Chorus-Trio Expander Service Manual Rev. 2 07.2021 en

SERVICE MANUAL
FOR CHORUS TRIO (REF. 81200) AND CHORUS TRIO RAS (REF. 81220)
REVISION 2 Issued in July 2021

Software version 1.xx and Firmware version 7.xxx
THIS MANUAL IS TO BE USED FOR CHORUS TRIO INSTRUMENTS STARTING

FROM S/N 4000 OR UPDATED WITH CHORUS EXPANDER UPGRADE KIT
(REF 83600)
FOR IN VITRO DIAGNOSTIC USE ONLY

This page is intentionally left blank
CHORUS TRIO models:
The present manual refers to the following CHORUS TRIO models with the 7.xx family
of firmware installed:
Catalog number Description
81200 CHORUS TRIO
81220 CHORUS TRIO RAS
Manual revisions list:
Manual revision Description of changes
0 of 03/2021 First issue relative to Chorus TRIO with Expander

Correction of paragraph 2.2 following the replacement of the
1 of 04/2021
internal barcode reader
Correction of paragraphs 10.1.5 and 10.1.9 to mitigate the risk of
wrong date. Added paragraph 10.1.8 following the enabling of
2 of 07/2021
the backup function. Added paragraph 10.2 following the
insertion of a macro for the Chorus + Autosampler system
Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 3

Manufacturer
DIESSE DIAGNOSTICA SENESE SpA
Strada dei Laghi 39, 53035 Monteriggioni (SI) Italy
Tel. +39 0577 307109, Fax. + 39 0577 307106
www.diesse.it
TECHNICAL SUPPORT
Strada dei Laghi 39, 53035 Monteriggioni (SI) Italy
Tel. +39 0577 307109, Fax. + 39 0577 307106
Numero Verde: 800 606932
e-mail: technicalsupport@diesse.it
No page in this manual may be reproduced in any form or by any means, electronic,
mechanical or otherwise, for any use whatsoever without prior written permission
from DIESSE Diagnostica Senese S.p.A.

Symbols:
Key of graphic symbols
Instrument meeting the requirements of the European Directive

98/79/EC on in vitro diagnostic medical devices (98/79/CE).
In vitro diagnostic medical device
Manufacturing date
Serial number
Manufacturer
Key of electric and safety symbols
Protective conductor
WEEE: Waste electrical and electronic equipment – Separate

Collection is required pursuant to Legislative Decree No. 49 of
March 14. 2014 (Italy), on “implementation of Directive 2012/19/EC.”
Attention: please read this manual carefully and comply with the
safety symbols.
Caution: risk of electrical shock
Caution: laser beam
BIOHAZARD: potential risk of contamination handling infectious

substances
Crush hazard: moving parts can crush and cut; keep hands away
Risk of thermal shock due to the warming of the tray for samples
Risk of puncture to hands and fingers due to the presence of

needles for collection and dispensing

LIMITATIONS AND WARNINGS
Firmware version 7.00, revision 0 of this manual corresponds to the CHORUS TRIO
model of the instrument with the 7.xx family of firmware installed.
It was drafted and carefully reviewed and this version is closely related to the
instrument model (data can be obtained from the instrument’s ID plate) and the
version of the software that controls it (data can be obtained through a procedure on
the instrument itself).
It must be read carefully before using the instrument, especially the parts relating to
safety.
ATTENTION
Do not use this manual except in its complete form.
If this manual is used in an incomplete form, DIESSE Diagnostica Senese S.p.A.
declines any responsibility for adverse results.
ATTENTION
Any instrument updating done with the customer’s authorization requires that the
user manual be updated in a corresponding manner.
DIESSE Diagnostica Senese SpA accepts no responsibility for damage caused

directly or indirectly by errors, defects, or incidents due to any use of this manual that
does not correspond with the version of the supplied instrument.

Index:
1 MOVING THE STRIPS ................................................................................................................................................................... 11

1.1 THE WORKSTATIONS............................................................................................................................................................. 11
1.2 THE TRAY ....................................................................................................................................................................................... 12
1.3 TRAY ROTATION ....................................................................................................................................................................... 12
1.3.1 ABSOLUTE SENSOR ............................................................................................................................................................ 14
1.3.2 STEP CHECK............................................................................................................................................................................... 14
1.3.3 SYNCHRONIZATION ............................................................................................................................................................. 15
1.4 STRIP HOUSING ........................................................................................................................................................................ 16
1.5 TRAY LOCK ................................................................................................................................................................................... 17
1.6 CALIBRATIONS AND CONTROL PARAMETERS .................................................................................................. 17
1.6.1 ALIGNMENT AND CENTERING OF THE PLATE. .............................................................................................17
2 Strip recognition unit .................................................................................................................................................................. 19
2.1 Strip presence sensor (SPS)............................................................................................................................................... 19
2.1.1 Check SPS sensor (Strip Presence Sensor) .........................................................................................................19
2.2 Internal barcode reader ......................................................................................................................................................20
2.2.1 Internal barcode reader check and calibration ............................................................................................ 20
3 Transfer unit ..................................................................................................................................................................................... 22
3.1 Dispensing hydraulic circuit ............................................................................................................................................ 22
3.2 The strip, needles and the well....................................................................................................................................... 23
3.3 Dispenser...................................................................................................................................................................................... 23
3.4 X-axis movement .................................................................................................................................................................... 25
3.5 The syringe unit........................................................................................................................................................................ 26
3.6 The transfer function ............................................................................................................................................................ 27
3.6.1 Transfer function parameters ......................................................................................................................................27
3.6.2 The double dispensing needle ....................................................................................................................................27
3.6.3 Priming of the dispensing and wash circuit ................................................................................................... 28
3.6.4 Withdrawal................................................................................................................................................................................. 28
3.6.5 Drying of the tip...................................................................................................................................................................... 30
3.6.6 Perforation of the cuvette membrane ................................................................................................................ 30
3.6.7 Level detection ..........................................................................................................................................................................31
3.6.8 Mixing ..............................................................................................................................................................................................32
3.6.9 Simple transfer .........................................................................................................................................................................33
3.7 CALIBRATIONS AND CONTROL PARAMETERS ................................................................................................. 35
3.7.1 Circuit transfer ..........................................................................................................................................................................35
3.7.2 Dispensers ...................................................................................................................................................................................35
3.7.3 X-axis movement .................................................................................................................................................................. 36
3.7.4 Level sensor test ......................................................................................................................................................................37
3.7.5 Transfer test ................................................................................................................................................................................37
3.7.6 Strip perforation ..................................................................................................................................................................... 39

4 Optical unit ...................................................................................................................................................................................... 40
4.1 Light source ............................................................................................................................................................................... 40
4.2 The optical device .................................................................................................................................................................. 40
4.3 The optical channel ................................................................................................................................................................41
4.4 Positioning of filters ...............................................................................................................................................................42
4.5 Optical calibration ..................................................................................................................................................................42
4.5.1 Transmittance and absorbance ................................................................................................................................ 42
4.5.2 Alignment of the optical fibres...................................................................................................................................44
4.5.3 Calibration of the optical channels ......................................................................................................................... 46
4.5.4 Calibration of the dark electronic offset.............................................................................................................. 46
4.5.5 Calibration of light emission......................................................................................................................................... 46
4.5.6 The control ramp ................................................................................................................................................................... 47
4.5.7 Report of the virtual ramp.............................................................................................................................................. 48
4.5.8 Control window ...................................................................................................................................................................... 50
4.6 Optical unit testing procedure ....................................................................................................................................... 51
4.6.1 Setting of the optical filter offset.................................................................................................................................51
4.6.2 Calibrating the offset (dark reading) ....................................................................................................................... 51
4.6.3 Calibrating the light .............................................................................................................................................................. 51
4.6.4 Check of absorbance at 650 nm with control solutions ...................................................................52
4.6.5 check of absorbance at 450 nm with control solutions..........................................................................53
5 WASHING unit ................................................................................................................................................................................ 55
5.1 Hydraulic wash circuit.......................................................................................................................................................... 55
5.2 Tank probes ................................................................................................................................................................................ 56
5.3 The washer .................................................................................................................................................................................. 57
5.4 The drying station ...................................................................................................................................................................58
5.5 Collection wells .........................................................................................................................................................................58
5.6 Washing procedure ............................................................................................................................................................. 60
5.7 Washing circuit testing procedure .............................................................................................................................. 61
5.7.1 Supplying of buffer from washer #1 .........................................................................................................................61
5.7.2 Supplying of buffer from washer #2 ........................................................................................................................61
5.7.3 Washing of the piping for washer #1.......................................................................................................................61
5.7.4 Washing of the piping for washer #2 .....................................................................................................................61
5.7.5 Aspiration at drying station #3 ................................................................................................................................... 62
5.8 CONTROL PARAMETERS................................................................................................................................................... 62
5.8.1 Filling level of washer #1 (step 21) ............................................................................................................................. 62
5.8.2 Filling level of washer #2 (step 25) ........................................................................................................................... 62
6 The drain circuit ............................................................................................................................................................................ 64
6.1 The main waste well............................................................................................................................................................. 64
6.1.1 Normal operation.................................................................................................................................................................. 65
6.1.2 Obstructed drain ................................................................................................................................................................... 66
6.1.3 Full waste tank ........................................................................................................................................................................ 66
6.1.4 Faulty drain pump................................................................................................................................................................ 67
6.2 Waste circuit testing procedure ...................................................................................................................................67

6.2.1 Checking of waste level warning sensor (WS)............................................................................................... 67
6.2.2 Checking of waste level error sensor (ES) .......................................................................................................... 68
7 Temperature control ..................................................................................................................................................................69
7.1 Temperature control of the instrument ..................................................................................................................69
7.2 Measuring chamber..............................................................................................................................................................69
7.3 Heater ............................................................................................................................................................................................ 70
7.3.1 Electrical properties of the heater ........................................................................................................................... 70
7.4 Cycle temperature .................................................................................................................................................................. 71
7.5 Stand-by temperature.......................................................................................................................................................... 71
7.6 Procedure for testing the temperature control system ................................................................................ 71
7.6.1 Checking of the instrument temperature sensor ........................................................................................71
7.6.2 Chamber temperature control ....................................................................................................................................71
7.6.3 Strip temperature correction .......................................................................................................................................72
8 Speaker-printer display ............................................................................................................................................................ 73
8.1 Display ............................................................................................................................................................................................ 73
8.2 The speaker ................................................................................................................................................................................. 73
8.3 The printer ................................................................................................................................................................................... 73
8.3.1 Printer testing .......................................................................................................................................................................... 74
9 Electronic Parts .............................................................................................................................................................................. 75
9.1 General Map ............................................................................................................................................................................... 75
9.2 Carrier+IMX8 Board ............................................................................................................................................................... 77
9.2.1 Power supply and connections ................................................................................................................................. 77
9.3 CPU 2010 Board and Driver 2010 Board...................................................................................................................78
9.3.1 Power supply ............................................................................................................................................................................ 79
9.3.2 Description of the Test Points and CPU 2010 board jumpers ........................................................... 88
9.3.3 DESCRIPTION OF THE TEST POINTS AND THE DRIVER 2010 BOARD JUMPERS ........... 89
9.3.4 Troubleshooting ..................................................................................................................................................................... 89
9.4 Low Power .................................................................................................................................................................................. 89
9.4.1 Description ................................................................................................................................................................................. 89
9.4.2 Power supply and connections ................................................................................................................................. 89
9.4.3 Troubleshooting ..................................................................................................................................................................... 96
9.5 Power Supply.............................................................................................................................................................................96
9.6 DESCRIPTION ............................................................................................................................................................................97
9.6.1 Troubleshooting ................................................................................................................................................................... 102
9.7 Connectors board ................................................................................................................................................................. 102
9.7.1 Description ............................................................................................................................................................................... 102
9.7.2 Troubleshooting ................................................................................................................................................................... 105
10 Service Procedures....................................................................................................................................................................106
10.1 Programming firmware CPU 2010............................................................................................................................ 106
10.1.1 Service application ............................................................................................................................................................. 106
10.1.2 Successful connection with CPU 2010 board ......................................................................................... 106
10.1.3 Unsuccessful Connection with CPU 2010 board.................................................................................. 107
10.1.4 Firmware upload on the CPU 2010 board ................................................................................................. 108
10.1.5 Replacement of the Carrier+IMX8 board .....................................................................................................110

10.1.6 Methods saving.................................................................................................................................................................110
10.1.7 Calibrations saving .......................................................................................................................................................... 111
10.1.8 Backup on board Carrier+IMX8 board ........................................................................................................... 112
10.1.9 Software upgrade on the Carrier+IMX8 board ........................................................................................ 112
10.1.10 Methods and Calibrations upload on the Carrier+IMX8 board ..................................................114
10.2 AUTOSAMPLER ....................................................................................................................................................................... 114
10.3 Programming BarCode reader Zebex Z 3080 ................................................................................................... 115
10.3.1 Connect the reader to the instrument through the RS232 cable............................................ 115
10.3.2 Disconnect the RS232 cable ...................................................................................................................................116
10.3.3 PROGRAMMING PARAMETERS.......................................................................................................................... 116
10.4 Maintenance ............................................................................................................................................................................ 122
10.4.1 Routine maintenance................................................................................................................................................. 122
10.4.2 Periodic maintenance ................................................................................................................................................ 122
10.4.3 Wash well for the dispenser needles.............................................................................................................. 123
10.4.4 Dispensers #1 and #2................................................................................................................................................... 125
10.4.5 X-axis guide ......................................................................................................................................................................... 125
10.4.6 Washers 21 – 25 – 28 ......................................................................................................................................................126
10.4.7 Optical unit .......................................................................................................................................................................... 127
10.4.8 Washer wells ......................................................................................................................................................................129
10.4.9 Upper plate......................................................................................................................................................................... 130
10.4.10 Carousel ................................................................................................................................................................................ 130
10.4.11 Peristaltic pumps .......................................................................................................................................................... 130
10.4.12 Diaphragm pump .......................................................................................................................................................... 131
10.4.13 Hydraulic waste and syringe unit....................................................................................................................... 131
10.4.14 Hydraulic unit .................................................................................................................................................................... 132
10.4.15 Syringe Unit ........................................................................................................................................................................ 132
10.4.16 Rotation.................................................................................................................................................................................. 133
10.4.17 Tray synchronization device .................................................................................................................................. 133
10.4.18 Led box and filter handler ....................................................................................................................................... 133
10.4.19 Tank probes ........................................................................................................................................................................ 133
10.4.20 Tubing .................................................................................................................................................................................... 134

1 MOVING THE STRIPS
1.1 THE WORKSTATIONS
The functioning of the system is based on the carrying out of hydraulic, optical and
mechanical operations in certain positions called workstations. The workstations are
mounted on a base located above the tray called the upper level, shown in the figure
below:
Fig. 1-1

Pos. Function
fluid transfer station, where liquids are transferred from one well to another. The
1 positioning unit is able to move from one well to another and to transfer the
liquids.
2 1st reading station
6 station where the presence of the strip is checked
7 station for the reading of the strip’s barcode
12 2nd reading station
22 3rd reading station
21 1st well washer for the strip
25 2nd washer
28 3rd washer (drying)
Since the strip has two reaction cuvettes, wash and reading stations are created so
that the operations can be performed on both cuvettes simultaneously.
1.2 THE TRAY

The device in which the strips are inserted. Composed of a circular plate, mounted on
a pin ending with a pulley at the bottom, is able to rotate between two levels (one
upper and one lower) strengthened by four columns. The support surfaces also
border the upper and lower part of the measuring chamber, which is completed with
the special circular plastic crown fastened around the tray.
The tray is locked in place by tightening the locking ring-nut (see Fig. 1-2).
1.3 TRAY ROTATION

The rotation direction of the tray is determined by a motor whose shaft is joined to a
pulley which drives the rotor by means of a rotational belt.
The motor is mounted on a tensioning bracket so that the belt can be tightened to
one’s liking. Tensioning is done by turning the adjustment screw so that the bracket
moves closer or farther from the tray’s axis. A temporary fastening screw locks the
tensioning bracket in place so that the belt tightness can be checked. Locking the
fastening screws on the bracket holds the motor in position and maintains the belt
tension.
Tray positioning is checked by:

1. absolute positioning sensor (7) which sets the mechanical zero position
2. relative hole sensor (13) that check the movement of the tray (step check)
3. synchronization device abbreviated TSD (6) that allows the tray to be locked in
each of the work positions.

Fig. 1-2
No. Description
1 Locking ring-nut
2 Upper surface
3 Column
4 Lower surface
5 Strip tray
6 Tray synchronization device (TSD)
7 Absolute tray sensor
8 Tray shaft with pulley
9 Drive belt
10 Drive shaft with pulley
11 Temporary lock nut
12 Tensioning bracket
13 Hole sensor (relative)

Fig. 1-3
No. Description
1 Motor
2 Temporary fastening nut
3 Motor unit movement slide
4 Belt tensioning screw
1. locking ring-nut
2. upper surface
3. column
4. lower surface
1
2
5. strip tray
6. Tray Synchronization
13 Device (TSD)
3
7. absolute tray sensor
12 8. drive shaft with pulley
5
4
9. drive belt
11 10. motor with pulley
9
8 6
11. temporary fastening
10
7
nut
12. tensioning bracket
13. hole sensor
14. (relative)
Fig. 1-4
1.3.1 ABSOLUTE SENSOR

A small magnet is mounted on the rotational pulley of the drive shaft which is
detected by a Hall sensor located on a small plate fastened by an angular bracket.
The magnet ensures an absolute mechanical zero position and therefore alignment
of the tray.
1.3.2 STEP CHECK

Every step that the tray makes during the cycle needs to be checked to ensure that
it was done correctly.

The check is done using an infra-red reflection sensor that “detects” the passage
between the plate full area (illuminated sensor) and the area with the hole (dark
sensor).
The rotation control software analyses the time intervals of the passages between the
dark zones and the illuminated zones and checks that the rotor is turning correctly.
1. hole sensor (relative)

2. reference hole
Fig. 1-5
1.3.3 SYNCHRONIZATION
Once the rotation is finished, or after the shaking of the plate has ended, the tray is
correctly positioned by a mechanical unit made up of a special device called the Tray
Synchronization Device (TSD) or simply the tray synchronizer, which inserts a cone-
headed cylinder in one of the holes beneath the tray that correspond to each of the
30 strip insertion positions.
The wedge-shaped pin is quickly moved by a motor on which a worm screw is

mounted. Two sensors check the positioning. The first (limit switch) checks the
starting mechanical position (detail A in the Fig. 1-6). The other is used to check the
alignment of the plate before carrying out the complete insertion of the pin (detail B
in the Fig. 1-6). At the end of the operation the pin completely enters the hole and
locks the tray in the desired position. (detail C in the Fig. 1-6).

2
1 A
3
1. conical pin of the TSD
4
2. positioning hole
3. relative position sensor
B 4. absolute sensor (at rest)
Fig. 1-6
1.4 STRIP HOUSING

The 30 strips housing is made of radial slots situated 12° from each other, which were
specially shaped in order to assure easy insertion and to prevent the strip from
moving during the movement of the plate (rotation and mixing). Above all, the seat
allows the strip to maintain the same positioning under the three optical reading
stations.
The strip is inserted in the slot and is kept in position by the spring located at the end
of the slot, which keeps the strip locked in position by holding the last well.
Upon insertion the strip must be pushed to the bottom of the seat so it can be held
by the spring.
The insertion of the strip into the slot is aided by the bevelling of the lower edge of
the plate.
There are two holes at the bottom of every slot that allow the optical ray to pass
through. The diagram below shows the top view of a plate with 28 strips fully inserted,
one strip partially inserted and one position empty.

1. spring locking sector
2. spring
1 3. holes for optical reading
2
4. strip slot
5. strip
6. strip slot (front view)
7. bevel for strip insertion
4 3
7 6
Fig. 1-7
1.5 TRAY LOCK

When the instrument is switched off, or there is a power outage, the manual or
random rotation of the tray needs to be blocked in order to prevent damage to the
dispenser needles and to the workers. This function is carried out by the Tray Lock
Device (TLD). It is composed of an electro-magnet which is released and
mechanically locks the tray when the power is cut off. Vice versa, when the system is
powered up, the mechanical lock is removed and the tray may be moved by the
control system.
1. lock pin
2. centering hole
3. solenoid
1
3
Fig. 1-8
1.6 CALIBRATIONS AND CONTROL PARAMETERS

1.6.1 ALIGNMENT AND CENTERING OF THE PLATE.
Plate alignment is one of the operations for setting the instrument.

The aligning of the plate is designed to position the plate in the exact work point
where the following conditions have to be checked:
▪ Plate position no. 1 must be centered with the dispenser slit; in particular, the
direction of the dispensing needles must be centered with the strip cuvettes.
▪ Cuvettes no. 5 and 6 of the strips must be perfectly centered with the two
optical channels of the interleavers.
▪
The plate is aligned when the TSD enters the tray cavity without generating any
visible movement of the tray.
The operations to align the tray must be done using the service program present on
The Chorus Trio equipped with the Expander (IMX8) module.
To access the service program, proceed as follow:
Chorus / Utility / Service
The login Password is “diesse”
The plate alignment is obtained acting on the Tray offset parameter. This parameter
represents the number of steps that the tray must carry out, starting from the
absolute position (which is determined by the absolute sensor Fig. 1.4), to reach the
correct alignment. The following operations can be performed to check the
calibration:
1. Open the Motor window:
Chorus / Utility / Service / Diagnostics / Motors
2. Run the Reset Tray with TSD command.
3. Check that the tray doesn’t move when the TSD enters in the tray cavity.
4. If the TSD drag the tray counterclockwise, decrease the Tray offset parameter
until the desired result is obtained.
If the TSD drag the tray clockwise, increase the Tray offset parameter.
To change the parameter, open the Mechanical Calibration window:
Chorus / Utility / Service / Settings / Parameters / Mechanical Calibration
Double click on the row Tray offset and enter the number of correction steps, then
confirm with OK.

2 STRIP RECOGNITION UNIT
2.1 STRIP PRESENCE SENSOR (SPS)
The Strip Presence Sensor (SPS) is composed by a light emitter located on the upper
level and a corresponding receiver located on an electronic board, located in a special
housing on the lower level.
If a strip has been inserted into the tray housing, the handle stops the light beam, and
the receiver can detect the presence of the strip. An unlabelled strip cannot be
recognized.
2
1. light emitter
2. receiver
Fig. 2-1
2.1.1 Check SPS sensor (Strip Presence Sensor)

1. Insert a labelled strip in position no. 26 of the plate
2. Open the Motors window:
3. Select the Tray item and press the Reset command.
4. Open the Sensors window:
Chorus / Utility / Service / Diagnostics / Sensors
5. Check at the row Strip not present that the sensor is off (grey colour)
6. Come back to the Motor window and select again the Tray item, then press
Power Off
7. Move manually the plate of one position and come back to the Sensors window
8. Check at the row Strip not present that the sensor is on (yellow colour)

2.2 INTERNAL BARCODE READER
The internal barcode reader is an Opticon model MDC-220A linear CCD auto-scan
reader. Specifically, the barcode reading takes place under station n° 7, as
represented below:
1. barcode reader
3
2. reader bracket
4 3. barcode reading beam
4. tray upper surface
5. strip being read
Fig. 2-2
Figure 2-3 shows the connections diagram of the internal barcode reader (front view).
CAB533 connects directly with the 2010 CPU while the LD2 LED represents the power
supply LED.
Fig. 2-3
2.2.1 Internal barcode reader check and calibration

1. Insert a strip with a valid code in the position n° 25 of the tray

2. Open the Motors window:
3. Run the Reset Tray whith TSD command
4. Open the Barcode window:
Chorus / Utility / Service / Diagnostics / Barcode
5. Run the Read Internal barcode command
6. Check that the barcode is read correctly and that the light beam emitted by
the reader hits the barcode in the initial part of the code (the part near the
centre of the label)
7. If these conditions are not respected, loosen the 2 screws that lock the reader
support to the upper plane and move the support until reaching the optimal
position, repeating the operations at points 5 and 6, then tighten the screws
again
8. Open the Test Macros window:
Chorus / Utility / Service / Diagnostics / Test Macros
9. Run the Startup Check command and wait the reset of all the motors.
10. Insert others strips in the tray and open the Identification Test window:
Chorus / Utility / Service / Diagnostics / Test Macros / Identification Test
11. Run the Scan command and check that all the strips are read correctly.

3 TRANSFER UNIT
3.1 DISPENSING HYDRAULIC CIRCUIT
The part of the hydraulic circuit that supervises the fluid transfer operation is shown
in the following diagram:
Bput
CS sen.
(1-4)
250ul
closure
cap
SV9 SV8
SV3 Aput
ON
ON
closure
cap SV7
disp #1
disp #2
SV4
ON level sensor
ON level sensor
Pp3
SV5 Sput#2 Sput#1
Pasc Pasc
Plav
Fig. 3-1
pp3: the peristaltic pump that takes in wash water from the tank and distributes it
inside the instrument.
SV3: enables the connection of the dispensing needles or the liquid coming from
pump pp3 or the syringes.
SV4: enables the delivery of water for the external washing of the needles
SV5: enables the external wash flow on disp1 or disp2.
SV7: enables the flow selected by ev3 on disp1 or disp2.
SV8: guides the inlet/outlet flow from the 250 ml syringe.
SV9: ---
As can be seen in the figure, each needle has a pair of wells (Plav, Pasc) with the
following characteristics:
▪ The wash wells (Plav) have an internal spout that delivers a jet of water onto
the tip of the needle when it is inserted into the well.
▪ The drying well (Pasc) has a large mesh sponge that retains any drops of wash
water that collect on the outer side of the needle.
Each of these wells has a drain that directs the water to the main waste well.

The syringe is a device that precisely draws up and dispenses the liquids. The syringe
has a capacity of 250 µl. It is connected to the wash water tank, as the circuit
connecting it to the needle is filled with wash water.
Every needle has a capacitive level sensor that is able to detect a minimum of 50 µl
and has a sensitivity of 10 µl. The inside and outside of every needle tip is covered with
a ceramic material that reduces carry-over to almost zero.
3.2 THE STRIP, NEEDLES AND THE WELL

The figure below gives a cross-sectional view of the physical layout of the strip, the
wash needles and their wash well:
1 2 3 4
1. measuring cuvette (#6)

2. measuring cuvette (#5)
3. sealed cuvette
5 6 4. cuvette with serum
5. independent up-down movement
#1
#2
6. independent up-down movement

7. radial movement for the two needles
7
8. drying well
9. wash well
10. dispensing needle
11. needle wash nozzle
12. waste duct
8 9 10 11 12
Fig. 3-2
As shown, the pair of dispensing needles is mounted on a bracket which

simultaneously moves them in a radial manner with respect to the tray (X-axis), while
each can move independently in a vertical direction.
3.3 DISPENSER
The dispenser is a device that is designed to move the dispensing needle up and
down within the wells of the strips, for drawing up or dispensing liquid.
The dispensing needle is a stainless steel tube with its tip cut at 45°, and which has
been sharpened to help cut through the protective film of the wells. The coarseness
of the end of the needle, both internally and externally, is increased by a micrometric
ceramic deposit that helps reduce carry-over to a minimum. The upper part of the
needle is shaped to stop the tube.

The needle is also used as a level sensor, by connecting it to a piezoelectric circuit
through a special screened cable soldered to the needle.
It is mounted on an insulating block, inserting it in a pass-through hole (see cross
section A-A) and compressing the spring inside the block with the cylinder, which
enlarges the section.
The two prongs of the block’s fork are then inserted in the special holes to prevent
the needle from coming out of position. The thrust of the spring ensures needle
stoppage. The stability of the needle is also ensured by the fork which stops the tube.
The needle block is mounted on a bracket that is connected to the slider which moves
up and down along the slide. The bracket is integrated with a rack and therefore the
rotation of the motor, with flush fit shaft pinion, produces the vertical movement of
the needle.
A magnetic sensor mounted on an electronic board with magnets mounted on a

connecting rod is used to set the starting vertical position.
A U-shaped aluminium bracket supports all the parts and its base is fixed to the
sliding base plate of the Dispenser Carriage.
1. bracket
2. tube
3. connecting bracket
sinistra destra 2
4. needle
1
A 14
5. level sensor wire
6. needle cylinder block fork
3
13 7. insulated needle-holding
block
12 4 5 15 8. slider
9. slide
6
10. toothed rack
7
11. pinion
11 8 16
12. motor
17
10
9 18
13. position sensor
A 14. fork
sezione
15. slider for the drum slide
DESTRA FRONTE SINISTRA A-A
16. spring
17. tapering
18. tip
Fig. 3-3

3.4 X-AXIS MOVEMENT
The moving of the two dispensers along the strip is carried out by an X-axis carriage,
which is a device assembled on the upper surface of the instrument’s frame. The
dispensers are fastened to the base of the bracket on the sliding carriage where the
holes for the fastening screws are located.
The carriage runs along the slide since it is fastened to the slider (which cannot be
seen in the diagram). The carriage is attached to the toothed belt by a hook that
comes out of the belt.
The toothed belt is driven by a motor through the pulley. The other end of the belt is
kept taut by a base plate on which an idle pulley is fastened.
The motor is fastened to the upper surface by an angular bracket. The position of this
angular bracket can be adjusted along the special slots, so that the belt tension can
be modified.
A magnetic sensor mounted on an electronic board and the relative magnets

mounted on sliding carriage is used to set the start position of the carriage.
To allow the dispensing needles to reach the wash well, a special passage area is
opened on the upper surface in the area for accessing the strip area.
3 4 5 6 7 8
9
1. drive hook
2
2. frame’s upper surface
10
11 3. motor
4. angular bracket
5. adjustment slots
12
6. motor pulley
1 7. position sensor
8. sliding carriage
9. threaded holes
10. wash access area
11. slide
12. access to the strip wells
13. toothed belt
14. idle pulley
13
15. base plate pulley
15 14
Fig. 3-4

3.5 THE SYRINGE UNIT
The function of the syringe unit is to move the syringe for the withdrawal and
dispensing of liquids.
The unit is made up of a stepper motor connected by a joint to a worm screw. Based
on the motor’s direction of rotation, this unit acts on the sliding block and, therefore,
the slider mounted on its lower part, to provide movement in one direction or the
other.
For positioning, the magnetic sensor mounted on the electronic board and the
corresponding magnet mounted on the slider is used.
Two Teflon pads allow the slider to move fluidly over the guide slot of the base plate.
The thrust plate and the end bracket keep the worm screw in line through the use of
internal bearings.
The upper part of the two syringes are coupled to the Plexiglas syringe unit and the
middle portion of the syringes is coupled to the clamping bracket. The pistons are
mounted on the fixing bracket located on the slider.
Based on the amount of liquid to be processed, the solenoid valve (14) mounted on
the top of the syringe unit opens and closes the syringe lines, thus allowing the
instrument to withdraw or dispense liquids.
1. motor
2. joint
3. thrust plate
4. worm screw
5. sliding block
6. slider
7. end bracket
8. pads
9. guide slot
10. syringe unit
11. syringes
12. clamping bracket
13. fixing bracket
14. solenoid valves
15. position sensor
Fig. 3-5

3.6 THE TRANSFER FUNCTION
3.6.1 Transfer function parameters
To proceed in describing the transfer function, the parameters that characterize it
should first be described.
The table below lists the parameters that will be described in detail in the successive
paragraphs. Firstly, every transfer must be identified with an identification number
(ID) in order to be recognized for the operating procedure of a cycle.
Transfer Identification Number. A value of 0 means that no

ID transfer will be performed. Refer to this value in the archive
Methods / Transfer settings and in Methods / Mode settings.
This field is designed to optimize the cycle. During the pre-cycle
Family phase, transfers of the same family are done in sequence. This
greatly reduces the number of washing operations.
Needle to use for the transfer. The possible values are 1
Needle
(standard) or 2 (conjugated).
Starting cuvette of the strip, from which the liquid is withdrawn.
Starting cuvette
The possible values range from 0 to 7.
Syringe Syringe type. The value of 0 is for that of 250 µl.
Delay, in seconds, before starting the transfer. Some methods
Start delay
require a delay from 10 to 15 seconds before starting.
Number of the first destination cuvette. The possible values
Cuvette #1
range from 0 to 7.
Amount of liquid to transfer into the first well. Possible values
Quantity #1
range from 0 to 250 µl.
Number of the second destination cuvette. The possible values
Cuvette #2
range from 0 to 7.
Amount of liquid to transfer into the second well (if required).
Quantity #2
Possible values range from 0 to 250 µl.
This field indicates the mode for washing the needle after the
Wash mode
Transfer. The values range from 0 to 6.
The number shakes to perform in the last cuvette. The
Shaking number
maximum number is 6 (from 0 to 5).
Shaking quantity Amount of mixed liquid. The maximum value is 100 µl.
3.6.2 The double dispensing needle

To prevent the conjugate from coming into contact with the substrate, even
minimally, a dedicated withdrawal needle must be used. This needle must have the
ascent/descent movement and all the other controls, independent from the other.
Operation is completely interchangeable from a hydraulic point of view. Solenoid
valve Ev7 selects which of the two needles must operate.
▪ Disp no. 1 is dedicated to the transfer of serum, diluent and substrate

▪ Disp no. 2 is dedicated to the conjugate.

In a transfer, the Needle parameter establishes which needle must be used.
▪ Needle = 1 sets the use of dispenser no. 1

▪ Needle = 2 sets the use of dispenser no. 2
3.6.3 Priming of the dispensing and wash circuit

To ensure correct dispensing, all the hydraulic circuits involved in dispensing must be
properly filled.
In particular:
▪ the section of the circuit that goes from the cleaning solution tank to the
syringe
▪ the syringe
▪ the section connecting Sv3 to Sv7
▪ the tubing that connects the two outlets of ev7 with the dispensing needles
▪ the needles (2/3 of their capacity, thus leaving the entire tip dry).
This operation is managed using an automatic procedure by the instrument which

uses the syringes to fill all the tubes and checks that it was done using the main waste
well warning sensor.
The tubing in which wash water flows must be completely filled so that the system
functions properly for all the tests.
To do this, allow water to flow through the tubes until it exits into the main waste and
can be detected. This procedure is also performed automatically when the
instrument priming is started.
3.6.4 Withdrawal
The removal of liquid from a well, done at the cuvette bottom level, which guarantees
that the entire contents of the well can be drawn up.
Starting cuvette is the starting cuvette (or well) number from which the liquid must
be drawn up.
The dispensing function is organized so that, after the liquid has been withdrawn
from the starting cuvette, the amount equal to the Quantity #1 parameter can be
dispensed into the cuvette defined to be Cuvette #1 and the amount equal to the
Quantity #2 parameter can be dispensed into the cuvette defined to be Cuvette #2.
The amount withdrawn from the Starting cuvette is therefore the total of the
Quantity #1 and Quantity #2 amounts.
The amount withdrawn is actually increased by a preset amount, in order to prevent

the final emptying from coinciding with a bubble.
▪ For quantities up to 20 μl and if the large syringe is used, a total of 25 μl is taken.

▪ For quantities from 21 μl to 100 μl, an extra 5 μl is taken.
▪ For quantities above 100 μl, an extra 20 μl is taken.
When the amount of liquid is destined for mixing, no extra amount is taken.

3.6.4.1 Needle washing
The needle must be washed after every transfer.
The washing is done in two stages:
1. washing of the internal part
which involves (ex. washing of disp1):

▪ positioning of the pair of needles over the respective wash well with an x-axis
movement (step 1)
▪ descending into the well to a predetermined depth so that the external nozzle
coincides with the start of the needle’s tapering
▪ activation of ev3 so that water flows towards ev7
▪ activation of pump pp3, putting wash water into circulation
▪ ev7 is not controlled and liquid overflows into the collection well, which drains
by gravity into the main waste well (step 2).
▪
2. washing of the external part
which involves (ex. washing of disp1):
▪ activation of ev4 so that water flows towards ev5

▪ activation of pump pp3, putting wash water into circulation.
▪ ev5 is not controlled and liquid comes out of the wash nozzle and washes the
outside of the needle and then drops into the collection well, which is then
drained by gravity into the main waste well (step 3).
▪ simultaneous activation of the needle’s slow ascent from the well until the
nozzle reaches the tip of the needle and externally wash the entire needle (step
4)
▪ shutting off of pump pp3 and ev4 and return to the resting position (step 5).
1. ready for washing

2. internal washing
3. first external
washing stage
4. last external washing
stage
5. final resting position
1 2 3 4 5
Fig. 3-6
The duration of the needle washing is defined in the Wash mode parameter, which
is set whenever a certain transfer procedure is defined.
It can have a value from 0 to 5, according to the following table.

Pos. Function
0 No washing
1 10-1.5 ml water
2
3
4
5
The final washing of the needle is skipped if the next transfer belongs to the same
family as that being processed. This functional characteristic can save considerable
amounts of wash water.
3.6.5 Drying of the tip

After washing, the needle remains immersed in the Plav, where the water drops
begin to drip off the inside and outside of the needle. These drops must be completely
removed at the start of a transfer procedure. To do this, the needle needs to be
inserted into the drying well, Pasc.
The steps are the following:

1. Ascent from Plav
2. Shifting to Pasc
3. Descent into Pasc and drying of the needle
4. Ascent from Pasc.
Drying is only done if the tip of the needle was washed.
3.6.6 Perforation of the cuvette membrane

The test strip requires that some wells, containing liquids or lyophilized product, be
sealed with a thin plastic membrane. The withdrawal and dispensing of liquids in the
sealed cells require that the membrane be pre-bored in a position different from that
of the successive suction hole.
The pre-boring creates a hole in the membrane where air can safely enter.
This is necessary since the sides of the hole made in the membrane for withdrawing
can seal around the needle itself, thus reducing or preventing air from entering.
The lack of incoming air into the well during the suction phase causes a lesser
amount of liquid to be removed with respect to that programmed, thus leading to
measurement errors.
Pre-boring is done automatically by the procedure, before proceeding with the

suction hole. Nevertheless, this is avoided if the well is already perforated.

3 4
2 1. cuvette bottom level
2. membrane
3. pre-boring
4. suction hole
5. sharp needle tip
1 5
Fig. 3-7
The dispensing needles are made with oblique tips and with sharp edges. The cutting
of the membrane may be imperfect due to a problem on the needle caused by
wearing or an accidental impact on the tray or if the membrane is too tough due to
an imperfect heat sealing.
A check of the hole and the tip’s cutting ability must therefore be included for every
perforation operation.
To do this, use the following procedure:

1. Descent of the needle at the preset speed, starting from the home vertical
level, down to the cuvette bottom level and withdrawal of liquid (for pre-
boring, the level is preset and withdrawal is not performed)
2. Return to the home vertical level
If the return to the home vertical level is correct, the difference between the
theoretical number of steps between cuvette bottom level and home vertical level
and that actually performed is calculated.
If the difference is:
▪ outside the ± acceptance range: a membrane error is sent and the sample is
not processed.
Note that with this condition the return to the home vertical position cannot be
carried out.
In this case, try vertical repositioning two times. If only the first reset is wrong, the
sample is skipped and the run continues. If the second reset is also wrong, the run is
stopped.
3.6.7 Level detection

The level detector, found on each of the needles, is designed to control the amount
of liquids dispensed into the cells of the strip by checking the dispensed liquid level.
The sensitivity of the sensor is measured as: minimum detectable amount of liquid (≥
50 μl) and min 10 μl discrimination, which indicate the minimum level difference that
can be detected in cuvettes containing at least 50 μl.

After dispensing the set amount of liquid, the needle returns to the home position
and then descends again and stops when in contact with the liquid. The number of
steps between the bottom of the cuvette and the detected level is calculated.
The sensor is used in the following cases:

▪ detection of the amount of serum present in the well n° 1 before withdrawal
(verify)
▪ detection of the amount of integer or diluted serum distributed in the
measuring well (#5 and #6)
▪ detection of the amount of substrate distributed in the measuring well (#5 and
#6)
▪ detection of the amount of conjugate distributed in the measuring well (#5
and #6)
The limiting factor is that it cannot be used for membrane covered cuvettes, as this
would cause measurement errors.
The detection procedure is simple and involves two situations:
1. checking of the level in a cuvette, before the withdrawal of liquid

▪ the needle, starting from the home vertical level, descends into the well with
the level sensor on
▪ when it stops or has detected the liquid or is at its end stroke, the liquid level is
calculated by the difference in steps.
▪ if the amount is insufficient with respect to that expected, an error is reported
and the strip is not processed.
2. checking of the level of liquid that has just been dispensed

▪ After the liquid has been dispensed, the needle returns to the home vertical
position
▪ it then descends into the well with the sensor on
▪ when it stops or has detected the liquid or is at its end stroke, the liquid level is
calculated by the difference in steps.
▪ If the difference between the expected value and the measured value is
greater than Max diff an error is issued and the strip is not processed. (The
MaxDiff threshold is set by default to 50µl).
3.6.8 Mixing
After having distributed a liquid in a cuvette which already had other liquid (ex: serum
in the diluent cuvette), the solution needs to be mixed in order to make it
homogeneous.
The shaking of the plate is only sufficient for keeping homogeneous solutions in
suspension.
Mixing is controlled by two transfer function parameters:
▪ Shaking number: number of withdrawals/dispensings to perform NumAg

▪ Shaking quantity: the amount that is withdrawn and dispensed to perform the
mixing

The initial situation is the following:
1. The needle gets to the bottom cuvette level, where it dispensed the liquid into
the cuvette and the dosing syringe is completely closed.
Warning: the mixing mode requires that the liquid to be mixed be taken without any
extra amount, in order to avoid bubbles from forming.
2. Now, with the needle still at the cuvette bottom level, the Shaking quantity is
drawn in for the first time and then expelled. This is done the number of times
indicated by the Shaking number.
3. When finished, the needle exits the cuvette and is washed.
3.6.9 Simple transfer

We will now analyze a simple transfer function using the procedures partially
described beforehand.
There are two types of transfer:
3.6.9.1 Transfer for dilution of the serum (without mixing)

This is the transfer that brings the serum from well no. 1 to well no. 3
The transfer stages are:
1. Drying of the needle tip

2. withdrawal of Quantity #1 from cuvette 1 (Starting cuvette)
3. shifting to cuvette 3 (Cuvette #2)
4. pre-boring and boring of the hole with membrane check
5. dispensing of Quantity #1
6. shifting to the home position
7. expulsion of the extra amount and washing of the needle
#1 #2
1. washing of Disp #1
#2 #1 #2
#1
1. drying of
Disp #1
1 2
2. disp #1 carries out a
vertical reset

#2 #1 #2
#1 1. disp #1 moves to the

1 2 starting cuvette, check
the presence of the
sample, withdraws
Quantity #1
vertical reset
#2 #1 #2
#1 1. disp #1 moves and
makes a hole in the
1 2 membrane of Cuvette #1
vertical reset
#2 #1 #2
1. disp #1 dispenses
#1 Quantity #1
1 2
vertical reset
#2
#1 #2 1. disp #1 is washed and

#1
dried
1 2
2. disp #1 returns to the
home position
Fig. 3-8
3.6.9.2 The transfer of conjugate

The stages involved in this type of transfer are:

2. Withdrawal of Quantity #1 from Cuvette 3 (Starting cuvette) with extra amount.
3. Shifting to well 6 (Cuvette #1)
4. Dispensing of Quantity #1
5. Shifting to the home position
6. expulsion of the extra amount and washing of the needle.

3.6.9.3 Double transfer
The transfer stages for this case are:
2. Withdrawal of Quantity #1 + Quantity #2 from Cuvette #3 (Starting cuvette)
with extra amount
7. Shifting to the home position
8. expulsion of the extra amount and washing of the needle
3.7 CALIBRATIONS AND CONTROL PARAMETERS

3.7.1 Circuit transfer
3.7.1.1 Testing procedure for dispenser needle external wash
1. Connect the tank with cleaning solution
2. Connect the waste tubes to the waste tank.
3. Open the Switches windows:
Chorus / Utility / Service / Diagnostics / Switches
4. Activate solenoid valve SV4 (Solenoid valves / SV4) and pump PP3 (Pumps /
Pp3)
5. Check that the flow of water comes out of UGEL 1.
6. Activate solenoid valve SV5 (Solenoid valves / SV5)
7. Check that the flow of water comes out of UGEL 2.
Warning: check that the nozzles that supply wash water are correctly positioned so that the
water hits the needle.
NOTE: since the error check was activated, the warning alarm must activate once the warning
level has been reached and pump PP8 must switch on to empty the waste well.
3.7.1.2 Testing procedure for dispenser internal wash

1. Make sure the needles are cantered in the wash wells, activate solenoid valve
SV3 (Solenoid valves / SV4) and pump PP3 (Pumps / Pp3) and check that water
flows from disp1
2. Activate solenoid valve ev7 (Solenoid valves / SV3) and and check that water
flows from disp2
3.7.2 Dispensers
3.7.2.1 Dispensers Needles Height Calibration
For the calibration of the heights of the dispensers needles, proceed as follow:
1. Dispense 100µl of Cleaning solution with a calibrated pipette in well #5 and #6

of a strip and insert it in position #1 of the tray;
2. Open the Level Sensor Test window:
Chorus / Utility /Service / Diagnostics / Test Macros / Level Sensor Test
3. Double click on the Iterations line and insert the intended measurements
number (ex. 5). Then click Ok;

4. Double click on the Expected Volume line and insert “100” as value (i.e. the
same volume dispensed in the strip). Then click Ok;
5. Press the Start button and wait for the measurements execution. During the
measurements, verify that the needles are cantered in the #5 and #6 wells.
The following information will be displayed on screen:
Fig. 3-9
Disp = dispensing needle (0 = needle#1; 1 = needle#2)

Well = well where the measurement is executed (#5 or #6)
MaxLvl = well bottom level steps currently set
Measured = measured volume (µl)
Exp = expected level (µl)
Diff = difference between expected and measured volume (µl)
Toll = maximum difference allowed during transfers
6. The difference between the expected and measured volume must be equal to
0±10 µl.
If the difference is higher, act on Dispenser #1 Bottom Level and Dispenser #2

Bottom Level parameters. These parameters identify the steps number that
the dispensing neddles must do in order to reach the wells #5 and #6 bottoms.
If the measured volume is lower than the expected one, increase the steps
number. On the contrary, if the measured volume is higher than the expected
one, lower the steps number. This can be done accessing to the Mechanical
Calibrations window:
Chorus / Utility /Service / Settings / Parameters / Mechanical Calibrations
7. If the above-mentioned parameters have been modified, repeat the test
starting from step 2 of the process.
3.7.3 X-axis movement

3.7.3.1 Setting of the X-axis offset
The offset of the X-axis is determined by the Carriage offset parameter. This
parameter indicates the steps correction necessary to bring the dispensing needles
from the home position (determined by the absolute sensor) to the washing position
(reset position).

To verify if the needles are correctly centered on the corresponding washing wells,
follow the steps below:
1. Enter the Motors window:
Chorus / Utility /Service / Diagnostics / Motors
2. Select the Carriage line and press Reset;
3. Manually lower the dispensing needles and verify the correct centering on the
washing wells. Then lift the dispensing needle, bringing them to the Home
position;
4. If they are not centered, it is necessary to correct the Carriage Offest
parameter. For changing the parameter, open the Mechanical Calibrations
window:
Chorus / Utility /Service / Settings / Parameters / Mechanical Calibrations
5. Double click on the Carriage Offest line and modify the value (increase the
steps if you want to move towards the tray center, lower them if you want to
move towards the Home sensor). Press Ok to confirm the new value, then
repeat the procedure from step 1.
3.7.3.2 Serum cuvette position

Represents the number of steps needed to position dispensing needle #1 from the
home position to the centre of wells #1 on the strip (serum), when the strip is inserted
in the tray.
The procedure to verify if the positioning is correct is the following:

1. Insert a strip in position #1 of the tray then press the Reset Tray with TSD button
(Chorus / Utility /Service / Diagnostics / Motors);
2. Select the Tray line, press Move and insert the steps number shown in Sample
Well Position entry in the parameters window (Chorus / Utility / Service /
Settings / Parameters / Mechanical Calibrations);
3. Press Ok to confirm, then insert the speed value (i.e. 18) and wait for the needle
positioning;
4. Push down manually the dispenser#1 and verify that the position is correct,
then raise the needle back to the home position;
5. If the position is not correct, act on the Sample Well Position parameter
(increase the steps if you want to move towards the tray centre, lower them if
you want to move towards the Home sensor)
6. In case of correction, repeat the procedure from step 2.
FUNCTIONAL TESTS
3.7.4 Level sensor test

To test the level sensor, follow the procedure described in paragraph 3.7.2, setting the
desired volume and number of iterations.
3.7.5 Transfer test

A personalized transfer can be launched through the Transfer Test command (Chorus
/ Utility / Service / Diagnostics / Test Macros / Transfer Test) in order to check all the
devices involved in the transfer function.

Fig. 3-10
Tray Position: The tray position where the strip has been inserted
Dispenser
Needle to use for the transfer. The possible values are 1
(Disp#1=norm,
(standard) or 2 (conjugated).
Disp#2=conj):
Source well: Start cuvette from where the liquid is withdrawn.
Number of the first cuvette in which the liquid will be

Target well 1:
transferred.
Quantity 1 (l): Amount of liquid transferred into the first cuvette.
Number of the second cuvette in which the liquid will be

Target well 2:
transferred.
Quantity 2 (l): Amount of liquid transferred into the second cuvette.
Wash Mode: Needle washing time
Shakes Number Number of times the liquid in the cuvette is shaken.
Amount of liquid used during shaking. The maximum is 100
Shake quantity (l):
µl.
Family: Transfer family
Modify the height of the tranfer depending on the type of
Drill Mode:
selected well
The procedure to perform the test is the following:

1. Insert a strip with one of the wells filled with liquid;
2. Set all the parameters needed to perform the desired transfer;
3. Start the transfer
If the transfer was successful, the instrument will not print any report.
If, during the test, the instrument finds an error, a report with the difference between
the expected values (Ex) and the measured ones (Ms) will be printed:
Ex. TRASF:Smp# -; Stp# -; Tr# -Ex: 100; Ms:90; diff : -10 ; MaxDiff :50

3.7.6 Strip perforation
This test is useful to verify the capacity of perforate the strips. To perform the test,
proceed as follow:
1. Insert the desired number of strips, with intact membranes, starting from
position #1 of the tray;
2. Enter the Drill Test window:
Chorus / Utility / Service / Diagnostics / Test Macros / Drill Test
3. Double click on Dispenser and select the needle to be tested:
Dispenser #1 (only needle#1)
Dispenser #2 (only needle #2)
Alternating (both needle are tested in an alternating way: strip#1 – needle#1;
strip#2 – needle#2; strip#3 – needle#1,…)
4. Insert the Number of Devices to be tested;
5. Select the Device Type to be tested (7-well device or 8-well device);
6. Press Start and wait the test execution. The instrument perforates twice all the
membranes wells of the strip.
7. At the end of the test, a report will be displayed:
Fig. 3-11
Disp = Dispensing needle (0 = needle#1, 1 = needle#2)

Well x = well where the test is performed
Carr.Pos = X-carriage position
Drill = Number of exepected steps for the perforation
Reset = Number of steps measured during the perforation
Diff = Difference between Reset and Drill
Toll = maximum difference allowed during drilling
8. Since two perforations are performed, each well is characterized by two data
lines. The maximum Diff must be lower then 15 steps. If during the test the Diff
measured is higher then 15 steps, it is necessary to replace the needle.

4 OPTICAL UNIT
4.1 LIGHT SOURCE
The source is structurally composed of a low cost halogen lamp with parabolic
dichroic filter able to focus the light of all the microfibres that make up the 6 lines of
the optical fibre onto the head of the collection cylinder.
The pairs of lines then go to the optical interleavers.
The focused light passes through a monochromatic filter, which is selected based on
the type of test to perform. A heat filter is inserted in order to prevent the filter and
the optical fibre from overheating.
1. optical fibres
2. cylinder
3. monochromatic
filter
4. LED group
5. Power control
6. Electronic control
Fig. 4-1
The electronic circuit for regulating the control voltage is what makes the lighting
device particular. It is interesting to analyze the control circuit starting from the
power circuit.
The premises are the following:
1. the light that each line can transmit is different from the other, even by 30%,
depending on the light gradient that covers the head of the cylinder and the
lack of radial symmetry of the line terminals collected in the cylinder.
2. If, in the three measuring stations, the same amount of light does not traverse
each cuvette, homogeneity of the measuring points cannot be reached.
In order for all the lines in an optical fibre to be homogeneous from a light emission
point of view, a calibration procedure is required, managed by the central
microprocessor, that guides the lamp’s electronic control, which in turn is able to
generate approximately 800 voltage values within the lamp’s operating range of 5V
DC to 12 V DC.
Therefore, a voltage value is determined for each optical line in order to generate light
beams of the same intensity.
4.2 THE OPTICAL DEVICE

As shown in the figure, the optical device used to take the measurements, in each of
the three positions, is made up of a light transmitter mounted on the upper plate and
a light receiver mounted on the lower plate

These two parts make up an optical path that is intercepted by the strip, which passes
through it, in order to perform an optical measurement.
The upper part supports two of the six lines of the optical fibre. Each line terminates
with a ferrule, which blocks the fibre capillaries that make up the line.
The light emitted from each line is sent through an optical channel to the first
focusing lens (this is true for each of the two channels on the optical device).
5 7 1. optical fibre
2 1 2. optical fibre terminus
8 ferrule
4 3 6 3. optical channel
4. lenses
5. optical fibre support
6. upper surface
7. strip tray
10 8. strip
9. focalization point
10. lenses
11. optical channel
12. optical receiver
9
13 13. receiver card
14. lower surface
12 11 14
Fig. 4-2
The light ray focuses a 1.5 mm spot about 1 mm from the bottom of the cuvette.
After it has passed through the strip, the light beam is focalized by a pair of dual lenses
on the optical receiver positioned on the electronic receiving board. The diameter is
3 mm and ensures a good signal/disturbance ratio.
The translated voltage signal is sent from the conditioning electronics to the A/D
converter.
4.3 THE OPTICAL CHANNEL

The optical channel is a unit that has the following parts:
▪ an optical fibre line

▪ two focusing lenses found on the interleaver’s optical path
▪ the sensor and its pre-amplification circuit
When one of these elements is modified, the characteristics of the optical channel
are modified.
An interleaver thus combines an odd optical channel (the most external,

corresponding to well no. 5) and an even optical channel (the most internal,
corresponding to well no. 6).

4.4 POSITIONING OF FILTERS
The device for positioning the filters moves the filter block forward and backward in
order to position one of the two filters or the empty position in front of the fibre optic
cylinder.
The filter block is mounted on the plate which, in turn, is fastened onto a bracket (3)
that connects it to the slider, which is moved up and down along the slide (5). The
bracket has a toothed rack and therefore the rotation of the motor (8), with flush fit
shaft pinion (7), allows the filter block to move.
A magnetic sensor mounted on an electronic board with magnets mounted on a

connecting rod is used to set the vertical position.
A U-shaped aluminium bracket supports all the parts and is fixed to the support of
the fiber optic cylinder.
1
1. bracket
left right 2 2. filter block
3
10 3. connecting bracket
11
9 4. slider
5. slide
8
12
6. toothed rack
7. pinion
13
8. motor
7 4
9. position sensor
10. plate
6
5 11. filter #1
12. filter #2
RIGHT FRONT LEFT 13. no filter
Fig. 4-3
4.5 OPTICAL CALIBRATION

4.5.1 Transmittance and absorbance
The transmittance of the solution being measured is the measurement of the
amount of incident light on the receiver.
The higher the value of the received signal, with regard to emitted light, means more
light has passed through the test solution and therefore less turbidity. Transmittance
is thus the primary measurement that is made in the optical channel.
In the Chorus TRIO, the amount of light received (transmittance) is initially detected
as electrical voltage and then converted with a 12-bit A/D into a number that can
range from 0-1023.
0 corresponds to the absolute lack of transmitted light in the optical channel (dark)
and 1023 is the maximum value of receivable light (channel completely free).

1000
1800
800
1500
1200
600
900
400
600
200
300
0 0,01 0,02 00,3 00,4 0,05 0,06

1/64
1/512
1/256
1/32
1/128
1/16
Fig. 4-4
Transmittance is however a relative measurement that does not take into account
the characteristics of the optical channel. Therefore, in the presence of more than one
optical channel, a different parameter must be used to have comparable
measurements: absorbance. Absorbance is a measurement of the ability to absorb
(and therefore not allow to pass through) light emitted by the emitter. The higher the
absorbance the lower the turbidity of the solution.
The absorbance (Abs), for an optical channel, in its theoretical formulation, is given by
the formula:
Abs = log (TH20 / Tsoln),
where TH20 is the transmittance value of water,
Tsoln is the transmittance value of the test solution.
This formulation does not consider the problem of using electronic amplifiers and
analogue/digital converters. In fact, the transmittance voltage reading of a
transmittance signal is such that the darkness value (theoretical transmittance = 0) is
a residual voltage value (Toff.set), which is subtracted from every transmittance reading.
The formula to be used therefore becomes:
(𝑇𝐻20 – 𝑇𝑜𝑓𝑓−𝑑𝑎𝑟𝑘 )
𝐴𝑏𝑠 = 𝑙𝑜𝑔
(𝑇𝑠𝑜𝑙𝑛 − 𝑇𝑜𝑓𝑓−𝑑𝑎𝑟𝑘 )
the measurement includes two parameters:
TH20 - transmittance in water

Toff-dark - voltage off-set value for the dark
These two parameters are determined:

▪ for each optical channel
▪ for each filter
and make up the system’s optical calibration phase.
Since the optical calibration must be done in a completely automatic manner, thus
without operator intervention, the measurement of transmittance in water was
made the same as that in air. A modest absolute error is therefore added for the
absorbance differences with regard to the instrument, but which does not influence
the final result.
It should be noted that the assessment of the optical values is done in digital terms,
on a numeric scale that theoretically ranges from 0 to 1023.
This is because the system uses a 10 bit analogue/digital converter.
4.5.2 Alignment of the optical fibres

As mentioned previously, the non homogeneity of the light emitted by the individual
optical fibres is an unacceptable work condition since the system operates by
calculating the differences between optical readings made on individual channels.
Given that an optical reading depends primarily on the light emitted by the light
source and then by the upstream amplification device, six optical fibres must emit
the same amount of light, with a precision on the order of  5 ‰.
4.5.2.1 First concept

Given that the amount of incident light on the surface of the group of optical fibres is
distributed according to a gradient that diminishes when moving away from the
centre, and given that the layout of the microfibers inside the collection cylinder is
random and can therefore be arranged more or less towards the centre (see example
3), the six optical fibres composed of the microfibers themselves can have a different
luminosity, not because they are physically different, but because they collect more
or less light.
1. optical fibre collection cylinder

1
2. microfibers
2
3. examples of a microfiber unit that makes up an optical fibre

3
4. gradient of the incident light field on the surface of the cylinder
gradiente del campo luminoso
Fig. 4-5
To obtain the same optical response from displaced optical fibres, the incident light
must be different depending on the optical fibre taken into consideration. This means
that the lamp is powered with a different voltage depending on the optical fibre to
be controlled.

4.5.2.2 Second concept
In the Chorus TRIO system, the time that the tray stays in each of the 30 positions is
never less than 18 seconds, and of this time, no less than 6 seconds is dedicated to
mixing.
Given that, during a step, all six optical channels may need to be read, the time
available for each channel is slightly higher.
Since the adjustment time for lamp luminosity (from 5V to 12 volt) is less than 2
seconds, emission stability can be obtained for enough time to perform a reading of
an optical channel after this interval. IV° fibra
V° fibra
VI° fibra
I° fibra
II° fibra
III° fibra
vibration time
11 sec
18 sec
0 sec
Fig. 4-6
In each of the time intervals in which the tray waits for the step, it’s therefore possible
to:
▪ modify the lamp’s control voltage to the required value, for example for the 1st
optical fibre
▪ perform the reading on the relative optical channel.
120
100
80
60
40
20
0
0 1 2 3 4 5 6 7 8
Fig. 4-7
4.5.2.3 Third concept

The previous concepts indicate the need to have a power supply for the lamp that
can scan the range from 5 to 12 Volts in steps not less than 10 mVolts. This is to ensure
that the six optical fibres are adjusted to within  5 of the reference value.

4.5.3 Calibration of the optical channels
Calibration of the optical channels involves two phases to be performed in order:
▪ The determination of the dark offset voltage value
▪ The determination of the control voltage of the lamp in order to obtain the
transmittance value in air, set as the reference value.
This is done for each filter used by the instrument.
4.5.4 Calibration of the dark electronic offset

This is the first calibration to be performed in order to continue with the “reset”
channel, meaning that it is able to detect valid digital values above 0. By darkening
the optical receiver, the indicated value could be:
digital value > 0

value = 0
In the second case, the digital indication at 0 does not mean that the output from the optical channel’s
amplifier is exactly at 0 analogical volts, but could have a negative value due to the amplifier’s inherent
offset. If we were to accept this value, it would mean losing the evaluation of optical values which, in
analogical terms, come from the negative value of the offset up to zero. A digital value for the dark should
therefore be set that gives an indication > 0, for example 20 digit.
The calibration of the dark offset therefore requires (see diagram) that a voltage ramp
be generated that progresses from -1 Volt to +1 Volt until a value not greater than 20
digit coming out of the A/D converter is obtained.
optical
receiver A/D converter
Fig. 4-8
The voltage generator is obtained with the control of a digital potentiometer.
The potentiometer setting value for each optical channel is stored in the instrument’s
Flash-ROM and is loaded at start-up or recalculated after every optical calibration.
The calibration must be done with the instrument closed, or properly darkened, so
that the interleaver sensors do not receive external light.
4.5.5 Calibration of light emission

The transmittance in air measurement coincides with the voltage measurement for
piloting the lamp for each optical fibre.

When the system, for a certain optical filter, measures water, it must read the
maximum transmittance value possible. This value must correspond to 1023 digit for
the system.
Like for the offset, here too it’s best not to reach the limit, otherwise higher analogical
values won’t be recognized, since all readings would be 1023 (saturation).
The light intensity that allows a digital value of 1000 to be read is therefore set as the
maximum reference intensity for each optical fibre and for each of the available
optical filters.
fixed gain
amplifier
light
power optical
supply receiver A/D converter
digital voltage
ramp ramp
generator generator
Fig. 4-9
Having then set the gain of the amplification and conditioning circuits of the six
optical channels, the only way to obtain a light reception equal to 1000 is to act on
the lamp’s control voltage by aligning the intensities of the light transmitted by the
six optical fibres (as described previously).
The calibration system of each channel is done through an automatic procedure.
The control voltage of each channel is scanned from 5 to 12 Volts in 10 mV steps using
the “bisection” method, until the value that gives a reading of 1000 is determined.
The control of the power occurs digitally and the digital value that corresponds to the
calibration of the optical fibre, for a certain wavelength, is stored in the flash memory
and loaded at instrument start-up. It is modified with each calibration.
4.5.6 The control ramp

The lamp’s control voltage must be generated from 5 to 12 Volts in steps less than or
equal to 10 mV. This means that no less than 700 (7000/10) control points are needed.
These points are generated with two devices:
One of them functions as the control range selector (lamp voltage range) and varies
from 0 to 7, and the other as a fine selector (lamp volt. lev.) and varies from 0 to 127.
This allows 8 linear characteristics to be arranged, which could be “connected”

together to form one unique characteristic of 128x8 = 1024 points. In reality, however,
the start and end voltage in each of the 8 characteristics cannot be precisely defined
and this prevents a true connection.
To therefore prevent gaps between one characteristic and another, the 8

characteristics are generated so that the adjoining characteristics partially overlap
each other (see Fig. 4-10 a):

volt volt
12.0 12.0
8.0 8.0
4.0 4.0
127
31
41
38
37
43
29
48
0 127
0
a) b)
Fig. 4-10
As can be seen in Fig. 4-10 b), the passage from one characteristic to the next takes
place, increasing the range and restarting the count from 0, when the connection
point with the next characteristic is reached. This gives a lesser number of resolution
points since the characteristics no longer start from 0, but instead from the value
corresponding to the intersection and indicated in the figure.
This provides a true characteristic equal to that in fig. C, where there is a virtual
counter that lays out 749 horizontal points [ 127 + (127-31) + (127 – 41) + (127 – 38) + (127
– 37) + (127 - 43) + (127 – 29) + (127 – 48) for scanning voltages from 5 to 12 Volts.
volt
12.0
8.0
4.0
784
0
Fig. 4-11
The measurement of this characteristic is done automatically for a certain

instrument.
A report is printed at the end.
4.5.7 Report of the virtual ramp

Each ramp segment represents a range (0, 1, …,7). Each range has a starting point,
which is not 0, but depends on the intersection point with the ramp (the range) that
precedes it. This number of points, which is lost in the calculation of the totalramp, is
reported as the start index. The first val, on the other hand, indicates the A/D
conversion value of the lamp voltage in correspondence with the start index.

Fig. 4-12
The voltage on the lamp can be determined using the following formula:
Vlamp = 4.3 * 4000 * first value / 1024
An example of a virtual ramp report is the following:

Range…0 first value 333 start index 0
Nramp 773
FVD 407
SIT 147
V-: 5212.99
V+ 12833
The criteria for evaluating this report are the following:

▪ first value for range0 values from 310 to 330
▪ first value for range7 values from 710 to 740
▪ each individual value of the start indexes values from 5 to 40
▪ Nramp from 700 to 800
▪ FVD 40015
▪ SIT <200
▪ 5100.00 > V- > 5000.00
▪ 13000.00 > V+ > 12500.00

4.5.8 Control window
Controlling the calibration of the optical channels is done with the commands and
indications found on the calibration window.
Chorus / Utility / Service / Diagnostics / Optical System / Optical Calibration
Fig. 4-13
V. ramp starts the control procedure for the virtual ramp
Dark calibrates the offset values and reports them in the dark column
Light starts the adjustment of the light emission at a value of 1000 dgt for each
channel, using an empty cuvette
The following data are reported:
the transmittance (Air) the virtual ramp value (Vir)
the voltage control value inside the range (Val)
The selected range (Ran)
The dark value (Dark)
Check: performs a complete reading of the optical channels using the selected
parameters
Print: Prints the calibration report displayed on the screen

4.6 OPTICAL UNIT TESTING PROCEDURE
4.6.1 Setting of the optical filter offset
The exact position of the filter at the centre of the light ray outlet hole can be checked
by the Optical Filter Offset parameter. This parameter indicates the correction steps
that the filters carriage must take with respect to the home sensor so to reach the
reset position.
If the exactness of this parameter needs to be checked, calibrate it as follows:
1. Loosen the grain that blocks the fiber cylinder;

2. Open the Motors window (Chorus / Utility / Service / Diagnostics / Motors);
3. Select Filter and press Reset;
4. The filter carriage moves outwards until the end stroke sensor is reached. Then
the filter carriage adjust its position based on the steps reported at the Optical
Filter Offset parameter;
5. Check that the fibre housing hole is perfectly aligned with the empty position
of the filter carriage;
6. If the alignment is incorrect, modify the Optical Filter Offset parameter
Chorus / Utility / Service / Settings / Parameters / Mechanical Calibrations
7. Check again the alignment by issuing the filter reset command.
8. Repeat the procedure until the ideal correction value is find.
4.6.2 Calibrating the offset (dark reading)

The dark calibration can be controlled in the Optical Calibration window:
Chorus / Utility / Service / Diagnostics / Optical System / Optical Calibrations
1. Cover the instrument with a sheet so that it cannot be influenced by ambient

light (or reducing the ambient light), then activate the Dark command;
2. After resetting the plate, the instrument turn off the LED and start the
calibration.
The obtained values must be:
▪ >0 for the programming digits;

▪ Between 20 5 digit for the dark value.
4.6.3 Calibrating the light

One must make sure that the offset has been calibrated before adjusting the light.
The light calibration can be checked in the Optical Calibration window:
Chorus / Utility / Service / Diagnostics / Optical System / Optical Calibrations
4.6.3.1 Calibration of the 650 nm filter

1. In the Optical calibration window, doble click on the Filter 450 button and
select Filter 650 nm. Press the Light button, taking care to cover the
instrument with a cloth so that it is not influenced by ambient light.
The system determines, channel by channel, the driving current of the LED to
obtain an air reading approximated to 1000 dgt. The calibration has to occur in
a range value not higher than 2 for each channel.

4.6.3.2 Calibration of the 450 nm filter
2. In the Optical calibration window, doble click on the Filter 450 button and
select Filter 450 nm. Press the Light button, taking care to cover the
instrument with a cloth so that it is not influenced by ambient light.
The system determines, channel by channel, the driving current of the LED to
obtain an air reading approximated to 1000 dgt. The calibration has to occur in
a range value not higher than 2 for each channel.
4.6.4 Check of absorbance at 650 nm with control solutions

Please Note: the optical calibration is performed in air and does not need of control
solutions.
The check of the optical system is carried out during the testing phase of the
instrument with specific control solutions.
To do this, proceed in the following way:

Note: the solutions must be kept at room temperature (25°) and away from light
1. Prepare six LAB type strips (1899), with the 2 Labsystem reaction wells (#5 and
#6) correctly inserted and both filled with the following solutions:
strip no. 1 100 l solution SL 4298

and place them in the first six positions in the carousel.

2. Open the Read Session window:
Chorus / Utility / Service / Diagnostics / Optical System / Read Session
3. Click the Start button, double click on Filter, select Filter 650, double click on
Device Count, insert the value “6”, then confirm with Ok;
4. At the end of the reading cycle, the absorbances are shown on the display and
they can be printed or exported through a USB key;
5. Record the data on the test sheet and check that the ranges are respected.
Warning: The values can change if the calibration solutions are changed or if they were
improperly stored

Tab. 1 Solution Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Mean Range St. Dev. CV % Rif Cv%
0,03125 SL4298 73 64 84 86 79 79 78 50-100 8 10,3% 25
0,0625 SL4297 153 144 165 172 160 161 159 110-200 10 6,1% 13
0,125 SL4296 293 279 312 306 302 297 298 250-380 12 3,9% 8
0,25 SL4295 563 549 577 578 567 567 567 500-650 11 1,9% 6
0,5 SL4294 1037 1018 1061 1050 1043 1034 1041 900-1100 15 1,4% 6
1 SL4293 1690 1736 1712 1734 1691 1733 1716 1500-1800 22 1,3% 6
Fig. 4-14
4.6.5 check of absorbance at 450 nm with control solutions

To check the absorbance at 450nm, proceed in the following way:
Note: the solutions must be kept at room temperature (25°) and away from light
1. Prepare six LAB type strips (1899), with the 2 Labsystem reaction wells (#5 and
#6) correctly inserted and both filled with the following solutions:

and place them in the first six positions in the carousel.

2. Open the Read Session window:
Chorus / Utility / Service / Diagnostics / Optical System / Read Session
3. Click the Start button, double click on Filter, select Filter 450, double click on
Device Count, insert the value “6”, then confirm with Ok;
4. At the end of the reading cycle, the absorbances are shown on the display and
they can be printed or exported through a USB key;
5. Record the data on the test sheet and check that the ranges are respected.

Tab. 2 Solution Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Mean Range St. Dev. CV % Rif Cv%
0,03125 SL4461 90 75 109 106 106 91 96 50-110 13 13,7% 22
0,0625 SL4460 153 143 175 177 171 160 163 110-190 14 8,3% 15
0,125 SL4459 281 271 305 309 300 289 293 230-330 15 5,1% 8
0,25 SL4458 545 539 568 574 560 553 557 470-610 13 2,4% 7
0,5 SL4457 1070 1040 1092 1066 1083 1049 1067 950-1150 20 1,8% 5
1 SL4456 2035 2035 1990 2036 1992 2035 2021 1800-2200 23 1,1% 5
Fig. 4-15

5 WASHING UNIT
5.1 HYDRAULIC WASH CIRCUIT
The part of the hydraulic circuit that supervises the washing of the wells is shown in
the following diagram:
CS sen.
(1-4) closure
cap Pp7-1
21
SV10
Pp7-2
Pp2
SV2 S1
Pp6
closure
Buff. Sol. cap 25 Pp4-1
Autoimm. SV11
SV1
Pp4-2
Pp1
SV12 S2
B1S sen
(1-4) Pp5
Buff. Sol.
Infective SV6 28
P1
B2S sen
(1-4) Wasting
Fig. 5-1
SV1: solenoid valve for exchange between the autoimmunity washing-buffer solution and the air
SV2: solenoid valve for exchange between the ev12 selection and the cleaning solution
SV6: solenoid valve for exchange between the infective washing-buffer solution and the air
SV10: solenoid valve for stopping the flow of washer #1
SV11: solenoid valve for stopping the flow of washer #2
SV12: solenoid valve for the exchange of the buffer tanks
Pp1: supply pump in the needles of washer #2
Pp2: supply pump in the needles of washer #1
Pp4: aspiration pump from the needles of washer #2
Pp5: aspiration pump from the collection basin of washer #2
Pp6: aspiration pump from the collection basin of washer #1
Pp7: aspiration pump from the needles of washer #1
P1: aspiration pump from the needles of washer #3

5.2 TANK PROBES
The instrument has three probes (infective washing-buffer solution, autoimmunity
washing-buffer solution and cleaning solution) whose function, besides that of
withdrawal, is to check and report the amount of liquid present in the tank in which
they are inserted.
Each probe has two terminals:
▪ a plastic tube with relative connector (6) for the drawing up of the liquid,
highlighted with a blue, green or white band (8)
▪ an electric wire, with relative connector (7), for detecting the liquid level
which are attached to the respective connectors located in the instrument’s tank
chamber
Warning: Each probe must always be used with the same solution in order to prevent cross
contaminations.
Use the probe with the blue band for the tank with the Infective Washing Buffer, that with the
green band for the tank with the Autoimmunity Washing Buffer and that with the white band
for the Cleaning solution, following the color-coding indicated on the instrument’s connectors
Once connected, the probe takes the liquid from the spout and puts it into the
hydraulic circuit through the fitting.
The four sensors, located on the probe rod, report the liquid level in the tank. The
sensor signals are sent to the instrument through the electric connector.
7 1. withdrawal spout
2. 0% level sensor
3. 25% level sensor
1 2 3 4 5 8 4. 50% level sensor
6
5. 75% level sensor
6. hydraulic fitting
7. electric connector
8. band
Fig. 5-2
The levels managed by the Chorus TRIO are:
0%: tank empty – the instrument stops any ongoing cycle and reports a
warning
25%: tank almost empty – if the buffer solution drops below this level, a
warning will be generated during the initial check and the cycle cannot
be started
50%: if the washing solution drops below this level, a warning will be
generated during the initial check and the cycle cannot be started
75%: first control level

5.3 THE WASHER
The washer is a device that is designed to move the wash needles up and down in
the two reaction wells (no. 5 and no. 6) to repeatedly draw up or dispense the buffer
solution with which the two wells are “cleaned”.
The wash needle is composed of a pair of stainless steel tubes: one for washing and
one for aspirating. The aspiration tube is straight and works to reach the bottom of
the well to ensure the complete aspiration of the liquid present. The upper part is
shaped in order to stop the tube.
The dispensing tube is of a small diameter, has a tapered end and never touches the
liquid in the well. The upper end is bent to separate the two tubes at their connection
point. The upper part is shaped to stop the tube.
Both tubes have a teflon tip for better runoff of water particles. The two tubes are
joined together by a case, which slide inside an axial bearing, while the needle is held
in the upward movement by a spring. To ensure that the needle adheres to the
bottom of the well, the needle drops below the level of the well bottom, making the
spring intervene. The needle must therefore slide vertically, which occurs along the
axial bearing.
The needles, with the parts described above, are positioned in the needle block, which
is made up of two parts fastened together by a central screw.
The needle block is mounted on a bracket that is connected to the slider which moves
up and down along the slide. The bracket is integrated with a toothed rack and
therefore the rotation of the motor, with flush fit shaft pinion, produces the vertical
movement of the needle.
A magnetic sensor mounted on an electronic board, and relative magnets, mounted
on a connecting rod is used to set the vertical position.
A U-shaped aluminium bracket supports all the parts and the base of this bracket is
fixed to the upper surface of the instrument.
1
A sezione
left A-A
right
2
12
11 1. bracket
3 2. connecting bracket
10
3. needles
4. needle-holding block
9
13 5. slider
6. slide
14
7. toothed rack
8. pinion
4
9. motor
8 5 15 10. position sensor
7
11. aspiration tube
6 12. supply tube
A 16
13. tube casing
14. spring
15. axial bearing
RIGHT FRONT LEFT 17 16. tapering
17. Teflon covering
Fig. 5-3

5.4 THE DRYING STATION
As can be seen from the hydraulic circuit and from the structure, after the two
washing stations (washers #1 and #2) there is a third station for drying (in pos. no. 28).
The drying station is a device that can drop an unifilar needle into either of the
reaction wells in order to remove the contents.
The mechanics are the same as with the washer
Fig. 5-4
5.5 COLLECTION WELLS

As can be seen from the hydraulic circuit and the structure, the instrument has three
washing stations, or rather two washing stations (washer #1 in pos. no. 21 and washer #2 in pos.
no. 25) and a third station for drying (washer #3 in pos. no. 28).
A washing station is a device that can drop a bifilar needle into either of the reaction
cuvettes. The needle is composed of one larger diameter straight needle and one
smaller diameter needle that is tapered at the end. The two tips are Teflon coated in
order to prevent the formation of drops.
The straight needle is used to remove the liquid in the well. The tapered needle is
used to dispense washing buffer.
The two needles move up and down together and the descent into the bottom of the
well is dampened by a spring.

2 1. straight needle
1 2. tapered needle
3. sensors
Fig. 5-5
The diagram shows the section below the strip introduction tray.
As can be seen, there is a collection basin. When there are no strips in the tray, the
contents of the needles are unloaded in the well during the priming or cleaning of
the needles.
The well is drained by pump pp6, if we are in position 21 or by pump pp5 if we are in
position 25.
For safety purposes, each well is equipped with a pair of sensors that can report any
overflowing of liquid.

5.6 WASHING PROCEDURE
The sequences described below show how the pair of cuvettes are washed in
correspondence with Washer #1 (pos. 21) and Washer #2 (pos. 25), whether one or both
of the cuvettes are filled. The duration of the operation is equal to the standstill time
during the step (approx. 7-8 sec).
We will describe the operation of Washer #1:
1 2 3 4
5 6 7
Fig. 5-6
1. The needles are in the resting position

2. Spring dampened descent into cuvette, with simultaneous aspiration of the liquid
through pump pp7. At the bottom of the descent, the cuvettes are dry and the needles
remain in the cuvette for approximately 3 seconds.
3. Raising of the needles and successive dispensing of the washing buffer. Dispensing is
done by pump pp2, with ev1 and ev2 off.
4. Spring dampened descent into cuvette, with simultaneous aspiration of the liquid
through pump pp7. At the bottom of the descent, the cuvettes are dry.
5. Raising of the needles and successive dispensing of the washing buffer. Dispensing is
done by pump pp2, with ev1 and ev2 off.
6. Spring dampened descent into the well, with simultaneous aspiration of the liquid
through pump pp7. At the bottom of the descent, the cuvettes are dry.
7. Return to the resting position.

5.7 WASHING CIRCUIT TESTING PROCEDURE
Have available:
▪ one tank with infettivology washing buffer and connect it to the probe marked
with blue colour;
▪ one tank with cleaning solution and connect it to the probe marked with white
colour;
▪ remove the strips from the carousel and reset the tray.
5.7.1 Supplying of buffer from washer #1

1. Lower washer no. 21 to the end of stroke;
2. Access to the Switches window:
3. Switch on Sv12 and then Pp2.
Check that the infettivology washing buffer begins to flow through the tubes
and goes into the needles of washer #21.
4. When the liquid touches the contacts of the basin, pump Pp2 must stop and
pump Pp6 must switch on to empty the well;
5. Retry activating Pp2 again. At the end of the test, disable Sv12 and lift the
washer.
5.7.2 Supplying of buffer from washer #2

Check that the infettivology washing buffer begins to flow through the tubes
and goes into the needles of washer #25.
washer.
5.7.3 Washing of the piping for washer #1

Check that the cleaning solution begins to flow through the tubes and goes
into the needles of washer #21.
washer.
5.7.4 Washing of the piping for washer #2


Check that the cleaning solution begins to flow through the tubes and goes
into the needles of washer #25.
washer.
5.7.5 Aspiration at drying station #3

1. Put a strip with two cuvettes filled with liquid under the drying station position
and lower the needles until they are inside the cuvettes.
2. Activate Pp1 for a few seconds and check that the liquid is completely aspirated
5.8 CONTROL PARAMETERS

5.8.1 Filling level of washer #1 (step 21)
This is the number of steps needed to position the aspiration needle near the upper
edge of wells 5 and 6 during the dispensing phase. The needle must be inside the
wells at approximately 2mm from the upper edge, so that any excess liquid can be
aspirated.
The procedure to calculate this parameter is the following:

1. Insert a strip with wells 5 and 6 in position 1 of the tray;
2. Open the Washer Test window:
Chorus / Utility / Service / Diagnostics / Test Macros / Washer Test
3. Double click on Washer item and select Washer 1, then press Start;
4. At the end of the test, a report with the expected values (E_lvl) and the
measured values (M_lvl) is displayed and printed. The measured values must
be between 250 and 280 µl. Extract the strip and check that the measured level
corresponds to the level actually present in wells 5 and 6 (about 2 mm from the
edge);
5. If the measured level is out of the above-mentioned range, act on the Washer
#1 Bottom Level parameter:
Increase the steps number to lower the volume or decrease the steps number
to increase the volume.
5.8.2 Filling level of washer #2 (step 25)

This is the number of steps needed to position the aspiration needle near the upper
edge of wells 5 and 6 during the dispensing phase. The needle must be inside the
wells at approximately 2mm from the upper edge, so that any excess liquid can be
aspirated.
The procedure to calculate this parameter is the following:

1. Insert a strip with wells 5 and 6 in position 1 of the tray;
2. Open the Washer Test window:
Chorus / Utility / Service / Diagnostics / Test Macros / Washer Test
3. Double click on Washer item and select Washer 2, then press Start;
4. At the end of the test, a report with the expected values (E_lvl) and the
measured values (M_lvl) is displayed and printed. The measured values must
be between 250 and 280 µl. Extract the strip and check that the measured level

corresponds to the level actually present in wells 5 and 6 (about 2 mm from the
edge);
5. If the measured level is out of the above-mentioned range, act on the Washer
#2 Bottom level parameter:
Increase the steps number to lower the volume or decrease the steps number
to increase the volume.

6 THE DRAIN CIRCUIT
The part of the hydraulic circuit that supervises the discharge of the liquids is shown
in the diagram below.
The circuit is designed so that the Chorus TRIO can be connected to a collection tank
or to a central drain.
Fig. 6-1
The following devices intervene:
pp8: pump for main waste well
6.1 THE MAIN WASTE WELL
11
10 3 1. aspiration pump a
2. waste intake (blue)
9 3. liquids intake
4. pump expulsion
2 5. waste outlet (red)
1 6. outlet line
4 7. outlet closed return

8 connector
8. warning sensor S4
9. error sensor S3
5
7 6 10. outlet closed return
inlet
Fig. 6-2
11. wash well drain
The waste well is the device that regulates the evacuation of the liquids not needed
by the Chorus TRIO.

The liquids coming from the waste collection tube of the pumps reach the well
through the fitting, while the liquids coming from the dispenser wells arrive from the
hole in the cover through a tube.
Peristaltic pump pp8 takes in the liquid collected from the fitting and sends it
towards the red outlet, connected to the well by the junction, through the outlet line;
the connection to the blue outlet is ensured by the fitting.
Besides collecting and expelling waste liquids, the well monitors the proper
functioning of the circuit through the use of an auxiliary waste outlet well, connected
to the outlet line by the fitting and to a series of level sensors.
Since the hydraulic circuit is directly controlled by the waste well, the use of external
level sensors are therefore not necessary.
6.1.1 Normal operation
Fig. 6-3
The liquids to be discarded are sent through one inlet (waste inlet).
When the liquid reaches the level of the warning sensor WS (S4), drain pump pp8 is
immediately activated and the liquid is evacuated through the output indicated with
the colour red on the rear panel.
The liquid flows toward the outlet without entering in the recirculation circuit, as the
diameter of the tube for this circuit is much smaller.
The intervention of the warning sensor is not reported during normal operation.

6.1.2 Obstructed drain
Fig. 6-4
When the drain is obstructed or cannot be used, for example if the tank is not
connected, the liquid pushed by pump pp8 is sent into the recirculation circuit and
then returns into the waste well, raising the liquid level inside the well.
The main waste well therefore begins to fill.
There is an error sensor ES (S3) in the well, placed at the maximum allowable filling
level.
The instrument stops and a fatal error is generated when the sensor is reached.
If the obstructed drain is resolved before the ES is reached, the liquid is evacuated as
normal by pump pp8.
6.1.3 Full waste tank
Fig. 6-5

When the waste tank is full and the cap has been screwed on correctly in order to
seal the tank, the waste liquid will come back into the instrument through the blue
pathway (safety input), filling the auxiliary well until the error sensor is triggered, at
which time the instrument will generate a fatal error.
To summarize:
ES activated = drain problems
6.1.4 Faulty drain pump
Fig. 6-6
When drain pump pp8 has broken down, the liquid continues to flow into the waste
well, initially activating the warning sensor (WS), and then the error sensor (ES) when
the well is full. A fatal error is generated at this point.
To summarize: ES activated = drain problems
6.2 WASTE CIRCUIT TESTING PROCEDURE

6.2.1 Checking of waste level warning sensor (WS)
1. Connect the cleaning solution tank;
2. Interconnect the two outlets of the waste tubes;
3. Activate SV4 (Valves / SV4) and Pp3 (Pumps / Pp3);
4. Check that the flow of water comes out of UGEL 1;
5. Activate SV5 (Valves / SV5);
6. Check that the flow of water comes out of UGEL 2;
7. Let the water rise up to the level of the warning sensor S4 (Waste well half full);
8. Check that the Warning alarm activates (Waste well half full) and that PP8
drains the well.

6.2.2 Checking of waste level error sensor (ES)
1. Continue filling until the water that comes out of the RED pathway returns into
the well through the BLUE pathway;
2. Wait until the waste level error sensor S3 is reached;
while Pp8 continues to run, the Waste well full alarm must activate;
3. Disconnect the waste line from the RED PATHWAY, then insert it in the tank
and wait for the well to empty and Pp8 to stop.

7 TEMPERATURE CONTROL
7.1 TEMPERATURE CONTROL OF THE INSTRUMENT
The diagram of the temperature control devices present on the instrument is shown
in the figure.
First of all, the instrument is considered to be “closed” from a thermal point of view,
since the container that houses it is thermally insulated. It should be noted that there
are heat sources inside the instrument: heater, power supply, lamp, motor drivers,
motors, etc.
The following components are found inside the instrument to regulate the
temperature:
▪ Cooling fans that take in the air inside the instrument;

▪ Air vents with dust filter, where air is drawn in for internal cooling;
▪ Internal temperature sensor.
1. fans
2 2. protective housing
3. instrument temperature
sensor
1 4. air vents
Fig. 7-1
7.2 MEASURING CHAMBER

One of the specifications for performing a test is the temperature at which the
reaction must occur. The operating temperature range can vary from 25°C to 40°C
and is automatically programmed before every cycle.
Heating occurs by the emission of hot air into the heat chamber (where the tray
rotates) by means of a heater, where a fan directs hot air into the measuring chamber.
The hot air also heats the upper part of the tray for the strips and consequently the
strips themselves.
The input of hot air is regulated by a system that uses the temperature sensor inside
the chamber.

The tray must get to temperature before the instrument can be used.
At start-up, if the instrument is cold, a wait of up to 25’-30’ may be required to allow

the heat chamber and the tray to get up to cycle temperature (typically 38°C).
6 1. lower base
2. heater
4 3. strip temperature sensor
4. measuring chamber walls
5. heat chamber (internal)
3 1
5 2 6. tray
Fig. 7-2
7.3 HEATER
1 Fan
2 Housing
3 Heating coil
7
5 6 4 Dust filter
5 Flange
2
6 Fastening holes
4 1
Fig. 7-3
The heater is the device that works to keep the temperature in the heat chamber
stable.
It is composed of a coil wrapped around the heating unit and encased by a PVC cover;
a 50x50 mm wide fan with a 24 V DC power supply is used to transfer the heat into
the chamber. This hot air then passes into the heat chamber through the heater
cylinder.
The impurity filter is positioned between the fan and the protective grill.
The heater is mounted on the upper plate of the Chorus TRIO by means of the 2
fastening holes in the support flange.
7.3.1 Electrical properties of the heater

▪ Rated voltage: 24V DC
▪ Resistance value: 3 ohms
▪ Power output: 192 W

7.4 CYCLE TEMPERATURE
The cycle temperature is determined through the operating temperature of the tests
identified on the tray.
If the operating temperature of the tests is not homogeneous:
▪ the cycle does not start;

▪ the incongruent strips are indicated on the display.
The cycle will only restart if there are tests in the identification that have the same
operating temperature.
If the temperature of the tray is not at the required temperature, the cycle will only
restart when the system will reach the cycle temperature.
7.5 STAND-BY TEMPERATURE

When the cycle is finished, the temperature of the tray is regulated by the stand-by
value: Idle Temperature.
The stand-by temperature prevents the tray from cooling and reduces the successive
heating time of the cuvettes. This stand-by temperature is normally set at 38°C (380
tenths of a degree) but it can be changed through the General Settings window:
Chorus / Utility / Service / Settings / Parameters / General Settings
7.6 PROCEDURE FOR TESTING THE TEMPERATURE CONTROL

SYSTEM
7.6.1 Checking of the instrument temperature sensor
1. Remove the protective housing;
2. Safely heat the instrument’s temperature sensor and check that, once the
temperature exceeds the stand-by value (Idle temperature), the rear fans will start.
The temperature inside the instrument can be checked through the Check window
(during all seasons and in ambient temperature conditions <30°C, the temperature
of the instrument does not normally exceed 35°C).
7.6.2 Chamber temperature control

The following conditions are required to start this test:
▪ The instrument, complete with housing, switched off and at room

temperature;
▪ A strip in position 1 with 300l of water in well 6 and a thermometer.
▪ The Idle Temperature value set at 38°C.
Switch on the instrument and verify in the Check window the rise of the strip
temperature. With the thermometer, check that the temperature in the strips falls
within the range 36÷38 °C within 30 minutes.

7.6.3 Strip temperature correction
If the strip measured temperature is outside the range, it is possible to perform a
correction of the temperature detected by the sensor by modifying the Strip
temperature correction parameter (increasing the value causes the instrument to
heat up more):
Chorus / Utility / Service / Settings / Parameters / General Settings
Attention: the temperature in the various positions of the plate is not perfectly
homogeneous when the plate is still. Therefore, before changing the correction value,
insert more strips in different positions of the plate and wait 15 minutes. The average
between the measured temperatures in the various positions must be between 36°
and 37°C.

8 SPEAKER-PRINTER DISPLAY
8.1 DISPLAY
1. Display
2. Touch screen
display area
3. Display lamp cable
4. Display data cable
Fig. 8-1
The Chorus TRIO is equipped with a liquid crystal display touch screen; this allows you
to interact with the instrument by simply touching the screen with your fingers.
8.2 THE SPEAKER

The speaker is a device that emits sound signals for instrument errors that are
modulated according to the error detected.
8.3 THE PRINTER
1. Roller
2. Trolley opening
lever
Fig. 8-2
The Chorus TRIO is fitted with a thermal printer that reports the results of the various
instrument tests and the results of previous tests onto paper.
Thermal paper must be used for this type of printer and is supplied in rolls. As can be
seen in the figure above, to insert the paper one must raise lever 2, place the edge of
the paper under roller 1, let it pass under the roller until it comes out above, then lower
the lever.

8.3.1 Printer testing
8.3.1.1 Loading the paper
From the Sensors window:
Chorus / Utility / Service / Diagnostics / Sensors
1. Raise the lever, remove the paper and lower the lever again;
2. Check that the signals below are in the following state:
▪ Printer paper Ok sensor must be switch off (grey color);
▪ Printer carriage open sensor must be switch off (grey olor).
3. Manually introduce the paper until the roller begins to drag it, then check that
the signals below are in the following state:
▪ Printer paper Ok sensor must be switch on (yellow color);
▪ Printer carriage open sensor must be switch off (grey color).
4. Raise the lever and check that the signals bolow are in the following state:
▪ Printer paper Ok sensor must be switch on (yellow color);
▪ Printer carriage open sensor must be switch on (yellow color).

9 ELECTRONIC PARTS
The main electronic boards of the Chorus Trio Expander are described in this chapter.
9.1 GENERAL MAP

Fig. 9-1 shows the overall diagram of the instrument with the electronic boards and
all the devices that are connected to it.
The Carrier+IMX8 is the board that manages: all the other boards (i.e. CPU 2010, Low
Power, Connectors, Power Supply), all the motors (i.e. Wash1-3, Syringe, Tray, Disp1-2,
X Carriage, Filter and TSD), the two thermostats (i.e. instrument and chamber), the
optical channels, the LCD display (i.e. touch screen & display), the printer and the
Internal Bar Code Reader.

Fig. 9-1

9.2 CARRIER+IMX8 BOARD
The Carrier+IMX8 board represents the central unit of the instrument; it sends all the
commands to the other peripherals, including the CPU 2010, which is limited to
execute the received commands. Furthermore, all the data processing and storage
functions are delegated to it.
The Carrier board is located on the left side, looking at the instrument from the back,
under the display/printer assembly.
Carrier+IMX8 Board
Fig. 9-2
9.2.1 Power supply and connections

The Carrier+IMX8 board is powered directly from the Power Supply Unit, precisely
from the Chorus Expander External Connection Board through the connector J4
(+12V).

Fig. 9-3
Fig. 9-4
9.3 CPU 2010 BOARD AND DRIVER 2010 BOARD

The CPU 2010 and the Driver 2010 are the boards that deal with the execution of all
the commands coming from the Carrier+IMX8 board.
All the functions of the Chorus TRIO refer to them, from the moving of the motors, to
the management of the hydraulics, to the acquiring of analogue signals coming from
the optical sensors, etc.

The boards are found on the left side, looking at the instrument from the rear, under
the display/printer unit, and is fixed to the frame by 4 screws in its 4 corners (see Fig.
57).
The DRIVER 2010 board is mounted alongside the CPU 2010 and most of the
connectors are mounted on it (in particular, connectors for the motors and the
thermometers).
CPU 2010 + Driver 2010
Fig. 9-5
9.3.1 Power supply

The CPU 2010 board is powered directly from the Power Supply Unit through
connector CN11 (+5V, +12V, -12V) and cable CAB 536. The voltages are reported by
means of 4 LEDs (+5V - DL5, +12V - DL6, -12V - DL7, +24V - DL8). The DRIVER 2010 board
is powered through connector CN11 (+24V).

Fig. 9-6 Layout and connections – Complete view

Fig. 9-7 Layout and connections – Sheet 1

Fig. 9-8 Layout and connections - Sheet 2



Fig. 9-11 Test Points and Settings (complete view)

Fig. 9-12 Test Points and Settings Sheet 1

Fig. 9-13 Test Points and Settings Sheet 2

9.3.2 Description of the Test Points and CPU 2010 board jumpers
Test
Point Description
Number
Positive of the tester on TP2 and negative on TP15. Measure of the analogue signal
TP2
of CH2. Signal variations from 0 to 2.5V
TP3
TP4
Positive of the tester on TP10 and negative on TP15. Measure of the analogue
TP10
signal of CH6. Signal variations from 0 to 2.5V
TP11
TP13
signal of CH5. Signal variations from 0 to 2.5V
Positive of the tester on TP14 and negative on TP24. Check the presence of -12V.
TP14
Also reported by the start-up of DL6.
TP15 Analogical Ground
Positive of the tester on TP16 and negative on TP24. Check the presence of +12V.
TP16
Positive of the tester on TP22 and negative on TP24. Check the presence of +5V.
TP22
TP24 Digital Ground
TP26
signal of the lamp voltage. Signal variations from 0 to 2.5V
TP27
signal of the accelerometer. Signal variations from 0 to 2.5V
TP28
signal of the lamp voltage. Signal variations from 0 to 2.5V
[1-2] (Default). On/off control of the back light of the display. [2-3], lamp display
JP1
always on.
J1 Programming condition for the microprocessor
J2 Reset condition for the microprocessor
J3 Reset condition for the microprocessor
J4 No Maskable Interrupt of the microprocessor
JS1 Closed (default). Programming signal FPGA IC3, IC6
JS2 Open (default). Programming signal FPGA IC3, IC6

9.3.3 DESCRIPTION OF THE TEST POINTS AND THE DRIVER 2010 BOARD
JUMPERS
Jumper
Description
Number
Positive of the tester on TP23 and negative on TP24. Check the presence
TP23
of +24V. Also reported by the start-up of DL8.
Pad1 [2-3] (Default). Current setting for Wash1 motor. Minimum value
Pad4 [Open] (Default). Current setting for Syringe motor. Maximum value
Pad5 [1-2] (Default). Current setting for Filter motor. Mean value
[2-3] (Default). Current setting for Tray Synchronization Device motor.
Pad6
Minimum value
Pad7 [2-3] (Default). Current setting for Disp1 motor. Minimum value
Pad8 [2-3] (Default). Current setting for Disp2 motor. Minimum value
Pad9 [Open] (Default). Current setting for Tray motor. Maximum value
Pad10 [Open] (Default). Current setting for Sliding motor. Maximum value
9.3.4 Troubleshooting
The CPU 2010-DRIVERS 2010 boards have been completely realized in Surface Mount
Technology (SMT), and therefore integrated circuits cannot be replaced unless SMT
reworking equipment is made available.
9.4 LOW POWER

9.4.1 Description
The Low Power board controls all the hydraulic actuators (solenoid valves,
electromagnets, pumps) and in which all the instrument’s functional sensors (error
sensors, tank sensors, alarm sensors) enter and are mixed.
The board is found on the right side, looking at the instrument from the rear, and is
fixed to the frame by 4 automatic hooks located in its 4 corners (see Fig. 9-14).
9.4.2 Power supply and connections

Fig. 9-15 and Fig. 9-16 show all the connections for the board, which is powered
directly from the Power Supply Unit through connector CN4 and cable CAB 358.
The power supply voltages are +24V and +5V, in addition to the the ground (GND),
and their presence on the board is indicated through two LEDs (DL1, +5V and DL2,
+24V).
There are also two fuses on the socket (F3 at 5V and F4 at +24V) to protect the board
and the instrument.
All these components can be seen in Fig. 9-17.

Fig. 9-14 Layout of the Low Power board in the instrument


Fig. 9-16 Layout and connections - Sheet 2 of 2

Fig. 9-17 Test Points and Settings Sheet 1 of 2

Fig. 9-18 Test Points and Settings Sheet 2 of 2

Fig. 9-19 Low Power board upgraded with Kit Expander

All the integrated circuits (I.C.) mounted on the board are on the socket, therefore
they can be easily replaced in case of breakdown. The components that are more
susceptible to breakdown than the others are those controlling the actuators
(pumps, solenoid valves, solenoids).
Listed below are the actuators and the I.C. that control them.
Actuator I.C. Type

SV1, SV2, SV3, SV4 IC8 L293E
SV5, SV7 IC9 L293E
SV8, SV9 IC10 L293E
P1, Pp1, Pp2, Pp3 IC11 L293E
Pp4, Pp5, Pp6, Pp7 IC12 L293E
Pp8, SV12 IC13 L293E
Other possible board anomalies could be:
Anomaly Countermeasures
LED DL1 is off
Replace fuse F3
(the +5V are not present)
LED DL2 is off
Replace fuse F4
(the +24V are not present)
Needle1 or 2 sensors does not work Responsible I.C.: IC1, IC2, IC3, IC4,
(also LED DL3 does not turn on) IC5, IC6, IC7
The level sensors do not work
Responsible I.C.: IC15, IC16, IC18
(various wells, tanks)
9.5 POWER SUPPLY

The power supply unit is located in the lower left part of the Chorus TRIO (see Fig.
9-20) and can be accessed from the rear.
Its main function is to transform the line voltage into low voltage direct current
needed to power the instrument.
Fig. 9-20 Location of the power supply unit

If the power supply unit needs to be repaired or replaced, follow the procedure below:
1. Disconnect the power supply cable from the instrument;

2. Remove the protective housing;
3. Disconnect all the connections;
4. Loosen the 4 screws (F1-F4, Fig. 9-21), that fasten it to the frame.
5. Lift the rear part to allow it to come out of the profile of the plastic housing and
take it out of the instrument.
If it needs to be opened, unscrew the 6 screws (V1-V6) that fasten the sheet metal
cover and then remove it by sliding it towards the rear part of the power supply unit.
The boards contained in the power supply unit will be described in the following
chapters.
Fig. 9-21 Power Supply Unit
9.6 DESCRIPTION
The Rev.3 Power Supply board is responsible for different things inside the power
supply unit; from regulating the LED voltage, to the controlling of the heater, to the
switching of the output voltages from the power supply unit, to powering the cooling
fans.
Fig. 9-22 shows the positioning of the board in the case of the power supply unit. Fig.
9-24 and 78 are shown the connections that go in and out of the power supply unit.

Power Supply Board
Fig. 9-22 Location of the Power Supply Board

Fig. 9-23 Power Supply Board connections



Listed below are possible problems that may be caused by the Power Supply Board.
The LED does not switch on

Is D2 on?
YES check the connection that goes to the LED group or check the
LED itself
NO 1) Are there 24V between TP1 (GND) and Pin 1 of CN2?
2) Are there 5V between TP1 and R1?
If both conditions are met this indicates that IC1 is damaged and
the board needs to be replaced.
If 1) is yes and 2) is no, then the command is not arriving from the
CPU. Vice versa, if 2) is yes and 1) is no, then the power supply unit
that regulates the 24V (PSU1) is damaged and it needs to be
replaced.
The heater doesn’t work

Place the tester between TP1 (GND) and TP3.
22V can be registered as soon as the instrument is turned on? YES

1) The heater is OK? (check the resistance continuity)
2) Are there 24V between TP1 (GND) and Pin 1 of CN2?
Replace the heater if 1) is not true while replace the power supply unit PSU1 if 2) is not
true.
22V can be registered as soon as the instrument is turned on? NO

Try to replace IC5. If the defect continues, change the board.
To replace the board, disconnect all the wires and unscrew the 4 screws located in its
corners.
9.7 CONNECTORS BOARD

9.7.1 Description
The function of the Chorus Expander Connection Board is to interface the Chorus
TRIO with the outside world. There are connectors to connect it to different peripheral
devices. Any faults to the board can affect the possibility of connecting to the Chorus
TRIO.
Power supply
The Connectors Board is powered at +5V and at +24V through the cabling 30147041
and the cabling 30147050. It is possible to check the presence of the power supplies
by observing the lighting of the LD5 (+ 5V), LD3 (+ 12V) and LD1 (+ 24V) LEDs.
The board is fastened to the chassis with 5 screws located in the corners of the board.
If it must be replaced, just remove the connections, the fastons to the power
connector and unscrew the 5 screws. To make the extraction of the board easier, the
power socket must also be removed by loosening the two screws holding it to the
rear panel of the power supply unit.
Fig. 9-26 shows the layout of the board inside the chassis.

Chorus External Connection Board
Fig. 9-26 Location of the Connectors 2010 Board

Fig. 9-27 Layout and connections

Fig. 9-28
To CHORUS EXPANDER
Code Description EXTERNAL CONNCECTION
BOARD 30146921
30147060 12Vdc J6
30147070 OFF SIGNAL CONTROL CABLE J5
21890410 RJ45 UTP ETHERNET CABLE, CAT 5e 1mt J9
30147090 BC EXTERNAL SERIAL CABLE FOR CHORUS J11
21890360 USB CABLE 2.0 A-B M/M 1,5 Mt J12
30147082 CPU CHORUS SERIAL & HOST RS232 CABLE CN3
The board was realized using SMD technology, therefore the board cannot be
repaired in the field.

10 SERVICE PROCEDURES
10.1 PROGRAMMING FIRMWARE CPU 2010
If it is necessary to replace the board, following a failure of the same, the next
procedures must be followed in order to speed up and guarantee the positive
outcome of the technical intervention. First of all, it is necessary to check if the
Expander IMX8 board is able to connect to the CPU 2010 board. It is possible to check
the connection status either by clicking on the small square in the status bar next to
the Diesse logo or from the main window by observing if the firmware release present
in the CPU is displayed. The two boards are normally connected to each other via a
serial connection; if the serial connection is not active, it is possible to interface the
two boards with a USB A-B cable, by connecting the two USB ports on the rear panel
of the instrument (USB HOST and EXT SERV). In this case, it will be necessary to
change the type of connection by accessing the service application on the
instrument.
10.1.1 Service application

To access the service application, proceed as follow:
Chorus / Utility / Service

Insert the password: “diesse”
Fig. 10-1 Entry into the service application
At this point, depending on whether we managed to connect with the instrument,

we have two paths available.
10.1.2 Successful connection with CPU 2010 board

The first operation to be carried out is to download the instrument hardware
parameters file on a USB key so to be able to reload them on the new CPU 2010 board.
Then insert a USB key into the port next to the printer and from the service
application click on Settings and then Parameters.

Fig. 10-2 Fig. 10-3 HW parameters
Clicking on Export, the following window will open:
Fig. 10-4
Check in the bar at the top that the proposed path is correct (run/media/sda1).
Confirm with Ok if you want to save the file on the USB key with the name proposed
by the software or modify it by double clicking on the file name (ex. Chorus Trio
followed by serial number).
10.1.3 Unsuccessful Connection with CPU 2010 board

If it was not possible to connect to the CPU 2010 board, it means that something
happened at the serial link level. There are therefore 3 possible scenarios:
1. It is possible to attempt a USB connection via a USB type A-B cable, by

connecting the 2 USB ports on the rear panel of the instrument (USB HOST
and EXT SERV). In this case it will be necessary to change the type of
connection to the CPU, by accessing the service application on the instrument.
To do this, click on Settings and then on Core Settings. Double click on Core
Connection Type and select USB (PC);

Fig. 10-5
2. The fault is related to the hardware component; in this case it is not possible to
connect to the CPU 2010 board and it is also not possible to retrieve the
parameter file in any way;
3. The microcontroller present in the CPU 2010 board has lost the information so
to communicate with the outside; in this case it will be necessary to connect
to the CPU with a special device called Loader and with an external PC on
which the Chorus manager service application is loaded. To do this, download
the dedicated procedure from www.diesse.it website.
10.1.4 Firmware upload on the CPU 2010 board

To load the firmware on the CPU 2010 board, the connection with the Carrier+IMX8
board must be established. The firmware upload can be either requested
automatically by the instrument if the software recognizes that there is an outdated
firmware on the CPU board, or it is possible to upload it manually.
In the first case, when the instrument is turned on, the following message will appear:
Fig. 10-6
Press on the Yes button and wait for the firmware upgrade.
If instead you want to force the update, it is possible to access the service from the
following path:

Chorus / Utility / Service / Software Update / Core Firmware
Fig. 10-7 Fig. 10-8
Select Upload Firmware from File to Chorus and select the file related to the firmware
intended to be uploaded.
Attention: if the CPU board has been replaced, it will be necessary to re-enter the
parameters and the serial number of the instrument. If it was possible to download
the parameters before replacing the CPU board, access the Parameters window and
then press Import. Otherwise, it will be necessary to repeat all the mechanical
calibrations and re-insert them manually.
If the CPU board is new, a manual optical calibration procedure must be performed
the first time the instrument is turned on.
Access the Optical Calibration window:
Chorus / Utility / Service / Diagnostics / Optical System / Optical Calibration
Fig. 10-9
Run in sequence: V.Ramp, Dark then Light.
Double click on Filter 450, select the Filter 650 then repeat the above-mentioned

sequence.
10.1.5 Replacement of the Carrier+IMX8 board
If replacing the CPU did not solve the problem and there are no problems in the
connections, it may be necessary to replace the Carrier+IMX8 board.
Attention: the operating system, the Chorus Expander software, the methods file, and
the calibration file are saved on a µSD card. In case of Carrier+IMX8 board
replacement, all information can be transferred simply by transferring the µSD to the
new Carrier board. Anyway, if the instrument allows it, before carrying out any
operation, it is advisable to retrieve the methods file (if it is not possible to download
the updated file from the Diesse website) and the calibrations of the tests processed
up to that moment. Starting from software version 1.1.0, it is possible to backup the
archive of sessions, calibrations and methods using a single command.
Important: In case of replacement of the Carrier + IMX8 board it will be necessary

to synchronize the date of the new board with that of the 2010 CPU. Once all the
connections have been restored, turn on the instrument, open the Utility window,
select Clock, check the settings of date and time and then press Save.
10.1.6 Methods saving

In the methods file are collected all the information required by the instrument so to
process a specific test group. To save the methods file, proceed as follow:
Insert the USB key into the port near the printer.
From the service application, select Settings then Core Settings.
Fig. 10-10
Then click on Export Methods and the following window will open:

Fig. 10-11
Verify on the top bar that the proposed path is correct (run/media/sda1).
Click on OK if you want to save the file on the USB key with the name proposed by
the software, otherwise modify the name double-clicking on the file name itself.
10.1.7 Calibrations saving

To save the calibrations file, proceed as follow:
Insert the USB key into the port near the printer.
From the service application, press the Settings button then the Calibrations button:
Fig. 10-12
At this point, click on Export and the following window will open:
Fig. 10-13

Click on OK if you want to save the file on the USB key with the name proposed by
the software, otherwise modify the name double-clicking on the file name itself.
10.1.8 Backup on board Carrier+IMX8 board

Starting from software version 1.1.0 it will be possible to create a partial backup of the
board using a single command. This function will generate an encrypted file
containing the following information:
• Session archive
• Calibration archive
• Method files
• Instrument configuration
To be able to generate the backup file, proceed as follows:

Insert a USB key into the port near the printer, then from the service application click
on Backup and then on Create (Fig. 10-14).
Fig. 10-14 Fig. 10-15
Check in the top bar that the proposed path is correct (run/media/sda1). Confirm with
OK if you want to save the file in the USB key with the name proposed by the software,
or modify it by double clicking on the file name (Fig. 10-15).
To restore the information previously saved on the new board, insert the USB key into
the port near the printer, then open the service application again, click on Backup
and then on Restore (Fig. 10-14).
Check in the bar at the top that the proposed path is correct (run/media/sda1). Select
the backup file previously saved on the USB key (file with .cbk extension) and confirm
with OK. Follow the directions on the screen to complete the process.
10.1.9 Software upgrade on the Carrier+IMX8 board

If the Carrier+IMX8 board has been replaced and it was not possible to recover the
microSD card, you must check that the installed software is updated.
To view the information about the software, follow the path:
Chorus / Utility / About

IMPORTANT: In case of card replacement, remember to synchronize the date of the
Carrier + IMX8 card with that of the CPU 2010 card as specified in paragraph 10.1.5.
If the software is not updated to the latest version, go to Diesse website and download
the latest version on a USB key.
Then insert the USB key into the port near the printer and open the Software Update
window:
Chorus / Utility / Service / Software Update / Install From file
Fig. 10-16 Fig. 10-17
Select the file containing the update (characterized by the .cpk extension) then click
on OK. If the software update also requires a firmware update, the latter will be
requested automatically.
Once the software is updated, check that the configuration is correct:
Chorus / Utility / Service / Settings / Core Settings
Fig. 10-18
Enable the Autosampler (if present) and the RDP connection (if you want to connect
the instrument to the network).

10.1.10 Methods and Calibrations upload on the Carrier+IMX8 board
To upload the methods and calibrations files, insert the USB key and follow the paths
depicted at 10.1.6 and 10.1.7, then select the files to be uploaded and click on the
Import button.
Fig. 10-19 Fig. 10-20
10.2 AUTOSAMPLER
Starting from version 1.1.0 of the software it is possible to execute some service
operations to test the correct functioning of the Chorus + Autosampler system,
without necessarily perform an analysis cycle. To do this, open the service application
and go to Sampler:
Chorus / Utility / Service / Diagnostics / Test Macros / Sampler
Fig. 10-21
The following operation can be performed:

• Request the Autosampler firmware version
• Request the status of the Autosampler
• Request the reading of the samples present in the Autosampler
• Carry out a dispensing test
• Give the command to end the dispensing test

• Give the Autosampler a door opening command
By selecting the Dispense command it is possible to change the settings of the

dispensing cycle.
Fig. 10-22
By double clicking on each single line, it is possible to modify the quantity to be

dispensed, the position of the tube from which to take the sample, the starting
position of the strips in the Chorus plate, the number of strips to be dispensed and
the type of tube from which the sample is taken.
10.3 PROGRAMMING BARCODE READER ZEBEX Z 3080

The CCD Z 3080 reads barcodes automatically as well as on contact. The front window
projects a line of light which must cross the entire code. The best conditions for
reading are obtained when the reader handle is kept parallel to the surface on which
the code is found (Fig. 10-23and Fig. 10-24).
Fig. 10-23 Fig. 10-24
10.3.1 Connect the reader to the instrument through the RS232 cable
Insert the RJ connector of the RS232 cable (CAB350) into the socket located at the
base of the reader and push until the tab clicks into place; connect the other end of
the cable to the serial port on the Chorus TRIO labelled Barcode (Fig. 10-25).
Warning: since the serial port also supplies the power, it is best to connect the reader with the
instrument off.

Fig. 10-25
10.3.2 Disconnect the RS232 cable

To disconnect the cable from the reader, just lightly push a pointed object (i.e. a paper
clip) into the hole located near the base and slip off the RJ connector (Fig. 10-26).
Fig. 10-26
Normally the readers arrive already programmed to work in serial mode. If problems
occur, it is possible to try to reprogram the reader, reading on the Quick guide the
following barcodes sequence:
Start of configuration / RS-232C / End of Configuration
10.3.3 PROGRAMMING PARAMETERS

This table gives the default settings of all the programmable parameters. The default
settings will be restored whenever the "Reset" programming label is scanned and the
laser scanner is in programming mode.
DEFAULT VALUES OF OPERATING PARAMETERS

Function Default Values
Scanning Mode Selection Trigger mode
Header and trailer None
Inter-Message delay Normal
Inter-Character delay Normal
Message/Block mode selection Message
Send command in block mode Communication Disable
Good read beeper tone selection Medium
Code identifier transmitting Disable

PREDEFINED BARCODE IDENTIFIERS*
Code 39 barcode identifier code M
ITF 2 of 5 barcode identifier code I
Chinese post code identifier code H
UPC-E barcode identifier code E
UPC-A barcode identifier code A
EAN-13 barcode identifier code F
EAN-8 barcode identifier code FF
Codabar barcode identifier code N
Code 128 barcode identifier code K
Code 93 barcode identifier code L
MSI barcode identifier code P
MATRIX 25 barcode identifier code G
*
DEFAULT VALUES OF KEYBOARD EMULATION PARAMETERS SETTING

Keyboard type selection IBM PC/AT USA
Message terminator Enter/ carriage
Return
DEFAULT VALUES OF RS-232C SERIAL COMMUNICATION PARAMETERS

Handshaking protocol None
ACK/NAK response time setting 300 msec
Baud rate 9600
Data bit 8
Stop bit 1
Parity Mark
Message terminator selection CR/LF
DEFAULT VALUES OF WAND EMULATION PARAMETERS

Wand emulation speed Normal
Wand emulation output Black = High
Note: For wand emulation, the configuration is only effective for the items with asterisk (*).
DEFAULT VALUES OF USB EMULATION PARAMETERS

Keyboard Type US Keyboard
Message Terminator Enter

DEFAULT VALUES OF DECODING PARAMETERS
Function Code Default Value
Code 39 Enable
ITF 2 of 5 Enable
Chinese Post Code Disable
UPC/EAN/JAN Enable
Coda bar Enable
Reading codes * MSI Disable
Selection Code 128 Enable
Code 93 Enable
* ITAT Disable
* EAN-128 Disable
* MATRIX 25 Disable
*Italian Pharmacy Disable
ISSN/ ISBN Disable
Codes Standard
Code 39 Start/stop characters Not transmitting
Check digit Disabled
Concatenation Off
Interleaved Length 6-32 digits
2 of 5 Check digit Disable
Chinese Post Length 10~16 digits
Code Check digit Transmit
Format All
Addendum Disable
UPC-E=UPC-A Disabled
UPC/EAN/JAN UPC-A leading digit Transmit
UPC-A check digit Transmit
UPC-E leading digit Transmit
UPC-E check digit Transmit
Type Standard
Coda bar Start/stop characters A, B, C, D
Length 6~32 digits
Code 128 FNC 2 append Disable
Check digit Disable
MSI Length Variable
Check digit Transmit
Italian Pharmacy Transmit "A" Character Not transmitting
MATRIX 25 Length Fix 10 digits
Check digit Disable
Note: The configuration of the items with asterisk
(*) is effective when being appointed in advance.

PROGRAM PROCEDURE USING BARCODE MENUS
Fig. 10-27

SYSTEM SETTING
Start of Configuration
 The reading of the "RESET” label turns all the

parameters back to default values.
 When you intend to turn your scanner back to
default parameter, please scans the "Start of
RESET
configuration" label first, then scan "RESET" label
and finally scan the "End of configuration" label.
• The reading of the "ABORT" label discards all the

parameters read prior to the "End of configuration".
ABORT
• The scanner remains in the last interface mode
when the scanner is reset. The label below should
be scanned if the scanner is configured the first
RS-232C time.
⚫ The reading of the “SHOW VERSION” label will be

show firmware version.
PC/AT
USB
WAND EMULATION
SHOW VERSION
End of Configuration

QUICK SETTING
1. Quick Settings for Keyboard Wedge Mode
Program Reset
PC/AT End
2. Quick Settings for RS 232 Mode
Program Reset
RS-232C End
3. Quick Settings for German Language Keyboard
Program German Keyboard
End

10.4 MAINTENANCE
10.4.1 Routine maintenance
Must be done as needed by the user and involves the replacing of consumables,
which are:
▪ The replacement of the wash and buffer tanks when indicated by the
instrument;
▪ The replacement or emptying of the waste tank;
▪ The thermal paper for the printer.
If an initial check is performed at instrument start-up, a control procedure of every

device (electronic, mechanical, and hydraulic) is carried out.
This procedure involves:
▪ priming if the instrument was idle for more than 5 hours;

▪ washing of the internal parts;
▪ checking the functionality of the syringes, washers and dispensers;
▪ check of the optical calibration.
Any anomalies or errors will appear in the error window and, depending on the type,
may or may not be removed by the user (see Operating Manual).
The washing procedure must be launched at the end of the work day in order to
prevent incrustations from forming on the needles, tubes, etc. (see Operating
Manual).
The sanitization procedure is one of the maintenance operations to be performed at

the user’s discretion.
This procedure is similar to the washing procedure, except that a tank of antibacterial
solution is used in place of the cleaning solution.
The purpose of this procedure is to eliminate bacterial colonies and fungi which, over
time, can begin to grow in the hydraulic circuit.
This procedure can be even performed twice a month, if more than 30.000 tests are
performed on the instrument per year.
Refer to the operating manual for the performing of this procedure.
10.4.2 Periodic maintenance

Must be performed by Technical Personnel and involves working on the inside of the
instrument. The material needed to perform the maintenance, besides the standard
supplied replacement parts, are the following:
1. Sponges for the dispenser needles

2. Springs for the dispenser needles
3. Springs for the washer needles
4. Strip holder springs
5. Dispenser needle
6. Aspiration needle
7. Washer needle
8. Sleeve DBL 408 or LBBR4
9. Novoprene tube 2.5 x 1 for Sr 10/30
10. Novoprene tube 4.1 x 1.6 for Sr 10/50
11. Tuva tube 1.5 x 3

12. Cristal tube 3 x 5
15. Diaphragm for pump NF 30
16. Hydraulic fittings:
▪ CPC MS 2
▪ CPC ME 2
▪ Standard WES 6 1/8
▪ Standard GES 6 1/8
▪ Standard WES 8 1/4
▪ Value X230-6
▪ Value Y220-6
▪ Value Y210-6
▪ Value T210-6
▪ Value AC-6
17. OR 2-015
18. OR 2-004
19. OR 2-007
20. OR internal diameter 8 mm thickness 1mm
21. Optical filter 650
22. Optical filter 610
23. Heat filter 03FHA007
24. Toothed belt T 2.5 x 305 H 20
25. Toothed belt T 2.5 x 480 H 6
26. Probe
27. Sensor screws
28. Miscellaneous screws
29. Gloves
30. Safety glasses
31. Small jars (20 x 20 x 15) for immersing the parts
32. Cleaning liquid with disinfecting and degreasing properties
33. WD40 (lubricant spray)
34. Silicone oil
35. Silicone grease
36. Needle cleaning pads (0.6 0.8 mm drill bit)
37. Pad for cleaning the probes (steel or PVC rod, diameter 2.5 mm length 30 cm)
Use the following precautions before starting any intervention:
▪ Check the number of tests performed since the last maintenance intervention;
▪ Start the sanitization procedure;
▪ Disconnect the instrument from the network;
▪ Wear protective glasses and gloves
The maintenance for each device will be described in the following paragraphs.
10.4.3 Wash well for the dispenser needles

Dirt accumulates in the flat area around the slit from which the well is accessed,
above and inside the well itself (see Fig. 10-28)

The following is therefore required:
▪ Disassemble the wash well;

▪ Remove and replace the sponges with new ones;
▪ Disassemble all the hydraulic fittings, including the sprayers, removing all
possible gaskets or sealing elements;
▪ Dip all the parts in good condition in a disinfecting and cleanser solution and
replace any worn parts.
Fig. 10-28
Dry and reassemble all the parts of the well, making sure that the teflon gaskets have
been replaced. Before remounting it on the platform, clean it.
Fig. 10-29

10.4.4 Dispensers #1 and #2
Dirt mainly accumulates on the needles, at the base of the dispensers, on the drive
and around the slider guide.
The following is therefore required:
▪ Disassemble the two dispensers from the X carriage;

▪ Disassemble the needles;
▪ Check that the needles are in good condition and that the line is perfectly open
and free of incrustations. If the user complains about perforation errors, replace
the suspected needle, and replace both after 5000 tests;
▪ Check the needle-cable sensor contact;
▪ Disassemble the bracket guide, clean any incrustations with WD40 and
lubricate the guide with silicone oil;
▪ Check the needle spring and replace it if rusted;
▪ Reassemble the unit without mounting it onto the drive.
Fig. 10-30 Dispenser Fig. 10-31 Dispensers #1 and #2 mounted on

the X carriage
10.4.5 X-axis guide

▪ Loosen the screws holding the motor in order to loosen the belt;
▪ Remove the drive from the guide carriage and clean it;
▪ Disassemble the plate guide, being careful that the carriage does not come off,
then clean and lubricate it;
▪ Check that the belt is not worn, otherwise replace it;
▪ Clean the platform before remounting everything.

Fig. 10-32
10.4.6 Washers 21 – 25 – 28
Dirt mainly accumulates on the needles and at the base of the washers
(see Fig. 10-33)
▪ Remove the three washers from the plate;
▪ Remove the needles from the washers;
▪ Check that the needles are in good condition and that the lines are perfectly
open and free of incrustations;
▪ Remove the guide from the bracket for all washers;
▪ Clean the bracket and the guide and any incrustations with WD40 and
lubricate the guide with silicone oil;
▪ Check the needle springs and replace them if rusted or after 5000 tests;
▪ Check the spherical slide couplings of the needles. Replace if worn or
encrusted.
After the platform has been cleaned, the units can be remounted.
Fig. 10-33 Washer dirtiness Fig. 10-34 Washers #1 and #2

10.4.7 Optical unit
During normal operation dirt and dust deposit on the tray and on the lenses of the
optical unit, which must therefore be removed and cleaned separately.
The optical unit is made up of two parts:

▪ Emitter: a plastic block on which the 2 optical fibres and the lens plate are
mounted. This piece is mounted on the upper platform;
▪ Receiver: a plastic block on which the printed circuit for the optical receivers
and the lens plate are mounted. This piece is mounted below the lower
platform.
In the following figures are depicted the placements inside the instrument for all the
components.
Layout of the emitters
Fig. 10-35
To remove the emitter from the machine, just loosen the two screws fastening it to
the upper platform. When lifting it from the platform, we can now see from below
the lenses that are going to be taken out.
Using a cloth, delicately clean the lenses, being careful not to scratch them.
Warning: when the lenses are remounted, their convexity direction must be
respected.

Light emitter
Fig. 10-36
Positioning of the Receivers
As mentioned previously, the receivers are mounted below the lower platform. The
figure below shows their layout
Fig. 10-37

To remove the receiver, loosen the two screws fastening it to the lower platform. Slide
it from its seat and unplug the wire from the board. Now that we can see the lenses,
take off the plastic by removing the two screws.
Using a cloth, delicately clean the lenses, being careful not to scratch them.
Warning: when the lenses are remounted, their convexity direction must be
respected.
Receiver
Fig. 10-38
10.4.8 Washer wells

▪ Remove the two wells from the lower platform by loosening the screws;
▪ Clean the sensor contacts, removing any incrustations on the contacts and in
the body of the well;
▪ Check the conductivity of the sensors;
▪ Make sure that the platform is clean before repositioning them.
Fig. 10-39

10.4.9 Upper plate
Dirt accumulates in the points where the devices are mounted, therefore clean the
platform around the devices, especially in the slits and any other places where dirt is
found. Use disinfecting/cleaning liquid and dry.
10.4.10 Carousel
The cleaning of the carousel is done in two phases:
Upper plate of the tray, accessing the slit on the platform in correspondence with the
x-axis shifting (see Fig. 10-40) and clean, sector by sector, both the upper part and
inside the strip positioning chamber.
Be sure not to use abrasive liquids and/or substances that can remove the numbering printed
on the tray.
Fig. 10-40
Check of the strip holding springs.
Insert a strip in each of the thirty strip positions and check that the spring holds it in
place. Replace it if it does not hold.
To remove the springs, take off the sealing ring to which the fastening screws access
from the special opening in the platform.
10.4.11 Peristaltic pumps

▪ Disassemble the heads, leaving the pump in its place;
▪ Remove and clean the plastic residues on the rollers and on the internal walls
of the head;
▪ Replace the tube;
▪ Remount the head.

Fig. 10-41
10.4.12 Diaphragm pump

▪ Disassemble the head of the pump;
▪ Clean the internal diaphragm and the head.
Remount the head, being careful of its direction of flow in order to avoid switching
the aspiration/expulsion flow (see Fig. 10-42)
Fig. 10-42
10.4.13 Hydraulic waste and syringe unit

Dirt mainly accumulates in the contact points between removable parts (ex: covers,
hydraulic fittings, sensors, caps, brackets, etc. (See Fig. 10-43). Perform the following
steps for a deep cleaning, using the normal disinfecting/cleaning liquid.
▪ Disassemble the waste well unit by removing the two screws holding it to the
instrument’s frame;
▪ Remove the syringe unit (Fig. 10-45) from the bracket.
Fig. 10-43

10.4.14 Hydraulic unit
▪ Disassemble the head of the peristaltic pump (PP8);
▪ Remove and clean the plastic residues on the rollers and on the internal walls
of the head;
▪ Replace the tube and remount the head;
▪ Remove the waste well (from the rod) and completely disassemble it;
▪ Clean them by immersing in cleaning liquid for 30’;
▪ Clean the sensor contacts;
▪ Check all the hydraulic fittings and replace those that are worn;
▪ Reassemble the wells, remount the fittings and replace the seals (teflon and
silicone).
▪ Check the conductivity of the sensors;
▪ Check the cleanliness of the tubes and replace them if they are not clean;
▪ Reposition the well on the rod (see Fig. 10-44)
Fig. 10-44
10.4.15 Syringe Unit

▪ Unscrew the syringe from the Plexiglas support;
▪ Extract the piston from the syringe, substitute the teflon tip, grease with
silicone grease and then mount the piston back on the syringe;
Warning: when handling the syringe, do not push the piston so that it exits the side of the ring
nut otherwise the tip will become damaged when it is reinserted.
▪ Check the conditions of the syringe O-rings and replace them if necessary;
▪ Screw the syringe onto the Plexiglas support and fasten the piece;
▪ Check the hydraulic fittings by disassembling them from the Plexiglas
manifold, removing the silicone;
▪ Put new silicone on the fittings and reposition them on the Plexiglas manifold;
▪ Clean the syringe feed screw with WD40 and lubricate with silicone oil;
▪ Check the tightness of the screws, especially those for the joint;
▪ Reposition the syringe on the cross beam (Fig. 10-45) and remount everything
on the instrument’s frame.

Fig. 10-45
10.4.16 Rotation
The rotation requires no special maintenance operations besides cleaning of the dust
and checking the voltage and the condition of the belt.
10.4.17 Tray synchronization device

Check the tightness of the screws of the coupling for the tray synchronization device.
10.4.18 Led box and filter handler

▪ Remove the LED box from the printer-display assembly;
▪ Remove the filter handler from the LED box;
▪ Remove the support guide, clean it and lubricate it;
▪ Clean the filters, being careful not to scratch them or leave halos. Check their
overall condition and replace if necessary;
▪ Remove any trace of residue and dust;
▪ Remount the filter handler;
▪ Remount the LED box;
▪ Remount the box onto the printer-display assembly.
▪
10.4.19 Tank probes
Dirt mainly accumulates in the hydraulic piping (i.e. incrustations) and on the sensor
contacts (i.e. incrustations and rust).
For incrustations on the sensors, clean them with disinfecting/cleaning liquid.
In case of rust, clean with WD40 and disinfecting/cleaning liquid and/or replace the
probe.
Check the conductivity of the sensors.

Check the hydraulic piping.
10.4.20 Tubing
This check pertains to all the tubes in the instrument. Replace any tube that has
mould or other residues.


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SERVICE MANUAL

REVISION 2 Issued in July 2021

THIS MANUAL IS TO BE USED FOR CHORUS TRIO INSTRUMENTS STARTING

FOR IN VITRO DIAGNOSTIC USE ONLY

Catalog number Description

81200 CHORUS TRIO

81220 CHORUS TRIO RAS

Manual revisions list:

Manual revision Description of changes

0 of 03/2021 First issue relative to Chorus TRIO with Expander

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 3

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 4

Instrument meeting the requirements of the European Directive

In vitro diagnostic medical device

Key of electric and safety symbols

WEEE: Waste electrical and electronic equipment – Separate

Caution: risk of electrical shock

Caution: laser beam

BIOHAZARD: potential risk of contamination handling infectious

Risk of puncture to hands and fingers due to the presence of

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 5

DIESSE Diagnostica Senese SpA accepts no responsibility for damage caused

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 6

1 MOVING THE STRIPS ................................................................................................................................................................... 11

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 7

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 8

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 9

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 10

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 11

1.2 THE TRAY

1.3 TRAY ROTATION

Tray positioning is checked by:

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 12

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 13

1.3.1 ABSOLUTE SENSOR

1.3.2 STEP CHECK

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 14

1. hole sensor (relative)

The wedge-shaped pin is quickly moved by a motor on which a worm screw is

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 15

B 4. absolute sensor (at rest)

1.4 STRIP HOUSING

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 16

1.5 TRAY LOCK

1.6 CALIBRATIONS AND CONTROL PARAMETERS

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 17

To access the service program, proceed as follow:

Chorus / Utility / Service

The login Password is “diesse”

To change the parameter, open the Mechanical Calibration window:

Chorus / Utility / Service / Settings / Parameters / Mechanical Calibration

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 18

2.1.1 Check SPS sensor (Strip Presence Sensor)

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 19

2.2.1 Internal barcode reader check and calibration

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 20

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 21

Rev 2 (07-2021) CHORUS TRIO | SERVICE MANUAL 22

3.2 THE STRIP, NEEDLES AND THE WELL

1. measuring cuvette (#6)

6. independent up-down movement

As shown, the pair of dispensing needles is mounted on a bracket which