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HUMAN -
ELISYS QUATTRO
Service Manual
Date of issue: December 2004
We reserve the right to make changes in the course of technical development

without previous notice.
System Manufacturer: HUMAN GmbH
Software-copy- The ELISYS QUATTRO software is the intellectual property of HUMAN GmbH.
rights Intellectual property rights shall remain with HUMAN GmbH.
You are entitled to use the ELISYS QUATTRO software and the printed accompany-
ing material at your place of work only.
Any violations of property rights or copyright or trademark may be subject to legal ac-
tion.
Copyright © 2004, HUMAN GmbH. All rights reserved.
HUMAN GmbH
Max-Planck-Ring 21
D-65205 Wiesbaden, GERMANY
Neither this manual nor any parts of it may be duplicated or transmitted in any way without the written
approval of HUMAN GmbH.
Table of Contents
Intended Use 1
1.1 Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.1 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.2 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.3 Symbol Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.4 Special Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.2 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.3 Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.4 Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2.5 Biological Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.6 Cleaning the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.2.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3 Positions of Safety Labels and Type Label . . . . . . . . . . . . . . . . . 1-8
1.3.1 General Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.2 Biological Hazard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.3.3 Electrical Hazard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.4 Laser Hazard Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.5 Type Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4 Definitions, Acronyms and Abbreviations . . . . . . . . . . . . . . . . 1-12
System 1
2.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Mechanical Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Electronic Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation 1
3.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Contents of the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.1 Contents of Box A (Analyzer) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.2 Contents of Box B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.3 Contents of Box C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.4 Contents of Box D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 Installation of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.1 Setup of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5.2 Installation of the Wash Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.3 Installation of Waste Bag System . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.5.4 Installation of the Pipetting System. . . . . . . . . . . . . . . . . . . . . . 3-10
3.5.5 Installation of the Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.6 Installation of the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.7 Installation of System Fluid and Waste Containers . . . . . . . . . 3-16
3.5.8 Installation of Computer and Cable Connections . . . . . . . . . . . 3-17
3.6 Preparations for the User Software . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.1 Installation of the Assay Definitions . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.2 Installation of the Reagent Database . . . . . . . . . . . . . . . . . . . . 3-19
3.7 Check of the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.1 Preparations for the Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.2 Check with Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ELISYS QUATTRO - Service Manual HUMAN TOC-1

3.7.3 Check of the Pipettor Positions with the Teacher. . . . . . . . . . . . 3-21
3.8 Check with User Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.9 Save System Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Maintenance 1
4.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Overview about Maintenance Kits. . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Half-Yearly and Yearly Maintenance Kits . . . . . . . . . . . . . . . . . . . 4-2
4.3.1 Half-Yearly and Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.2 Yearly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Lubrication Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.1 X-axis: Cleaning and Lubrication of X-Guiding Mechanism. . . . . 4-7
4.4.2 Y-axis: Cleaning and Lubrication of Y-Guiding Mechanism . . . . . 4-8
4.4.3 Z-axis: Lubrication of Z-Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.4 X-Axis of Plate Transport: Cleaning and Lubrication of Guiding Rod
4-10
4.4.5 Z-Spindle of Plate Transport: Cleaning and Grease of Z-Spindle . 4-
10
Service Software 1
5.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Installation of Service Software. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.2 Global Settings in gSERVICE.INI . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.3 COM Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Replacement of Service Software . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Start of Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.1 About Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4.2 Load Module Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.3 Activate all Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.4 Low Level Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4.5 Write Global Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.6 View Global Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.7 Hex View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.4.8 Port Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.9 Terminate Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.5 Results of the Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Photometer 1
6.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 Description of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5.1 Photometer Adjustment and Testing Tools. . . . . . . . . . . . . . . . . . 6-5
6.5.2 Replacement of the Photometer Module . . . . . . . . . . . . . . . . . . . 6-6
6.5.3 Replacement of Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.5.4 Replacement of Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.5.5 Replacement of Primary Optics (Lower Optic Block). . . . . . . . . 6-11
6.5.6 Replacement of Fibre Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.5.7 Replacement of Photometer X-Movement Motor. . . . . . . . . . . . 6-13
6.5.8 Cleaning of Fibre Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.9 Filter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.5.10Replacement of Photometer PCB . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.5.11 Glass Fibre for Plate Detection . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.6.1 Adjustment of Optical Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.7 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
TOC-2 ELISYS QUATTRO - Service Manual HUMAN

6.7.1 Functions of the Photometer Service Software . . . . . . . . . . . . 6-19
6.7.2 Test Procedure for Module Test . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.7.3 Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.7.4 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.8 Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.8.1 Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 6-26
6.8.2 Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . . 6-26
Washer 1
7.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Fluid Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.1 Wash Buffer Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.2 Instrument Waste Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Description of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.1 Washer Adjustment and Testing Tools . . . . . . . . . . . . . . . . . . . . 7-9
7.6.2 Replacement of Washer Module. . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.3 Replacement of Vacuum Switch . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.6.4 Replacement and Cleaning of Wash Head. . . . . . . . . . . . . . . . 7-13
7.6.5 Replacement of Peristaltic Pump Motor and Tubing Cassette . 7-15
7.6.6 Replacement of Plate Transport Belt . . . . . . . . . . . . . . . . . . . . 7-15
7.6.7 Replacement of Aspiration Pump . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.6.8 Replacement of Dispense Pump . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.6.9 Replacement of Dispense Valve . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.6.10Replacement of Z-motor (Wash Head up and down Motor) . . . 7-20
7.6.11 Replacement of Washer Light Barriers . . . . . . . . . . . . . . . . . . . 7-22
7.6.12Plate in Fibre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.6.13Replacement of Washer PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.6.14Internal Waste Bottle and internal Froth Trap Bottle . . . . . . . . . 7-23
7.7 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.7.1 Alignment of Wash Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.7.2 Adjustable of Washer Bottles Float Switches . . . . . . . . . . . . . . 7-26
7.7.3 Volume Calibration of the Washer . . . . . . . . . . . . . . . . . . . . . . 7-27
7.8 Washer Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.8.1 Functions of the Washer Service Software. . . . . . . . . . . . . . . . 7-29
7.8.2 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.8.3 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.8.4 Test Procedure for Module Test . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.8.5 Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.9.1 Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 7-39
Plate Transport 1
8.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Electronic Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.5.1 Plate Transport Alignment Tools . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.5.2 Replacement of Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.5.3 Replacement of Plate Transport PCB. . . . . . . . . . . . . . . . . . . . . 8-9
8.5.4 Replacement of High Flex Cable . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.5.5 Replacement of Y-Transport Belt . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5.6 Replacement of X-Transport Belt . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.5.7 Replacement of X-Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.5.8 Replacement of Z-Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.5.9 Replacement of X-Light Barrier (Init Position) . . . . . . . . . . . . . . 8-15
8.5.10Replacement of Carrier Detect Light Barrier . . . . . . . . . . . . . . . 8-15
8.5.11 Replacement of Z-light barrier (Init Position) . . . . . . . . . . . . . . . 8-16
8.5.12Replacement of Z-Incremental Encoder . . . . . . . . . . . . . . . . . . 8-16
8.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.6.1 Alignment of Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.6.2 Use of the Shaft X-Drive Alignment Tool . . . . . . . . . . . . . . . . . . 8-22
8.6.3 Use of the X-Gantry Alignment Plate . . . . . . . . . . . . . . . . . . . . . 8-23
8.7 Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.7.1 Start Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.7.2 Continue Teaching the Plate Transport . . . . . . . . . . . . . . . . . . . 8-25
8.7.3 Save Plate Transport Coordinates . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.7.4 Load Plate Transport Coordinates . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.7.5 Store Plate Transport Coordinates. . . . . . . . . . . . . . . . . . . . . . . 8-28
8.8.1 Functions of the Plate Transport Service Software . . . . . . . . . . 8-29
8.8.2 Adjust Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.8.3 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
8.8.4 Test Procedure for Module Tests . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.8.5 Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.8.6 XZ-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.9.1 Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . . 8-39
Incubator 1
10.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3 Mechanical Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.5.1Replacement of Incubator Module . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.5.2Replacement of Incubator PCB . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5.3Open Incubator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.5.4Replacement of Incubator Box . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.5.5Replacement of Shake PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.5.6Replacement of Sensor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.5.7Replacement of Shaking Solenoid. . . . . . . . . . . . . . . . . . . . . . 10-13
10.5.8Replacement of upper Heater . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10.5.9Replacement of lower Heater . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10.5.10Replacement of Foam Flap or Flap Spring . . . . . . . . . . . . . . 10-16
10.5.11Replacement of Incubator and Stacker Fan . . . . . . . . . . . . . . 10-16
10.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10.6.1Calibration of the Shake Function . . . . . . . . . . . . . . . . . . . . . . 10-18
10.7 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.7.1Functions of the Incubator Service Software . . . . . . . . . . . . . . 10-21
10.7.2Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.7.3Shake Status Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.7.4Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.7.5Test Procedure for Module Tests . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.7.6Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.8 Firmware Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.8.1Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 10-29
10.8.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . 10-29
Pipettor 1

11.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.3 Fluid Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.4 Description of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.5.1 Replacement of Disposable Tip Adapter . . . . . . . . . . . . . . . . . 11-9
11.5.2 Replacement of Pipettor Tubing . . . . . . . . . . . . . . . . . . . . . . . 11-10
11.5.3 Replacement of Wash Pump . . . . . . . . . . . . . . . . . . . . . . . . . .11-11
11.5.4 Replacement of Dispense Pump . . . . . . . . . . . . . . . . . . . . . . 11-12
11.5.5 Replacement of Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
11.5.6 Replacement of three way Valve . . . . . . . . . . . . . . . . . . . . . . 11-15
11.5.7 Replacement of Pipettor Bridge . . . . . . . . . . . . . . . . . . . . . . . 11-18
11.5.8 Replacement of X-Sledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
11.5.9 Replacement of Bridge High Flex Cable. . . . . . . . . . . . . . . . . 11-20
11.5.10Replacement of Y-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
11.5.11Replacement of Y-Motor/Encoder . . . . . . . . . . . . . . . . . . . . . 11-22
11.5.12Replacement of Waste Pump (on the back Side) . . . . . . . . . 11-24
11.5.13Replacement of Waste Pump (on the left Side) . . . . . . . . . . 11-25
11.6 Adjustment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-27
11.6.1 Adjustment of the X- and Z-Axis . . . . . . . . . . . . . . . . . . . . . . . 11-27
11.6.2 Adjustment of the X-Axis Roller . . . . . . . . . . . . . . . . . . . . . . . 11-30
11.6.3 Adjustment of the Y-Axis Roller . . . . . . . . . . . . . . . . . . . . . . . 11-32
11.6.4 Adjustment of Timing Y-Belt Tension . . . . . . . . . . . . . . . . . . . 11-35
11.6.5 Free Movement of the Bridge on the Guiding Mechanism . . . 11-36
11.6.6 Free Movement of the Upper Rollers on Guiding Mechanism 11-38
11.6.7 Wear of the Roller Bearings on the Bridge Holder . . . . . . . . . 11-39
11.6.8 Alignment of Z-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
11.7 Teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
11.7.1 Teaching Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
11.7.2 Start of Teacher Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45
11.7.3 Mechanical Z-Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11.7.4 Teaching Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11.7.5 Teaching Disposable Tip Racks . . . . . . . . . . . . . . . . . . . . . . . 11-49
11.7.6 Teaching Dilution Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50
11.7.7 Teaching Pipette Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50
11.7.8 Teaching Eject Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-50
11.7.9 Teaching Wash/Waste Position . . . . . . . . . . . . . . . . . . . . . . . 11-51
11.7.10Teaching Sample and Reagent Area . . . . . . . . . . . . . . . . . . 11-52
11.7.11Teaching MTP's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52
11.7.12Teaching Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-55
11.8 Check and Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57
11.8.1 Check Function of Disposable Tip Adapter. . . . . . . . . . . . . . . 11-57
11.9 Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-58
11.9.1 Functions of the Pipettor Service Software. . . . . . . . . . . . . . . 11-60
11.9.2 Pipettor Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-61
11.9.3 Pumps Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65
11.9.4 Coordinates Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-66
11.9.5 Prime Dialogue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-68
11.9.6 Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-69
11.9.7 Automatic Module Test Dialogue . . . . . . . . . . . . . . . . . . . . . . 11-71
11.10.1Firmware Upgrade with Service Software . . . . . . . . . . . . . . . 11-73
11.10.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . 11-73
Pipetting Station 1
12.1 Safety and Hints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12.3.1Replacement of Light Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Stacker 1
13.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
13.3.1Replacement of Light Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Rack System 1
14.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
14.4.1Replacement of Rack System . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4
14.4.2Replacement of Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . 14-4
14.4.3Replacement of Rack Insert Light Barrier . . . . . . . . . . . . . . . . . 14-5
14.4.4Replacement of Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
14.5.1Functions of the Rack System Service Software . . . . . . . . . . . . 14-8
14.5.2Initialise and Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
14.5.3Test Procedure for Module Tests . . . . . . . . . . . . . . . . . . . . . . . 14-11
CPS Module (COP) 1

15.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
15.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15.3.1DIP-Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15.3.2Replacement of COP PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
15.4.1Functions of the COP Service Software . . . . . . . . . . . . . . . . . . 15-6
15.4.2Test Procedure for Module Test . . . . . . . . . . . . . . . . . . . . . . . . 15-10
15.4.3Test Procedure for Board Test . . . . . . . . . . . . . . . . . . . . . . . . . 15-11
15.5.1Firmware Upgrade with Service Software . . . . . . . . . . . . . . . . 15-13
15.5.2Firmware Upgrade with User Software . . . . . . . . . . . . . . . . . . 15-13
Power Supply 1
16.1 Safety and Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
16.2.1Replacement of the Power Supply. . . . . . . . . . . . . . . . . . . . . . . 16-1
Troubleshooting and Error Messages 1

17.1 Error Messages of the User Software . . . . . . . . . . . . . . . . . . . . . 17-1
17.2 Plate System Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
17.2.1Received String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
17.2.2ASCII Codes used in Plate System Error Messages . . . . . . . . 17-14
17.2.3Virtual Module Errors (Module ID 41) . . . . . . . . . . . . . . . . . . . 17-14
17.2.4Plate Transport Errors (Module ID 42) . . . . . . . . . . . . . . . . . . . 17-15
17.2.5Photometer/Colorimeter Errors (Module ID 43) . . . . . . . . . . . . 17-16
17.2.6Washer Errors (Module ID 44) . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
17.2.7Incubator Errors (Module ID 45) . . . . . . . . . . . . . . . . . . . . . . . 17-19
17.3 COP and Sample Rack Scanner Error Messages . . . . . . . . . . 17-20
17.3.1COP Errors (Module ID 00) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
17.3.2Sample rack scanner errors (Module ID 00) . . . . . . . . . . . . . . 17-21
17.4 Pipettor Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-21
17.4.1Pipettor Errors (Module ID FD) . . . . . . . . . . . . . . . . . . . . . . . . 17-22
17.4.2Pipettor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-25

Technical Data 1
18.1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.2 Mains Voltage and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
18.3 Laser of the Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . . . . 18-2
18.4 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.4.1System with Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
18.4.2System without Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
Circuit Diagrams 1
19.1 Photometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
19.2 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
19.3 Plate Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16
19.4 Incubator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
19.5 Pipettor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-31
19.6 Rack System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-33
19.7 CPS Module (COP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-34

Intended Use
1 Intended Use
The purpose of this document is to guide trained field service engineers on installa-
tion, adjustment, maintenance service and troubleshooting of the ELISYS QUAT-
TRO, a fully automated microplate based ELISA analyzer.
It has to be pointed out that the service procedures on the ELISYS QUATTRO are
designed to be handled in a module exchange fashion in the field. Only limited ad-
justments and repairs of modules an be performed in the field. Faulty modules are
repaired by the manufacturer. Therefore the scope of this document does not reach
into every detail of the modules.
In addition certain functionality of the software used by service engineers are imple-
mented by and for development engineers to perform their tasks of concurrent engi-
neering or for manufacturing tests. Although available to field service engineers
these functionality need and should not be used in field service and are therefore
only described in limited detail in this document.
This document is intended for field service engineers for training and per-
forming field service.
ELISYS QUATTRO - Service Manual HUMAN 1-1

Intended Use
1.1 Typographical Conventions
Please consider the following typographical conventions.
1.1.1 Warning Messages

Warning messages are indicated with a safety symbol and printed in special types.
For special situations the following security symbols were used.
Caution, risk of danger! Consult instructions for use!
Biohazard!
Electrical hazard!
Caution, hot surface!
Mechanical hazard!
Automatic start-up!
Laser hazard!
1.1.2 Notes
Notes are indicated with a symbol and printed in special types. For special situations
the following symbols were used.
Consult instructions for use!
Notes are indicated by this symbol and printed in special types.
Disconnect mains power connector before servicing!
1-2 ELISYS QUATTRO - Service Manual HUMAN

Intended Use
1.1.3 Symbol Keys
Manufactured by
In Vitro Diagnostic Medical Device
Lot Number
Expiration Date
Storage Temperature
CE Mark
Catalogue Number
Serial Number
1.1.4 Special Types
LEDs LEDs (light emitting diode) are printed in special type.

Example: PWR LED, ERR LED
Menu items and Menu items and fields are spaced type.
fields Example: Fil e Menu
Buttons Buttons are printed in spaced type.

Example: Open button.
Keys Keys are printed in slanted type.

Example: Press Enter
File examples File examples are printed in typewriter font.

Example: DRIVER=C:\SERVICE\DRIVERS

Intended Use
1.2 Safety Instructions
Read all of these instructions! Save these instructions for later use!
Please always act according to the following safety instructions, before as

well as during operation of the system!
The operating manual must be kept near the system and must be accessible
for the user at any time.
ELISYS QUATTRO is designed and manufactured in accordance with the safety re-
quirements for electronic and medical systems. If the law lays down regulations on
the installation and/or operation of microplate analyzers, then it is the operator's re-
sponsibility to adhere to them.
The manufacturer has done everything possible to guarantee that the equipment
functions safely, both electrically and mechanically. The systems are tested by the
manufacturer and supplied in a condition that allows safe and reliable operation.
1.2.1 General Safety
Follow all warnings and instructions marked on the instrument and in this
manual.
The instrument must only be operated by personnel who have been trained on
the use of the system.
It is strongly recommended that all first time personnel read this manual prior to use.
Use the system only for the designated application.

Use only the consumables and accessory prescribed herein (e. g. microplates,
tubes, disposable tips etc.).
The manufacturer assumes no liability for any damages, including those to third par-
ties, caused by improper use or handling of the system.
The service personnel may only perform the maintenance work described in
this manual.
Use only the parts prescribed in this manual for servicing.
The tests and maintenance work defined by the manufacturer should be performed
to make sure that the operator remains safe and that the instrument continues to
function correctly.
Any service and maintenance work not described in this manual must be performed
by authorised service personnel and technicians.
Any changes on the system which are not authorised by the manufacturer lead to the
loss of guarantee obligation.

Intended Use
The system was developed and tested according to the regulations of the IvD
directive (98/79/EC).
Any changes on the system which are not authorised by the manufacturer lead to the
loss of the validity of the conformity with the applicable regulations the manufacturer
has declared. In this case, the customer is responsible for the fulfilment of the appli-
cable regulations.
The instrument should be opened, serviced and repaired by qualified and au-
thorised service personnel only.
1.2.2 Electrical Safety
Country-specific regulations regarding safe electrical operation of the in-

stalled system have to be observed.
Check that the operating voltage is set correctly on all system components be-
fore you connect the system to the mains supply.
This product must be operated from the type of power source indicated on the type
label. If you are not sure of the type of power available, consult an authorised sales
person or your local electric power company.
Use a 3-wire grounding type plug to connect all instrument and peripherals to
mains supply.
Use only extension cables with a protective conductor and grounded contact.
Grounding of the instrument, computer and its peripheral devices to the same pro-
tective earth potential must be ensured.
Never knowingly interrupt the grounding contacts.
There is the risk of an electrical shock if the protective conductor is interrupted within
or outside the device, or has been disconnected.
The instrument must be connected with a delivered connection cable to dedi-

cated socket. The use of a multi plug is not allowed!
Do not allow anything to rest on the power cord.
If you can see that the instrument has become unsafe to use, switch it off and
disconnect it from the mains supply.
If liquid gets inside the instrument, switch it off and disconnect it from the
mains supply. Clean and dry the respective parts.
Surfaces (floors, work table) must be dry when you are working with the sys-
tem.
Only use the bottles, tubing and components supplied and recommended for con-
taining liquids on the instrument.
Spare fuses must match the values (nominal voltage, nominal current, and
type) specified by the manufacturer.

Intended Use
Always replace blown fuses, don't try to repair them.

Never short-circuit the fuse holder.
Switch the instrument off and disconnect it from the mains supply before serv-
icing.
Only when directed to do so, should power be applied. If power is applied while any
covers are removed, use extreme caution while servicing the system.
Never remove protective guards or secured components since you could ex-
pose live parts in this way.
Electrical connection contacts (plugs, sockets etc.) can be electrically live.
Even after the device has been switched off, components (e. g. capacitors) can be
under voltage as the result of an electrical charge.
All current-carrying parts are sources of danger for an electrical shock.
Don't position the instrument so that it is difficult to operate the disconnecting

device (power supply switch, mains power connector)!
1.2.3 Laser Safety
Care must be taken when operating and testing the bar code scanners as they
use a laser class 2. Never look directly into the laser beam!
Output causes iritations of the eye if stared into the beam for long periods of time.
See chapter 18.3 on page 18-2for technical data of the laser (bar code scanner).
For operating and testing the laser, no optical devices may be used.
For operating and testing the laser, watches and mirroring jewellery should be re-
moved.
Use of controls or adjustments or performance of procedures other than those

specified herein may result in hazardous radiation exposure.
1.2.4 Mechanical Safety
Do not place the instrument on a unstable table, cart, or similar.

The instrument may fall, causing serious damage to the system or injure the user.
Don't load the completely opened drawer! This instrument could tip forward!
Never open screw-attached housing parts while the instrument is on.

There is a risk of injury due to moving parts (fan, motor drives).
Only when directed to do so, should power be applied. If power is applied while any
covers are removed, use extreme caution while servicing the system.
Do not take off the protective cover during a run and do not reach into the
working area.
Improper handling may cause serious damage to the instrument or injure the user.

Intended Use
If you open the flap or cover, verify that the movement of the pipettorhas stopped be-
fore you reach in the working area.
Avoid touching the pipettorand other moving parts while the system is in operation.
Notice that it is possible that the instrument continues processes independently, even
without computer.
Slots and openings are provided for ventilation.

To ensure reliable operation of the instrument and to protect from overheating, these
openings must not be blocked or covered.
1.2.5 Biological Safety
Risk of infection! Handling of samples and reagents:

Avoid contact between skin/mucous membrane and samples/test reagents or parts
of the instrument which were in contact with samples/test reagents.
The above-mentioned parts are to be treated as being potentially infectious.
Reagents can lead to irritation of the skin and mucous membranes.
Use appropriate gloves!
Observe the instructions in the package inserts for a correct use of the reagents.
If sample material is spilled in the system, clean and disinfect it immediately

by the use of a validated method.
For reagent containers and tubings (system liquid and waste), no guarantee
can be provided for any resistance against organic solvents.
For this reason, do not use any organic solvents unless such solvents are expressly
authorised.
It is not possible to autoclave the containers for liquids and waste!
1.2.6 Cleaning the System
Switch the instrument off and disconnect it from the mains supply before
cleaning, disinfection or decontamination.
Liquid detergents, disinfectants or decontamination liquids may not be poured

or sprayed into the system.
For the cleaning, disinfection or decontamination, a cloth moistened with detergent,
disinfectant or decontamination liquid should be used.
Only approved detergents, disinfectants or decontamination liquids may be used.
Only approved cleaning, disinfection or decontamination methods may be used.
For cleaning, disinfection or decontamination, the regulations of the local authorities
must be observed.

Intended Use
1.2.7 Disposal
Potentially infectious material and all parts that may come in contact with po-
tential infectious material must be disposed according to national legislations.
All parts which have been replaced, must be disposed according to national
legislations.
Disposal of the instrument according to national legislations.
Disposal of the packaging material according to national legislations.
Containers intended for single-strip use may not be used repeatedly.
1.3 Positions of Safety Labels and Type

Label
If any label gets lost, replace it by an equivalent label!
1.3.1 General Warning Labels
General warning labels are positioned on:

• the flap of the rack system (see figure 1-1: on page 1-8), and
• the flap of the plate transport system (see figure 1-2: on page 1-9).
Figure 1-1: Warning label on the rack system flap

Intended Use
Figure 1-2: Warning label on the plate transport system flap
1.3.2 Biological Hazard Labels
Biological hazard labels are positioned on:

• the washer waste bottle (see figure 1-3: on page 1-9),
• the washer foam bottle (see figure 1-3: on page 1-9), and
• the waste container (see figure 1-4: on page 1-10).
Figure 1-3: Biological hazard labels on the waste bottle and the foam bottle

Intended Use
Figure 1-4: Biological hazard labels on the waste container
1.3.3 Electrical Hazard Labels
Electrical hazard labels are positioned on:

• the rear side of the instrument near the mains switch.
1.3.4 Laser Hazard Labels
Laser hazard labels are positioned on:

• next to the rack system bar code scanner outlet (see figure 1-5: on page 1-11), and
• next to the microplate bar code scanner outlet (see figure 1-6: on page 1-11).

Intended Use
Figure 1-5: Laser hazard labels next to the rack system bar code scanner
outlet
Figure 1-6: Laser hazard labels next to the microplate bar code scanner
outlet
1.3.5 Type Label

The type label is positioned on the back of the instrument (near the mains switch).

Intended Use
1.4 Definitions, Acronyms and

Abbreviations
Abbreviation: Definition: Explanation:
A Ampere Unit of the electrical current.

COP Central opera- Central host processor in ELISYS QUATTRO
tion processor distributing worklist commands to the mod-
ule's processors.
DC Direct current E.g.: DC-motor
EEPROM Electrically
erasable pro-
grammable
read only mem-
ory
ID Identification
LED Light Emitting A LED can be bicoloured, i.e. it can be con-
Diode trolled to either emit green or red light (theo-
retically also mixed orange light)
m Meter • mm: Millimeter
• µm: Micrometer
Microplate 96 well microtiter plate used for holding sam-
ple/reagent mixtures for dilutions or analysis.
PCB Printed circuit Electronics board
board
Run Analytical session, consisting of all actions
related to the scheduling and analysis of a
group of samples, beginning with an operator-
initiated start and ending when the analyzer
returns to ready state.
V Volt(s) Unit of the electrical voltage.
Well One of the 96 positions in a microplate.
X-direction - left Left/Right direction as seen from the operator
+ right standing in front of the instrument.
Y-direction - back Back/Front direction as seen from the opera-

+ front tor standing in front of the instrument.
Z-direction - up Up/Down direction as seen from the operator

+ down standing with his feet toward the earths centre
of mass.
Table 1-1: Definitions, acronyms and abbreviations

System
2 System
2.1 Safety and Hints
Follow all safety instructions before servicing the machine (see

chapter 1.2 on page 1-4) to avoid personal and material damage!
2.2 Mechanical Architecture
Figure 2-1: Mechanical architecture 1
The mechanical architecture for the system is functionally modular. Various function-
al modules for performing the plate processes are contained in the system. The sys-
tem consists of two main areas. The area for pipetting fluid into the plate and the
module drawer ('function drawer').
The samples and reagents are to be stored in a rack mechanism. The disposable tips
and dilution plates are to be located in an open drawer mechanism. A XYZ-drive
mechanism moves the pipettor around the working area of the system. The pipettor
is used for sample and reagent distribution into plates located in the plate preparation
area. The pipettor uses disposable tips. The pipettor uses a syringe pump with a sys-

System
tem fluid. The incubators are located below the pipetting area. Once a plate is pre-
pared, it can be moved by the plate transport system to the other functional modules
of the system located in the module drawer.
The photometer, washer and stacker are mounted in a module drawer mechanism
below the pipetting area. The washer unit is located towards the front, then the stack-
er, and lastly the photometer behind. The plate transport mechanism is attached to
the side that will be able to move the micro plates between the various modules and
pipette areas.
The following sketch shows the layout of the modules (shown with the module drawer
open for clarity).
Figure 2-2: Mechanical architecture 2
1 Pipettor
2 Dilution plates and dilution tubes
3 Tip racks
4 Patient sample and reagent unit
5 Pipettor station
6 Tip ejection station and pipettor wash station
7 Incubator
8 Wash buffer and internal waste bottles
9 Photometer
10 Stacker
11 Washer
12 Plate transport unit

System
2.3 Electronic Architecture
Figure 2-3: Electronic architecture
An external PC, via a RS232 communications link, controls the instrument.

The instrument is divided into a number of functional modules. Each module has its
own processor to allow multitasking of various operations on the system (e.g. plate
reading and sample pipetting of another plate). The serial messages sent by the con-
trolling PC go to a communications processor system (COP). This module processes
the messages and instructs the appropriate module to perform the required tasks.
The modules are connected to the COP via a serial communication interface.
Power for the instrument is provided by the local mains power supply. The mains
power voltage is converted to 24 V DC for distribution to the functional modules of
the system.
The functional modules are connected to the COP via a single cable connection that
must house the necessary power, communications and control signals required.
The architecture allows automatic update of the firmware for the system to be per-
formed by the controlling PC.

System
The system is a fully automated system for ELISA processing, with a capacity of up
to 4 plates as standard. However the PC software scheduler is able to schedule more
than 4 plates at the same time in the system. The system will automate the steps re-
quired to process micro plate assays from sample distribution, dilution, incubation,
washing, reagent addition, and detection using absorbance technologies. The prod-
uct is controlled by Microsoft Windows® software for all operations, including assay
creation and worklist generation, time scheduling, data reduction and reporting of re-
sults. The software will also focus on in-process control, validation and verification.
The product is targeted for laboratories running between 20,000 and 100,000 tests
per year.

Installation
3 Installation
Aim of this document is to give the main guidelines for a correct installation of the
analyzer.

chapter 1.2 on page 1-4) to avoid personal injuries and material damage!
3.2 Environment
Don't position the equipment so that it is difficult to operate the discon-

necting device!
Place this product on an stable platform, cart, stand or table (see

chapter 18.4.2 on page 18-3)!
The entire ELISYS QUATTRO system (analyzer, computer, monitor and printer) re-
quires a space of approximate 200 cm x 85 cm x 120 cm (W x D x H). The total depth
(with wall distance and completely opened drawer) is 176 cm. The workbench on
which the ELISYS QUATTRO system is set up should have a size of at least
75 x 200 cm.
The ventilation slits on the rear panel of the analyzer, the computer and the monitor
must not be covered and should be away from the wall at least 20 cm.
The room where the ELISYS QUATTRO is should be evenly heated (summer and
winter), since most immuno assays are temperature sensitive. The operation tem-
perature is between 15°C and 25°C (see chapter 18.1 on page 18-1). We recommend to
set up the ELISYS QUATTRO in air-conditioned rooms.
3.3 Packaging
Save the packaging to allow for safe transportation back to the manufacturer in case
the instrument needs to be serviced.

Installation
3.4 Contents of the System
3.4.1 Contents of Box A (analyzer)

The analyzer box contains:
• analyzer
• 6 sample racks
• 4 plate carriers
• 4 washer bottles with level switch
• 2 washer waste bottles with level switch
• ELISYS QUATTRO backup disk
3.4.2 Contents of Box B

The accessories box contains:
• Computer with keyboard and mouse
• Monitor
• Printer
• Waste container 10 litres
• System fluid container 10 litres
3.4.3 Contents of Box C

The cover box contains:
• Side covers
• Instrument cover
3.4.4 Contents of Box D

The box contains:
• RS232 cable
• Mains plug
• ELISYS QUATTRO software CD
• ELISYS QUATTRO firmware disk
• Washer cleaning kit
• Components of the washer (silicon tubing, wash head)
• Components of the pipettor system (disposable tip adapter, Z-axis rack, tub-
ing guidance)
• Components of the instrument cover (4 knurled head screws)
• Spare parts (2 fuses 4 A, 1 lamp)
• Set of Allen keys
• Final check procedure
• Waste bag holder
• Printer cable

Installation
3.5 Installation of the System
3.5.1 Setup of the System

1. Lift the carton and remove it.
2. Remove the foil from the analyzer.
3. Remove the foam rubber parts 'A' to 'C' from the analyzer.
Figure 3-1: analyzer with all foam rubber parts
4. Write down the serial number on the rear panel of the analyzer for later use.
5. Put the analyzer on the workbench (see chapter 18.1 on page 18-1 and chapter 3.2 on
page 3-1).
The analyzer is heavy! Use lifting device or handle!
6. Remove the foam rubber part 'D' from the pipettor bridge.

Installation
Figure 3-2: Foam rubber part on pipettor bridge
7. Remove the foam rubber part 'E' from the rack system.
Figure 3-3: Foam rubber part on rack system
8. Open the instrument drawer.

9. Remove the cardboard covering 'F' from the drawer.

Installation
Figure 3-4: Instrument drawer
10. Remove the foam rubber part 'G' from the plate transport.
11. Remove the tip eject ramp '2-1' and put it aside for later use.
12. Remove the foam rubber part 'H' from the photometer.

Installation
Figure 3-5: Foam rubber part on photometer
13. Open the washer.

14. Remove the foam rubber part 'I' from the washer.
Figure 3-6: Foam rubber part on the washer module

Installation
3.5.2 Installation of the Wash Head

1. Take the wash head out of the accessories box.
2. Open the washer.
3. Connect the aspirate tube '1-2' to the wash head '1-1'.
Figure 3-7: Connect tubing to the wash head
4. Connect the dispense tube '1-3' to the wash head.

5. Take the two wash head fixing screws out of the accessories box.
6. Fix the wash head with the two screws '1-4'.

Installation
Figure 3-8: Wash head fixing
7. Close the washer.
3.5.3 Installation of Waste Bag System

1. Take the waste bag holder, the waste bag and the waste bag cover out of the
accessories box.
2. Put the waste bag holder '2-2' in the slot of the instrument drawer.

Installation
Figure 3-9: Waste bag holder
3. Place the waste bag '2-3' into the holder.
Figure 3-10: Waste bag
4. Lock the bag with the four black clips.

5. Put in the cover with the tip eject ramp '2-1'.

Installation
Figure 3-11: Tip eject ramp
6. Put the waste bag cover '2-4' onto the waste bag.
Figure 3-12: Waste bag cover
3.5.4 Installation of the Pipetting System

1. Take the disposable tip adapter, the Z-guide and the tubing guide out of the
accessories box.
2. Check if the tubing guide '3-1' can easily be moved.

Installation
Figure 3-13: Dispense pump and pipettor tube
3. Pull the pipettor tube '3-2' to the front of the analyzer.

4. Move the pipettor bridge to the front of the analyzer.
5. Put the Z-axis rack '3-3' into the X-sledge.
Figure 3-14: Upper side of the X-sledge

Installation
Figure 3-15: Z-axis rack
6. Move the X-sledge over the eject pin.

7. Insert the pipettor tube '3-2' in the second tubing guide '3-4'.

Installation
Figure 3-16: Second tubing guide
8. Insert the second tubing guide and the pipettor tube in the Z-axis rack.
9. Insert the pipettor tube in the needle adapter '3-5'.
Figure 3-17: Pipettor tube and needle adapter

Installation
10. Insert the needle adapter into the Z-axis rack. The metal pin must be on the
back.
11. Tighten the needle adapter with the upper hexagon screw '3-6'.
Figure 3-18: Needle adapter
12. Check that the lower hexagon screw '3-7' is tightened.

13. Put the needle adapter sensor plug '3-8' in the socket on the lower side of the
X-sledge.
Figure 3-19: Needle adapter sensor plug and socket

Installation
3.5.5 Installation of the Side Covers

1. Take the side covers out of the cover box.
2. Open the drawer.
3. Hang the top of the side cover on the top of the analyzer.
Figure 3-20: Installation of the side cover
4. Press the side cover on the side of the analyzer.

5. Repeat step 3 and 4 for the other side cover.
6. Close the drawer.
3.5.6 Installation of the Top Cover
Locking Mecha- 1. Take the cover of the locking mechanism out of the accessories box.
nism of the 2. Open the screws '5-1'.
Hinged Cover 3. Put the cover on the locking mechanism.
4. Tighten the screws '5-1'.
Figure 3-21: Locking mechanism

Installation
Top Cover 1. Take the top cover out of the cover box.
2. Put the cover on the top of the analyzer.
3. Open the hinged cover.
4. Tighten the four screws '5-2' on the left and right side.
Figure 3-22: Gas spring (left)
Figure 3-23: analyzer with covers and waste bag cover
3.5.7 Installation of System Fluid and Waste

Containers
1. Take the system fluid container and the waste container out of the accesso-
ries box.
2. Put the system fluid tube in the CPC quick connection '6-1'.

Installation
Figure 3-24: Back of the analyzer
3. Put the system fluid sensor plug in the socket '6-2'.

4. Put the thick waste container tube in the CPC quick connection '6-7'.
5. Put the thin waste container tube in the CPC quick connection '6-5'.
6. Put the waste container sensor plug in the socket '6-6'.
The waste container should be below the level of the analyzer.
3.5.8 Installation of Computer and Cable

Connections
1. Take the computer (with keyboard, mouse and cables), the monitor, the
printer and the all cables out of the accessories box.
2. Set up the computer near the analyzer.
3. Set up the monitor near the computer or onto the computer housing.
4. Set up the printer near the computer.
5. Set up the keyboard near the computer.
6. Set up the mouse near the computer.
7. Put the plugs in the correct sockets (see the example in following figure and
table).

Installation
Figure 3-25: Back of a computer
Plug/Socket: Equipment:
7-1 RS232 to the analyzer
7-2 Mouse
7-3 Keyboard
7-4 Printer
7-5 Monitor
7-6 Mains plug
7-7 Mains voltage selector
Table 3-1: Computer sockets
8. Put the second RS232 plug in the analyzer socket '6-3' (see figure 3-24: on
page 3-17).
9. Put the second printer plug in the printer socket.
Check whether the correct computer voltage is selected on the mains

voltage selector switch '7-7'. If necessary select the correct voltage.
Use a 3-wire grounding type plug to connect all instruments and periph-
erals to mains voltage!
Grounding of the analyzer, computer and its peripheral devices to the

same protective earth potential must be ensured.
Country-specific regulations regarding safe electrical operation of the

installed equipment have to be observed.
10. Put the mains plug in the monitor.

11. Put the mains plug in the printer.
12. Put the mains plug from computer, monitor and printer in the mains voltage.
13. Put the mains plug in the analyzer '6-4' (see figure 3-24: on page 3-17).
14. Put the mains plug from the analyzer in the mains voltage.

Installation
The analyzer must be connected with a delivered connection cable to a

dedicated socket. The use of a multi plug is not allowed!
3.6 Preparations for the User Software
3.6.1 Installation of the Assay Definitions

The assay definitions must be copied into the ELISYS QUATTRO software directory.
1. Power on the computer and the monitor.
2. Insert the floppy disc or CD-ROM with the assay definitions into the drive.
3. Open the Windows explorer.
4. Select the correct drive with your floppy-disc or CD-ROM.
5. Choose Edit | Select All from the Windows explorer menu to select all
assay definitions (*.asy files).
6. Select Edit | Copy in the Windows explorer menu.
7. Select Drive (C:).
8. Select the user software directory.
9. Select the directory Assays.
10. Choose Edi t | Paste from the Windows explorer menu.
3.6.2 Installation of the Reagent Database

The reagent database must be copied into the ELISYS QUATTRO software directo-
ry.
2. Insert the floppy disc or CD-ROM with the reagent database into the drive.
4. Select the correct drive with your floppy-disc or CD-ROM.
5. Select the reagent database file (reagents.db).
6. Select Edit | Copy in the Windows explorer menu.
3.7 Check of the System
Prior to operation of the analyzer and its peripherals the user must en-
sure correct and safe connection to the mains voltage.
3.7.1 Preparations for the Check

1. Fill in distilled water in the system fluid container.
2. Fill in distilled water in the four washer bottles.
4. Power on the analyzer.

Installation
5. Wait for the end of the analyzer self test and the start up of Microsoft Win-
dows.
3.7.2 Check with Service Software
Please look up in the other chapters of the service manual for detailed infor-
mation.
1. Start the system (see chapter 3.7.1 on page 3-19).

2. Start the service software.
3. Enter the password.
4. Select the COP driver.
5. Click on the Load Module driver... button.
6. Click on the Sel ftest button.
7. Wait for the message Self test OK.
8. Click on the Close button.
9. Repeat steps from step 4 for the following drivers:
• Incubator
• Rack
• Reader
• Washer
10. Select the Pipettor driver.
12. Click on the Automat ic Modul e Test button (see chapter 11.9.7 on
page 11-71).
The automatic module test runs almost completely independently. Only at the
beginning tips and a rack must be placed. The different parts can be dese-
lected by removing the ticks in the check boxes except for the initialisations.
13. Click on the St art button to start the test.
14. Place short tips at the shown position.
15. Click on the OK button.
16. Place long tips at the shown position.
18. Place a T-rack, filled with tubes (with and without liquid), on the first track.
The test runs itself with the selected parts. The result window for the level
detection is constantly updated. At the end a log file is created automatically.
21. The automatic module test dialogue shows the test results.
22. Click on the Cancel button.
23. Click on the Close button.
24. Select the Incubat or driver.
26. Select Overri de for the four incubators.
27. Click on the Set Parameters button.
28. Change to the service software application window.
29. Select the Plate Transport driver.
31. Click on the Modul e Test.. . button.
32. Enter your Name.
33. Select Manual.

Installation
35. Click on the No button for the firmware download.

36. Click on the No button for the serial number test.
37. Click on the No button for the parameters test.
38. Click on the No button for the plate in sensor test.
39. Click on the No button for the door test.
40. Click on the No button for the LED test.
41. Click on the No button for the stacker sensor test.
42. Click on the No button for the X-motor test.
43. Click on the No button for the Y-motor test.
44. Click on the No button for the Z-motor test.
45. Click on the No button for the Shake test.
46. Click on the Yes button for the self test.
47. Click on the Yes button for the position test.
48. Insert a plate carrier.
50. Remove the plate carrier.
52. Click on the Cl ose button.
53. Change to the Incubator window.
54. Deselect Override for the four incubators.
55. Click on the Set Parameters button.
56. Click on the Cl ose button.
57. Click on the Terminate Program button.
58. Open the Windows Explorer.
59. Select the directory 'C:\Program Files\...service software installation
path...\gSddmmyy' (dd=day; mm=month; yy=year).
60. Open the file 'PLxxxxxx.txt'. (xxxxxx=Number).
The positions are correct, if all tests are passed.
3.7.3 Check of the Pipettor Positions with the

Teacher
Please look up in (see chapter 11.7 on page 11-44) for detailed information about
the teaching software.
3.7.3.1 Protect the positions files

1. Start the ELISYS QUATTRO system (see chapter 3.7.1 on page 3-19).
5. Select all files with the ending 'rac', 'dat' and 'mpc'.
6. Choose Fil e | Properties from the Windows explorer menu.
7. Select Read-only
8. Click on the Appl y button.

Installation
If you modify positions with the teacher, then the teacher displays an error
message and doesn't execute the modification. For modifications you must
remove the write protection.
Figure 3-26: Teacher error message
3.7.3.2 Check
1. Start the teacher software.
Reference Posi- 3. Click on the Ref. left button.

tion 4. Click on the Prev. Z button.
The correct reference position '7' is reached if the tip adapter (without a tip)
touches the reference point.
Figure 3-27: Reference position
5. Click on the Cancel button.

6. Click on the Yes button.
Dilution Area 7. Click on the dilution area '1'.

8. Check all positions.
Disposable Tip 9. Remove all disposable tip racks.

Racks 10. Insert an empty disposable tip rack on position '2-1'.
11. Click on the first disposable tip rack '2-1'.

Installation

13. Repeat steps for the four other disposable tip racks.
Sample and Re- 14. Insert the rack teaching tool in the far left position of the rack.
agent Positions 15. Click on the sample and rack position '3'.
16. Check position 1 and 2.
17. Remove the rack teaching tool.
18. Insert the rack teaching tool in the far right position of the rack.
19. Check position 3.
Pipette Posi- 20. Insert the MTP teaching tool (placed in a plate carrier) on pipette position '4-
tions 1'.
21. Click on the pipette position '4-1'.
23. Remove the MTP teaching tool (placed in a plate carrier).
24. Repeat steps for the pipette positions '4-2', '4-3' and '4-4'.
Eject Position 25. Click on the eject position '5'.

Wash/Waste Po- 27. Click on the wash/waste position '6'.

sition 28. Check all positions.
MTP Positions 29. Click on the MTP' s button.

30. Select a MTP file.
31. Click on the Edi t button.
32. Insert the correct microplate on position '4-1'.
33. Click on the Teach button.
36. Repeat steps for the other MTP files.
Rack Positions 38. Insert a small tip (300 µl) into position 1 of the disposable tip rack '2-1'.
39. Click on the Pickup D button.
40. Click on the Racks button.
41. Select a rack file.
42. Click on the Edi t button.
43. Insert the correct sample/bottle rack in the far left position of the rack.
44. Insert a bottle or tube into the first position of the sample/bottle rack.
45. Click on the Teach button.
46. Check the position.
47. Click on the arrow button ^ for the next position.
48. Repeat steps for all positions.
50. Repeat steps for the other rack files.
51. Click the Quit button.

Installation
3.8 Check with User Software
1. Start the ELISYS QUATTRO system (see chapter 3.7.1 on page 3-19).
2. Start the ELISYS QUATTRO software.
4. Wait for the end of initialisation of the analyzer.
3.9 Save System Files
1. Insert a floppy disc into the floppy disc drive A.

5. Select all existing files with the ending 'rac', 'dat', 'glb', 'h86' and 'mpc'.
6. Choose Edi t | Copy from the Windows explorer menu.
7. Select 3 Floppy (A:).

Maintenance
4 Maintenance

The waste system could have had contact with dangerous material! Pay
attention to safety regards! Always wear gloves!
Never use bio-hazardous liquids when testing the washer!
Care must be taken when operating and testing this module as moving
parts may cause injury if obstructed by user!
Don't weight the complete opened drawer! The analyzer could tip for-
ward!
4.2 Overview about Maintenance Kits
Half-yearly The half-yearly maintenance kit contains the tubings and accessories which have to
Maintenance Kit be changed every half year (see chapter 4.3 on page 4-1).
Yearly Mainte- The yearly maintenance kit contains the half-yearls maintenance kit, a syringe, and
nance Kit a valve which have to be changed every year (see chapter 4.3 on page 4-1).
Lubrication Kit The lubrication kit consists oil, grease and a monovette for cleaning and lubrication
(see chapter 4.4 on page 4-7).
4.3 Half-Yearly and Yearly Maintenance Kit
The following figures and tables are showing the tubings and accessories of the half-
yearly and the yearly maintenance kits.

Maintenance
Figure 4-1: Tubing of the half-yearly and yearly maintenance kits
Figure 4-2: Tubing and accessories of the half-yearly and yearly mainte-
nance kits
Figure 4-3: Syringe and valve of the yearly maintenance kits

Maintenance
No.: Tubing or Accessories: Location:
1 Tubing (length 22 cm) • Wash head

• Water trap (input)
2 Tubing (length 25 cm) • Water trap (output)
• Internal waste bottle (red mark)
3 Tubing with fitting (length 25 cm) • Internal waste bottle (grey mark)
• Tubing cassette (input) of the washer
peristaltic pump
4 Tubingtubingss with fitting and Y- • Tubing cassette (output) of the
fitting washer peristaltic pump
• Waste pump (output)
• CPC quick connector (small one)
5 Tubing (length 160 cm) • Pipettor wash station
• Waste pump (input)
6 Tubing (length 200 cm; transpar- • CPC quick connector (small one)
ent) • Waste container
7 Tubing cassette • Washer peristaltic pump
8 Wash buffer filters • Washer dispense pumps
9 System liquid filter • System liquid container
10 Liquid level detection cable • Pipettor disposable tip adapter
11 Syringe • Pipettor dispense pump
12 Three way valve • Pipettor dispense pump
Table 4-1: Tubings and Accessories

Maintenance
4.3.1 Half-Yearly and Yearly Maintenance
Place a container or put a cloth under the end of the tubing which
should be removed, because (dangerous) liquid could be in the tub-
ings!
Preparations The preparations are only necessary if the waste pump on the back of the instrument:
• Tubing 4: Cut the 44 cm long tubing to 25 cm.
• Tubing 5: Cut the tubing to 120 cm.
1. Switch off the system.

2. Disconnect main power from the system.
3. Open the system liquid container.
4. Remove the old system liquid filter ’9’.
Figure 4-4: System liquid filter
5. Put the new system liquid filter ’9’ on the suction tube.
6. Close the system liquid container.
The system liquid filter ’9’ should stay in system liquid 30 minutes before a
run should be started. Otherwise air bubbles can reach the pipette tubing.
7. Open the functional drawer completely (open locking mechanism on left side
of the functional drawer).
8. Remove the four wash buffer bottles.
9. Remove the wash bottle tray.
10. Remove the front cover with the tip eject ramp.
11. Remove the old tubing ’5’ from the pipettor wash station.
12. Remove the old tubing ’5’ from the pipettor waste pump (input) see
chapter 11.5.12 on page 11-24 or chapter 11.5.13 on page 11-25).
13. Remove the old tubing ’5’ from the instrument.
14. Install the new tubing ’5’ in the instrument.
15. Put the new tubing ’5’ on the pipettor wash station.
16. Put the new tubing ’5’ on the pipettor waste pump (input).
17. Install the front cover with the tip eject ramp.
18. Remove the old tubing cassette ’7’ from the peristaltic pump (see chapter 7.6.5
on page 7-15). It isn’t necessary to remove the washer.
Press the clips ’A’ at the top and the bottem at the same time and pull down
the tubing cassette .
It isn’t necessary to remove the tubings!

Maintenance
Figure 4-5: Waste pump cassette
19. Remove the old tubing ’4’ from the pipettor waste pump (output) see
chapter 11.5.12 on page 11-24 or chapter 11.5.13 on page 11-25).
20. Remove the old tubing ’4’ from the CPC quick connector (small one).
21. Put the new tubing ’4’ on the pipettor waste pump (output).
22. Put the new tubing ’4’ on the CPC quick connector (small one).
23. Remove the old tubing ’3’ from the internal waste bottle (grey mark) (see
chapter 7.6.14 on page 7-23).
24. Remove the old tubing ’3’, the old tubing ’4’, and the old tubing cassette ’7’
from the instrument.
25. Install the new tubing cassette ’7’ of the peristaltic pump.
26. Remove the guards from the new tubing cassette tubings.
27. Put the new tubing ’4’ on the tubing cassette ’7’ (output).
See arrows on the tubing cassette ’7’ to find the output.
28. Put the new tubing ’3’ on the tubing cassette ’7’ (input).
29. Put the new tubing ’3’ on the internal waste bottle (grey mark).
30. Remove the old tubing ’1’ from the wash head (see chapter 7.3 on page 7-3).
31. Remove the old tubing ’1’ from the water trap (input).
33. Put the new tubing ’1’ on the wash head.
34. Put the new tubing ’1’ on the water trap (input).
35. Remove the old tubing ’2’ from the water trap (output).
36. Remove the old tubing ’2’ from the internal waste bottle (red mark).
38. Put the new tubing ’2’ on the water trap (output).
39. Put the new tubing ’2’ on the internal waste bottle (red mark).
40. Remove the old tubing ’6’ from the CPC quick connector (small one).

Maintenance
41. Remove the old tubing ’6’ from the waste container.
43. Put the new tubing ’6’ on the waste container.
44. Put the new tubing ’6’ on the CPC quick connector (small one).
45. Remove the old filters ’8’ from the washer dispense pumps tubings (see
46. Remove the old filters ’8’ from the system.
47. Put the new filters ’8’ on the washer dispense pumps tubings
48. Install the wash bottle tray.
49. Install the four wash buffer bottles.
50. Close the functional drawer completely (close locking mechanism on left side
51. Disconnect the old liquid level detection cable ’10’ of the disposable tip
adapter from the X-sledge (see chapter 11.5.1 on page 11-9).
52. Open the cover of the disposable tip adapter.
53. Disconnect the old liquid level detection cable ’10’ from the disposable tip
adapter.
54. Remove the old liquid level detection cable ’10’ from the system.
55. Connect the new liquid level detection cable ’10’ to the disposable tip adapter.
56. Close the cover of the disposable tip adapter.
57. Connect the old liquid level detection cable ’10’ to the X-sledge.
58. If planned start with the yearly maintenance procedure (see chapter 4.3.2 on
page 4-6) or the lubricate procedure (see chapter 4.4 on page 4-7).
59. Check the pipettor reference position (see chapter 11.7.4 on page 11-48).
4.3.2 Yearly Maintenance

1. Start with the ’Half-Yearly and Yearly Maintenance’ (see chapter 4.3.1 on page 4-
4).
2. Remove the old syringe ’11’ from the pipettor dispense pump (see chapter 11.5.5
on page 11-15).
3. Remove the old syringe ’11’ from the system.
4. Remove the old three way valve ’12’ from the pipettor dispense pump (see
5. Remove the old three way valve ’12’ from the system.
6. Install the new three way valve ’12’ to the pipettor dispense pump (see
7. Install the new syringe ’11’ to the pipettor dispense pump (see chapter 11.5.5 on
page 11-15).

Maintenance
4.4 Lubrication Kit
Figure 4-6: Lubrication kit
4.4.1 X-axis: Cleaning and Lubrication of X-

guiding Mechanism

3. Remove all dirt from the X-guiding mechanism 'O-5', 'O-6' and 'O-7' with a
cleaning paper.
Figure 4-7: Cleaning and lubrication of X-rollers on X-axis
4. Use in a second step a cleaning paper with alcohol (standard disinfection flu-
ids of the laboratories).
5. Remove all dirt from all rollers 'O-1', 'O-2', 'O-3', 'O-4', 'O-8', 'O-9', 'O-10', 'O-
11', 'O-12' and 'O-13' with a cleaning paper on both sides of the bridge.
6. Lubricate all roller bearings with max. 0.25 ml oil each via the monovette '23'.
7. Remove oil from the X-guiding mechanism 'O-5', 'O-6' and 'O-7' with a clean-
ing paper.

Maintenance
4.4.2 Y-axis: Cleaning and Lubrication of Y-guiding

Mechanism
Figure 4-8: Cross-sectional picture of the pipettor bridge
Figure 4-9: Top view of the pipettor bridge


Maintenance
3. Remove all dirt and old oil from the pipettor bridge (guiding mechanism) with
a cleaning paper.
5. Clean the rack completely especially also on the top.
6. Clean also the ends of the sledge in the area of the bearing to the guiding
mechanism.
7. For refilling the oil reservoirs of the sledge 'O-19' and 'O-20' use the
monovette '23'. Soak up a volume of 0.5 ml.
8. Move the sledge to the right side of the bridge. In the top of the bridge is a
small hole (see figure 4-9: on page 4-8). Via this hole the oil reservoirs of the
sledge can be accessed.
9. Move the sledge so that the right bearing holder is symmetric to the access
hole.
10. Place the pipette and find the reservoir hole 'O-19' in the sledge.
11. Place the oil into the reservoir slowly.
12. Move the sledge so the left bearing holder is symmetric to the access hole.
13. Place the pipette and find the reservoir hole 'O-20' in the sledge.
14. Place the oil into the reservoir slowly.
15. Lubricate the roller bearings 'O-14' and 'O-16' with max. 0.25 ml oil each via
the monovette.
16. Remove oil from the Y-guiding mechanism 'O-15' with a cleaning paper.
17. Put the oil on the guiding rod 'O-17'.
Do not place too much oil on the guiding rod! Dropping oil is absolutely not
allowed!
18. Move the sledge all across the Y-axis 10 times to build up a completely oiled
surface on the guiding mechanism.
4.4.3 Z-axis: Lubrication of Z-rack

3. Remove all dirt and old oil from the Z-rack 'O-18' with a cleaning paper (see
figure 4-8: on page 4-8 and figure 4-9: on page 4-8).
5. Place with your finger tip oil on the Z-rack.
6. Put the oil on the complete surface of the Z-rack but not into the teeth of the
rack.
Do not place too much oil on the rack! Dropping oil is absolutely not allowed!
7. Move the Z-rack all across the Z-axis 10 times to build up a completely oiled
surface on the Z-rack.

Maintenance
4.4.4 X-axis of Plate Transport: Cleaning and

Lubrication of Guiding Rod
Figure 4-10: Plate transport

3. Open the functional drawer.
4. Remove all dirt and old oil from the guiding rod 'O-21' with a cleaning paper.
6. Place with your finger tip oil on the guiding rod.
7. Put the oil on the complete surface of the guiding rod.
Do not place too much oil on the guiding rod! Dropping oil is absolutely not
allowed! Do not oil other parts of the plate transport!
8. Move the plate transport across the whole length of the guiding rod 10 times
to build up a complete oiled surface on the guiding rod.
4.4.5 Z-spindle of Plate Transport: Cleaning and

Greasing of Z-spindle

4. Remove all dirt and old grease from the spindle 'G-1' with a cleaning paper
(see figure 4-10: on page 4-10).
5. Press the cleaning paper into the thread grounds of the spindle and turn the
spindle on top of the plate transport with a screw driver.
6. Pick up some grease out of the grease box '25' with a cleaning paper.

Maintenance
7. Place the grease on the spindle.

8. Wipe the grease with the paper into the spindle surface.
Do not place too much grease on the spindle! Do not grease other parts of
the plate transport!
9. Turn the spindle with the screw driver at least 5 times up and down to build up
a closed and homogeneous film of grease on the spindle.

Maintenance

Service Software
5 Service Software

Care must be taken when operating and testing using this module as
moving parts may cause injury if obstructed by user!
Care must be taken when operating and testing the bar code scanners
as they use a laser class 2. Never look directly into the laser beam!
5.2 Installation of Service Software
The family of service software modules or dll's (dynamic linked library) required for
the system are accessed via the parent application gSERVICE.exe. gSERVICE.exe
also requires five other dll's and the serial client to communicate with the system. In-
stallation should be automatic from the original installation disks, simply follow the in-
structions. However, if any problems do occur, ensure the structure is as follows
within the main sub-directory containing the application gSERVICE.exe. There
should also be the following files:
gSERVICE.INI Global settings, this must be set up correctly.

Rs232s32.exe RS232 serial driver, required to communicate with system
Stclms.dll Library functions
Stmfcext.dll Library functions
Stth32dll.dll Library functions
Stth32link.dll Library functions
ServiceUtils.dll Library functions
Table 5-1: Files for the application gSERVICE.exe
5.2.1 Installation
To install, run the Setup application from whatever media the software was distribut-
ed. When you attempt to install and the installation program detects a previous instal-
lation, it will automatically uninstall it. This will require you to run the installation
program again.
1. First, you will be prompted to select a language.

Service Software
2. Next, the welcome banner will appear. Exit all Windows programs before run-
ning the setup, as recommended.
3. You may select a different destination folder than the default.
4. Next, the type of installation can be selected, choose Typi cal.
5. Next, you may select a different folder name for the Windows start menu.
6. Last, if installation is successful, press on the Fi nish button.
5.2.2 Global Settings in gSERVICE.INI

This INI file contains the path names for all the installed modules as well as the def-
inition for the serial communications. It must have the correct path names for each
module, otherwise gSERVICE will not show the module. There are a number of di-
rectives within the INI file: A directive is enclosed within square brackets '[-]'.
DEVICE1 (number increments for each module) is the directive that informs gSERV-
ICE of a module. Below the DEVICE1 label are three attributes, DEVICENAME, DE-
VICEDRIVER and DEVICE_PHYSADDR. PORTMAP allows COM port 2 to be used.
[MAIN]
Contains the path for data, DATA_PATH=path
[DEVICE1]
DEVICENAME=Name that appears in gSERVICE module window
DEVICEDRIVER=pathname/filename. Path and dll name, example
C:\SERVICE\WASHER.DLL.
DEVICE_PHYSADDR=Physical address for module, example 68
For the washer, the entry in the INI file would be like, depends on device
number and installation path;
[DEVICE1]
DEVICENAME=Washer
DEVICEDRIVER=c:\...installation_path...\Washer\Washer.dll
DEVICE_PHYSADDR=68
For the reader, the entry in the INI file would be like, depends on device number
and installation path;
[DEVICE2]
DEVICENAME=Reader
DEVICEDRIVER=C:\...installation_path...\Reader\Reader.dll
DEVICE_PHYSADDR=67
For the incubator, the entry in the INI file would be like, depends on device
[DEVICE3]
DEVICENAME=Incubator
DEVICEDRIVER=C:\...installation_path...\Incubator\Incuba-
tor.dll
DEVICE_PHYSADDR=69
For the plate transport, the entry in the INI file would be like, depends on device
[DEVICE4]
DEVICENAME=Plate Transport
DEVICEDRIVER=C:\...installation_path...\PlateTx\PlateTx.dll
DEVICE_PHYSADDR=66
For the Rack module, the entry in the INI file would be like, depends on device
[DEVICE5]
DEVICENAME=Rack
DEVICEDRIVER=C:\...installation_path...\Rack\Rack.dll
DEVICE_PHYSADDR=0

Service Software
For the COP module, the entry in the INI file would be like, depends on device
[DEVICE6]
DEVICENAME=COP
DEVICEDRIVER=C:\...installation_path...\COP\Cop.dll
DEVICE_PHYSADDR=0
For the pipettor module, the entry in the INI file would be like, depends on de-
vice number and installation path;
[DEVICE7]
DEVICENAME=Pipettor
DEVICEDRIVER=C:\...installation_path...\Pipettor\PipDrv.dll
DEVICE_PHYSADDR=253
For the PCB utilities, the entry in the INI file would be like, depends on device
[DEVICE8]
DEVICENAME=PCB Utilities
DEVICEDRIVER=C:\...installation_path...\PCBUtils\PCBUtils.dll
DEVICE_PHYSADDR=0
For the cycle, the entry in the INI file would be like, depends on device number
and installation path;
[DEVICE9]
DEVICENAME=Cycle
DEVICEDRIVER=C:\...installation_path...\PCBUtils\Cycle.dll
DEVICE_PHYSADDR=0
Additionally the pipettor needs further information:
[Pipettor]
Machine=FPS
LongTips=4845
ShortTips=2440
TipsLeft=1
TipsRight=0
TipLenLeft=3
TipLenRight=3
Polar=0
Direct=0
CooFile=C:\...user software path...\koordina.dat
Entry: Meaning:
Machine Machine: 4-Plate-System: FPS
LongTips Length of long tips in steps (4845)
ShortTips Length of short tips in steps (2440)
TipsLeft Number of needles on left arm: 0
TipsRight The same for the right arm
TipLenLeft 0
TipLenRight The same for the right arm
Polar 0
Direct 0
CooFile Path and name of the coordinates-file
Table 5-2: Meaning of further information for pipettor

Service Software
5.2.3 COM Ports

The gSERVICE application only supports a limited set of COM ports. Within the
gSERVICE.INI file is the directive [PORTMAP], that informs gSERVICE if the default
COM port1 is not available and to use another.
[PORTMAP]
COM1=COM2
The above entry within the INI file will use COM port 2 to communicate to the system.
The default is to use COM1. To edit the file to make the above change, open with
notepad.
If COP port is changed, you must also change the teacher by opening and
editing the 4PScoo.ini file ([COMPORT] PortNo=1).
5.3 Replacement of Service Software
To uninstall the software:

1. Select the Control Panel, which you can access from the START but-
ton, Setti ngs...
2. Select the Add/Remove Programs icon.
3. Find in the list of software, which can be automatically removed, the entry for
the Service software.
4. Select Servi ce.
5. Click the Add/Remove button.
The sub-directory is locked so it is likely you will be prompted during the proc-
ess that certain files can not be removed at this time, select the reboot button
if this occurs.
6. At the end of the process you may be requested to Restart your computer,
select this option.
5.4 Start of Service Software
The main application gSERVICE must be run to access any of the service modules.
The service modules will not run by themselves.
If the teaching software or the user software was running before, this program
has to be closed!
To start gSERVICE.EXE, double click the icon. Before the application starts you must
enter the service software password.

Service Software
Figure 5-1: Service software log-on screen
The user name (if entered) will become the default value used in reports, but can be
overwritten. If a password is not entered, no EEPROM values can be changed.
Figure 5-2: Service software main window
The list of available drivers will vary depending on what you have installed and the
contents of the INI file. The window on the right hand side will show the communica-
tion log.
5.4.1 About Service Software

Displayed in the top left hand corner is the Service Sof tware icon, clicking on
the icon displays a drop down menu, with the standard Move and Cl ose (Alt +
F4). Below this is the menu item About Service Soft ware…. This displays
an about box, showing the versions of all components.

Service Software
Figure 5-3: About service software dialogue
When reporting any problems with the software, please include this information.
5.4.2 Load Module Driver

Loads the selected driver and opens its main dialogue. If the driver is already loaded,
only the dialogue is shown.
5.4.3 Activate all Drivers

Loads all drivers in the list without displaying the dialogues.
5.4.4 Low Level Command

When the low level commands button is pressed, the following dialogue box is dis-
played to allow the user to select or enter a low level command.
Figure 5-4: Low level commands dialogue
Refer to module specifications for low level commands. Typing 44 41 04 49 and

clicking Send will send the ABORT to the washer which will abort a current wash
or aspirate operation for instance.
The drop down list box displays the commands as described in the INI file, under the
[LOW_LEVEL] directive. Data in command box must be correctly formatted.Example
(gService.INI):
[LOW_LEVEL]
COMMAND1=FD CF FF FF 00 00 10 00
Send To Port allows for different COM port to be selected.

Service Software
5.4.5 Write Global Parameters

Lets you select a new global data file (*.glb) and calls the WriteGlobalVar(CGlobFile
* pMyFile) function of each loaded driver. Forces all activated dll's to write any useful
parameters into a specified file. Uses Microsoft Windows Save As dialogue
box.This will write a global file of all active dll's parameters. Within some loaded dll's,
it is possible to write their parameters only. When either the global file containing oth-
er module parameters or a module only parameter file is loaded by a module dll, only
that module parameters are overwritten.
5.4.6 View Global Parameters

Shows the content of a selected global data file. Each module parameter is identified
by its module ID number, the following shows typical parameters for a reader and
washer module:
Figure 5-5: Global parameters
5.4.7 Hex View

Invokes the Hex View Parameter dialogue.
Figure 5-6: Hex view parameter dialogue

Service Software
5.4.8 Port Status

Returns current status of communication port.
5.4.9 Terminate Program

Unloads all active drivers and exits the service program.
5.5 Results of the Service Software
All modules generate result files. The result files are in a special folder in the service
software folder. The name of the special folder is gSddmmyy (dd=day; mm=month;
yy=year). The following table shows the names of the result files:
Module: File:
COP CPxxxxxx.txt
Incubator INxxxxxx.txt
Plate Transport PLxxxxxx.txt
Rack RAxxxxxx.txt
Reader RDxxxxxx.txt
Washer WAxxxxxx.txt
Table 5-3: Result files (xxxxxx=Number)
Show a result file with the Microsoft Notepad:

2. Select the directory 'C:\Program Files\...service software path...\gSddmmyy'.
3. Open a result files.

Photometer
6 Photometer

Module uses halogen lamp, it will be hot even after short periods of use
and takes time to cool down. Handle with care!
Don't weight the complete opened drawer! The analyzer could tip for-
ward!
Take care not to touch any optic surfaces!
Every time the photometer module or plate transport is disturbed, the calibra-
tion of the positions used to insert and remove plate carriers must be re-
viewed and potentially re-calibrated. Please refer to the plate transport
section for detailed information (see chapter 8 on page 8-1).

Photometer
6.2 Overview
The absorbance photometer module has eight way optics with a ninth reference
channel. It uses up to 8 interference filters, between the range of 400 nm and
700 nm. A tungsten halogen lamp provides the light source.
Figure 6-1: Photometer module

Photometer
Figure 6-2: Photometer mechanical architecture

Photometer
6.4 Description of Connections
Figure 6-3: Reader top view without cover schematic
Figure 6-4: Power and signal cable

Photometer
6.5 Maintenance
Routine maintenance to be carried out according to published schedules.
Every time the photometer module or plate transport is disturbed, the calibra-
6.5.1 Photometer Adjustment and Testing Tools
Figure 6-5: Absorbance reader adjustment and testing tools
1 Black plate
2 Alignment plate
3 Adjustment plate and two metal pins
4 Reader verification plate
6.5.1.1 Reader Verification Plate

For detailed information on the reader verification plate, refer to its manual. The read-
er verification plate has been designed to provide the following functions:
• Accuracy
To verify measurements are within the stated accuracy of the absorbance
photometer specification and the accuracy, uncertainty of the reference
standard used.

Photometer
• Linearity
To verify measurements are within the stated linearity of the absorbance pho-
tometer specification.
• Uniformity
To verify every optic channel measures the same value, within the stated
accuracy of the photometer specification.
• Alignment
To verify the measurements are taken at the optimum position within the
micro plate well.
• Dynamic Range
To verify the measurements can span the dynamic range as stated within the
absorbance photometer specification.
• Cross Talk
To verify cross talk is below limits that maintain the stated specifications.
• Filter
To verify the correct filter is installed and has no major defects.
• Long Term Drift
To verify the measurements remain constant within the accuracy limits over
time.
6.5.2 Replacement of the Photometer Module
Prior to replacing the photometer module, try to get a screen capture of the
current reader module driver for reference. If you do not follow these direc-
tions, the new photometer module could simulate an out of box failure.
Removal


Photometer
Figure 6-6: Unlocking safety lock of drawer
4. Remove the tip disposal ramp cover and the door for the sample rack area.
5. After the screw on the left side hinge has been removed, the rack door can be
removed.
Figure 6-7: Screw on left side hinge
6. Release the two retaining screws at the back of the photometer.

Photometer
Figure 6-8: Photometer retaining screws to function drawer
7. Remove the two screws on the plate transport bulkhead.
Figure 6-9: Photometer retaining screws to bulkhead
8. Hold the photometer module and disconnect the 15 pin cable connected to
the photometer top cover (see figure 6-4: on page 6-4).
9. Remove the module.
Installation 10. Insert the photometer module in the rear position.

11. Insert the two screws on the plate transport bulkhead, holding the front of the
photometer.
Do not tighten!
12. Insert the two retaining screws holding the rear of the photometer to the func-
tion drawer (see figure 6-8: on page 6-8).
Do not tighten!
13. Tighten the two screws on the plate transport bulkhead and then the two rear
screws.
14. Connect the 15 pin cable to the photometer top cover (see figure 6-4: on page 6-
4).
15. Before the photometer can be verified, the interface to the plate transport will
need to be calibrated.

Photometer
6.5.3 Replacement of Lamp
Module uses halogen lamp, it will be hot even after short periods of use
and takes time to cool down. Handle with care!
In the event of a lamp failure, replace the lamp with the recommended part only. Use
of other lamps is not acceptable.
Removal To replace the lamp:

3. Open the functional drawer completely.
4. Release the two retaining screws on the back of the photometer and pull out
the photometer back.
Figure 6-10: Photometer rear access
Figure 6-11: Open lamp and filter access door
5. Remove the lamp connector.

6. Lift the lamp retaining clip and remove the lamp.

Photometer
Figure 6-12: Lamp removal
Installation 7. Reverse the process after inserting the new lamp.

8. To verify the new lamp, power up the system.
9. Run the verification plate process.
6.5.4 Replacement of Filter
Removal Always use the recommended filter part. Use of other filters is not acceptable.

4. Release the two retaining screws on the back of the photometer and pull out
the photometer back (shown in figure 6-10: on page 6-9 and figure 6-11: on page 6-9).
5. Exchange the filter.
Take care not to touch any optic surfaces!

Photometer
Figure 6-13: Filter replacement
Installation 6. Reverse the process after installing the new filter.

7. Ensure filters are inserted correctly.
• Arrow on filter indicates the direction of light through the filter.
• Filters must be positioned starting from position 1.
• Filters must occupy every position in sequence, no omissions.
8. After a new filter with a different wavelength has been installed the settings
for the filters in the system setup of the user software has to be changed.
9. To verify new filter, power up the instrument.
10. Execute the verification plate process.
6.5.5 Replacement of Primary Optics (Lower Optic

Block)
The lamp shines light through an interference filter onto the collection of 9 plastic fi-
bres directly behind the filter. Each fibre carries the light into the lower optic block. A
lens within the block focuses the light onto the photometer PCB directly above. The
depth each fibre end is inserted into the lower optic block is critical. Incorrect posi-
tioning will cause the light beam to scatter. The depth is set so that the image pro-
jected onto the photo diodes is a crisp, round circle, with no optic aberrations (like
light seals). One method of reviewing the beam is to shine white light (remove a filter)
through the optics and project onto a sheet of paper held where the photometer-
board would be. The circles should all be consistently the same, in line and clearly
defined. This is best viewed in a darkened room.
Removal 1. Remove the photometer module (see chapter 6.5.2 on page 6-6).
2. Remove the photometer cover.
3. Disconnect all cables at the photometer PCB and the plate in sensor fibre
(turn the cap of the connector and pull out the fibre) and remove the photom-
eter PCB.
4. Remove optic fibre bundle (see chapter 6.5.6 on page 6-12).
5. Turn the reader and pull gently the plate in sensor fibre and turn it out of the
lower optic block.

Photometer
Figure 6-14: Lower optic block
6. Remove the six optic block slit screws from top and take it out.
Installation 7. Before installing the new one, check the optic channels and clean if neces-
sary (use oil free compressed air or soft brushes only).
8. Set the optic block slit screws softly.
9. Put in the adjustment plate into the plate sledge (see chapter 6.5.1 on page 6-5).
10. Place it in top of the adjustment holes.
11. Set the metal pins through adjustment plate into the lower optic block.
12. Tighten the six screws.
13. Remove metal pins and adjustment tool.
14. Place the photometer PCB onto the fixing bolts set the metal pins through the
photometer PCB, upper optic block to the lower optic block and tighten the
photometer PCB screws.
15. Connect all cables (see chapter 6.4 on page 6-4).
16. Connect the plate in sensor fibre.
17. Turn the fibre into the lower optic block.
18. Lay the fibre on photometer PCB and push the fibre into the open connector
as deep as possible.
19. Pull back the fibre 1 mm and tighten it.
20. Check the plate-home and plate-in position sledge movement. The sledge init
metal at the belt must move through the light barrier.
21. Place the cover.
22. Install the absorbance reader into the instrument.
23. Connect main cable.
24. Check with the service software, alignment (see chapter 6.6.1 on page 6-17), and
other functions.
6.5.6 Replacement of Fibre Optics
Don't pull at the single fibres!

Photometer
Don't bend the fibres (min. radius 2,5 cm / 1 inch)!
Don't touch the end of fibres!
Removal 1. Remove the photometer module (see chapter 6.5.2 on page 6-6).
2. Pull out the lamp and filter drawer approx. 14 cm / 5,5 inch.
3. Unscrew the fibre tubing clamp near the filter motor and remove it.
4. Turn the absorbance reader on it’s top.
5. Pull out the lamp and filter drawer.
6. Remove single fibre clamp at the lower optic block (see figure 6-14: on page 6-12).
7. Lift the lower optic block and the single fibre tubing carefully without turning
out.
Figure 6-15: Lower optic block schematic
Installation 8. Mount the new fibre bundle in reverse steps.

9. Check assembly by testing with service software.
6.5.7 Replacement of Photometer X-movement

Motor
Removal

4. Remove the photometer cover.
5. Loosen screws 1 and 2.

Photometer
Figure 6-16: Plate transport motor schematic
6. Press the seal and tighten the screws.

7. Lift the belt out of the fixing slits and remove.
8. Disconnect the motor (photometer PCB ST3).
9. Remove screws 3 and 4.
10. Remove the motor.
Installation 11. Install the new motor.

12. Connect the motor to the photometer PCB.
13. Set the belt around the wheels into the belt fixing slits soft tension.
14. Loosen screws 1 and 2, so that the belt is tensioned by the seal.
15. Tighten the screws.
6.5.8 Cleaning of Fibre Optics
Don't pull at the single fibres!
Don't bend the fibres (min. radius 2,5 cm / 1 inch)!
Don't touch the end of fibres!
1. Remove the fibre optic (see chapter 6.5.6 on page 6-12).

2. Place a soft fleece on a flat surface.
3. Press the end of the fibre tubings straight to the fleece and move in a circular
notion.

Photometer
Figure 6-17: Cleaning of fibre optics
4. Rebuild the optic fibres bundle.
6.5.9 Filter Drive

The filter drive should not require any maintenance or calibration during the service
life of the photometer module. The two light barriers provide the feedback path for
the firmware to detect the home position and index to each filter.
Only replace light barriers with the appropriate part.
Figure 6-18: Filter drive
6.5.10 Replacement of Photometer PCB

There are no electronic adjustments to make on the photometer PCB. However, if a
new photometer PCB is installed, it must be fitted using the alignment tools to ensure
the lower optics are correctly aligned. Always observe static precautions when han-
dling any circuit boards.
Prior to replacing the PCB, try to get a screen capture of the current reader
module driver for reference. If you do not follow these directions, the new
photometer PCB could simulate an out of box failure.
Removal 1. Remove the photometer from the system (see chapter 6.5.2 on page 6-6).
2. Remove the top cover of the photometer and disconnect the COM cable.
3. Remove the cables and fibre optic.

Photometer
4. Remove the photometer PCB.
Installation 5. Take the black cover from bottom of the old photometer PCB and put it on
the new photometer PCB.
6. Load the Adjustment plate (see chapter 6.5.1 on page 6-5).
7. Place the new photometer PCB on the standoffs and stick the metal align-
ment pins (see chapter 6.5.1 on page 6-5) through the photometer PCB to the
lower optic block.
8. Tighten the four-photometer PCB screws (see figure 6-21: on page 6-18).
9. Connect the cables and the plate in sensor fibre.
10. Put the cover on and connect the cable.
11. Reconnect the reader to the instrument.
12. Reconnect main power and switch on the instrument.
13. Start service software.
14. Load the reader module driver (DO NOT perform self test!).
15. Upgrade reader firmware (see chapter 6.8.1 on page 6-26).
The values that are displayed after the firmware upgrade need to be
changed!
16. Input wet test filter configuration, test filter 405 nm and ref. filter 690 nm.
17. Input read plate filter settings, test 405 nm and ref. 690 nm.
18. Input filter configuration with filter 1 at 405 nm, filter 2 at 450 nm, filter 3 at
492 nm, filter 4 at 620 nm, filter 5 at 650 nm, filter 6 at 690 nm, filter 7 and fil-
ter 8 at 0 nm.
19. Press on the Wri te Fil ters button to store the information to the EEP-
ROM.
20. Press on the Yes button to confirm.
21. Enter in the field Serial the serial number of the reader.
22. Press on the Set Seri al Number button.
23. Press on the Yes button to confirm.
24. The A/D values should initially be set to 0.
25. Perform the filter drive auto align (approx. 5 min.).
26. Place the alignment plate with holes in a plate carrier.
27. Press on the Auto Ali gnment button.
28. Insert the plate carrier with the alignment plate into the reader either directly
into the reader or via the plate transport.
29. Complete the verification process by running the reader verification plate.
6.5.11 Glass Fibre for Plate Detection

The Plate-in signal is derived from using a Siemens SFH450 V LED device and a
photo-transistor mounted on the PCB. A fibre carries the light from the Siemens de-
vice into the lower optic block. The beam is directed onto a photo-transistor directly
above. When a plate carrier obscures the light beam, the firmware assumes the car-
rier is in position.
If this is not functioning correctly, first check the optical alignment for any obstruction
in the light path.
Otherwise, replace the fibre optic assembly (see chapter 6.5.6 on page 6-12).

Photometer
6.6 Adjustment and Calibration
6.6.1 Adjustment of Optical Axis

4. Open the photometer cover.
5. Loose slit screws at the lower optic block.
Figure 6-19: The slit screws at the lower optic block
6. Place the adjustment plate above the lower optic block (see chapter 6.5.1 on
page 6-5).
7. Stick the metal pins through the lower optic block into the adjustment holes of
the optic block.
8. Tighten all slit screws of the lower optic block.

Photometer
Figure 6-20: Use of the adjustment plate
9. Place the photometer PCB to the bolts and stick the metal pins through the
photometer PCB to the lower optic block.
10. Tighten the four photometer PCB screws.
Figure 6-21: The photometer PCB
11. Connect the cables and the plate in sensor fibre.

12. Replace the cover.
13. Connect the absorbance reader with the PC.
14. Switch on the system.
16. Load the reader module.
17. Perform a self test.
18. Place the alignment plate (with 96 holes) into the sledge.
19. Start the auto alignment test.
20. Complete verification of the photometer can be carried out by executing the
verification plate process.

Photometer
6.7 Service Software
When the photometer (reader) is invoked, the application attempts to communicate

to the system and photometer module. When successful the following dialogue will
be displayed with the version and serial number displayed. Defaults such as instru-
ment offsets will be read from the module EEPROM. If no module is detected, the
version # will be left blank.
Figure 6-22: Photometer service software main window
6.7.1 Functions of the Photometer Service

Software
6.7.1.1 Instrument
Field or Button: Meaning:
Versi on # Shows the firmware version number, if connection is

established with the module.
Serial # Shows the serial number, if connection is established
with the module. The edit allows to change the serial
number.
Set Serial Number Programs serial number. User is warned before any
changes are made.
Table 6-1: Fields and buttons of the Instrument area

Photometer
6.7.1.2 Lamp
Lamp on Turns the lamp ON.

Lamp off Turns the lamp OFF.
Check Lamp Checks lamp status.
Table 6-2: Fields and buttons of the Lamp area
6.7.1.3 Select Filter
Fil ter No Enter the required filter number in the edit box.
Goto Filt er Moves to the selected filter.
Table 6-3: Fields and buttons of the Select Fil ter area
6.7.1.4 Plate Sensor

Status Displays the status of the plate sensor. 'No' repre-
sents no plate, 'Yes' represents plate carrier
detected.
Get Status Updates the plate sensor Status field.
Table 6-4: Fields and buttons of the Pl ate Sensor area
6.7.1.5 Filter Configuration

Allows user to read or set the filter wavelengths.
Fil ters 1 to Fi lters 8 Shows the filter values or when edited allow the val-
ues to be updated (see chapter 6.5.10 on page 6-15).
Read Fil ter Reads the current filter wavelengths and displays
them in the edit boxes.
Wri te Fi lter Writes filter wavelengths from the contents of the edit
boxes.
Table 6-5: Fields and buttons of the Fi lt er Confi guration area

Photometer
6.7.1.6 Plate Alignment
Home to Col .1 The plate alignment values for Home to Col 1

offset will be different for each instrument, it is used
to adjust for the position of well A1 and the drive
home position. It should be checked if the PCB has
been moved - use the alignment test to do this.
I nter col . offset Define the plate dimensions and should be the same
on all readers.
I nter-well offset Define the plate dimensions and should be the same
on all readers.
Read Al ignment Reads and displays alignment parameters in
Home to Col.1, Inter col. off set, and
Inter-well offset.
Set Al ignment Writes values to EEPROM for alignment.
Table 6-6: Fields and buttons of the Pl at e Al ignment area
6.7.1.7 Read Plate

Allows user to read plate using specified measurement wavelength, reference wave-
length, and number of readings.
Test Allows to enter the measurement wavelength.

Ref. Allows to enter the reference wavelength. To read in
single mode, leave reference wavelength blank.
Number of read- Allows to enter the number of readings.
i ngs
Read Pl ate Performs plate read, using parameters defined in the
fields Test, Ref. and Number of readings.
Stati sti cs Displays multiple readings and statistics. When the
number of reads is set below 5, a minimum of 5
reads is used anyway.
Table 6-7: Fields and buttons of the Read Pl at e area
6.7.1.8 Shake
Drives the plate drive in shake mode using the parameters shown in amplitude,
speed, and time edit boxes.

Photometer
Amp. Allows to enter the shaking amplitude. Amplitude will

only accept integers between 5 and 22.
Freq. Allows to enter the shaking frequency.
Time Allows to enter the shaking time.
Shake Shakes for the duration of time, at amplitude and fre-
quency supplied. If amplitude and frequency exceed
the drives capability, a motor error will occur.
Table 6-8: Fields and buttons of the Shake area
6.7.1.9 Reader Test

Allows user to test reader module using parameters defined in wet tests, test filter,
and reference filter.
Test fil ter Allows to enter the measurement wavelength.

Ref. fil ter Allows to enter the reference wavelength.
Modul e Test (see chapter 6.7.2 on page 6-23)
Board Test (see chapter 6.7.3 on page 6-24)
Table 6-9: Fields and buttons of the Reader Test area
6.7.1.10 High Level Commands
Sel ftest (see chapter 6.7.4 on page 6-24)

Ini t Axi s Initialises filter and plate drive.
Vi ew Raw Data Displays selftest results.
Auto Al ignment Executes the auto alignment routine. Requires oper-
ator to have alignment tool.
Verifi cation Pl ate Executes the verification plate tests. Requires opera-
tor to have a verification plate and valid certificate file
for verification plate.
Load Displays a warning message before allowing the
user to select a file containing module parameters.
Save Allows the module parameters to be saved to a file.
Upgrade Firmware (see chapter 6.8.1 on page 6-26)
Table 6-10: Fields and buttons of the High Level Commands area

Photometer
6.7.1.11 Filter Drive Parameter

Allows operator to set filter drive offset

Fil ter Dri ve Offset Set filter drive offset.
Set Off set Writes offset to EEPROM.
Show Moves the filter wheel to position 1 using the current
offset. Set offset must be pressed to change offset.
Auto Al ign Runs auto align software to determine offset. After
completion the user is prompted to confirm new off-
set, filter wheel will be at position 1 with the new off-
set. The user must visually check if offset is correct
before acceptance.
Table 6-11: Fields and buttons of the Filter Drive Parameter area
6.7.1.12 General
Close Closes application

Command Li ne The line at the bottom of the screen displays the
Displ ay devices’ reply.
Table 6-12: General fields and buttons
6.7.2 Test Procedure for Module Test

Runs the sequence of tests that verify correct operation of the reader module. When
the Modul e Test button is pressed, the module test dialogue appears.
The user must update the User field. This data is stored in the results file. Test
modes allow for automatic sequencing through all the tests or allows the user to se-
lect and skip tests manually.
1. Unique identifications
The data report produced will display the User ID, input from the above dia-
logue, as well as the test software version.
2. Firmware download
Allows new firmware to be installed.
3. Serial number
Allows the serial number to be written to the module EEPROM.
4. Parameter test
Verifies current values stored in EEPROM.
5. Filter test
Verifies filter drive.
6. Drive test
Verifies plate drive
7. Plate sensor test
Checks plate-in sensor.

Photometer
8. Selftest
Performs selftest.
9. Plate alignment test
Checks X and Y alignment using a series of offset holes.
10. No plate test
Reads with no plate inserted, testing for 0.000 OD.
11. Black plate
Reads opaque plate, testing for OVER or greater than 3.000 OD.
12. Verification plate test
Reads using the reader verification plate.
13. Wet test plate
Reads plate with reagent and compares multiple readings. Nominal value
1.000 OD.
14. Wet test reference read
Reads plate with reference filter only; low OD expected, typically 0.050 OD.
15. Turn plate test
Reads wet plate, turns plate 180 degrees, reads again to test values are sim-
ilar.
6.7.3 Test Procedure for Board Test

Runs the sequence of tests that verify correct board operation. When the Board
test button is pressed, the board test dialogue appears. The user must update the
User field. This data is stored in the results file.
Test modes allow for automatic sequencing through all the tests or allows the user to
select and skip tests manually.
The data report produced will display the user ID, input from the above dia-
3. Serial number
4. Parameter test
Verifies current values stored in EEPROM.
5. Filter test
Verifies filter drive
6. Drive test
Verifies plate drive
7. Plate sensor test
Verifies plate-in sensor.
8. Selftest
Executes the selftest routine.
6.7.4 Selftest
When the Self test button is clicked, selftest command is processed. Performs the
following tests in sequence:
• Tests the EEPROM checksum
• Moves X-axis home
• Moves Y-axis to each position 1 to 8, then checks that it goes back to home at
position 1.

Photometer
• Measures reference voltages of front end

• Measures photo diode dark background signals
• Tests lamp signals
• Tests each filter for gain and noise
• Measures optic channel transmissions
If an error occurs during any test, the appropriate error response is given and the test
stops (see chapter 17.2.5 on page 17-16).
Otherwise command responds with OK, successful command execution.

Photometer
6.8 Firmware Upgrade
6.8.1 Firmware Upgrade with Service Software

Invokes the Firmware Upgrade dialogue box. It is assumed the new firmware file
*.h86 resides within the reader sub-directory, as described within the INI file.
Figure 6-23: Firmware upgrade dialogue
If direct connection has been selected, you must place the module in bootstrap
mode. The following message box will prompt you to do so.
Figure 6-24: Module bootstrap mode prompt
If power is applied to the board, turn ON Pin 1 of the 4-way DIP switch SW1, and tog-
gle Pin 2. This puts the device into bootstrap mode. If the module power is off, turn
ON Pin 1 and turn ON the module.
Press OK; the download should then start. If the progress indicator does not
change, cancel, cycle the power and repeat the process.
Once the download is completed, you must turn OFF Pin 1, otherwise the de-
vice remains in bootstrap mode and will not operate.
6.8.2 Firmware Upgrade with User Software

To upgrade the firmware:
1. Open the user software.
2. Select Uti li ties | System Setup... from the main menu bar.
3. Click on the Colorimet er tab.
4. Click on the Upgrade Fi rmware button.

Photometer
The file (READ.H86) used to update the firmware must be stored in the PC
software directory (e. g. C:\...user software path...).
5. Follow the instructions.

6. When completed, click the OK button.
If failure during firmware update, please change photometer PCB!

Photometer

Washer
7 Washer

The wash head could have had contact with dangerous material! Pay at-
tention to safety regulations! Always wear gloves!
Don't weight the completely opened drawer! The analyzer could tip for-
wardcould tip forward!
Every time the washer module or plate transport is disturbed, the calibration
of the positions used to insert and remove plate carriers must be reviewed
and potentially re-calibrated. Please refer to the plate transport section for de-
tailed information (see chapter 8 on page 8-1).

Washer
7.2 Overview
The washer module is an 8 way washer with 8 dispense and 8 aspirate tubes. It has
4 reagent bottles, each with their own low level float switch. There is an internal waste
bottle with full alarm and froth trap bottle. A vacuum sensor verifies aspiration air flow.
Figure 7-1: Washer module

Washer
Figure 7-2: Pattern of washer module
1 Washer PCB
2 Aspirate pump, air compressor, vacuum pump
3 Peristaltic pump, waste pump
4 Z- motor, washer lift
5 X- motor, plate transport motor with incremental encoder
6 Dispense pump
7 Dispense manifold
8 Wash buffer fitting
9 Wash buffer alarm
10 Dispense fitting
11 Water trap
12 Wash head axle
13 Wash head arm
14 Dispense valve, solenoid valve
15 Wash head
16 Vacuum sensor
17 Purge station
18 Plate-in sensor fibre

Washer
19 Plate sledge
20 X-init light barrier
21 Tooth belt
22 Washer fixing screws
23 Wash head init light barrier
24 Filter

Washer
7.4 Fluid Architecture
7.4.1 Wash Buffer Tubing
Figure 7-3: Wash buffer tubing
No Start tube (flow to) End tube Medium
1 Wash buffer bottles 1, 2, 3, 4 CPC quick connector Liquid

2a Manifold out 1/16-1/8 Tube connector Liquid
2b 1/16-1/8 Tube connector Wash head valve in Liquid
3 Wash head valve out Wash comb Liquid
5a CPC quick connector out Tube filter in Liquid
5a Tube filter in Buffer pump in Liquid
Table 7-1: Wash buffer tubing

Washer
7.4.2 Instrument Waste Tubing
Figure 7-4: Instrument waste tubing

Washer
No Start tube (flow to) End tube Medium
4 Waste bottle Waste pump in Liquid

6 Waste pump cassette - Liquid
7 Waste bottle Foam bottle Air vacuum
8a Aspirate pump out With fitting connect to tube Air blow
12
8b Foam bottle Aspirate pump in Air vacuum
9a Wash head Vacuum snorkel Liquid
9b Vacuum snorkel junction Vacuum switch Air vacuum
9c Vacuum snorkel Waste bottle input Liquid
10a Waste pump out Y-fitting Liquid
10b Waste pump wash station Y-fitting Liquid
out
10c Y-fitting CPC quick connector (small Liquid
one)
11 Wash station Waste pump wash station in Liquid
12 Aspirate out 8a CPC quick connector (big Air blow
one)
13 CPC quick connector (big Waste container Air blow
outside)
14 CPC quick connection (small Waste container Liquid
outside)
Table 7-2: Instrument waste tubing

Washer
Figure 7-5: Washer PCB
Connections
Meaning:
LD1 Plate-in sensor (fibre)

ST1 Plate drive - NPN photo transistor
ST2 Head drive - home sensor
ST3 Plate drive - home sensor
ST4 Sensors - dispense level sensors
ST5 Sensors - dispense level sensors
ST7 Pump drives 0, 1 (pump connector 1 and 2)
ST8 Pump drives 2, 3 (pump connector 3 and 4)
ST9 Sensors - ASP flow sensors
ST10 Sensors - DSIP flow sensors
ST12 Sensors - internal waste full
ST15 Pump drives - aspirate
ST16 Pump drives - waste
ST17 Plate drive - stepper motor drive
ST18 Head drive - stepper motor drive (Z-motor)
ST19 Pump drives - pinch (sole) valve drive
ST21 Wash verification interface
ST22 Plate drive - encoder
ST24 Power
ST25 RS232 - COP
Table 7-3: Meaning of washer PCB connections

Washer
7.6 Maintenance
Routine maintenance is to be carried out according to published schedules.
7.6.1 Washer Adjustment and Testing Tools
7.6.1.1 Washer Adjustment Tool
Figure 7-6: Washer alignment plate
The alignment plate is used to set the parallelism of the wash head and the X-drive
offset. It has 2 mm holes in place of the first and last column of wells.

Washer
7.6.1.2 Washer Calibration Tool
Figure 7-7: Washer calibration tool with plate carrier
With the washer calibration tool it can be tested whether the wash head dispenses
uniformly.
7.6.2 Replacement of Washer Module
Removal

4. Disconnect and remove all bottles and waste tubing.
5. Remove the bottle tray.
6. Release the two retaining screws at the back of the washer.
Figure 7-8: Module retaining screw next to waste pump

Washer
Figure 7-9: Module retaining screw next to tubing filter
7. Remove the two screws on the plate transport bulkhead holding the washer
module.
Figure 7-10: Bulkhead retaining screws
8. Move the module out to gain access to the cables.

9. Disconnect the power cable and the serial cable from the washer PCB.
10. Remove the module.
Installation 11. Insert the washer module in the front position.

12. Connect the power cable and the serial cable to the washer PCB.
13. Insert the two screws on the plate transport bulkhead holding the front of the
washer.
Do not tighten!
14. Insert the two retaining screws holding the rear of the washer to the function
drawer.
Do not tighten!
15. Tighten the two screws on the plate transport bulkhead.
16. Tighten the two rear screws.

Washer
7.6.3 Replacement of Vacuum Switch
Removal 1. Remove the washer module (see chapter 7.6.2 on page 7-10).
2. Remove screws at position 'A'.
Figure 7-11: Washer vacuum switch
3. Take the vacuum switch 'D' out of the washer housing.

4. Disconnect cable and tubing 'B' from the vacuum switch.
Installation 5. Install the new vacuum switch.

6. Connect the cables and tubings as shown. The tubings must be air tight at
the vacuum switch.
7. Check that the internal waste bottles are air tightened.
8. Set the vacuum switch into the washer housing, position 'C' behind position
'A'.
9. Set the screws and tighten.
10. Have a look at tubing 'B' and the cable. They must not touch the moving parts
of the plate transport.
The vacuum switch will have to be adjusted in any case! Test the switching
point when connecting all tubing's and wash comb only. The tubing system
must be wet. See chapter 7.8 on page 7-28 for general instructions.

Washer
11. After the installation power on the system.

13. Open the module "washer".
14. Press the Sel ftest button in the menu High Level Commands and
wait until the initialisation routine is finished.
15. Press the Aspi rate on button in the menu Aspi rate.
16. Press the Conti nuous button in the menu Aspirate.
17. For the vacuum switch adjustment you will need a small screw-driver. Stick
through hole 'F' into the adjustment screw 'E'.
Figure 7-12: Vacuum switch adjustment
18. If the Aspirate Flow value is 0, then turn the adjustment screw to the right until
it changes to 1.
19. If the Aspirate Flow value is 1, then turn the adjustment screw to the left until
it changes to 0.
20. Turn the adjustment screw half rotation left. The Aspirate Flow value must
remain on 0.
21. Performance control: The Aspirate Flow value changes to 1 when:
• the waste bottles are not closed tightly or
• the tubing behind the sensor is disconnected.
7.6.4 Replacement and Cleaning of Wash Head
For actions at the wash head it's not necessary to remove the washer.
Removal

4. Remove dispense and aspirate tubing from the back.
5. Remove knurled screws 'A'.

Washer
6. Remove the wash head.
Figure 7-13: Wash head
Cleaning 7. Remove the four screws 'B'.

8. Insert through the 16 washer needles 'D' a stainless steel wire style (the
longer ones are aspirate, the shorter are dispense needles).
9. Wash the drilling across the wash head under running water.
10. Install a new O-seal ´C´ to bolt 'B' if necessary.
11. Close the drillings.
Tighten screws 'B' so they don't squeeze the O-seal 'C' plus 90° up to 180°
degrees.
Figure 7-14: Wash head (chart)
Installation 12. Insert the wash head and tighten knurled screws 'A'.
13. Check by hand free swinging.
Normally it's not necessary to align the wash head.

Washer
7.6.5 Replacement of Peristaltic Pump Motor and

Tubing Cassette
3. To remove the pump motor: Remove the washer module (see chapter 7.6.2 on
page 7-10).
4. Remove the tubing cassette 'A' by pressing the clips 'C' at top and bottom of
the cassette and pulling down the tubing cassette.
Figure 7-15: Peristaltic pump (washer bottom view)
5. Disconnect cable 'F'.

6. Remove the four screws 'B'.
7. T Remove the pump motor.
Installation 8. To install the pump motor: Install a new pump motor.

9. Tighten the four screws ’B’.
10. Connect cable ’F’ (+ brown; - green).
Figure 7-16: Cable connections of the peristaltic pump motor
11. Push the cassette onto the motor axle until the clips snap in.
7.6.6 Replacement of Plate Transport Belt
2. Loosen both screws at position 'D'.

Washer
Figure 7-17: Plate transport belt
3. Push the roller to loosen the belt tension.

4. Tighten the screws ’D’ in this pushed position again.
5. Place the plate sledge 'C' into the very right position.
6. Lift the belt 'A' out of the slits 'B'.
7. Remove the belt.
Installation 8. Install the new belt.

9. Lay it around the rollers.
10. Attach end of belt in the slits 'B’.
Figure 7-18: Plate transport belt (chart)
11. Release both screws at position 'D'.

The belt is tensioned automatically.
12. Tighten the screws ’D’.
7.6.7 Replacement of Aspiration Pump
2. Remove screws 'C'.

Washer
Figure 7-19: Aspiration pump (washer bottom view)
3. Pull off tubing's 'A' after removing clamp.

4. Disconnect cable 'B'.
5. Remove the aspiration pump.
Installation 6. Insert the new aspiration pump.

7. Tighten screws, reconnect tubings and set the clamps.
8. Connect the cable (- brown; + green).
Figure 7-20: Cable connection aspiration pump (chart)
7.6.8 Replacement of Dispense Pump

The four dispense pumps are fitted to the rear of the module.
There are no serviceable parts. When it is faulty then replace it.
2. Disconnect the pump plugs inside of the washer case.
3. Pull down all 4 tubings 'B' from pumps 'A.0 - A.3'.

Washer
Figure 7-21: Dispense pumps
4. Remove both screws at position 'E' and take away the bracket 'F'.
5. Pull the pumps out of the manifold 'C'.
6. Remove 4 screws 'D'.
7. Take away the sheet metal and remove the O-seals inside the manifold.
Figure 7-22: Dispense pump (chart)
Installation 8. Insert new O-seals inside the manifold.

9. Insert new dispense pumps and reassemble.
Pay attention for direction of liquid flow of pump.

Washer
Connect correct plugs. See name at the washer PCB "pump0,1; pump 2,3".
10. The liquid flow of replaced pumps must be adjusted by service software (see
chapter 7.8 on page 7-28).
7.6.9 Replacement of Dispense Valve
To replace the dispense valve or tubings it's not necessary to remove the
washer.
Removal

4. Pull down the silicon tubings 'A' and 'B' from the valve head.
Note the correct silicon tubing connection.

Washer
Figure 7-23: Dispense valve
5. Remove both fixing screws 'C'.

6. Release plug screw 'D' and remove plug.
7. Remove the valve.
Installation 8. Install the new valve.

9. Install the plug.
10. Tighten the plug screw ’D’.
11. Install the silicon tubings 'A' and 'B' from the valve head.
7.6.10 Replacement of Z-motor (Wash Head up and

down Motor)
2. Remove screws 'C'.

Washer
Figure 7-24: Installed Z-motor
3. Push the motor 'A' inside the case 'B'.

4. Disconnect motor plug 'E' from washer PCB.
Figure 7-25: Z-motor
Installation 5. Set the silicon rubber seal 'D' on to the new Z-motor.
6. Install the new parts from the bottom into the washer case.
7. Tighten screws.
8. Connect Z-motor to washer PCB.

Washer
Figure 7-26: Z-motor (chart)
7.6.11 Replacement of Washer Light Barriers
First check the optical alignment and ensure that the light barrier is not dirty
or has fluid on it.
1. Remove the washer module (see chapter 7.6.2 on page 7-10).
Figure 7-27: Washer light barriers
Replace Plate 2. Remove metal bridge 'A'.

Transport Init 3. Disconnect cable from washer PCB (see chapter 7.5 on page 7-8).
and plate-in 4. Pull cable to the top of the washer.
Light Barrier 5. Replace the light barrier.
6. After reassembling the washer check the movement of the sledge.
7. The metal flag 'D' must break the light barrier 'F' in init position.
8. The height can be adjusted with two screws 'E'.

Washer
Replace Wash 9. Disconnect cable from washer PCB.

Head Init Light 10. Pull cable to the top of the washer.
Barrier 11. Replace the light barrier 'G'.
7.6.12 Plate-in Fibre

The Plate-in signal is derived from using an IR LED device and a photo-transistor
mounted above the plate drive. A fibre carries the light from the LED device into a
bolt mounted underneath the main chassis. The beam is directed onto a photo-tran-
sistor directly above. When a plate carrier obscures the light beam, the firmware as-
sumes the carrier is in position (see also chapter 7.3 on page 7-3 and chapter 7.5 on page 7-8).
Figure 7-28: Plate-in sensor
7.6.13 Replacement of Washer PCB

There are no settings on the circuit board.
2. Remove all the connectors.
3. Release the PCB from its 4 retaining bolts.
Installation 4. Install the new PCB.

5. Set all DIP switches "off".
6. Install all the connectors.
7. Install the washer module (see chapter 7.6.2 on page 7-10).
8. After the PCB is replaced, the calibration procedure will need to be executed.
7.6.14 Internal Waste Bottle and internal Froth Trap

Bottle
Waste bottle and froth trap must be air tight. Ensure O-seals are used to provide
good air seal.

Washer
Figure 7-29: Internal froth trap bottle (left) and internal waste bottle (right)
No.: Description:
1 Internal waste bottle

2 Internal froth bottle
3 Tubing between internal waste bottle (red mark) and water trap (out-
put)
4 Tubing between internal waste bottle (grey mark) and peristaltic
pump (input)
5 Liquid level detection sensor cable
6 Tubing between internal waste bottle (yellow mark) and internal froth
trap bottle (yellow mark) and
7 Tubing between internal froth trap bottle (black mark) and aspirate
pump (input)
Table 7-4: Description

Washer
7.7.1 Alignment of Wash Head

4. Put the alignment plate into the plate sledge.
5. Loosen the two fixing screws 'A' of the wash head.
Figure 7-30: Wash head fixing screws
6. Put the aspirate needles (see figure 7-14: on page 7-14) into the drillings of the
alignment plate.
7. Tighten the two fixing screws 'A' of the wash head.
For rough alignment:
• Loosen the two fixing screws 'B' of the wash head arm.

Washer
Figure 7-31: Fixing screws of the wash head arm
8. Tighten the two fixing screws 'B' of the wash head arm after rough alingn-
ment.
9. Check the alignment with service software (see chapter 7.8.3 on page 7-35).
10. Check default heights of the dispensing needle during washing with the user
software system setup.
7.7.2 Adjustment of Washer Bottles Float Switches

The orientation of the float on the float switch sets the switch action, normally opened
or normally closed.
Figure 7-32: Adjustable float switch
Adjustment float switch length on 1 or 2 litre washer bottles:

1. Open the screw.
2. Adjust the float switch to the correct length value L.
• 1 litre bottles: Length = 168 +/- 1 mm
• 2 litre bottles: Length = 183 +/- 1 mm

Washer
Figure 7-33: Float switch length
3. Tighten the screw.
7.7.3 Volume Calibration of the Washer

1. Start the service software and the washer driver module.
2. Press on the Cal ibrate button.
The message "Do you want to perform a gravimetric calibrate using labora-
tory scales?" will appear.
• If you select Yes, please follow the known calibration procedure using
a scale.
• If you select No, please select the Channel and follow the following
procedure:
3. Load the washer calibration tool (see chapter 7.6.1 on page 7-9) into the washer
(opening is equal to strip 1).
4. Press the OK button to confirm the message "Please load the Volume Cali-
bration plate in the Washer".
5. At the end of the calibration step remove the washer calibration tool.
6. Move the washer calibration tool into vertical position.
7. Add up all eight values and divide by eight.
8. Insert the value into the Vol ume (µl ) field.
9. Press the OK button.
10. Empty the washer calibration tool.
11. Place the washer calibration tool back into the washer.
13. Repeat this for all four channels.

Washer
7.8 Washer Service Software
When the washer module is invoked, the application attempts to communicate to the
system. When successful, the following dialogue will be displayed with the version
and serial number. Defaults, such as instrument offsets will be read from the module
EEPROM and shown. If no module is detected, ??? will be shown for the version.
Figure 7-34: Washer main window

Washer
7.8.1 Functions of the Washer Service Software
7.8.1.1 Instrument
X Of fset X-offset of the wash head. Automatically set by the

alignment function (see page 7-34)
Z Offset Z-offset of the wash head. Automatically set by the
alignment function (see page 7-34).
Set offset s X-offset and Z-offset edit boxes provided; Pressing
set offsets sends offsets to module.
Versi on Shows the firmware version number, if connection is
Serial Shows the serial number, if connection is established
number.
Set Serial number Sends contents of Serial Number edit box to
washer. It will only accept up to 10 alphanumeric
characters. Warning displayed when request to
update.
7.8.1.2 Plate Sensor
Status Displays the status of the plate sensor. 'No' repre-

sents no plate, 'Yes' represents plate carrier
detected.
Get Status Updates the plate sensor Status field.
Table 7-6: Fields and buttons of the Pl at e Sensor area
7.8.1.3 X-Motor
Allows user to control the X-motor (plate drive).
Home Moves to the home position.

Move to Enter coordinate in edit box provided.
Energi se Energises coils of motor, locks motor.
De-energi se De-energises coils of motor, allows motor to free run.
Table 7-7: Fields and buttons of the X-Motor area

Washer
7.8.1.4 Z-Motor
Refer to X-motor. Allows user to control the Z-motor (wash head drive).

The values assigned to the parameters within this section are used for other se-
quences and command buttons. It is important that they are set correctly when run-
ning the calibration, accuracy, repeatability, and residual tests within the module test
as the tests will fail otherwise.

Washer

Reagent Numbers 0 to 3.
• 0 = RED channel
• 1 = BLUE channel
• 2 = YELLOW channel
• 3 = BLACK channel
First Strip First strip number defaults to 1
Last St ri p Last strip number defaults to 12, therefore default is
for whole plate.
Wash Cycles Number of cycles to wash defaults to 1, range 0 to
100.
Top Wash Top wash duration defaults to 1000 ms.
Disp. Speed Dispense speed, 255 is equivalent to 100 %. (See
note)
Top Height Defaults to 20.
Min. Cycl e Ti me Sets the minimum cycle time defaults to 0, no delay.
Aspi rate Height Defaults to 170.
Aspi rate Mode Always ensure the correct sweep mode is selected
for the plate used: No sweep for U plates, Sweep for
flat and V type plates.
Purge Speed Default is 255. Purging is most effective at the fastest
speed.
Time Purge time defaults to 2000 ms.
Purge Purges reagent channel. Edit boxes for purge speed
and time (ms) provided. Purging is most effective
when the highest speed (255) is used.
Dispense as head If this item is selected, the wash heads dispenses
rises wash fluid already while moving upward.
Bottom Cycles Number of bottom cycles defaults to 0, range 0 to
100.
Bottom Wash Duration of bottom wash defaults to 500 ms.
Bottom Hei ght Height of head during bottom wash operation
defaults to 100.
Wash Washes plate using the parameters assigned.
Partial Mode Defaults to ASAP, other option Constant. (See note)
Aspi rate Aspirates plate using the parameters assigned.
If you pause the wash process, do not immediately click on Abort or Con-
ti nue , wait until the washer has paused, before selecting either Abort or

Washer
Conti nue . If you press Abort too early, flooding may occur! Pressing
Selftest will reset the module.
Dispense speed ranges from 0 to 255. This equates to a frequency drive to

the dispense pump. 255 is equivalent to 50Hz and 0 is equivalent to 10Hz.
However, the 100% used in the user software can be adjusted by the rate 100
parameter (in the registry of the application software) to lower frequencies
than 50Hz. Typically this parameter is 75%, i.e. 191.
Partial mode is used to alter the method of washing when less than 12 strips
are being washed. ASAP means the plate will be washed as soon as possi-
ble. Constant means that the wash time will be the same as for a full plate.
If you pause the aspirate process, do not immediately click on Abort or

Conti nue . Wait until the washer has paused, before selecting either Abort
or Continue . If you press abort too early, the aspiration cycle will not move
home correctly. Pressing Selftest will reset the module.
7.8.1.6 Dispense
Allows user control of dispense pumps.
Running the pump with full reagent bottles connected will result in flooding.

Washer
Pump Allows to enter the pump number (0 - 3)

Speed Dispense speed.
Pump on Turns on the pump selected from list, pump #, pump
speed determined by contents of edit box for speed.
Pump of f Turns pump off.
Fire valve for Edit box to enter time in ms, pressing 'Fire Valve for'
button will activate the valve for the period of time
given.
Sensors Displays sensor float status for reagent pumps, the
first position is reagent 0. 0 = reagent present, 1 =
empty. Example 0101 would indicate reagent 0 & 2
present, reagent 1 & 3 empty.
Get status Updates the sensor float status of the Sensors
field.
Table 7-9: Fields and buttons of the Dispense area
7.8.1.7 Aspirate
Aspi rate On Turns on the aspirate pump.

Aspi rate Off Turns off the aspirate pump.
Waste On Turns on the waste pump (peristaltic pump).
Waste Off Turns off the waste pump.
I nternal Sensor Displays internal float switch (full) sensor status. 0 =
Okay, 1 = Fluid Low or low vacuum.
Aspi rate Flow Displays aspirate flow sensor. 0 = Okay, 1 = Fluid
Low or low vacuum.
Get Sensor Status Updates the sensor float status of the Internal
Sensor and Aspi rate Fl ow fields.
Continuous Continuous aspirate sensor check that updates dia-
logue until Abort pressed.
Table 7-10: Fields and buttons of the Aspi rate area
The external float switch connection is not used. The system waste sensor is
connected to the COP (see chapter 15.4.1 on page 15-6).

Washer
7.8.1.8 Cycle
X Dri ve Enables the X-drive for cycle test.

Z dri ve Enables the Z-drive for cycle test (12 movements to
simulate a full plate per cycle).
Aspi rate/Waste Enables aspirate/waste function for cycle test.
Dispense Enables dispense function for cycle test.
Cycl e Starts the cycle test.
Table 7-11: Fields and buttons of the Cycle area
7.8.1.9 Miscellaneous
Al ignment (see chapter 7.8.3 on page 7-35)

Cali brate Runs the calibration process. Follow the instructions
in each dialogue box. Requires empty plates and
precision scales.
Read Pl ate. .. Allows a plate dispensed from the washer using a
dyed solution to be read in the reader module. This
allows the C.V. across the plate to be calculated from
each OD reading.
Load... Loads the module alignment parameters from a file.
Modul e Test... (see chapter 7.8.4 on page 7-36)
Board Test... (see chapter 7.8.5 on page 7-37)
Save Saves the current module alignment parameters to
file. It uses the standard file dialogue.
Upgrade Firmware (see chapter 7.9.1 on page 7-39)
Table 7-12: Fields and buttons of the Miscel laneous area
7.8.1.10 General

Close Closes application.
Command Line The line at the bottom of the screen displays the
Displ ay devices reply.

Washer
7.8.2 Self Test

When the Sel ftest button is clicked, selftest command processed. It performs the
• Move X-axis home
• X-axis encoder test.
• Move Z-axis home.
• Check the aspirate pump operates.
• Check the dispense pump operates.
7.8.3 Alignment
The "Z-Offset Alignment" is required to guarantee the same wash height parameters
for each individual instrument defined in the assay protocol and in the washer system
set up.
The alignment procedure in the service software calculates a "Z-Offset" which works
like a "Reference point" (point 0), which varies from instrument to instrument due to
mechanical tolerances.
All the defined wash height parameters are based on the reference point.
This means that all wash heights like "Aspirate height", "Top wash height" and "Travel
height" are based on the reference position.
Different Wash Head positions:
• Home position (detected by home sensor).
• Travel height (movement from strip to strip) is equal the reference point (point
0).
• Top wash height: programmed height is added to the reference point.
• Aspirate height: programmed height is added to the reference point.
Alignment proc-
ess
Follow the instructions in each dialogue box!
Requires the washer alignment plate.

2. Select the washer module.
3. Press the Sel ftest button.
4. Press the Al ignment button to start the procedure.
5. After performing the X-alignment the Z-alignment dialogue box will be dis-
played.

Washer
Figure 7-35: Z-alignment dialogue
6. Use the Up and Down keys to move the wash head up and down.
The aspirate pins of the wash head have to touch the flat surface of the align-
ment plate.
7. Confirm by pressing the OK button.
A dialogue box with the offset parameters is displayed.
Figure 7-36: Drive offsets dialogue
8. Confirm the dialogue box by pressing the Yes button to store the offset-
value.

Runs the sequence of tests that verify correct operation of the washer module. When
the Modul e Test... button is pressed, the following sequence is performed. The
User must update the user field. This data is stored in the results file.
The data report produced will display the user ID input from the above dia-
logue as well as the test software version.
3. Serial number
4. Volatile parameters
Verifies default values stored within the EEPROM.

Washer
5. Plate drive
Verifies the Plate drive. Requires a plate drive motor to be attached to the
PCB and the home sensor.
6. Plate-in sensor
Verifies the plate-in sensor.
7. Z-drive
Verifies the Z-drive.
8. Pump control
Verifies the pumps.
The dispense pumps will function in this test. If reagent bottles are connect-
ed, reagent will be dispensed!
9. Level sensors
Verifies the level sensors by detecting a change on each input.
10. Selftest
Performs the self test.
11. Alignment
Verifies correct alignment of wash head. Requires washer alignment tool.
12. Calibration
Calibrates each dispense channel. Requires scales, empty micro plates and
reagent.
13. Dispense Accuracy
Verifies dispense accuracy. Requires scales, empty micro plates and reagent.
One channel should contain reagent that has an OD of approximately 1.000
O.D. at 300 µl using the 405 nm filter. The plate dispensed with the colour
dye is required for the repeatability test.
Channel should use colour reagent. Keep plate for repeatability. The last 'ze-
ro' plate should also be kept for the 'aspirate' test.
14. Repeatability
Verifies washer consistency in dispensing, by using the absorbance reader to
read every well. The plate used from the above 'Dispense Accuracy' test,
using a reagent of known O.D. (water with colour dye) is required. The User
must place the plate into the absorbance reader before selecting Ok. The
C.V. of the plate will be determined, default number of reads is set to 10.
Requires full micro plate of coloured dye from previous test and reader.
15. Aspirate
Verifies the residual volume after aspiration. The 'empty' plate is weighed to
determine the residual volume. Requires scales and 'full' micro plate from dis-
pense test. The last plate of the dispense test should have its empty weight
stored on the scales, therefore use this plate to aspirate from.

Test... button is pressed, the following sequence is performed. The user must up-
date the user field. This data is stored in the results file.

Washer
The data report produced will display the user ID input from the above dia-
logue as well as the test software version.
3. Serial number
4. Volatile parameters
5. Plate drive
Verifies the plate drive. Requires a plate drive motor to be attached to the
PCB and the home sensor.
6. Plate-in sensor
Verifies the plate-in sensor.
7. Z-drive
Verifies the Z-drive.
8. Pump control
Verifies the pumps.
The dispense pumps will function in this test. If reagent bottles are connect-
ed, reagent will be dispensed!
9. Level Sensors
Verifies the level sensors by detecting a change on each input.
10. Selftest
Performs the self test.

Washer

Invoke the firmware upgrade dialogue box. It is assumed the new firmware file *.h86
resides within the washer sub-directory, as described within the INI file. Otherwise
you may browse all available drives.
Direct connection allows upgrade using a RS232 cable directly connected to a PC.
mode, the following message will prompt you to do so.
gle Pin 2. This puts the device into Bootstrap mode. If the module power is off, turn
ON Pin 1 and turn ON the module.
change, Cancel , cycle the power and repeat the process.

2. Select Utilities | Syst em Setup. .. from the main menu bar.
3. Click on the Washer tab.

Washer
The file (WASHER.H86) used to update the firmware must be stored in the
PC software directory (e. g. C:\....user software path...).


Plate Transport
8 Plate Transport

ward!
If you have done service actions on the plate transport, it's necessary to do
new calibration (see chapter 8.7 on page 8-25 and chapter 8.8 on page 8-29)!
If you have done service actions at washer, incubator, photometer, pipetting

station or stacker, it's necessary to check all positions and if necessary to do
new calibration (see chapter 8.7 on page 8-25 and chapter 8.8 on page 8-29)!

Plate Transport
Figure 8-1: Mechanical architecture of the plate transport (chart)
1 Small cogwheel
2 Big cogwheel
3 Z-motor PCB
4a/b Plate transport Z-high flex cable
5 Z-motor
6 Z-incremental encoder
7 Z-spindle

Plate Transport
8 Y-cog belt fixing

9 Y-axle slide bearing
10 X-incremental encoder
11 X-motor
12 X-transport belt
13 Roller
14 X-motor PCB
15 X-guide rail
16 Z-spindle nut
17 Z-guide block
18 Plate carrier detect light barrier
19 Plate carrier moving sheet
20 X-light barrier (init position)
21 Z-guide ball bearing
22 Z-guide rail
23 Z-light barrier (init position)

Plate Transport
8.3 Electronic Architecture
Figure 8-2: Electronic architecture of the plate transport
4 Plate transport high-flex cable

24 Plate transport PCB
25 Y-motor with encoder
26 Y-init position light barrier

Plate Transport
Figure 8-3: Plate transport PCB
Number: Connection:
ST1 X-motor (high-flex cable)

ST2 Z-motor (high-flex cable)
ST3 Y-encoder
ST4 Stacker light barrier 1
ST5 Y-init position light barrier
ST6 Washer LED
ST7 Door sensor
ST8 Power supply (+ 24V)
ST9 RS232
ST10 Y-motor
Table 8-1: Connections of the plate transport PCB

Plate Transport
Figure 8-4: X- and Z-motor PCB (two boards)
Number: Connection:
X-motor PCB: Z-motor PCB:

ST1 X-motor Z-motor
ST2 X-motor incremental encoder Z-spindle incremental encoder
ST3 Plate carrier detect light barrier N.C.
ST4 X-init position light barrier Z-init position light barrier
ST5 Plate transport PCB (high-flex Plate transport PCB (high-flex
cable) cable)
Table 8-2: Connections of the X- and Z-motor PCB

Plate Transport
8.5 Maintenance
8.5.1 Plate Transport Alignment Tools
8.5.1.1 Shaft X-Drive Alignment Tool

Tool to align the X-guide rails (see chapter 8.6.2 on page 8-22).
8.5.1.2 X-Gantry Alignment Plate

Tool to align the plate carrier moving sheet and the plate carrier guides (see
8.5.2 Replacement of Plate Transport
Removal

Figure 8-5: Plate transport inside drawer
4. Loosen Y-belt fixing screws 'B'.

Plate Transport
Figure 8-6: Y-belt fixing
5. Compress the spring.

6. Tighten Y-belt fixing screws 'B'.
7. Take out the Y-belt on both sides.
8. Open screw 'C' by holding the screw and turning Y-guiding rod '2'.
Do not damage the Y-guide rail surface!
Figure 8-7: Guiding rod fixing
9. Pull the Y-guiding rod ’2’ to the back of the instrument out of the Y-axle slide
bearings.
10. Disconnect the high flex cable from X-motor PCB (see chapter 8.4 on page 8-5).
11. Disconnect the high flex cable from Z-motor PCB.
12. Lift the plate transport out of the drawer.

Plate Transport
Installation 13. Insert the new plate transport.

14. Connect the high flex cable to the Z-motor PCB.
15. Connect the high flex cable to the X-motor PCB.
16. Insert the Y-guiding rod ’2’.
17. Tighten screw 'C' by holding the screw and turning Y-guiding rod.
18. Insert the Y-belt on both sides.
19. Loosen Y-belt fixing screws 'B'.
20. Tighten Y-belt fixing screws 'B'.
21. It's necessary to do new calibration (see chapter 8.7 on page 8-25 and chapter 8.8 on
page 8-29).
8.5.3 Replacement of Plate Transport PCB
Removal

4. Remove screws 'A'.
Figure 8-8: Plate transport PCB cover
5. Remove the plate transport PCB cover '1'.

6. Disconnect cables from plate transport PCB (see chapter 8.4 on page 8-5).

Plate Transport
Figure 8-9: Plate transport PCB
7. Remove screws 'B'.

8. Remove screws 'C' from the electronic components.
9. Remove the plate transport PCB '2'.
Installation 10. Install the plate transport PCB '2'.

11. Tighten screws 'C' from the electronic components.
12. Tighten screws 'B'.
13. Connect cables to the plate transport PCB.
14. Install the plate transport PCB cover '1'.
15. Tighten screws 'A'.
8.5.4 Replacement of High Flex Cable
To replace the high flex cable use a folded spare part only!
Removal 1. Open the plate transport PCB cover (see chapter 8.5.3 on page 8-9).
2. Disconnect high flex cable from plate transport PCB (see chapter 8.4 on page 8-5).

Plate Transport
3. Disconnect high flex cable from X-motor PCB.

4. Disconnect high flex cable from Z-motor PCB.
5. Remove the faulty high flex cable.
Installation 6. Install new high flex cable.
Figure 8-10: High flex cable
7. Push the high flex cable through the slit in left side of the washer, to plate
transport PCB.
Figure 8-11: High flex cable fixing 1
8. Connect high flex cable to plate transport PCB.

9. Connect high flex cable to X-motor PCB.
10. Connect high flex cable to Z-motor PCB. Set fold ’A’ like in figure 8-11:.
11. Place the high flex cable in the middle of the fixing points at the bottom of the
drawer.

Plate Transport
12. Cover the high flex cable with the protector foil.
13. Fix the high flex cable with rubbers.
Figure 8-12: High flex cable fixing 2
8.5.5 Replacement of Y-Transport Belt
Removal

4. In the back of the Y-guide rail the belt is bent around the roller.
Loose screws 'A'
Figure 8-13: Belt tension adjust
5. Press spring at roller and tighten screws ’A’.

The belt is slack now.
6. Loose nuts at transport unit '1'.
Figure 8-14: Y-transport belt fixing
7. Lift up the slit sheet metal 'B'.

8. Pull out the faulty belt.
Installation
The new Y-transport belt must have a length of 1200 mm +/- 2 mm.

Plate Transport
9. Install the new belt around the Y-motor and belt tension roller.
10. Attach it at the Y-transport.
11. Loose screws 'A' to stretch belt.
12. Tighten screws again.
8.5.6 Replacement of X-Transport Belt
Stretch belt every 12 month!
Removal

4. Loose screws 'A'.
Figure 8-15: Plate transport lift (top view)
5. Press roller 'B' with a screw driver.

6. Tighten screws. The belt is slack now.
7. Remove faulty X-transport belt.
Installation 8. Install new X-transport belt.

9. Put the belt 'C' around the Y-Motor and belt tension roller.
10. Attach the belt at the X-transport.
11. Loose screws 'A' to stretch belt.
12. Tighten screws again.

Plate Transport
8.5.7 Replacement of X-motor
Removal 1. Loose X-transport belt tension (see chapter 8.5.6 on page 8-13).
2. Disconnect cables from X-motor PCB (see chapter 8.4 on page 8-5).
3. Remove screws 'A'.
Figure 8-16: Plate transport lift
4. Remove the faulty X-motor.
Installation 5. Install the new X-motor.

6. Put the X-transport belt around the motor wheel.
7. Set the screws 'A'.
8. Connect the cables.
9. Tighten X-transport belt (see chapter 8.5.6 on page 8-13).
8.5.8 Replacement of Z-motor
Removal 1. Remove the plate transport (see chapter 8.5.2 on page 8-7).
2. Disconnect connector ST1 from Z-motor PCB (see chapter 8.4 on page 8-5).
3. Push out the pin 'A' inside the shaft of the cogwheel '2'.

Plate Transport
Figure 8-17: Z-motor and cogwheels
4. Pull down the cogwheel '2'.

5. Remove screws and cable fixings.
6. Replace the faulty Z-motor.
Installation 7. Install the new Z-motor.

8. Tighten screws and cable fixings.
9. Install the cogwheel '2'.
10. Insert the pin 'A' into the shaft of the cogwheel '2'.
11. Connect connector ST1 to Z-motor PCB.
12. Install the plate transport (see chapter 8.5.2 on page 8-7).
8.5.9 Replacement of X-light Barrier (Init Position)
After replacement the light barrier, the position must be taught!
Removal

4. Disconnect connector ST4 from X-motor PCB (see chapter 8.4 on page 8-5).
5. Remove cable fixings.
6. Remove the X-light barrier ’20’ (see figure 8.2 on page 8-2).
Installation 7. Install the new X-light barrier.

8. Install cable fixings.
9. Connect connector ST4 to X-motor PCB (see chapter 8.4 on page 8-5).
8.5.10 Replacement of Carrier Detect Light Barrier
Removal

Plate Transport

4. Disconnect connector ST3 from X-motor PCB (see chapter 8.4 on page 8-5).
6. Remove the carrier detect light barrier ’18’ (see figure 8.2 on page 8-2).
Installation 7. Install the new carrier detect light barrier.

9. Connect connector ST3 to X-motor PCB (see chapter 8.4 on page 8-5).
8.5.11 Replacement of Z-light barrier (Init Position)
Removal

4. Disconnect connector ST4 from Z-motor PCB (see chapter 8.4 on page 8-5).
6. Remove the Z-light barrier ’23’ (see figure 8.2 on page 8-2).
Installation 7. Install the new Z-light barrier.

9. Connect connector ST4 to Z-motor PCB (see chapter 8.4 on page 8-5).
8.5.12 Replacement of Z-Incremental Encoder
Removal 1. Remove the plate transport (see chapter 8.5.2 on page 8-7).
2. Turn the Z-spindle ’7’ to move the Z-sledge up to the top (see chapter 8.2 on
page 8-2).
3. Remove the dowel sleeve ’A’ of the small cogwheel ’1’.
Figure 8-18: Cogwheels on the bottom side of the lower part
4. Remove the small cogwheel ’1’.

5. Remove the six fastening screws ’B’.

Plate Transport
Figure 8-19: Fastening screws on the bottom side of the lower part
6. Disconnect connector ’ST4’ (see chapter 8.4 on page 8-5).

7. Remove all cables from the cable clamb.
8. Turn the Z-spindlel ’7’ out of the Z-sledge.
9. Remove the lower part of the plate transport.
10. Disconnect the connector on the Z-incremental encoder ’6’.
Figure 8-20: Lower part of the plate transport
11. Open the Z-incremental encoder ’6’.

Plate Transport
Figure 8-21: Open/Close encoder
Figure 8-22: Open/Close of the binding screw
12. Open the small cylindrical pin screw with a small Allen key ’C’.
13. Remove the Z-spindlel ’7’.
14. Press the pin ’D’ with a screwdriver.
15. Remove the top part of the Z-incremental encoder ’6’.
16. Remove the three fastening screws ’E’.
Figure 8-23: Opened encoder
17. Remove the lower part of the Z-incremental encoder ’6’.
Installation 18. Install the lower part of the new Z-incremental encoder ’6’.
19. Install the three fastening screws ’E’.
20. Install the top part of the Z-incremental encoder ’6’.

Plate Transport
21. Insert the Z-spindlel ’7’.

22. Close the small cylindrical pin screw with a small Allen key ’C’.
23. Close the Z-incremental encoder ’6’.
24. Connect the connector on the Z-incremental encoder ’6’.
25. Turn the Z-spindlel ’7’ into theZ-sledge.
26. Insert all cables into the cable clamb.
27. Connect connector ’ST4’ (see chapter 8.4 on page 8-5).
28. Install the lower part of the plate transport.
29. Install the six fastening screws ’B’.
30. Install the small cogwheel ’1’.
31. Insert the dowel sleeve ’A’ of the small cogwheel ’1’.
32. Install the plate transport (see chapter 8.5.2 on page 8-7).

Plate Transport
8.6.1 Alignment of Plate Transport

4. Open the screws 'A'.
Figure 8-24: Plate transport rollers screws
5. Align the plate transport.
The plate transport must be vertical! The distance between plate transport
and housing must be wide enough!

Plate Transport
Figure 8-25: Distance between plate transport and housing
6. Tighten the screws 'A'.

7. Open the screws 'B'.
Figure 8-26: Plate transport – top view (chart)
8. Align the X-drive.
The X-drive must be horizontal!

Plate Transport
Figure 8-27: X-drive alignment
9. Tighten the screws 'B'.
8.6.2 Use of the Shaft X-Drive Alignment Tool
In field do not disassemble the complete plate transport!
1. Insert parts.
2. Place X-transport belt ’12’ around the rollers.
3. Fix the parts with screws.
Don’t tighten the screws!
Figure 8-28: Opened X-drive
4. Insert the "Shaft X-Drive Alignment Tool" ’A’ as shown in the following figure.
The shafts must fit into the tool to guarantee the correct position.

Plate Transport
Figure 8-29: Use of the "Shaft X-Drive Alignment Tool"
5. Tighten the screws and protect with Loctide.
8.6.3 Use of the X-Gantry Alignment Plate
In field do not disassemble the complete plate transport!
1. Insert the plate carrier moving sheet ’19’.
Figure 8-30: Plate carrier moving sheet
2. Fix screws ’B’ and Loctide 222.

3. Insert 4 pins of the "X-Gantry Alignment Plate" ’C’ in the slots of the metal
carrier and tighten the screws of the plate carrier guides ’D’.

Plate Transport
Figure 8-31: X-Gantry Alignment Plate: alignment of the plate carrier guides
4. Insert 2 pins of the "X-Gantry Alignment Plate" ’C’ in the slots of the plate car-
rier moving sheet and move it into the correct position.
Figure 8-32: X-Gantry Alignment Plate: alignment of the plate carrier moving
sheet
5. Tighten the screws ’B’.

Plate Transport
8.7 Teaching
Before leaving the manufacturer the pipettor and the plate transport of the system are
adjusted exactly. Nevertheless, it is recommended to check the settings before start-
ing the system for the first time. This procedure has to be repeated when parts for
maintenance reasons have been changed.
8.7.1 Start Teaching
See service software for general instructions (see chapter 8.8 on page 8-29).
Password Pro- A window will come up to enter the password to have access to the service software.
tection 2. For editing, the 'High Level Password' must be entered. For checking, the
'Low Level Password' can be used.
3. Before you start to teach in different positions from the plate transport, the fol-
lowing modules must be initialised:
• Reader
• Washer
• Incubator
Reader 4. Load the reader module and press on the Sel ftest button.
The reader is checked and initialised and has to came back with the message
Sel ftest OK in the status line.
Washer 5. Load the washer module and press on the Selft est button.
The washer is checked and initialised and has to came back with the mes-
sage Selftest OK in the status line.
Incubator 6. Load the incubator module and press on the Sel ftest button.
The incubator is checked and initialised and has to came back with the mes-
sage Selftest OK in the status line.
7. Enable the Override box for incubator 1 to 4 in the Shake control
field.
8. Press on the Set Paramet ers button.
The magnets in all incubator chambers are switched on to have a defined
condition for load/unload position for the plate carriers.
8.7.2 Continue Teaching the Plate Transport

1. Load the plate transport module.

Plate Transport
2. Press on the Selftest button.

The plate transport is checked and initialised and has to come back with the
message Selftest OK in the status line. Also the plate transport moves to
the home position.
There are 20 positions stored within the module. Each position must be
taught.
3. Press on the Edit Posi tion button.

The adjust positions window gives access to all positions to teach in.
4. Place a plate carrier on to the plate transport.
Washer Posi- 5. Select in the Positi on area Washer.

tions The currently stored coordinates are displayed in the XYZ fields.
6. Press on the Move To... button.
The plate transport is moving to the current X- and Y-positions.
7. Press on the De-energise XYZ button.
The X-, Y- and Z-motors are switched off.
8. Move the plate transport by hand to the correct Y-position.
9. Use a screwdriver and move the plate transport by turning the lead screw to
the correct Z-position.
10. Move the plate carrier per hand into the module to get the correct X-position.
11. Press on the Get XYZ Posi tion button.
In the window below the transfer button the actual positions of XYZ are dis-
played.
X-axis Use the Transfer button to update the position.

Y-axis Use the Transfer button to update the position.
Z-axis pick-up Use the Transfer button to update the position.
Z-axis open Value(open) = Value(pick-up) + 6 mm
Z-axis closed Value(closed) = Value(pick-up)
Door mechanism Door fitted disabled / 0 mm
12. Press on the Update Positi on button to store the new coordinates into
the database
13. With the Put and Get buttons check again if the positions are correct and
the plate carrier moves into the module smoothly.
14. Also, check if the plate carrier moves in completely to the end position.
Reader Posi- 15. Repeat washer position steps for the reader positions.
tions
Incubator Posi- Before starting the teaching procedure for the incubator the magnets for the shake
tions mechanism have to be switched on as described in chapter 8.7.1 on page 8-25.
16. Repeat washer position steps for incubator 1 to 4, accept:
X-axis Use the Transfer button to update the position.

Y-axis Use the Transfer button to update the position.

Plate Transport
Z-axis pick-up Use the Transf er button to update the position.

Z-axis open Value(open) = Value(pick-up) + 6 mm
Z-axis closed Value(closed) = 18 mm
Door mechanism Door fitted enabled / 16 mm
Pipette Posi- 17. Repeat washer position steps for pipette position 1 to 4.
tions
Stacker Posi- 18. Repeat washer position steps for stacker position 1 to 4.
tions
Bar Code Start 19. Enter the bar code start positions manually:
Positions
X-axis 3
Y-axis 150
Z-axis (all) Visual check: The laser beam must be in the centre
of the bar code (e. g. value 92.5).
20. Press on the Update Position button.
Bar Code End 21. Enter the bar code end positions manually:
Positions
X-axis 3
Y-axis 10
Z-axis (all) Visual check: The laser beam must be in the centre
of the bar code (e. g. value 92.5).
22. Press on the Update Position button.
8.7.3 Save Plate Transport Coordinates

If all positions are taught, the coordinates must be stored on a disk for backup (disk
is included in the instrument).
Do not overwrite the file with the "manufacturer values".
1. To store coordinates press on the Save button.

The Save dialogue will come up to enter a file name.
2. Select the file name.
It is recommended to add the date to the default name 'PlateTx' to prevent
overwriting of existing files.
3. Press on the Save button.

Plate Transport
8.7.4 Load Plate Transport Coordinates
The coordinates will be loaded into the Posi tion Information area of the
service software. The old coordinates will be lost!
1. Press on the Load button to load plate transport teaching parameters.

2. Press on the Yes button to confirm the warning message.
3. Select the file name in the Load dialogue.
4. Press on the Load button.
The parameters will be transferred into the Positi on Informati on area
of the service software.
8.7.5 Store Plate Transport Coordinates
The coordinates, shown in the Positi on Information area, will be stored

into the EEPROM of the plate transport.
1. Press on the Set Positi ons button.

2. Press on the Yes button to confirm the warning message.
The coordinates will be stored into the EEPROM of the plate transport.

Plate Transport
When the Plate transport is invoked, the application attempts to communicate to the
system and plate transport module. When successful, the following dialogue will be
displayed with the firmware version number and serial number displayed. Defaults
such as instrument offsets will be read from the module EEPROM and shown. If no
module is detected, ??? will be shown.
Figure 8-33: Plate transport service software main window
8.8.1 Functions of the Plate Transport Service

Software
8.8.1.1 Instrument
Versi on # Shows the firmware version number, if connection is

number.
plate transport. It will only accept up to 10 alphanu-
meric characters. Warning displayed when request to
update.

Plate Transport
8.8.1.2 Plate Carrier Sensors
X Axis Displays status of the plate-in sensor on the X-axis of

the plate transport. No displayed if empty. Yes if plate
carrier detected.
#1 - #4 Displays status of the plate-in sensor of the ambient
stacker chambers 1 to 4. No displayed if empty. Yes
if plate carrier detected.
Get status Updates the plate carrier sensors.
Table 8-4: Fields and buttons of the Pl ate Carrier Sensors area
8.8.1.3 Position Information

There are several positions stored within the module. Each position must be taught.
Double clicking the display will automatically show the edit position dialogue box (see
Load... Reads positions stored in a global parameter file.

Save... Writes positions to a global parameter file.
Edi t Positi ons (see chapter 8.8.2 on page 8-32)
Set Posi tions The coordinates will be stored into the EEPROM of
the plate transport (see chapter 8.7.5 on page 8-28).
Table 8-5: Fields and buttons of the Posi tion Information area
8.8.1.4 X-Motor, Y-Motor and Z-Motor

Same for all drives. Each axis can be individually controlled.
Home Moves to drive's home position.

Move to Moves to the position in the edit box. Position set in
tenths of mm, i.e. 10 will move the drive 1.0 mm
away from home.
Energi se Leaves coils of motor energised, therefore locking
the motor.
De-energi se Leaves coils of motor de-energised, therefore
unlocking the motor.
Table 8-6: Fields and buttons of the X-Motor, Y-Motor, and Z-

Motor areas

Plate Transport
8.8.1.5 Door
Door Overri de The access door for the plates has a sensor to detect
its open or closed state. Normally if the door is
detected to be open, no movement of the plate trans-
port will occur. However for service it is possible to
override this safety feature. To disable, check the
door override.
Set Override Sends door override when check box enabled.
Get Status Returns status of door override.
Table 8-7: Fields and buttons of the Door area

Get.. . Using the position displayed in the drop down list
box, pressing this button will get a plate carrier using
the current coordinates.
Put... Using the position displayed in the drop down list
box, pressing this button will put a plate carrier using
the current coordinates.
Move To... Using the position displayed in the drop down list
box, pressing this button will move to that position
using the current coordinates.
This area contains the buttons that control sequences of commands.

Modul e Test.. . (see chapter 8.8.4 on page 8-37)
XZ Test... (see chapter 8.8.6 on page 8-38)
Upgrade (see chapter 8.9.1 on page 8-39)
Firmware...
Table 8-9: Fields and buttons of the Miscell aneous area

Plate Transport
8.8.1.8 Cycle
The user is not prompted to load a plate carrier.
It is unwise to run X- and P-cycles together.
X, Y, Z, and P Each axis, X, Y, Z and P can be enabled for continu-

ous cycling. P is for a position cycle.
Go Continuously cycles enable axis.
Table 8-10: Fields and buttons of the Cycle area
8.8.1.9 LEDs
Washer Provides a white LED to illuminate the wash area. To

turn on the check box must be enabled.
Spare Not used.
Set LEDs Drives LED outputs according to the status of the
check boxes.
Table 8-11: Fields and buttons of the LEDs area
8.8.1.10 General

8.8.2 Adjust Positions

Allows the user to edit and test every position. Pressing the Edi t Positi on button
invokes the adjust positions dialogue.

Plate Transport
Figure 8-34: Adjust positions dialogue
8.8.2.1 Position
Update Posi tion Transfers the data in the X, Y, Z, and door mecha-
nism edit boxes to the data table and stores them in
the EEPROM.
Put... Puts plate carrier into position displayed in drop
down list box using the current values in the data
table.
Get.. . Gets plate carrier from position displayed in drop
down list box.
Move To... Moves to position displayed in drop down list box.
Cycl e... Repeats the put and get function again and again.
The cycle function can be stopped manually.
Table 8-13: Fields and buttons of the Posi tion area
8.8.2.2 X-Axis and Y-Axis

The first field displays the current coordinate for the position. New coordinates can
be written into this field.

Plate Transport
Transfer Transfer button will update the window above the

button with the contents of the gray background win-
dow.
Out Moves out by the value in the spin box. The value is
the number of steps moved relative from the current
position. The new position is shown in the gray box.
In Moves in by the value in the spin box. The value is
De-energi se De-energises or unlocks the motor. Allows the mech-
anism to be moved by hand.
Home Moves to the drive's home position.
Table 8-14: Fields and buttons of the X-Axis and Y-Axis areas
8.8.2.3 Z-Axis
Operates the same as X and Y, but there are 3 heights.

Plate Transport
Open The Open height is the height required to open a

door if present. It is the height that allows the X axis
to enter a module with its prongs below the carrier.
The heights are in millimetres, with zero at the top.
Increasing numbers moves the Z-drive lower.
Pi ck-up Pick-up is the height used to pull in or out a plate
on the prongs. It is a smaller number than the
Open height. Typically, the Z open is exactly 6 mm
greater than the Z pick-up.
Closed Cl osed is the height the drive approaches a door
or module. It should be just above (approx. 2 mm)
the door stops. The size value is used to make a
square obstacle that the drive will avoid (the value
added to the left and right and 2x the value in the Z
below the Closed coordinate).
Transfer Transfer button will update the widow above the but-
ton with the contents of the gray background window.
Up Moves up by the value in the spin box. The value is
Down Moves down by the value in the spin box. The value
is the number of steps moved relative from the cur-
rent position. The new position is shown in the gray
box.
De-energi se De-energises or unlocks the drive. Allows the Z-axis
to be moved manually. A screwdriver can be used to
turn the lead screw.
Home Moves to the drive's home position.
Table 8-15: Fields and buttons of the Z-Axi s area
8.8.2.4 Door Mechanism
Door fi tted Door fitted flag indicates the presence of a door.
Table 8-16: Fields and buttons of the Door Mechani sm area
The edit box allows for a size parameter to be entered that is used to calculate an
obstacle that the drive avoids. This allows the drive not to crash into the door stops.
The value represents a square shape in millimetres. The size value is used to make
a square obstacle that the drive will avoid (the value added to the left and right and
2x the value in the Z below the Cl osed coordinate).

Plate Transport
8.8.2.5 Motors
Get XYZ Positi on Reports the current encoder values in the gray
boxes.
Home XYZ Drives home all axises.
De-energi se XYZ De-energises all the drives.
Table 8-17: Fields and buttons of the Mot ors area
Overrides On Incubator shaking solenoids will be deactivated.

Overrides Off Incubator shaking will stop and solenoids will be acti-
vated to allow load/unload of plates by plate trans-
port mechanism.
Lock Draw Locks the drawer.
Unlock Draw Unlocks the drawer.
Table 8-18: Fields and buttons of the Miscel laneous area
8.8.2.7 General

Close Closes window and returns to main plate transport
window.
8.8.3 Selftest
When the Self test button is clicked, selftest command is processed. Performs the
• Moves X-axis home
• Moves Y-axis home
• Moves Z-axis home.
• Plate carrier detection

Plate Transport
8.8.4 Test Procedure for Module Tests

Runs the sequence of tests that verify correct operation of the plate transport mod-
ule. When the Modul e test.. . button is pressed, the following sequence is per-
formed. The user must update the user field. This data is stored in the results file.
logue box, as well as the test software version.
3. Serial number
4. Parameters
5. Plate-in sensor
Verifies the plate-in sensor. Passed, if set and clear states detected.
6. Door
Verifies door sensor. Passed, if open and closed states detected.
7. LED
Allows user to verify LED drive. Passed, if the user confirms the washer LED
went on and off.
8. Stacker position
Verifies stacker plate-in sensors. Passed, if set and clear states detected.
9. X-motor
Passed, if 5 cycles completed without error.
10. Y-motor
11. Z-motor
12. Shake
Shakes plate carrier drive. Passed, if shake completed without error.
13. Selftest
Performs Selftest. Passed, if selftest completes without error.
14. Position test
Cycles the mechanism to all the positions. Positions are: Load/Unload,
Washer, Reader, Incubator 1, Incubator 2, Incubator 3, Incubator 4, Pipette 1,
Pipette 2, Pipette 3, Pipette 4, Stacker 1, Stacker 2, Stacker 3, Stacker 4, Bar-
code Start, Barcode End.
Passed if 5 cycles completed without error.

Test... button is pressed, the following sequence is performed. The user must up-

Plate Transport
3. Serial number
4. Parameters
5. Plate-in sensor
6. Door
Verifies door sensor. Passed, if open and closed states detected.
7. LED
Allows user to verify LED drive. Passed, if the user confirms the washer LED
went on and off.
8. Stacker position
Verifies stacker plate-in sensors. Passed, if set and clear states detected.
9. X-motor
10. Y-motor
11. Z-motor
12. Shake
13. Selftest
8.8.6 XZ-Test
Runs the sequence of tests that verify correct operation of the X and Z drives of the
plate transport module. When the XZ Test... button is pressed, the following se-
quence is performed. The user must update the user field, this data is stored in the
results file.
3. Serial number
4. Parameters
5. Plate-in sensor
6. X-motor
7. Z-motor
8. Shake

Plate Transport

Invokes the Firmware Upgrade dialogue box. It is assumed the new firmware file
*.h86 resides within the reader sub-directory, as described within the INI file.
If Direct connection has been selected, you must place the module in bootstrap
mode, the following message will prompt you to do so.
ON Pin 1, and turn ON the module.
change, Cancel , cycle the power, and repeat the process.
Once the download is completed, you must turn OFF Pin 1. Otherwise, the de-

3. Click on the Plate Transport tab.

Plate Transport
The file (PLATETX.H86) used to update the firmware must be stored in the
PC software directory (e. g. C:\...user software path...).


Incubator
10 Incubator

Care must be taken when operating and testing this module as heaters
can be at elevated temperatures and may cause injury if touched by us-
er!
ward!
For all actions it's necessary to remove the incubator out of the instrument,
otherwise noted.
If you have done service actions on the incubator, it's necessary to do new
calibration (see chapter 10.6 on page 10-18)!
Every time the incubator module or plate transport is disturbed, the calibra-
10.2 Overview
The incubator module has four chambers only for heating and shaking. The temper-
atures and shake frequencies are software adjustable. The temperature range is
min. 21oC or ambient +5oC to max. 55oC. The frequency to shake is adjustable from
5 Hz to 20 Hz. The amplitude of shaking is fixed 0.5 mm +/- 0.1 mm and will be ad-
justed by the service software.

Incubator
Figure 10-1: Mechanical architecture (chart)
1 Shake PCB
2 Position sensor PCB, sensor
3 Shake solenoid
4 Solenoid fixing plate
5 Anchor plate
6 Plate-in light barrier
7 Plate shake sledge
8 Incubator foam flaps (front side)
9 Upper and lower heating plate with temperature sensor
10 Incubator box insulation
11 Door spring
12 Incubator fan with foam fixing
13 Stacker fan

Incubator
14 Incubator main PCB

15 Solenoid fixing plate
Incubator Posi- • Incubator position 1: Front side of the instrument

tions • Incubator position 4: Rear side of the instrument

Incubator
Incubator PCB
Figure 10-2: Incubator PCB connectors
Number: Connection:
ST1 Incubator box 4 (shake PCB)

ST2 Incubator and stacker fan
ST4 Power supply (+24V)
ST7 RS232
ST8 Ambient temperature sensor
SW1 DIP switch (normally OFF)

Incubator
Shake PCB
Figure 10-3: Shake PCB connectors
Number: Connection:
ST1 Lower heating foil

ST2 Lower temperature sensor
ST3 Incubator PCB
ST4 Upper heating foil
ST5 Upper temperature sensor
ST6 Shaking solenoid
ST7 Position sensor

Incubator
10.5 Maintenance
Every time the incubator module or plate transport is disturbed, the calibra-
10.5.1 Replacement of Incubator Module
Removal

4. Loosen screws 'A' and turn two times only.
Don’t remove the screws!
Figure 10-4: Plate transport cover fixing screws
5. Pull the plate transport cover '1' to the left and remove it.

Incubator
Figure 10-5: Incubator fixing screws
7. Loosen screws 'C' from bottom and turn two times only.
Don’t remove the screws!
8. Pull out the incubator carefully into the plate transport area.
9. Disconnect the RS232, the power supply, and the ambient temperature sen-
sor plugs from the PCB in the back of the instrument.
Installation 10. Connect the RS232, the power supply, and the ambient temperature sensor
plugs from the PCB in the back of the instrument.
11. Put the incubator carefully under the pipetting area.
12. Tighten screws 'B' and 'C'.

Incubator
Figure 10-6: Alignment of incubator module
13. Align the incubator module.
The incubator module must be parallel to the plate transport housing, with a
tolerance of +/- 0.5 mm!
14. Tighten screws 'B' and 'C'.

15. Install the plate transport cover '1'.
16. Close the drawer.
17. Teach the plate transport positions for the incubator (see chapter 8.7 on page 8-
25).
10.5.2 Replacement of Incubator PCB
There are no serviceable parts on the circuit board. If it is faulty then replace
it.
Removal 1. Remove the incubator module (see chapter 10.5.1 on page 10-6).
2. Disconnect all connectors.
3. Remove the four PCB retaining screws.
4. Remove the incubator PCB.

Incubator
Installation 5. Install the incubator PCB.

6. Tighten the four PCB retaining screws.
7. Connect all connectors.
8. Install the incubator module.
9. Calibrate the incubator module (see chapter 10.6 on page 10-18).
10.5.3 Open Incubator Housing
2. Remove the six screws at the bottom first.
3. Remove the bottom sheet metal '3' with stacker fan.
Figure 10-7: Open incubator housing
4. Remove the 14 screws ’D’ as shown.

5. Remove the front sheet metal '1'.
6. Remove the top sheet metal '2'.
Installation 7. Install the top sheet metal '2'.

8. Install the front sheet metal '1'.
9. Tighten the 14 screws ’D’ as shown.
10. Install the bottom sheet metal '3' with stacker fan.
10.5.4 Replacement of Incubator Box
Removal There are four incubator boxes:

1. Open the incubator housing (see chapter 10.5.3 on page 10-9).
2. Disconnect upper heating foil of the selected incubator box.
3. Disconnect temperature sensor of the selected incubator box.
4. Remove the 4 nuts at the bottom.
5. Take the box at the metal and pull carefully (cable move through slits).
Installation 6. Take the box at the metal and push carefully (cable move through slits).
7. Install the 4 nuts at the bottom.
8. Connect temperature sensor of the selected incubator box.
9. Connect upper heating foil of the selected incubator box.
10. Close the incubator housing.

Incubator
10.5.5 Replacement of Shake PCB
There are no serviceable parts on the circuit board. If it is faulty, replace it.
Removal There are four shake PCBs:

1. Remove the incubator box (see chapter 10.5.4 on page 10-9).
2. Remove two screws at the bottom.
Figure 10-8: Incubator box bottom view
3. Remove two screws at the left and right side of the stainless steel box.
4. Remove two screws M4x5 from plate carrier sledge inside the incubator
chamber.
5. Pull at the solenoid fixing plate carefully and remove it (including anchor plate
and sensor PCB.
6. Remove three PCB screws.
7. Move the shake PCB sideways to heat foil cable and lift out.
Between metal case and PCB 3 mm spacers are mounted.

Incubator
Figure 10-9: Replacement of shake PCB
Installation 8. Install the new shake PCB.

Between metal case and PCB 3 mm spacers are mounted.
9. Tighten three PCB screws.
10. Push the solenoid fixing plate careful and install it inclusive anchor plate and
sensor PCB.
11. Tighten two screws M4x5 from plate carrier sledge inside the incubator cham-
ber.
12. Tighten two screws at the left and right side of the stainless steel box.
13. Tighten two screws at the bottom.
14. Install the incubator box.
10.5.6 Replacement of Sensor PCB
After all service actions on the position sensor, programming hall sensor and
calibrate the incubator are necessary!
In field do not change anything!
There are four shake PCBs:
Removal 1. Remove the incubator box (see chapter 10.5.4 on page 10-9).
2. Disconnect ST7 on shake PCB (see chapter 10.4 on page 10-4).
3. Remove screw at sensor PCB.

Incubator
Figure 10-10: Sensor PCB at the solenoid fixing plate
4. Lift sensor PCB out of centre bore.
Figure 10-11: Sensor PCB
5. Remove Sensor PCB.
Installation 6. Install the new sensor PCB.

Incubator
Figure 10-12: Sensor PCB and position magnet
7. Tighten the screw at sensor PCB.

8. Connect ST7 on shake PCB.
A software calibration is necessary after reassembling the incubator. Use the

service software to start the calibration.
10.5.7 Replacement of Shaking Solenoid
2. Disconnect shaking solenoid at shake PCB (see chapter 10.4 on page 10-4).
3. Loosen screw inside the solenoid fixing plate in top of the solenoid.
Figure 10-13: Part top view to shaking solenoid
4. Pull out the solenoid to the back.

5. Carry the cable through the drilling at the bottom of the fixing plate.

Incubator
Installation 6. Set the silicon washer onto the position magnet at the anchor plate (see
figure 10-12: on page 10-13).
7. Carry the cable through the drilling at the bottom of the fixing plate.
8. Push the solenoid into the fixing plate.
9. The distance between solenoid and anchor plate is set to 2.0 mm +/- 0.1.
10. Tighten screw inside the solenoid fixing plate in top of the solenoid.
11. Connect shaking solenoid at shake PCB.
A software calibration is necessary after reassembling the incubator. Use the

service software to start the calibration.
10.5.8 Replacement of Upper Heater
2. Disconnect cables of the upper heater and the temperature sensor ST4 and
ST5 at shake PCB (see chapter 10.4 on page 10-4)
3. Lift the upper insulation.
4. Lift up the upper heater 2-3 mm from insulation.
5. Press down and pull out all four rivets.
Figure 10-14: Upper heater (view twisted)
6. Remove the heater.
Installation 7. Install the heater.

8. Install the four rivets.
9. Connect cables of the upper heater and the temperature sensor ST4 and ST5
at shake PCB.
10. Use foam rubber to insulate the grommet.

Incubator
10.5.9 Replacement of Lower Heater
Removal 1. Remove the shake PCB (see chapter 10.5.5 on page 10-10).
2. Disconnect cables of the lower heater and the temperature sensor ST1 and
ST2 at shake PCB (see chapter 10.4 on page 10-4)
3. Remove screws sideways of the metal housing.
Figure 10-15: Opened incubator box with lower heater
1 Locking ring
2 Washer metal
3 Washer plastic
4 Bushing
5 Standoff
6 Stainless steel housing
7 Screw M3x4 mm
8 Standoff
4. Lift out plate carrier sledge.

5. Lift up 2-3 mm the heating plate from insulation.
6. Press down and pull out all four rivets.
7. Remove the heater.
Installation 8. Install the heater.

9. Install the four rivets.
10. Install the plate carrier sledge.
11. Tighten the screws side wards of the metal housing.
12. Connect cables of the lower heater and the temperature sensor ST1 and ST2
at shake PCB.
13. Use foam rubber to insulate the grommet.
14. Install the shake PCB.
In front of the lower box insulation iron blocks must be inserted.

Incubator
10.5.10 Replacement of Foam Flap or Flap Spring
2. Remove the ten incubator front screws (see figure 10.5.3 on page 10-9).
3. Remove the foam flap and/or the flap spring.
Figure 10-16: Incubator without front sheet
1 Locking ring
2 Washer metal
3 Washer plastic
4 Standoff
5 Stainless steel housing
Installation 4. Install the foam flap and/or the flap spring.

5. Tighten the ten incubator front screws.
10.5.11 Replacement of Incubator and Stacker Fan
2. The incubator fan is only fixed inside the foam body at the right side of the
incubator.
Pull incubator fan out.
3. Disconnect connector ST2 at the incubator PCB (see chapter 10.4 on page 10-4).
4. Remove the six screws at the bottom (see figure 10-7: on page 10-9).
5. Remove the bottom sheet metal with stacker fan.
6. Remove the four retaining screws of the stacker fan.
7. Remove both fans.
Installation 8. Install the stacker fan.

Incubator
Figure 10-17: Incubator and stacker fan
9. Tighten the four retaining screws of the stacker fan.

10. Install the bottom sheet metal with stacker fan.
11. Tighten the six screws at the bottom.
12. Connect connector ST2 at the incubator PCB.
13. Install incubator fan out.

Incubator
10.6.1 Calibration of the Shake Function
See see chapter 10.7 on page 10-20 for general instructions.
1. Power on the system.

3. Open the module incubator.
4. Press on the Selftest button in the High Level Commands area
and wait until the initialisation routine is finished.
5. Press on the Get Status button in the Shake control area.
6. Press on the Cal ibrat ion Shake button in the High Level Com-
mands area.
7. Load incubator 1 with a full micro plate (250 µl water each well).
8. Press on the OK button to calibrate incubator 1 for 20 Hz.
9. Press on the Update button several times.
The current position will be changed.
Figure 10-18: Shake amplitude calibration dialogue
10. View the average value of the Current Posi tion values.
11. Compare average value with Ideal Posi ti on values. The average value
must be:
Ideal Position >= current position <= Ideal Position + 2%
Example: Ideal Position 121%: Current Position 121 - 123%
12. If the average value isn't correct, then change the value in the Ampli tude
Cal ibration % field and press on the Set Cali brati on button.
13. Repeat steps 9 to 12 until the average value is correct.

Incubator
14. Control visual the shake function in the incubator 1 (approx. 1 mm +/-
0.15 mm).
15. If the average value is correct, press the OK button.
16. The same dialogue box will appear.
Repeat steps 9 to 15 to calibrate the incubator 1 for 5 Hz.
17. The micro plate loading dialogue box will appear.
Repeat steps 7 to 16 to calibrate all other incubators.

Incubator
When the incubator is invoked, the application attempts to communicate to the sys-
tem and incubator module. When successful, the following dialogue will be displayed
with the firmware version and serial number. Defaults such as instrument offsets are
read from the module EEPROM and shown. If no module is detected, ??? will be
shown for the firmware version number.
Figure 10-19: Incubator service software main window

Incubator
10.7.1 Functions of the Incubator Service Software
10.7.1.1 Instrument
No. of Incubators Allows to enter the numbers of the incubators (incu-

bator positions). Value from 1 - 4.
Set No. of Incuba- Used to pass parameter in No. of incubator
t ors edit box.
Versi on Shows the firmware version number if connection is
Serial Shows the serial number, if connection is established
number.
incubator. It will only accept up to 10 alphanumeric
update.
10.7.1.2 Temperature Control

Allows the user to set and control the heaters.
Column: Meaning:
Set poi nt Set point edit boxes for Incubator 1 to Incubator 4 are used to
input set point temperatures. These will only accept integers
between 21 and 55.
Enable Enable check box to enable heaters. When the Set Parame-
ters button is pressed, all set points and enables are sent to the
module.
Lower Displays lower heater temperature. Only updated when Get
t emp Temperatures button is pressed.
Upper Displays upper heater temperature. Only updated when Get
t emp Temperatures button is pressed.
Status Displays 0 if heaters connected, 1 if an error is detected. Only
updated when the Get Status button is pressed.
Ambient Displays temperature of ambient sensor. Only update when Get
Temperature pressed. If the sensor is unplugged 0 is displayed.
Table 10-2: Temperature control

Incubator
Set Temperatures Sends all enabled temperature values (field Set-

Poi nts and checkbox Enable) to the incubator.
Get Temperatures Retrieves current temperatures.
Get Status Retrieves current status.
Get act ual temper- Retrieves current temperatures automatically.
atures
Table 10-3: Fields and buttons of the Temperature Control area
• Set Parameters
Sends set points and enable settings to the module.
10.7.1.3 Shake Control

Allows user to verify shake mechanism.
Column: Meaning:
Fre- Frequency edit boxes for Incubator 1 to Incubator 4 are used to
quency input the chamber shake frequencies; these will only accept inte-
gers between 5 and 22.
Enable Enable check box must be set to shake. These settings are only
updated when the Set Paramet ers button is pressed.
Override Override check box, if set, shaking will stop and solenoids will be
activated to allow load/unload of plates by plate transport mecha-
nism. These are only updated when the Set Parameters
button is pressed.
Cali bra- (see chapter 10.7.2 on page 10-24)
ti on Mi n
Cali bra- (see chapter 10.7.2 on page 10-24)
ti on Max
Status Displays the shake status for the incubator. A 0 indicates that the
shake is good; a 1 indicates the shake is outside acceptable toler-
ances. The status is updated when the Get Status button is
pressed. Once the status has been read the incubator automati-
cally clears the value and sets it to read good (0). The status that
is reported by the firmware is updated every 5 seconds. This
allows for the mechanism to start shaking before an invalid status
is flagged. Whenever new incubator shake parameters are sent
(using the Set Parameters button), the status is also reset
to good (0) by the incubator firmware.
Table 10-4: Shake control

Incubator
Set Parameters Sends frequency, enable, and override settings to

the module.
Set Cali brations (see chapter 10.7.2 on page 10-24)
Get Status Updates the Status fields and the Shake Sta-
tus Detai ls dialogue values.
. .. (see chapter 10.7.3 on page 10-25)
Table 10-5: Fields and buttons of the Shake Control area
For firmware version 2.10 and above the hardware generates a frequency
signal that can be measured by the microprocessor to determine the position
of the shaking mechanism. Details of these additional parameters can be ob-
tained using the '...' buttons alongside the status results; a dialogue box will
be displayed.
10.7.1.4 Plate Carrier Sensors
I nc 1 - Inc 2 Displays status for each chamber of the plate in sta-

tus. No displayed if empty, Yes if plate carrier
detected.
Get Status Updates the plate in sensor status.
Table 10-6: Fields and buttons of the Pl at e Carrier Sensors area

Incubator

Cali brate Shake. .. (see chapter 10.6.1 on page 10-18)
Log Shake... Starts the shaking process and logs the results in a
file.
Accuracy Test... Allows the user to verify the accuracy of each incuba-
tor chamber. Turns ON the heaters and waits up to
12 minutes for all temperatures to reach a 37.0oC set
point. A dialogue box with Devi ce Busy -
Testi ng Temperature Accuracy is dis-
played while heating. When the set point is reached,
a dialogue box is shown requesting the user to enter
an independent temperature measurement. The test
passes if temperature entered is within 0.8oC of the
set point. (36.2oC <=T<=37.8oC).
A suitable calibrated temperature measurement
device must be used to obtain the independent tem-
perature measurement. The temperature device may
need to be left within the incubation chamber for a
period of time to reach the appropriate temperature.
Modul e Test... (see chapter 10.7.5 on page 10-26)
Load Parameters... Displays a warning message before the user can
select a file containing module parameters.
Save Parameters Saves module parameters to a file.
Firmware...
10.7.1.6 General

10.7.2 Calibrations
The calibration values are used to adjust the shake amplitude at various shake fre-
quencies.

Incubator
The 'Min' calibration value is used to adjust the shake amplitude at low frequencies.
This is set for the 5 Hz shake. The 'Max' calibration value (only for firmware 2.10 and
above) is used to adjust the shake amplitude at high frequencies. This is set for the
20 Hz shake (firmware version 2.10 or above).
The values can be manually adjusted and updated using the Set Cali bration
button. Note that these parameters are stored in the EEPROM of the module. Use
the Cal ibrate Shake button to set these calibration values.
10.7.3 Shake Status Details
Figure 10-20: Shake status details

Incubator
Cali brated 0 if the shake self-test calibration has not been performed, 1 if
it has.
Sel f-test This is the shake calibration factor obtained during a self-test
Cali bration calibration.
Override Off This is the position frequency obtained during a self-test cali-
Frequency bration when the shake override is off.
Override On This is the position frequency obtained during a self-test cali-
Frequency bration when the shake override is on.
Lower This will display the lower shake test limit. If the measured
Shake Limit position frequency is below this value, the status of the incuba-
tor will be marked as bad.
Upper This will display the upper shake test limit. If the measured
Shake Limit position frequency is above this value, the status of the incuba-
tor will be marked as bad.
Last Error This displays the last position frequency that was measured
Frequency that caused a bad status to be reported.
Current This is the measured position frequency.
Posi tion
Shake Con- Shows all adjustment steps since the last calibration of the
trol shake mechanism. 15 steps are allowed.
OK Closes the dialogue.
Update This will update the current position frequency and last error
frequency (if the chamber status has gone bad since the previ-
ous status was read).
Table 10-9: Fields and buttons of the shake status details dialogue
10.7.4 Selftest
When the Sel ftest button is clicked, the incubator selftest command is processed.
It performs the following tests in sequence:
• Tests the EEPROM checksum.
• Performs the shake selftest.
This is for firmware 2.10 and above.
• Checks the temperature sensors are reading within a valid range.
• Checks if the heater drives are not open circuit.

Runs the sequence of tests that verify correct operation of the incubator module.
When the Modul e test... button is pressed, the following sequence is per-
formed. The user must update the user field. This data is stored in the results file.

Incubator
3. Serial number
4. Parameters
5. Plate-in sensor
6. Temperature sensors
Verifies temperature sensors.
7. Ambient sensor
Verifies ambient sensor. Passed, if temperature between 5.0oC and 35.0oC
inclusive.
8. Selftest
Performs selftest. Passed, if self test completes without error.
9. Heaters
Verifies heater circuits.
10. Shake mechanisms
Verifies shake circuits.

test.. . button is pressed, the following sequence is performed. The user must up-
3. Serial number
4. Parameters
5. Plate-in sensor
6. Temperature sensors
Verifies temperature sensors.
7. Ambient sensor
Verifies ambient sensor. Passed, if temperature between 5.0oC and 35.0oC
inclusive.
8. Selftest
9. Heaters
Verifies heater circuits.

Incubator
10. Shake mechanisms

Verifies shake circuits.

Incubator

Invoke the Fi rmware Upgrade dialogue box. It is assumed the new firmware
file *.h86 resides within the reader sub-directory, as described within the INI file.
mode. The following message will prompt you to do so.
ON Pin 1, and turn ON the module.
change, Cancel , cycle the power, and repeat the process.

3. Click on the Incubator tab.

Incubator
The file (INCUBATE.H86) used to update the firmware must be stored in the


Pipettor
11 Pipettor

The wash and waste position, and the waste tubings could have had di-
rect contact with dangerous material! Pay attention to safety regula-
tions! Always wear gloves!
ward!
Fill liquid into valve and syringe before starting operation, otherwise the seal-
ing surfaces will damage!
If you have done service actions on the pipettor, it's necessary to do new cal-
ibration (see chapter 11.9 on page 11-58)
The technical X- and Y-coordinates of the pipettor are exchanged with the
displayed messages! I. e., the displayed x-coordinate means the technical y-
coordinate and the displayed Y-coordinate means the technical X-coordinate.

Pipettor
Pipettor
Figure 11-1: Pipettor
1 Pipettor PCB and belt tension cover

2 Pump unit
3 Y-motor cover
4 Pipettor bridge
5 Disposable tip adapter
6 Switch instrument flap

Pipettor
Figure 11-2: Pipettor top view (chart)
4 Pipettor bridge
7 Y-init light barrier
8 System liquid sensor
9 CPC system liquid
10 Instrument cover switch
11 Y-belt tension spring
12 Pipettor PCB
13 Pipettor wash pump
14 Pipettor dispense pump
15 Wash pump PCB
16 Y-motor (DC)
17 High flex cable bridge
18 Y-belt
20 Z-motor
21 X-Z PCB

Pipettor
22 Belt bridge connection left

23 X-motor
24 X-cog rail
25 Belt bridge connection right
X-Sledge
Figure 11-3: X-sledge

20 Z-motor
21 X/Z PCB
23 X-motor
D X-cog wheel
E Z-cog rail break
F X-cog rail bearing
G Z-cog rail bearing

Pipettor
Disposable Tip
Adapter
Figure 11-4: Parts of the disposal tip adapter
A Liquid Level detection cable

B Fixing screw Z-rail
C Teflon tubing link
D Clamp screw pick up
E Z-init pin
F Tip dropping pin
G Tip discarding device
H Metal pick up

Pipettor
11.3 Fluid Architecture
Figure 11-5: Pipettor tubing
5 Disposable tip adapter

9 CPC system liquid
A Stainless steel tube guide
T1 PVC tubing 1000 mm
T2 PVC tubing 150 mm
T3 Teflon tubing 1710 mm

Pipettor
Figure 11-6: Pipettor PCB
Meaning:
ST1 Power supply (+24V)
ST2 RS232
ST3 Modular pump (dispense pump)
ST4 Pipettor bridge
ST5 Y-init light barrier
ST6 Y-encoder
ST7 Y-motor
ST8 Diluter pump (wash pump)
ST9 Waste pump
ST10 Power out (not used)
ST11 Power out (not used)
ST12 Digital in/out Reserve 1
ST16 Monitor
Table 11-1: Connections of the pipettor PCB

Pipettor
Meaning:
F1 3.15L/250V
Table 11-2: Fuses of the pipettor PCB
Switch Meaning: Default:
1 D4 bootstrap OFF
2 Reset OFF
3 P5.14 OFF
4 P5.15 OFF
Table 11-3: DIP switches of the pipettor PCB
Meaning: Colour:
LED 1 Disposal Tip yellow

LED 2 LLD yellow
LED 3 Init red
LED 4 +5 V white
LED 5 +24 V white
Table 11-4: LEDs of the pipettor PCB

Pipettor
11.5 Maintenance
11.5.1 Replacement of Disposable Tip Adapter
Removal

3. Disconnect liquid level detection cable 'A'.
Figure 11-7: Y-sledge bottom view
4. Remove hexagon screw 'B' at disposable tip adapter '5'.

Pipettor
Figure 11-8: Disposable tip adapter
5. Hold the stainless steel Z-guide and pull down the tip adapter '5'.
6. Pull down the teflon tubing from adapter needle 'C'.
Installation 7. Insert the teflon tubing into the adapter needle ’C’ of the new needle adapter.
8. Insert the needle adapter into the Z-axis rack.
The metal pin must be on the back.
9. Tighten the needle adapter with the upper hexagon screw 'B'.
10. Check that the lower hexagon screw 'D' is tight.
11. Put the needle adapter sensor plug 'A' in the socket on the lower side of the
X-sledge.
12. Check the function of the disposable tip adapter (see chapter 11.8.1 on page 11-
57).
13. Check the reference position (see chapter 11.7.4 on page 11-48).
11.5.2 Replacement of Pipettor Tubing
Removal 1. Remove the disposable tip adapter (see chapter 11.5.1 on page 11-9).
2. Remove pump unit and tubing fitting at the dispense pump valve.
3. Pull the tubing back.
Installation
Use only original tubing!
4. Insert the new tubing, beginning at the dispense pump.

5. Insert the teflon tubing into the tubing fitting.

Pipettor
Figure 11-9: Dispense pump valve fitting
6. Install the pump unit and tubing fitting at the dispense pump valve.
Figure 11-10: Pump unit rear side
7. Install the disposable tip adapter (see chapter 11.5.1 on page 11-9).
8. Check sealing after replacement of the tubing.
11.5.3 Replacement of Wash Pump
Removal

3. Remove the cover with wash and dispense pump (see chapter 11.2 on page 11-2).
4. Disconnect the cable.

Pipettor
Figure 11-11: Wash pump (rear side of pump unit '2')
5. Disconnect all tubing's
Pay attention to the system liquid in the tubings!
6. Remove the two retaining screws 'I'.

7. Remove the wash pump ’13’.
Installation 8. Install the new wash pump.

9. Tighten the two retaining screws 'I'.
10. Install the tubings.
Pay attention to the flow direction (see arrows on the pump!
11. Connect the cable.

12. Install the cover with wash and dispense pump
11.5.4 Replacement of Dispense Pump
Removal

3. Remove the cover with wash and dispense pump (see chapter 11.2 on page 11-2).
4. Disconnect connector ’G’.

Pipettor
Figure 11-12: Pump unit '2' (back view)

A Piston fixing screw
B Syringe drive
C Cylinder fixing screw
D Two way valve
E Sensor plug (not used)
F DIP switch
G Main connector (15 pin Sub D)
H Address switch
I Fixing screws 2pcs.
J Fixing screws 8pcs.
5. Disconnect all tubings.
6. Remove the four retaining screws 'J' at the back.

7. Remove the four retaining screws 'J' at the front.

Pipettor
Figure 11-13: Dispense pump (pump unit '2')
8. Remove the wash pump ’14’.

9. Remove the syringe (see chapter 11.5.5 on page 11-15).
10. Remove the two way valve (see chapter 11.5.6 on page 11-15).
Installation 11. Set the arrowhead of the address switch ’H’ to address 0.
12. Set the DIP switches ’F’:
• 1 to 5: OFF
• 6: not used
• 7 and 8: ON
13. Install the two way valve (see chapter 11.5.6 on page 11-15) on the new dispense
pump.
14. Install the syringe (see chapter 11.5.5 on page 11-15) on the new dispense pump.
15. Install the new dispense pump.
16. Tighten the four retaining screws 'J' at the front side.
17. Tighten the four retaining screws 'J' at the back side.
Fill liquid into valve and syringe before start operation otherwise the sealing
surfaces will damage!
18. Connect all tubing's.

19. Connect connector ’G’
20. Install the cover with wash and dispense pump.

Pipettor
11.5.5 Replacement of Syringe
Removal

3. Open syringe fixing screw 'A'.
Figure 11-14: Syringe (pump unit '2')
4. Pull down pump drive 'B'.

5. Turn out the syringe nut at 'C'.
Installation
Fill liquid into syringe before start operation otherwise the sealing surfaces
will damage!
6. Fill liquid into the syringe.

7. Set the cylinder to 'C' tighten nut.
8. Push pump drive 'B' to piston rod.
9. Tighten fixing screw 'A'.
11.5.6 Replacement of Three Way Valve
Preparation To prevent deformation of valve body and valve inlet during storage, the inlet is not
completely pressed into the valve body. The inlet has to be pressed into the valve
before attaching to the dispense pump. Finally check if the valve insert hole is posi-
tioned in the centre of the valve body hole.

Pipettor
Figure 11-15: Delivered condition (left) and assembled condition (right)
Removal 1. Remove the dispense pump (see chapter 11.5.4 on page 11-12).
2. Screw out both tubing fittings 'E'.
3. Remove the syringe (see chapter 11.5.5 on page 11-15).

4. Remove the three screws 'A' in front of the valve.
Figure 11-16: Two way valve (Pump unit '2')
5. Pull down the valve.
Installation 6. Turn valve inlet 'B' to position as shown.

7. Set valve motor 'C' to position as shown.
8. Set valve into coupling.
9. Drive in the three screws 'A'.
10. Insert the valve alignment tool (see chapter 11.7.1 on page 11-44) into the valve.

Pipettor
Figure 11-17: Use of the valve alignment tool
11. Tighten the syringe fixing screw.

12. Tighten the three screws 'A'.
13. Remove the valve alignment tool.
14. Install the syringe (see chapter 11.5.5 on page 11-15).
Fill liquid into valve before start operation otherwise the sealing surfaces will
damage!
15. Fill liquid into the valve.

16. Screw in both tubing fittings 'E' into valve.
17. Install the dispense pump (see chapter 11.5.4 on page 11-12).

Pipettor
11.5.7 Replacement of Pipettor Bridge
Removal

3. Remove the top cover of the instrument.
4. Remove left and right side cover of the instrument.
5. Remove pipettor cover left '1' (see chapter 11.2 on page 11-2).
6. Remove clamp and ferrite 'D'.
Figure 11-18: High flex cable connection on pipettor PCB
7. Pull the cable through the frame.

8. Remove disposable tip adapter '5' (see chapter 11.5.2 on page 11-10).
9. Pull down the pipettor tubing.
10. Remove Z-cog guide.
11. Remove belt bridge connection screws 'A' (see also chapter 11.2 on page 11-2 posi-
tion '22' and '25').
Figure 11-19: Pipettor bridge fixing

Pipettor
Do not loosen bridge adjustment screws 'b' at belt to bridge fixing right side!
Figure 11-20: Pipettor bridge to belt fixing side (left/right)
12. Pull the left and right belt to bridge fixing plate out of the positioning pins 'C'.
13. Pull the bridge gently to the front out of the guides.
Installation 14. Push the bridge gently to the back into the guides.
15. Press the left and right belt to bridge fixing plate into the positioning pins 'C'.
16. Tighten belt bridge connection screws 'A'.
17. Install the Z-cog guide.
18. Install the pipettor tubing and the disposable tip adapter '5' (see chapter 11.5.2 on
page 11-10).
19. Install the high flex cable.
20. Connect the high flex cable connector on pipettor PCB.
21. Install clamp and ferrite 'D'.
22. Install pipettor cover left '1'.
23. Install left and right side cover of the instrument.
24. Install the top cover of the instrument.
11.5.8 Replacement of X-sledge
Removal 1. Remove the pipettor bridge (see chapter 11.5.7 on page 11-18).
2. Remove the four screws 'A'.
Figure 11-21: Bridge guide

Pipettor
3. Pull out the bridge guide 'B'.

4. Remove the X-sledge (see chapter 11.2 on page 11-2).
Installation 5. Insert the X-sledge.

6. Pull in the bridge guide 'B'.
7. Tighten the four screws 'A'.
8. Install the pipettor bridge.
11.5.9 Replacement of Bridge High Flex Cable
Removal 1. Remove the pipettor bridge (see chapter 11.5.7 on page 11-18).
2. Remove the screws 'C' (see figure 11-21: on page 11-19).
3. Remove the X-sledge (see chapter 11.5.8 on page 11-19).
4. Remove high flex cable fixing clip ’A’.
Figure 11-22: High flex cable fixing clip
5. Disconnect the high flex cable from pipettor PCB (see chapter 11.4 on page 11-7).
6. Disconnect the high flex cable from the X-sledge.
7. Remove the high flex cable.
Installation 8. Install the high flex cable.
Figure 11-23: Bridge high flex cable
9. Connect the high flex cable to the X-sledge.

10. Connect the high flex cable to the pipettor PCB.
11. Push the high flex cable fixing clip ’A’ onto the flex cable holder between the
plunger pins.
12. Install the X-sledge (see chapter 11.5.8 on page 11-19).

Pipettor
13. Tighten the screws 'C' (see figure 11-21: on page 11-19).
14. Install the pipettor bridge (see chapter 11.5.7 on page 11-18).
11.5.10 Replacement of Y-belt
Removal

3. Open pipettor metal sheets '1' and '3' (see chapter 11.2 on page 11-2).
4. Loosen screws 'D'.
Figure 11-24: Y-belt tension mechanism (behind metal sheet ’1’)
5. Push the roller to the right side against the spring.

6. Tighten the screws 'D'. The belt is slack now.
7. Open screws 'B'.
Figure 11-25: Pipettor bridge and belt fixing (side left/right)
8. Take away the slit sheet metal where the cog belt is fixed.
9. Pull out the belt.
Installation 10. Insert the new belt.

11. Fix the belt at the slit sheet metal.
12. Set the screws 'B'.
13. Tighten the belt.
14. Adjust the distance Y1 to the front rollers of the right bridge to belt fixing. It
must be the same as left.

Pipettor
Figure 11-26: Left/right distance Y1

16. Adjust the timing of the Y-belt tension (see chapter 11.6.4 on page 11-35).
17. Install pipettor metal sheets '1' and '3'.
All pipettor positions must be taught new!
18. Teach the pipettor (see chapter 11.7 on page 11-44).
11.5.11 Replacement of Y-motor/Encoder
Removal

3. Open pipettor metal sheets '1' and '3' (see chapter 11.2 on page 11-2).
4. Loosen screws 'D’ (loosen belt tension figure 11-24: on page 11-21).
5. Press the roller to the right side against the spring.
7. Disconnect encoder cable 'A'.

Pipettor
Figure 11-27: Y-motor with encoder
8. Disconnect Y-motor cable at pipettor PCB (see chapter 11.4 on page 11-7).
10. Lift out the Y-motor '16'.
Installation 11. Insert the new Y-motor '16'.
Pay attention to the belt guide!
Figure 11-28: Y-belt guiding mechanism

Pipettor

13. Connect Y-motor cable at pipettor PCB.
14. Connect encoder cable 'A'.
15. Adjust the timing of the Y-belt tension (see chapter 11.6.4 on page 11-35).
16. Install pipettor metal sheets '1' and '3'.
11.5.12 Replacement of Waste Pump (on the back

Side)
The waste pump and the waste tubings could have had direct contact
with potentially infectious material! Pay attention to safety regulations!
Always wear gloves!
Removal

of the functional drawer see chapter 6.5.2 on page 6-6).
4. Pull out the waste pump ’A’.
Figure 11-29: Waste pump (on the back)
5. Disconnect connector ’B’.

6. Lay a cloth or a bowl under the waste pump to absorb the residual liquid.
7. Disconnect tubing ’C’.
8. Disconnect tubing ’D’.
9. Remove the waste pump.
Installation 10. Install the new waste pump.

11. Connect tubing ’D’ (from the wash/waste position).

Pipettor
Pay attention to the flow direction!
12. Connect tubing ’C’.

13. Remove the cloth or bowl.
14. Connect connector ’B’.
15. Push in the waste pump ’A’.
of the functional drawer.)
11.5.13 Replacement of Waste Pump (on the Left

Side)
The waste pump, and the waste tubings could have had direct contact
with potentially infectious material! Pay attention to safety regulations!
Always wear gloves!
Removal

of the functional drawer see chapter 6.5.2 on page 6-6).
4. Disconnect connector ’B’ (black).
Figure 11-30: Waste pump (on the left)
5. Disconnect connector ’C’ (brown).

6. Open the two retaining screws ’D’.
7. Lay a cloth or a bowl under the waste pump to absorb the residual liquid.
8. Disconnect tubing ’F’.
9. Disconnect tubing ’E’.
10. Remove the waste pump.
Installation 11. Install the new waste pump.

12. Connect tubing ’F’.

Pipettor
Pay attention to the flow direction!
13. Connect tubing ’E’ (from the wash/waste position).

14. Tighten the two retaining screws ’D’.
15. Remove the cloth or bowl.
16. Connect connector ’C’ (brown).
17. Connect connector ’B’ (black).
of the functional drawer.)

Pipettor
11.6.1 Adjustment of the X- and Z-Axis
A metric steel ruler with 0.5 increments length 500 mm or a standard metric
ruler are recommended.
1. Start the service software (see figure 11.9 on page 11-58).

2. Start the pipettor sub-routine.
3. The following entries must be marked:
• Arm type: Left arm Needle
• Type left: One Needle
• Cartesian Coordinates
4. Press on the OK button.
5. In the next window, press on the Pi pet tor button.
6. Initialise the pipettor by pressing the Left Arm button in the Initi ali ze
area.
The pipettor is now moving to left back corner!
7. If initialising is ready the coordinate window will appear automatically.

Now you must load the following coordinates.
8. In the rack box, you must choose the rack type T. Load it to Track-No. 1
and 12 by pressing the Add button after each input.
9. In the mi cro plates box, choose the default plate type 8x12 and load it
to position 03 and 08.
The coordinates will be sent to the pipettor. If sending is completed, the dis-
play will return the pipettor dialogue box.
11. Set the specified position numbers in the absolute movement box and if nec-
essary, the step value for the Z-axis in the relative movement box.
12. Press the Move button after each input.
13. Activate the Z-axis by setting the button Z.
Test position: Position-No.: Z-steps:

1 2692 0
2 2403 -1500
3 1559 -3000
4 1251 -5000
Table 11-5: Values
14. Now each position must be reached by using the values shown in the table.

Pipettor
15. Check the gear space now and if necessary adjusted by using a ruler as
shown in the picture below. Before adjusting the mechanical space, check
each position.
16. After these mechanical adjustments, all positions must be checked again.
11.6.1.1 Mechanical Adjustment

17. The ruler must be aligned to a fixed point on the arm.
If no such a ruler is available, it must be fixed by another way.
Figure 11-31: Check the X-positions
18. Now the gear space is to be checked by moving the X-sledge manually in X
direction.
Do not use too much force!
19. The back lash must be between min. 0.1 mm/0.2 mm to max. 0.5 mm.
20. If the space is to big or to small it has to be adjusted.
First loosen the motor screw 'A' by using a hex screwdriver of 3 mm.
Figure 11-32: X-motor adjustment screw
21. Adjust by moving the motor.

22. After adjusting tighten screw again.
11.6.1.2 Checking Play of Z-Drive

23. Put the ruler on the top of the X-sledge.

Pipettor
Figure 11-33: Checking play of Z-axis
24. Try to move the gear rod manually up and down.
Use no force!
25. The back lash must be between min. 0.1 mm/0.2 mm and max. 0.5 mm.
26. If the space is not within these limits, the Z-motor space must be adjusted.
First loosen the two screws 'B' on the Z-motor slightly by using a 2.5mm hex
screw-driver.

Pipettor
Figure 11-34: Z-motor adjustment screws
27. Now set the Z-motor in the correct position while checking the movement
space as described above.
28. Tighten screws after alignment.
11.6.2 Adjustment of the X-axis Roller

In some cases the adjustment of the rollers on the sledge are too close to the sheet
metal guiding. The following instructions show how to check the correct adjustment
and how to correct in case of a wrong adjustment.

11.6.2.1 How to Check the Correct Adjustment

3. Fix the sledge with the right hand to ensure the sledge can not move. Then
try with a finger to turn the lower roller (roller with O-ring).

Pipettor
Figure 11-35: Check X-axis roller
Checkup:
• In case the roller is turnable without any friction to the sheet metal guiding
there is too much air.
The roller must be adjusted closer to the sheet metal guiding.
• In case the roller is only turnable with high friction to the sheet metal guiding
there is too much friction by the deformation of the O-ring which can cause a
blockage of the sledge.
The roller must be adjusted away from the sheet metal guiding.
• In case the roller is easy turnable with a low friction to the sheet metal guiding
the adjustment is in the correct level.
No readjustment is necessary.
11.6.2.2 How to Adjust the X-axis Roller

4. Open the lower hex-screw with a 7 mm wrench.
Figure 11-36: Lower hex-screw
5. Turn the eccentric roller screw via the slots in the back of the bridge in clock
or counter clock direction.

Pipettor
Figure 11-37: Turn the eccentric roller screw (back of the bridge)
6. Tighten the hex screw again.

7. Check the correct adjustment again.
11.6.3 Adjustment of the Y-axis Roller

The pipettor bridge is guided at the left side against up and down and at the right side
against up down and left right movement. This is done by two rollers per direction.
These rollers must be adjusted correctly for smooth running and long life. If you ad-
just the rollers, check the teach positions afterwards.

3. Remove the left and right instrument cover.
11.6.3.1 How to Check the Correct Adjustment

4. Fix the bridge with the right hand to ensure the bridge can not move. Then try
with a finger to turn the lower roller (roller with O-ring).

Pipettor
Figure 11-38: Check lower Y-axis front roller
Figure 11-39: Check lower Y-axis back roller
Checkup:
• In case the roller is turnable without any friction to the sheet metal guiding
there is too much air.
The roller must be adjusted closer to the sheet metal guiding.
• Is case the roller is only turnable with high friction to the sheet metal guiding
there is too much friction by the deformation of the O-ring which can force a
blockage of the bridge.
The roller must be adjusted away from the sheet metal guiding.
• Is case the roller is easy turnable with a low friction to the sheet metal guiding
the adjustment is in the correct level.
No readjustment is necessary.

Pipettor
11.6.3.2 How to Adjust the Y-axis Roller.

5. Open the lower screw '1' on the inside of the bridge holder in the bridge or on
the back of the bridge '2'.
There is easy access to the eccentric roller screw via a hole '3' on the pipettor
side panels (therefore remove outer covers). Turn the eccentric roller screw
in clock or counter clock direction to adjust via the eccentrically design of the
roller screw the distance between roller and guiding.
Figure 11-40: Bottom view inside the bridge
Figure 11-41: Rear view of bridge holders

Pipettor
Figure 11-42: Side view from outside on pipettor side panel
6. Tighten the inner screws again.
Never press the o-seal!
7. Check the correct adjustment again.
11.6.4 Adjustment of Timing Y-Belt Tension
Important Back- • A too high adjusted timing belt tension can cause higher friction and so prob-
ground Informa- lems in the positioning of the bridge.
tion • A too low adjusted timing belt tension can cause a jumping of the timing belt
on the timing belt pulley. This is causing faulty positioning of the system which
can not be recognized by the control software. So a too low adjusted timing
belt tension is dangerous!

3. Remove pipettor cover left '1' (see chapter 11.2 on page 11-2).
11.6.4.1 How to Check the Timing Y-Belt Tension
You will need a spring gauge (range min. 20 N) to check the tension.
4. Place the spring gauge as close as possible on the left of the pump unit.
5. Place the hook of the spring gauge around the timing belt in the back.

Pipettor
Figure 11-43: Check the tension
6. Pull the timing belt from the back to the position of the timing belt to the front.
7. Read the necessary force of the spring gauge.
Values of 17-20 Newton are valid. In other cases the tension must be
adjusted.
11.6.4.2 How to Adjust the Timing Y-Belt Tension

8. Loosen screws 'D' (see figure 11-24: on page 11-21).
9. Press the roller to the right side against the spring.
11. Loosen screws 'D' to stretch the belt by the spring '11' (see figure 11-24: on
page 11-21).
12. Tighten screws 'D' again.
13. Check the correct belt tension again.
11.6.5 Free Movement of the Bridge on the Guiding

Mechanism

3. Move the bridge by hand.

Pipettor
4. Take a look on the right roller plate.

5. Check the air between the roller plate and the edge of the sheet metal guid-
ing.
There must be air at least of about 1 mm all across the movement area of the
bridge.
Figure 11-44: Air between the roller plate and the edge of the sheet metal
guiding

7. Take a look on the left roller plate.
8. Check the air between the roller plate and the edge of the sheet metal guid-
ing.
There must be air at least of about 1 mm all across the movement area of the
bridge.
10. Take a look on the lower roller plate on the right side.
11. Check regarding any collisions in this area all across the movement area of
the bridge.

Pipettor
Figure 11-45: Lower roller plate
12. In case of a problem in the upper three areas the bridge must be removed
from the system.
• Remove the bridge (see chapter 11.5.7 on page 11-18).
• Then adjust via the 2 rollers (see figure 11-45: on page 11-38) to the needed
direction (left or right) to fix the collision problem.
• Reassemble the bridge again.
• Check the free movement.
14. Take a look on the foil cable holder plate on the left side.
15. Check regarding any collisions in this area all across the movement area of
the bridge.
16. In case there is a collision with the high flex cable holder or the O-ring fix the
problem by bending the sheet metal part.
11.6.6 Free Movement of the Upper Rollers on

Guiding Mechanism
See also chapter 11.6.7 on page 11-39 regarding missing washer for wear protec-
tion.

3. Place a mark on both white rollers (left and right) for better judgment regard-
ing correct function.

Pipettor
Figure 11-46: Mark on a white roller

5. Take a look on all 4 rollers and check for a correct turning along the sheet
metal guiding.
In case:
• A roller is not turning. Check the roller regarding correct adjustment towards
the guiding. In case there is too much air adjust the roller according to other
rollers.
• The adjustment is ok but doesn't turn. Remove the roller, clean the bearing or
change the roller against a new part.
11.6.7 Wear of the Roller Bearings on the Bridge

Holder
On several 4PS systems (serial number < 50) the following described wear on the
roller bearings can occur. In bad conditions (depending on force directions etc.) a
change of the left and right roller plate against new parts is necessary.
On newer systems (serial number > 50) there is a wear protective washer mounted
between the roller bearing and the aluminium roller plate. This washer protects the
bearing of getting polluted by material of the roller plate.

3. Check all rollers.

Pipettor
Figure 11-47: Detail view into gap between roller and bridge holder
• In case a thin washer is placed between the roller and the plate the following
wear condition can not occur.
• In case of non mounted washers and massive black particles visible between
the roller and the bridge holder must be at least cleaned and lubricated again.
• In case this doesn't help a change of the complete roller plate with the imple-
mented washer is necessary.
11.6.8 Alignment of Z-drive

3. Replace the disposable tip adaptor (see chapter 11.5.1 on page 11-9).
4. Push in the Z-alignment tool into the rack teaching tool. The nose of the Z-
alignment tool shows to the left side (see chapter 11.7.1 on page 11-44).
5. Insert the Z-alignment tool with rack teaching tool into the left positions of the
rack system.

Pipettor
Figure 11-48: Z-alignment tool with rack teaching tool in the left positions of
the rack system
6. Loosen both screws ’1’ of upper Z-axis bearing.
Figure 11-49: Upper Z-axis bearing
7. Loosen both screws ’2’ of lower Z-axis bearing.

Pipettor
Figure 11-50: X-sledge (bottom view)
8. Loosen both screws '3' which fix the Z-motor to X-sledge.

After that the Z-axis gear rack should be moveable up and down without
resistance.
9. Guide the Z-axis gear rack into Z-adjustment tool until it’s completely
inserted.

Pipettor
Figure 11-51: Z-axis gear rack in the Z-alignment tool
10. Tighten both screws ’1’ of upper Z-axis bearing.

11. Tighten both screws ’2’ of lower Z-axis bearing.
12. Push the Z-motor to the right side to define the backlash.
13. Try to move the Z-axis gear rack up and down.
The Z-bar has to move easily without scratching.
14. After right adjustment is reached tighten both motor holding screws '3'.
15. Install the disposable tip adaptor (see chapter 11.5.1 on page 11-9).
16. Adjust Z-bar break after installing disposable tip adapter.
To adjust the right brake force screw in both screws ’4’ until Z-bar doesn’t
move down, on its own.

Pipettor
11.7 Teaching
Before leaving the manufacturer, the pipettor and the plate transport of the system
are adjusted exactly. Nevertheless, it is recommended to check the settings before
starting the system for the first time. This procedure has to be repeated also when
parts for maintenance reasons have been changed.
11.7.1 Teaching Tools
11.7.1.1 MTP Teaching Tool

Teaching of dilution and pipette position coordinates.
Figure 11-52: MTP teaching tool
11.7.1.2 Rack Teaching Tool

Teaching of sample and reagent rack coordinates.
Figure 11-53: Rack teaching tool
11.7.1.3 Z-Alignment Tool

Tool to align the Z-drive.

Pipettor
Figure 11-54: Z-alignment tool with rack teaching tool
11.7.1.4 Valve Alignment Tool

Alignment of the tree way valve.
Figure 11-55: Valve alignment tool
11.7.2 Start of Teacher Software
The icon Teacher on the desktop gives you access to the coordinate teaching
program 4pscoo.exe.
If the service software or the user software were running before, these pro-
grams have to be closed!
Password Pro- By starting the teacher program two password levels are available.
tection • With the high level password there is access to all parts of the teacher soft-
ware.
• With the low level password there is just access to the reference position.
The pipettor is initialised and a graphical representation of the working area with the
different working positions appears.

Pipettor
Figure 11-56: Teacher overview
1 Dilution area
2 Disposable tip rack 1-5
3 Patient and reagent racks
4 Pipette positions 1-4
5 Eject position
6 Wash/waste position
7 Reference position
The positions of the pipetting stations are reversed in the teacher software
(e. g. pipetting station 1 = teach position 4) (see chapter 12.2 on page 12-2)!
Moving the mouse arrow to a specific position of the graphical display and clicking
with the left mouse button allows modification of the coordinates at the different po-
sitions. The pipettor moves to the currently set X- and Y-coordinates and a window
like following appears:
Figure 11-57: Adjust position dialogue

Pipettor
In order to avoid damage of the disposable tip adapter, the Z-axis does not move au-
tomatically. The following keys of the keyboard can be used for adjusting the pipettor
to the correct position:
Key: Action:
Cursor left Moves the pipettor to the left (X-axis - changes steps of Y on
screen).
Cursor right Moves the pipettor to the right (X-axis - changes steps of Y on
screen).
Cursor down Moves the pipettor to the front (Y-axis - changes steps of X on
screen).
Cursor up Moves the pipettor to the rear (Y-axis - changes steps of X on
screen).
Page up Moves the pipettor up (Z-axis).
Page down Moves the pipettor down (Z-axis).
Shift Moves the pipettor down the Z-axis in five steps to 1/2, 3/4 and
6/ of the previous set Z-position.
8
+ Increases the step size.

- Decreases the step size.
Table 11-6: Keys
Generally the step size of the movements can be adjusted by the step size bar (see
figure 11-57: on page 11-46). If the bar is adjusted to the bottom, the pipettor can be
moved with minimum steps. The Prev. Z button moves the pipettor to the Z-posi-
tion which was stored before.
This button should only be used if it is sure that the needle can not hit the bot-
tom! To reach the final position in X/Y/Z, small step sizes must be used!
Except for the eject and the waste position, all positions have three alignment points
which are marked in red and must be taught. For the teaching of the dilution posi-
tions, pipette positions and sample/reagent rack positions teaching tools (see
chapter 11.7.1 on page 11-44) have to be used. The correct position is reached, when the
tip adapter is inside the specific point of the teaching tools.
When checking the coordinates, be careful of the technical error of the axis
in X-,Y- and Z-direction; a tolerance of 3 steps (minimal step size) can be ac-
cepted!
Pick-up Dispos- Put a 300 µl disposal tip into the disposal tip rack 1 position 1 and press the Pi ckup
al Tip D button. The pipettor picks-up the disposal tip.

Pipettor
Figure 11-58: Disposal tip position
11.7.3 Mechanical Z-alignment

Before starting to teach different positions, the Z-drive must be adjusted. This is done
with the Z-alignment tool (see chapter 11.7.1 on page 11-44).
11.7.4 Teaching Reference Position
There is no need to use a tip to teach in the following positions. The positions
where you need a tip are the individual reagent/sample racks, the plate types
and the dilution area which will be described later - a note will inform you that
for that positions a tip has to be used.
Due to the fact that the setting of dilution positions, disposable racks, etc. are all re-
lated to the reference positions in the most cases, it is enough to teach the reference
position. Therefore, it is also important to teach the reference position before all other
positions.
By clicking on the Ref . left button, the pipettor moves to the last taught reference
position (except the Z-axis).
Figure 11-59: Reference position
The correct reference position is reached when the tip adapter (without a tip) touches
the reference point. If this position has been adjusted, it can be stored by pressing
the OK button.

Pipettor
If the positions are only checked (not changed in any direction), the teaching
of this position (before saving the last position) must be finished by pressing
the Cancel . This has to be done for all different positions in the teacher!
If the pipettor crashes (Z-motor deenergised) while teaching any position, the
teacher program must be closed by pressing the Cancel button.
11.7.5 Teaching Disposable Tip Racks

All five tip areas have to be taught beginning with the first tip rack (rear of the instru-
ment area - see chapter 11.7.2 on page 11-45). A empty tip rack has to be positioned on
the 1st tip area. By clicking on this tip rack icon on the screen the pipettor moves to
the stored X, Y coordinates of position 1.
Figure 11-60: Positions
A dialogue to adjust the first position appears (see figure 11-57: on page 11-46).
The pipettor has to be moved in the tip pick up position. It should be centred in the
middle of the opening. The black cover of the tip adapter must just touch the upper
area of the empty tip rack. When the pipettor is positioned correctly, the OK button
must be clicked.
This procedure must be repeated for all positions. The last height which has to be
taught is Z-start. To adjust Z-start, move down 400 digits from the current position (Z-
travel).
Figure 11-61: Adjust Z-start
This is the way the positions of all other tip racks have to be adjusted.

Pipettor
11.7.6 Teaching Dilution Area
11.7.6.1 Dilution Plate Area

All dilution plate positions have to be taught beginning with the first in the rear of the
dilution plate area. The MTP teaching tool (see chapter 11.7.1 on page 11-44) has to be po-
sitioned on the specific dilution position. By clicking on the dilution plate position on
the screen the pipettor moves to the stored X and Y position 1 of this dilution plate
position.
For adjustment, the pipettor can be moved as described. The pipettor must be ad-
justed so that the tip is positioned in the centre of the MTP teach tool holes (X-,Y-
position). For the Z-position use the position alignment tool. After position 1 is adjust-
ed by pressing the OK button, the pipettor moves to position 2 which can be taught
in the same way as described for position 1. When the 3 positions are taught, all po-
sitions are stored and you can begin teaching the other dilution plate positions.
11.7.7 Teaching Pipette Positions

All four pipette positions have to be taught beginning with the first in the rear of the
working area. The MTP teaching tool is placed in a plate carrier and has to be posi-
tioned on the specific pipetting position. By clicking on the first pipette position on the
screen the pipettor moves to the stored X- and Y-coordinates of position 1).
The teaching for this position is correct, if the tip adapter is in the same plane as the
specific drill hole of the alignment tool. All three points have to be taught. This proce-
dure has to be repeated for the other three pipette positions as well.
The teaching for this position is correct, if the tip adapter is in the same plane as the
specific drill hole of the alignment tool. All three points have to be taught. This proce-
dure has to be repeated for the other three pipette positions as well.
11.7.8 Teaching Eject Position

After the eject position is clicked on the screen a dialogue to adjust the eject position
appears (see figure 11-57: on page 11-46).
If the button for tip release (on the bottom of the tip ejector) is pressed by the tip eject
pin the correct height of the eject point is set. After you have confirmed this height by
pressing the OK button on the screen you are asked for the Z-start height.
This should be reached by teaching 2800 digits below Z-travel.

Pipettor
Figure 11-62: Teaching eject position
Please check that the tip will not get in contact with the housing during eject,
otherwise it will not drop correctly (distance between tip adapter and housing
> 1 mm).
11.7.9 Teaching Wash/Waste Position

The adjustment of the correct wash/waste position is done as described for the other
positions. By clicking on the wash position on the screen the adjust left wash position
window appears. Now the set point for the wash position can be adjusted. The end
of the tip on the tip adapter should be in the centre of the wash station and 700 digits
below Z-travel as shown in the following figure.
Figure 11-63: Z-travel of wash/waste position
After you have confirmed this height by pressing the OK button on the screen, you
are asked for teaching the waste position on the adjust left waste position window.
Since you use disposable tips, the wash/waste positions are equal. This means the
position values for X/Y/Z can be taught to the same X/Y/Z coordinates as done before
with the wash position.

Pipettor
11.7.10 Teaching Sample and Reagent Area

For teaching of the patient sample and reagent rack, the rack teaching tool (see
chapter 11.7.1 on page 11-44) has to be used and must be inserted in the far left position
of the rack. The three positions must be taught.
Figure 11-64: Positions in the primary area
Clicking on the above shown area on the screen makes the pipettor move to X- and
Y-coordinates of position 1. The correct position is reached if the tip adapter touches
the reference point of the rack teaching tool. If this position has been adjusted, it can
be stored by pressing the OK button.
Figure 11-65: Adjust position with rack teaching tool
This procedure is to be repeated for positions 2 and 3. For teaching position 3 re-
move the rack tool from the far left position and insert the tool in the far right position
of the sample and reagent rack.
11.7.11 Teaching MTPs
Normally there isn’t a need to use a tip to teach in the MTP’s.

Pipettor
Change the value MTPs (area [OFFSETS]) in the teacher ini-file (4psCoo.ini - stored
in the user software directory) to teach with:
• Tip adapter: 0
• 300 µl tip: -2440
• 1100 µl tip: -4845
There are master files for the different MTP's available:
• Micro plate (8x12.mpc)
• Dilution plate (mtpdil2.mpc)
These files are stored in the user software directory.
There is no additional teaching necessary for these MTP's!
A disk is included in the ELISYS QUATTRO where all the files are stored as backup.
The coordinates which will be set for a specific MTP will be related to the coordinates
which have been taught in the above mentioned steps. Therefore a specific MTP has
to be taught only in one position. In our case we use the pipette position 3.
For all plates the same procedure can be use as explained below.
Therefore, the micro plate in a plate carrier has to be positioned in position '4-1' (see
chapter 11.7.2 on page 11-45). The changing in the setting of the MTP's can be done by
clicking on the MTP's button on the screen. The following window appears on the
screen:
Figure 11-66: MTPlate selection dialogue
Select the MTP file which shall be edited and click on the Edi t button. Now the win-
dow shown below appears.

Pipettor
Figure 11-67: MTPlate edit dialogue
In this window the changes concerning the actual micro plate can be done. In the
MTP Detail s the number of cavities in the X- and Y-direction and even the diam-
eter of the cavity must be inserted. Pressing the Teach button, the adjust window
appears on the screen. The pipettor moves to the previous set X- and Y-coordinates
for position 1. The correct coordinates can be set in the usual way. The tip shall be
in the centre of the cavity A1.
The Zmax position is adjusted in a way that the tip adapter is touching the bottom of
the well and then moved up 4 steps with minimal step size. Positions 2 and 3 have
to be taught in the same way. After confirming the correct position for 3, the user is
asked to set the Z-dispense position.
Therefore the pipettor has to be moved up until the end of the tip adapter is in the
same plane as the top of the MTP plus one step with minimal steps size down.
Figure 11-68: Z-dispense position

Pipettor
After confirming the correct position for Z-dispense adjust the Z-travel. Therefore the
pipettor has to be moved up until the end of the tip adapter is in the same plane as
the top of the MTP plus 8 steps with minimal step size up.
11.7.12 Teaching Racks

There are master files for the different racks available:
• Samples rack (T.rac)
• Reagents racks (*.rac)
These files are stored in the directory C:\ETI-Max 3000\System.
There is no additional teaching necessary for these racks!
A disk is included in the analyzer where all the files are stored as backup.
There is a need to use a 300 µl tip to teach in the racks.
The rack which has to be taught must be inserted in track 1 (far left position).
The coordinates which will be set for a specific rack will be related to the coordinates
which have been taught in chapter 11.7.10 on page 11-52. Therefore a specific rack has
to be taught only in one track.
For teaching the rack positions the Racks button on the screen has to be clicked
with the mouse. The rack you want to adjust can be selected by marking it with the
cursor. It will be highlighted.
Select a rack and press on the Edi t button.

Pipettor
Figure 11-69: Rack definition dialogue
In the upper part of the Rack Defini tion dialogue the number of positions of the
selected rack is displayed. Under this the actual set position is shown. The position
you want to teach can be selected by the up and down arrow buttons. When you
open the dialogue, it is usually position 1. Enter the tube surface (mm2) of the tube
which is positioned in position 1 and begin the teaching by pressing the Teach but-
ton. Pressing this button makes the pipettor move to the previously stored X and Y
coordinates of position 1. For each position in the rack, X/Y/Zmax has to be taught
first, then Z-dispense.
11.7.12.1 Samples Rack 'T'

Definition of samples rack 'T':
Positions 1 to 20:
Tube surface 78 mm2

X/Y Insert a small 10 mm tube into the rack and centre
the tip for X and Y.
Zmax Touch the bottom of the tube and move 4 steps (min-
imum step size) up.
Z-dispense Z-Dispense = Z-Travel

Pipettor
Figure 11-70: Samples rack ’T’
11.8 Check and Verification
11.8.1 Check Function of Disposable Tip Adapter

2. Open metal sheet '1' (see chapter 11.2 on page 11-2)
3. Switch on the system.
4. Start the service software (see chapter 11.9 on page 11-58).
5. Initialise the pipettor with the service software.
6. Move to position 2.
7. Watch the LED in front of the pipettor PCB (see chapter 11.4 on page 11-7).
Disp. Level Init +5 V +24 V
If there is no tip at the adapter and no

light barrier interrupted.
Lift the tip discarding device 'G' (see

figure 11-4: on page 11-5).
Normal condition of tip adapter after

0.5 sec off (level LED).
Lift the tip discarding device 'G'. Touch

a little the metal top with finger.
Lift the tip discarding device 'G'. Touch

more the metal pick up 'H' with finger.
Press the Z init pin 'E' at the top of the

adapter.

Pipettor
Disp. Level Init +5 V +24 V
Interrupt the light barrier '7' and/or 19'.
LED on: LED off: LED on/

off:
Table 11-7: Check function of the disposable tip adapter

9. Install metal sheet '1'.
After the start of the service software and the selection of the pipettor (with double-
click) the following dialogue appears:
Figure 11-71: Pipettor start up dialogue

Pipettor
Operator Here the user name of the log in dialogue box is

shown. For the pipettor this name can be changed.
Serial Number Enter the serial number of the machine.
Arm Type Arm type of the pipettor:
• Lef t Arm
Don’t use another arm type!
Needl e Type Left Number of needle adaptors:
• One Needl e
Don’t use the Four Needle entry!
Extended Protocol Activates the recording of the communication in the
protocol file (PIP000000.txt).
Path and Name of Path and name of the coordinate file should be auto-
Coordinates matically indicated. If this field is empty, the path in
the configuration file (gService.ini) must be cor-
rected.
Cartesi an Coordi - Type of coordinate system.
nates Default!
Pol ar Coordinates Don’t use this coordinate system!
OK Starts the pipettor main dialogue.
Don’t know If you don't know the correct parameters and press
the Don't Know button a warning is shown.
Table 11-8: Fields and buttons of the Setup Parameters dialogue
The pipettor could crash if the parameters aren't correct. This button should
only be used to have a look on the dialogues but not to work with.
After successful input, the pipettor main dialogue is shown.

Pipettor
Figure 11-72: Pipettor main window
11.9.1 Functions of the Pipettor Service Software
11.9.1.1 Setup Parameters
Operat or Shows the user name.

Serial Number Shows the serial number of the machine.
Machine Type of the machine (FPS).
Firmware Shows the firmware version number, if connection is
Path and Name of Path and name of the coordinate file.
Coordinates
Type Shows type of coordinate system.
• Default: Cartesian coordinates.
Arm Type Arm type of the pipettor:
• Default: Left arm
Needl e Type Number of needle adaptors:
• Default: One needle left
Change The parameters can be modified if necessary.
i The version of the pipettor-DLL (service software) is
shown.
Table 11-9: Fields and buttons of the Setup Parameters area

Pipettor
11.9.1.2 Single Components
Pi pettor (see chapter 11.9.2 on page 11-61)

Pumps (see chapter 11.9.3 on page 11-65)
Coordinates (see chapter 11.9.4 on page 11-66)
Prime (see chapter 11.9.5 on page 11-68)
Level Sensor (see chapter 11.9.6 on page 11-69)
Automat ic Modul e (see chapter 11.9.7 on page 11-71)
Test
Firmware upgrade (see chapter 11.10.1 on page 11-73)
Table 11-10: Fields and buttons of the Si ngl e Components area
11.9.1.3 General

11.9.2 Pipettor Dialogue

The pipettor dialogue looks as follows:
Figure 11-73: Pipettor dialogue

Pipettor
Depending on the pipettor type and previous actions some buttons are activated or
deactivated.
11.9.2.1 Initialize
Left Arm First, the pipettor must be initialised.
Table 11-12: Fields and buttons of the Ini tiali ze area
During a movement the following dialogue appears:
Figure 11-74: Pipettor moving dialogue
Cancel Only the current sending of commands will be

stopped.
Emergency Stop An emergency stop command is sent to the pipettor.
After this, the pipettor must be initialised again.
Table 11-13: Fields and buttons of the Device i s busy dialogue
After the first initialisation you automatically get to the Coordinates dialogue (see

Pipettor
11.9.2.2 Relative Movement
Steps Enter the number of steps for relative movement.

The steps can be entered positive or negative
depending on the desired direction of the movement.
X, Y, and Z Select the axis to move. The Z-axis moves to ZTravel
before each movement, so it can be avoided that the
Z-axis is too deep and possibly hangs during an XY-
movement. That means that it also moves to ZTravel
if the Z-axis itself is to move. The relative movement
then starts from this height.
Move By pressing the button the selected arm moves with
the selected axis and the entered number of steps.
Table 11-14: Fields and buttons of the Rel ative Movement area
11.9.2.3 Absolute Movement (XY only)

Posi ti on-No. Enter the absolute position number. These numbers
must correspond with those of the transmitted coordi-
nates.
Move By pressing the button the selected arm moves to
this position without moving the Z-axis.
At the third position of the system (EJECT position)
the Z-axis is moved to the top before the movement,
so the arm doesn't get caught. This applies to each
movement to the third position with the system.
Table 11-15: Fields and buttons of the Absol ute Movement (XY
only) area
11.9.2.4 Coordinates
In the area Coordinates appear the coordinates sent to the pipettor.

Pipettor
Move to select ed If you select some coordinates (marking with the

Coord(s) mouse by pressing the key Shift or Ctrl while marking
several coordinates that are not contiguous can be
selected), the button Move to selected
Coord(s) becomes active. By pressing this button
the pipettor moves to the selected coordinates.
Repeat Enter the number of repetitions of the movements.
Step by Step The pipettor waits before each movement for the
confirmation of the user.
Table 11-16: Fields and buttons of the Coordinates area
11.9.2.5 Random Movement
Move to All Coordi- By pressing the button the pipettor moves to all coor-
nates dinates in the same order as sent before. The pipet-
tor will move alternately with the defined arm.
Repeat Enter the number of repetitions of the movements.
Table 11-17: Fields and buttons of the Random Movement area
11.9.2.6 Disposable Tips

Long Tips and Short Select the type of the used disposable tips.
Tips
Pi ckup The pipettor will move down and pickup a tip.
Ej ect To eject a tip, the pipettor must be moved to the eject
position (FPS: No 3). Only there, the button Eject
becomes active and can be pressed. The tip then is
ejected.
Ej ect after I ni t If there is a disposable tip attached to the needle
after an initialisation, it can be ejected immediately
after the initialisation by pressing the Eject after
Init button.
Table 11-18: Fields and buttons of the Disposable Tips area
After each picking up or ejecting of tips, the result is checked and a No t ip ... mes-
sage is reported on the screen if necessary.

Pipettor
11.9.2.7 General
OK Closes the window and returns to main pipettor win-

dow.
11.9.3 Pumps Dialogue

If the pipettor was not initialised with the pipettor dialogue (see chapter 11.9.2 on page 11-
61) or there were no coordinates sent, the question "Pipettor initialized and Coordi-
nates sent?" is shown when calling the Pumps dialogue. This question appears
only once. By pressing Yes, the pipettor moves to the waste position and the pumps
dialogue is shown.
Figure 11-75: Pumps dialogue
11.9.3.1 Wash-Pump(s)
Time Enter the time of switching on the wash pump.

On Switches the wash pump on
Table 11-20: Fields and buttons of the Wash Pump(s) area
If the wash pumps are turned on, the waste pump is not switched on auto-
matically! The wash position can overflow then.

Pipettor
11.9.3.2 Waste Pump
Time Enter the time of switching on the waste pump.

On Switches the waste pump on
Table 11-21: Fields and buttons of the Waste Pump area
11.9.3.3 Syringe Pump(s)

Firmware Versions By pressing the button, the firmware version of the
selected pump is shown.
Ini t - Input - Output - By pressing the corresponding button, the movement
Bypass of the plunger (initialisation or normal movement) or
of the valve (movement to input-, output- or bypass-
position) can be tested.
Move With the button, the pump moves 3000 steps, alter-
nating downward or upwards.
For the movement, the currently programmed speed
parameters are used. That means that the pump
moves quite slow after an initialisation but faster after
a prime cycle.
Table 11-22: Fields and buttons of the Syringe Pump(s) area
While a pump is working the dialogue "Device is busy" appears (see chapter 11.9.2 on
page 11-61).
11.9.3.4 General
OK Closes the window and returns to main pipettor win-

dow. Parameters are stored.
Cancel Closes the window and returns to main pipettor win-
dow. Parameters aren’t stored.
11.9.4 Coordinates Dialogue

61), the question "Pipettor initialized?" is shown when calling the coordinates dia-
logue. This question appears only once. By pressing the Yes button the coordinates
dialogue opens.
After the first initialisation the coordinates dialogue is shown automatically.

Pipettor
Figure 11-76: Coordinates dialogue
11.9.4.1 Racks
Racktype Select the type of the rack (name of the rack file).
Track-No Enter the number of the track where the rack is
placed. The numbering of the tracks starts with zero.
Add Take over the racktype and the track-number and
add the rack into the list.
Remove sel ected By marking one or several racks and pressing
Rack(s) Remove select ed Rack(s) these racks can
be removed from the list.
Table 11-24: Fields and buttons of the Racks area
11.9.4.2 µPlates
Pl atetype Select the type of the plate (name of the plate file).
Posi ti on Enter the number of the plate position. The number-
ing of the plate positions starts with zero.
Add Take over the plate type and the position and add the
plate into the list.
Remove sel ected By marking one or several plates and pressing
Pl ate(s) Remove sel ected Plate(s) these plates
can be removed from the list.
Table 11-25: Fields and buttons of the µPl at es area

Pipettor
11.9.4.3 Send all Coords
OK By pressing OK the static coordinates (init position,

wash- and waste position) are sent together with the
just entered dynamic coordinates if they are defined
in the coordinates-file.
While the coordinates are sent the dialogue "Device
is busy" appears (see chapter 11.9.2 on page 11-61).
After transmitting the coordinates you get back to the
pipettor main dialogue (see chapter 11.9 on page 11-58),
except after the first initialisation. Then you get back
to the pipettor dialogue (see chapter 11.9.2 on page 11-61).
If you want to change the dynamic coordinates you
get, go again to the Coordi nates dialogue by
pressing the Coordi nates button in the main dia-
logue. Have already coordinates been sent, the
warning messages "Old Coordinates will be deleted!"
appears.
By pressing OK the old coordinates in the service
software are deleted and the coordinates dialogue
appears.
Cancel Drops all parameters, closes window and returns to
main pipettor window.
Table 11-26: Fields and buttons of the Send al l Coords area
11.9.5 Prime Dialogue

61) or there were no coordinates sent, the question "Pipettor initialized and Coordi-
nates sent?" is shown when calling the prime dialogue. This question appears only
once. By pressing Yes the pipettor moves to the waste position and the prime dia-
logue is shown.
Figure 11-77: Prime dialogue

Pipettor
11.9.5.1 Primeparameters
Number of Prime- Enter the number of prime cycles.

cycl es
Time Bypasspump Enter the time of switching on the bypass pump.
On
Table 11-27: Fields and buttons of the Primeparameters area
11.9.5.2 General

OK By pressing OK the priming starts. First the valve of
the pump is turned to the bypass position and the
bypass pump is switched on for the specified time.
After that the pump moves for the given number of
cycles. In the meantime the "Device is busy" dia-
logue is shown (see chapter 11.9.2 on page 11-61).
Cancel Closes window and returns to main pipettor window.
11.9.6 Level Sensor

When calling the level sensor dialogue some buttons are active and some are inac-
tive according to previous actions.
If there are no coordinates sent to the pipettor no level sensor test can be started.
Figure 11-78: Level sensor dialogue

Pipettor
11.9.6.1 Coordinates
The transmitted coordinates are shown in the area Coordi nates.

Submerge St eps Not used for service.
track Not used for service.
Table 11-29: Fields and buttons of the Coordinates area
11.9.6.2 LLD-Frequency
Left The actual LLD-Frequency is shown. The value is

updated every half second if no level sensor test is
running. When a test is started, the updating stops.
Table 11-30: Fields and buttons of the LLD-Frequency area
11.9.6.3 Results
Clear Li st With the Clear Li st button you can clear the

result list in the display.
Load from Fi le If a file of target coordinates exists, it can be loaded
now by pressing Load from Fi le.
Wri te to Fi le After the test is finished the result list can be stored
by pressing Write to Fil e. At the same time a
target data file is created.
Table 11-31: Fields and buttons of the Resul ts area

Pipettor
11.9.6.4 General
Repeat In the field Repeat, the number of repetitions can

be entered.
Start Level Test Before pressing Start Level Test load a target
coordinates file (Load from Fi le). Otherwise the
target coordinates for the test must now be selected
(marking with the mouse by pressing the key Shift or
Ctrl while marking several coordinates that are not
contiguous can be selected). The marked coordi-
nates are copied automatically into the Resul ts
area.
After pressing Start Level Test, the test starts.
The pipettor moves to the selected coordinates one
after the other and searches for liquid at each posi-
tion. At the same time the result list is continuously
updated. The minimum and the maximum height are
determined as well as the number of positive and
negative results.
During the test the "Device is busy" dialogue is
shown (see chapter 11.9.2 on page 11-61).
OK If you leave a dialogue with the OK button the soft-
ware remembers the entered values when reopening
the dialogue.
Cancel With Cancel the entered values are not stored.
11.9.7 Automatic Module Test Dialogue

The automatic module test runs almost completely independently. Only at the begin-
ning tips and a rack must be placed. The different parts can be deselected by remov-
ing the ticks in the check boxes except for the initialisation.
Figure 11-79: Automatic module test dialogue
After deselecting some parts the display changes from To Do to Skipped.

Pipettor
By pressing Start the automatic module test starts.

1. First, short tips must be placed at the shown position.
3. Long tips must be placed at the position that is shown now.
5. A T-rack filled with tubes (with and without liquid) must be placed on the first
track.
The test runs itself with the selected parts. The result window for the level detection
is constantly updated. At the end a log file is created automatically.

Pipettor

Invoke the Fi rmware Upgrade dialogue box. It is assumed the new firmware
file *.h86 resides within the washer sub-directory, as described within the INI file. Oth-
erwise you may browse all available drives.
Direct connection allows upgrade using a RS232 cable directly connected to a PC.
In the first field the name and the path of the new firmware can be entered. If the
name and the path shown as default are not correct, the correct file can be searched
with the Browse... button.
The upgrade process starts by pressing OK. The dialogue is left without upgrading
by pressing Cancel.
After the upgrade process the following message is shown:
Figure 11-81: Message after firmware upgrade
The pipettor must be reinitialised after an upgrade process and the coordinates have
to be transmitted again.
In some cases it is recommented to use the user software to upgrade the pi-
pettor firmware (see also ’Release Notes’).


Pipettor
3. Click on the Pi pette tab.

The file (PDANCE.H86) used to update the firmware must be stored in the


Pipetting Station
12 Pipetting Station

Every time the pipetting station or plate transport is disturbed, the calibration

Pipetting Station
Figure 12-1: Pipetting station (rack system removed)
1 Pipetting station 1 (front side of the instrument)

2 Pipetting station 2
3 Pipetting station 3
4 Pipetting station 4 (back of the instrument)
5 Plate carrier guide (8x)
6 Stainless steel COP cover
7 Cable throughput to COP

Pipetting Station
8 Incubator (back view)

9 Plate transport
10 Tip eject pin
The positions of the pipetting stations are reversed in the teacher software
(e. g. pipetting station 1 = teach position 4) (see chapter 11.7 on page 11-44)!
12.3 Maintenance
Every time the pipetting station or plate transport is disturbed, the calibration
12.3.1 Replacement of Light Barriers
Removal

3. Open stainless steel cover '6' (see chapter 12.2 on page 12-2).
4. Remove the rack system (see chapter 14.4.1 on page 14-4).
5. Remove both retaining screws of the faulty light barrier.
6. Disconnect the connector ST40, ST42, ST43 or ST44 of the faulty light bar-
rier (see chapter 8.4 on page 8-5).
7. Remove the faulty light barrier.
Installation 8. Install the new light barrier.

9. Connect the connector of the light barrier.
10. Tighten the retaining screws.
11. Install the plate transport cover.

Pipetting Station

Stacker
13 Stacker

ward!
Every time the stacker module or plate transport is disturbed, the calibration
Figure 13-1: Stacker in opened drawer (back view)
1 Stacker position 1 (front side of the instrument)

2 Stacker position 2 (front side of the instrument)
3 Stacker position 3 (back side of the instrument)
4 Stacker position 4 (back side of the instrument)
5 Photometer
6 Stacker housing
7 Plate transport PCB cover

Stacker
8 Washer
13.3 Maintenance
Every time the stacker module or plate transport is disturbed, the calibration
13.3.1 Replacement of Light Barriers
Removal

4. Remove plate transport cover '7' (see chapter 13.2 on page 13-1 and chapter 8.5.3 on
page 8-9).
5. Remove both retaining screws of the faulty light barrier.
6. Disconnect the connector ST4, ST11, ST12 or ST13 of the faulty light barrier
(see chapter 8.4 on page 8-5).
7. Remove the faulty light barrier.
Installation 8. Install the new light barrier.

9. Connect the connector of the light barrier.
11. Install the plate transport cover.

Rack System
14 Rack System

Do not touch the glass windows and mirror surfaces with fingers!
Do not damage the coated surface of glasses!
For all actions it's necessary to remove the rack system (see chapter 14.4.1 on
page 14-4)!

Rack System
Figure 14-1: Mechanical architecture
1 Bar code scanner

2a Rack insert detection light barrier emitter
2b Rack insert detection light barrier sensor
3 Door switch
4 Rack fixing
5 Rack system PCB

Rack System
Figure 14-2: Rack system PCB
ST1 Main Connection (Power and Data)

ST2 Not used
ST3 Door switch
ST4 Not used
ST5 Rack insert light barrier
ST6 not used

Rack System
14.4 Maintenance
14.4.1 Replacement of Rack System
Removal

3. Remove tip disposal ramp cover.
4. Remove the stainless steel cover in the rear left to reach the COP PCB.
5. Loosen rack fixing screws '4' turn two times only (see chapter 14.2 on page 14-2).
6. Pull out the rack about 10 cm to the front.
7. Disconnect the 15 pin connector of the Sub-D bar code scanner.
8. Disconnect the 2 pin connector at COP PCB (ST18 Mirror).
9. Disconnect the 16 pin flat cable connector at rack system PCB '5'.
10. Remove the rack system.
Installation 11. Insert the rack system.

12. Connect the 16 pin flat cable connector at rack system PCB ’5’.
13. Connect the 2 pin connector at COP PCB (ST18 Mirror).
14. Connect the 15 pin connector of the Sub-D bar code scanner.
15. Tighten the rack fixing screws ’4’.
16. Install the stainless steel cover in the rear left to reach the COP PCB.
17. Install dispose ramp.
18. Teach the rack system (see chapter 11.7.10 on page 11-52).
14.4.2 Replacement of Bar Code Scanner
CAUTION: Laser radiation - do not stare into beam!
Removal 1. Remove the rack system (see chapter 14.4.1 on page 14-4).
2. Remove the two nuts 'A'.

Rack System
Figure 14-3: Bar code scanner at rack system (right view)
3. Remove Phillips screws 'B'.

4. Open rack door and remove screw 'C' from inside of the rack.
5. Remove the bar code scanner.
Installation 6. Install the new bar code scanner.

7. Open rack door and tighten screw 'C' from inside of the rack.
8. Tighten Phillips screws 'B'.
9. Tighten the two nuts 'A'.
10. Install the rack system (see chapter 14.4.1 on page 14-4).
14.4.3 Replacement of Rack Insert Light Barrier
Removal 1. Remove the rack system (see chapter 14.4.1 on page 14-4).
2. Disconnect rack insert light barrier connector on rack system PCB (see
3. Replace rack insert light barrier emitter '2a'.
4. Replace rack insert light barrier sensor '2b'.

Rack System
Figure 14-4: Rack insert light barrier and cable
Installation 5. Install the new rack insert light barrier sensor '2b'.
6. Install the new rack insert light barrier emitter '2a'.
7. Connect rack insert light barrier connector on rack system PCB (see
14.4.4 Replacement of Door Switch
Removal 1. Remove the bar code scanner (see chapter 14.4.2 on page 14-4).
2. Disconnect door switch connector on rack system PCB (see chapter 14.3 on
page 14-3).
3. Remove nuts.
4. Remove the faulty door switch.
Installation and 5. Insert the new door switch

Adjustment 6. Install the nuts. Don’t tighten the nuts!
7. Close the rack door.
8. Hold parallel the outer edge of the rack door to the edge of the stainless steel
housing.

Rack System
Figure 14-5: Adjustment of rack door switch
9. Tighten nuts.
10. Install the bar code scanner (see chapter 14.4.2 on page 14-4).

Rack System
When the rack system is invoked, the application attempts to communicate to the
system and rack system module. When successful the following dialogue will be dis-
played with the firmware version number, and serial number displayed. Bar code op-
tions will be read from the module EEPROM and shown. If no module is detected,
nothing will be shown for the firmware version number.
Figure 14-6: Rack system main window
14.5.1 Functions of the Rack System Service

Software
14.5.1.1 Instrument
Version # Shows the firmware version number, if connection is

number.

Rack System
14.5.1.2 Rack Sensor Status
1 - 12 Each of the twelve check boxes indicates the status

of the corresponding rack position. Checked means
occupied.
Door Open The door open field is checked when the door sensor
detects an open door
Tri gger The trigger is checked when the light barrier across
the opening of the rack is broken by a rack insertion.
Get Status Updates the status for the rack sensors, door sensor
and trigger.
Table 14-2: Fields and buttons of the Rack Sensor Status area
14.5.1.3 Scanner Configuration
Scanner Versi on # Shows the scanner version number.

Bar code types To enable specific bar code types check the appro-
priate boxes (see note). For the most reliable opera-
tion only enable bar codes actually used.
Lengths: To improve the reading detection further, the user
• Mi n. can program the minimum and maximum character
• Max. length a specific bar code must be. If a bar code is
read outside these limits, it is presumed invalid.
Load Orientati on 1 Load orientation check boxes allows the user to
- 12 define a rack position for horizontal bar codes.
Get Versi on Retrieves and displays the firmware version of the
bar code scanner.
Set Parameters Sends the enabled bar code types to the scanner.
Get Parameters Returns scanner configuration, bar code types ena-
bled and default horizontal rack settings.
Mirror Horiz. Not used.
Set Mirror When the mirror horizontal check box is enabled, this
will set the mirror to the horizontal position.
Table 14-3: Fields and buttons of the Scanner Conf igurati on area
A maximum of 8 bar code types can be enabled. This configuration does not
effect the configuration when using the PC software to run the system.
14.5.1.4 Barcodes
Displays the bar codes read for all the rack positions.

Rack System
Read barcodes Reads the bar codes currently read within the sys-
tem.
Table 14-4: Fields and buttons of the Barcodes area

Ini tial ise and Selft- (see chapter 14.5.2 on page 14-11)
est
Auto Load Starts the auto load sequence. The value in the
Rack Posi tion field sets the starting rack posi-
tion.
Auto load mode is used, so that the user can quickly
load a selection of sample racks without the need for
control from the PC. This allows racks to be loaded.
The bar codes can be read later using the read bar-
codes button. Note that auto load mode should be
stopped before trying to send other commands to the
rack by pressing the Stop Auto Load button.
Stop Auto Load Stops the auto load sequence. The rack will be
returned to the idle state.
Rack Posi tion The value sets the starting rack position.
Reset The scanner will be initialised.
Focus Sets laser focus to current rack position.
Laser On Turns on the laser of the scanner.
Laser Off Turns off the laser of the scanner.

Rack System
Hori zontal Opti on Check the Horizontal Opti on Fi tted if the

Fitted mirror mechanism for reading horizontal and vertical
bar codes is fitted.
Test LEDs. .. Performs the LED test. This will illuminate each LED
for a short period of time starting at position 1 on the
left of the rack.
RS485 Test... Performs the RS485 test. Performs a loop back test
on the RS485 communications link.
This does not check whether the scanner is func-
tioning!
14.5.1.7 General

14.5.2 Initialise and Selftest

Sends the commands to the rack scanner to initialise and execute its selftest. Resets
the laser scanner bar code. The rack bar code scanner is initialised ready for use dur-
ing rack loading. This command can take over 30 seconds to complete.
The scanner is configured as below:
1. External trigger signal disabled ("PT00026001")
2. Reset with the scanner 'H' command
3. Motor is turned on and the motor status is monitored for the motor to turn on.
4. Scanner focused at position 0.
5. Scanner focused at position 11.
6. Laser turned on.
7. Laser turned off.
The response will contain any error messages.
This command must be sent before the scanner can be used for any rack loading
operations.

Performs a sequence of tests to verify the rack module. When the Module Test button
is pressed, the following sequence is performed. The user must update the user field,
this data is stored in the results file.

Rack System
1. Selftest
Performs the selftest. Performs the following tests in sequence:
• Door test
• Trigger test
• LED test
• Sensors test
• RS485 test
• Tests the scanner
• Executes a selftest
2. Rack RS485
Performs a loop back test on the bar code scanner RS485 link. No external
connection is required for this test.
3. Rack scanner communications
Checks the BCL148 is communicating by obtaining it's firmware version.
4. Rack LEDs
Tests that each LED is working correctly.
5. Rack sensors
Checks that each rack sensor is working.
6. Rack door sensor
Checks that the door sensor in functioning.
7. Rack trigger
Checks that the rack trigger sensor is functioning.

CPS Module (COP)
15 CPS Module (COP)

Figure 15-1: COP
ST1 LED 01 - LED front left ERROR/DRAWER

ST2 LED 23 - LED front left POWER/READY
ST3 BSL

CPS Module (COP)
ST4 PC RS232 (rear side)

ST5 Lock sensor right
ST6 Lock sensor left
ST7 Left and right closed
ST8 Tip closed
ST9 Cover sensor
ST10 Tip lock sensor
ST11 Sample rack
ST12 Plate bar code SQ 40
ST13 Spare Out
ST14 Plate bar code SRP100
ST15 Lumino / RS232
ST16 Pipettor / RS232
ST17 POWER
ST18 Tip draw lock
ST19 Left and right lock
ST20 Power lumino
ST21 Power pipettor
ST22 Washer / RS232
ST23 Reader / RS232
ST24 Module 3 / RS232
ST26 Sample rack bar code
ST27 Power washer
ST28 Power reader
ST29 Power module 3
ST30 Power module 2
ST32 Plate bar code / RS232
ST34 Plate transport / RS232
ST35 Incubators / RS232
ST36 Power Plate bar code
ST37 Power module 8
ST38 Power Plate Transport
ST39 Power Incubators
ST40 Pipette station area 1
ST41 Waste sensor

CPS Module (COP)

ST45 LED 67 - LED front right (LED Reserve)
ST46 LED 56 - LED front right (LED Instrument Drawer and Plate
load / unload)
ST47 System fluid
ST48 Rack and mirror
ST49 Left and right lock

CPS Module (COP)
15.3 Maintenance
15.3.1 DIP-Switches
Positions of DIP-Switch 1 (SW1) and 2 (SW2) see chapter 15.2 on page 15-1.
DIP switch Function OFF ON
1 Download no yes
2 Reset no yes
3 - x -
4 - x -
Table 15-1: DIP-Switch 1 (SW1)
DIP switch Function OFF ON
1 SRP100 no yes
2 SRP100 no yes
3 SQ40 no yes
4 SQ40 no yes
Table 15-2: DIP-Switch 2 (SW2) - bar code scanner selection SRP100
15.3.2 Replacement of COP PCB
Removal

3. Open stainless steel cover above the tip drawer.
4. Disconnect all connectors.
Figure 15-2: COP PCB

CPS Module (COP)
Pay attention to the lettering of the connectors!
5. Open the retaining screws.

6. Remove the COP PCB.
Installation 7. Set the DIP switches (see chapter 15.3.1 on page 15-4).
8. Install the new COP PCB.
10. Connect all connectors (see back of the metal sheet or chapter 15.2 on page 15-1).
11. Install the firmware (see chapter 15.5 on page 15-13).

CPS Module (COP)
When the COP module is invoked, the application attempts to communicate to the
system and COP module. When successful the following dialogue will be displayed
with the firmware version number and serial number displayed. If no module is de-
tected, nothing will be shown for the firmware version number and serial number.
Figure 15-3: COP module main window
15.4.1 Functions of the COP Service Software
15.4.1.1 Instrument
Version # Shows the firmware version number if connection is

Serial # Shows the serial number if connection is established
number.
washer. It will only accept up to 16 alphanumeric
update.

CPS Module (COP)
15.4.1.2 Rack
1 - 12 Each of the twelve check boxes indicates the status

of the corresponding rack position. Checked means
occupied.
Tri gger The trigger is checked when the light barrier across
the opening of the rack is broken by a rack insertion.
Door Open The door open field is checked when the door sensor
detects an open door
Get Status Updates the status for the rack sensors, door sensor
and trigger.
Get Versi on Retrieves and displays the scanner firmware version
number.
Test LEDs. .. Tests operation of the rack indicator LEDs.
Table 15-4: Fields and buttons of the Rack area
15.4.1.3 Plate Carrier Sensor
#1 - #4 Shows for each of the 4 pipette positions the status

of the plate carrier sensor. No displayed if empty.
Yes if plate carrier detected.
Get Status Updates the status in status display boxes.
Table 15-5: Fields and buttons of the Pl at e Carrier Sensors area
15.4.1.4 Waste and Fluid Sensors
Waste Ful l Check boxes will be checked, if sensor active.

System Fluid Low Check boxes will be checked, if sensor active.
Get Status Updates the status in status display boxes.
Table 15-6: Fields and buttons of the Waste and Flui d Sensors
area

CPS Module (COP)
15.4.1.5 Instrument Draw
Open The check box indicates the status of the draw,

checked means open.
Lock Locks the drawer, the open status is updated.
Unlock Unlocks the drawer, the open status is updated.
Table 15-7: Fields and buttons of the Instrument Draw area
15.4.1.6 Microplate Barcode
IC Versi on The bar code IC version will be read and displayed.

Barcode Enabled The check box turns on the scanner laser when the
Set Enable button is pressed to send the com-
mand to the bar code reader.
Set Enable If the barcode enable check box is active, pressing
this button sends the command. Only the last code
read can be stored for retrieval by the read com-
mand.
Read Prompts the user to load a plate and read the code.
This requires the plate transport service software
to be active!
Sel ftest The decoder IC is sent a hard reset command. The
configuration string, a disable scanning command,
and the version string is checked to ensure the
decoder IC is communicating.
Table 15-8: Fields and buttons of the Microplate Barcode area
15.4.1.7 Tip Draw
Open The check box indicates the status of the draw,

checked means open.
Lock Locks the draw, the open status is updated.
Unlock Unlocks the draw, the open status is updated.
Table 15-9: Fields and buttons of the Ti p Draw area

CPS Module (COP)
15.4.1.8 Cover
Open The check box indicates the status of the cover,

checked means open.
Lock Locks the cover, the open status is updated.
Unlock Unlocks the cover, the open status is updated.
Table 15-10: Fields and buttons of the Cover area
Sel ftest Performs the selftest. Performs the EEPROM check-

sum and the UART serial ports tests in sequence.
If an error occurs during any test, the appropriate
error response is given and the test stops.

Firmware...
15.4.1.11 LEDs
Control for the ELISYS QUATTRO system LEDs.
Power, Ready, Check the appropriate box to turn on a specific indi-

Error, Tip Draw, cator LED.
Pl ate Load, and
I nstrument Draw
Set LEDs Depending on the status of each LED's check box,
this command turns on or off the LED.
Table 15-13: Fields and buttons of the LEDs area

CPS Module (COP)
15.4.1.12 General

Displ ay devices reply.

Runs the sequence of tests that verify correct operation of the COP module. When
the Modul e Test... button is pressed, the following sequence is performed. The
user must update the user field, this data is stored in the results file.
1. Unique identification
3. Serial number
4. Parameter
5. Selftest
Performs selftest.
6. LED
Tests status of LEDs
7. Plate carrier sensors
Tests plate carrier sensors.
8. Waste sensor
Tests waste sensor.
9. System fluid sensor
Tests system fluid sensor.
10. Instrument draw sensor
Tests draw sensor.
11. Instrument draw lock
Tests draw lock.
12. Tip draw sensor
Tests draw sensor.
13. Tip draw lock
Tests tip draw lock.
14. Serial port test
Loop back test on each serial port. Requires loop back cable.
15. Rack RS485
Loop back test on RS485 communication link.
Reads scanner firmware version.
17. Rack LEDs
Flashes each rack LED.

CPS Module (COP)
18. Rack Sensors

Tests each rack sensor.
19. Rack door sensor
Tests door sensor.
20. Rack trigger
Tests trigger signal.
21. Micro plate barcode
Reads the HP decoder IC version.

Runs the sequence of tests that verify correct operation of the COP board. When the
Board Test... button is pressed, the following sequence is performed. The user
must update the user field, this data is stored in the results file.
1. Unique identification
3. Serial number
4. Parameter
5. Selftest
Performs selftest.
6. LED
Tests status of LEDs
7. Plate carrier sensors
Tests plate carrier sensors.
8. Waste sensor
Tests waste sensor.
9. System fluid sensor
Tests system fluid sensor.
10. Instrument draw sensor
Tests draw sensor.
11. Instrument draw lock
Tests draw lock.
12. Tip draw sensor
Tests draw sensor.
13. Tip draw lock
Tests tip draw lock.
14. Serial port test
Loop back test on each serial port. Requires loop back cable.
15. Rack RS485
Loop back test on RS485 communication link.
Reads scanner firmware version.
17. Rack LEDs
Flashes each rack LED.

CPS Module (COP)
18. Rack Sensors

Tests each rack sensor.
19. Rack door sensor
Tests door sensor.
20. Rack trigger
Tests trigger signal.
21. Micro plate barcode
Reads the HP decoder IC version.

CPS Module (COP)

1. Invoke the firmware upgrade dialogue box with the Upgrade
Firmware... button. It is assumed the new firmware file *.h86 resides
within the COP sub-directory, as described within the INI file.
If front panel LEDs don’t light up then firmware upgrade didn’t take!
Figure 15-4: COP firmware upgrade dialogue
If no firmware has ever been installed you must use recovery mode or if an
error occurred during a previous upgrade!
2. After you press the OK button the message to enter recovery mode is dis-
played.
3. Assuming power is applied to the board, on the 4-way DIP switch SW1 turn
ON Pin 1 (see chapter 15.2 on page 15-1).
4. Switch off the instrument.
5. Switch on the instrument.
6. Toggle Pin 2, this will put the board into bootstrap (or Recovery) mode.
The download should then follow.
8. If the progress indicator does not change, press the Cancel button, cycle
the power, and repeat the process.
9. Once the download is complete, you must turn OFF Pin 1. Otherwise the
device remains in bootstrap mode and will not work.

3. Click on the System tab.

CPS Module (COP)
The file (COP.H86) used to update the firmware must be stored in the PC
software directory (e. g. C:\...user software path...).
If an error should occur during the upgrade carry out the following steps or
use the service software (see chapter 15.5.1 on page 15-13)!
4. Assuming power is applied to the board, on the 4-way DIP switch SW1 turn
ON Pin 1 (see chapter 15.2 on page 15-1).
5. Toggle Pin 2, this will put the board into bootstrap (or recovery) mode.
8. Once the download is complete, you must turn OFF Pin 1, otherwise the
device remains in bootstrap mode and will not work.
9. When finished click the OK button.

Power Supply
16 Power Supply

16.2 Maintenance
16.2.1 Replacement of the Power Supply
There are no serviceable parts! When it is faulty, then replace the power sup-
ply!
Removal

3. Open stainless steel cover above the tip drawer.
4. If no short cross tip screwdriver is available, then remove the rack system (see
5. Pull out the tip drawer.
6. Disconnect the power connector at COP PCB ST17 (see chapter 15.2 on page 15-
1)
7. Open the nuts of the earth bolt.
8. Remove the toothed washers and the ground wires.
Figure 16-1: Power supply

Power Supply
Figure 16-2: Earth bolt
9. Remove screws 'A' at the ground plate.

10. Lift out the power supply unit.
11. Remove screws from ground plate rear side.
12. Remove the power supply.
Installation 13. Insert the new power supply.

14. Tighten screws from ground plate rear side.
15. Insert the power supply unit.
16. Tighten screws 'A' at the ground plate.
17. Install the toothed washers and the ground wires. Consider the order.
18. Tighten the nuts of the earth bolt.
19. Connect the power connector at COP PCB ST17 (see chapter 15.2 on page 15-1)
20. Push in the tip drawer.
22. Close stainless steel cover ’1’ above the tip drawer (see chapter 11.2 on page 11-
2).

Troubleshooting and Error Messages
17 Troubleshooting and Error Messages
displayed messages! I. e., the displayed X-coordinate means the technical Y-
17.1 Error Messages of the User Software
System messages appear in the status bar of the user software, error messages are
displayed in a separate window, which has to be confirmed.
"%1" and "%2" are place holders for a system module or the designation of a plate,
a reagent or an error number.
Error: Cause: Action:
Argument error in com- During initialisation procedure. Reinstall the firmware for the con-
mand ... Faulty firmware is installed. cerning module (see chapter 17.2 on
page 17-12, chapter 17.3 on page 17-20, or
chapter 17.4 on page 17-21). If error
recurs the PCB of concerning mod-
ule has to be checked.
Aspirate check failed During the run. Retry button: Pipettor will dis-
for reagent %1 Aspirate step of reagent was faulty. pense back the aspirated liquid and
repeats the aspirate step.
Abort Pl ate button: Plate will be
aborted.
Conti nue button: System goes
on but all concerning samples will be
flagged.
Clot detected in patient During the run. Ski p Sample button: System
sample %1 will skip the concerning sample and
will go on with the worklist.
aborted.
Conti nue button: System goes
on but concerning sample will be
flagged.
Colorimeter %1 not During initialisation procedure or Please restart the software and sys-
homed during a reading step. tem. If the error recurs the colorime-
The X-motor of the colorimeter is not ter module has to be checked (see
in the home position. chapter 6 on page 6-1). If the error
occurs during a run, please press
the Abort button to cancel the
worklist. After this error occured a
recovery is not possible.

Colorimeter A/D error During the initialisation procedure or Please restart the system. If the
during a run. error recurs, the colorimeter module
Error of the analog/digital converter has to be checked (see chapter 6 on
of the colorimeter. page 6-1).
Colorimeter A/D over During the initialisation procedure or Retry button: System will try to
range error during a run. repeat the last step.
Upper limit of colorimeter A/D has Ignore button: Not advisable
been exceeded due to the signal because the system cannot go on
height of the pre-selected resolution. without sequence errors.
Press the Retry button. If the error
recurs, abort the worklist and check
the filters. If the error recurs after
checking the filters, the whole color-
imeter module has to be checked
(see chapter 6 on page 6-1).
Colorimeter A/D under During the initialisation procedure or Retry button: System will try to
range error during a run. repeat the last step.
Too less light reaches the electronic Ignore button: Not advisable
of the colorimeter. because the system cannot go on
without sequence errors.
Abort button: The worklist will be
aborted.
recurs, abort the worklist. The whole
colorimeter module has to be
checked.
The halogen lamp of the colorimeter
is faulty and has to be replaced. If
the error persists, the optical compo-
nents in the photometer (filter, upper
or lower optic block) may be dirty.
Clean the photometer or replace it
Colorimeter back- During the initialisation procedure or Restart the software to initialise the
ground light level error during a run. colorimeter again. Please check if
Typically occurs when light entered the colorimeter flap is closed and all
the measurement chamber. filters are installed.
Colorimeter EEPROM Error during EEPROM reading or Initialize the module again. If the
error writing. error recurs the colorimeter PCB has
to be checked. Replace the photom-
eter PCB or replace the photometer
Colorimeter filter %1 During initialisation procedure. Restart the software to initialise the
error The gain factor for the respective fil- colorimeter again, after checking the
ter cannot be identified. filter configuration. If error recurs,
change the concerning filter (see
chapter 6 on page 6-1).

Colorimeter filter motor During the initialisation procedure. Restart the software. If the error
home error The system does not recognize the recurs, the filter wheel has to be
current position of the filter motor. checked.
Colorimeter filter motor During the initialisation procedure. Restart the software. If the error
movement error The movement of the filter wheel is recurs, the filter wheel has to be
faulty. checked.
Colorimeter lamp error During the initialisation procedure. Replace the halogen lamp (see
Halogen lamp of colorimeter is chapter 6.5.3 on page 6-9) and restart
faulty. the software to initialize the colorim-
eter again.
Colorimeter optic chan- During the initialisation procedure. Clean the optical blocks or replace
nel %1 error One of the optical channels is dirty the photometer (see chapter 6 on
or faulty. page 6-1).
Colorimeter plate motor During the initialisation procedure. Restart the software to initialize the
movement error The plate movement is faulty. colorimeter again. If the error recurs
the moving mechanism has to be
checked (see chapter 6 on page 6-1).
Colorimeter plate motor During the initialisation procedure. Restart the software to initialize the
movement home error The plate doesn’t find its home posi- colorimeter again. If the error recurs
tion. the light barriers have to be
checked.
COMGEN error '%1' At start-up. Check correct connection between
Cable connection between PC and PC and analyzer. Start PC and ana-
analyzer is faulty. lyzer again.
COP serial port test At start-up. Check connection between PC and

error Error in the serial interface on COP analyzer. Start PC and analyzer
board. again. Check the connections
between COP and the other compo-
nents. If error recurs the COP has to
be replaced.
Crash cover file After power failure. Yes button: following message
detected. Do you want appears “Is the system still running”
to try and recover the No button: software continuous with
worklist? initialising the system. Old worklist
will be deleted.
• Is system still running:
Yes button: systems continuous
with the next worklist step.
No button: system initializing
first the modules before continu-
ous the next worklist step.
Error during assay lay- After adding assay and patient to the Push OK button and reduce the
out reduction. Reduce plate. Too many samples are used numbers of patients, that a maxi-
the number of patient on this plate. mum of 96 wells on one plate are
samples. Check that used.
the assay layout is
reducible.

Error scheduling plate After adding plate and assay. The worklist or the assay has to be
'...' The Assay programming is not cor- changed accordingly.
rect or the combination of different
plates cannot be scheduled.
Error: Argument error in During initialisation procedure. Restart software and analyzer. If the
... Component cannot be actuated. error recurs, the concerning module
has to be checked (see chapter 17.2 on
page 17-12, chapter 17.3 on page 17-20, or
Incubator heater %1 During the initialisation procedure or The heater foil of concerning incuba-
error during the run. tor box has to be checked (see
The heater foil of the incubator box chapter 10 on page 10-1).
%1 is faulty.
Incubator sensor %1 During the initialisation procedure or The temperature sensor of the con-
error during the run. cerning incubator box has to be
The temperature sensor of the incu- checked (see chapter 10 on page 10-1).
bator box is faulty.
Insufficient volume of During the run. Retry button: System will try to
pre-dilution %1 System cannot find enough volume repeat the last measurement of level
in pre-dilution. height.
Abort button: The concerning
sample will be aborted.
Abort Pl ate button:Tthe whole
plate will be aborted.
Ignore button: The concerning
sample will be flagged. System goes
on with the next pre-dilution.
Insufficient volume of At reagent check if volume of rea- Abort check button: Reagent
reagent %1 gent is insufficient. check will be aborted. The system
goes on with the worklist.
Refi ll bott le button: Software
jumps back to the loading wi n-
dow where reagents can be filled
up.
Ignore button: System will go on
with checking the next reagent.
To make sure that worklist will run
without miss pipetting errors, please
press the Refil l bottl e button
and make sure that enough reagent
liquid is available.

Insufficient volume of During the run if the volume of a Retry button: System will try to
sample %1 sample is insufficient. Only possible repeat the last measurement of level
if Reagent check is disabled. height.
Abort button: The sample will be
aborted.
Abort Pl ate button: The whole
plate will be aborted.
Ignore button: The concerning
sample will be flagged. Systems go
on with the next sample.
Invalid pipettor coordi- After adding plate and assay. The Push the OK button. Modify the
nates on plate ..., label assay programming is faulty. A label assay definition and restart the work-
sample … Check that of a sample is undefined. list.
the dispense and aspi-
rate labels are consist-
ent.
No disposable tips left During the run. Automatically appearance of the
No more tips available or found. loading window after system mes-
sage occurs. Load the correct tips to
the suggested position. After push-
ing the OK button the worklist will
go on.
No liquid detected for ... During a run. Retry button: System will check
Insufficient volume for sample ... or level of sample or reagent, again.
reagent ... Ignore button: System will go on
although if there is not enough liquid
in the bottle. All concerning samples
will be flagged.
Note: Air can be pipetted if you
push the Ignore button.
aborted. To make sure that the work-
list will run without miss pipetting
errors, push the Abort button and
enable the Reagent check in
the panel options. After that, you
have to start the worklist again. The
old worklist cannot be recovered.
Abort Pl ate button: The plate
will be aborted.
The status is documented in the
active event log.
No respond to com- General software error. Communica- Abort button: The worklist will be
mand '%1' tion between PC and analyzer is aborted.
interrupted. Retry button: PC will try to connect
to system again. If error message
recurs after pushing Retry, check
RS232 cable or restart analyzer and
PC.

Pipettor error 0x0E - LX During a pipettor movement. Retry button: System will try to
position not reached Pipettor crashes or mechanical reach the position again, then the
problems. axis will initialise again.
Ignore button: Not advisable
because the system cannot go on
aborted.
Press the Retry button to repeat
the last step. If the error recurs
please open system flap and check
if there are any obstacles that dis-
turb the pipettor movement. If there
are no obstacles the pipettor module
has to be checked.
Pipettor open loop/ Pipettor crash during a run. Retry button: System will try to
overload error. repeat the former pipetting step.
Ignore button: System will con-
tinue with the next pipetting step.
Abort button: The whole plate will
be aborted.
If the system doesn’t go on after
pushing Retry or Ignore press
Abort and restart the system and
the software again.
Plate transport %1 During the initialisation procedure. When this error message occurs
motor home error Plate transport cannot reach or find check if something jammed the plate
the home position. transport.
Press the OK button and restart
software to initialise the plate trans-
port again. If the error recurs the
plate transport mechanism has to be
checked
Plate transport %1 During the initialisation procedure or Retry button: System will try to
motor movement error during the run. repeat the last movement step.
Plate transport motor (X, Y, or Z) Ignore button: Not advisable
can’t reach the demanded position. because the system cannot go on
Abort button: Plate will be aborted.
When this error message occurs,
make sure that there are no obsta-
cles that jammed the plate trans-
ports movement. Press the Retry
button. If the error recurs the plate
transport module has to be checked

Plate transport %1 During the initialisation procedure. Restart software to initialise the plate
motor not homed Plate transport motor (X, Y, or Z) transport again.
cannot find home position. If the error recurs the light barriers of
the plate transport have to be
Plate transport carrier During plate transport movement. Retry button: Plate transport will
error Plate transport crashes at load/ try to load/unload the plate again.
unload movement. Plate holder does Ignore button: Not advisable
not move far enough into the instru- because the system cannot go on
ment, so that the light barrier is not without sequence errors.
interrupted. Abort button: System will try to
abort the plate.
If the error recurs after pressing the
Retry button the plate transport
position has to be aligned again (see
Plate transport EEP- EEPROM error while reading/writ- Restart system again. If the error
ROM error ing procedure. recurs, the plate transport PCB has
to be changed (see chapter 6 on page 6-
1).
Plate transport error Error in plate transport in case of Push the Retry button. If the error
increased resistance. recurs, try to locate the cause of the
resistance (blocking) and eliminate
it. If no mechanical blockage is evi-
dent, check the plate transport (see
Please close system During initialisation procedure. Sys- Close the system flap and push the
flap. tem flap isn’t closed. OK button. If the error recurs after
closing the flap the closing mecha-
nism has to be checked.
Please close the instru- During initialisation procedure. Close instrument drawer and push
ment drawer. Instrument drawer isn’t closed. OK button. If the error recurs after
closing the instrument drawer, the
closing mechanism has to be
checked.
Please close the load/ After loading/unloading the micro Close load/unload door and push
unload door. plate. OK button. If the error recurs after
closing load/unload door, the closing
mechanism or the door switch has to
be checked.
Please close the tip During initialisation procedure. Tip Close tip drawer and push the OK
drawer. drawer isn’t closed. button. If the error recurs after clos-
ing the tip drawer, the closing mech-
anism has to be checked.
Please configure the After adding plate and assay. Wrong Push the OK button. Make sure
system in preparation pre-dilution area is defined. that the correct pre-dilution area is
for a standard worklist. chosen for this assay and start work-
Ensure that the dilution list again.
tube rack is inserted.

Rack scanner focusing During a reading step of bar coded If error occurs please use the possi-
error sample/reagent rack. bility to allocate the reagents and
The bar code scanner of the reagent samples manually. The bar code
and sample racks cannot be scanner has to be checked (see
focused. chapter 14 on page 14-1).
Rack scanner motor Motor error in scanner of reagent If error occurs please use the possi-
error and sample rack. Scanner firmware bility to allocate the reagents and
does not work correctly. Electronic or samples manually. The bar code
mechanical problems of scanner. scanner has to be checked (see
Rack scanner not During the initialisation procedure. If error occurs please use the possi-
detected Bar code scanner of the loading bay bility to allocate the reagents and
is not connected. samples manually. The bar code
scanner has to be checked (see
Reagent ... is undefined After adding plate, assay and sam- Open assay and add the missing
ple. reagent to reagent database. Restart
A reagent has not been defined. the worklist.
Note: the changes have to be saved,
with the Save button before they
will get active.
RS232 write error - Error in interface PC / analyzer. Check connection between PC and
command: '%1' analyzer. Start PC and analyzer
again. If error recurs, the system has
to be checked.
Some required After the loading dialogue. Push the OK button. Load all
resources have not Not all required reagents have been resources from the unallocated
been allocated to sys- allocated to a position. resources field into the appropriate
tem positions position (reagents, samples, dilution
tubes/plates, tips, buffers).
Suspect tip pick-up During tip pick-up When the error occurs the software
Pipettor cannot pick-up pipettor tip goes on with the next tip automati-
correctly (does not move deep cally. If the error recurs the teaching
enough into the tip). positions and the disposable tip
adapter have to be checked (see
System fluid low During the initialisation procedure or Fill up system fluid container with
during the run. deionised water and press the OK
System fluid for pipettor too low. button.
System waste full. During initialisation procedure or Empty the waste container and
Empty the waste con- during the run. press the OK button. If the error
tainer. recurs after emptying the waste con-
tainer the level sensor has to be
checked

The disposable tips During the tip type detection. After pushing the OK button the
have been incorrectly Software detected a wrong type of software displays the loading dia-
loaded. tip. logue where you have to check if the
correct type of tips (300 µl or
1100 µl) are loaded to the correct
position.
The plate transport can- During the run. Abort the worklist and restart soft-
not find a route from its Plate transport has no information ware to initialise the plate transport.
current position to its about its present position. Restart the worklist again. If the error
next destination recurs the plate transport has to be
There was an error After finishing a plate and getting a Retry button: software will try to
found when printing the result. start the print job again.
Document …to LPT1: Cancel button: The print job will
The device is not con- be cancelled.
nected. Do you want to
Please check that the printer is
retry or cancel the job?
switched on and all cables are con-
nected. Make sure that the right
printer driver is installed.
Tip eject failure Error during the tip ejection. Remove tip manually from the pipet-
tor or trigger the eject mechanism
manually. Press the Retry button
after removing the tip manually. The
system goes on with the next step. If
the error recurs the disposable tip
adapter has to be checked (see
Unknown colorimeter Unknown photometer error. Restart system and software. If the
error code'%1' error recurs, the whole colorimeter
module has to be checked (see
Unknown incubator Unknown incubator error. Restart system and software. If the
error code: '%1' error recurs, the whole incubator
Unknown plate trans- Unknown plate transport error. Abort the worklist and restart soft-
port error code: '%1' ware to initialise the plate transport.
Restart the worklist. If the error
recurs the plate transport has to be
Unknown washer error Unknown washer error. Restart system and software. If the
code '%1' error recurs, the whole washer mod-
ule has to be checked (see chapter 7 on
page 7-1).
Verification failed: %1 During the colorimeter verification. If the error occurs, change the lamp
The reader has failed the validation and check the filter configuration.
criteria. Repeat the colorimeter verification
test. If the error recurs the colorime-
ter module has to be checked (see

Washer %1 motor not The washer motor %1 is faulty or the Retry button: System will retry to
homed washer isn’t initialised. reach the home position again.
aborted.
Press the Retry button to repeat
the last step. If the error recurs press
Abort Pl ate button and restart
the software to initialise the washer
again. If the error recurs the washer
Washer aspirate pump During the initialisation procedure or Retry button: Software will try to
error during a wash step. activate the aspirate pump again.
The washer aspirate pump or the Abort Pl ate button: Plate will be
vacuum sensor is faulty. aborted.
Before pressing the Ret ry button,
please check that all tubings are
connected correctly. If the error
recurs the vacuum sensor and the
aspirate pump have to be checked
Washer dispense pump During the initialisation procedure or Retry button: Software tries to
error during a wash step. repeat the dispensing step.
The washer dispense pump is faulty. Abort Pl ate button: The plate
will be aborted.
recurs the dispense pumps have to
be checked (see chapter 7 on page 7-1).
Washer EEPROM error EEPROM error while reading/writ- Restart system again. If the error
ing procedure. recurs the washer PCB has to be
changed (see chapter 7 on page 7-1).
Washer head home During the initialisation procedure or OK button: Software will cancel the
movement error during a wash step. worklist and jump back to start
Washer lift cannot reach its home menu.
position. Press the OK button to come back
to the start menu. Restart software
and system. If the error recurs the Z-
motor and the light barriers have to
Washer plate home During the initialisation procedure. OK button: Software will cancel the
movement error Washer X-sledge cannot reach the worklist and jump back to start
home position. menu.
Press the OK button to come back
to the start menu. Restart software
and system. If the error recurs the X-
motor and the light barriers have to

Washer plate motor During initialisation procedure or Retry button: System will try to
movement error during a wash step. activate the X-motor again.
aborted.
Press the Retry button, if the error
recurs the X-motor has to be
Washer plate move- During a wash step. Retry button: System will try to go
ment error Plate transport motor of washer on with the wash step.
faulty. Abort Pl ate button: Plate will be
aborted.
Before pressing Retry check
washer if carrier sledge is jammed,
or a strip of the micro plate in not
inserted correctly.
Select the menu item Util it ies |
Selftest to initialise the system
again. If the error persists, check the
washer plate transport (see chapter 7
on page 7-1).
Washer reagent level After loading dialogue or during the Retry button: Software checks the
low run. level sensor again.
One of the washing liquids is empty. Abort button: The worklist will be
aborted.
Ignore button: The worklist goes
on without filling up the buffer.
Refill the washer reagent and press
the Retry button. If the error recurs
after refilling, check the cables con-
nections of the level sensors.
Washer strip error. Before wash step. Retry button: Strip check will be
One of the strips ofthe microplate repeated.
isn’t inserted correctly. Abort Pl ate button: Plate will be
aborted.
After error occurs press the Retry
button. The system will go on, if the
error recurs abort the plate.
Washer waste full During initialisation procedure or Retry button: System will check
during the run. the level sensor again.
Waste bottle “1” is full. Abort Pl ate button: Plate will be
aborted.
Empty washer waste bottle “1” man-
ually and press the OK button.
If the error recurs, the washer level
sensor has to be checked.
Table 17-1: Error messages of the user software

17.2 Plate System Error Messages
All error codes from the virtual module, plate transport, photometer/colorimeter,
washer and incubator are prefixed with the:
• Module ID (e.g. 42),
• Assembly code (e.g. 49),
• Control byte (usually 03 for errors),
• Sub assembly code (e.g. 56) and
• Reply code.
• The letters "ER" (hex: '45' + '52') indicate the command that contained
the error.
• The code following indicates the nature of the error as indicated below,
depending on the module.
The other devices do not follow the structure described above. Instead they
have individual codes.
Figure 17-1: Structure and example of an hex error string

17.2.1 Received String
First Byte: Mod- To recognize the module messages the first parameter in a command describes the
ule transmitted module.
ID Hex Module
41 Virtual module - Liquid container(see chapter 17.2.3 on page 17-14)

42 Plate transport (see chapter 17.2.4 on page 17-15)
43 Photometer/Colorimeter (see chapter 17.2.5 on page 17-16)
44 Washer (see chapter 17.2.6 on page 17-18)
45 Incubator (see chapter 17.2.7 on page 17-19)
00 COP (see chapter 17.3.1 on page 17-20)
Sample rack scanner (see chapter 17.3.2 on page 17-21)
FD Pipettor (see chapter 17.4.1 on page 17-22)
Table 17-2: First byte: module
Second Byte:
Assembly
Hex Description
00 to FF Assembly code
Table 17-3: Second byte: assembly
Third Byte: Con-

trol
Hex Description
00 Normal reply
01 Report
03 Fatal ERROR
Table 17-4: Third byte: control
Fourth Byte:
Sub Assembly
Hex Description
00 to FF Sub assembly code
Table 17-5: Fourth byte: sub assembly

Further Byte(s):
Reply
Hex Description
00 to FF Reply can have different length
Table 17-6: Further byte(s): reply
17.2.2 ASCII Codes Used in Plate System Error

Messages
Hex ASCII Hex ASCII Hex ASCII
41 A 4A J 53 S
42 B 4B K 54 T
43 C 4C L 55 U
44 D 4D M 56 V
45 E 4E N 57 W
46 F 4F O 58 X
47 G 50 P 59 Y
48 H 51 Q 5A Z
49 I 52 R
Table 17-7: Hex-/ASCII-Codes
17.2.3 Virtual Module Errors (Module ID 41)
Reply: Reason: Action:
ERW System waste container is full. Empty the system waste con-
tainer.
ERF System fluid low. Refill the system fluid con-
tainer.
Table 17-8: Virtual module (module ID 41)

17.2.4 Plate Transport Errors (Module ID 42)

ERA Argument error in command. Check that the firmware is the
correct version for the version
of software being run.
ERB Plate transport bar code IC Replace the plate transport
error. bar code scanner.
ERBC The plate bar code scanned Replace the plate with the cor-
was not what was expected. rect one.
ERD Plate load/unload door is 1. Close the plate load/
open while trying to move. unload door.
2. Check the connectors to
the switch.
ERHn Motor not home. n shows the 1. None. The software will
position: reset the plate transport
• ERHX: X-axis home and try again.
• ERHY: Y-axis home 2. Check the function of the
• ERHZ: Z-axis home light barriers (X/Y/Z).
ERMn Motor jammed during move- 1. Clear the obstruction.

ment. n shows the axis: 2. Check movement without
• ERMX: X-axis motor power.
• ERMY: Y-axis 3. Grease and oil again.
• ERMZ: Z-axis 4. Check belt tension.
ERP Plate carrier sensor failure. 1. Check that plate carrier is

breaking the sensor.
2. Check connectors and
function of light barrier.
ERR Firmware was unable to com-
pute a safe route between the
two positions.
ERW EEPROM error. 1. Download firmware.
2. Load global settings.
3. Replace the PCB.
Table 17-9: Plate transport (module ID 42)

17.2.5 Photometer/Colorimeter Errors (Module ID

43)
ERA Argument error in command. Check that the firmware is the

ERB Background light levels too 1. Check position of lamp.
high. 2. Check filter positions.
3. Replace the module.
ERC A/D conversion error. Replace the PCB.
ERFn Filter error. n shows the filter 1. Check luminosity of lamp.
position. 2. Replace the filter.
ERHn Motor not homed. n shows the 1. None. The software will
motor: reset the photometer and
• ERHX: X-motor (plate car- try again.
rier) 2. Check light sensors (func-
• ERHY: Y-motor (filter tion and position).
motor) 3. Check belt tension.
ERL Lamp has blown. Replace the lamp.

ERMn Motor is jammed. n shows the 1. Clear the obstruction.
motor: 2. Check movement without
• ERMX: X-motor (plate car- motor power.
rier) 3. Check belt tension.
• ERMY: Y-motor (filter
motor)
ERP Plate carrier error. 1. Check that the plate carrier
correctly breaks the sen-
sor.
2. Teach the plate transport
position again.
ERPD No scan data available. n
shows the filter position.
ERPOn A/D over-range error. n shows 1. Replace the PCB.
the filter position. 2. Check lamp position.
3. Check filters.
ERPUn A/D under-range error. n 1. Check filters.
shows the filter position. 2. Replace the PCB.
ERPW Reading over-run error. Replace the PCB.
ERR A/D reference voltage error. Replace the PCB.
ERTn Faulty optic channel. n shows Check that the optic channel
the filter position. is not obstructed.
3. Replace the PCB.

Table 17-10: Photometer/Colorimeter (module ID 43)

17.2.6 Washer Errors (Module ID 44)

ERA Argument error. Check that the firmware is the
ERE EEPROM error. 1. Load global settings.
2. Replace the EEPROM.
ERHn Motor not homed. n shows the 1. None. The software will
motor: reset the washer and try
• ERHX: X-axis home again.
• ERHZ: Z-axis home 2. Check function and posi-
tion of light barriers.
3. Check movement without
motor power.
4. Check function of Z- and
X-motor.
5. Check belt tension.
ERMn Motor has become jammed Clear the obstruction.
during movement. n shows
the motor:
• ERMX: X-motor
• ERMZ: Z-motor
ERP Plate carrier sensor error. Check that the plate carrier is
breaking the sensor.
ERSA Washer waste bottle is full. 1. Empty the washer waste
bottle.
2. Check cable connectors.
3. Check fill sensor
ERSR Reagent level is low. 1. Refill the reagent bottle.
2. Check cable connectors.
3. Check fill sensor
ERRA Aspirate pump error: Set the vacuum sensor.
Change the vacuum sensor.
Check aspirate pump electri-
cal connections. Replace the
aspirate pump.
ERRD Dispense pump error. 1. Check electrical connec-
tions.
2. Check tubing connections.
3. Replace the dispense
pump.
ERRW Waste pump error. Replace the waste pump.
ERV Valve error. Replace the valve.
3. Replace the PCB.
Table 17-11: Washer (module ID 44)

17.2.7 Incubator Errors (Module ID 45)

ERA Argument error. This is a criti- Check that the firmware is the
cal error condition. correct version for the version
ERHn Heater error. n shows the 1. Check cable connections.
incubator group number: 2. Replace the incubator.
• 1: Incubator 1 and 2
• 2: Incubator 3 and 4
ERKC Shake calibration failed. The
55% shake amplitude drive
signal value could not be
found.
ERKOI Shake override idle position Check that the shake PCB
frequency out of range. The and hall-sensor are connected
override off (or idle) position and functional.
was outside of the acceptable
limits.
ERKOO Shake override on position Check that the shake PCB
frequency out of range. The and hall-sensor are connected
override on was outside of the and functional.
acceptable limits.
ERKR Shake position frequency out Check that the shake PCB
of range. The shake fre- and hall-sensor are connected
quency measured did not and functional.
appear to be a valid measure-
ment.
ERKT Shake position edge time out. 1. Open incubator and look
No edge was detected to the for mechanical obstruc-
frequency signal from the tions.
shake PCB. 2. Check that the shake PCB
and hall-sensor are con-
nected and functional.
ERP Plate carrier sensor error. Check that the plate carrier
breaks the sensor.
ERTn Temperature sensor error. n 1. Check cable connections.
shows the sensor number or 2. Replace the incubator or
name: ambient sensor.
• A: ambient sensor is read-
ing outside of a valid range
• 0, 2, 4, 6: Incubator lower
sensor of incubator 1, 2, 3,
4
• 1, 3, 5, 7: Incubator upper
sensor of incubator 1, 2, 3,
4


3. Replace the PCB.
Table 17-12: Incubator (module ID 45)
17.3 COP and Sample Rack Scanner Error

Messages
All error codes from the COP and the sample rack scanner are prefixed with the:
• Module ID (e.g. 00),
• Command ID (e.g. D0),
• Command Parameters (e.g. 54) and
• Reply code (e.g. 11).
17.3.1 COP Errors (Module ID 00)
Code: Reason: Action:
00D05410 COP EEPROM error. Replace the EEPROM.

00D05411 COP serial port error. Replace the COP PCB.
Table 17-13: COP (module ID 00)
Error message: Meaning:
Instrument Draw Error: 01 Switch not closed.

Pipettor: Cover Lock Error Cover not closed.
Tip Draw Error: 01 Switch (black) left not closed.
Tip Draw Error: 02 Switch (black) right not closed.
Tip Draw Error: 03 Lock mechanism left misaligned.
Tip Draw Error: 04 Lock mechanism right misaligned.
Table 17-14: Error messages

17.3.2 Sample rack scanner errors (Module ID 00)
Code: Reason: Action:
00D5543C Scanner command timeout.

00D5543D Scanner not connected. Check the scanner connec-
tions.
00D5543E Rack command could not be
sent.
00D5543F Scanner motor error. Replace the scanner.
00D55440 Scanner focusing error. Replace the scanner.
Table 17-15: Sample Rack Scanner (module ID 00)
17.4 Pipettor Error Messages
displayed messages! I. e., the displayed X-coordinate means the technical Y-
All error codes from the Pipettor are prefixed with the:
• Module ID (e.g. FD),
• Error Classification:
• Fatal Error (FF),
• Warning (FE),
• Internal Time LSB and MSB (e.g. 3433),
• Error Code (e.g. 2A) and
• Parameters (e.g. 11).

17.4.1 Pipettor Errors (Module ID FD)
Error
Meaning: Fatal:
Code:
01 Unknown command. no
02 Execution delay. Unable to meet specified execution time. no
03 Transmission data lost. Receiver off line. no
04 The processor was reset by watchdog or trap. Software failure, yes
processor hardware failure.
0E Sledge drive (X-axis) position not reached. Too much friction. yes
10 DC-drive (Y-axis) position not reached. yes
12 Z-position not reached. yes
18 Access to undefined target. yes
1E Command parameter out of range. yes
2A Diluter answer time out (see table 17-18 on page 17-25). yes
2B Diluter checksum error (see table 17-18 on page 17-25). yes
2C Diluter error (see table 17-18 on page 17-25). yes
30 No liquid found. no
33 Not enough liquid. no
42 Can't clear reference switch. Reference switch does not turn yes
OFF.
43 Can't find limit switch / time out. Reference switch does not yes
turn ON.
45
50 Internal error. yes
5A No terminator in pump string. yes
5C Not enough parameters for specified command. yes
70 Disposable dropped. yes
82 Open loop / overload error. Missing encoder feedback. Motor yes
doesn't move. Excessive load, high friction
83 Left: No LLD signal. Missing cable connection to probe, hard- no
ware error.
85 Left: Bad LLD signal. Bad cable connection to probe, bad no
grounding conditions, not enough liquid.
Table 17-16: Pipettor Error Commands (module ID FD)
In the case that an axis parameter is included within the error message the following
assignment is valid:

Parameter Axis
0 X-axis
1 Y-axis
4 Z-axis
Table 17-17: Axis parameter

Parameter: Reason: Action:
00 No error -
01 Initialisation error This error occurs if the pump cannot be initial-
ised. Check the pump for possible obstruc-
tions or loose connections before you try a
new initialisation. The pump does not accept
commands as long as it was initialised suc-
cessfully.
02 Faulty command This error occurs if a faulty command was
given. Correct the command and send it again.
03 Faulty parameter This error occurs if a faulty parameter (<n>)
was entered with a command. Correct the
parameter and send the corrected command.
04 Faulty command This error occurs if the command structure or
sequence the communication protocol is faulty. Check
the command sequence and repeat the cor-
rected command sequence.
06 EEPROM error This error occurs if the EEPROM is faulty.
Check the pipettor PCB (see table 11 on page 11-
1).
07 Device not initial- This error occurs if the pump was not initial-
ised ised. To delete the error, initialise the pump.
08 No string found In the EEPROM no string was found at the
in EEPROM selected location. Select a correct location.
09 Piston over- This error occurs if the injector piston loses
loaded steps.The pump must be initialised new,
before a normal process can take place. This
error can be deleted by initialising the pump
new. Starting from firmware version 2.00, the
pump reports the error, but is able to continue
working. The actual absolute position is rede-
termined after losing steps. From this position
the next movement command is executed. In
connection with P- and D-commands (relative
movements) this may lead to aftereffects. If for
example, the plunger loses steps while moving
to position 100 and in the end stands at posi-
tion 97, then a following D100R-command
leads to a parameter error. Therefore, the
pump should be reinitialised after losing steps.
0A Valve overloaded This error occurs if the valve drive loses to
many steps. Frequent or repeated errors of
this kind indicate that the valve should be
replaced. This error can be deleted by initialis-
ing the pump new.
0B Piston movement If the valve is in [B]ypass (= flow-through posi-
not allowed tion) no piston movement commands are
allowed.

Parameter: Reason: Action:
0D Symbol Symbol sequence is too long for the EEPROM

sequence for (>63 bytes). Shorten the string.
EEPROM too
long
0E Excess Pressure This error occurs in connection with the Clot-
Detection, if the pressure becomes excessive
e.g. due to a total blockage. This error can
only be cleared by a new initialisation of the
pump. If the error appears also during initiali-
sation, the attached line and the needle must
be cleaned.
0F Command over- This error occurs if the buffer memory contains
flow too many symbols. Commands in the buffer
must be carried out first before further com-
mands can be sent.
Table 17-18: VP9100 precision syringe pump error codes parameter
17.4.2 Pipettor Troubleshooting
17.4.2.1 Testing the Function of the Z-Limit Switch

The function of the Z limit switch can only be tested if the 24V supply for the arm is
switched on. Therefore the pipettor must be initialised without initialising the drives.
Send Low-Level Command 'FD CF FF FF 00 00 00 00'. Now the LED displays
the limit switch status.
17.4.2.2 Open Loop Error Causes

The 'Open Loop/Overload' Error is generated if the closed loop driver remains satu-
rated too long. Distinguish the following cases for finding the problem:
1. The axis moves very fast (faster than normally)
• Missing encoder feedback
• Motor polarity exchanged (only X drive)
2. The axis does not move at all.
• Motor not connected.
• Missing power supply for motors, fuse blown.
• Power stage defect.
3. Initialisation is successful, when moving fast the error occurs, sometimes as
a rare event.
• High friction.
• Axis can not move free, moving parts come in contact to housing.
• Belt tension too high.
• When initialising: Limit switch out of order. Drive moves against
mechanical limitation.
17.4.2.3 Y-axis
When initialising the Y stepper motor, the encoder is not used. Successful initialisa-
tion does not proof the encoder function. DC drives always need the encoder.

17.4.2.4 LLD Trouble Shooting (Capacitive LLD)

Wrong Positive Detection:
• Bad contact from coax cable to the tip. Adapter screw not tightened or cor-
roded.
• Bad contact from coax cable shield to toothed rod. Screw not tightened or
corroded.
• Coax cable defective.
• Cable connection from oscillator to main board defect (1-tip arm).
• Air bubbles on the liquid surface.
• When moving down the tip comes in contact with anything else than the liquid
surface.
• Liquid inside the adapter makes a contact between tip and toothed rod.
Wrong Negative Detection:

• No contact from coax cable to the tip. Adapter screw not tightened or cor-
roded.
• Zstart below the liquid level.
• Zmax adjusted above the liquid level.
• Not enough liquid.
• Liquid with very low conductivity (deionised water).
• Liquid containment with very low capacity.
• Liquid inside the adapter makes a contact between tip and toothed rod.
• Disposable tip not conductive.
• LLD disabled (The software of some instruments has an enable switch for the
LLD).
• Instrument ground not connected to pipettor ground.
17.4.2.5 Standard Maintenance Procedure - Lubrication

Most of the problems are caused by insufficient lubrication of the guiding rack (see
17.4.2.6 Air Adjustment of the X-axis

Check the axis regarding too tight adjustment of the air between the pulley and the
rack (see chapter 11.6 on page 11-27).
17.4.2.7 Adjustment of the X-axis Rollers

In some cases the adjustment of the rollers on the sledge are too close to the sheet
metal guiding (see chapter 11.6 on page 11-27).
17.4.2.8 Adjustment of the Y-axis Rollers

In some cases the adjustment of the rollers on the bridge are too close to the sheet
metal guiding (see chapter 11.6 on page 11-27).
17.4.2.9 Timing Belt Tension

• A too high adjusted timing belt tension can cause higher friction and so prob-
lems in the positioning of the bridge.
• A too low adjusted timing belt tension can cause a jumping of the timing belt
on the timing belt pulley. This is causing fault positioning of the system which

can not be recognized by the control software. So a too low adjusted timing
belt tension is dangerous!
See chapter 11.6 on page 11-27
17.4.2.10 Free Movement of the Bridge on the Guiding Mechanism

The bridge must have a free movement in the Y-direction (see chapter 11.6 on page 11-
27).
17.4.2.11 Free Movement of the Upper Rollers on the Guiding Mech-

anism
The bridge must have a free movement in the Y-direction (see chapter 11.6 on page 11-
27).
17.4.2.12 Wear of the Roller Bearings on the Guiding Mechanism

On ELISYS QUATTRO systems (serial number > 50) there is a wear protective
washer between the roller bearing and the aluminium roller plate mounted. This
washer protects the bearing of getting polluted by material of the roller plate.
See chapter 11.6 on page 11-27


Technical Data
18 Technical Data
18.1 Environment
Environment This standard applies equipment designed to be safe at least under the following
Conditions (IEC conditions:
61010-1) • indoor use;
• altitude up to 2000 m;
• temperature 5 °C to 40 °C;
• maximum relative humidity 80% for temperatures up to 31 °C decreasing lin-
early to 50 % relative humidity at 40 °C;
• mains supply voltage fluctuations up to 10 % of the nominal voltage;
• applicable rated pollution degree.
Operation Tem- • 15 °C to 25 °C
perature
18.2 Mains Voltage and Fuses
Analyzer
Voltage range: 115 V to 230 V AC
Current range: 4 A (115 V) to 2 A (230 V)
Frequency range: 50 Hz to 60 Hz
Mains fuse: T4A
Computer, Mon- For electrical details of the PC equipment please refer to the technical documentation
itor and Printer of the respective manufacturer.

Technical Data
18.3 Laser of the Bar Code Scanner
Laser of the
rack system bar
Class: Class 2 laser product
code scanner
Maximum output radia- 1.3 mW
tion:
Pulse duration: 70 µs
Emitted wave length: 650 - 690 nm
Standards: EN 60825-1: 2001
Complies with 21 CFR 1040.10 and 1040.11
except for deviations pursuant to Laser Notice
No. 50, dated July 26th, 2001 at the date of man-
ufacture.
Laser of the
plate bar code
Class: Class 2 laser product
scanner
Maximum output radia- 0.5 mW
tion:
Pulse duration: 10 µs
Emitted wave length: 660 - 680 nm
Standards: EN 60825-1: 2001
Complies with 21 CFR 1040.10 and 1040.11
except for deviations pursuant to Laser Notice
No. 50, dated July 26th, 2001 at the date of man-
ufacture.

Technical Data
18.4 Weights and Dimensions
18.4.1 System with Packaging
Analyzer
Weight: 175 kg
Dimensions: 120 cm x 92 cm x 122 cm (W x D x H)
Accessories
and Cover Box-
Weight: Approximate 90 kg
es
18.4.2 System without Packaging
Analyzer with
Cover
Weight: 130 kg
(Depth with waste bag and completely opened
drawer)
Accessories
Weight: Approximate 84 kg
For details of the PC equipment please refer to the technical documentation of the
manufacturer.

Technical Data

Circuit Diagrams
19 Circuit Diagrams
19.1 Photometer
Figure 19-1: Photometer – Absorbance reader

Circuit Diagrams
Figure 19-2: Photometer – C1610 processor

Circuit Diagrams
Figure 19-3: Photometer – Plate drive

Circuit Diagrams
Figure 19-4: Photometer – Power supply

Circuit Diagrams
Figure 19-5: Photometer – Filter motor drive

Circuit Diagrams
Figure 19-6: Photometer – Absorbance A/D

Circuit Diagrams
Figure 19-7: Photometer – Lamp control

Circuit Diagrams
19.2 Washer
Figure 19-8: Washer

Circuit Diagrams
Figure 19-9: Washer – C1610 processor

Circuit Diagrams
Figure 19-10: Washer – Power supply

Circuit Diagrams
Figure 19-11: Washer – Plate drive

Circuit Diagrams
Figure 19-12: Washer – Head drive

Circuit Diagrams
Figure 19-13: Washer – Pump drives

Circuit Diagrams
Figure 19-14: Washer – Sensors

Circuit Diagrams
Figure 19-15: Washer – Wash verification interface

Circuit Diagrams
19.3 Plate Transport
Figure 19-16: Plate transport

Circuit Diagrams
Figure 19-17: Plate transport – C1610 processor

Circuit Diagrams
Figure 19-18: Plate transport – Power supply

Circuit Diagrams
Figure 19-19: Plate transport – X-drive

Circuit Diagrams
Figure 19-20: Plate transport – Y-drive

Circuit Diagrams
Figure 19-21: Plate transport – Z-drive

Circuit Diagrams
Figure 19-22: Plate transport – LED drive

Circuit Diagrams
Figure 19-23: Plate transport - Transition

Circuit Diagrams
19.4 Incubator
Figure 19-24: Incubator

Circuit Diagrams
Figure 19-25: Incubator – C1610 processor

Circuit Diagrams
Figure 19-26: Incubator – Power supply

Circuit Diagrams
Figure 19-27: Incubator – Heater drives

Circuit Diagrams
Figure 19-28: Incubator – Temperature sensors

Circuit Diagrams
Figure 19-29: Incubator – Shake control

Circuit Diagrams
Figure 19-30: Incubator – Incubator shaker

Circuit Diagrams
19.5 Pipettor
Figure 19-31: Pipettor

Circuit Diagrams
Figure 19-32: Pipettor - X-Z PCB

Circuit Diagrams
19.6 Rack System
Figure 19-33: Rack system

Circuit Diagrams
19.7 CPS Module (COP)
Figure 19-34: COP

Circuit Diagrams
Figure 19-35: COP – C1610 processor

Circuit Diagrams
Figure 19-36: COP – Power supply

Circuit Diagrams
Figure 19-37: COP – UARTS 1

Circuit Diagrams

Circuit Diagrams

Circuit Diagrams
Figure 19-40: COP – Logic

Circuit Diagrams
Figure 19-41: COP – Sensors, drives and LEDs

Circuit Diagrams
Figure 19-42: COP – IO expansion

Circuit Diagrams
Figure 19-43: COP – Rack and plate bar code decoder

Circuit Diagrams
Figure 19-44: COP – Module connections

Circuit Diagrams
Figure 19-45: COP – Isolated PC RS232

Circuit Diagrams
Figure 19-46: COP – SRAM

Human
Gesellschaft für Biochemica
und Diagnostica mbH
Max-Planck-Ring 21 ! D-65205 Wiesbaden
Germany
Telefon: +49 6122 9988 0
Telefax: +49 6122 9988 100
eMail: human@human.de
Internet: http://www.human.de
01/2004-12

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HUMAN -

We reserve the right to make changes in the course of technical development

System Manufacturer: HUMAN GmbH

Copyright © 2004, HUMAN GmbH. All rights reserved.

ELISYS QUATTRO - Service Manual HUMAN TOC-1

TOC-2 ELISYS QUATTRO - Service Manual HUMAN

ELISYS QUATTRO - Service Manual HUMAN TOC-3

TOC-4 ELISYS QUATTRO - Service Manual HUMAN

ELISYS QUATTRO - Service Manual HUMAN TOC-5

CPS Module (COP) 1

Troubleshooting and Error Messages 1

TOC-6 ELISYS QUATTRO - Service Manual HUMAN

ELISYS QUATTRO - Service Manual HUMAN TOC-7

ELISYS QUATTRO - Service Manual HUMAN 1-1

1.1 Typographical Conventions

Please consider the following typographical conventions.

1.1.1 Warning Messages

Caution, risk of danger! Consult instructions for use!

Caution, hot surface!

Consult instructions for use!

Notes are indicated by this symbol and printed in special types.

Disconnect mains power connector before servicing!

1-2 ELISYS QUATTRO - Service Manual HUMAN

1.1.3 Symbol Keys

In Vitro Diagnostic Medical Device

1.1.4 Special Types

LEDs LEDs (light emitting diode) are printed in special type.

Buttons Buttons are printed in spaced type.

Keys Keys are printed in slanted type.

File examples File examples are printed in typewriter font.

ELISYS QUATTRO - Service Manual HUMAN 1-3

1.2 Safety Instructions

Please always act according to the following safety instructions, before as

1.2.1 General Safety

Use the system only for the designated application.

1-4 ELISYS QUATTRO - Service Manual HUMAN

1.2.2 Electrical Safety

Country-specific regulations regarding safe electrical operation of the in-

The instrument must be connected with a delivered connection cable to dedi-

Do not allow anything to rest on the power cord.

ELISYS QUATTRO - Service Manual HUMAN 1-5

Always replace blown fuses, don't try to repair them.

Don't position the instrument so that it is difficult to operate the disconnecting

1.2.3 Laser Safety

Use of controls or adjustments or performance of procedures other than those

1.2.4 Mechanical Safety

Do not place the instrument on a unstable table, cart, or similar.

Never open screw-attached housing parts while the instrument is on.

1-6 ELISYS QUATTRO - Service Manual HUMAN

Slots and openings are provided for ventilation.

1.2.5 Biological Safety

Risk of infection! Handling of samples and reagents:

If sample material is spilled in the system, clean and disinfect it immediately

It is not possible to autoclave the containers for liquids and waste!

1.2.6 Cleaning the System

Liquid detergents, disinfectants or decontamination liquids may not be poured

ELISYS QUATTRO - Service Manual HUMAN 1-7

Disposal of the instrument according to national legislations.

Disposal of the packaging material according to national legislations.

Containers intended for single-strip use may not be used repeatedly.

1.3 Positions of Safety Labels and Type

If any label gets lost, replace it by an equivalent label!

1.3.1 General Warning Labels