Autosampler

Service Manual
v1.3

DIATRON MI PLC
39 Táblás street, Budapest, H-1097, HUNGARY
Tel.: +36 1 436 9800
Fax: +36 1 436 9809
www.diatron.com
E-Mail: support@diatron.com

Revision 1.3
2016-JUL-18
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SM-Autosampler-1.3

Revision history

Revision Date Edited by Sections affected

1.0 2014.06.06 Roland Windisch ALL – initial revision
1.1 2014.09.04 Eszter Tóth correction of Cable map
1.2 2015.10.01 Eszter Tóth add another cable map
Name correction of K mixer PCB on page 18, section 4.4; Diatron
1.3 2016.07.18. Roland Windisch
Logo change
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1 Description of the Auto Sampler ..................................................................................................... 4

2 Parts of the Auto Sampler ............................................................................................................... 5
2.1 Left side ................................................................................................................................... 5
2.2 Right side ................................................................................................................................. 6
2.3 Rear side .................................................................................................................................. 6
3 Operation ........................................................................................................................................ 7
3.1 How does it work? ................................................................................................................... 7
3.2 Detailed description of the operation ..................................................................................... 7
3.2.1 Connecting to the Abacus5 ............................................................................................. 7
3.2.2 Disconnecting from the Abacus5 .................................................................................... 7
3.2.3 Power on ......................................................................................................................... 7
3.2.4 Initializing ........................................................................................................................ 8
3.2.5 Loading samples .............................................................................................................. 8
3.2.6 Moving the sample rack to feeding position ................................................................... 8
3.2.7 Recognizing sample racks ................................................................................................ 9
3.2.8 Feeding sample vials into the system .............................................................................. 9
3.2.9 Recognizing vials and caps............................................................................................. 10
3.2.10 Mixing the sample and Reading the barcode ................................................................ 10
3.2.11 Feeding to sampling position ........................................................................................ 11
3.2.12 Ejecting the Samples ..................................................................................................... 11
3.3 Communication with the analyzer ........................................................................................ 12
3.4 Test functions in analyzer ...................................................................................................... 12
4 Adjustments .................................................................................................................................. 13
4.1 Removing the plexi-glass and curved metal cover ................................................................ 13
4.2 Removing the front cover plate of the mixer ........................................................................ 14
4.3 Removing the tray ................................................................................................................. 15
4.4 Adjusting opto sensors .......................................................................................................... 18
4.5 Verifying the operation of the latch ...................................................................................... 21
4.5.1 Adjusting the Y opto board............................................................................................ 21
4.6 Verifying the position of the rack feeder discs...................................................................... 22
4.7 Adjusting the mixer arm and its sensors ............................................................................... 23
4.8 Checking and setting up the barcode reader ........................................................................ 24
4.8.1 Adjusting the barcode reader........................................................................................ 24
5 Maintenance.................................................................................................................................. 26
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5.1 Replacing the cover ............................................................................................................... 26

5.2 Greasing the mixer mechanics .............................................................................................. 27
5.3 Check or replace the rubber wheel ....................................................................................... 27
5.4 Cleaning the barcode reader ................................................................................................. 27
6 Appendix........................................................................................................................................ 28
6.1 Recommended kit of tools .................................................................................................... 28
6.2 Cable map .............................................................................................................................. 29
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1 Description of the Auto Sampler

Abacus 5 Auto Sampler is designed to be connected to Abacus 5. It is capable of receiving 100 blood
sample tubes, in 10 racks each holding 10 sample tubes. The Auto Sampler cannot operate on its
own, and can only be used with Abacus 5.

The racks are specially designed to allow feeding the samples into the Abacus 5 and to allow mixing
the samples one by one.

The 10 racks are seated on a sample tray that can be moved back and forth by the Auto Sampler.

The Auto Sampler has a transparent plastic cover equipped with a safety switch feature. Opening the
cover will stop Auto Sampler operation to prevent injury to the operator.

The Auto Sampler can be powered on and off independently, but power is fed through the Abacus 5.
Auto Sampler is not capable of independent operation.

Built-in sample mixer and bar code reader allow walk-away operation of the Auto Sampler.

Plexi glass
cover
Tube cap
support

Sample vial
holder

Sample
rack for 10
Sample
vials
rack feeder
wheel
Power switch and
control LED’s
Sample tray
base plate Sample tray
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2 Parts of the Auto Sampler

Looking at the Auto Sampler from the front, when connected to the Abacus 5 the following parts can
be identified.

2.1 Left side

Sample
mixer

Connector
to A5

Left side has the electric connector to interface to the Abacus 5. Communication is realized through
serial communication. The Auto Sampler is connected to the low level PC of the Abacus 5 (see Abacus
5 service manual for details)

The left side has a protruding, elevated part housing the sample mixing mechanics and the bar code
reader along with the electronic board. The Auto Sampler
Bar code AS microcontroller
has its own
reader board
microcontroller.

Sample
mixer

Rack feeding
wheels
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2.2 Right side

The right side contains the power switch and the status lights of the Auto Sampler.

Status lights

Power

Lamp colors indicate the below status:

OFF RED GREEN

Upper light power off Uninitialized / OK
interrupted (cover open)
Lower light power off Error OK

2.3 Rear side

The rear side of the Auto Sampler holds the product ID and serial number label.
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3 Operation
3.1 How does it work?
The Auto Sampler receives movement commands from the Abacus 5. It is able to feed any sample to
the sampling position. It is also able to detect tube types (Vacutainer or compatible, Sarstedt
Monovette or compatible). It can also detect whether there is a cap on the tube.

Sample tube type detection is important so that Abacus 5 will know how deep the sampling needle
can go into the sample tube without damaging the tube itself.

If no cap is detected the Auto Sampler will not mix the sample to avoid spilling blood samples into
the Auto Sampler.

When a sample is at the mixing position (right before the sampling position) it is mixed by gentle
tilting the sample down to -110 degrees to allow homogenous mixing. The sample is inverted 8 times
by the Auto Sampler before measurement.

3.2 Detailed description of the operation

3.2.1 Connecting to the Abacus5
The Auto Sampler can be connected to the Abacus 5 at any time, either with abacus 5 on or off. If
connected when the Abacus 5 is ON, it is recommended to have the power switch of the Auto
Sampler in the OFF (0) state.

To connect the Auto Sampler, the opening on the Abacus 5’s right side must be removed. Retain the
plate fixing screws (5pcs) for future use.

Slide the Auto Sampler into the opening on the side of the Abacus 5 – guiding rods will help mechanic
alignment and electronic connection. The Auto Sampler, when connected is secured by plastic lock
pieces.

3.2.2 Disconnecting from the Abacus5

Prior to removing the Auto Sampler from the Abacus 5, make sure that the racks are in home
position and the measurements from the Auto Sampler is finished. Make sure the Auto Sampler is
powered off. The lever in the back of the Auto Sampler lifts both plastic locker pieces allowing the
Auto Sampler to be pulled off from the Abacus 5.

3.2.3 Power on
The Auto Sampler can be turned on by flipping the power switch to the “I” position. The Abacus 5 will
either recognize it during startup or, if the Abacus5 is running, the SW will recognize the presence of
the Auto Sampler and enable its icon.
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3.2.4 Initializing
The Auto Sampler, when powered on will not move by itself. All operations are controlled by the
Abacus5. The Abacus5 has a menu to control the Auto Sampler. To access it, double click on the AS
State area in the bottom left corner of the screen. This will bring up the Auto Sampler control menu.

Pressing the “Reset” button will initialize the Auto Sampler. During init, the tray will be moved back
and forth to identify home position of the tray.

Use the “Reset” command when the Auto Sampler gets to a state when it would not move. The SW
will instruct the Auto Sampler to move motors to their home positions. If there is a mechanical jam,
the SW might not be able to perform the reset action. This will be signaled by a grinding noise from
the motors, but it does not damage the unit.

3.2.5 Loading samples

The Auto Sampler can receive 100 sample vials. The 100 sample vials are loaded into 10 sample
racks, each providing space for 10 sample vials. The system can recognize vials and racks, therefore
you can load the racks in random manner, but this will result in longer processing time of the
samples. If barcodes are present, the Abacus 5 will read and assign them to the results. If there are
no barcodes, identifying samples and making sure they are run as required is the responsibility of the
operator.

When a sample is filled with vials, the rack has to be placed on the black tray. When loading the tray
is finished, the tray has to be put onto the Auto Sampler.

The Auto Sampler can only be operated with its cover closed. Opening the cover during operation
will interrupt sample processing. Closed state of the cover is indicated by a micro switch. The cover,
when closed pushes the metal pin of the switch down.

3.2.6 Moving the sample rack to feeding position

The Auto Sampler is responsible for getting specific sample vials to the sampling position. The tray
can move the racks back and forth to align them with the sampling path. There are positions for 10
sample racks. The system identifies the rack positions as letters from “A”-“J”. “A” is the rack in the
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front, “J” is the rack in the rear. During initialization the Auto Sampler locates the A rack position.
Rack positions are identified by small openings in the bottom of the tray support plate’s slides. A pair
of opto sensors is responsible for making sure that the specific rack is aligned with the sampling path.

3.2.7 Recognizing sample racks

When the required rack is inserted into the tray, the Auto Sampler checks for the presence of a rack
at the given position.

An opto sensor is looking for the rack. If it is sensed, the sampler will load it into the loading bay. If
the opto sensor cannot see the rack in position, the rack will be reported missing and will be skipped.

When the rack is present and it’s in position, the rack lock is released. The rack lock keeps the sample
vial holders in the sample vial rack bay. The rack lock is opened by a small pin on the right side of the
Auto Sampler. When the rack slides this pin, the rack lock is lifted up and the sample vial holders are
released. Now the Auto Sampler’s feeding mechanics can pull the vial holders into the Abacus 5 one
at a time.

Rack lock

Sample
vial rack
Sample
bay
vial holder Sample
in mixing vial holder
position

3.2.8 Feeding sample vials into the system

The rack lock is open, and vial holders are free to slide out of the rack bay into the Abacus 5. Two
discs, each equipped with a pin to grab the bottom of the vial holders are rotating synchronously. At
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the same time, a latch is pushed into the sample tray support plate to avoid accidental movement of
the tray while the vial holders are inside the Auto Sampler.

The vial holders are pulled in one by one. As the 10 vial holders are fixed to one another by a long axis,
they all move together. When the vial holders have been released and pulled out of the vial bay, they
are free to rotate along the axis that holds them together. This is important for the mixing and barcode
reading feature.

3.2.9 Recognizing vials and caps

The Auto Sampler is also capable of mixing vials. However, vials must be closed to avoid spilling of
the sample into the Auto Sampler. Presence of vials and caps are checked by opto sensors. If a vial is
found missing, its position is skipped both for mixing and sampling. If a cap is found missing, the
system will also skip both mixing and sampling.

This allows loading open vials to the Auto Sampler by accident. The system will recognize vials
without caps and will skip them.

3.2.10 Mixing the sample and Reading the barcode

If a vial is found and is found to have a cap, the system will feed it
to the mixing position. The mixing arm will be locked around the
vial, and mixing starts. Mixing is carefully tilting the vial up and
down 8 times prior to sampling. The mixing process is tilting the
vial from vertical to -110° and back. Besides tilting, a rubber wheel
pressed against the metal framework and ensures rotation of the
sample vial along its longitudinal axis. The barcode scanner is
powered on at the beginning and at the end of the mixing process.

Movements of a vial during mixing:

I. Tilting the vial
Tilting path positions:
1. From vertical (0°) to -110° position.
Time of the movement is
approximately 1.2 seconds.
2. Seven up and down tilting movements
(from -110° to -45° and back to 0°)
start. The movement stops on each
end position for 1 second. Tilting
between the two positions requires
approx. 0.7 second.
3. Tilt back to vertical position. Time of the movement is approximately 1.2 seconds.
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Vertical
position
1 sec -45°

1 2 3 4 5 6 7 8 -110°

Barcode reading is performed when the vial is tilted from 0° to -110° (mixing start) and from -
110° to 0° (mixing stop). These stages are marked with red arrows. Total time of mixing one
vial is approximately 26 seconds.

II. Rotating the vial around its axis during tilting.

Downward tilting movement of the vial is
accompanied with a clockwise rotation (by
means of a rubber edged wheel situated in
between the vial and the metal side plate of the
auto sampler). Upward tilting movement of the
vial is accompanied with a counter-clockwise
rotation (by means of the same rubber edged
wheel).

3.2.11 Feeding to sampling position

When mixing is over, and Abacus 5 is ready to measure the sample, the sample vial is fed to the
sampling position. This position is aligned with the sampling needle inside the Abacus 5. When the
sampling needle is placed over the vial, two small tube holders are centering the vial below the
piercing needle of Abacus 5.

When sampling is over, the sample vial is fed into the Abacus5’s sample bay. The sample bay
prevents the vial holders from tilting. It is a narrow bay accepting the vial holders.

3.2.12 Ejecting the Samples

When the last vial in the actual rack has been measured, the Auto Sampler is going to eject the vial
holders back into the rack bay. When the last vial position is inside the rack bay, the latch securing
the tray is retracted and the tray is free to bring the next sample rack to the position of the sampling
path.
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3.3 Communication with the analyzer

The Abacus 5 and the Auto Sampler communicate via a serial link. The user interface software is
sending commands to the DimmBoard and the DimmBoard controls and monitors AS operation.

The Auto Sampler needs to be connected to the Abacus 5 to receive power and communication
commands.

3.4 Test functions in analyzer

Abacus 5 Service menu offers AS commands to test operation. Any arbitrary sample can be moved to
mixing position, sampling position. Correct movement of racks can also be tested.
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4 Adjustments
4.1 Removing the plexi-glass and curved metal cover
The cover can be removed along with the curved metal cover of the Auto Sampler.

Open the cover, remove the tray. Remove the middle screw from top, 2x1 screws from both sides,
and 3 screws from next to the sample tray. Use screwdriver Torx size 9 (Tx9).

Remove the glass and the metal cover.

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4.2 Removing the front cover plate of the mixer

The front cover of the sample mixer is secured with 6 screws, 2 of them is covered by the tray. Pull
the tray to the front to access screws. Remove all screws fixing the front plate to the body of the
Auto Sampler to access opto sensors and the electronic boards. Use screwdriver Torx size 9 (Tx9).
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4.3 Removing the tray

The tray is secured against its moving mechanism with two screws. Remove these 2 screws. Now the
tray can be pulled to its outmost position. Use an Allen (hex) screwdriver size 2.0mm.

Remove the 6+4 screws which hold the plate below the tray. The plate below the tray needs to be
removed to access the moving mechanics. Use Allen (hex) screwdriver size 2.5mm.
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Now the tray cover plate can be lifted off.

With the tray still on, turn the AS around and stand it on its rear side.

Remove the 4 screws indicated on the image below to release the slide mechanism. Use Allen (hex)
screwdriver size 2.5mm.
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The tray can now be removed and you can access the timing belts and the opto boards beneath.
When reinstalling the slide mechanism, be careful not to cut or kink the electrical wires.
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4.4 Adjusting opto sensors

If the Auto-sampler has problems moving the tray forward or backward, the problem is mostly
caused by the ASXOPTO board. This problem happens because the damage of the sensor itself or
because the board is removed from its position. The system indicates these errors with the following
error messages:

CANNOT MOVE RACK

CANNOT REACH X HOME POSITION

With the tray in its place but the front cover removed you can access the X sensor. This sensor is
checking for the presence of openings on the sample moving tray.

X opto – for sensing the openings

on the sample tray

K opto – for sensing the home and Y opto – for sensing the home and
end positions of the mixer end positions of the vial holders
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Openings for the X opto on the

Openings for the latch to lock
bottom of the sample tray.
into.
(tray shown upside down)
(tray shown upside down)

The X sensor board is fixed to the

bottom plate with 2 screws. The screw
in the front can be accessed with a
2mm round headed Allen screwdriver.
The screw in the back can be accessed
with the same tool driven through a
special opening in the tray mechanism.

The tip of the tool can reach the

rear screw if the tool is driven
through the opening for the rear
screw.
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The X opto board is responsible for

sensing the correct alignment of the
sample racks with the sampling path.
It has 2 opto sensors. Both sensors
must see through the opening on the
bottom of the tray slide. Blocked
state is signaled by the
corresponding LED on. When the
sensors are seeing through the holes,
both LED’s are off. The opto board
must be aligned so that both opto
sensors are OFF when the sample
tray is in the sampling path position.

To adjust the tray position sensing X board, move the tray so that one of the sample rack positions
are aligned with the sampling path position. Start rotating the outer vial holder feeding disc
clockwise to push the latch into the opening on the bottom of the tray. If it’s difficult to move the
feeding disc, rotate the cogwheel to counter-clockwise. See that the latch is moving right to secure
the tray.

Now open the two screws fixing the opto board, and move the optoboard by hand towards the front
until both LEDs on the X opto board go on. Then slowly move it backwards until both LEDs go off.
When done, tighten the screws.
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4.5 Verifying the operation of the latch

To make sure that the tray does not move during the sample vial feeding process, a latch is locked
into the specific openings of the sample tray. The latch operating cogwheel has 15 positions, the 0
position (latch fully retracted) is the home position for the latch.

D1 pin

vial holder
feeding disc
D2

latch
operating
D3 cogwheel

latch

The home position of the latch must be verified by manually turning the cogwheel. When the latch is
in its HOME position, D1 must be ON. When the latch operating wheel is in its END position D2 will
turn ON.

During the rotation of the feeding discs, D3 will turn on at each complete round (when sample is in
the mixer).

The home position of the latch must be verified by manually turning the cogwheel. When the latch is
in its HOME position, D1 must be ON. When the latch operating wheel is in its END position D2 will
turn ON.

During the rotation of the feeding discs, D3 will turn on at each complete round (when sample is in
the mixer).

4.5.1 Adjusting the Y opto board

This board is fixed by two screws. It is possible
to loosen these screws and adjust the position
of the sensors on the boards. If the racks cannot
enter fully to the analyzer or the racks do not
return from end position, it’s possible that these
sensors are not positioned correctly.

 Check that the small metal rod on the

cogwheel can reach the opto sensor
when the vial holders are fully entered
the analyzer.
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 Check that the opto flag connected to the latch is

reaching the opto sensor correctly when the
sample vial holders are pulled back to home
position. Use the LED indicating the correct
positions.
 If there is a problem reaching the sensors, loose
the two holding screws and push the board left or
right, than tight the screws.

4.6 Verifying the position of the rack feeder discs

„Inner” wheel

„Outer” wheel

Alignment of the 2 discs is also important to make sure that the pins catch the sample racks correctly.
To verify alignment, rotate the discs so that the pins are aligned parallel. Verify synchronous state by
placing e.g. a screw driver over the two pins.

It is possible that the inner wheel gets misaligned. In this case you will have rack moving errors. The
inner wheel can be aligned to the outer wheel in the following way:

Remove the Auto Sampler from the A5. Turn the wheels so that the outer wheel is aligned as shown
on the image above. From the Abacus5 side, you can access the inner wheel’s set screw. Open it, and
align the wheel parallel with the outer wheel. Tighten the set screw.
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Be careful when moving the inner wheel. When the set screw is opened, the wheel can “fall down”
along the axis it is fixed to. Correct vertical position of the wheel must be ensured: the upper plane of
the wheel must be level, or slightly below the plastic part’s upper plane.

4.7 Adjusting the mixer arm and its sensors

The mixer arm opto board alignment is a one step process. The arm can be move manually. To set
the HOME position, the arm must be aligned so that it is coplanar with the flat surface of the plastic
vial rack support. Make sure that the arm and its plate is aligned as indicated in the image below.
Open the screws of the opto board. Move the board so that the upper LED comes ON. Tighten the
screws.

END LED
D2

HOME
LED D1

Plane of the
bottom of the
mixer arm and
the plastic
support plate of
the vial rack
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Both position of the arm has to be verified: Use the AS menu in A5 service menu to load one tube
into the mixer, observing the LEDs on the board. The arm must not get in contact with the bottom
plate of the Auto Sampler when the lower LED is ON.

4.8 Checking and setting up the barcode reader

After turning on the Auto-sampler, the barcode reader also turns on and initializing. This is a good
time to check the proper position of the barcode reader.

 First, make sure that the barcode reader can turn on and the red scanning beam is present.

It is also important that the beam must be in the correct position. The barcode reader flashes
the beam only for a few seconds. If you missed the beam and it’s already turned off, just turn
the sampler off and on to make the beam visible again. If the beam is not scanning the proper
direction, there will be no or only a few barcodes scanned during running.

 Check the position of the beam

The position of the beam is not strict, some barcode readers

can work when the laser light has ±1mm difference from the
position shown on the images.

To best way to find out that the barcode reader is working

and the beam is set correctly, is to run tubes with barcodes.
Make sure that the bar codes are well attached to the sample
tubes.

4.8.1 Adjusting the barcode reader

The barcode reader is attached to a spring plane behind the
mixer’s plate of the sampler. The Barcode is glued to the
plane with a two-sided glue TESA. The plane is attached to the
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mixer’s plate with two round headed screws (Allen hex 2.0mm). This attachment is fixes and does not
require any adjustments, unless barcode unit replacement.

The barcode reader is positioned by two screws

(Allen hex 2.5mm). One screw is pushing the
back side of the barcode reader to focus the
beam to the correct position. This screw is right
above the processor board of the sampler.

The other screw is pushing against from the

other side of the barcode reader. This screw is
responsible to keep the reader in position. This
screw is glued with Loctite 2400.

Note that these screws are not tightened fully,

because they are not responsible to hold the
frame or the covers, they have to position the
barcode reader. Adjusting these screws will
affect the barcode reader’s position and can
make improper readings.

If barcode reader needs to be adjusted, unscrew

the glued positioning screw first to make space
for the reader to move, then adjust the screw
above the processor panel.

If barcode reader has to be changed, remove

both screws, unscrew the round headed screws
holding the spring plate and remove the ribbon
cable from the processor board. Then the barcode reader is free to lift out.
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5 Maintenance
Auto sampler does not require many maintenance. The system’s mechanics are simple without too
many moving parts. Although, a minimal maintenance is required.

 Clean or replace the barcode reader’s cover

 Grease the mixer’s cogs with lubricant
 Check and replace the mixer’s rubber wheel

5.1 Replacing the cover

The cover of the Auto-Sampler is the most sensitive part of the unit. It can happen that the cover
gets scratched or broken, and it needs to be replaced. Removing the additional screws shown below
will detach the cover from the unit.
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 Remove the two screws on the top of the

black cover on the front and back.
 Remove the two screws attaching the
hinges to the top of the unit.
 Remove the three screws on the bottom
of the cover holding the metal rod.
 Unscrew the four Torx screws attaching
the hinges to the cover.
 Be careful when replacing the new cover.
The cover can get cracked if the screws
are tightened too much.
 After placing the new cover, make sure
that the metal rod can push the micro
switch on above the power on button.

5.2 Greasing the mixer mechanics

The mixer is the only part which is not covered and can get dirty or can lose the lubricant easily. If the
mechanics are not greased properly, it can cause pneumatic error or strange noise, making the
mixing and the barcode reading incomplete.

5.3 Check or replace the rubber wheel

The mixer rubber wheel is responsible to rotate the sample tubes
during mixing. The wheel is pushed to the back wall of the sampler
while mixing and the wheel starts rotating.

The wheel is pushing the sample vials directly. If the vials has barcode
stickers, it can happen that the rubber wheel is picking up paint from
the barcode printout. This paint can make the wheel slip during mixing
and it will not rotate the vial properly. Because the wheel is also in
contact with the inner side of the sampler’s back wall, it’s necessary to
check the wall and remove the paint if there is any.

If the paint is not removed from the wall, the wheel will pick it up
again.

If barcodes on the vials are not too close to the cap, the rubber wheel will not get in contact with the
barcode and it won’t pick up the paint. Placing the barcode on the vials properly will avoid this
problem.

5.4 Cleaning the barcode reader

Although the barcode reader is covered by the Auto-sampler’s top, the glass surface of the reader
can be covered with dust or dirt. It’s not needed to use a special cleaner solution. Simply blow the
dust and dirt from the surface with a duster.
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6 Appendix
6.1 Recommended kit of tools
Screwdrivers:

Slot Screwdrivers (for plexi cover holders)

Torx Screwdrivers (TX9)

Hexagon Screwdrivers (2.5, 2.0 mm sizes)

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6.2 Cable map

AS 160
ROS 3
BARCODE READER
VXBARIS4125

AS-RA
AS 163
K MOTOR ROS2 AS-RA
ASK-opto
cable
AS-TA
ROS1

Y MOTOR

AS 161 AS 162
ASYplus ASY-opto AS 501X
opto cable
cable Micro switch

X MOTOR

AS158 LED 2
AS158 LED 1

AS164 ASX-
opto cable
AS157 Power switch
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