cycle),
C (Cancel a previous test request)
P (plasma)
Intention of the information
contained in the record
1
String
1
Y
Y
Q (Response to query),
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
1
1
String
String
Max.
Lengt
h
1
1
Y
Y
N
N
L
1
1
String
1
Y
N
F (last request processed)
Field Name
Description
6
Record Type ID
Sequence
Number
Laboratory
patient ID
Patient Name
8
Birth date
Identifies the record as PIR
Defines the i’th occurrence of the
associated record type
A unique processing number
assigned to a patient by the LAB
Patient last name
Patient first name
Date of birth
9
Patient Sex
Sex
14
Attending
physician ID
1
2
4
Max.
Lengt
h
1
M (male), F (female), U
(unknown)
Test Order Record
Field
No.
1
2
3
4
5
6
7
12
16
26
Field Name
Record Type ID
Sequence
Number
Specimen ID
Identifies the record
Defines the i’th occurrence of the
associated record type
A unique identifier for the
specimen assigned by the HOST
Instrument
A unique identifier for the
Specimen ID
specimen assigned by TOP. This
must be retrieved from the LIS if
it is known.
Universal Test ID TOP defined Test ID
Priority
Requested/
Date and time the order was
Ordered Date and received or recorded
Time
Action code
The action that needs to be taken
with the order
Specimen
Descriptor
Report Type
Max.
Lengt
h
1
Message Terminator Record
Field
No.
1
2
3
Field Name
Description
Record Type ID
Sequence
Number
Termination
Code
Identifies the record as MTR
Defines the i’th occurrence of the
associated record type
Provides explanation of end of
session
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 43
Example
H | @ ^ \ |<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 anything 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
Level 0 records
Message header (H)
Message terminator (L)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Message Header RecordField No.Message Terminator Record
Field
No.
1
2
3
Field Name
Description
Record Type ID
Sequence
Number
Termination
Code
Identifies the record as MTR
Defines the i’th occurrence of the
associated record type
Provides explanation of end of
session
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
String
String
Max.
Lengt
h
1
1
1
1
Y
Y
N
N
L
1
1
String
1
Y
N
I (no info from last query)
Example
H | @ ^ \ | <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.
ACL-TOP Service Manual
5 - 44 Chapter 5 – Processor / Software
4.2.1 DOWNLOAD MESSAGE – LIS HOST INITIATED TEST ORDER DELIVERY
Message structure
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Patient Information (P)
Test Order (O)
…
…
Message terminator (L)
Message Header RecordField No.Patient Information Record Field No.Test Order Record
Field
No.
1
2
3
4
5
6
7
12
16
26
Field Name
Req
Allow
Repeat
Allowed values
Y
Y
N
N
O
1,2,3 … n
16
Y
N
String
30
N
N
4
1
1
Numeric
String
ASTM
Date
6
1
Y
N
N
Y
N
N
1
String
1
N
Y
Sample type
1
String
1
Y
N
0 - 999999
S (Stat), R(normal)
If empty, Requested/Ordered Date
and Time is set to current date and
Time.
A (Added in previous specimen
or creates a new specimen
following the rules of the sample
life cycle),
C (Cancel a previous test request)
P (plasma)
Intention of the information
contained in the record
1
String
1
Y
Y
O (Order record)
Description
Record Type ID
Sequence
Number
Specimen ID
Identifies the record
Defines the i’th occurrence of the
associated record type
A unique identifier for the
specimen assigned by the HOST
Instrument
A unique identifier for the
Specimen ID
specimen assigned by TOP
Universal Test ID TOP defined Test ID
Priority
Requested/
Date and time the order was
Ordered Date and received or recorded
Time
Action code
The action that needs to be taken
with the order
Specimen
Descriptor
Report Type
Comp
onent
Data type
1
1
String
Numeric
1
String
1
Max.
Lengt
h
1
Message Terminator RecordField No. Example
H | @ ^ \ | <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.
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 45
4.3.1 UPLOAD MESSAGE – HOST QUERY PERFORMED BY THE INSTRUMENT
Message structure
Message Header Record
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Request information (Q)
Message terminator (L)
Field No.Request Information Record
Fiel
d
No.
Field Name
Description
Com
p
onen
t
1
Record Type ID
Identifies the record
1
String
1
Y
N
H
2
Delimiter Definition
Define the delimiters to be used
throughout the subsequent
records of the message
1
String
4
Y
N
See section 2.3 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 sender
1
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 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
Field
No.
1
2
3
Field Name
Description
Record Type ID
Sequence
Number
Starting Range
ID Number
Identifies the record
Defines the i’th occurrence of the
associated record type
Specimen ID
Instrument specimen ID
13
Request
Information
Status Codes
Data type
Comp
onent
Data type
1
1
Max.
Leng
th
Re
q
Allow
Repeat
Allowed values
Req
Allow
Repeat
Allowed values
String
String
Max.
Lengt
h
1
1
Y
Y
N
N
Q
1
2
String
16
Y
Y
3
1
String
String
30
1
N
Y
Y
O (req. test order and demogs),
N (request new test orders still not
downloaded)
Message Terminator RecordField No. Example
H | @ ^ \ | <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>
ACL-TOP Service Manual
5 - 46 Chapter 5 – Processor / Software
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 delivery 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 discarded.
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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Patient Information (P)
Test Order (O)
…
Message terminator (L)
Note: Only one test order record will be placed under a patient information record.
Message Header RecordField No. Patient Information Record
Field
No.
1
2
4
Field Name
Description
Record Type ID
Sequence
Number
Laboratory
patient ID
Identifies the record as PIR
Defines the i’th occurrence of the
associated record type
A unique processing number
assigned to a patient by the LAB
ACL-TOP Service Manual
Comp
onent
Data type
1
1
String
Numeric
1
String
Max.
Lengt
h
1
15
Req
Allow
Repeat
Allowed values
Y
Y
N
N
P
1,2,3 … n
N
N
Chapter 5 – Processor / Software
6
Patient Name
Birth date
Patient last name
Patient first name
Date of birth
1
2
1
8
1
String
String
ASTM
Date
String
9
Patient Sex
Sex
14
Attending
physician ID
Id of the attending physician
1
String
Description
Comp
onent
Data type
1
1
String
Numeric
1
String
1
20
20
5 - 47
N
N
N
N
N
1
N
N
14
N
N
Req
Allow
Repeat
Allowed values
Y
Y
N
N
O
1,2,3 … n
16
Y
N
String
30
Y
N
4
1
1
Numeric
String
ASTM
Date
6
1
Y
N
N
Y
N
N
1
String
1
Y
Y
0 - 999999
S (Stat), R(normal)
If empty, Requested/Ordered Date
and Time is set to current date and
Time.
P (pending specimen)
1
String
1
Y
N
P (plasma)
1
String
1
Y
Y
O (Order record),
I (Pending in instrument)
M (male), F (female), U
(unknown)
Test Order Record
Field
No.
1
2
3
4
5
6
7
12
16
26
Field Name
Record Type ID
Sequence
Number
Specimen ID
Identifies the record
Defines the i’th occurrence of the
associated record type
A unique identifier for the
specimen assigned by the HOST
Instrument
A unique identifier for the
Specimen ID
specimen assigned by TOP
Universal Test ID TOP defined Test ID
Priority
Requested/
Date and time the order was
Ordered Date and received or recorded
Time
Action code
The action that needs to be taken
with the order
Specimen
Sample type
Descriptor
Report Type
Intention of the information
contained in the record
Max.
Lengt
h
1
Message Terminator RecordField No. Example
H | @ ^ \ | <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 cannot be triggered by a request from the LIS host. Remember, IL instruments do not support a request message for test results uploading.
4.5.1 UPLOAD MESSAGE – TEST RESULTS DELIVERY CARRIED OUT BY THE INSTRUMENT
Message structure
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Patient Information (P)
Test Order (O)
Result (R)
ACL-TOP Service Manual
5 - 48 Chapter 5 – Processor / Software
Comment (C)
…
…
…
…
Message terminator (L)
Message Header RecordField No.Patient Information Record Field No. Test Order Record
Field
No.
1
2
3
4
5
6
7
12
16
26
Field Name
Description
Record Type ID
Sequence
Number
Specimen ID
Identifies the record
Defines the i’th occurrence of the
associated record type
A unique identifier for the
specimen assigned by the HOST
Instrument
A unique identifier for the
Specimen ID
specimen assigned by TOP
Universal Test ID TOP defined Test ID
Priority
Requested/
Date and time the order was
Ordered Date and received or recorded
Time
Action code
The action that needs to be taken
with the order
Specimen
Sample type
Descriptor
Report Type
Intention of the information
contained in the record
Comp
onent
Data type
1
1
String
Numeric
1
String
1
Max.
Lengt
h
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
O
1,2,3 … n
16
Y
N
String
30
N
N
4
1
1
Numeric
String
ASTM
Date
6
1
Y
N
N
Y
N
N
0 - 999999
S (Stat), R (normal)
1
String
1
N
N
1
String
1
Y
N
Q (mandatory when quality
control)
P (plasma)
1
String
1
Y
Y
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
Y
Y
N
N
R
1,2,3 … n
Y
N
0 – 999999999
O (Order record),
F (All tests results are Final or
could not be done - see R9),
P (This test triggers a rerun)
Result Record
Field
No.
1
2
3
4
5
Max.
Lengt
h
1
Field Name
Description
Record Type ID
Sequence
Number
Universal Test
ID
Data or
Measurement
Value
Units
Identifies the record
Defines the i’th occurrence of the
associated record type
TOP defined Test ID
1
1
String
Numeric
4
Numeric
Observed, calculated or implied
result value
1
String
30
N
Y
Abbreviation of units for
numerical results
Indicates the normalcy status of
the result
1
String
15
N
Y
1
String
2
Y
N
1
String
1
Y
Y
7
Result Abnormal
Flags
9
Result Status
ACL-TOP Service Manual
For information on specific unit
values see section 6
L (Below low normal),
H (Above high normal),
N (Normal),
< (Below absolute low),
> (Above absolute high)
F (final result),
P (preliminary result, because a
rerun has been set),
V (result validated),
X (result cannot be done)
Chapter 5 – Processor / Software
11
Operator
Identification
13
Date Time Test
Completed
Instrument
Identification
14
Operator ID for the test
performer
Operator ID for the test verifier
Date and time the instrument
completed the test
Identifies the instrument that
performed this measurement
Rack id
Rack position
1
String
30
N
N
2
1
30
N
Y
N
1
String
ASTM
Date
String
14
Y
N
2
3
String
String
2
2
Y
Y
N
N
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
1
1
String
String
Y
Y
N
N
C
1,2,3 … n
1
1
2
3
1
String
String
String
String
String
Y
N
N
N
Y
N
N
I
N
I (instrument flag comment),
N (negative comment)
5 - 49
Instrument ID as specified in TOP
Comment Record
Field
No.
Field Name
Description
3
4
Record Type ID
Sequence
Number
Comment Source
Comment Text
5
Comment Type
Identifies the record
Defines the i’th occurrence of the
associated record type
Comment origination point
Comment ID
Comment description
Comment area
Comment type qualifier
1
2
Max.
Lengt
h
1
1
50
500
50
1
Message Terminator RecordField No. Example
H | @^\ | 123 | | ACL-TOP-52 | | | | | LIS-HOST-31 | | P | 1394-97 | 20000614060520
P|1||||||||||||
O | 1 | Normal Control | <1034241923_260> | ^ ^ ^ 555 | R | | | | | | | | | | P | | | | | | | | | | O @ F
R | 1 | ^ ^ ^ 555 | 106.01 | % | | N | | F @ V | | ^ IL | | 20021211163215 | ACL-TOP-21 ^ B ^ 5
C | 1 | I | 1025 ^ reagent temperature warning ^ HW | I
C | 2 | I | 1030 ^ cuvette shuttle temp warning ^ HW | I
R | 2 | ^ ^ ^ 555 | 12.65 | sec | | N | | F @ V | | ^ IL | | 20021211163215 | ACL-TOP-21 ^ F ^ 3
R | 3 | ^ ^ ^ 555 | 0.97 | INR | | L | | F @ V | | ^IL | | 20021211163215 | ACL-TOP-21 ^ G ^ 2
C | 1 | I | 1017 ^ probe temperature warning ^ HW | I
L|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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
ACL-TOP Service Manual
5 - 50 Chapter 5 – Processor / Software
Request information (Q)
Message terminator (L)
Message Header RecordField No.Request Information Record
Field
No.
1
2
13
Field Name
Description
Record Type ID
Sequence
Number
Request
Information
Status Codes
Identifies the record
Defines the i’th occurrence of the
associated record type
Comp
onent
Data type
1
1
String
String
Max.
Lengt
h
1
1
1
String
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
Q
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)
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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Comment (C)
Message terminator (L)
Message Header RecordField No.Comment Record
Field
No.
Field Name
Description
3
4
Record Type ID
Sequence
Number
Comment Source
Comment Text
5
Comment Type
Identifies the record
Defines the i’th occurrence of the
associated record type
Comment origination point
Comment id
Comment description
Comment type qualifier
1
2
ACL-TOP Service Manual
Comp
onent
Data type
1
1
String
String
1
1
2
1
String
String
String
String
Max.
Lengt
h
1
1
50
500
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
C
1,2,3 … n
Y
N
N
Y
N
N
I
invalidTransmissionInformation
Request not allowed
N (negative result/error info)
N
Chapter 5 – Processor / Software
5 - 51
Message Terminator Record
Field
No.
1
2
3
Field Name
Description
Record Type ID
Sequence
Number
Termination
Code
Identifies the record as MTR
Defines the i’th occurrence of the
associated record type
Provides explanation of end of
session
Comp
onent
Data type
Req
Allow
Repeat
Allowed values
String
String
Max.
Lengt
h
1
1
1
1
Y
Y
N
N
L
1
1
String
1
Y
N
Q (error in last request)
Example
H | @ ^ \ | <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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Comment (C)
Message terminator (L)
Message Header RecordField No.Comment Record
Field
No.
Field Name
Description
3
4
Record Type ID
Sequence
Number
Comment Source
Comment Text
Identifies the record
Defines the i’th occurrence of the
associated record type
Comment origination point
Comment id
5
Comment Type
Comment description
Comment type qualifier
1
2
Comp
onent
Data type
1
1
String
String
1
1
String
String
2
1
String
String
Max.
Lengt
h
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
C
1,2,3 … n
1
50
Y
N
N
N
500
1
N
Y
I
invalidMessage
invalidSyntax
invalidValue
missingMandatoryValue
incompleteMessage
invalidTransmissionInformation
N
N (negative result/error info)
Message Terminator Record
ACL-TOP Service Manual
5 - 52 Chapter 5 – Processor / Software
Field
No.
1
2
3
Field Name
Description
Record Type ID
Sequence
Number
Termination
Code
Identifies the record
Defines the i’th occurrence of the
associated record type
Provides explanation of end of
session
Comp
onent
Data type
1
1
String
String
Max.
Lengt
h
1
1
1
String
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
L
1
Y
N
E (unknown system error)
Example
H | @ ^ \ | <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
Level 0 records
Message header (H)
Level 1 records
Level 2 records
Level 3 records
Level 4 records
Patient Information (P)
Test Order (O)
Comment (C)
Message terminator (L)
Message Header RecordField No.Patient Information Record Field No.Test Order Record
Field
No.
1
2
3
4
5
6
7
16
26
Field Name
Record Type ID
Sequence
Number
Specimen ID
Description
Identifies the record
Defines the i’th occurrence of the
associated record type
A unique identifier for the
specimen assigned by the HOST
Instrument
A unique identifier for the
Specimen ID
specimen assigned by TOP
Universal Test ID TOP defined Test ID
Priority
Requested/
Date and time the order was
Ordered Date and received or recorded
Time
Specimen
Sample type
Descriptor
Report Type
Intention of the information
contained in the record
Comment Record
ACL-TOP Service Manual
Comp
onent
Data type
1
1
String
Numeric
1
String
1
Max.
Lengt
h
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
O
1,2,3 … n
16
N
N
String
30
N
N
4
1
1
Numeric
String
ASTM
Date
6
1
N
N
N
Y
N
N
0 - 999999
S (Stat), R(normal)
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)
Chapter 5 – Processor / Software
Field
No.
Field Name
Description
3
4
Record Type ID
Sequence
Number
Comment Source
Comment Text
Identifies the record
Defines the i’th occurrence of the
associated record type
Comment origination point
Comment id
5
Comment Type
Comment description
Comment type qualifier
1
2
Comp
onent
Data type
1
1
String
String
1
1
String
String
2
1
String
String
Max.
Lengt
h
1
Req
Allow
Repeat
Allowed values
Y
Y
N
N
C
1,2,3 … n
1
50
Y
N
N
500
1
N
Y
I
invalidDemographicData
invalidSpecimenData
invalidTestData
duplicatedTest
N
N (negative result/error info)
5 - 53
Message Terminator RecordField No. Example
H | @ ^ \ | 123 | | ACL-TOP-02 | | | | | LIS-HOST-01| | P | 1394-97 | 20020421073718
P|1||||||||||||
O | 1 | 8642 | | ^ ^ ^ 1234 | R | | | | | | | | | | P | | | | | | | | | | O @ Y
C | 1 | I | invalidTestData ^ duplicated test | N
L|1|N
5.
TRANSMISSION SCENARIOS RELATIONSHIPS
5.1
MANUAL OR AUTOMATIC JOB ORDERS DOWNLOADING
ACL-TOP Service Manual
5 - 54 Chapter 5 – Processor / Software
M a n u a l o r a u to m a tic jo b o r d e r s d o w n lo a d in g
In s tr u m e n t
L IS H o s t
te s t o rd e r re q u e s t (4 .1 .1 )
T h e L IS H o s t re s p o n d s th e re q u e s t
[n o te s t o r d e r a v a ila b le ]: n o d a ta a v a ila b le ( 4 .1 .4 )
[te s t o r d e r s a v a ila b le ]: te s t o r d e r d e liv e r y ( 4 .1 .3 )
[te s t o rd e r O K ]:
s to r e r e c e iv e d o r d e r s
[in s tr u m e n t s p e c im e n t- ID a c tiv a te d ]: u p lo a d in s tr u m e n t s p e c im e n t ID ( 4 .4 .1 )
{O R }
[b a d te s t o rd e r]:
r e je c t r e c e iv e d o r d e r s
[u p lo a d e r r o r s a c tiv a te d ]: e r r o r in fo r m a tio n m e s s a g e ( 4 .7 .1 /4 .7 .2 )
T h e In s tr u m e n t c a n c e ls th e r e q u e s t
[r e q u e s t tim e o u t]: te s t o r d e r r e q u e s t c a n c e la tio n ( 4 .1 .2 )
5.2
HOST-INITIATED JOB ORDERS DOWNLOADING
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 55
Host initiated job orders downloading
Instrument
LIS Host
test order delivery (4.2.1)
[test order OK]:
store received orders
[instrument speciment-ID activated]: upload instrument speciment ID (4.4.1)
[bad test order]:
reject received orders
[upload errors activated]: error information message (4.7.1/4.7.2)
5.3
HOST QUERY
ACL-TOP Service Manual
5 - 56 Chapter 5 – Processor / Software
H o s t q u e ry
In s tru m e n t
L IS H o s t
H o s t q u e ry (4 .3 .1 )
T h e L IS H o s t re s p o n d s th e re q u e s t
[n o te s t o r d e r a v a ila b le ]: n o d a ta a v a ila b le ( 4 .1 .4 )
[te s t o r d e r s a v a ila b le ]: te s t o r d e r d e liv e r y ( 4 .1 .3 )
[te s t o rd e r O K ]:
s to r e r e c e iv e d o r d e r s
[in s tr u m e n t s p e c im e n t- ID a c tiv a te d ]: u p lo a d in s tr u m e n t s p e c im e n t ID ( 4 .4 .1 )
{O R }
[b a d te s t o rd e r]:
r e je c t r e c e iv e d o r d e r s
[u p lo a d e r r o r s a c tiv a te d ]: e r r o r in fo r m a tio n m e s s a g e ( 4 .7 .1 /4 .7 .2 )
T h e In s tr u m e n t c a n c e ls th e r e q u e s t
[r e q u e s t tim e o u t]: h o s t q u e r y c a n c e la tio n ( 4 .3 .2 )
5.4
MANUAL OR AUTOMATIC JOB RESULTS UPLOADING
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 57
M
a
n
u
a
lo
ra
u
to
m
a
ticre
s
u
ltsu
p
lo
a
d
in
g
In
s
tru
m
e
n
t
L
IS
H
o
s
t
te
s
tre
s
u
ltu
p
lo
a
d
(4
.5
.1
)
LISHost requests results
Instrument
LISHost
test results request (4.6.1)
All requestsfor test resultsreceivedfromLIShost will berejected.
This instrument doesn't support tooperateinthis way.
request rejectedby instrument (4.6.2)
6.
APPENDIX A – FUTURA COMPATIBILITY MODE
When 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 the
instrument. Futura did not support this feature in its original version and it has been disabled in the
new Futura driver implementation for TOP. To allow the Futura driver to work as originally, you have
to activate the automatic downloading of test orders.
•
The Futura documentation does not require LIS drivers to respond to all test orders requests by
TOP. Due to that, when a request is not responded in Futura compatibility mode no error message
is displayed.
DATA MAPPINGS
ACL-TOP Service Manual
5 - 58 Chapter 5 – Processor / Software
•
Futura test IDs and TOP test IDs have changed. The communication will be performed using the
new test IDs defined by TOP. Changes may be required in the LIS/driver to accommodate to these
new identifiers.
•
Futura result units and TOP result units have changed. Futura driver for TOP implements the
required mapping to conform as much as possible to the original Futura units. Units not supported
by Futura are sent in TOP original’s format and the limitation of 6 digits detailed in the Futura documentation has been changed to 15 characters. These are the mappings performed by TOP in
Futura mode:
Top
Futura/
Comment
Advance
Measured s
sec
Mean
Not supported
T
Not supported
%T
Not supported
DT
delta
"delta" for Delta Deriv. Algorithm
T/min
ct/min
D %T
delta
%T/min
Not supported
mAbs
Not Supported Used by Endpoint Algorithm - not available on Futura/
Advance
D mAbs
mA
"mA" maps to Top Final - Initial Algorithm
"delta" maps to Top Delta Derivative Algorithm. The
delta
use of the unit in this case is always mapped to “mA”
mAbs/min
mA/min
Calculated Ratio
R
INR
INR
%
%
Calibrated g/L
g/L
mg/L
Not supported
mg/dL
mg/dL
ng/mL
ng/mL
U/mL
U/mL
IU/mL
IU/mL
mU/mL
Not supported
nmol/L
Not supported
%vWF:Ag
Not supported
User Defined Not supported
Not 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 supported
Slope
Not supported
Paired
TR
Not supported
%NTR
Not supported
D
Not supported
DN
Not supported
ACL-TOP Service Manual
Chapter 5 – Processor / Software
5 - 59
Parallelism mean of 100% Not supported In Futura, unit label corresponds to the Unit label
selected by the user as primary unit.
mean CR
aveCR
mean CR 100% Not supported
slope
slope
r2
Not supported r equivalent to: (r2)1/2
y-intercept
y-int
%CV of CR
%CV-CR
%CV of CR
Not supported
100%
•
Error descriptions have changed in TOP, but they will be sent using the old Futura format. Only one
comment record with all flags and errors concatenated with a ‘+’ sign. The number used to indicate
the 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 record
field 6). In the original version of futura, the patient name and last name was stored in the first component.
•
Specimen ID length has changed from 20 characters to 16. 16 is the maximum number of characters supported by the TOP device. In case the number of characters sent by the LIS is bigger than
16 the messages is rejected.
•
When uploading test results Futura added the Rack ID and the Sample position in the field four in
the ASTM Order record. This field now includes the same data but the Rack ID and Sample position
has changed to the new values in TOP.
•
Futura supported the uploading of calibrations and checkpoints. These features have been
removed in TOP
•
TOP is not capable to distinguish automatically validated and manually validated results. Futura did
that sending an ‘F’ or an ‘V’ flag in R9 respectively. Due to that limitation in TOP, the driver of Futura
always 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 message, 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 maximum length allowed.
• Invalid date in a record makes the complete record to be invalidated and error info is sent to the
application. 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.
ACL-TOP Service Manual
5 - 60 Chapter 5 – Processor / Software
THIS PAGE IS INTENTIONALLY LEFT BLANK.
ACL-TOP Service Manual
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 attachment point for the line cord.
ACL-TOP Service Manual
Chapter 6 – Power Management
6-2
6-2 Physical Layout
Figure 6-1 "Layout of the Power Management System" shows the physical layout of the Power Management System. The +5V/+15V/-15V Power Supply is shown
in blue, the +24V/+28V Power Supply is shown in magenta, the Fuse Board is shown in green, and the Power Entry Module is shown in yellow.
Figure 6-1 Layout of the Power Management System
Power Entry
Module
Fuse Board
+5V/15V/-15V Power Supply
+24V/+28V Power Supply
ACL-TOP Service Manual
Chapter 6 – Power Management
6-3
6-3 Interconnect Diagrams
Figure 6-2 "Interconnect Diagram for Power Management" contains the Interconnect Diagram for the Power Management.
Figure 6-2 Interconnect Diagram for Power Management
ACL-TOP Service Manual
6 - 4 Chapter 6 – Power Management
6-4 Theory of Operation
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
Instrument
Power Switch
ACL-TOP Service Manual
Attachment
Point for the
Line Cord
Chapter 6 – Power Management
6-5
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
+24V/+28V Power
Supply Cover
+5V/15V/-15V Power
Supply Cover
The Power Supplies are auto ranging and are compatible with a wide range of input voltages and frequencies. 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
ACL-TOP Service Manual
6 - 6 Chapter 6 – Power Management
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 are
of 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.
ACL-TOP Service Manual
Chapter 6 – Power Management
6-7
Figure 6-7 Fuse Diagram for the ACL TOP/Cavro
The following table shows the secondary voltages for the ACL TOP/Cavro.
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
F5
+5V_BACKPLANE
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
F17
+15V_BACKPLANE
4A/250V TIME DELAY
IL #00014871708
F18
-15V_BACKPLANE
2A/250V TIME DELAY
IL #00014871705
**Current schematic and board notation refers to this value as 10A.
ACL-TOP Service Manual
6 - 8 Chapter 6 – Power Management
The following table lists the spares for the ACL-TOP board.
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
**Current schematic and board notation refers to this value as 10A.
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.
ACL-TOP Service Manual
Chapter 6 – Power Management
6-9
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
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
F5
+5V_BACKPLANE
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
F17
+15V_BACKPLANE
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
ACL-TOP Service Manual
6 - 10 Chapter 6 – Power Management
Table 6-3 Fuse Ratings and Secondary Voltages for the CTS TOP Model
FUSE
SIGNAL NAME
RATING
PART NUMBER
F21
+15V_PWR_F_UA1
2A/250V TIME DELAY
IL #00014871705
F22
+15V_PWR_F_UA2
2A/250V TIME DELAY
IL #00014871705
F23
+5V_PWR_F_UA1
4A/250V TIME DELAY
IL #00014871708
F24
+5V_PWR_F_UA2
4A/250V TIME DELAY
IL #00014871708
F25
CAN_BUS_FUSE
2A/250V TIME DELAY
IL #00014871705
The following table lists the spares for the CTS TOP board.
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
**Current schematic and board notation refers to this value as 10A.
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)".
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 11
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.
Table 6-5 Supply Voltages
Value of supply voltage for
normal function
Current (A)
Value as shown on the label
240V AC ± 10%
5A
100-240 VAC
115V AC ± 10%
10 A
100-240 VAC
100V AC ± 10%
10 A
100-240 VAC
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 configurations of the TOP AM.
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
ACL-TOP Service Manual
6 - 12 Chapter 6 – Power Management
Volt-Amps Specifications for the TOP Computer Module (CM)
Table 6-7 "TOP CM Volt-Amps Specifications" contains the Volt-Amps specifications for all configurations of the TOP CM.
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
Volt-Amps Specifications for the TOP Monitor
Table 6-8 "TOP Monitor Volt-Amps Specifications" contains the Volt-Amps specifications for all configurations of the TOP Monitor.
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
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.
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 13
Figure 6-9 Power Supply Access
+5V/15V/-15V Power Supply
Mounting Screws
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
Red and Black
Wires
+5V Adjustment
Potentiometer
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 .
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 14
6-6 Diagnostics
The diagnostics for Power Management are on the Voltages tab. The Voltages tab contains three main areas: the ORU area, and the Controllers area, and the Arm
Controllers area. Figure 6-11 "The Voltages Tab" shows the Voltages Tab.
Figure 6-11 The Voltages Tab
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 15
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.
ACL-TOP Service Manual
6 - 16 Chapter 6 – Power Management
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).
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 17
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).
ACL-TOP Service Manual
6 - 18 Chapter 6 – Power Management
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 Module, 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
Mounting
Screws
Wires Attached to
the Power Entry
Module
2. Remove the wires attached to the rear of the Power Entry Module (see Figure 6-15 "Power Entry Module").
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 Module".
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
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 19
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
ACL-TOP Service Manual
6 - 20 Chapter 6 – Power Management
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 Figure 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
Mounting Screws for the +5V/+15V/-15V Power Supply
Non-adjustable Power Supply Installation
1. Place the new Power Supply on a sturdy, flat surface. The holes for the mounting screws should be facing 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").
ACL-TOP Service Manual
Chapter 6 – Power Management
6 - 21
3. For a +5V/+15V/-15V Power Supply, re-connect the wires in the following fashion (terminals as indicated with supply installed):
•
Leftmost screw terminals:
Blue - top terminal
Black - bottom terminal
•
Middle screw terminals:
Black - top terminal
Brown - bottom terminal
•
Rightmost screw terminals:
Black - top terminal
Red - 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 yellow
NEW – white
LINE – black
•
Right side:
Leftmost screw terminals:
Black on top terminal
Yellow on bottom terminal
Rightmost screw terminals: Black on top terminal
White 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 Figure 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.
ACL-TOP Service Manual
6 - 22 Chapter 6 – Power Management
Figure 6-19 The Fuse Board
Mounting Screws
Note: Figure 6-19 "The Fuse Board" shows the Fuse Board for the CTS TOP. The Fuse Board for the ACL
TOP/Cavro does not have the Reagent Arm fuses, which are located on the lower right-hand side of
the 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. Ensure
that 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 Arm
connectors exist only on the CTS Fuse Board.)
ACL-TOP Service Manual
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, calibrators, diluents, and reagents from rack locations to the cuvette wells.
•
The "The Bulk Fluidic Subsystem" provides the necessary fluids to maintain precision and accuracy, 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
ACL-TOP Service Manual
7 - 2 Chapter 7 – Fluid Movement
7-3 Interconnect Diagrams
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 provided in “Interconnect Diagrams” in Chapter 8.
Figure 7-2 Fluid Movement System Interconnect Diagram
277582
FLOPPY DRIVE
P1
00027754000
P2
P1
Battery
Speaker
277587-00
277625-00
P11
J4
Speaker
Power From
Fuse Board
J8
J8
Battery
J3
Mouse
J18
IDE HD
J6
SVGA CRT
J15
Floppy
J2
Keyboard
J3
Power
J3
COM1/2
INSTRUMENT
SIDE PANEL
From Fluid
Driver Board
J9
Ethernet
J7
PC Video
J16
LPT1
J5
Flat Panel
Waste
Fluid
Full
From
Backplane
J14
CAN BUS
277626-00
278000
Level 2 CPU
J17
COM5
SCSI
J12
EZ I/O
J11
Video
OPTOA/OPTOB
Ethernet
277624-00
To Cavro CCU9000
J15
(Both) 00027758300
J14
COM3/COM4
PC/104
J1
TO J3 OF 28632000
X-AXIS DRIVER
DUAL ARM
Clean
Pump #1
Clean
Pump #2
Sample Rinse
Pum p
Accumulator 1
Full Sensor
Accumulator 2
Full Sensor
Reagent Rinse
Pump 1
Sample Clean
Valve
Reagent
Solenoid
Valve 1
Reagent Rinse
Pump 2
J1, J2
J8
286400
CAN Bus LAS
TO J3 OF 28632000
X-AXIS DRIVER
CTS ARM
J4
PC/104 CAN Bus
J7
J2
277552
J1
277626
To Side Panel
Fluidics LED
275070
J14
CANBUS
277551
277518
J2
FLUIDICS
CONTROLL ER
BOARD
J3
275050
J19
CTS Rinse
Pum p
277608
Waste Pum p
Rinse Bottle #1
Warn Sensor
J6
J9
J3
Rinse Bottle #1
Empty Sensor
Fluidics Connector Board
27506000
00027760600
J4
Rinse Bottle #2
Warn Sensor
J5
J2
J8
J1
Rinse Bottle # 2
Empty Sensor
277536
14 Pin Cable
277519
14 Pin Ribbon
J25
Reagent
Solenoid
Valve 2
00027760700
CTS Clean
Valve
00027760300
Digital I/O
00027760400
CAN Bus
J3
J36 Power
J32
Fluidic and
System
Status LED’s and
Cavro Reset
To Front Panel
Disconnect Board
277621
Clean Bottle
Warn
J3
J1
Waste Sensor
Disconnect Board J1
J2
Backplane
189510-01
ACL-TOP Service Manual
Clean Bottle
Empty
Chapter 7 – Fluid Movement
7-3
7-4 Theory of Operation
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 dispensed 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 aspiration 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"
ACL-TOP Service Manual
7 - 4 Chapter 7 – Fluid Movement
Table 7-1 Components of the Precision Fluidic Subsystem(Continued)
Component
"Syringe Pump Addressing"
"Probes and Tubing, non-CTS, Cavro
Arms"
"Probes and Tubing, CTS"
The following subsections provide descriptions of the above listed components of the Precision Fluidic Subsystem 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 Figure 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 dispensing operations in the probe.
The following descriptions of syringe pump operation apply to both the Cavro and Hamilton pumps. Differences between the two are clearly defined.
Figure 7-3 Cavro XP3000 Syringe Pump
Syringe Drive Motor
Syringe
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7-5
Figure 7-4 Hamilton PSD4 Syringe Pump
Syringe Drive
Motor
Syringe
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 volume, 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 Hamilton syringes have a different design to the syringe mounting; however their function is identical.
ACL-TOP Service Manual
7 - 6 Chapter 7 – Fluid Movement
Figure 7-5 Cavro Syringe Parts
Teflon Tip
Plunger
Kel-F Body
Figure 7-6 Hamilton Syringe Parts
Kel-F Body
Plunger
Teflon Tip
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".
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7-7
Figure 7-7 Syringe Pump Valve
Teflon Plug
Valve
Pan Head
Screws
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
Rinse Input
Port
Probe (Sample
Tubing)Output
Syringe
Connection
ACL-TOP Service Manual
7 - 8 Chapter 7 – Fluid Movement
The valve is turned by a stepper motor with an encoder coupled to the motor that provides positional feedback. 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 Positions for All ACL-TOP Configurations" lists the three available valve positions and their function.
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
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
RS-485-B
RS-485-A
Pin 4
Pin 3
Pin 2
Pin 1
JP2
ACL-TOP Service Manual
Pin 3
Pin 2
Pin 1
JP4
Extra Jumper
Valve Mode
Chapter 7 – Fluid Movement
7-9
The lower set of Cavro jumpers are configuration jumpers and should be in the position shown on Figure 710 "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
- Baud Rate (9600 Baud)
JP1-4
JP1-3
JP1-2
- EEPROM Mode (EEPROM Autostart)
- Protocol (OEM)
- Overload Detection (Enabled)
JP1-1
Address
Address switch
(Rotary dial)
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.
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
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.
ACL-TOP Service Manual
7 - 10 Chapter 7 – Fluid Movement
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 Jumpers". 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
Address Selection
Address Switch
SW 1
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
Table 7-4 Hamilton Configuration Jumpers
ACL-TOP Service Manual
Pins
Setting
J1 -J2
No Jumper
J3 - J4
No Jumper
J5 - J6
Jumper Inserted
J7 - J8
Jumper Inserted
Chapter 7 – Fluid Movement
7 - 11
The Dip switches should be in the position shown on Figure 7-11 "Hamilton Syringe Pump Jumpers/
Switches".
Table 7-5 Hamilton DIP Switches
Switch
Description
Setting for ACLTOP
1
Syringe Overload Detection
Off
2
EEPROM AutoStart/Self Test
Off
3
Baud Rate 9600 or 3840Baud
Off
4
Off
5
Off
Valve Settings
6
Off
7
8
Off
Rs-485 Communication Termination
Off
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 addressable 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 manufacturing; 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)
ARM LOCATION
SYRINGE PUMP ADDRESS
SAMPLE
1
INTERMEDIATE REAGENT
1
START REAGENT
1
Table 7-7 Syringe Pump Addresses (Base TOP Instruments)
ARM LOCATION
SYRINGE PUMP ADDRESS
SAMPLE
4
INTERMEDIATE REAGENT
0
START REAGENT
4
ACL-TOP Service Manual
7 - 12 Chapter 7 – Fluid Movement
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 system software to perform volume tracking on reagents and diluents and to maintain the precision and accuracy 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 nonCTS 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 connection 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 calibration 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 thermal control of the probe, refer to “Reagent Probes for Cavro Thermal Regulation” in Chapter 12 and
“Cavro Sample Probe Thermal Regulation” in Chapter 12.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 13
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 resistor 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 during 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 control 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 tightened by hand and then given ¼ turn with a wrench to properly seal the O-ring attached to the fitting. The Oring provides compression to the Teflon Flange as it seals against the bottom of the threaded valve port.
ACL-TOP Service Manual
7 - 14 Chapter 7 – Fluid Movement
The Bulk Fluidic Subsystem
The Bulk Fluidic Subsystem consists of the following components:
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"
The following subsections provide detailed descriptions of the components, and operation, of the Bulk Fluidic 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
Onboard Rinse
Fluid Bottle
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 15
Figure 7-14 Rinse, Clean Sensors
Clean Warning
Sensor
Clean Empty
Sensor
Rinse
Warning
Sensor
Rinse Empty
Sensor
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 number 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 initialized and during regularly scheduled maintenance activities. See "Priming the Rinse System" and "Priming 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.
ACL-TOP Service Manual
7 - 16 Chapter 7 – Fluid Movement
Figure 7-15 Rinse Pump Box Location
Waste Pump Cover
Rinse
Pump
Box
Waste
Pump
Waste
Drawer
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 approximately 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".
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Chapter 7 – Fluid Movement
7 - 17
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
Drain
Clean Cup
Rinse Cup
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.
ACL-TOP Service Manual
7 - 18 Chapter 7 – Fluid Movement
NOTE: Each Sample and Reagent Probe performs its coordinates check on the metal surface 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 recommended.
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
Deep Wash
Rinse Cup
Figure 7-18 CTS Reagent Rinse/Clean Cup
Drain Hole
Clean Cup
Rinse 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.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 19
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 configuration. 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 Accumulators.
The Clean A Fluid enters the system via a chemically compatible Aspirator inserted into the Clean Fluid Bottle (see Figure 7-19 "The Clean Fluid Bottle"). The fluid height in the Clean Fluid is checked by two capacitance sensors mounted on the inside of the right outer panel (see Figure 7-19 "The Clean Fluid Bottle").
ACL-TOP Service Manual
7 - 20 Chapter 7 – Fluid Movement
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
Clean Fluid
Bottle
Figure 7-20 Clean Fluid Sensors
Clean Warning
Sensor
Clean Empty
Sensor
Rinse
Warning
Sensor
Rinse Empty
Sensor
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.)
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Chapter 7 – Fluid Movement
7 - 21
Figure 7-21 Clean Fluid LED Indicator
Clean Fluid LED
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 module are as shown on Figure 7-22 "Clean Pumps", with the clean pump mounted just below the clean well.
Figure 7-22 Clean Pumps
Clean Well
Clean Pump
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.
ACL-TOP Service Manual
7 - 22 Chapter 7 – Fluid Movement
Figure 7-23 CTS Sample Clean Pump
CTS Sample Clean Well
CTS Sample Clean Pump
The clean pumps are powered via the cable assembly for the Sample Accumulator or the Reagent Accumulator, 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 coming 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.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 23
Figure 7-24 CTS Bulk Fluids Module
Rinse Pump
Fluidics
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 instrument 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
Air Pump
Air Cylinder
ACL-TOP Service Manual
7 - 24 Chapter 7 – Fluid Movement
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 N86style 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 margin 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.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 25
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 propagate 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 differentials 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 several 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 addition, 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/Connector Board are ordered as one assembly.
Figure 7-27 Location of Fluidics Controller/Connector PCBs
Fluidics Controller,
Driver/Connector
PCBs
(under cover)
ACL-TOP Service Manual
7 - 26 Chapter 7 – Fluid Movement
Figure 7-28 Fluidic LED PCB
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 Fluidic Driver/ Connector Board.
•
Mounted under the Fluidics Controller PCB. (The cover protecting the PCBs from any fluid must be
removed 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 accumulators and external liquid waste bottle.
•
Provides solenoid power to cover interlocks, Sample and Reagent front cover sensors, and emergency stop button.
•
Mounted on top of the Fluidics Controller PCB. (The cover protecting the PCBs from any fluid must
be 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".
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 27
Figure 7-29 CTS ACL-TOP Fluidic Diagram
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 28
Figure 7-30 Non-CTS Fluidic Diagram
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 29
7-5 Adjustments and Verifications
Syringe Pump Addressing and Jumpers
The address and jumpers on a Syringe Pump must be set properly so the ACL-TOP instrument can communicate 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 ACLTOP 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 7-9 Syringe Pump Addresses for CTS Instruments
ARM LOCATION
SYRINGE PUMP ADDRESS
Sample
1
Intermediate Reagent
1
Start Reagent
1
Table 7-10 Syringe Pump Addresses non-CTS Instruments
ARM LOCATION
SYRINGE PUMP ADDRESS
Sample
4
Intermediate Reagent
0
Start Reagent
4
Table 7-11 "Syringe Pump Jumper Settings"shows the correct settings of Cavro Syringe Pump jumpers.
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
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7 - 30 Chapter 7 – Fluid Movement
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”
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
•
7 - 31
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 following
steps 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 Figure 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 container. 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.
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7 - 32 Chapter 7 – Fluid Movement
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
Base Top
Volume After 5 Seconds
5.15±0.5ml (4.65 to 5.65ml)
Flow Rate
1.03ml/sec
(±0.10ml)
CTS
Volume After 5 Seconds
5.58±1.04ml (4.54 to 6.61ml)
Flow Rate
1.12 ml/sec ±
(0.20ml)
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.
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Chapter 7 – Fluid Movement
7 - 33
Figure 7-35 Flowchart for Fluidic Functional Test
Replace Probes
Replace Probe
Rinse Tubing
Replace Syringes
and tubing
Perform Coordinates Adjustment
Replace/Repair
Pumps or Valves
Replace/Repair
Accumulator,
Tubing or Valves
Perform the
Rinse Flow Rate
Test
Perform the
Clean Pump Test
Verify that the
Virtual LED for
the Sample Clean
Pump is on
Perform the LLD
test inside a
cuvette (100 ul)
and inside a cup
(200 ul)
Verify that the
Virtual LED for
the Waste Pump
is on
Visually verify
alignment by
moving material
to several
locations with the
Move function.
Verify that the
Virtual LEDs for
the Waste
Sensors are all
off
Perform the Flow
Rate Test
Fluidic Precision
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 addition, 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 Figure 7-36 "Sensor Keys" to set the pump to turn on at 22psig and turn off at 24psig.
ACL-TOP Service Manual
7 - 34 Chapter 7 – Fluid Movement
Figure 7-36 Sensor Keys
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 limitations 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.
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Chapter 7 – Fluid Movement
7 - 35
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.
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Chapter 7 – Fluid Movement
7 - 36
Figure 7-37 Fluids Tab
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 37
Clean Sensors Area
The Clean Sensors area contains virtual LEDs for the cleaning-related valves and pumps in the Fluid Movement 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
Select Pull-down
List
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 Reagent
1 Probe.
•
Start Reagent arm – Select this option to open the Reagent 2 valve or clean the Reagent 2 Probe.
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7 - 38 Chapter 7 – Fluid Movement
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 Figure 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 checkbox 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 system 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.
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Chapter 7 – Fluid Movement
7 - 39
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 reenabled 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 decontamination 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.
ACL-TOP Service Manual
7 - 40 Chapter 7 – Fluid Movement
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 dilution, four replicates are prepared and measured and one reading is collected from each of the 4 ORU channels. 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 control, the head volume, air gap, and transport air gap can be specified.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 41
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
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 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 second) 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 dilutions 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.
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7 - 42 Chapter 7 – Fluid Movement
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 calculated 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.
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
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.
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Chapter 7 – Fluid Movement
7 - 43
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
Mounting
Screws
Rinse Tubing
Barbed
Fitting
4.
Precision
(Probe)
Tubing
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.
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7 - 44 Chapter 7 – Fluid Movement
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 necessary 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)
Mounting
Screws
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Chapter 7 – Fluid Movement
7 - 45
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
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
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
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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 specified 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.
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7 - 46 Chapter 7 – Fluid Movement
Figure 7-48 Cavro Syringe Pump Back
Jumpers
15 Pin Electrical
Connector
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
Mounting
Screws
Rinse Tubing
Barbed
Fitting
ACL-TOP Service Manual
Precision
(Probe)
Tubing
Chapter 7 – Fluid Movement
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").
7 - 47
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
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(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 Sample 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.
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.)
Figure 7-50 Cavro Sample Arm Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6.
Move the arms to the side so they will not be damaged when removing the pump assembly.
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7 - 48 Chapter 7 – Fluid Movement
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
Screws
Mounting
Screws
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..
9.
Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as
shown on Figure 7-52 "Cavro Syringe Pump Back".
Figure 7-52 Cavro Syringe Pump Back
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
10. Carefully remove the syringe pump from the instrument.
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Chapter 7 – Fluid Movement
7 - 49
11. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate from
the pump.
Base TOP Cavro Sample Syringe Pump Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
See Figure 7-59 "Cavro Syringe Pump Back" for steps 1 through 3.
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.
Figure 7-53 Cavro Syringe Pump Back
Jumpers
15 Pin Electrical
Connector
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.
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
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7 - 50 Chapter 7 – Fluid Movement
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
Mounting
Screws
Mounting
Screws
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
Rinse Tubing
Precision
(Probe)
Tubing
10. Re-install the Sample Area interior skins.
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Chapter 7 – Fluid Movement
7 - 51
Reagent Cavro Syringe Pump Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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").
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.
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.)
Figure 7-56 Reagent Cavro Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6.
.Move the probes to the side so they will not be damaged when removing the pump assembly.
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7 - 52 Chapter 7 – Fluid Movement
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
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..
9.
Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as
shown on Figure 7-58 "Cavro Syringe Pump Back".
Figure 7-58 Cavro Syringe Pump Back
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
10. Carefully remove the syringe pump from the instrument.
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Chapter 7 – Fluid Movement
7 - 53
11. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate from
the pump.
Reagent Cavro Syringe Pump Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
See Figure 7-59 "Cavro Syringe Pump Back" for steps 1 through 3.
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.
Figure 7-59 Cavro Syringe Pump Back
Jumpers
15 Pin Electrical
Connector
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).
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.
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7 - 54 Chapter 7 – Fluid Movement
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
Mounting
Screws
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
Rinse Tubing
Precision
(Probe)
Tubing
10. Re-install the Reagent Area interior skins.
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Chapter 7 – Fluid Movement
7 - 55
Cavro Syringe Tip Removal/Replacement
Cavro Syringe Tip Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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/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.)
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.
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.
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.
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
Rinse Tubing
Probe Tubing
Barbed Fitting
Syringe Glass
Screw
Syringe
Thumbwheel
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7 - 56 Chapter 7 – Fluid Movement
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
Teflon Tip
Plunger
Glass Tube
Cavro Syringe Tip Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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.
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Chapter 7 – Fluid Movement
7 - 57
Figure 7-64 Cavro Syringe Tip Installation
Plunger
Syringe Tip
Installation
Tool
Teflon Tip
Syringe
Glass Tube
O-Ring
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
Rinse Tubing
Probe Tubing
Barbed Fitting
Syringe Pump
Valve
Syringe Glass
Screw
Thumbwheel
12. Install the Reagent or Sample area interior skins.
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7 - 58 Chapter 7 – Fluid Movement
Cavro Syringe Valve Removal/Replacement
Cavro Syringe Valve Removal
CAUTION: Ensure 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.
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.)
See Figure 7-66 "Cavro Syringe Removal" for steps 2 through 11.
Figure 7-66 Cavro Syringe Removal
Rinse Tubing
Probe Tubing
Barbed Fitting
Phillips Screws
Syringe Glass
Tube
Syringe Glass
Screw
Thumbscrew
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.
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.
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.
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.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
9.
7 - 59
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.
3.
Screw the Syringe Glass tube onto the Syringe Pump Valve.
Figure 7-67 Cavro Syringe Installation
Rinse Tubing
Probe Tubing
Barbed Fitting
Phillips Screws
Syringe Glass
Tube
Syringe Glass
Screw
Thumbscrew
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.
7.
Attach the Rinse tubing to the barbed fitting.
8.
Screw the Probe tubing onto the Syringe Pump Valve.
9.
Install the sample or Reagent area interior skins.
ACL-TOP Service Manual
7 - 60 Chapter 7 – Fluid Movement
Hamilton Syringe Pump Assembly Removal/Replacement
CTS Sample Hamilton 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 7-68 "Hamilton CTS Sample Syringe Pump Assembly").
(Fluid will drain from the probe.)
Figure 7-68 Hamilton CTS Sample Syringe Pump Assembly
Mounting Screws
Rinse
Input
Fitting
4.
Rinse Tubing
Barbed
Fitting
Precision
(Probe)
Tubing
Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-68 "Hamilton CTS Sample
Syringe Pump Assembly").
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.
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.)
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
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 necessary 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..
7 - 61
Figure 7-69 CTS Fluidics Mounting
Rinse
Input
Fitting
Syringe
Pump
Mounting
Screws
Mounting
Screws
ACL-TOP Service Manual
7 - 62 Chapter 7 – Fluid Movement
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
Address Selection
(shown at 0)
Address Switch
15 Pin Electrical
Connector
SW 1
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
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 Hamilton Syringe Pump Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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 specified 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 information on the proper settings for Syringe Pump addresses.
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Chapter 7 – Fluid Movement
7 - 63
Figure 7-71 Hamilton Syringe Pump Back
Address Selection
(shown at 0)
Address Switch
15 Pin Electrical
Connector
SW 1
DIP Switches
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
2.
Ensure the Configuration jumpers are at the proper settings. Refer to "Hamilton Syringe Pump Settings" for more information on the proper jumper settings.
3.
Set the DIP switches for the pump as stated in "Hamilton Syringe Pump Settings".
4.
Attach the drip plate to the bottom of the pump using the screws previously removed.
5.
Re-connect the 15-pin electrical connector(s) to the back of the Syringe Pump(s).
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.
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7 - 64 Chapter 7 – Fluid Movement
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
Mounting Screws
Rinse
Input
Fitting
9.
Rinse Tubing
Barbed
Fitting
Precision
(Probe)
Tubing
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").
12. Re-install the Sample Area interior skins.
Base TOP Hamilton Sample Arm 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.)
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
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").
7 - 65
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.
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.)
Figure 7-73 Hamilton Sample Arm Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6.
Move the arm to the side so they will not be damaged when removing the pump assembly.
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7 - 66 Chapter 7 – Fluid Movement
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
Mounting
Screws
Mounting
Screws
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.
9.
Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as
shown on Figure 7-75 "Hamilton Syringe Pump Back".
Figure 7-75 Hamilton Syringe Pump Back
Address Selection
Address Switch
15 Pin Electrical
Connector
SW 1
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
10. Carefully remove the syringe pump from the instrument.
11. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate from
the pump.
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Chapter 7 – Fluid Movement
7 - 67
Base TOP Hamilton Sample Syringe Pump Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
See Figure 7-76 "Hamilton Syringe Pump Back" for steps 1 through 3.
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.
Figure 7-76 Hamilton Syringe Pump Back
Address Selection
(shown at 0)
Address Switch
SW 1
15-Pin
Electrical
Connector
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
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".
4.
Attach the drip plate to the bottom of the pump using the screws previously removed.
5.
Re-connect the 15-pin electrical connector(s) to the back of the Syringe Pump(s).
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 "Hamilton Sample Arm Pump Assembly Mounting".
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7 - 68 Chapter 7 – Fluid Movement
Figure 7-77 Hamilton Sample Arm Pump Assembly Mounting
Mounting
Screws
9.
Mounting
Screws
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
Rinse Tubing
Precision
(Probe)
Tubing
11. Re-install the Sample Area interior skins.
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Chapter 7 – Fluid Movement
7 - 69
Reagent Hamilton Syringe Pump Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
1.
Remove the Reagent Area interior skins as described in “Reagent Area Interior Skins Removal/
Replacement” in Chapter 4.
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.)
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").
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.
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.)
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7 - 70 Chapter 7 – Fluid Movement
Figure 7-79 Hamilton Reagent Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
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
Mounting
Screws
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
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..
9.
Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as
shown on Figure 7-81 "Hamilton Syringe Pump Back".
7 - 71
Figure 7-81 Hamilton Syringe Pump Back
Address Selection
Address Switch
15-Pin
Electrical
Connector
SW 1
DIP Switches
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
10. Carefully remove the syringe pump from the instrument.
11. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate.
Reagent Hamilton Syringe Pump Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
See Figure 7-82 "Hamilton Syringe Pump Back" for steps 1 through 3.
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.
ACL-TOP Service Manual
7 - 72 Chapter 7 – Fluid Movement
Figure 7-82 Hamilton Syringe Pump Back
Address Selection
Address Switch
15-Pin
Electrical
Connector
SW 1
DIP Switches
SW 8
J1 - J2
J3 - J4
Configuration
Jumpers
J5 - J6
J7 - J8
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.
5.
Re-connect the 15-pin electrical connector(s) to the back of the Syringe Pump(s).
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.
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Chapter 7 – Fluid Movement
8.
7 - 73
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
Mounting
Screws
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 784 "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").
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7 - 74 Chapter 7 – Fluid Movement
Figure 7-84 Reagent Hamilton Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
11. Re-install the Reagent Area interior skins.
Hamilton Syringe Tip Removal/Replacement
Hamilton Syringe Tip Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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/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.)
Reference Figure 7-85 "Removing the Hamilton 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.
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.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
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.
Loosen the Thumbscrew at the bottom of the Syringe Tube.
7.
Raise the plunger within the syringe.
8.
Unscrew and remove the Syringe.
7 - 75
Figure 7-85 Removing the Hamilton Syringe
Rinse Tubing
Probe Tubing
Barbed Fitting
Syringe
Screw
Connection
Syringe
Thumbwheel
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").
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7 - 76 Chapter 7 – Fluid Movement
Figure 7-86 Hamilton Syringe Tip Removal
Teflon Tip
Plunger
Glass Tube
Hamilton Syringe Tip Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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.
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Chapter 7 – Fluid Movement
7 - 77
Figure 7-87 Hamilton Syringe Tip Installation
Syringe Tip
Installation
Tool
Plunger
Teflon Tip
Syringe
Glass Tube
O-Ring
See Figure 7-88 "Hamilton Syringe Valve Assembly/Tubing" for steps 6 through 12.
6.
Screw the Syringe Glass tube onto the Syringe Pump Valve.
7.
Manually lower the plunger so the metal knob at the bottom of the syringe plunger seats in the thumbwheel 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.
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7 - 78 Chapter 7 – Fluid Movement
Figure 7-88 Hamilton Syringe Valve Assembly/Tubing
Probe Tubing
Rinse Tubing
Barbed Fitting
Syringe Pump
Valve
Syringe Glass
Tube
Thumbwheel
12. Install the Reagent or Sample area interior skins.
Hamilton Syringe Valve Removal/Replacement
Hamilton Syringe Valve Removal
CAUTION: Ensure 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.
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.)
See Figure 7-89 "Hamilton Pump Syringe Removal" for steps 2 through 10.
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.
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.
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
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.
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.
7 - 79
10. Gently pull the Syringe Pump Valve from the front face of the Syringe Pump Assembly.
Figure 7-89 Hamilton Pump Syringe Removal
Probe Tubing
Rinse Tubing
Barbed Fitting
Syringe Pump
Valve
Phillips Screws
Syringe Glass
Tube
Thumbwheel
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.
3.
Screw the Syringe Glass tube onto the Syringe Pump Valve.
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7 - 80 Chapter 7 – Fluid Movement
Figure 7-90 Hamilton Syringe Installation
Rinse Tubing
Probe Tubing
Barbed Fitting
Syringe Pump
Valve
Phillips Screws
Syringe Glass
Tube
Thumbwheel
4.
Lower the syringe plunger so the metal knob at the bottom of the syringe plunger seats in the thumbwheel block.
5.
Tighten the thumbwheel until it is finger-tight.
6.
Use pliers to tighten the thumbwheel an additional 1/4 turn to ensure tightness.
7.
Attach the Rinse tubing to the barbed fitting.
8.
Screw the Probe tubing onto the Syringe Pump Valve.
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.
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Chapter 7 – Fluid Movement
7 - 81
Figure 7-91 Rinse Box Connections
CTS Fitting
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
Retaining 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 Figure 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 Retaining Screws".
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7 - 82 Chapter 7 – Fluid Movement
Figure 7-93 Rinse Pump Retaining Screws
Retaining Screws
Captive Screws
Rinse Pump
Connector
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.
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 7-94 "The Probe
Tubing"). (Fluid will drain from the probe.)
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Chapter 7 – Fluid Movement
7 - 83
Figure 7-94 The Probe Tubing
Probe Tubing
Rinse 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
ACL-TOP Service Manual
7 - 84 Chapter 7 – Fluid Movement
Figure 7-96 Precision Tubing Strain Relief on Base TOP Sample Arm
Strain Relief
Bracket
Figure 7-97 Precision Tubing Strain Relief on Intermediate (R1) Arm
Strain Relief Bracket
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 85
Figure 7-98 Precision Tubing Strain Relief on Start (R2) Arm
Strain Relief Bracket
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 the
probe.
c. Dress the tubing as shown in the appropriate figure below.
d. Install the Sample or Reagent area interior skins.
ACL-TOP Service Manual
7 - 86 Chapter 7 – Fluid Movement
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
ACL-TOP Service Manual
Chapter 7 – Fluid Movement
7 - 87
Figure 7-100 Dressing the Tubing on Base TOP Sample Arm
ACL-TOP Service Manual
7 - 88 Chapter 7 – Fluid Movement
Figure 7-101 Dressing the Tubing on Intermediate (R1) Arm
Figure 7-102 Dressing the Tubing on Start (R2) Arm
ACL-TOP Service Manual
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 assembly 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
X Axis
Y
Axis
Z
Axis
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.
ACL-TOP Service Manual
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 instrument configuration as shown on Table 8-1 "Robotic Arm/Probe Configurations".
Table 8-1 Robotic Arm/Probe Configurations
Arms
Instrument Type
ACL-TOP with Cavro
Arms
Sample
Arm
Probes
Reagent
Arm
Sample Probe
Left Reagent
Probe
Right Reagent
Probe
Cavro
Cavro
Heated
Heated*
Heated*
CTS
IL
Double
Piercer (NonHeated)
Heated*
Heated*
(000028000)
ACL-TOP Closed
Top System
(0000280020)
* 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 Assemblies 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
Sample Arm
ACL-TOP Service Manual
Left Reagent Arm
Right Reagent Arm
Chapter 8 – Robotic XYZ Arms
8-3
8-3 Interconnect Diagrams
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 83 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")
ACL-TOP Service Manual
8 - 4 Chapter 8 – Robotic XYZ Arms
Figure 8-3 Interconnect Diagram - CTS/IL Double Sample Arm
Figure 8-4 Interconnect Diagram - CTS/IL Double Reagent Arm
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
J
3
J
5
J
6
J11
J13
J10
J12
J
9
J
4
J14
J15
J16
J
2
J
1
J
7
J
8
J
3
J
4
J
3
J
1
J
6
J
J
7
J
1
J
2
J
5
J
5
J
6
2
J
7
J
4
J
7
J
7
J
9
J
8
J
2
J
5
J
3
J
6
J
5
J
5
J
6
J
2
J
6
J
1
J
2
J
4
J
8
J
8
J
8
J
1
J
3
J
1
J
3
J
4
8-5
J
1
J
7
J
9
J
2
J
5
J
3
J
6
J
4
J
4
ACL-TOP Service Manual
8 - 6 Chapter 8 – Robotic XYZ Arms
Figure 8-5 Interconnect Diagram - Sample-side Cavro Arm
XP3000
Diluter
Pum p
27756500
J1
J21
From Fuse Board J5
00027751100
J2
J7
To LEVEL 2 CPU (278000)
J14 00027758300
+24V OUT
MODULO 1
Y-AXIS
ALIDUM
RS 485 Diluter
MODULO 1
Z-AXIS
+24V IN
Cavro Arm Module
CCU9000
Diagnostic s
J15
232 External
PC
J16
232 Aux
Devic e
J17
RS 485 / 422
EXT
00027763300
To Sample Probe
ADRI-9
Cavro Single Arm Module
CCU9000
MODULO 1
Y-AXIS
MODULO 1
X-AXIS
ALIDUM
MODULO 1
Z-AXIS
ADRI-9
Figure 8-6 Interconnect Diagram - Reagent-side Cavro Arms
XP3000
Diluter
Pum p
XP3000
Diluter
Pum p
27756500
J1
+24V OUT
J21 RS 485 Diluter
From Fuse Board J5
00027751100
MODULO 1
Y-AXIS
MODULO 1
X-AXIS
ADRI-9
Cavro Arm Module
CCU9000
J15
232 External PC
J16
232 Aux
Devic e
J17 RS 485 / 422
EXT
Cavro Dual Arm Module
CCU9000
MODULO 1
Y-AXIS
MODULO 1
X-AXIS
00027763300 To
Reagent 2 Probe
ALIDUM
MODULO 1
Z-AXIS
ADRI-9
ACL-TOP Service Manual
00027763300 To
Reagent 1 Probe
MODULO 1
Z-AXIS
J2 +24V IN
J7 Diagnostic s
To LEVEL 2 CPU (278000)
J14 00027758300
ALIDUM
Chapter 8 – Robotic XYZ Arms
8-7
8-4 Theory of Operation
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
Cavro Sample Arm
Cavro Reagent 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 89 "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.
ACL-TOP Service Manual
8 - 8 Chapter 8 – Robotic XYZ Arms
Figure 8-8 X Frame
X Frame
Figure 8-9 Vibration Isolators
Reagent
Left
Vibration
Isolators
Sample Arm
Right
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
X Rails
Rollers
X Axis
Drive Belt
Drive Belt
Carriage Attachment
Y Axis Assembly
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8-9
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
Drive Pulley
Encoder
Disk
Optical Sensor
Drive Belt
For the X-Axis Assembly on the Reagent side, the two arms require two motors and two drive belts. The layout 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
R1 (Left Arm) Motor
R2 (Right Arm) Motor
ACL-TOP Service Manual
8 - 10 Chapter 8 – Robotic XYZ Arms
Figure 8-13 X Axis Belts - Reagent Side
R1 (Left Arm) Belt
R2 (Right Arm) Belt
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
Z Axis Drive Belt
Roller
Z Carriage
Y Drive Belt
Guide Rail
Tandem Pulleys
ACL-TOP Service Manual
Square Shaft
Chapter 8 – Robotic XYZ Arms
8 - 11
As shown on Figure 8-15 "Y Axis Stepper Motor", the Y Axis Stepper Motor is mounted on top of the YAxis 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 Encoder
Y Axis Motor
Z Axis Motor
Z Axis Drive Belt
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 Encoder
Z axis Motor
Z axis Drive Belt
Square Shaft
that drives the
Z-Axis Assembly
ACL-TOP Service Manual
8 - 12 Chapter 8 – Robotic XYZ Arms
Figure 8-17 "Z-Axis Assembly" depicts the Z-Axis Assembly. As shown, the Z Rack mounting hole provides 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
Z-Axis Assembly
Z Rack Mounting
Hole
Y axis Drive Belt
Square Shaft
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 Positions
Table 8-3
Arm/
Axis
Home Position
All
Z
Up
Sample arm
X
Rear, right side of the Sample Area
Left Reagent arm
X
Rear, left side of the
Reagent Area
Right Reagent
arm
X
Rear, right side of the
Reagent Area
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 13
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
Slotted
Sensor
Sensors
Flag
Flags
Left Flag/Sensor
Right Flag/Sensor
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.
ACL-TOP Service Manual
8 - 14 Chapter 8 – Robotic XYZ Arms
Figure 8-19 Y Limit Flag and Travel Limit Sensor
Sensor
To Be Added.
Flag
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 hitting 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 processor. 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 connector 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 XAxis 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.
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 15
Figure 8-20 Central Control Unit (CCU) for Cavro Arms
LEDs
CCU Board
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 Alidum 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 visible 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.
ACL-TOP Service Manual
8 - 16 Chapter 8 – Robotic XYZ Arms
Figure 8-21 ADRI-9 PCBs
Figure 8-22 ADRI 9 Dip Switches
S4 S3 S2
S1
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 Settings
Table 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
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 17
Table 8-5
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
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 provides 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.
ACL-TOP Service Manual
8 - 18 Chapter 8 – Robotic XYZ Arms
Figure 8-23 Heater Probe PCB
Probe Heater
Board
Probe Fuse
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 positioning 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
CTS Sample
Arm
Reagent
IL Double Arm
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 XFrame are:
•
two rails
•
X-Axis Stepper Motor/encoder assembly
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
•
X-Axis idler pulley
•
X-Axis PCB.
8 - 19
Figure 8-25 X-Axis Assembly
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. Figure 8-26 "X Axis Drive Belt (Sample Side)" shows the rails and the drive belt.
Figure 8-26 X Axis Drive Belt (Sample Side)
X Axis Rails
Drive
Pulley
X Drive Belt
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 encoders that are visible, the Y Axis motor encoder is enclosed and not visible. The encoder disk is read by an
optical sensor.
ACL-TOP Service Manual
8 - 20 Chapter 8 – Robotic XYZ Arms
Figure 8-27 X Axis Drive Motor
End of Limit
Travel Sensor
X Axis
Frame
X Axis Motor
X Axis Motor
Encoder
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
R2 (Right) Drive Belt
ACL-TOP Service Manual
R1 (Left)
Drive Belt
Chapter 8 – Robotic XYZ Arms
8 - 21
Figure 8-29 Reagent Side X Axis Motors
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
Y Axis Drive Pulley
Y Axis
Drive Motor
Y Axis Drive Belt
ACL-TOP Service Manual
8 - 22 Chapter 8 – Robotic XYZ Arms
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
Y Axis
Stepper
Motor
Figure 8-32 Y Axis Drive Belt
Front Pulley
Y Axis
Drive Belt
Drive Motor
Drive Pulley
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 23
Z-Axis Assembly
The Z-Axis Assembly attaches through the Y Axis carriage. The Z-Axis Assembly include the mounting bulkhead, 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
Z-Axis
Assembly
(Bottom
View)
Z Axis
Motor
Z Drive
Rack
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.
ACL-TOP Service Manual
8 - 24 Chapter 8 – Robotic XYZ Arms
Figure 8-34 CTS Piercer Z-Axis Assembly
Piercer Air & Fluid
Solenoid Valves
Gear Box
Brake Rack Opening
As shown in Figure 8-35 "Z Axis Controller PCB", the Z Axis controller PCB, which is enclosed in a casing, 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
Z Axis
Controller
PCB
Z-Axis
Assembly
(Top View)
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".
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 25
Table 8-6 CTS Sample and IL Double Arm X, Y, Z Home Positions
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
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
Left Side Travel Limit Flag
Travel Limit Sensors
Right
Side
Travel
Limit
Flag
ACL-TOP Service Manual
8 - 26 Chapter 8 – Robotic XYZ Arms
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
X Travel Limit
Flag
X Travel Limit
Sensor
X Travel Limit
Sensor
X Travel Limit
Flag
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
Front of Arm
Flags
Sensors
ACL-TOP Service Manual
Rear of Arm
Chapter 8 – Robotic XYZ Arms
8 - 27
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.
ACL-TOP Service Manual
8 - 28 Chapter 8 – Robotic XYZ Arms
Figure 8-39 CTS Sample and/or IL Double Arm PCB Locations
XYZ Controller PCB
Y Driver PCB
Z Axis Controller PCB (under cover)
X Axis Driver PCB
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 processing 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 modulated 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.
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 29
Figure 8-40 XYZ Controller Interface PCB, Y-Driver PCB
XYZ
Controller
PCB
Y Driver PCB
X Travel
Limit Sensor
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 positioning.
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.
ACL-TOP Service Manual
8 - 30 Chapter 8 – Robotic XYZ Arms
Figure 8-41 X Axis Driver PCB
LEDs
The Can Bus interface splits to both arms while the RS232 ports are specific to one arm. The RS232 connections 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 utilized 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.
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 31
Figure 8-42 Z-Axis Controller PCB
J5
J8
J9
J1
J3
J4
J2
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 different 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 procedures 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.
ACL-TOP Service Manual
8 - 32 Chapter 8 – Robotic XYZ Arms
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 flowchart of the “Coordinate Adjustment” procedure is included in the "Probe and Arm Initialization Flowcharts" 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 coordinates 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 reference 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 Instrument.
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.
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
8 - 33
Figure 8-43 Reference Point Positions for Base TOP Instruments (Cavro Arms)
Shuttle
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INCUBATOR #2
INCUBATOR #1
CTS Hold Area
Cuvette Pivot Arm
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O
Zone- Logical
Arm #2
M
E
Sample Arm Zone - Logical Arm #1
Barcode Reader Module ( BC ) Zone
Reagent Arm #2 Zone Logical Arm #3
R
Reference point
Figure 8-44 Reference Point Positions for CTS Instruments
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Barcode Reader Module ( BC ) Zone
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Reagent Arm #2 Zone Logical Arm #3
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Reference point
ACL-TOP Service Manual
8 - 34 Chapter 8 – Robotic XYZ Arms
Reference Point Search
The adjustment operates on the premise that reference screws are, by definition, circular. The probe diameter 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 contact was made.
Figure 8-45 Reference Screw Detection
2
1
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 center. 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 / 2
YStartSearch: 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 the
measured position of the first screw; in this way the instrument is able to touch the second and third
screw 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.
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Chapter 8 – Robotic XYZ Arms
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b. If the screw is not found, the instrument performs another attempt updating the LLD start and end
position 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 end
position as follows:
ZStartLld = 4.25mm above Zcad
ZEndLld = 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 position 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 three
times, 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. Therefore, 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 possibility 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:
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X1measured = (X2measured + X3measured) / 2
Y2measured = Y1measured + (Y2cad - Y1cad)
Y3measured = Y2meas
Figure 8-46 Well Area Cutout Reference Points for Non-CTS Probes
1
2
R
X
R
R
R
R
R
R
R
3
R
Y
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
2
R
X
R
R
R
Y
R
R
R
R
R
3
1
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.
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The file name and path are: C:\Program Files\IL\ACL-TOP\AMSw\FTPBoot\Coordinates\XX-XX-XX-XX-XXXX-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 coordinates. 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 cannot 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 station 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:
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1. Set start and cap detection positions.
XStartSearch: Adjusted X coordinate of the wash station
YStartSearch: 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 reference
points
zEnd: the bottom face of the foot 3mm below the measured Z coordinate of the wash reference
points
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: This
position maybe still be inaccurate, because the start search position could be far from the center on
both 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 the
current 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 “surface
found”).
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
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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 arm
controller 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 with
the reference point: Steps loss on Z axis - cavro error 22 (cavro arms), Slippage on Z Axis (CTS
Sample Arms).
•
LLD falsely triggers. (Transform matrix corruption or alignment procedure failure.)
•
Mechanical modules not grounded (alignment procedure failure).
•
Arms not at 90 degrees.
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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.
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Chapter 8 – Robotic XYZ Arms
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Figure 8-49 Probe Initialization for CTS Sample Arms
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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
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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
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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
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8 - 45
Coordinates Checking Procedure Flowchart
Figure 8-53 "Coordinates Checking Procedure" contains the flowchart for the Coordinates Checking
Procedure.
Figure 8-53 Coordinates Checking Procedure
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Tube Release Procedure Flowchart
Figure 8-54 "Tube Release Procedure" contains the flowchart for the Tube Release Procedure.
Figure 8-54 Tube Release Procedure
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Chapter 8 – Robotic XYZ Arms
8 - 47
8-5 Adjustments and Verifications
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 instrument. 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"
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Figure 8-55 The Probes Tab
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Chapter 8 – Robotic XYZ Arms
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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 leakage.
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 disabled, 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 4044 step lost). The number of steps lost during a positive calibration test is 1 or 2 maximum.
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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 investigate 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 Position values that are available for each Arm.
Table 8-8 LLD Module, Slot, and Position Settings
Arm
Sample
ACL-TOP Service Manual
Module
Track/Slot
Position
Sample Rack
S1-S12
1-10
Diluent Rack
D1-D2
1-8
CTS
2-14
1-4
Incubator 1
1-8
1-4
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Table 8-8 LLD Module, Slot, and Position Settings
Arm
Reagent Arm 1
Reagent Arm 2
Module
Track/Slot
Position
Clean
1
1
Diluent Rack
D3
1-8
Reagent Rack
R1-R4
1-6
Incubator 2
1-8
1-4
Clean
1
1
Reagent Rack
R3-R6
1-6
ORU
1-4
1-4
Clean
1
1
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:
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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 "Selectable Cleaning Locations" lists the Modules, slots, and positions that can be selected for each arm.
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Table 8-9 Selectable Cleaning Locations
Arm
Sample
Reagent Arm 1
Reagent Arm 2
Module
Slot
Position
Diluent Rack
D1-D2
1-8
Clean
1
1
Reagent Rack
R3-R4
1-6
Clean
1
1
Reagent Rack
R3-R4
1-6
Clean
1
1
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.
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Figure 8-59 The Move Area
Table 8-10 "Allowable Source and Destination Positions" shows the allowable source and destination
positions for each arm.
Table 8-10 Allowable Source and Destination Positions
Arm
Sample Arm
Reagent Arm 1
Reagent Arm 2
Module
Track/Slot
Sample Rack
S1-S12
1-10
Diluent Rack
D1-D2
1-8
Predilution Area
2-14
1-4
Incubator 1
1-8
1-4
Diluent Rack
D3
1-8
Reagent Rack
R1-r4
1-6
Incubator 2
1-8
1-4
Reagent Rack
R3-R6
1-6
ORU
1-4
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.
ACL-TOP Service Manual
Position
Chapter 8 – Robotic XYZ Arms
•
Transport Air gap – The Transport air gap in uL.
•
Head – The Head Volume (in uL) for the material move.
8 - 55
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.
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Figure 8-60 Probe Troubleshooting Flowchart
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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
Signal
Ground
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 circuit in the LLD system.
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•
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
Housing for
Z-Rod
Assembly
Tubing
Connector
Bar
Universal Arm Diagnostic Screen
The diagnostics for the CTS Sample and/or IL Double Arms are on the Universal Arm tab as shown on Figure 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.
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Figure 8-64 Diagnostic Screen - Universal Arm
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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 operation, 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.
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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
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 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.
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 operation, 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: 8. 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. The Intermediate Arm should be about 900 counts when the probe is
not in contact with anything and 0 when touching a coordinate screw.
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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
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 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.
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 operation, 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: 8. 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. 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..
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Chapter 8 – Robotic XYZ Arms
8 - 63
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 servicing 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
Sensor Cable
6 Pin Connector
Rinse Input &
Output
Connectors
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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
J9
J11
J13
J3
J5
J7
LED
Front of Board
LED
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").
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.
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Chapter 8 – Robotic XYZ Arms
8 - 65
Figure 8-67 Syringe Pump Tubing
Precision
(Probe)
Tubing
Rinse 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
Mounting
Screws
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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
Rear of Syringe Pump
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
Air Valve
Bracket
Grommet
Air Line
Connection
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.
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Chapter 8 – Robotic XYZ Arms
8 - 67
Figure 8-71 CTS Arm Assembly Mounting Screws
Mounting Screws
Closed Tube Sample (CTS) Arm Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
1. Mount CTS arm assembly on the left and center pylons. Ensure the arm assembly is aligned with the
alignment pins on the pylon.
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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
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.
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Chapter 8 – Robotic XYZ Arms
8 - 69
Figure 8-73 CTS X Axis Driver PCB Cable Connections
J11
J3
J13
J7
(Front of Board)
LEDs
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.
Figure 8-74 Syringe Pump Cable
Rear of Syringe Pump
Syringe Pump Cable
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.
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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
Mounting
Screws
Screws
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
Rinse Tubing
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Precision
(Probe)
Tubing
Chapter 8 – Robotic XYZ Arms
8 - 71
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
Rinse Input &
Output
Connectors
Sensor Cable
Connector
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 Figure 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
Air Valve
Bracket
Grommet
Air Line
Connection
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.
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Reagent IL Double Arm Removal/Replacement
Reagent IL Double Arm Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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 servicing 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").
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.
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Chapter 8 – Robotic XYZ Arms
8 - 73
Figure 8-79 Reagent Syringe Pumps
Rinse Tubing
Connectors
Precision
Tubing
Connection
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
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Figure 8-80 Reagent IL Double Arms X Axis Driver PCB Cabling
J3
J14
J5
J6
J7
LED
Front of Board
LED
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 and
remove 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.
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Chapter 8 – Robotic XYZ Arms
8 - 75
Figure 8-81 Reagent IL Double Arm Assembly Mounting Screws
Mounting Screws
Reagent IL Double Arm Installation
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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 Figure 8-72 "CTS Arm Assembly Mounting Screws"
Figure 8-82 Reagent IL Double Arm Assembly Mounting Screws
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")
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8 - 76 Chapter 8 – Robotic XYZ Arms
•
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
J3
J5
J6
J7
J8
LED
Front of Board
LED
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.
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8 - 77
Figure 8-84 Syringe Pump Cable
Rear of Syringe Pump
Syringe Pump Cable
5. Mount the syringe pump assembly on the arm as shown on Figure 8-85 "Reagent Arm Pump Assembly 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
Mounting
Screws
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.
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Figure 8-86 Reagent Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
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 stainless steel support tube while connecting the tubing to ensure it doesn’t bend.
Figure 8-87 Probe Top
Stainless Steel
Probe Tubing Fitting
12. Verify the Reagent Arms as described in "Adjustments and Verifications". Ensure coordinate adjust
is run as part of the verification.
13. Reinstall the instrument skins.
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Cavro Sample Arm Removal/Replacement
Cavro Sample Arm Removal
CAUTION: Ensure 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 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.
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8 - 80 Chapter 8 – Robotic XYZ Arms
Figure 8-89 Probe Top
Stainless Steel
Probe Tubing Fitting
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
J2
(Fuse Board)
J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
9. Remove the Sample flex cable from the DC Driver PCB as shown on Figure 8-91 "DC Driver PCB
Connections".
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Figure 8-91 DC Driver PCB Connections
Sample
Arm Cable
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
Mounting
Screw
Ground
Cable
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
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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 assemblies.
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.
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Figure 8-93 Ground Wire and Mounting Screw
Mounting
Screws
Ground
Wire
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
Figure 8-94 CCU Connections
J2
(Fuse Board)
J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
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".
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Chapter 8 – Robotic XYZ Arms
8 - 83
Figure 8-95 DC Driver PCB Connections
Sample
Arm
Cable
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.
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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 stainless steel support tube while connecting the tubing to ensure it doesn’t bend.
Figure 8-97 Probe Top
Stainless Steel
Probe Tubing Fitting
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".
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Figure 8-99 Flex Cable to Probe Assembly
Probe Cable
Routing
16. Verify the Sample Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is
run as part of the verification.
17. Reinstall the instrument skins.
Cavro Reagent Arm Assembly Removal/Replacement
Cavro Reagent Arm Assembly Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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"
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Figure 8-100 Cable Clamps
Left Reagent Arm (R1) Clamp
Right Reagent Arm (R2) Clamp
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.)
Figure 8-101 CCU Connections
J2
(Fuse Board)
J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
10. Remove both Reagent flex cables from the DC Driver PCB as shown on Figure 8-102 "DC Driver
PCB Connections".
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Chapter 8 – Robotic XYZ Arms
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Figure 8-102 DC Driver PCB Connections
Reagent
Arm 2
Reagent
Arm 1
11. Using a 5mm Allen wrench, remove the front right mounting screw and the 277588-00 cable (GND).
Figure 8-103 Ground Cable Connection
Front
Mounting
Screw
Ground
Cable
Rear
Mounting
Screw
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
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
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 isolators.
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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, Mounting 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
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
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Chapter 8 – Robotic XYZ Arms
8 - 89
Figure 8-105 CCU Connections
J2
(Fuse Board)
J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
6. Connect the reagent flex cables to the reagent probe connector of the DC Driver PCB as shown in Figure 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.
Figure 8-106 DC Driver PCB Connections
Reagent
Arm 2
Reagent
Arm 1
Sample
Arm
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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 Orientation".
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
Probe Tubing Fitting
Clamp Screw
Cable Clamp
LLD
Sensing Cable
ACL-TOP Service Manual
Chapter 8 – Robotic XYZ Arms
•
8 - 91
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 Figure 8-111 "R2 Flex Cable to Probe Assembly".
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Figure 8-111 R2 Flex Cable to Probe Assembly
Flex Cable Exits
From Bottom of
Probe Cover
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.
Figure 8-112 Probe Top
Fitting for
Probe Tubing
•
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".
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Chapter 8 – Robotic XYZ Arms
8 - 93
Figure 8-113 Flex Cable Routing for Left Reagent Arm
Cable Guide
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
Cable Bracket Screw
Cable Bracket
•
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.
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8 - 94 Chapter 8 – Robotic XYZ Arms
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
LLD Coaxial
Cable
Cable Clamp
•
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.
10. Reinstall the instrument skins.
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Chapter 8 – Robotic XYZ Arms
8 - 95
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
Hex Screws
Front Bracket Screws
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.
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Cavro Arm Insulation Block/Cable Assembly Removal/Replacement
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
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
Gold Coax Connector
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).
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Chapter 8 – Robotic XYZ Arms
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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
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
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
Protective Strip
Flex Cable Connector
ADRI-9 Board
Flex Cable Channel
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8 - 98 Chapter 8 – Robotic XYZ Arms
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
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
Y- and Z-axis Optical Sensor Removal
1. Remove the ADRI-9 board cover.
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
Z-Axis Slotted Optical Sensor
Z-Axis Mounting Screws
Encoder Wheel
Y-Axis Mounting Screws
Z-Axis Slotted Optical Sensor
3. Using wire cutters, cut the plastic cable binders holding the optical sensor wires in place.
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Chapter 8 – Robotic XYZ Arms
8 - 99
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
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
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 "Optical Switch Block".)
Figure 8-122 Optical Switch Block
Slotted Optical Switches
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.
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8 - 100 Chapter 8 – Robotic XYZ Arms
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 Xaxis 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
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
ALIDUM Removal
1. Remove the ADRI-9 board cover.
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.
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Chapter 8 – Robotic XYZ Arms
8 - 101
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
Gold Coax Connector
6. Discard the old ALIDUM.
ALIDUM Installation
Install the ALIDUM by following the "ALIDUM Removal" directions in reverse order (Step 5 through Step 1).
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8 - 102 Chapter 8 – Robotic XYZ Arms
Cavro Arm ADRI-9 Board Removal/Replacement
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
ADRI-9 Board Removal
1. Remove the ADRI-9 board cover.
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.
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Chapter 8 – Robotic XYZ Arms
8 - 103
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
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
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 appropriate connections.
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8 - 104 Chapter 8 – Robotic XYZ Arms
Figure 8-126 CCU-9000 Board Diagram
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Chapter 8 – Robotic XYZ Arms
8 - 105
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
Tensioner Screws
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.)
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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
Belt Bracket Screws
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 8128 "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.
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Chapter 8 – Robotic XYZ Arms
8 - 107
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
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
Belt Clamp
Screw
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.
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THIS PAGE IS INTENTIONALLY LEFT BLANK.
ACL-TOP Service Manual
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.
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Chapter 9 – Cuvette Handling System
9-2
9-2 Physical Layout
Figure 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 CARD
LEFT POSITION
INCUBATOR #1 ASSY
OPTICAL READ UNIT ASSY
CUVETTE WASTE
SHELF ASSY
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Chapter 9 – Cuvette Handling System
9-3
9-3 Interconnect Diagrams
Figure 9-2 "Interconnect Diagram for the Cuvette Handling System" contains the Interconnect Diagram for the Cuvette Handling System.
Figure 9-2 Interconnect Diagram for the Cuvette Handling System
ACL-TOP Service Manual
9 - 4 Chapter 9 – Cuvette Handling System
9-4 Theory of Operation
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
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Chapter 9 – Cuvette Handling System
9-5
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/Replacement" for information on making adjustments.) Figure 9-4 "The Gripper Assembly" shows the Gripper
Assembly.
Figure 9-4 The Gripper Assembly
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 consists 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.
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9 - 6 Chapter 9 – Cuvette Handling System
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
Solenoid
Linear Rail
Wheel
Solenoid
Assembly
Shuttle Pivot
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 information on using the Shuttle Pivot Assembly to adjust the Cuvette Handling Plane.
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Chapter 9 – Cuvette Handling System
9-7
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
Adjustment Screws
Shuttle Alignment Tool
In addition to the three main subassemblies, the Shuttle Assembly has thermal control. For more information 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.
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9 - 8 Chapter 9 – Cuvette Handling System
Figure 9-7 The Cuvette Loader Assembly
Indexer
Assembly
Loader Shown in
Number One Position
of the Indexer
Transport Deck
Assembly
Transport Belts
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 recognizes
the presence of a cuvette clip so that the Indexer Rotating Platform may be prepared with a new clip
every ten cuvettes.
•
The reflective sensor at the number three cuvette clip position is used to generate a User warning
when only two cuvette clips (20 cuvettes) remain in the Cuvette Loader Assembly. When this condition occurs, the operator must load more cuvette clips before the Instrument goes into a "controlled stop" (standy mode). (Refer to the Operator’s Manual for more information on controlled
stops.)
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Figure 9-8 The Transport Deck Sensors
Front Sensor (#1 cuvette
clip position)
Rear Sensor (#3 cuvette
clip position)
Indexer Assembly
The Indexer Assembly is comprised of a Lead Screw Assembly that works in conjunction with a rotating platform. 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
Rotating
Platform
Pick-up Position
for Cuvettes
Pusher
Assembly
Components of
the Lead Screw
Assembly
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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 combination 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 Platform (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 horizontal position (Indexer position).
Figure 9-10 The Cuvette Rotating Platform (in Horizontal Down Position)
Flexible O-ring
Belt
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 cuvette
clip from the Transport Deck.
•
Horizontal down position – This position allows horizontal cuvette indexing by the Lead Screw
Assembly.
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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 Incubator #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 Hold/Incubator #2
Assembly
Cuvette Indexer
Assembly
Incubator #1 Assembly
Cuvette Indexer Assembly
CTS Incubator #1 Assembly
The CTS Incubator #1 Assembly (PN 288168-00) is an 8-slot heated incubator. Figure 9-11 "The Incubators 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 Incubator #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 Subassembly, an Emitter Board, and a Fiber Bundle Subassembly. Figure 9-12 "The ORU Assembly" shows the
ORU Assembly.
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Figure 9-12 The ORU Assembly
Reader Head Assemblies
Cuvette Indexer Assemblies
Each Reader Head has a Cuvette Indexer Assembly mounted to the top of it. The Cuvette Indexer Assembly 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
Emitter Board
Emitter
Subassembly
Reader Head
Subassemblies
Fiber Subassembly
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.
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Emitter Subassembly and Fiber Bundle Subassembly
The Emitter Assembly is mounted at the bottom of the ORU as shown in Figure 9-13 "ORU Subassemblies". This subassembly produces the 405nm and 660nm light sources that are used to analyze the reaction.
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 wavelengths 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 Subassembly.
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 Platform, 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 the
pick-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.
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Figure 9-14 The Left and Right End-of-limit Sensors
Left End-of-Limit Sensor (on left
side of chassis)
Right End-of-Limit Sensor
(on right side of chassis)
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 Shuttle".)
Figure 9-15 Sensors on the Front of the Cuvette Shuttle
Cuvette In Slot Sensor
Gripper Front Sensor
Shuttle Position Sensor
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Figure 9-16 Sensors on the Rear of the Cuvette Shuttle
Gripper Back Sensor
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.
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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 transport cuvette strips from the Loading location to Incubator, ORU and Waste locations within the ACL
TOP 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 forward
sensor, Gripper Reverse Sensor, Module Position Sensor, Cuvette in Module Sensor and Cuvette
in Shuttle Sensor).
•
Includes a 12-bit Analog-to-Digital converter for thermal measurements; sends serial SPI Data to
the 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 transport cuvette strips from the Loading location to Incubator, ORU and Waste locations within the ACL
TOP system.
•
Provides the ability to move the Rack Barcode Scanner Assembly to sample and reagent positions
for Rack loading.
•
Offers re-buffering of digital signals that feed through the board to, and from, the Cuvette Handling
Y-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 Subsystems,
•
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 thermal regulation for each of the ORU heads.
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•
Accepts four 30HZ pulse width modulated signals from the controller to proportionally control the
heating 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 data
which 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 light
source.
•
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 consistent
power output on each LED (Closed Loop Control).
•
Includes a hardware timer circuit as a safety device. (In the unlikely event of a software failure, the
LED's are shut off to prevent burnout.)
9-5 Adjustments/Verification
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.
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9-6 Diagnostics
The diagnostics for the Cuvette Handling System are on the Cuvettes tab. The Cuvettes tab contains three main areas: the Shuttle area, the Waste area, and the
Loader area. Figure 9-17 "The Cuvettes Tab" shows the Cuvettes tab.
Figure 9-17 The Cuvettes Tab
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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 Shuttle to pick up a new cuvette from the Cuvette Loader. The shuttle status is displayed and includes the following: 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.
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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 number 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:
Table 9-1 Selectable Modules and Positions
Module
Position
Loader
Not Applicable
Hold Area
Positions 1-14
Incubator 2
Positions 1-8
Incubator 1
Positions 1-8
ORU
Positions 1-4
Waste
Not Applicable
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.
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Note: This operation is not executed if a cuvette is present in the cuvette shuttle and the shuttle is at the
Cuvette 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 extend
operation is started, the gripper extends to its pick-up cuvette position and then retract into the
Cuvette 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 operations is performed, and then the Gripper pulls the cuvette into the shuttle. If the shuttle is in the Waste position, 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 Incubator #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 Outer
Pylons at each end of the Shuttle Travel. The virtual LEDs for these sensors turn green when the
Cuvette Shuttle reaches its left or right limit.
•
Gripper front and Gripper back – The Gripper Front sensor is enabled as the Gripper moves forward. The Gripper Back sensor is enabled as the Gripper moves backward. The virtual LED's for
the 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 detected
as the shuttle passes in front of that slot. The virtual LED for the cuvette in slot sensor turns green
when a cuvette is detected in a slot.
•
Cuvette in shuttle – The Cuvette in shuttle sensor is enabled when a cuvette is detected inside the
Shuttle. The virtual LED for the Cuvette in shuttle sensor turns green when a cuvette is detected
inside the shuttle.
•
Shuttle position – The shuttle position sensor is a slot sensor that detects if a slot is correctly
aligned to allow a cuvette to be moved into the slot. The virtual LED for the Shuttle position sensor
turns green when a correctly aligned slot is detected.
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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 Container.
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 or
removed. The virtual LED for this sensor turns green when the Waste Container is inserted and red
when the Waste Container is removed.
•
Cuvette waste door – This sensor indicates whether the Waste Door is open or closed. The virtual
LED 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 the
Accumulator is in the "up" position, the shelf is horizontal and can hold cuvettes. When the Accumulator is in the "down" position, the shelf is tilted down and any cuvettes on the shelf are dumped
into the Waste Container.)
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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 information 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 following:
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.
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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 for
this 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 Sensors"). 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 Sensors"). The virtual LED for this sensor turns red when there are no cuvette strips remaining in the
Loader.
•
Pivot arm up – This sensor is located in the Pivot Table. The virtual LED for this sensor turns green
when 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 turns
green 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 leftmost
position. (This occurs when the Loader is full.)
•
Indexer right limit – The virtual LED for this sensor turns green when the Indexer is in its rightmost
position. (This occurs when the Loader is empty.)
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Cuvette Shuttle and Loader Functional Checks
Use the flowchart in Figure 9-21 "Cuvette Shuttle and Loader Troubleshooting Flowchart" for performing 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
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9-7 Removal/Replacement
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)
Screw Locations
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.
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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
Screw Locations
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 Assembly, 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:
ACL-TOP Service Manual
9 - 28 Chapter 9 – Cuvette Handling System
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 924 "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
Screw Locations
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.
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Chapter 9 – Cuvette Handling System
9 - 29
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
Mounting Screw
Mounting Bracket
3. Carefully remove the Cuvette Shuttle Assembly from the mounting bracket so not to damage the position 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 Locking Screws").
5. Remove the cable from connector J6 (see Figure 9-26 "The Y-Axis Adjustment and Locking
Screws").
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9 - 30 Chapter 9 – Cuvette Handling System
Figure 9-26 The Y-Axis Adjustment and Locking Screws
J6 Connector
Strain Relief Bracket
The Orange Thumbscrews
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 position 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.
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.
Cuvette Shuttle Y-Axis Motor Removal/Replacement
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
Y-Axis Motor Removal
1. Remove the Shuttle Assembly from the ACL-TOP instrument as described in "Cuvette Shuttle Assembly Removal".
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Chapter 9 – Cuvette Handling System
9 - 31
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
Cover screws
Cover Y-Axis
PCB
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
Standoffs
Y-Axis PCB
5. Remove the Motor and Shuttle Heater cables from the cable clamp on the bottom of the shuttle assembly, as shown on Figure 9-29 "Cables and Cable Clamp", and remove the cable ties.
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9 - 32 Chapter 9 – Cuvette Handling System
Figure 9-29 Cables and Cable Clamp
Cable Clamp
Motor Cable
Drive Belt
Shuttle Heater
Cable
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
Bracket Mounting Screws
Tension Adjustment Set 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".
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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
Cable Clamp
Motor Cable
Drive Belt
Shuttle Heater
Cable
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
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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
Standoffs
Y-Axis PCB
7. Secure the motor cable and the Shuttle Heater cable with cable ties as shown on Figure 9-34 "Completed Assembly".
8. Secure the Y-Axis PCB Cover by re-installing the four cover screws as shown on Figure 9-34 "Completed Assembly".
Figure 9-34 Completed Assembly
Cable Ties
Cover Screws
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 Assembly Removal"
2.
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Chapter 9 – Cuvette Handling System
9 - 35
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
Left End-of-Limit Sensor (on left
side of chassis)
Right End-of-Limit Sensor
(on right side of chassis)
5. Do the following to check the Shuttle Alignment Tool:
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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, perform 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
Adjustment Screws
Z height and Tilt Locking
Screws
Shuttle Alignment Tool
Orange Thumbscrews
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 Alignment 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 Alignment 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 follows
1) 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.
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Chapter 9 – Cuvette Handling System
9 - 37
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
Z Height and Tilt Adjustment Screws
Z Height and Tilt Locking Screws
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 the
Y-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.
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9 - 38 Chapter 9 – Cuvette Handling System
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
Y-Axis LED
Turning Wheel
Figure 9-39 The Y-Axis Adjustment and Locking Screws
Y-Axis Sensor Adjustment
Screw
Y-Axis Adjustment Locking
Screw
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/Incubator #2.
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Chapter 9 – Cuvette Handling System
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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.
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9 - 40 Chapter 9 – Cuvette Handling System
Figure 9-40 The X-Axis Adjustment and Locking Screws
X-Axis Sensor Adjustment
Screw (Located behind the
Locking Screw)
X-Axis Adjustment Locking
Screw
Figure 9-41 LEDs on the Cuvette Shuttle Assembly
Cuvette In-slot
Sensor LED
Y-Axis LED
X-Axis LED
After the X-Axis Sensor Adjustment is performed, do the following to verify proper alignment of both the Xand 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.
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9 - 41
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.
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 alignment.
7. If there is a gap between the cuvette front face and the Gripper front face, re-adjust the Y-Axis alignment.
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THIS PAGE IS INTENTIONALLY LEFT BLANK.
ACL-TOP Service Manual
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.
10-2 Theory of Operation
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 information 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.
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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 Sample 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 various 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 detector chip on the Detector PCB. The output of the reference path is used for automatic adjustment of the Emitter PCB by the Optical Reading Controller.
Detector PCB
Light passing through the reaction cuvette well enters the detector chips on the Detector PCB. The corresponding 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 accuracy 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 collecting 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 reaction.
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Chapter 10 – Reaction Detection
10 - 3
Figure 10-1 ORU Light Path
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10 - 4 Chapter 10 – Reaction Detection
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.
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Chapter 10 – Reaction Detection
10 - 5
Figure 10-2 Reaction Detection Block Diagram/Interconnections
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10 - 6 Chapter 10 – Reaction Detection
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 ACLTOP 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.
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Chapter 10 – Reaction Detection
10 - 7
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.
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Chapter 10 – Reaction Detection
10 - 8
3. 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 Voltages
Emitter Voltages
ORU Controller
Voltages
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10 - 9
4. Check the ORU Controller, Emitter and ORU voltages as shown in Figure 10-4 "Voltage Tab in Diagnostics Window" and verify that they are all within the limits shown on the screen. (Out of Limit readings 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".
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Chapter 10 – Reaction Detection
10 - 10
Figure 10-5 ORU Tab of Diagnostic Screen
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10 - 11
7. Verify that ORUs 1-4 are enabled (Green LED) as indicated on Figure 10-6 "ORUs Enabled Indicators 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
Limit
(Maximum Value)
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
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10 - 12 Chapter 10 – Reaction Detection
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 optical 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 Blanking 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 Diagnostic 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
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10 - 13
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
Air Blanking for
all ORUs button
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 Assembly".
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.
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10 - 14 Chapter 10 – Reaction Detection
Figure 10-12 Factor Diluent Blanking for all ORUs
Factor Diluent Blanking
for all ORUs button
21. Upon completion of the Factor Diluent Blanking (approximately 30 minutes), a message box is displayed 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. Continue 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/correcting voltage errors.
NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following
the flowchart includes all actions required.
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Chapter 10 – Reaction Detection
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Figure 10-13 Testing/Correcting Voltage Errors
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10 - 16 Chapter 10 – Reaction Detection
N
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.
1. Check the ORU controller voltages on the Voltage tab of the diagnostic screen as shown in Figure 1014 "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 Assembly) as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".
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 "Emitter 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.
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Enabling ORUs
The overall flow of the procedure for enabling ORUs is shown in Figure 10-16 "Enabling ORUs Flowchart".
NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following
the flowchart includes all actions required.
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10 - 18 Chapter 10 – Reaction Detection
Figure 10-16 Enabling ORUs Flowchart
Enabling ORUs
B
Re-enable ORU in
Diagnostic mode.
Can ORU be
re-enabled
No
Replace ORU
Yes
I
Change to
Operating Mode
Reinitialization
OK?
Yes
No
Review Error log,
check for
extraordinary light.
Clean head.
Verify System
Change to
Operating Mode
Reinitialize
OK?
Yes
I
No
Verify ORU
Replace ORU
1. If all four ORU Enabled LEDs are not lit, click on any box without a check mark as shown in Figure 1017 "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".
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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 procedures 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 buttons (Sample, Reagent, and Diluent) in the upper right of the window as shown in Figure 10-18 "Sample, 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.
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NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following
the flowchart includes all actions required.
Figure 10-19 Testing/Correcting Dark Readings Flowchart
Testing/Correcting Dark Readings
C
Does instrument
have extraordinary
light?
Yes
Move equipment
out of the light or
shield it from light.
No
Good grounding
connections on ORU
heads?
No
Verify ground
connections.
Yes
I
Check remainder of ORU
diagnostic readings.
Correct as necessary.
Problem
resolved?
Yes
No
Replace ORU
Verify operation
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 testing 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 "Verifying the ORU" should be performed to verify the ORU operation. If any reading is not below the limit,
continue to step 4.
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10 - 21
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 resistance 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
Ground connections for ORU heads
ORU Chassis Plate
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.
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Testing/Correcting Optical Blanking Errors
Figure 10-22 "Testing/Correcting Optical Blanking Errors" shows the overall flow of the procedure.
NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following
the flowchart includes all actions required.
Figure 10-22 Testing/Correcting Optical Blanking Errors
Testing /Correcting Optical
Blanking Errors
E
Are they cracked,
scratched,
damaged?
Spillage?
Clean ORU heads
Yes
G
Replace ORU.
No
Problem
Corrected?
Yes
I
No
Verify ORU
Tune ORU Optics.
Remove the ORU
Connect the ORU via the
extended cables.
Readings Okay
Now?
Yes
I
No
Inspect unit cables for
damage, dirt and spills .
Verify ORU.
Replace Emitter
Block Assembly .
Damage, dirt,
or spill?
No
Power up instrument in
Diagnostic Mode.
Yes
Clean or Replace
cables as needed.
Min./Max.
Reference
Readings Okay
Now?
Yes
I
Remove/check and, if
necessary, clean Fiber
Bundle Ends (at ORU end).
No
G
Replace ORU.
Verify ORU.
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".
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3. If the readings are now within specifications, the problem has been corrected and all steps of the "Verifying 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 "Removing/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 "Verifying 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"
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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.
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Figure 10-24 ORU Diagnostic Tab
Temperature Area
Optical Blanking Area
Reference Reading Area
Dark Readings Area
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10 - 26 Chapter 10 – Reaction Detection
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
ORU Status
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 blanking 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
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10 - 27
•
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 air
reading 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 displayed 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 channels.
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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 currently 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 discarded. 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.
Volume
200ml
Air gap
15ml
Transport Air gap
10ml
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.
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10 - 29
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 initialized 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 Reference 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.
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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 displayed 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.
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Figure 10-29 ORU Linearity Diagnostic
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10 - 32 Chapter 10 – Reaction Detection
10-5 Removal/Replacement
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/Replacement Procedures” in Chapter 4.
3. Place a table or cart that is approximately the same height as the Instrument base in front of the instrument.
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
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".
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Figure 10-31 ORU Cable Connections
J1
J1
J2
ORU Interface PCB
J3
Emitter PCB
6. Remove the ribbon cable from J1 of the Emitter PCB as shown on Figure 10-31 "ORU Cable Connections".
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 instrument.
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.
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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
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10 - 35
Figure 10-33 ORU Backplane PCB Connections
J15
J16
J17
Figure 10-34 ORU Cable Connections
J1
J2
ORU Interface PCB
J1
J3
Emitter PCB
5. Tighten the four screws securing the ORU in the instrument as shown in Figure 10-34 "ORU Cable
Connections".
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10 - 36 Chapter 10 – Reaction Detection
Figure 10-35 ORU Retaining Screws
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 Disconnect".
Figure 10-36 Fiber Bundle Disconnect
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Small fiber bundle
set screw
Large fiber bundle
holder set
screws
5. Carefully pull to remove the large fiber bundle from the emitter block.
CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.
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.
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10 - 38 Chapter 10 – Reaction Detection
Figure 10-37 Emitter Head Attachment Screws
Allen head
screws securing
emitter head.
Set screw
securing small
fiber bundle
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.
13. Apply power to the ACL-TOP instrument and enter the ORU diagnostics screen.
14. Slowly slide the large optic bundle out of the emitter head while watching the DAC readings being displayed on the diagnostic screen. (Move the optic bundle in small increments and pause to allow the
DAC readings to stabilize for each movement.)
CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.
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.
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Chapter 10 – Reaction Detection
10 - 39
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
J15
J16
J17
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10 - 40 Chapter 10 – Reaction Detection
Figure 10-39 ORU Cable
Connections
J1
J2
ORU Interface PCB
J1
J3
Emitter PCB
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".
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Chapter 10 – Reaction Detection
10 - 41
Figure 10-40 Power Cable Connection
Extended
power cable
(male end)
Original ORU
power cable
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".
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10 - 42 Chapter 10 – Reaction Detection
Tuning the ORU Optics
Figure 10-42 "Tuning ORU Optics" shows the overall flow of the procedure for tuning the ORU optics.
NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following
the flowchart includes all actions required.
Figure 10-42 Tuning ORU Optics
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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 instrument 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 recognized 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
Large fiber bundle
holder set screws.
Fiber
Bundle
Holder
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".
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10 - 44 Chapter 10 – Reaction Detection
Figure 10-44 Fiber Bundle Disconnect
Small fiber
bundle
Large fiber
bundle
5. Carefully pull to remove the large and small fiber bundles from the emitter blocks.
CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.
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
Small Fiber
Bundle
Large
Fiber
Bundle
7. Insert both fiber bundles all the way into the emitter head.
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Chapter 10 – Reaction Detection
10 - 45
CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.
8. Apply power to the ACL-TOP instrument and enter the ORU diagnostics screen.
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 displayed on the diagnostic screen. (Move the optic bundle in small increments and pause to allow the
DAC readings to stabilize for each movement.)
CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.
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 corrected 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.
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10 - 46 Chapter 10 – Reaction Detection
Figure 10-46 ORU Cover Attachment Screws
ORU Cover
Screws
2. Remove the set screw for the large fiber optic bundle as shown in Figure 10-47 "Fiber Bundle Disconnect". (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".
Figure 10-47 Fiber Bundle Disconnect
Small fiber bundle
Small fiber
bundle set
screw.
Large fiber
bundle set
screw
Large fiber bundle
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"
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10 - 47
Figure 10-48 Cover Hardware Removal
Center
Cover
Standoff
ORU Interface Board
Retaining Screw
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
Bracket Attachment
Screws
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.
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10 - 48 Chapter 10 – Reaction Detection
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
Cover
retaining
screws
11. Return to the procedure “"Tuning ORU Optics" to properly adjust the focal lengths of the optical fiber
bundles.
ACL-TOP Service Manual
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.
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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/assemblies, 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.
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11 - 3
11-3 Interconnect Diagrams
Figure 11-2 "Rack Handling Interconnections" shows the interconnections between the various elements in the Rack Handling System.
Figure 11-2 Rack Handling Interconnections
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11 - 4 Chapter 11 – Rack Handling
11-4 Theory of Operation
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
Diluent Racks
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 positions 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.
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Chapter 11 – Rack Handling
11 - 5
Figure 11-4 Sample Racks
CTS
NON CTS
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 outputs 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.
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11 - 6 Chapter 11 – Rack Handling
Figure 11-6 Sample Presence PCB
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 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 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 diluent 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 Flag
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Chapter 11 – Rack Handling
11 - 7
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 accommodates 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 positions 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
D3
R1
R2
R3
R4
R5
R6
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.
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11 - 8 Chapter 11 – Rack Handling
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 indicate 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
Reagent Presence PCB
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Chapter 11 – Rack Handling
11 - 9
Reagent Mounting Plate
The Reagent Module mounting plate provides stirring for the two rear positions in each reagent rack. In addition, 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 Stirrers 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
Stirrers
Heat Sink
Reagent
Flag
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 indicated 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 signal 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 27755901 can be used to upgrade.
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11 - 10 Chapter 11 – Rack Handling
Figure 11-12 Reagent Cooling with Fan Speed Controller PCB
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 Figure 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
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11 - 11
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, containing 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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11 - 12 Chapter 11 – Rack Handling
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 position 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 sensor 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
Optical
Sensor
RTI PCB
Tabs for Travel Limit
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.
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Chapter 11 – Rack Handling
11 - 13
Figure 11-16 Bar Code Reader Travel Limit Sensor
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.
11-5 Adjustments/Verification
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 frequency along with the individual situation. The minimum verification after servicing the Rack Handling system 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.
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11 - 14 Chapter 11 – Rack Handling
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 following paragraphs to describe the area.
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Chapter 11 – Rack Handling
11 - 15
Figure 11-17 SW, Covers, and Racks Diagnostic Screen
Rack Handling
Area
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11 - 16 Chapter 11 – Rack Handling
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.
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11 - 17
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 Control 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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11 - 18 Chapter 11 – Rack Handling
11-7 Removal/Replacement
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 Assembly 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.
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Figure 11-21 Sample Assembly Removal
Sample Module
Mounting
Screws
CTS
Sample Module
Mounting
Screws
Non-CTS
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.
ACL-TOP Service Manual
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Figure 11-22 Sample Presence PCB
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.
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Figure 11-23 Sample Flag
Alignment Pins
Attachment Screws
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 1124 "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).
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Figure 11-24 Reagent Module Screws (Left Side)
Mounting
Screws
(Left Side)
Figure 11-25 Reagent Module Screws (Right Side)
Mounting
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.
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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
J1
Reagent Cooling with Fan Speed Controller PCB
See below.
J3
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 outputs can be attached to any fan even though they are labeled as attaching to a specific fan.)
Figure 11-27 Reagent Cooling with Fan Speed Controller PCB
J1
J4
J8
J3
J2
J5
J6
J9
J7
10. Remove the drain tube connecting the reagent module to the waste pump at the waste pump connection. Tube can be removed by pulling while twisting.
11. Carefully lift and remove the reagent module.
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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
Barb Fitting
Barb Fitting
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.
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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
Short End
Top Clamp
Long End
Bottom Clamp
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
“Y” Base
TEC Cable
Stirrer Board
Double Clamp
Single Clamp
Short End
Long End
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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
Cable Clamp
Tie Wrap
Tie Wrap
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
Reagent Presence PCB
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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 Controller PCB to the Reagent Module as shown on Figure 11-33 "Reagent Cooling with Fan Speed
Controller PCB".
Figure 11-33 Reagent Cooling with Fan Speed Controller PCB
Mounting Screws
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".
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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
Mounting Screws
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".
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Chapter 11 – Rack Handling
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Figure 11-35 Bar Code Reader Home Position
Reagent
Module Left
Edge
Bar Code
Bar Code
Reader
Reader
Left Edge
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 figure shows the screws at the left end of the bar code reader.)
Figure 11-36 BCR Mounting Screws Location
Bar Code Reader
Mounting Screw Locations
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Figure 11-37 Mounting Screws
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
CAUTION: Ensure the instrument is powered OFF before performing the
following procedure.
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 correct "Ghosting" errors. A Ghosting error is caused by a reflection from the cover interfering with the transmission 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.
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11 - 31
3. Unplug the Barcode Scanner Interface Board from the Microscan unit as shown in Figure 11-38 "Barcode Scanner Interface Board".
Figure 11-38 Barcode Scanner Interface Board
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
Plate Mounting
Screws
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11 - 32 Chapter 11 – Rack Handling
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
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
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 Scanner Interface Board").
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11 - 33
5. Connect the indicator LED cable.
6. Place the cover and replace the three cover mounting screws.
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.
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
J2
J1
X Axis PCB
RTI PCB
Mounting Screws
RTI PCB Installation
To replace the RTI PCB, 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.
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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
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Figure 11-43 X Axis PCB
J1
J2
J8
J4
J6
J7
J9
J3
J5
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 performing 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 p88 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 lock
securely.
3. Check electrical continuity between pins p8-1 and p8-3, p8-6 and p8-8.
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11 - 36 Chapter 11 – Rack Handling
Figure 11-44 Jumper Placement
P8-1/P8-3
Note
Orientation
P8-6/P8-8
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
Positioning Screw
Setscrew
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.)
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Figure 11-46 Encoder
Positioning screw in
unlocked position
(Uninstalled)
Positioning screw in
locked position
(Installed)
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 procedure 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 mounting bracket securing the curtain to the Bar Code Reader as shown on Figure 11-47 "BCR Curtain
Attachment".
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11 - 38 Chapter 11 – Rack Handling
Figure 11-47 BCR Curtain Attachment
Right
Curtain
Right Side
Mounting
Screws
Left Side
Mounting Screws
Left Curtain
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
Curtain/Spool
Attachment
Screws
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 orientation 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
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Chapter 11 – Rack Handling
11 - 39
Figure 11-49 "Right Curtain Spool Attachment". Turn the spool clockwise (CW) nine turns (to provide 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
Mounting
Screws
Mounting
Bracket
Right
Curtain
Right Spool Assembly
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 Attachment". 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.
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11 - 40 Chapter 11 – Rack Handling
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
Tension Adjustment
Screws
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.
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Figure 11-52 Bar Code Reader Drive Belt Fastening
RTI
Bracket
Screws
Drive Belt Clamp
Screws
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
Belt Bracket Screws
Drive Belt Clamps
Ensure cogs in belt
and clamp align.
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11 - 42 Chapter 11 – Rack Handling
2. While holding the clamp together over the belt, ensuring the last cog on the belt fits within the indentation 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
Ensure Straight Across
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 indentation 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 1152 "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 tension.
3. Using an Allen wrench, remove the two screws and remove the motor bracket and motor from the bar
code reader assembly.
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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
Torx Screws
Securing
Motor
Drive Belt tension Adjustment
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.
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THIS PAGE IS INTENTIONALLY LEFT BLANK.
ACL-TOP Service Manual
Chapter 12 – Thermal Control
12 - 1
Chapter 12 –
Thermal Control
12-1 Overview
Temperature Control
Certain 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 controlled elements as shown in Figure 12-2 "Temperature Tab of Instrument Status Display".
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12 - 2 Chapter 12 – Thermal Control
Figure 12-2 Temperature Tab of Instrument Status Display
12-2 Physical Layout
Physical layout for the thermal elements is included in the description of the module in which the element is
contained.
12-3 Interconnect Diagrams
Interconnect diagrams for the thermal elements are included in the description of the module in which the
element is contained.
12-4 Theory of Operation
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Chapter 12 – Thermal Control
12 - 3
Thermal Sensing
Each thermal sensing circuit consists of a Thermistor, a conditioning circuit, may include a filter, and an analog to digital converter as shown on Figure 12-3 "Thermal Sensing Block Diagram". A thermistor is a temperature-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 analog 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 converter and produces a digital output proportional to the analog output of the conditioning circuit (and therefore 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
Thermistor
Conditioning
Circuit
Filter
(Optional)
Analog to
Digital
Converter
To Thermal
Control Circuit
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 element actually performs the heating or cooling of the area.
Figure 12-4 Thermal Control Block Diagram
Thermal
Control
Circuit
Power
Switch
Coils and
Capacitors for
Fluctuations
(Optional)
Thermal
Element
ACL-TOP Service Manual
12 - 4 Chapter 12 – Thermal Control
Cuvette Shuttle Thermal Regulation
The Cuvette Shuttle is kept at 37° Centigrade. The heater is a heating pad and is located as shown on Figure 12-5 "Cuvette Shuttle Heater". The thermistor for the cuvette shuttle is on the other side of the assembly 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 circuit, that is lower than the cut-off temperature. The cuvette thermal control is provided by the Cuvette Controller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power
switch.
Figure 12-5 Cuvette Shuttle Heater
Overload
Protection
Heater
Element
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Chapter 12 – Thermal Control
12 - 5
Figure 12-6 Cuvette Shuttle Thermistor
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 troubleshooting, etc. the instrument.
Incubator #1 is kept at 37° Centigrade. The heater is a heating pad and is located as shown on Figure 127 "Incubator 1". The thermal control for Incubator #1 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.
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12 - 6 Chapter 12 – Thermal Control
Figure 12-7 Incubator 1
Thermistor
Overload
Protection
Heater
Element
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 128 "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
Heater Element
Thermistor
ACL-TOP Service Manual
Overload
Protection
Chapter 12 – Thermal Control
12 - 7
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 stations 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
Thermistors
Overload Protection
Heater Element
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".
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12 - 8 Chapter 12 – Thermal Control
Figure 12-10 Cooling Fan Ductwork
Air Filter
Exhaust Duct
Intake Duct
Exhaust
Duct
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
Inlet Fans
Exhaust Fans
Air Inlet Vent
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.
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Chapter 12 – Thermal Control
12 - 9
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 indicated 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.
Figure 12-12 Reagent Cooling with Fan Speed Controller PCB
Reagent Rack Presence
PCB
Reagent Cooling with Fan Speed Controller PCB
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 provided by a fuse in the Probe Integrated Controller PCB.
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12 - 10 Chapter 12 – Thermal Control
Figure 12-13 Cavro Reagent Probe
Probe Integrated
Controller
PCB
Probe Heaters and
Thermistors
(within 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 thermistors 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 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 12-14 Universal Arms Reagent Probe
Probe Heaters and
Thermistors
(within probe)
ACL-TOP Service Manual
Probe Integrated
Controller PCB
Chapter 12 – Thermal Control
12 - 11
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
Probe Integrated
Controller
PCB
Probe Heaters and
Thermistors
(within probe)
CTS Sample Probe Thermal Regulation
The CTS Sample probe is not thermally controlled.
12-5 Adjustments/Verification
Adjustments
Mechanical adjustments and verification for the thermally controlled modules are covered in the Rack Handling, Cuvette Handling and Robotics XYZ chapters of this manual.
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12 - 12 Chapter 12 – Thermal Control
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 controlled 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 instrument which are required to be calibrated by the manufacturer. Nor does it cover the calibration 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 manual mode by clicking on the “Go To Manual Mode” button at the top left of the window.
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Chapter 12 – Thermal Control
12 - 13
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 (manual
mode) 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.
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12 - 14 Chapter 12 – Thermal Control
Figure 12-17 Thermal Dialog after Changing to Manual Mode
Mode selection
and display
Temperature
Entry
ACL-Top Analytical
Module Connection and Status
Calibration
Status and
Control
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 Analytical Module and is running the ThermalCal application. Once this is in place:
ACL-TOP Service Manual
Chapter 12 – Thermal Control
•
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.
12 - 15
The application connects automatically and updates the “TOP Status” to “AM Connected” as shown on Figure 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 example 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.
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12 - 16 Chapter 12 – Thermal Control
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 location
R3.
•
ICU 1 – Incubator 1 – The fourth slot (from the left) of the incubator on the sample side of the TOP
AM.
•
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.
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Chapter 12 – Thermal Control
12 - 17
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 Remaining".)
Figure 12-20 Display of the Soaking Time Remaining
Soak Time Remaining
N
NOTE: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
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12 - 18 Chapter 12 – Thermal Control
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
Temp Stable
Indication
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 calculate the temperature error from the target temperature versus the entered temperature. The entered temperature, 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 displayed showing the calibration offset that is saved in the TOP AM as shown in Figure 12-23 "Screen showing 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”.
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Chapter 12 – Thermal Control
12 - 19
Figure 12-23 Screen showing Offset (Coefficient)
The preceding process is be repeated for each module that requires calibration. When all modules are completed, the “EXIT” button in the upper right corner of the window is clicked. This displays a confirmation dialog 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 Coefficients 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 Coefficient 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 documented 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.
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12 - 20 Chapter 12 – Thermal Control
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 1225 "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
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Chapter 12 – Thermal Control
12 - 21
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
N
NOTE: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.
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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 covers 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".
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Chapter 12 – Thermal Control
12 - 23
Figure 12-30 Connecting ThermalCal Application to the AM
Connection Button
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 module on it.
N
NOTE: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
ACL-TOP Service Manual
12 - 24 Chapter 12 – Thermal Control
Figure 12-32 AM Connected
Connected Status
Selection of
Module To Be
Tested
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
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".
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Chapter 12 – Thermal Control
12 - 25
Figure 12-34 ICU2 Thermistor Placement
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
ORU 4
ORU 1
ORU 2
ORU 3
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12 - 26 Chapter 12 – Thermal Control
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, location 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
Rack Thermistor Mount
(IL PN 285211-00)
Thermistor Probe Assembly
(IL PN 189960-00)
Futura Connection
Futura Test Fixture
(IL PN 189937-00)
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".
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Chapter 12 – Thermal Control
12 - 27
Figure 12-37 Soak Time Remaining
Soak Time
Remaining
13. After the soaking period ends and “Temp Stable” is displayed as shown on Figure 12-38 "Temperature 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
Temperature
Submission
Temperature
Stable
Indication
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12 - 28 Chapter 12 – Thermal Control
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 generated as part of the ThermalCal procedure, initiate a new soaking period, and initiate a new calibration check using the new coefficients.
Figure 12-39 Temperature Difference
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
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Chapter 12 – Thermal Control
12 - 29
17. Verify that the button for the module tested states “Done” as shown in Figure 12-42 "Done Indication". If so, select the next module by returning to "Test the Thermal Modules".
Figure 12-42 Done Indication
Done Indication
Save the Coefficients
18. If all modules to be calibrated are complete, click the “Display Coefficients”