Acl Top PDF

ACL-TOP
Service Manual
October, 2006 PN 28166900 Rev 03

IL, ACL-TOP, and ACL-TOP CTS are a trademark of Instrumentation Laboratory.
Instrumentation Laboratory, 2006.
This publication and any and all materials (including software) concerning the products of IL Coagulation
Systems are of proprietary nature and are communicated on a strictly confidential basis; they may not be
reproduced, recorded, stored in a retrieval system, transmitted or disclosed in any way and by any means
whatsoever, whether electronic, mechanical through photocopying or otherwise, without ILs prior written
consent.
Information contained herein is believed to be accurate. In any event, no responsibility, whether express or
implied, is assumed by IL for or in connection with the use thereof, or for infringement of any third party
rights which might arise therefrom, or from any representation or omissions contained therein. Information
is subject to change and/or update without notice.
Contents
Table of Contents
Chapter 1
Instrument Overview
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Instrument Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
AM Safety Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
AM Power Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Cuvette Loading Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Cuvette Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Bar Code Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Sample Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Closed Tube Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Diluent Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Reagent Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Probe Syringes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Incubators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Optical Reading Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
System Fluids Rinse and Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Fluid Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Waste Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Cuvette Waste Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Coagulometric (Turbidimetric) Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Chromogenic (Absorbance) Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
Immunological Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 19
Chapter 2
Pre-Installation and Installation
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Reception Area and Transportation Pathway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Working Area / Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Ambient Conditions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
DMS / LIS Interface Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Site Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Software Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Software Version Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Touch Screen Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
ACL-TOP Service Manual 1

Contents
Ghost Image Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14

Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
ACL TOP Pre - Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Start Up Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
Chapter 3
Troubleshooting
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Warning-Level Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Error-Level Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
System Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
General Log List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Temperature Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
SW Version Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
Alarms Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 130
Chapter 4
Enclosure/Chassis
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Sample and Reagent Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Cover Status Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Door Lock/Unlock Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Sample Door Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Reagent Door Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Locking/Unlocking the Sample and Reagent Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Removal/Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Sample Door Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Sample Door Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Sample Door Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Reagent Door Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Reagent Door Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Reagent Door Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Sample Door Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Sample Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Sample Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Reagent Door Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Reagent Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Reagent Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
2 ACL-TOP Service Manual

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

Top Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Top Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Front Panel Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Front Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Front Panel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Monitor Control Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Monitor Control Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Monitor Control Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Sample Area Interior Skins Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Sample Area Interior Skins Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Sample Area Interior Skins Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Inner Left Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Inner Left Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Inner Left Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
Left Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
Left Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
Left Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Reagent Area Interior Skins Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Reagent Area Interior Skins Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Reagent Area Interior Skins Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Inner Right Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Inner Right Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Inner Right Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Right Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
Right Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
Right Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
Center Skin Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
Center Skin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
Center Skin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
Upper Back Wall Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
Lower Back Wall (Power Supply Assembly) Removal/Replacement . . . . . . . . . . . . . . . . . . . . . 4 - 30
Chapter 5
Processor / Software
Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Analytical Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Theory of Operation/Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Upgrades: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
LIS Specifications (ASTM E 1381-95 Protocol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11
Chapter 6
Power Management
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Contents
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Fuse Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Fuse Board Diagram for the Non-CTS TOP Model (Cavro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Fuse Board Diagram for the CTS TOP Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10
Volt-Amps Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Volt-Amps Specifications for the TOP Analytical Module (AM) . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Volt-Amps Specifications for the TOP Computer Module (CM) . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Volt-Amps Specifications for the TOP Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Verification and Adjustment of the 5Volt Rail on the ACL TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14
ORU Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15
Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
Arm Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Power Entry Module Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Power Entry Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Power Entry Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Non-adjustable Power Supply Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19
Non-adjustable Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19
Non-adjustable Power Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Fuse Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21
Fuse Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 21
Fuse Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
Chapter 7
Fluid Movement
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Aspirating and Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
The Precision Fluidic Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Syringe Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Syringe Pump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Cavro Syringe Pump Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Hamilton Syringe Pump Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
Syringe Pump Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
Probes and Precision Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
Probes and Tubing, non-CTS, Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
Probes and Tubing, CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
The Bulk Fluidic Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14
Onboard Rinse Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14
Rinse Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
Rinse and Clean Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
Rinse/Clean Cups, non-CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
Rinse/Clean Cups, CTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
Clean Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
Clean Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
CTS Bulk Fluids Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22

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

Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24
CTS Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25
PCB Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25
Fluidic Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
Fluidics Driver/Connector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
Fluidic LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
Fluidics Diagrams for the TOP Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
Syringe Pump Addressing and Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 29
Priming the Rinse System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30
Priming the Clean System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 30
Performing the Rinse Flow Rate Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31
Verifying the Fluidics after Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 32
Adjusting the CTS Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 33
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 35
Clean Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
Clean Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
The Select Pull-down List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 37
The Set Valve Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38
The Duration Selection Field and the Start and Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . 7 - 38
Stirring Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38
Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
Shipping Preparation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 39
Fluid Precision Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
Cavro Syringe Pump Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
CTS Sample Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 43
CTS Sample Cavro Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 45
Base TOP Sample Arm Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 47
Base TOP Cavro Sample Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 49
Reagent Cavro Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 51
Reagent Cavro Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 53
Cavro Syringe Tip Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
Cavro Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 55
Cavro Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 56
Cavro Syringe Valve Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58
Cavro Syringe Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 58
Cavro Syringe Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 59
Hamilton Syringe Pump Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 60
CTS Sample Hamilton Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 60
CTS Sample Hamilton Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 62
Base TOP Hamilton Sample Arm Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 64
Base TOP Hamilton Sample Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 67
Reagent Hamilton Syringe Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 69
Reagent Hamilton Syringe Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 71
Hamilton Syringe Tip Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 74
Hamilton Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 74
Hamilton Syringe Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 76
Hamilton Syringe Valve Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78
Hamilton Syringe Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78
Hamilton Syringe Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79
Rinse Pump Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80

Contents
Rinse Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80

Rinse Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
Precision Tubing Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82
Precision Tubing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82
Precision Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 85
Chapter 8
Robotic XYZ Arms
Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2
Cavro Arms (Used on ACL-TOP model 0000280000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Arm Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
X, Y, Z Travel Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
CCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
ADRI-9 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
Probe Interconnect PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
DC Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
Heater Probe PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 17
CTS Sample Arm (Used on ACL-TOP model 0000280020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 23
Arm Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24
CTS Probe Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27
PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27
XYZ Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
Y Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 28
X Axis Driver PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29
Z Axis Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30
Probe Alignment and Coordinates Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 31
Reference Point Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32
Reference Point Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34
Measurement of the Reference Screw Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 34
Waste stations Reagent and Cavro Arm Sample Probes . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 35
Waste Stations CTS Sample Arm Sample Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
Air gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
Coordinates File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 36
Coordinate Calculation and Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 37
CTS Instruments Alignment of Piercer Probe Foot to the Wash Station . . . . . . . . . . . . . . . . . 8 - 37
Probe and Arm Initialization Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 40
Probe and Arm Initialization on CTS Sample and/or IL Double Arm . . . . . . . . . . . . . . . . . . . . . 8 - 40
Probe and Arm Initialization on CTS Sample Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 42
IL Double Arm Homing Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 43
Probe and Arm Initialization on Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 44
Coordinates Checking Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 45
Tube Release Procedure Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 46

Contents

Verifying a CTS Arm or a Universal Dual Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
Alidum Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
Probes Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47
Initialize All Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
Home All Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
Disable Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
Disable Reagent Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
Coordinate Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 49
Set Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50
LLD Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 50
Rinse Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 51
Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 52
Move Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 53
Probe Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 55
Probe LLD Error Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57
Cavro Probe Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 57
Universal Arm Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 58
Sample Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60
Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60
LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 60
Intermediate Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 61
Start Arm Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
Encoder Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
LLD Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
ZDAC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 62
Removal/Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63
CTS Arm (283777-00) Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63
Closed Tube Sample (CTS) Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 63
Closed Tube Sample (CTS) Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 67
Reagent IL Double Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 72
Reagent IL Double Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 72
Reagent IL Double Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 75
Cavro Sample Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
Cavro Sample Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
Cavro Sample Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
Cavro Reagent Arm Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85
Cavro Reagent Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85
Cavro Reagent Arm Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87
Individual Cavro Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95
Individual Cavro Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95
Individual Cavro Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95
Cavro Arm Insulation Block/Cable Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . 8 - 96
Insulation Block/Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96
Insulation Block/Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96

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

Cavro Arm Flex Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97
Cavro Arm Flex Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97
Cavro Arm Y- and Z-axis Optical Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98
Y- and Z-axis Optical Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98
Y- and Z-axis Optical Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99
Cavro Arm X-Axis Optical (SLD) Sensor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99
X-Axis Optical (SLD) Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99
X-Axis Optical (SLD) Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 100
Cavro Arm ALIDUM Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 100
ALIDUM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 100
ALIDUM Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 101
Cavro Arm ADRI-9 Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102
ADRI-9 Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102
ADRI-9 Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103
CCU-9000 Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103
CCU-9000 Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103
CAVRO Arm Belt Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105
CAVRO Arm X-Axis Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105
CAVRO Arm X-Axis Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 106
CAVRO Arm Y-Axis Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107
CAVRO Arm Y-Axis Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107
Chapter 9
Cuvette Handling System
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2
Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4
Gripper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Shuttle Pivot Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6
Cuvette Loader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7
Transport Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8
Indexer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9
Pusher Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10
CTS Hold and Incubator #2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11
CTS Incubator #1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11
Optical Read Unit (ORU) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11
Reader Head Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12
Emitter Subassembly and Fiber Bundle Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13
Sensors in the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13
Cuvette Loader Sensors and How They Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13
Cuvette Shuttle Sensors and How They Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13
Shuttle Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 13
Gripper Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14
Cuvette In Slot Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
Shuttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
Cuvette in Shuttle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
Cuvette Loader PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16
Cuvette Shuttle Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16

Contents
Cuvette Handling/Rack Handling X-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16

ORU Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16
ORU Detector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17
ORU Emitter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17
Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 17
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18
Shuttle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19
Disable Shuttle Motors Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19
Initialize Shuttle Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19
Cuvette Shuttle Temperature Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20
Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20
Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20
Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 20
Grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21
Pullback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21
Clear All Cuvettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 21
Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22
Start, Stop, and Clear Accumulator Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22
Virtual LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22
Other Sensors in the Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23
Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23
Initialize Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23
Move Indexer (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23
Move Indexer (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24
Up Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24
Down Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24
Virtual LEDs in the Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 24
Cuvette Shuttle and Loader Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25
Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26
Cuvette Loader Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26
Cuvette Loader Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26
Loader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26
CTS Hold/Incubator #2 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 26
CTS Hold/Incubator #2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
CTS Hold/Incubator #2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
Incubator #1 Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
Incubator #1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
Incubator #1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
Optical Reading Units Cradle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
Cuvette Shuttle Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
Cuvette Shuttle Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
Cuvette Shuttle Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30
Cuvette Shuttle Y-Axis Motor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30
Y-Axis Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30
Y-Axis Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
Cuvette Shuttle Solenoid Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34
Aligning the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35
Cuvette Shuttle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35
Z Height and Tilt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 36
Y Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37
X Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38

Contents
Chapter 10
Reaction Detection
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
ORU Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
Emitter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Optical paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Detector PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
ORU Light Generation, Flow and Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
Adjustments/Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
Verifying the ORU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
Testing/Correcting Voltage Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14
Enabling ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17
Testing/Correcting Dark Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19
Testing/Correcting Optical Blanking Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 22
Temperature Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 23
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 24
ORU Diagnostics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 24
Optical Blanking Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25
ORU Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 26
ORU Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 26
Optical Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 27
ORU Air Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 27
Temperatures Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 28
Reference Readings Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29
Dark Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29
Linearity Test Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 30
Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31
Removing/Replacing the ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31
Removing the ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31
Installing the ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 33
Removing/Installing the Emitter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36
Removing the Emitter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36
Connecting the ORU for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 38
Tuning ORU Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 43
Installing the ORU Optics Alignment Kit (PN 280033-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 45
Chapter 11
Rack Handling
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2
Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
Sample Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4
Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6
Reagent Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7
Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8
Reagent Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9
Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9

Contents
Reagent Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
Bar Code Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11
Rack Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11
Rack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12
Remote Travel Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12
Bar Code Reader Travel Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12
Bar Code Reader Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13
Bar Code Reader Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13
Bar Code Reader Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13
Adjustments/Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14
Rack Handling Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14
Racks area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16
Encoder Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16
Perform Loop Back Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16
Track Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17
Bar Code Label Reading and Rack Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17
Reagent temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17
Stirrers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17
Sample Module Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 18
Sample Module Assembly Removal (Both CTS and non-CTS models) . . . . . . . . . . . . . . . . . . 11 - 18
Sample Module Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19
Sample Presence PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19
Sample Presence PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19
Sample Presence PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20
Sample Flag Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20
Sample Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20
Sample Flag Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21
Reagent Module Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21
Reagent Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21
Reagent Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24
Reagent Drain Tube Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24
Reagent Module Tubing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24
Reagent Module Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25
Reagent Presence PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26
Reagent Presence PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26
Reagent Presence PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27
Reagent Cooling with Fan Speed Controller PCB Removal/Replacement . . . . . . . . . . . . . . . . . . 11 - 27
Reagent Cooling with Fan Speed Controller PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27
Reagent Cooling with Fan Speed Controller PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27
Reagent Flag Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27
Reagent Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 27
Reagent Flag Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28
Bar Code Reader Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28
Bar Code Reader Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28
Bar Code Reader Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30
Bar Code Reader Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30
Bar Code Reader Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30
Bar Code Reader Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 32
RTI PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33
RTI PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33
RTI PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33
X Axis PCB Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 34

Contents
X Axis PCB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 34

X Axis PCB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 35
Earlier version X Axis PCB Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 35
Encoder Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36
Encoder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36
Encoder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37
Curtain Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37
Curtain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37
Curtain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 38
Bar Code Reader Drive Belt Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 40
Bar Code Reader Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 40
Bar Code Reader Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 41
Bar Code Reader Drive Motor Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 42
Bar Code Reader Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 42
Bar Code Reader Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 43
Chapter 12
Thermal Control
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2
Thermal Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3
Thermal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3
Cuvette Shuttle Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4
Incubator #1 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5
Incubator #2 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 6
Optical Reading Unit (ORU) Cradle Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7
Reagent Module Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7
Reagent Cooling with Fan Speed Controller PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9
Reagent Probes for Cavro Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9
Reagent Probes for Universal Arms Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10
Cavro Sample Probe Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
CTS Sample Probe Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
ThermalCal Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 12
Mode Selection and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
Temperature Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
ACL-TOP Connection and Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
Calibration Status and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15
Display Coefficients Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
Other Handled Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
ThermalCal Instructions for Adjusting Coefficients/Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21
Load the ThermalCal Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21
Test the Thermal Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23
Save the Coefficients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 29
Inputting Thermal Coefficients using ThermalCal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 31
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 35
Temperature Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 37

Contents
Chapter 13
Waste Management System
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 2
Bulk Fluid Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3
Sample and Reagent Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 3
Reagent Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4
Sample Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 5
Waste Fluid Removal in the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 6
Cuvette Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7
Fluidics Connector/Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9
Fluidic LED Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9
Cuvette Waste Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 9
Verification of the Bulk Fluid Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 10
Verification of the Cuvette Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 10
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 11
Bulk Fluid Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 11
Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
Diagnostics for the Cuvette Waste Management Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14
Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15
Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15
Clear All Cuvettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16
Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16
Start, Stop, and Clear Accumulator Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16
Virtual LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17
Other Sensors in the Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17
Waste Shelf Assembly Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17
Waste Shelf Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17
Sample Accumulator Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 20
Sample Accumulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 21
CTS Accumulator Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 22
CTS Accumulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23
Reagent Accumulator Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23
Reagent Accumulator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25
Waste Pump Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25
Waste Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25
Waste Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 26
Chapter 14
Preventive Maintenance
Base TOP Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 1
CTS PreventiveMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 27
Chapter 15
CTS Piercer

Contents
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 1
Physical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 2
CTS X Axis Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
CTS Controller Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
CTS Y Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
CTS Z Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6
CTS Travelling Signal Interconnect) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6
CTS Piercer Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6
Piercer and Sample Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 6
Probe Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7
Sample and Piercer LLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8
Probe Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8
Piercer Lock/Lock Solenoid/Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 9
Cap Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10
Piercer Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10
Operation of the CTS Piercer Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 11
Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 13
Initialize Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15
Adjust Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15
Disable CTS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
Piercer Loop Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
Foot Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18
Air Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18
Air Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
Probe-n-Seal Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
Probe-n-Seal Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
Probe-n-Seal Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21
Piercer Probe Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24
Piercer Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 25
Piercer Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 26
Telescoping CTS Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 27
Telescoping CTS Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 27
Telescoping CTS Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30
Chapter 16
Schematics
Overview: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1
Chapter 17
Assembly Drawings/Part Numbers
Saleable Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 1
Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 8

List of Illustrations
Chapter 1 -
Instrument Overview
Figure 1-1. ACL TOP Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Figure 1-2. Analytical Module with Open Safety Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Figure 1-3. Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Figure 1-4. Cuvette Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Figure 1-5. Cuvette Strip being picked up by Cuvette Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Figure 1-6. Bar Code Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Figure 1-7. Sample Area with Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Figure 1-8. Sample Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Figure 1-9. Sample Arm CTS probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Figure 1-10. CTS Cap Piercing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Figure 1-11. CTS Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Figure 1-12. Diluent Area with Sample Probe (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Figure 1-13. Diluent Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Figure 1-14. Reagent Area Showing Intermediate (left) and Start (right) Reagent Arms . . . . . . . . . . . . 1 - 12
Figure 1-15. Reagent Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Figure 1-16. Probe (in foreground) and Syringe (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Figure 1-17. Sample Probe and Incubator Slots (non CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Figure 1-18. Rinse (left) and Clean Bottles on ACL TOP with Fluid Waste Container Underneath . . . . 1 - 16
Figure 1-19. Cuvette Waste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Figure 1-20. Cuvette Waste Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Chapter 2 -
Pre-Installation and Installation
Figure 2-1. Duch Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Figure 2-2. Shipping Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Figure 2-3. Reagent Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Figure 2-4. Reagent Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Figure 2-5. Sample/Reagent Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Figure 2-6. Probe/Arm Tie Wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Figure 2-7. TOP Sample Arm Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Figure 2-8. CTS Internal Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Figure 2-9. CTS Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Figure 2-10. CTS Assy. tie wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Figure 2-11. Shuttle tie wraps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Figure 2-12. Monitor Arm Mounting Studs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
Figure 2-13. Computer/Monitor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
Figure 2-14. System Software Versions Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Figure 2-15. Software Version Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Chapter 3 -
Troubleshooting
Figure 3-1. Maintenance Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-2. The Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-3. General Log List Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-4. General Log List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-5. General Log Entry Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-6. Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-7. Temperature Tab on Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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

Chapter 6 -
Power Management
Figure 6-1. Layout of the Power Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
Figure 6-2. Interconnect Diagram for Power Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
Figure 6-3. The Power Entry Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Figure 6-4. The Power Supply Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Figure 6-5. The +5V/+15V/-15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Figure 6-6. The +24V/+28V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Figure 6-7. Fuse Diagram for the ACL TOP/Cavro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Figure 6-8. Fuse Diagram for the CTS TOP Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Figure 6-9. Power Supply Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13
Figure 6-10. +5/+15/-15V Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 13
Figure 6-11. The Voltages Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 14
Figure 6-12. The ORU Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15
Figure 6-13. The Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
Figure 6-14. The Arm Controllers Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
Figure 6-15. Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Figure 6-16. Non-Adjustable Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19
Figure 6-17. Wire Terminals on a +5/+15/-15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Figure 6-18. The Power Supply Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
Figure 6-19. The Fuse Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
Chapter 7 -
Fluid Movement
Figure 7-1. Layout of the Fluid Movement System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
Figure 7-2. Fluid Movement System Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
Figure 7-3. Cavro XP3000 Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Figure 7-4. Hamilton PSD4 Syringe Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Figure 7-5. Cavro Syringe Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-6. Hamilton Syringe Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Figure 7-7. Syringe Pump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-8. Syringe Valve Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 7
Figure 7-9. Cavro Syringe Pump Communication/Valve Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 8
Figure 7-10. Cavro Syringe Pump Lower Jumpers and Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 9
Figure 7-11. Hamilton Syringe Pump Jumpers/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 10
Figure 7-12. The Probe for the non-CTS instrument with Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
Figure 7-13. The Onboard Rinse Fluid Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 14
Figure 7-14. Rinse, Clean Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
Figure 7-15. Rinse Pump Box Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16
Figure 7-16. Cavro Sample/Reagent Rinse/Clean Cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
Figure 7-17. CTS Sample Rinse/Clean Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
Figure 7-18. CTS Reagent Rinse/Clean Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
Figure 7-19. The Clean Fluid Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20
Figure 7-20. Clean Fluid Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 20
Figure 7-21. Clean Fluid LED Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Figure 7-22. Clean Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
Figure 7-23. CTS Sample Clean Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22
Figure 7-24. CTS Bulk Fluids Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
Figure 7-25. CTS Air Pump/Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
Figure 7-26. Air Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24
Figure 7-27. Location of Fluidics Controller/Connector PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25
Figure 7-28. Fluidic LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
Figure 7-29. CTS ACL-TOP Fluidic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27

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

Figure 7-84. Reagent Hamilton Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 74
Figure 7-85. Removing the Hamilton Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 75
Figure 7-86. Hamilton Syringe Tip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 76
Figure 7-87. Hamilton Syringe Tip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 77
Figure 7-88. Hamilton Syringe Valve Assembly/Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 78
Figure 7-89. Hamilton Pump Syringe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 79
Figure 7-90. Hamilton Syringe Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80
Figure 7-91. Rinse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
Figure 7-92. Rinse Pump Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 81
Figure 7-93. Rinse Pump Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 82
Figure 7-94. The Probe Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 83
Figure 7-95. Precision Tubing Strain Relief on CTS Sample Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 83
Figure 7-96. Precision Tubing Strain Relief on Base TOP Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84
Figure 7-97. Precision Tubing Strain Relief on Intermediate (R1) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 84
Figure 7-98. Precision Tubing Strain Relief on Start (R2) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 85
Figure 7-99. Dressing the Tubing on CTS Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 86
Figure 7-100. Dressing the Tubing on Base TOP Sample Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 87
Figure 7-101. Dressing the Tubing on Intermediate (R1) Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 88
Figure 7-102. Dressing the Tubing on Start (R2) Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 88
Chapter 8 -
Robotic XYZ Arms
Figure 8-1. XYZ Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
Figure 8-2. Layout of the Robotic XYZ Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 2
Figure 8-3. Interconnect Diagram - CTS/IL Double Sample Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
Figure 8-4. Interconnect Diagram - CTS/IL Double Reagent Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
Figure 8-5. Interconnect Diagram - Sample-side Cavro Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Figure 8-6. Interconnect Diagram - Reagent-side Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Figure 8-7. ACL-TOP with Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
Figure 8-8. X Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
Figure 8-9. Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
Figure 8-10. X Axis Rollers and Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
Figure 8-11. Motor, drive belt and encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
Figure 8-12. X Axis Motors - Reagent Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9
Figure 8-13. X Axis Belts - Reagent Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Figure 8-14. Y Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
Figure 8-15. Y Axis Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Figure 8-16. Z Axis Motor, Pulley and Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 11
Figure 8-17. Z-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12
Figure 8-18. X Limit Flags and Travel Limit Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 13
Figure 8-19. Y Limit Flag and Travel Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 14
Figure 8-20. Central Control Unit (CCU) for Cavro Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 15
Figure 8-21. ADRI-9 PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
Figure 8-22. ADRI 9 Dip Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 16
Figure 8-23. Heater Probe PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Figure 8-24. ACL-TOP CTS with CTS Sample and IL Double Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 18
Figure 8-25. X-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
Figure 8-26. X Axis Drive Belt (Sample Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 19
Figure 8-27. X Axis Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
Figure 8-28. Reagent Side Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 20
Figure 8-29. Reagent Side X Axis Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
Figure 8-30. Y-Axis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 21
Figure 8-31. Y Axis Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 22

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

Figure 8-86. Reagent Syringe Pump Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 78
Figure 8-87. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 78
Figure 8-88. Cable Clamp on Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 79
Figure 8-89. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
Figure 8-90. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 80
Figure 8-91. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
Figure 8-92. Ground Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 81
Figure 8-93. Ground Wire and Mounting Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 82
Figure 8-94. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 82
Figure 8-95. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 83
Figure 8-96. Heater Probe PCB and Heater Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 83
Figure 8-97. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
Figure 8-98. Coax Cable Connection to Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 84
Figure 8-99. Flex Cable to Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 85
Figure 8-100. Cable Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86
Figure 8-101. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 86
Figure 8-102. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87
Figure 8-103. Ground Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 87
Figure 8-104. Cavro Reagent Ground Wire, Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 88
Figure 8-105. CCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 89
Figure 8-106. DC Driver PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 89
Figure 8-107. Probe Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 90
Figure 8-108. Probe Top Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 90
Figure 8-109. R2 Heater Probe PCB and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 91
Figure 8-110. Coax Cable Connection to R2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 91
Figure 8-111. R2 Flex Cable to Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 92
Figure 8-112. Probe Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 92
Figure 8-113. Flex Cable Routing for Left Reagent Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93
Figure 8-114. Left Reagent Arm Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93
Figure 8-115. Cable Bracket Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 93
Figure 8-116. Reagent Left Arm LLD Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 94
Figure 8-117. Coax Cable Connection to Left Reagent Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 94
Figure 8-118. Removing the Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 95
Figure 8-119. ALIDUM Coax Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 96
Figure 8-120. Installing the Flex Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 97
Figure 8-121. Slotted Optical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 98
Figure 8-122. Optical Switch Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 99
Figure 8-123. ALIDUM Coax Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 101
Figure 8-124. Diagram of the ADRI-9 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 102
Figure 8-125. SW Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 103
Figure 8-126. CCU-9000 Board Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 104
Figure 8-127. Tensioner Screw Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 105
Figure 8-128. Belt Bracket Screw Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 106
Figure 8-129. Y-Axis Tensioning Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107
Figure 8-130. Y-Axis Belt Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 107
Chapter 9 -
Figure 9-1. Layout of the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Figure 9-2. Interconnect Diagram for the Cuvette Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Figure 9-3. The Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Figure 9-4. The Gripper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Figure 9-5. The Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Figure 9-6. The Shuttle Pivot Assembly and the Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 7
Figure 9-7. The Cuvette Loader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8
Figure 9-8. The Transport Deck Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9
Figure 9-9. The Indexer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 9
Figure 9-10. The Cuvette Rotating Platform (in Horizontal Down Position) . . . . . . . . . . . . . . . . . . . . . . 9 - 10
Figure 9-11. The Incubators and the Cuvette Indexer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 11
Figure 9-12. The ORU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12
Figure 9-13. ORU Subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12
Figure 9-14. The Left and Right End-of-limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14
Figure 9-15. Sensors on the Front of the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14
Figure 9-16. Sensors on the Rear of the Cuvette Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15
Figure 9-17. The Cuvettes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 18
Figure 9-18. The Shuttle Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 19
Figure 9-19. The Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 22
Figure 9-20. The Loader Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 23
Figure 9-21. Cuvette Shuttle and Loader Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 25
Figure 9-22. The Cuvette Loader Assembly (seen from above and behind). . . . . . . . . . . . . . . . . . . . . . 9 - 26
Figure 9-23. Captive Screws on the CTS Hold/Incubator #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 27
Figure 9-24. Captive Screws on the Incubator #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 28
Figure 9-25. The Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 29
Figure 9-26. The Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 30
Figure 9-27. Y-Axis PCB Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31
Figure 9-28. Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 31
Figure 9-29. Cables and Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
Figure 9-30. Motor Bracket Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 32
Figure 9-31. Cables and Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
Figure 9-32. Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 33
Figure 9-33. Y-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34
Figure 9-34. Completed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 34
Figure 9-35. The Left and Right End-of-limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 35
Figure 9-36. Location of the Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 36
Figure 9-37. The Z Height and Tilt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 37
Figure 9-38. The Y-Axis LED and the Turning Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38
Figure 9-39. The Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 38
Figure 9-40. The X-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 40
Figure 9-41. LEDs on the Cuvette Shuttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 40
Chapter 10 -
Reaction Detection
Figure 10-1. ORU Light Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3
Figure 10-2. Reaction Detection Block Diagram/Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5
Figure 10-3. Overall ORU Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 7
Figure 10-4. Voltage Tab in Diagnostics Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
Figure 10-5. ORU Tab of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
Figure 10-6. ORUs Enabled Indicators Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
Figure 10-7. Dark Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
Figure 10-8. Reference Readings Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 11
Figure 10-9. Optical Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Figure 10-10. Temperature Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Figure 10-11. Air Blanking of All ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13
Figure 10-12. Factor Diluent Blanking for all ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14
Figure 10-13. Testing/Correcting Voltage Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15
Figure 10-14. ORU Controller Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17

Figure 10-15. Emitter Voltage Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17
Figure 10-16. Enabling ORUs Flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 18
Figure 10-17. ORU Enabling Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19
Figure 10-18. Sample, Reagent, Diluent Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 19
Figure 10-19. Testing/Correcting Dark Readings Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 20
Figure 10-20. Dark Readings Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21
Figure 10-21. ORU Head Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21
Figure 10-22. Testing/Correcting Optical Blanking Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 22
Figure 10-23. Temperature Portion of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 23
Figure 10-24. ORU Diagnostic Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25
Figure 10-25. Optical Blanking Area of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 26
Figure 10-26. Temperature Area of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 28
Figure 10-27. Reference Readings Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 29
Figure 10-28. Dark Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 30
Figure 10-29. ORU Linearity Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 31
Figure 10-30. ORU Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 32
Figure 10-31. ORU Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 33
Figure 10-32. Calibration Offsets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 34
Figure 10-33. ORU Backplane PCB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 35
Figure 10-35. ORU Retaining Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36
Figure 10-36. Fiber Bundle Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 36
Figure 10-37. Emitter Head Attachment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 38
Figure 10-38. Backplane Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 39
Figure 10-40. Power Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 41
Figure 10-41. ORU Positioned For Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 41
Figure 10-42. Tuning ORU Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 42
Figure 10-43. Fiber Bundle Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 43
Figure 10-45. Fiber Bundle Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 44
Figure 10-46. ORU Cover Attachment Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 46
Figure 10-48. Cover Hardware Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 47
Figure 10-49. Bracket Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 47
Figure 10-50. New Cover Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 48
Chapter 11 -
Rack Handling
Figure 11-1. Rack Handling System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2
Figure 11-2. Rack Handling Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
Figure 11-3. Sample Module (CTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 4
Figure 11-4. Sample Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
Figure 11-5. Sample Rack Sensing Indications (all positions filled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 5
Figure 11-6. Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6
Figure 11-7. Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 6
Figure 11-8. Reagent Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7
Figure 11-9. Reagent Rack Sensing Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8
Figure 11-10. Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 8
Figure 11-11. Reagent Mounting Plate Stirrers and Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 9
Figure 11-12. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
Figure 11-13. Reagent Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
Figure 11-14. Bar Code Reader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 11

Figure 11-15. RTI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12
Figure 11-16. Bar Code Reader Travel Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 13
Figure 11-17. SW, Covers, and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15
Figure 11-18. Racks Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 16
Figure 11-19. Reagent Temperature Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17
Figure 11-20. Stirring Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 17
Figure 11-21. Sample Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 19
Figure 11-22. Sample Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 20
Figure 11-23. Sample Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 21
Figure 11-24. Reagent Module Screws (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 22
Figure 11-25. Reagent Module Screws (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 22
Figure 11-26. Reagent Cooling with Fan Speed Controller PCB Mounting. . . . . . . . . . . . . . . . . . . . . . 11 - 23
Figure 11-28. Barb Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 24
Figure 11-29. Double Clamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25
Figure 11-30. Reagent Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 25
Figure 11-31. Secured Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26
Figure 11-32. Reagent Presence PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 26
Figure 11-34. Reagent Flag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 28
Figure 11-35. Bar Code Reader Home Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 29
Figure 11-36. BCR Mounting Screws Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 29
Figure 11-37. Mounting Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 30
Figure 11-38. Barcode Scanner Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31
Figure 11-39. Plate Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 31
Figure 11-40. Cable Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 32
Figure 11-41. Bar Code Reader Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 32
Figure 11-42. RTI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 33
Figure 11-43. X Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 35
Figure 11-44. Jumper Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36
Figure 11-45. Encoder Assembly Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 36
Figure 11-46. Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 37
Figure 11-47. BCR Curtain Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 38
Figure 11-48. Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 38
Figure 11-49. Right Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 39
Figure 11-50. Left Curtain Spool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 39
Figure 11-51. Bar Code Reader Drive Belt Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 40
Figure 11-52. Bar Code Reader Drive Belt Fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 41
Figure 11-53. Bar Code Reader Drive Belt Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 41
Figure 11-54. Bar Code Reader Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 42
Figure 11-55. Bar Code Reader Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 43
Chapter 12 -
Thermal Control
Figure 12-1. System Temperature Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
Figure 12-2. Temperature Tab of Instrument Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 2
Figure 12-3. Thermal Sensing Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3
Figure 12-4. Thermal Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 3
Figure 12-5. Cuvette Shuttle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 4
Figure 12-6. Cuvette Shuttle Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5
Figure 12-7. Incubator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 6
Figure 12-8. Incubator 2 Thermal Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 6
Figure 12-9. Optical Reading Unit Thermal Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7

Figure 12-10. Cooling Fan Ductwork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
Figure 12-11. Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
Figure 12-12. Reagent Cooling with Fan Speed Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 9
Figure 12-13. Cavro Reagent Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10
Figure 12-14. Universal Arms Reagent Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10
Figure 12-15. Cavro Sample Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 11
Figure 12-16. ThermalCal Dialog Initial State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13
Figure 12-17. Thermal Dialog after Changing to Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14
Figure 12-18. Screen after connecting to the TOP AM. (Manual Mode) . . . . . . . . . . . . . . . . . . . . . . . . 12 - 15
Figure 12-19. Calibration Process for a Single Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 16
Figure 12-20. Display of the Soaking Time Remaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17
Figure 12-21. Time-out Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 17
Figure 12-22. Temperature Stable Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 18
Figure 12-23. Screen showing Offset (Coefficient) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
Figure 12-24. Display Coefficient Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 19
Figure 12-25. Message Box Confirming a Stop Calibration Request . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
Figure 12-26. Message Warning that a Second Module cannot be Selected . . . . . . . . . . . . . . . . . . . 12 - 20
Figure 12-27. Complete Calibration before Exiting message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 20
Figure 12-28. ThermalCal Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 21
Figure 12-29. ThermalCal Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 22
Figure 12-30. Connecting ThermalCal Application to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23
Figure 12-31. Time-out Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 23
Figure 12-32. AM Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24
Figure 12-33. ICU1 Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 24
Figure 12-34. ICU2 Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25
Figure 12-35. ORU Thermistor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25
Figure 12-36. Thermistors and Futura Test Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 26
Figure 12-37. Soak Time Remaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27
Figure 12-38. Temperature Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 27
Figure 12-39. Temperature Difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28
Figure 12-40. Save Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28
Figure 12-41. Calibration Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 28
Figure 12-42. Done Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 29
Figure 12-43. Display Coefficients. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 30
Figure 12-44. Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 30
Figure 12-47. Connecting ThermalCal to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 33
Figure 12-48. Connection Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 34
Figure 12-49. Thermal Coefficient Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 34
Figure 12-50. Controllers, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 36
Figure 12-51. Reagent Temperature Area of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 37
Figure 12-52. ORU Tab of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 38
Figure 12-53. Temperature Portion of ORU Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 39
Figure 12-54. Software, Covers and Racks Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 40
Figure 12-55. Reagent Block Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 40
Chapter 13 -
Figure 13-1. Layout of the Waste Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 2
Figure 13-2. The Sample and Reagent Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4
Figure 13-3. The Reagent Side Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4
Figure 13-4. The Sample Side Accumulator (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 5

Figure 13-5. The Parts of the Waste Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 6
Figure 13-6. The Waste Shelf Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7
Figure 13-7. Tilt Adjustment and Positional Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 8
Figure 13-8. The Fluids Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 12
Figure 13-9. The Waste Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
Figure 13-10. The Waste Pump Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
Figure 13-11. The Cuvettes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14
Figure 13-12. The Move Cuvette(s) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 15
Figure 13-13. The Waste Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16
Figure 13-14. Connectors on the Cuvette Waste PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 18
Figure 13-15. Three Captive Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 18
Figure 13-16. The Fluidic Connector/Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 20
Figure 13-17. The Sample Accumulator (with the Sample Module Removed) . . . . . . . . . . . . . . . . . . . 13 - 21
Figure 13-19. CTS Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 23
Figure 13-21. The Reagent Accumulator (with the Reagent Module Removed). . . . . . . . . . . . . . . . . . 13 - 24
Figure 13-22. Waste Pump Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 25
Figure 13-23. Waste Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 26
Figure 13-24. Waste Pump Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 27
Figure 13-25. Assembly with Waste Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 27
Chapter 14 -
Figure 14-1. Use of Precision Tubing as Threader for Rinse Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 3
Figure 14-2. I/O Fluidics Panel Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 4
Figure 14-3. I/O Fluidic Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 5
Figure 14-4. Fluidics Panel Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 6
Figure 14-5. I/O Fluidics Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 7
Figure 14-6. Waste Pump Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 8
Figure 14-7. Flex Cable Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 9
Figure 14-8. X Frame and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 10
Figure 14-9. Y Frame and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 10
Figure 14-10. .ORUs Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 11
Figure 14-11. ORU Enabling Portion of Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 11
Figure 14-12. Air Blanking of All ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 12
Figure 14-13. Air Blanking Value Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 12
Figure 14-14. Factor Diluent Blanking for all ORUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13
Figure 14-15. Factor Diluent Blanking Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 13
Figure 14-16. Left and Right End-of-Limit Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 14
Figure 14-17. Shuttle Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15
Figure 14-18. Z Height and Tilt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15
Figure 14-19. Y Axis LED and Turning Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16
Figure 14-20. Y-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 16
Figure 14-21. X-Axis Adjustment and Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 18
Figure 14-22. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
Figure 14-23. Arm Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
Figure 14-24. Flow Rate Test Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 19
Figure 14-25. System Software VersionsDisplay Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 20
Figure 14-26. Software Revisions Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21
Figure 14-27. System Temperature Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 21
Figure 14-28. Temperature Tab of Instrument Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 22

Figure 14-31. Connecting ThermalCal to the AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 24
Figure 14-32. Connection Status - Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 24
Figure 14-33. Thermal Coefficient Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 25
Chapter 15 -
CTS Piercer
Figure 15-1. CTS Piercer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 2
Figure 15-2. CTS Piercer Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 3
Figure 15-3. CTS Piercer Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 4
Figure 15-4. Piercer Probe in Piercer and Sample Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7
Figure 15-5. Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8
Figure 15-6. LLD Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 8
Figure 15-7. Piercer Lock Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 9
Figure 15-8. Cap Detect Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10
Figure 15-9. Piercer Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 10
Figure 15-10. Z-Drive Rack and Brake Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 11
Figure 15-11. Retraction Shaft and Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 12
Figure 15-12. Probes Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 14
Figure 15-13. CTS Tab of Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 16
Figure 15-14. Piercer Loop Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
Figure 15-15. Sensors Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18
Figure 15-16. Air Valve, Pressure Release Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
Figure 15-17. Probe-n-Seal Assembly Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20
Figure 15-18. Sampling Probe LLD Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20
Figure 15-19. CTS Assembly Thumbscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21
Figure 15-20. Probe-n-Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21
Figure 15-21. Probe-n-Seal Hold Down Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 22
Figure 15-22. Inserting the Probe-n-Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 23
Figure 15-23. CTS Thumbscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 23
Figure 15-24. Sampling Probe LLD Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24
Figure 15-25. Probe-n-Seal Assembly Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 24
Figure 15-26. Piercer Probe Knurled Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 25
Figure 15-27. CTS Piercer Probe Removal/Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 26
Figure 15-28. Removal of Telescoping CTS Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28
Figure 15-29. CTS Piercer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28
Figure 15-30. Brake Rack Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29
Figure 15-31. Telescoping CTS Assembly Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29
Figure 15-32. Z-Drive Rack Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30
Figure 15-33. Z-Drive Rack Screw (Bottom View of Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 30
Figure 15-34. Brake Rack Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 31
Figure 15-35. Telescoping CTS Assembly Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 32
Figure 15-36. CTS Piercer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 32
Figure 15-37. Ribbon Cable Routing/Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 33
Figure 15-38. Connection of Telescoping CTS Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 34
Figure 15-39. Connecting Air Tube to the Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 34
Chapter 16 -
Schematics
Figure 16-1. Power Interconnect Fuse PCB (Drawing # 27501100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 3
Figure 16-2. Back Plane PCB (Drawing # 27502100, Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 4

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

Figure 16-62. Cuvette Waste Interface PCB (Drawing # 27605100). . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 64
Figure 16-63. X Motion Control PCB W/ out Dip (Drawing # 27613100). . . . . . . . . . . . . . . . . . . . . . . . 16 - 65
Figure 16-64. CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 of 9) . . . . . . . . . . . . . . . . 16 - 66
Figure 16-73. Y Axis U Arm PCB (Drawing # 28631100, 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 75
Figure 16-74. Y Axis U Arm PCB (Drawing # 28631100, 2of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 76
Figure 16-75. Z Driver PCB (Drawing # 28633100, Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 77
Figure 16-78. CTS Traveling Interconnect PCB (Drawing # 28634100) . . . . . . . . . . . . . . . . . . . . . . . . 16 - 80
Figure 16-79. U Arm Fuse Board PCB (Drawing # 28641100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 81
Chapter 17 -
Assembly Drawings/Part Numbers
Figure 17-1. 2811001, ASSY, WASTE SHELF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 10
Figure 17-2. 28116301 ASSY, WASTE DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 11
Figure 17-3. 28116401 ASSY, WASTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 12
Figure 17-4. 28141701 ASSY, LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 13
Figure 17-5. 28161601 X-MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 14
Figure 17-6. 28165001 ASSY CUVETTE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 15
Figure 17-7. 28200001 ASSY, BARCODE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 16
Figure 17-8. 28201501 MOTOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 17
Figure 17-9. 28209001 ASSY, MONITOR/KEYBOARD SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 18
Figure 17-10. 28200300 ASSY, 2-ARM RIGHT CAVRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 19
Figure 17-11. 28300500 ASSY, 1-ARM, LEFT CAVRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 20
Figure 17-12. 28321001 ASSEMBLY, ARM, DOUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 21
Figure 17-13. 28320901 ASSEMBLY, ARM, CTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 22
Figure 17-14. 28395001 PROBE, HEATED, ACL-TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 23
Figure 17-15. 28445001 ASSY SAMPLE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 24
Figure 17-16. 28446001 ASSY REAGENT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 25
Figure 17-17. 28512501 ASSY, REAGENT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 26
Figure 17-18. 28519700 DUCT ASSY, REAGENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 27
Figure 17-19. 28578601 ASSY, SAMPLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 28
Figure 17-20. 28578621 ASSY, CTS SAMPLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 29
Figure 17-21. 28602701 ASSY, COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 30
Figure 17-22. 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY). . . . . . . . . . . . . . . . 17 - 31
Figure 17-23. 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY). . . . . . . . . . . . . . . . 17 - 32
Figure 17-24. 28608101 ASSY, BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 33
Figure 17-25. 28608201 ASSY, COMPUTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 34
Figure 17-26. 28608301 DC DRIVER ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 35
Figure 17-27. 28612000 ASSY, FRONT, TOP SKIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 36
Figure 17-28. 28612701 SNAP DETENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 37
Figure 17-29. 28621201 PCB, CUVETTE ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 38

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

1
Safety and Compliance

This section describes the Safety and Compliance Requirements for the ACL TOP, including Site Require-
ments, Environmental Requirements, Reagent Specifications, Limitations, Important Symbols, and Certifi-
cations.
Site Requirements
Only IL personnel or other person(s) duly authorized by IL must install the ACL TOP.
CAUTION: The ACL TOP weighs over 158 Kg (350 lbs). Extreme care
should be exercised in the event that the ACL TOP needs to be lifted or
moved. A total of four people should be used; two people should lift
using the two molded handles in the rear of the unit; the third and fourth
persons should each lift a front corner.
Limited Warranty
Instrumentation Laboratory is responsible for the safety and electrical performance of this equipment if and
only if:
Persons authorized by IL carry out assembly operations, extensions, adjustments, modifications or
repairs.
The electrical installation of the room complies with the local, state, or national requirements (includ-
ing power supply circuit with independent grounding).
The equipment is used in accordance with these instructions for use.
IL brand products are used. Non-IL brands are not covered.
Spatial Requirements
The maximum external dimensions for the analytical module (AM) are:
Height: 73 cm 29 inches
Width: 151 cm 59 inches
Depth (at footprint): 76 cm 30 inches
Weight (approx.): 158.76 Kg 350 lbs
ACL-TOP Service Manual

2
The instrument must be positioned so that a waste tube can be connected to the right side of the unit without
any kinks or bends that could lead to an obstruction.
The instrument must be positioned so that there is at least 15.2 cm (6 inches) clearance on all sides, back
and top for proper air circulation.
The maximum external dimensions for the control module (CM) are:
Height: 44.4 cm 17.5 inches

Width: 19.0 cm 7.5 inches
Depth: 48.2 cm 19 inches
Weight (approx.): 16.8 Kg 37.0 lbs
The maximum external dimensions for the monitor are:
Height 43.1 cm 17 inches

Width: 35.5 cm 14 inches
Depth: 7.6 cm 3 inches
Environmental Conditions
The instrument will function correctly in an ambient temperature of 15C to 32C (59F to 89F) with a rela-
tive humidity of 5% to 85% (non-condensing).
In accordance with the IEC regulations, no instrument failures will occur in the presence of short-term ambi-
ent temperatures as low as 5C or as high as 40C.
The instrument has been tested per Mil Spec to 2000 meters and functioned per the specification. The ACL
TOP should not be used at an altitude greater than 2000 meters.
The audible noise emission passes the safety requirements for electrical and laboratory equipment,
EN61010.1.
Reagent Specifications
Reagent specifications for the ACL TOP are published separately and distributed in the reagent packaging.
Non-IL Reagents
The use of non-IL brand reagents or supplies for testing may cause a clinically significant degradation of
performance and results. IL does not assume any obligation or warranty engagement concerning precision
and/or accuracy of the measurements nor for any damage to the instrument directly or indirectly resulting
from the use of reagent, consumables and/or expendable supplies other than those produced by IL.

3
Limitations
Instrumentation Laboratory, Co. (IL) is responsible for the safety and electrical performance of this equip-
ment if and only if:
Assembly operations, extensions, adjustments, modifications or repairs are carried out by persons
authorized by IL.
The electrical installation of the room complies with the local, state or national requirements (includ-
ing a power supply circuit with independent grounding).
The equipment is used in accordance with these instructions for use.
IL does not assume any obligation or warranty engagement concerning precision and/or accuracy of the
measurements or for any damage to the instrument directly or indirectly resulting from the use of reagents
and/or consumables other than those produced by IL.
THIS WARRANTY IS GIVEN EXPRESSLY AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED
OR IMPLIED. PURCHASER AGREES THAT THERE IS NO WARRANTY OR MERCHANTABILITY AND
THAT THERE ARE NO OTHER REMEDIES OR WARRANTIES, EXPRESSED OR IMPLIED, WHICH
EXTEND BEYOND THE CONTENTS OF THIS AGREEMENT.
No agent or employee of IL is authorized to extend any other warranty or to assume for IL any liability except
as above set forth.
Disclaimer Regarding User-Defined Tests
A user with the appropriate security level can create new tests or copy an existing test. All responsibility for
parameter development and validation of new or copied tests belongs to the user alone.
Document Symbols
Only trained operators following the procedures described in this manual should use the ACL TOP. IL
declines any responsibility otherwise.
Good laboratory practices dictate that biohazard precautions are taken while operating the ACL TOP and
when handling patient samples, controls, calibrators, or similar materials.
Throughout this manual, you should pay particular attention to paragraphs marked "WARNING", "CAU-
TION", "NOTE", and "BIOHAZARD." These paragraphs are labeled with the following symbols and contain
important information:
WARNING Warning statements provide information about

electrical hazards.
CAUTION Caution statements provide information about per-

sonal injury hazards and product damage hazards.

4
NOTE Note statements contain important user information.
BIOHAZARD Biohazard statements alert you to potentially

biohazardous conditions.
WARNING Use extreme caution. (CTS Probe is moving)

Can cause potential cutting or piercing injury.
Label Symbols
The following symbols appear on the labels of ACL TOP components.
Symbol Description
CE Mark
Temperature Limitation
Use by
Manufacturer
Batch Code
Biological Risk
Attention: See Instructions for Use

5
Caution: Risk of Electric Shock
Note: Important User Information
Attention: Consult Documents
Catalog Number
Serial Number
In Vitro Diagnostic Device
Authorized Representative
Contents sufficient for <n> tests
Protective Conductor Terminal - Earth
Earth Ground
Off (supply)
On (supply)

6
Bar Code Reader Hazard
Stop Action Instrument will stop all moving parts

immediately
Warning: Personal Injury
Certification
CE Certification:
The CE label on the back of the instrument indicates that the ACL TOP conforms to the European Directives
as stated in ILs Declaration of Conformity,
EU Directive:
IVD - 98/79/EC (27/10/1998) Annex I and III
Applicable standards:
EN 61326-1: 1998 (Class A)

EN 61010-2-04
CSA Certification:
The CSA label on the back of the instrument indicates that the Canadian Standards Association (CSA) has
certified the ACL TOP to the applicable standards.
Applicable standards:
CAN/CSA C22.2 No. 1010.1-92

UL Std. No. 61010-1, 2nd Edition
LOPD (Data Protection Organic Law):
Directive 95/46/CE of the European Parliament and the Council Directive of October 24th, 1995.

7
European regulation on data protection, concerning:
Luxembourg Ireland Greece

United Kingdom Belgium Portugal
Austria Germany Italy
Denmark France Netherlands
Sweden Finland Spain
European parliament and council directives and regulations on data protection

Spanish Constitution of 1978
Organic Law 15 of December 13th, 1999, on Personal Data Protection (LOPD)
Royal Decree 994/1999 on Security Measures. Royal Decree 1332/1994
Regulation of the Computerized Processing of Personal Data
Spanish Data Protection Agency instructions
Other Certification:
The ACL TOP meets CEI/IEC 61010-2-04, 2001 Mod, Second Edition, for the following:
External Surface Temperature
Flame Resistance
Fluid Resistance
Internal Air Flow and Temperature
Audible Noise
Product Labeling
The ACL TOP shipping package, US or overseas, complies with the International Safe Transit Packaging
Testing Procedure ISTA 1B (June, 1999) and ASTM 999.
CAUTION: Only authorized service personnel should perform field service

on the instrument. The instrument contains potentially hazardous
electrical voltages and many mechanical parts.
CAUTION: The ACL-TOP contains moving parts, and hazardous

chemicals, which can cause injury if handled improperly. Only authorized
service personnel should perform service on the ACL-TOP.
NOTE: Throughput performance is established based on a 100 second PT acquisition time

and a 120 second APTT acquisition time.

8
CAUTION: Do not bypass safety switches. The moving CTS Pierce Probe
can cause serious personal injury.
AM Safety Covers
The locking sample and reagent access covers are designed to provide increased operating safety. The
sample area cover is on the left and the reagent area cover is on the right. These covers must remain
closed during system operation.
The covers enhance operator safety and reduce the effect of the external environment on the instrument
when operating at environmental extremes and minimize the evaporation from samples and reagents. They
help to maintain temperature control and reduce the effect of stray light on sample data acquisition.
The software controls the unlocking of the sample and reagent access covers. The ACL TOP is able to
detect whether one or both of the access covers are open or closed. If it detects that an access cover is
open, an emergency stop is automatically initiated. The ACL TOP will not operate with either of the access
covers open.

Chapter 1 Instrument Overview 1-1
Chapter 1
Instrument Overview
1-1 Intended Use
The ACL TOP is a bench top, fully automated, random access analyzer designed specifically for in vitro
diagnostic clinical use in the hemostasis laboratory for coagulation and fibrinolysis testing in the assessment
of thrombosis and hemostasis.
The system provides results for both direct hemostasis measurements and calculated parameters.
The ACL TOP is used to perform the following types of tests:
Coagulometric (Turbidimetric) Tests
Chromogenic (Absorbance) Tests
Immunological Tests
1-2 Instrument Description
The ACL TOP system is composed of two modules:

Control Module (CM) - User interface and operation control
Analytical Module (AM) - Primarily sample and reagent handling hardware
The CM consists of a personal computer running Windows software, keyboard, touch screen display moni-
tor, mouse, and communications interfaces to the AM and external devices/systems. The CM provides the
major functionality associated with the User Interface (UI) including data management, data reduction, LIS
(Laboratory Information System) communications, sample identification, test materials management, fluid
management, reporting, test tracking and QC management, and monitoring.
The AM consists of the functionality required to handle and process reagents and auxiliary materials. It can
perform coagulometric (turbidimetric), chromogenic (absorbance), and immunological measurements.
The major parts of the ACL TOP instrument are the Control Module and the Analytical Module as shown on
Figure 1-1 "ACL TOP Instrument".
The Control Module includes:
personal computer running Windows software
keyboard
touch screen display monitor
mouse

1 - 2 Chapter 1 Instrument Overview
The Analytical Module includes:

AM Computer
Cuvette Handling
Sample Area
Diluent Area
Reagent Area
Bulk Fluids
Waste Handling
Sample Handling
Reagent Handling
Reaction and Detection
Interconnect and Power Supply
Access-restricting Cover with Safety Interlocks
Instrument-supporting Structure-chassis
Safety Interlock for Cuvette Waste Drawer
Figure 1-1 ACL TOP Instrument
AM Safety Covers
The locking sample and reagent access covers, as shown on Figure 1-2 "Analytical Module with Open
Safety Covers", provide increased operating safety. The sample area cover is on the left and the reagent
area cover is on the right. These covers must remain closed during system operation.
The covers enhance operator safety and reduce the effect of the external environment on the instrument
when operating at environmental extremes and minimize the evaporation from samples and reagents. They
help to maintain temperature control and reduce the effect of stray light on sample data acquisition.

The software controls the unlocking of the sample and reagent access covers. The ACL TOP is able to
detect whether one or both of the access covers are open or closed. If it detects that an access cover is
open, an emergency stop is automatically initiated. The ACL TOP does not operate with either of the access
covers open.
Figure 1-2 Analytical Module with Open Safety Covers
AM Power Connector
The ACL TOP AM power switch is located on the right side of the analytical module, adjacent to the power
cord connection. This switch is for the main power supply and controls all power to the AM.
CAUTION: This switch must be turned off prior to service and the power
cord must be disconnected.
During normal operation, the ACL TOP is powered on continuously. Please note the following concerning
the AM power connector:
The power supply carries UL/CSA approvals.
Maximum power requirements for the AM do not exceed 1100 watts.
The power supplies in both the AM and CM incorporate a power factor correction in order
to prevent harmonic distortions in the power lines and to satisfy requirements for EMC/EMI
Standard 61326.
The AM incorporates a standard AC input IEC 1010.1-92 connector.

Emergency Stop Button

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

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

Figure 1-4 Cuvette Loader Area
Cuvette Loader
The cuvette loader can be filled with up to 20 clips of 10 cuvette strips each, for a maximum of 200 cuvette
strips (800 cuvette cells).
A conveyor belt transports the cuvette clips to the front of the loading area.
Electrical sensors detect when additional cuvette clips need to be loaded onto the instru-
ment and inform the operator.
The indexer pushes the cuvette clip to the right to position it so one strip can be picked up
by the cuvette shuttle.
As the cuvette strips are used, new cuvette clips are brought forward and positioned for
pickup. Additional cuvette strips can be added in the loading area while the analyzer is run-
ning.
Cuvette Shuttle
The cuvette shuttle, as shown on Figure 1-5 "Cuvette Strip being picked up by Cuvette Shuttle", picks
up a single cuvette strip from the cuvette clip and transports it from one position or slot to another.

Figure 1-5 Cuvette Strip being picked up by Cuvette Shuttle
Bar Code Reader

The bar code reader, as shown on Figure 1-6 "Bar Code Reader", moves to each track position to allow
for insertion of the sample, diluent or reagent racks. Bar coded information on sample tubes or diluent or
reagent bottles is scanned into the instrument as the racks are inserted.
The bar code reader is moved to the desired track using the track buttons on the front of the AM or by click-
ing the virtual track buttons displayed on the Reagent Area screen on the CM. With the bar code reader
positioned in front of the track position, the rack can be inserted. A track guides the insertion of the rack into
its correct position.
After the bar code reader has been at a track position for 30 seconds, it moves back to its home position.
CAUTION: A flashing red LED on the front of the bar code reader indicates
that the bar code reader is about to move. When the red LED is flashing,
keep the bar code reader path clear of obstacles, keep hands away and do
not attempt to load racks.
N
NOTE:In the event of a Bar Code Reader Blocked error, wait 30 seconds
until the bar code reader homes itself; do not attempt to move the bar
code reader manually.

Figure 1-6 Bar Code Reader
Sample Area
On the left side of the instrument, as shown on Figure 1-7 "Sample Area with Sample Arm", is the sample
area where patient samples are placed on the AM. The sample material is placed on racks, as shown on
Figure 1-8 "Sample Rack", that are inserted through a bar code reader.
The sample area is at ambient temperature and can hold 12 racks, each capable of holding 10 samples.
When the rack is in use (during aspiration of sample material) it is locked and an amber LED (Light Emitting
Diode) is displayed for the track position. When the rack is no longer in use, the LED changes to green.
The sample rack holds both sample tubes and sample cups.
CAUTION: When using sample cups they must be Instrumentation

Laboratorys 2.0 mL sample cups. The use of non-IL sample cups may
lead to improper sampling and incorrect results.
The wash station for the sample probe is located in the back right side of the sample area.

Figure 1-7 Sample Area with Sample Arm
Figure 1-8 Sample Rack
Sample Arm
The sample arm consists of a heated probe and syringe used for aspirating and dispensing samples. The
CTS uses an unheated probe.

Closed Tube Sampling

The CTS probe is a specially designed unit comprised of both a piercer and a sample probe, which is
located within the piercer as shown in Figure 1-9 "Sample Arm CTS probe". The Sample Arm CTS probe
has a foot to hold the sample tube in place, allowing the piercer to cut through the cap. After the piercer cuts
through, it remains in the cap long enough to allow the probe to move down and into the tube to aspirate
material as shown in Figure 1-10 "CTS Cap Piercing".
Figure 1-9 Sample Arm CTS probe
Figure 1-10 CTS Cap Piercing
1 2
CAUTION: Due to the force of the piercing, glass sample tubes may break.
To avoid this potential breakage please use plastic tubes where possible.

Following aspiration the CTS/Sample arm moves to the wash station and performs a deep wash. Pressur-
ized air is released through the piercer/probe to blow out any material that might remain following a wash or
rinse.
Special CTS racks are used for cap piercing; these racks are identified by labels having "CTS" in bold on
the front of the rack as shown in Figure 1-11 "CTS Rack".
Figure 1-11 CTS Rack
CTS mode is Enabled/Disabled in the Global Definitions screen. With the CTS mode enabled, the instru-
ment accepts both CTS racks and open tube racks. Only closed tubes may be used on CTS racks. Regular
uncapped sample tubes, and sample cups belong on open tube racks.
With the CTS mode disabled, the instrument does not accept CTS racks; if a CTS rack is inserted an error
message is displayed with "CTS rack rejected". In the disabled mode, the instrument runs uncapped tubes
and sample cups on open tube racks only.

Chapter 1 Instrument Overview 1 - 11
Diluent Area
The diluent area, as shown on Figure 1-12 "Diluent Area with Sample Probe (non CTS)", includes the 2
right-most tracks in the sample area and the left-most track in the reagent area. This area holds up to 24
calibration plasmas, QC materials, and dilution materials in original bottles placed on diluent racks as shown
on Figure 1-13 "Diluent Rack".
When the rack is in use (during aspiration of material) it is locked and an amber LED is displayed for the
track position. When the rack is no longer in use, the LED changes to green and the rack is released.
The sample arm aspirates and dispenses materials from diluent racks placed in the sample area.
The reagent arm aspirates and dispenses materials from the diluent rack placed in the reagent area.
Figure 1-12 Diluent Area with Sample Probe (non CTS)
Figure 1-13 Diluent Rack

Reagent Area
The reagent area, as shown on Figure 1-14 "Reagent Area Showing Intermediate (left) and Start (right)
Reagent Arms", is on the right side of the AM. This area has 6 tracks that hold up to 36 reagents in original
bottles placed on reagent racks as shown on Figure 1-15 "Reagent Rack". As with samples, reagent racks
are inserted into reagent tracks by means of the bar code reader assembly.
The reagent area is cooled to 15oC 3oC and positions 1 and 2 of each rack (rearmost positions) are
enabled for the use of magnetic stir bars.
Figure 1-14 Reagent Area Showing Intermediate (left) and Start (right) Reagent Arms
Figure 1-15 Reagent Rack
Reagent Arms
There are two reagent arms. The left reagent arm is used for aspirating/dispensing materials placed in the
diluent rack in the reagent area and intermediate reagents from positions 1-24 of the reagent area. (An inter-
mediate reagent is one that when mixed with sample activates certain constituents of the sample but is not
enough to bring the reaction to completion.)

The right reagent arm is used for aspirating/dispensing start reagents from positions 13-36 of the reagent
area. (A start reagent is one that when mixed with the sample or sample mixture begins the reaction of inter-
est. It must be the final reagent added to the cuvette cell.)
Both reagent arms can access positions 13-24 in the reagent area.
The wash station for the left reagent probe is located in the back left side of the reagent area; the wash sta-
tion for the right reagent arm is located in the back right side of the reagent area.
Probe
The probes, as shown on Figure 1-16 "Probe (in foreground) and Syringe (non CTS)", are the vertical
part of the sample and reagent arms that are in contact with the liquid.
Each probe has a sensor that recognizes the presence of liquids and stops at the optimized liquid level.
Each is preheated and heats liquids being pipetted to 37C 1C. A Teflon tube connects the probe to a
syringe that is capable of delivering 4 to 250 L. The CTS sample probe is not heated.
The probes on non CTS instruments are interchangeable, but if they are replaced, arm coordinates need to
be recalibrated.
If a probe appears to be damaged, bent, shows visible corrosion, or if frequent liquid level detection failures
are being detected, the probe may need to be replaced.
Figure 1-16 Probe (in foreground) and Syringe (non CTS)
Probe Syringes
There are three syringe pumps in the AM. Each probe has its own syringe pump to enable the separate
movement of rinse, clean, sample or reagent through the probe. The syringe has plastic tips that may wear
out and need to be replaced. It is recommended they be replaced annually. The knob located at the bottom
of each syringe is used when changing tips.

Incubators
There are two incubators, one behind the right side of the sample rack area and the other behind the left
side of the reagent rack area, see Figure 1-17 "Sample Probe and Incubator Slots (non CTS)".
An incubator can hold up to 8 cuvette strips (32 cells) for the sample or reagent incubation phase. The tem-
perature for both incubators is maintained at 37.0 0.5C.
In the first incubator, sample material is pipetted into the cuvette cells. The cuvette strips are moved into the
second incubator where intermediate reagents are dispensed.
Figure 1-17 Sample Probe and Incubator Slots (non CTS)
Optical Reading Unit

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

The rinse solution system and the clean solution system remove contaminants from the system to reduce
the risk of carryover affecting test results. Figure 1-18 "Rinse (left) and Clean Bottles on ACL TOP with
Fluid Waste Container Underneath" provides a view of the rinse and clean elements.
These fluids clean not only the internal surfaces of the probe and the related tubing, but also the external
surface of each probe tip, removing contaminants that may have contacted the probe during fluid aspiration.

The rinse solution is used to rinse the probes after the aspiration and dispensation of a test fluid. Typically,
the probe is rinsed after each syringe pump cycle. However, in instances where a common reagent is being
dispensed into consecutive cells, the rinse pump may not be operated until after the final dispense. The
amount of rinse solution used is not test-dependent.
The rinse solution system is comprised of the system rinse solution bottle, the rinse solution tubing, three
rinse pumps, the rinse pump tubing, the rinse/clean stations in the sample and reagent areas, and the waste
fluid. For CTS, an additional rinse pump is used to rinse the outside of the sample probe and the inside of
the piercer probe. An air pump is also used to aid in drying the piercer and sample probes.
Each probe is connected to a dedicated rinse pump and has a dedicated rinse/clean station at which it is
positioned during the operation of the rinse cycle. The probe is positioned above the rinse cup and rinse is
dispensed through the probe into the rinse cup. Rinse dispensed from the probe enters the rinse cup, dis-
placing any rinse that is in the rinse cup. Any excess fluid that overflows from the rinse cup drains into the
accumulator through an opening in the bottom of the rinse/clean station.
The rinse solution is placed on the ACL TOP in a 4L rinse bottle. A sensor (Rinse Fluid) located on the front
of the AM monitors the level of rinse solution and displays an amber warning light when the level drops
below 1000 mL and displays a red error light when the level drops below 600 mL. If the Rinse Fluid sensor
changes to red while busy (conducting testing), the instrument performs a controlled stop to finish running
the active tests. The remaining tests are not run until the operator replaces the rinse and presses Start
again. If the rinse solution drops below 100 mL the system performs an Emergency Stop.
CAUTION: Do not replace the Rinse Fluid during Busy (while tests are
being conducted) or Controlled Stop.
The clean solution system is comprised of the system clean solution bottle, the clean solution tubing, a
pump, a manifold, three valves, clean cup tubing, the rinse/clean stations and fluid waste. A pump is used
to transport clean solution from the clean solution bottle to the clean stations. Each rinse/clean station con-
tains a clean cup that serves as a reservoir for the clean solution. The clean cups are filled from the bottom.
The probe enters the clean solution and aspirates fluid from the clean cup, the pump is operated and the
valve dedicated to the clean cup is opened. Clean solution is pumped into the clean cup. The volume of
clean solution pumped into the clean cup is sufficient to not only fill the clean cup, but to also flush any con-
taminants from the clean cup. Any excess fluid that overflows from the clean cup drains into the accumulator
through an opening in the bottom of the rinse/clean station.
A cleaning cycle is used to clean the probe at specific times during the operation of the instrument. It cleans
the probe more completely than the rinse system. The probe aspirates clean solution from the clean cup in
the rinse/clean station or from a bottle of clean material place on a rack and dispenses the clean solution
into the rinse/clean station.
A sensor (Clean Fluid) located on the front of the AM monitors the level of clean solution and displays an
amber warning light when the level drops to 75 mL and displays a red error light when the level drops to 25
mL. If the Clean Fluid sensor changes to red during busy, the instrument performs a controlled stop to finish
running the active jobs. Wait until the system comes to a complete stop, replace the bottle with a new one,
then restart the testing.
CAUTION: Do not replace the Clean Fluid during Busy or Controlled Stop.

Figure 1-18 Rinse (left) and Clean Bottles on ACL TOP with Fluid Waste Container Underneath
Fluid Waste
The fluid waste pump is used to remove fluid from the internal waste reservoirs located under the clean and
rinse stations in the sample area and the reagent area. There is a sensor in each reservoir that senses when
the accumulator is full and turns on the pump for a predetermined amount of time to empty the waste into
the waste container.

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

changing or emptying the fluid waste bottle.
Refer to local and state regulations for disposal of potentially hazardous materials.
Cuvette Waste Container

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

emptying the cuvette waste drawer.
Refer to local and state regulations for disposal of potentially hazardous materials.
Cuvette waste liners are used in the cuvette waste drawer to contain used cuvette strips, keep the waste
drawer clean and free of contaminants, and ensure proper disposal of the waste cuvettes.
Figure 1-19 Cuvette Waste

When the waste drawer is removed, the analyzer performs a controlled stop, allowing completion only of
tests that have been started, providing the cuvette accumulator is not full. If the drawer is re-inserted before
the in-process tests are completed, the AM revokes the controlled stop and finishes running all the samples.
If the active tests are completed before the drawer is reinserted, the AM goes to the "Ready" state and the
operator needs to restart the run to finish the remaining tests. If the cuvette waste drawer is not reinserted,
the ACL TOP does not restart and informs the operator.
There are two status indicators on the front of the AM for the cuvette waste. The "Door Open" indicator turns
green when the waste door is opened and the "Cuvette Waste" indicator turns amber (warning) when the
drawer is nearly full, and red (error) when the waste drawer is full or removed as shown in Figure 1-20
"Cuvette Waste Drawer".
Figure 1-20 Cuvette Waste Drawer
1-3 Operating Principles
Coagulometric (Turbidimetric) Measurements

The principle of coagulometric (turbidimetric) clot detection is used in the system to measure and record the
amount of time required for a plasma specimen to clot. This technique assesses coagulation endpoint by
measuring change in optical density.
Clot detection is based on the principle that light passing through a medium in which fibrinogen is converted
to fibrin is absorbed by the fibrin strands. Light (671 nm) is transmitted though a sample onto a photodetec-
tor, which is positioned 180 incident to the source.
Light absorption increases as fibrin clot formation progresses. Consequently, light transmittance through the
sample continuously decreases and is measured by the photo detector.
The corresponding electrical signal output from the photo detector changes according to the detected light.
The signal output is processed via software through a series of algorithms to determine the clot point.

Chromogenic (Absorbance) Measurements

Chromogenic tests can be either direct or indirect.
Direct tests are those in which the analyte of interest (e.g. protein C, plasminogen) acts directly on
a specified synthetic substrate.
Indirect tests are those in which the analyte of interest (antithrombin, plasmin inhibitor) reacts with
a fixed quantity of enzyme to form inactive complexes. Under optimized test conditions, residual
enzyme activity is then measured using a specific synthetic substrate.
In most cases, the reaction is monitored at 405 nm by the continuous release of paranitroaniline (pNA) from
the synthetic substrate.
The chromogenic channels use the colorimetric principle of measuring absorbance in the cuvette. An optical
sensor reads light (405 nm) that passes through the cuvette. The light is absorbed by the solution in the
cuvette in direct proportion to the concentration of pNA. The amount of light reaching the photodetector is
converted into an electrical signal that is proportional to the enzyme activity.
Immunological Measurements
The principle of immunological measurement is used on the system to directly measure and record the
amount of an analyte. This technique assesses the physical concentration of the analyte (and not its activity)
by measuring change in optical density.
Although similar to the turbidimetric method, the immunological method relies on the formation of antigen-
antibody complexes to affect light transmission.
Immunological testing of the ACL TOP uses the 405 nm or the 671 nm channels depending on the test and
the reagent formulation.
Both the 405 nm and the 671 nm channels use the principle of measuring absorbance in the cuvette. An
optical sensor reads the light (405 nm or 671 nm) that passes through the cuvette. The light is absorbed by
the solution in the cuvette in direct proportion to the concentration of antigen-antibody complexes. The
amount of light reaching the photodetector is converted into an electrical signal that is proportional or
inversely proportional to the analyte concentration.

THIS PAGE IS INTENTIONALLY LEFT BLANK.

Chapter 2 Pre-Installation and Installation 2-1
Chapter 2
Pre-Installation and
Installation
2-1 Overview
This chapter guides the IL authorized engineer through the process of ensuring the facility can accommo-
date and is ready for the installation of the ACL TOP. This chapter also guides the IL authorized engineer
through the installation process.
2-2 Pre-Installation
This document guides the Service Representative through all aspects of the on-site verification to be made
prior to installing the ACL TOP. The physical dimensions as well as power requirements are such that a suit-
able working environment must be established prior to delivery and installation of the system.
All checks listed in Table 2-1 "Table One Pre-Installation Check List" should be carefully executed and
the checklist completed during the pre-installation visit by the installing engineer.
Reception Area and Transportation Pathway

Verification of the reception and uncrating area, as well as transportation pathway from reception area to
installation location to allow easy and safe transport once the system is uncrated is of the utmost impor-
tance. For that specific purpose the following items should be carefully verified:
Adequate access to loading dock.
Facilities to offload the crates from the truck or lift gate truck required for delivery.
Space available to uncrate the system at the unloading site.
Transportation pathway from reception / uncrating area to final installation site meets the following
conditions:
Minimum acceptable doorway width 91.44 cm or 36 inches.
The customer has facilities to dispose of the shipping crate.

2 - 2 Chapter 2 Pre-Installation and Installation
Table 2-1 Table One Pre-Installation Check List

Item to be Checked Acceptable Unacceptable Construction Comments
In Progress
Reception Area
Transportation
Pathway
Working Area
Environment
Direct Waste Drain
Electrical Power
Requirements
DMS / LIS Interface

Functional
Customer Training
Complete
Supplies on Order
The physical dimensions for the shipping crate are as follows:
Table 2-2 Crated Instrument Size/Weight Specifications

Total height 172.8 cm (68 inches)
Width 180.4 cm (71 inches)
Depth 96.6 cm (38 inches)
Weight (approximate) 484.4 Kg. (1068 lbs)

Working Area / Environment

The physical dimensions of the system are as follows:
The instrument must be positioned so that a waste tube can be connected to the right side of the unit without
any kinks or bends that could encourage the formation of biological obstructions.
The instrument must be positioned so there is at least 15.2 cm (6 inches) clearance on all sides, back and
top for proper air circulation
The maximum external dimensions for the control module are:
Table 2-3 Control Module Size/Weight Specifications

Total height 44.5 cm. (17.5 inches)
Width 19 cm. (7.5 inches)
Depth 48.2 cm. (19 inches)
Weight (approximate) 16.8 Kg. (37.0 lbs.)
The maximum external dimensions for the Monitor are:
Table 2-4 Monitor Size Specifications

Total height 43.1 cm (17 inches)
Width 35.5 cm (14 inches)
Depth 7.6 cm (3 inches)
The maximum external dimensions for the Analytical Module on the shipping table are:
Table 2-5 Analytical Module Size Specifications
Total height 73 cm (29 inches)
Width 151 cm (59 inches)
Depth 76 cm (30 inches)
Weight (approximate) 158.76 Kg. (350 lbs)
Width of table 152.4 cm. (60 inches)
Height of Instrument on
154.7 cm. (60.5 inches)
table
Height of instrument on table
189.25 cm. (74.5 inches)
with doors open

Ambient Conditions:
The instrument functions correctly in an ambient temperature of 15 C to 32 C with relative humidity up to
85% (noncondensing). The instrument should be placed in a position free from dust, fumes, vibrations and
excessive variations in temperature. The TOP operates to elevations of 2,000 meters.
NOTE:The instrument should not be exposed to direct sunlight.

The TOP produces 2,049 BTU per hour
Electrical Power Requirements

The instrument works using an AC mains voltage line meeting the requirements specified below. Inspect the
working area and verify, with the support of the electrician (from Hospital Technical Department), that the fol-
lowing conditions are met.
Electrical Requirements
The instrument operates correctly with electrical variations of up to 10% on the nominal supply and with
supply frequencies between 47 and 63 Hz.
NOTE: Check that the supply voltage in the laboratory is compatible with the label on the rear of the
instrument as shown in the following table:
Table 2-6 Supply Voltage Values
Value of supply voltage for normal Value as shown on the label
function
230 Vac 10% 230 Vac
115 Vac 10% 100-115 Vac
Power Consumption
The analytical module is rated at 115 Vac at 10 amps and at 230 Vac at 5 amps. The power cords used for
the analytical and control modules are in accordance with IEC and /or national safety requirements. Should
the dedicated cords supplied have plugs that do not conform to the national standard, replace only with
appropriately conforming cords, bearing in mind the power consumption at the local supply voltage.
NOTE: The average power consumption of the analytical module is approximately 230 W; for the control
module it is 100 W. However, during peak loads or when turning power on, the instrument can
temporarily exceed these values.
Power should be stable and free from line noise. If this cannot be assured, consideration should be given to
the installation of a line conditioner.

DMS / LIS Interface Requirements

If the TOP is to be interfaced to DMS / LIS system, review the following.
Will the TOP be interfaced to an LIS system?
Is the communication software (driver) being written for the LIS interface?
Does the customer need a copy of the TOP data stream protocol?
Site Modifications
Document all site modifications required to be completed prior to installing the ACL TOP. Also include the
expected completion date for each.
2-3 Installation
NOTE:THE INSTALLATION OF THE ACL TOP SHOULD BE

PERFORMED ONLY BY AN AUTHORIZED INSTRUMENTATION
LABORATORY REPRESENTATIVE!
It is highly desirable to perform the unpacking and transporting of the unit with two people.
Inspect the crate for damage.
Remove the unit from the shipping crate by:
Opening the Dutch door on the rear wall of the crate (See Figure 2-1 "Duch Door Open").
Figure 2-1 Duch Door Open

Lower the front door / ramp as shown on Figure 2-2 "Shipping Packaging".
Remove the molded polystyrene foam from the top of both ends.
Unlock the wheel brakes and turn the wheels so they are positioned under the cart toward the
back of the crate.
Remove the front blocks by utilizing the 2 x 4 board located in the shipping crate
Remove the two retaining boards from the ramp side of the unit.
Figure 2-2 Shipping Packaging
Polystyrene
Foam
Retaining
Boards
Slowly and carefully remove the unit from the crate.

Observe if the Tip and Tell indicators have been tripped or if the shock watches have registered
an impact. They are adhered to the inside walls of the shipping crate. In the event of shipping
damage, stop the installation and make the proper notifications.
Transport the unit to its installation location.
Remove the packaging from the exterior of the unit.
Remove the cardboard box used to restrain the bar code reader.

Open the sample and reagent door covers. Note: The sample and reagent cover may be locked for
shipping. To unlock the reagent cover, remove the waste drawer and manually release the solenoid
door lock located under the lower right hand corner of the reagent cover. With the reagent door open
it is possible to unlock the sample door. The sample door solenoid is located under the lower left
hand side of the reagent cover.
Remove the cardboard support boxes under the sample and reagent arms. (See Figure 2-3
"Reagent Internal Packing Material" and Figure 2-4 "Reagent Internal Packing Material".)
Figure 2-3 Reagent Internal Packing Material
Cardboard
Support Box
Figure 2-4 Reagent Internal Packing Material

Remove the shipping brackets from the sample and reagent arms. (See Figure 2-5 "Sample/
Reagent Shipping Brackets".)
Figure 2-5 Sample/Reagent Shipping Brackets
Shipping
Bracket
Carefully remove the tie wraps around the probes and arms. (See Figure 2-6 "Probe/Arm Tie
Wraps".)
Figure 2-6 Probe/Arm Tie Wraps
Tie Wraps
For non CTS units, remove the cardboard boxes under the sample arm. (See Figure 2-7 "TOP
Sample Arm Packing".)
Remove the shipping bracket from the sample arm. (See Figure 2-7 "TOP Sample Arm Packing".)
Carefully remove the tie wraps around the probe and arm. (See Figure 2-7 "TOP Sample Arm
Packing".)

Figure 2-7 TOP Sample Arm Packing

Tie Wrap
Shipping
Bracket
Cardboard
Support for
Arm
For TOP CTS units remove the cardboard support boxes under the CTS arm (See.Figure 2-8 "CTS
Internal Packing Material")
Figure 2-8 CTS Internal Packing Material
Cardboard
Support Boxes

Carefully remove the tie wraps around the CTS Piercer/Probe assembly. (See Figure 2-9 "CTS
Assy. tie wraps")
Figure 2-9 CTS Assy. tie wraps
Tie Wrap Shipping

Bracket
Tie Wrap
Remove the shipping bracket from the CTS arm. (See Figure 2-10 "CTS Shipping Brackets")
Figure 2-10 CTS Shipping Brackets
Shipping
Bracket
Remove the interior covers.

Chapter 2 Pre-Installation and Installation 2 - 11
Cut and remove the nylon tie wrap from around the shuttle (see Figure 2-11 "Shuttle tie wraps").
Figure 2-11 Shuttle tie wraps
Loosen the shuttle shipping and alignment tool and slide it out of the shuttle and into its normal stor-
age position.
Install the monitor arm support to the left side mounting studs and install the monitor on the arm
(See Figure 2-12 "Monitor Arm Mounting Studs").
Figure 2-12 Monitor Arm Mounting Studs
Monitor Arm
Mounting Studs

Connect the monitor, keyboard and mouse as shown on Figure 2-13 "Computer/Monitor Con-
nections".
Figure 2-13 Computer/Monitor Connections
Power
Keyboard
Sound Touchscreen
Touchscreen Monitor
Mouse
Sound
Monitor
Install the correct fuses ( 2 required) into the fuse holder (5 Amp for 220VAC and 10 Amp for 110
VAC).
Install the waste presence sensor assembly (00028762900) onto the waste bottle. Connect the
waste presence sensor signal cable. Connect tubing bulkhead connector to the instrument.
Insert the clean bottle aspirator (00028713200) into the clean bottle. Place the bottle on to the sys-
tem and connect the bulkhead connector.
Insert the rinse bottle aspirator (00028713400) into the clean bottle. Place the bottle on to the sys-
tem and connect the bulkhead connector.
Close both sample and reagent doors, boot up the Command module and power up the Analytical
module. Log in using the password provided at training session. The instrument initializes and goes
to Adjusting Thermal and then to Ready.
Enter the diagnostic mode and Initialize and perform the coordinate adjustment for each arm (see
Probe Alignment and Coordinates Adjustment in Chapter 8).
Initialize the Loader and Cuvette Shuttle (see Initialize Shuttle Button in Chapter 9 and Ini-
tialize Loader in Chapter 9).
Check and adjust the Cuvette shuttle alignments (see Cuvette Shuttle Alignment Check in
Chapter 9).
Reinstall and close all of the covers and blank the Optical Reading Unit (ORU) with air and factor
diluent (PN 9757600). Refer to Optical Blanking in Chapter 10 for specific instructions on how
to blank the ORU.
Exit diagnostics and allow the system to initialize and stabilize the temperatures normally.
Observe while the customer calibrates and runs at least one chromagenic and one coagulation test.

2-4 Software Verification
Software Version Verification

Software version display is provided on the ACL-TOP system display by clinking on System -> Instrument
Status as shown on Figure 2-14 "System Software Versions Display Selection".
Figure 2-14 System Software Versions Display Selection
Clicking on the Software Version tab in the resulting screen display lists the present version of all installed
software as shown in Figure 2-15 "Software Version Area of Diagnostic Screen"
Figure 2-15 Software Version Area of Diagnostic Screen

Touch Screen Calibration

Touch Screen Calibration can be done by one of two methods.
The first method is to use the shortcut on the windows desktop, select Align and follow the
prompts.
The second method, if the short cut is missing, is Start->Settings->Control Panel->Select Elo,
click on Align and follow the prompts.
Ghost Image Verification

The Ghost Image procedure creates an image of the entire Control Module hard drive content including
Windows 2000 and all ACL-Top application software. This image must be created any time there is a major
system upgrade or during PM and can be used to restore the CM computer to its condition at the time of the
ghost Image generation.
NOTE: It is highly recommended that Medical Grade Media be used to store the
image created by this procedure. Always store the media according to manufac-
tures specifications.
Per the Symantec Ghost license agreement, this tool may only be used on ONE CM PC for each CM
Recovery Kit obtained from IL.
NOTE: Read through this entire process before beginning. Be sure to read each
step fully before executing.
1. Click on Start -> Shutdown ->Shutdown -> OK to power off the computer (if it is not already shutdown).
2. Turn on the CM computer and immediately insert the Symantec Ghost Boot CD into the CD/DVD Drive.
3. Select OK in the Ghost message box.
4. In the Ghost application, select Local Partition To Image
5. When the Select local source drive by clicking on the drive number window is displayed, select
the correct drive (only one should be available), and select OK.
6. When the Select source partition(s) from Basic drive: 1 window is displayed, select the correct par-
tition (only one should be available), and select OK.
7. The File name to copy image to window is displayed.
8. Insert a blank CD-R into the CD Drive.
NOTE: If the CM has a DVD R/RW Drive, the door of the drive will have DVD R/
RW label, then a DVD-R may be used to create the image.
9. Select the CD/DVD Drive (@CD-R1. DVD Drive) from the Look in: dropdown list, and then select
Save
10. A message box is displayed asking to compress the image. Select High.
11. A message box is displayed asking to copy a bootable floppy to the CD/DVD disc. Select NO.
12. A message box is displayed asking to proceed. It also provides an estimate of the number of CDs or
DVDs that are needed to store the image, although the estimate is usually very high. Select Yes.

13. A warning message about spanned NTFS images is displayed. Select Yes.
14. The image starts to be created, and a progress bar is displayed indicating how long it will take the
image to be created.
15. If more than one CD/DVD is necessary to save the image file, a prompt is displayed requiring another
blank CD/DVD to be inserted.
16. Label each CD/DVD with the name of the CM computer, the number of the CD/DVD used, and the
date.
17. After completion of the Ghost image, it must be verified for correct content. In the Ghost application,
select Local Check Image File.
18. Insert the Ghost image CD/DVD (Disk 1 if there are multiple discs) into the CD/DVD Drive.
19. Select the CD/DVD Drive (@CD-R1) from the Look In dropdown menu, and click on Open.
20. A message box is displayed asking to proceed with the image file integrity check. Select Yes and the
verification process begins. A progress indicator is displayed showing what percentage of the validation
has been completed.
NOTE: If more than one CD/DVD is required to store the image file, a prompt is
displayed to insert the next CD/DVD at the appropriate time.
21. When the validation has completed successfully, a message box is displayed, Image file passed
integrity check. Click on Continue.
22. If the integrity check fails, the Ghost Image procedure must be re initiated using high-quality media. If it
fails again, contact technical support.
23. Exit Ghost by selecting Quit from the menu, remove the CD/DVD, and restart the computer.
24. Provide the CD/DVD(s), labeled as stated in step 16, to the Lab Supervisor for proper storage.

2-5 Pre-Installation Checklist
The Pre-Installation Checklist is used at the service office to verify operation prior to installation at the end
users' site under the following circumstances:
New shippers have been used
A demo is scheduled
Previous units have sustained damage in shipment
Units have Installation failures

ACL TOP Pre - Installation Checklist

Serial Number:__________________________Date Received:___________________________
Inspected By: __________________________ Date Inspected:___________________________
Set configurations as necessary. Refer to ACL TOP Service Manual. Check overall instrument appearance.
Test Action to Check / Perform Pass/Adjust/ Check

Number
1 Check Start Up kit for completeness.
2 Check Computer for damage and for proper operation.
3 Check Touch Screen for damage and for proper operation.
4 Check Keyboard and Mouse for proper operation.
5 Check Software Version in Status Screen
6 Check Cuvette Loader / Shuttle movement / Accumulator via Diagnostics
7 Perform Arm Coordinate in Diagnostics
8 Check Liquid Level Detection (LLD) in Diagnostics
9 Check sample / diluent / Reagent racks for ease of Insertion.
10 Check Barcode movement.
11 Check Magnetic Stirrer Bar Rotation.
12 Perform Air / Factor diluent Blanking via Diagnostics.
13 Check Voltages via Diagnostics.
14 Check Temperatures via Status Screen.
15 Check Sensors via Diagnostics.
16 Check Barcode Reader using Customer Sample Labels.
17 Check Waste Line Efficiency by Running Waste Pump in Diagnostics.
18 Check Rinse / Clean Solution Line Efficiency.
19 * Verify Air Pressure Maintains Pressure
20 * Perform 25 Switches of Loop Test in Diagnostics
21 * Perform Brake Test in Diagnostics
22 * Run Open and Closed Tubes in all S1, S6, and S12 positions
23 Calibration (PT / Fib)
24 Analytical Test (PT / Fib)
25* Check Piercing of Customer Sample Tubes. (CTS Units Only)
* CTS Units Only

2-6 Start Up Kit Contents
28623500 KIT START-UP,ACL TOP

Component Description Quantity
5575100 CUP SAMPLE 2 ML, 1000/PK 1
9746606 MAGNETIC, STIR BARS, ACL 6/PK 1
28713400 ASSY, 4L RINSE, ASPIRATOR, ACL TOP 1
28713200 ASSY, CLEAN ASPIRATOR, ACL TOP 1
18902000 BOTTLE, PLASTIC 30ML W/ CAP, FUTURA/ADVANCE 1
9831704 CLEANING AGENT, ACL, 4X500 ML 0.25
9832700 Critical Care/HemosIL CLEANING AGENT80ML 1
14871705 FUSE, 2.0AMP 250 VOLT, 682 5
14871713 FUSE 12.5A 250V 5x20MM TLAG 5
14871708 FUSE 4A 250V 5x20MM TLAG 5
14871711 FUSE 8A 250V 5x20MM TLAG 5
29400100 CUVETTES, ACL TOP, 6X100X4 1
28739800 SYRINGE, 250UL FOR XP3000 PUMP 3
28911600 SEAL (TIP), 250 UL SYRINGE 6
18924100 BOTTLE, GLASS, 10/PK, ACL FUTURA/ADVANCE 1
18924104 BOTTLE KIT, 10X4 ML 1
19006300 TOOL, STYLET, ACL FUTURA/ADVANCE 1
29400501 SAMPLE RACK SET 01-12, ACL TOP 1
29400711 ACL TOP DILUENT RACK SET DA-DC 1
29400601 RACK SET REAGENT, RA-RF ACL TOP 1
20009700 HEMOSIL RINSE SOLUTION, 4 LITER 1
28520500 ADAPTER FOR 4 ML VIAL ACL TOP 12
28520900 ADAPTER 10 ML VIAL, ACL TOP 12
18794300 TOOL, SYRINGE TIP INSTALLATION, ACL FUTURA/ADVANCE 1
28741600 ASSY, PUMP/PROBE TUBE 3
27764900 CABLE ASSY CAT5E CROSSOVER 1
14871709 FUSE 5A 250V 682 5
14871702 FUSE 1.25A 250V 5x20MM TLAG 5
27540300 CORD, POWER 115VAC, 15A SHIELDED 3
19725500 VDE APPROVED LINE CORD 220V 3
29401100 CUVETTE WASTE LINER 10 PK, ACL TOP 1
28525200 BARCODE SHEET, SOLUTIONS ACL TOP 1
28771800 ASSY WASTE BOTTLE PRESENCE SENSOR 1
18901300 BOTTLE, WASTE 10L, ACL FUTURA 1
14871712 FUSE 10A 250V 5x20MM TLAG 5
19085463 VIAL GLASS 8-PK 20ML 1
28525100 START-UP, ALIQUOT SET 1
28766600 CONTAINER, 10L WASTE BOTTLE 1
29240902 KIT SOFTWARE ACL V2.1/P4.6 INSTALL 1
9757600 DILUENT, FACTOR, 1X100ML 1
28780200 TRAY 6 SAMPLE RACKS ACL TOP 1 PCS 1
28526000 ADAPTER, DILUENT, 4ML, ACL-TOP 6

28760500 TUBE, WASTE PUMP ASSY, WASTE 3

29411100 CUSTOMER NOTICE WASTE CONT DECONTAMINATE 1
28470400 L-KEY WRENCH SET, METRIC 1.5MM TO 5.0MM 1
28001500 DOC., ACL TOP PHASE 1 VALUE ASSIGNMANT 1
28210900 KIT, 2D BARCODE ACL TOP 1
29242300 KIT, ACL TOP LANGUAGE TRANSLATION 1
28119500 SPEC. PRECISION PERFORMANCE REQUIREMENT ACL TOP 1
28623520 KIT START-UP,ACL TOP CTS

Component Description Quantity
5575100 CUP SAMPLE 2 ML, 1000/PK 1
9746606 MAGNETIC, STIR BARS, ACL 6/PK 1
28713400 ASSY, 4L RINSE, ASPIRATOR, ACL TOP 1
28713200 ASSY, CLEAN ASPIRATOR, ACL TOP 1
18902000 BOTTLE, PLASTIC 30ML W/ CAP, FUTURA/ADVANCE 1
9831704 CLEANING AGENT, ACL, 4X500 ML 0.25
9832700 Critical Care/HemosIL CLEANING AGENT80ML 1
14871705 FUSE, 2.0AMP 250 VOLT, 682 5
14871713 FUSE 12.5A 250V 5x20MM TLAG 5
14871708 FUSE 4A 250V 5x20MM TLAG 5
14871711 FUSE 8A 250V 5x20MM TLAG 5
29400100 CUVETTES, ACL TOP, 6X100X4 1
28739800 SYRINGE, 250UL FOR XP3000 PUMP 3
28911600 SEAL (TIP), 250 UL SYRINGE 6
18924100 BOTTLE, GLASS, 10/PK, ACL FUTURA/ADVANCE 1
18924104 BOTTLE KIT, 10X4 ML 1
19006300 TOOL, STYLET, ACL FUTURA/ADVANCE 1
29400501 SAMPLE RACK SET 01-12, ACL TOP 1
29400711 ACL TOP DILUENT RACK SET DA-DC 1
29400601 RACK SET REAGENT, RA-RF ACL TOP 1
20009700 HEMOSIL RINSE SOLUTION, 4 LITER 1
28520500 ADAPTER FOR 4 ML VIAL ACL TOP 12
28520900 ADAPTER 10 ML VIAL, ACL TOP 12
18794300 TOOL, SYRINGE TIP INSTALLATION,FUTURA /ADVANCE 1
27764900 CABLE ASSY CAT5E CROSSOVER 1
14871709 FUSE 5A 250V 682 5
14871702 FUSE 1.25A 250V 5x20MM TLAG 5
27540300 CORD, POWER 115VAC, 15A SHIELDED 3
19725500 VDE APPROVED LINE CORD 220V 3
29401100 CUVETTE WASTE LINER 10 PK, ACL TOP 1
28525200 BARCODE SHEET, SOLUTIONS ACL TOP 1
28771800 ASSY WASTE BOTTLE PRESENCE SENSOR 1
18901300 BOTTLE, WASTE 10L, ACL FUTURA 1
14871712 FUSE 10A 250V 5x20MM TLAG 5
19085463 VIAL GLASS 8-PK 20ML 1
28525100 START-UP, ALIQUOT SET 1
28766600 CONTAINER, 10L WASTE BOTTLE 1
9757600 DILUENT, FACTOR, 1X100ML 1

28780200 TRAY 6 SAMPLE RACKS ACL TOP 1 PCS 1

28760500 TUBE, WASTE PUMP ASSY, WASTE 3
28366800 FILTER, MOLDED 12
28666400 PIERCER PROBE, CTS 1
28660102 CRU, SAMPLE PROBE N SEAL 1
28470400 L-KEY WRENCH SET, METRIC 1.5MM TO 5.0MM 1
29315200 TUBE ASSY, PRECISION, UNIV. 3
29400901 SAMPLE RACK SET 01-12, ACL CTS 1
28386300 ASSY, FILTER CHANGER, CTS 1
28529400 ASSY, CTS TUBE ADAPTER 1
28210900 KIT, 2D BARCODE ACL TOP 1
29411100 CUSTOMER NOTICE WASTE CONTAINER DECONTAMINATION 1
29240920 KIT, ACL TOP V2.5.5 MAIN SYSTEM SOFTWARE INSTALLATION 1

Chapter 3 Troubleshooting 3-1
Chapter 3
Troubleshooting
3-1 Overview
The troubleshooting chapter provides information on troubleshooting resources the ACL TOP software pro-
vides to the field engineer and end user located under the menu tool bar. The information contained in this
chapter is intended for use by IL authorized personnel only.
Alarm Messages
In normal mode, the user is notified of alarm messages via Alarm Buttons on the status bar of the ACL
TOP. screens. The system notifies the user of new alarm messages in the following ways:
A blinking red or yellow exclamation point appears within the alarm button category on the status
bar
The system provides an audible beep
The ACL TOP produces two types of alarm messages:
Warning
Error
Message Windows are displayed as pop-up windows when information needs to be conveyed to the oper-
ator or operator intervention is required.
Alarm messages can be either warning-level or error-level.
Warning-Level Alarm Messages
This type of alarm message indicates that some user action may be required. Warnings do not affect the
operation of the instrument. However, an error condition may eventually occur if the operator does not per-
form the required action.
To view an Alarm Message:
Click the alarm button at the bottom of the screen for the specific type of alarm desired and open
that Alarm window. A list of all archived alarm messages can also be viewed by selecting System
-> General.
Warning-level alarms are indicated by a yellow exclamation point on the alarm button, for example:

3 - 2 Chapter 3 Troubleshooting
Error-Level Alarm Messages
This type of alarm message indicates that a condition has been detected that requires immediate action.
Failure to act may result in the instrument performing an Emergency Stop.
Error-level alarms display a red exclamation point on the alarm button, for example:
When the button is enabled but has no exclamation point superimposed over it there are no new alarms, for
example:
The following alarm buttons appear on the status bar:

Alarm Button Alarm Name Description
Materials Alarms related to the availability of materials on board the AM. This button is
displayed with the warning symbol.
Job Frequency Alarms related to the ability of the analyzer to complete a test. For example,
the materials to run a test may not be availible on the instrument. This button is
displayed with the error symbol.
Quality Control Alarms related to the Quality Control functionality.
Maintenance Alarms that indicate a maintenance operation must be performed. This button
is displayed without an exclamation point, indicating no new messages.
Analyzer Alarms related to the AM functionality.
LIS Alarms related to the host connection.

3-2 System Selections
Maintenance
The Maintenance screen is accessed under "System" on the menu tool bar or using the icon of the book in
the lower right hand side of the tray area. See Figure 3-1 Maintenance Selection
Figure 3-1 Maintenance Selection
The Maintenance screen is used to perform various maintenance tasks. Place a check mark next to the
desired maintenance activity. Click the Perform icon and enter a comment in the Comment dialog box if
appropriate. Click OK. Refer to the On Line Help for a detailed description of the Maintenance screen. See
Figure 3-2 "The Maintenance Screen".

Figure 3-2 The Maintenance Screen

General Log List

The General Log List is accessed under "System" on the menu tool bar or using the icon of the book in the
lower right hand side of the tray area. See Figure 3-3 "General Log List Selection"
Figure 3-3 General Log List Selection
The General Log contains system information including alarms, errors, warnings, and instrument mode
changes. Each line includes the associated date/time they occurred, functional area affected, user logged
in, and a brief description. Reviewed sequentially the general log can provide an account of recent events.
See Figure 3-4 "General Log List".

Figure 3-4 General Log List

Double clicking on an error brings up the General Log Detail pop up screen. This pop up screen contains tabs with detailed descriptions, causes, and operator actions
to correct the error as well as a tab for the end user to leave comments. See Figure 3-5 "General Log Entry Details".
Note: On occasion, additional information on a particular error is requested. In that event the Error code, File name and Line Number should be sent to the Software
Department of Instrumentation Laboratory per normal procedures.
Figure 3-5 General Log Entry Details

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

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

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

Chapter 3 Troubleshooting 3 - 11
Statistics
Selecting Statistics from the pull down brings up another two tab screen Status and Alarms.(see Figure 3-
9 "Statistics").
Figure 3-9 Statistics

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

Alarms Tab
The Alarms Tab lists all of the alarms the instrument has experienced as well of the percentage each alarm
accounts for as part of the total (see Figure 3-11 "Alarms Tab on Statistics Screen"). This tab can be
reset to restart monitoring.
Figure 3-11 Alarms Tab on Statistics Screen
3-3 Alarm List
The tables below represents a partial list of error codes. The errors listed are beyond the expertise of the
operator to resolve and require service resolution. The common service resolutions are listed with the error
code in the column titled Service Action.
Error codes for alarms resolvable at the operator level can be found in the Online Help .
NOTE: The Alarm List is sorted in ascending order by Error Code Number.

Alarm/ Alarm Description Code Message Cause Operator Action Service Action Service System Where
Error Manual Response raised
Name Section
DB down The database service An unrecoverable The database ser- Start SQL service. 1) Start SQL Server, Processor/ Perform an CM
is down and it is not data base excep- vice got discon- Start CM applica- 2) Restart CM Software emergency stop
accessible. tion has occurred. nected. tion. and shutdown
the application.
AM-CM A non-recoverable 0 Analyzer / Control Communication Check communica- Check cross over cable, Processor/ - Notify the AM Mas-
Communi- error occurred in the Module loss of cable disconnection cable. bulk head connector, Software alarm via the UI ter
cation CM/AM Communica- communication. tion. Software or Power off and and Level II CPU PCB. - Perform an CM
Error tions Manager (e.g. electronic failure. restart the instru- emergency stop
loss of connection). ment.
If the problem per-
sists, call Service.
Program Failure of LRC or CRC 0005 Master controller Master controller Power off and Check level II CPU, PC Processor/ - Notify the AM Mas-
Integrity check. failure. board malfunction. restart the instru- 104 and all computor Software alarm via the UI ter
(Failure): ment. housing connections. - Perform an
master If the problem per- emergency stop
sists, call Service.
(Proces- One of the AM proces- 0008 Sample Arm con- Sample Arm con- Power off and This is a software defect. Processor/ - Notify the AM Con-
sor) Initial- sors failed to initialize, troller initialization troller board did not restart the instru- Please obtain the log Software alarm via the UI trollers
ization due to an Invalid Con- failure. pass initialization ment. files / backups and sub- (if possible)
(Failure): troller ID. tests. If the problem per- mit a complaint into the - Do not go to
Sample sists, call Service. complaint system for READY state
Arm immediate attention.
(Proces- One of the AM proces- 0009 Intermediate Intermediate Power off and This is a software defect. Processor/ - Notify the AM Con-
sor) Initial- sors failed to initialize, Reagent Arm con- Reagent Arm con- restart the instru- Please obtain the log Software alarm via the UI trollers
ization due to an Invalid Con- troller initialization troller board did not ment. files / backups and sub- (if possible)
(Failure): troller ID. failure. pass initialization If the problem per- mit a complaint into the - Do not go to
Intermedi- tests. sists, call Service. complaint system for READY state
ate immediate attention.
Reagent
Arm

Name Section
(Proces- One of the AM proces- 0010 Start Reagent Arm Start Reagent Arm Power off and This is a software defect. Processor/ - Notify the AM Con-
sor) Initial- sors failed to initialize, controller initializa- controller board did restart the instru- Please obtain the log Software alarm via the UI trollers
ization due to an Invalid Con- tion failure. not pass initializa- ment. files / backups and sub- (if possible)
(Failure): troller ID. tion tests. If the problem per- mit a complaint into the - Do not go to
Start sists, call Service. complaint system for READY state
Reagent immediate attention.
Arm
(Proces- One of the AM proces- 0011 Cuvettes controller Cuvettes controller Power off and This is a software defect. Processor/ - Notify the AM Con-
sor) Initial- sors failed to initialize, initialization failure. board did not pass restart the instru- Please obtain the log Software alarm via the UI trollers
ization due to an Invalid Con- initialization tests. ment. files / backups and sub- (if possible)
(Failure): troller ID. If the problem per-mit a complaint into the - Do not go to
cuvette complaint system for
sists, call Service. READY state
immediate attention.
(Proces- One of the AM proces- 0012 Racks controller ini- Racks controller Power off and This is a software defect. Processor/ - Notify the AM Con-
sor) Initial- sors failed to initialize, tialization failure. board did not pass restart the instru- Please obtain the log Software alarm via the UI trollers
ization due to an Invalid Con- initialization tests. ment. files / backups and sub- (if possible)
(Failure): troller ID. If the problem per- mit a complaint into the - Do not go to
rack sists, call Service. complaint system for READY state
(Proces- One of the AM proces- 0013 Optical Reading Optical Reading Power off and This is a software defect. Processor/ - Notify the AM Con-
sor) Initial- sors failed to initialize, Units controller ini- Units controller restart the instru- Please obtain the log Software alarm via the UI trollers
ization due to an Invalid Con- tialization failure. board did not pass ment. files / backups and sub- (if possible)
(Failure): troller ID. initialization tests. If the problem per- mit a complaint into the - Do not go to
ORU sists, call Service. complaint system for READY state
Invalid Invalid parameter pro- 0015 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: master message queue or detected an unre- ment. files / backups and sub- - Perform an AM Con-
inter-task communica- coverable error. If the problem per- mit a complaint into the emergency stop trollers
tion mechanism. sists, call Service. complaint system for

Name Section
Invalid Invalid parameter pro- 0016 Cuvettes Control- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, ler software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: cuvette message queue or detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid parameter pro- 0017 Racks Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: rack message queue or detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid parameter pro- 0018 Optical Reading Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, Units Controller the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: ORU message queue or software error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid parameter pro- 0019 Sample Arm Con- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, troller software the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: Sample message queue or error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Arm inter-task communica- coverable error. If the problem per- mit a complaint into the emergency stop trollers
CTRL A non-recoverable 0020 Analyzer internal Built-in checks in Power off and Check Level II CPU, Processor/ - Notify the AM Mas-
Comm error occurred in the communication the software restart the instru- PC104, ALL controller Software alarm via the UI ter
Error Controller Communica- error. detected an unre- ment. PCBs and all software - Perform an AM Con-
tions Manager or the coverable error. If the problem per- revisions. emergency stop trollers
low level CAN bus sists, call Service.
driver (master or con-
troller side).

Name Section
Invalid Invalid parameter pro- 0021 Intermediate Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, Reagent Arm Con- the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: Inter- message queue or troller software detected an unre- ment. files / backups and sub- - Perform an AM Con-
mediate inter-task communica- error. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Reagent tion mechanism. sists, call Service. complaint system for
Invalid Invalid parameter pro- 0022 Start Reagent Arm Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Parame- vided in a function call, Controller software the software restart the instru- Please obtain the log Software alarm via the UI ter
ter: Start message queue or error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Reagent inter-task communica- coverable error. If the problem per- mit a complaint into the emergency stop trollers
Arm tion mechanism. sists, call Service. complaint system for
Memory Memory allocation 0025 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Allocation failed or stack usage software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
(Failure): exceeds limit. detected an unre- ment. files / backups and sub- - Perform an AM Con-
master coverable error. If the problem per- mit a complaint into the emergency stop trollers
sists, call Service. complaint system for
OS (Fail- Error detected when 0030 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): mas- calling kernel facilities. software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ter detected an unre- ment. files / backups and sub- - Perform an AM Con-
coverable error. If the problem per- mit a complaint into the emergency stop trollers
OS (Fail- Error detected when 0031 Cuvettes Control- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): calling kernel facilities. ler software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
cuvette detected an unre- ment. files / backups and sub- - Perform an AM Con-

Name Section
OS (Fail- Error detected when 0032 Racks Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): rack calling kernel facilities. software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
detected an unre- ment. files / backups and sub- - Perform an AM Con-
OS (Fail- Error detected when 0033 Optical Reading Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): ORU calling kernel facilities. Units Controller the software restart the instru- Please obtain the log Software alarm via the UI ter
software error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Software Software logic error 0035 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): mas- in a switch statement detected an unre- ment. files / backups and sub- - Perform an AM Con-
ter or if else branch. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Software Software logic error 0036 Cuvettes Control- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path ler software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): in a switch statement detected an unre- ment. files / backups and sub- - Perform an AM Con-
cuvette or if else branch. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Software Software logic error 0037 Racks Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): rack in a switch statement detected an unre- ment. files / backups and sub- - Perform an AM Con-
or if else branch. coverable error. If the problem per- mit a complaint into the emergency stop trollers

Name Section
Software Software logic error 0038 Optical Reading Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path Units Controller the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): ORU in a switch statement software error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
or if else branch. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Invalid Invalid state for an 0040 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: mas- event, function call, software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
ter message, etc. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid state for an 0041 Cuvettes Control- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: event, function call, ler software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
cuvette message, etc. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid state for an 0042 Racks Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: rack event, function call, software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
message, etc. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid state for an 0043 Optical Reading Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: ORU event, function call, Units Controller the software restart the instru- Please obtain the log Software alarm via the UI ter
message, etc. software error. detected an unre- ment. files / backups and sub- - Perform an AM Con-

Name Section
Stack Low: It was detected that 0045 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
master there is a potential for a software error. the software restart the instru- Please obtain the log Software alarm via the UI trollers
stack problem. detected an unre- ment. files / backups and sub- - Perform an
coverable error. If the problem per- mit a complaint into the emergency stop
Stack Low: It was detected that 0046 Cuvettes Control- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
cuvette there is a potential for a ler software error. the software restart the instru- Please obtain the log Software alarm via the UI trollers
Stack Low: It was detected that 0047 Racks Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
rack there is a potential for a software error. the software restart the instru- Please obtain the log Software alarm via the UI trollers
Stack Low: It was detected that 0048 Optical Reading Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
ORU there is a potential for a Units Controller the software restart the instru- Please obtain the log Software alarm via the UI trollers
stack problem. software error. detected an unre- ment. files / backups and sub- - Perform an
Unknown The command 0050 Master Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: ported. detected an unre- ment. files / backups and sub- - Perform an AM Con-
master coverable error. If the problem per- mit a complaint into the emergency stop trollers

Name Section
Unknown The command 0051 Cuvettes Control- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- ler software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: ported. detected an unre- ment. files / backups and sub- - Perform an AM Con-
cuvette coverable error. If the problem per- mit a complaint into the emergency stop trollers
Unknown The command 0052 Racks Controller Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- software error. the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: rack ported. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Unknown The command 0053 Optical Reading Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- Units Controller the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: ported. software error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
ORU coverable error. If the problem per- mit a complaint into the emergency stop trollers
AM Dis- The CM has lost the 0056 Interrupted commu- Communication Check communica- Check Level II CPU, Processor/ - Notify the user CM
connection connection with the AM nication between cable discon- tion cable connec- cross over cable, CM Software as appropriate.
module. the Analyzer and nected. Analyzer tion. Verify that the and connections. - The AM on its
the Control Module. powered off. Other Analyzer is pow- side performs
hardware/software ered on. Restart the an emergency
communication system (both Ana- stop
problems. lyzer and Control
Module); if the
problem persist call
Service.

Name Section
Controller Controller Upgrade has 0058 Downloaded con- Controller Upgrade Call Service. Verify software versions Processor/ - Notify user CM
Upgrade failed since down- troller Software ver- has failed. and controller card flash Software through alarms
Failed loaded SW version sion (<Downloaded version. Controller flash area.
does not match SW File Name>) is dif- version may not be com-
version actually used. ferent than Soft- patible.
ware version
actually used by
AM (<Used File
Name>).
OS (Fail- Error detected when 0061 Sample Arm Con- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): Sam- calling kernel facilities. troller software the software restart the instru- Please obtain the log Software alarm via the UI ter
ple Arm error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
OS (Fail- Error detected when 0062 Intermediate Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): Inter- calling kernel facilities. Reagent Arm Con- the software restart the instru- Please obtain the log Software alarm via the UI ter
mediate troller software detected an unre- ment. files / backups and sub- - Perform an AM Con-
Reagent error. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Arm sists, call Service. complaint system for
OS (Fail- Error detected when 0063 Start Reagent Arm Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
ure): Start calling kernel facilities. Controller software the software restart the instru- Please obtain the log Software alarm via the UI ter
Reagent error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Arm coverable error. If the problem per- mit a complaint into the emergency stop trollers
Software Software logic error 0066 Sample Arm Con- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path troller software the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): Sam- in a switch statement error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
ple Arm or if else branch. coverable error. If the problem per- mit a complaint into the emergency stop trollers

Name Section
Software Software logic error 0067 Intermediate Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path Reagent Arm Con- the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): Inter- in a switch statement troller software detected an unre- ment. files / backups and sub- - Perform an AM Con-
mediate or if else branch. error. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Reagent sists, call Service. complaint system for
Software Software logic error 0068 Start Reagent Arm Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Logic (Fail- such as an invalid path Controller software the software restart the instru- Please obtain the log Software alarm via the UI ter
ure): Start in a switch statement error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Reagent or if else branch. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Invalid Invalid state for an 0071 Sample Arm Con- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: event, function call, troller software the software restart the instru- Please obtain the log Software alarm via the UI ter
Sample message, etc. error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Invalid Invalid state for an 0072 Intermediate Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: event, function call, Reagent Arm Con- the software restart the instru- Please obtain the log Software alarm via the UI ter
Intermedi- message, etc. troller software detected an unre- ment. files / backups and sub- - Perform an AM Con-
ate error. coverable error. If the problem per- mit a complaint into the emergency stop trollers
Invalid Invalid state for an 0073 Start Reagent Arm Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
State: Start event, function call, Controller software the software restart the instru- Please obtain the log Software alarm via the UI ter
Reagent message, etc. error. detected an unre- ment. files / backups and sub- - Perform an AM Con-

Name Section
Stack Low: It was detected that 0076 Sample Arm Con- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
Sample there is a potential for a troller software the software restart the instru- Please obtain the log Software alarm via the UI trollers
Arm stack problem. error. detected an unre- ment. files / backups and sub- - Perform an
Stack Low: It was detected that 0077 Intermediate Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
Intermedi- there is a potential for a Reagent Arm Con- the software restart the instru- Please obtain the log Software alarm via the UI trollers
ate stack problem. troller software detected an unre- ment. files / backups and sub- - Perform an
Reagent error. coverable error. If the problem per- mit a complaint into the emergency stop
Stack Low: It was detected that 0078 Start Reagent Arm Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Con-
Start there is a potential for a Controller software the software restart the instru- Please obtain the log Software alarm via the UI trollers
Reagent stack problem. error. detected an unre- ment. files / backups and sub- - Perform an
Arm coverable error. If the problem per- mit a complaint into the emergency stop
Unknown The command 0081 Sample Arm Con- Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- troller software the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: ported. error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Sample coverable error. If the problem per- mit a complaint into the emergency stop trollers
Unknown The command 0082 Intermediate Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- Reagent Arm Con- the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: ported. troller software detected an unre- ment. files / backups and sub- - Perform an AM Con-
Intermedi- error. coverable error. If the problem per- mit a complaint into the emergency stop trollers
ate sists, call Service. complaint system for
Reagent immediate attention.
Arm

Name Section
Unknown The command 0083 Start Reagent Arm Built-in checks in Power off and This is a software defect. Processor/ - Notify the AM Mas-
Com- received is not sup- Controller software the software restart the instru- Please obtain the log Software alarm via the UI ter
mand: ported. error. detected an unre- ment. files / backups and sub- - Perform an AM Con-
Start coverable error. If the problem per- mit a complaint into the emergency stop trollers
Arm The CAVRO arm is 1001 <Arm> Arm failure. Software or The system per- Check all cabling in the Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- Cavro System, CCU 900 XYZ alarm via the UI ter
Fault) - Initialization error. gency stop: and all sensors. - Perform an
ERR 1 perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
(Device inoperable mechanical error. formed an Emer- Cavro System, CCU XYZ alarm via the UI ter
Fault) - Invalid Command. gency stop: 9000 and all sensors - Perform an
ery.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1003 <Arm> Arm failure. Software or The system per- Suspect CCU 9000. Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- XYZ alarm via the UI ter
Fault) - Invalid Operand. gency stop: - Perform an
ery.
If the problem per-
sists call Service.

Name Section
Fault) - Invalid command gency stop: - Perform an
ERR 4 sequence. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
Fault) - Device not imple- gency stop: - Perform an
ERR 5 mented. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1006 <Arm> Arm failure. Software or The system per- Check for loose connec- Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- tions at the cables and XYZ alarm via the UI ter
Fault) - Timeout error. gency stop: sensors. A malfunction- - Perform an
ERR 6 perform a Recov- ing syringe module may emergency stop
ery. also cause this error.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1007 <Arm> Arm failure. Software or The system per- Inspect the CCU 9000 Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- PCB and cabling to it. XYZ alarm via the UI ter
Fault) - Device not initial- gency stop: - Perform an
ERR 7 ized. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.

Name Section
Fault) - Command over- gency stop: - Perform an
ERR 8 flow. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1009 <Arm> Arm failure. Software or The system per- Error may be caused by Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- CCU 900 or more likely XYZ alarm via the UI ter
Fault) - No liquid detected gency stop: the DRI PCB. - Perform an
ERR 9 with ZX command. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
Fault) - Entered move for gency stop: - Perform an
ERR 10 Z-axis out of range. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
(Device inoperable mechanical error. formed an Emer- CCU 900 or, more likely, XYZ alarm via the UI ter
Fault) - Not enough liquid gency stop: the DRI PCB. - Perform an
ERR 11 detected with ZX perform a Recov- emergency stop
command. ery.
If the problem per-
sists call Service.

Name Section
Fault) - No liquid detected gency stop: the DRI PCB. - Perform an
ERR 12 with ZZ command. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
Fault) - Not enough liquid gency stop: the DRI PCB. - Perform an
ERR 13 detected with ZZ perform a Recov- emergency stop
command. ery.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1017 <Arm> Arm failure. Software or The system per- Check Arm Sensors. Robotic - Notify the AM Mas-
Fault) - Arm collision gency stop: - Perform an
ERR 17 avoided. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1020 <Arm> Arm failure. Software or The system per- Check for binding and Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- obstructions. XYZ alarm via the UI ter
Fault) - Step loss on X axis. gency stop: - Perform an
ery.
If the problem per-
sists call Service.

Name Section
Fault) - Step loss on Y axis. gency stop: - Perform an
ery.
If the problem per-
sists call Service.
Fault) - Step loss on Z axis. gency stop: - Perform an
ery.
If the problem per-
sists call Service.
Fault) - Step loss detected gency stop: - Perform an
ERR 23 on X-axis of oppos- perform a Recov- emergency stop
ing arm. ery.
If the problem per-
sists call Service.
Arm The CAVRO arm is 1024 <Arm> Arm failure. Software or The system per- Suspect the aldium or Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- DRI PCB. XYZ alarm via the UI ter
Fault) - ALDIUM pulse time gency stop: - Perform an
ERR 24 out. perform a Recov- emergency stop
ery.
If the problem per-
sists call Service.

Name Section
Arm The CAVRO arm is 1025 <Arm> Arm failure. Software or The system per- Clean probe and check Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- all LLD connections. XYZ alarm via the UI ter
Fault) - Tip not fetched. gency stop: - Perform an
ery.
If the problem per-
sists call Service.
Fault) - Tip crash. gency stop: - Perform an
ery.
If the problem per-
sists call Service.
Fault) - Tip not clean. gency stop: - Perform an
ery.
If the problem per-
sists call Service.
(Device inoperable mechanical error. formed an Emer- Cavro System, CCU 900 XYZ alarm via the UI ter
Fault) - Undefined error gency stop: and all sensors. - Perform an
ERR code reported. perform a Recov- emergency stop
UNDEF ery.
If the problem per-
sists call Service.

Name Section
Arm The CAVRO arm is 1029 <Arm> Arm failure. Software or The system per- Check for loose cable Robotic - Notify the AM Mas-
(Device inoperable mechanical error. formed an Emer- and sensor connections. XYZ alarm via the UI ter
Fault) - Communication gency stop: A malfunctioning sryinge - Perform an
TIME OUT timeout. perform a Recov- module may also cause emergency stop
ery. this error.
If the problem per-
sists call Service.
Syringe The pump used to 1031 <Syringe> Syringe Software or The system per- Initialization error. This Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- error occurs when the Movement alarm via the UI ter
(Fault) - ids is inoperable. Initialization error. gency stop: pump fails to initialize. - Perform an
ERR 1 perform a Recov- Check for blockages and emergency stop
ery. If the problem loose connections
persists call Ser- before attempting to
vice. reinitialize. The pump
will not accept com-
mands until it has been
successfully initialized.
This error can only be
cleared by successfully
initializing the probe.
Syringe The pump used to 1032 <Syringe> Syringe Software or The system per- Invalid command. This Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- error occurs when an Movement alarm via the UI ter
(Fault) - ids is inoperable. Invalid command. gency stop: unrecognized command - Perform an
ERR 2 perform a Recov- is issued. emergency stop
ery. If the problem Either Software defect or
persists call Ser- communication error.
vice.

Name Section
Syringe The pump used to 1033 <Syringe> Syringe Software or The system per- Invalid operand. This Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- error occurs when an Movement alarm via the UI ter
(Fault) - ids is inoperable. Invalid operand. gency stop: invalid parameter (<n>) - Perform an
ERR 3 perform a Recov- is given with a com- emergency stop
ery. If the problem mand.
persists call Ser- Either Software defect or
vice. communication error.
Syringe The pump used to 1034 <Syringe> Syringe Software or The system per- Invalid command Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- sequence. This error Movement alarm via the UI ter
(Fault) - ids is inoperable. Invalid command gency stop: occurs when the com- - Perform an
ERR 4 sequence. perform a Recov- mand structure or com- emergency stop
ery. If the problem munication protocol is
persists call Ser- incorrect.
vice. Either Software defect or
communication error.

Name Section
Syringe Fluid Detection Error. 1035 <Syringe> Syringe The sensor board The system per- Fluid detection. This Fluid - Notify the AM Mas-
Pump This error occurs when failure. detects fluid, which formed an Emer- error occurs when the Movement alarm via the UI ter
(Fault) - the sensor board is caused by leak- gency stop: sensor board detects - Perform an
ERR 5 detects fluid, which is ing out the back of perform a Recov- fluid, which is caused by emergency stop
caused by leaking out the valve. ery. If the problem fluid leaking out of the
the back of the valve. persists call Ser- back of the valve.
vice. To clear the error:
1. Power off the pump
2. Remove the valve
3. Wipe up any detect-
able fluid on sensor
board using a cotton
swab. You can insert the
swab through the valve
opening on the front
panel, and gently wipe
the circuit.
4. Assuming the valve is
leaking fluid, put a new
valve on the pump.
5. Reinitialize the pump
Syringe EEPROM Failure. This 1036 <Syringe> Syringe EEPROM is faulty. The system per- EEPROM Failure. This Fluid - Notify the AM Mas-
Pump error occurs when the failure. formed an Emer- error occurs when the Movement alarm via the UI ter
(Fault) - EEPROM is faulty. gency stop: EEPROM is faulty. - Perform an
ery. If the problem
persists call Ser-
vice.

Name Section
Syringe The pump used to 1037 <Syringe> Syringe Software or The system per- Device not initialized. Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- This error occurs when Movement alarm via the UI ter
(Fault) - ids is inoperable. Device not initial- gency stop: the pump is not initial- - Perform an
ERR 7 ized. perform a Recov- ized or when a command emergency stop
ery. If the problem is sent to the syringe
persists call Ser- when the syringe is in
vice. error status.
To clear the error, reini-
tialize the syringe.
Syringe The pump used to 1039 <Syringe> Syringe Software or The system per- Unrecognized error code Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- has been reported by the Movement alarm via the UI ter
(Fault) - ids is inoperable. Undefined error gency stop: syringe. - Perform an
ERR code reported. perform a Recov- The cause can be a emergency stop
UNDE- ery. If the problem communication error, a
FINED persists call Ser- problem in the syringe or
vice. a defect in software.
Syringe The pump used to 1040 <Syringe> Syringe Software or The system per- Communication timeout Fluid - Notify the AM Mas-
Pump aspirate/dispense flu- failure. mechanical error. formed an Emer- expired. Movement alarm via the UI ter
(Fault) - ids is inoperable. Communication gency stop: This failure can be - Perform an
TIME OUT timeout. perform a Recov- caused by: emergency stop
ery. If the problem 1. a previous error condi-
persists call Ser- tion
vice. 2. a communication fail-
ure between master
board and cavro module
3. A defect in the syringe
that slows down the
syringe operations
ORU Dis- The ORU Head has 1042 The Optical Read- The ORU has been Call Service. See code 1295 Reaction - Notify the AM Mas-
abled - been disabled due to ing Unit <ORU ID> disabled. Air read- Detection alarm via the UI. ter
Cause 2 low air limit. has been disabled. ing out of range
(low).

Name Section
Cause 3 due to a high air limit. has been disabled. ing out of range
(high).
Cause 4 air drift low limit. has been disabled. ing drift (low)
detected.
Cause 5 air drift high limit. has been disabled. ing drift (high)
detected.
ORU Dis- The ORU Head has 1046 The Optical Read- The ORU has been Call Service. Check power cables, Reaction - Notify the AM Mas-
abled - been disabled due to ing Unit <ORU ID> disabled. Detector fuses, and power supply. Detection alarm via the UI. ter
Cause 6 an ORU voltage prob- has been disabled. voltage error If power looks correct,
lem. detected. replace ORU module.
Syringe Plunger Overload. This 1047 <Syringe> Syringe Movement of the The system per- Plunger overload. THis Fluid - Notify the AM Mas-
Pump error occurs when failure. syringe plunger formed an Emer- error occurs when move- Movement alarm via the UI ter
(Fault) - movement of the was blocked by gency stop: ment of the syringe - Perform an
ERR 9 syringe plunger is excessive pres- perform a Recov- plunger is blocked by emergency stop
blocked by excessive sure. ery. If the problem excessive back pres-
pressure. persists call Ser- sure. The pump must be
vice. reinitialized before nor-
mal operation can
resume.

Name Section
Syringe Valve Overload. This 1048 <Syringe> Syringe Valve drive loses The system per- Valve Overload. This Fluid - Notify the AM Mas-
Pump error occurs when the failure. steps by blockage formed an Emer- error occurs when the Movement alarm via the UI ter
(Fault) - valve drive loses steps or excess back gency stop: valve drive loses steps - Perform an
ERR 10 by blockage or excess pressure. perform a Recov- by blockage or excess emergency stop
back pressure. Contin- ery. If the problem back pressure. The
ual valve overload persists call Ser- valve must be reinitial-
errors are an indication vice. ized before normal oper-
the valve should be ation can resume.
replaced. Continual valve overload
errors are an indication
the valve should be
replaced.
Syringe Plunger Move Not 1049 <Syringe> Syringe Plunger Move Not The system per- Plunger Move Not Fluid - Notify the AM Mas-
Pump Allowed. When the failure. Allowed. When the formed an Emer- Allowed. When the valve Movement alarm via the UI ter
(Fault) - valve is in bypass or valve is in bypass gency stop: is in bypass or through- - Perform an
ERR 11 throughput position or throughput posi- perform a Recov- put position plunger emergency stop
plunger movement tion plunger move- ery. If the problem movement commands
commands are not ment commands persists call Ser- are not allowed.
allowed. are not allowed. vice. This error can be caused
by a previous error con-
dition of by a defect in
software.
Syringe Command Overflow. 1050 <Syringe> Syringe Command Over- The system per- Command Overflow. Fluid - Notify the AM Mas-
Pump This error occurs when failure. flow. This error formed an Emer- This error occurs when Movement alarm via the UI ter
(Fault) - the command buffer occurs when the gency stop: the command buffer con- - Perform an
ERR 15 contains too many command buffer perform a Recov- tains too many charac- emergency stop
characters. contains too many ery. If the problem ters.
characters. persists call Ser- This error can be caused
vice. by a previous error con-
dition, a defect in soft-
ware or communication
error.

Name Section
CAVRO RS232 communica- 1105 Arm communica- Software or Hard- Call Service. If consistent, then check Processor/ - Notify the AM Mas-
Comm tions error with CAVRO tion error. ware failure. both cabling and power Software alarm via the UI ter
Error arms to the CAVRO control - Execute an AM Con-
unit board. If the problem emergency stop trollers
is intermittent, then
report a complaint to
record the incidence as
this is a documented
CAVRO problem.
Incubator Incubator temperature 1110 Cuvettes incubator Temperature out of Call Service. The heating wire could Thermal - Notify the
Tempera- defined to be out of No. 1 temperature range in cuvette be broken, the thermistor Control alarm via the UI
ture Error range for a period control failure. incubator. could be shorted, or the - Turn off power
(Incubator exceeding the fatal module could require to affected
#1) error limits. calibration. To help trou- heater.
bleshoot, use Diagnos- - Perform Con-
tics > ORU Tab. If the trolled Stop
temperature is fluctuat-
ing and barely out of
specification, then re-
calibrate. If the tempera-
ture is stuck solid then
the heating wires could
be not connected or bro-
ken. If the temperature is
fluctuating, then the ther-
mistor wires are proba-
bly okay.

Name Section
Incubator Incubator temperature 1111 Cuvettes incubator Temperature out of Call Service. The heating wire could Thermal - Notify the
Tempera- defined to be out of No. 2 temperature range in cuvette be broken, the thermistor Control alarm via the UI
ture Error range for a period control failure. incubator. could be shorted, or the - Turn off power
(Incubator exceeding the fatal module could require to affected
#2) error limits. calibration. To help trou- heater.
bly okay.

Name Section
ORU Tem- ORU temperature 1115 Optical reading unit Temperature out of Call Service. The heating wire could Thermal - Notify the
perature defined to be out of No. 1 temperature range in optical be broken, the thermistor Control alarm via the UI
Error (ORU range for a period control failure. reading unit. could be shorted, or the - Turn off power
#1) exceeding the fatal module could require to affected
error limits. calibration. To help trou- heater.
bly okay.

Name Section
bly okay.

Name Section
bly okay.

Name Section
bly okay.

Name Section
Cuvette Cuvette Shuttle tem- 1120 Cuvette shuttle Cuvette shuttle The system per- The heating wire could Thermal - Notify the
Shuttle perature defined to be temperature control temperature out of formed a controlled be broken, the thermistor Control alarm via the UI
Temp Error out of range for a failure. range. stop: the run has to could be shorted, or the - Turn off power
period exceeding the be re-started. If the module could require to affected
fatal error limits. problem persists calibration. To help trou- heater.
call Service. bleshoot, use Diagnos- - Perform an
tics > Cuvettes Tab. If controlled stop
the temperature is fluctu-
ating and barely out of
bly okay.
Reagent Reagent Area temper- 1125 Reagent area tem- Reagent area tem- The system per- Check the Thermistor for Thermal - Notify the
Temp Error ature defined to be out perature control perature out of formed a controlled open or short. If temp is Control alarm via the UI
of range for a period failure. range. stop: the run has to out high, check the fans - Turn off power
exceeding the fatal be re-started. If the for proper operation and to affected
error limits. problem persists bloackage. heater.
call Service. - Perform a con-
trolled stop
Data Detector interface fault, 1130 Optical reading Built-in checks Call Service. If error is persistent, then Reaction - Notify the AM Con-
Acquisition e.g. conversion did not units data acquisi- detected an error. replace the ORU mod- Detection alarm via the UI trollers
(Fault) complete, emitter light tion control failure. ule. If infrequent, report a - Perform an
source not correct. complaint. emergency stop
CRC CRC Error detected in 1132 Sample Arm con- Sample Arm con- Call Service. Replace the universal Processor/ - Notify the AM Con-
(Error): writing to or reading troller failure. troller board mal- sample arm controller. Software alarm via the UI trollers
Sample from a permanent stor- function. - Perform an
Arm age device (e.g. emergency stop
EEPROM)

Name Section
CRC CRC Error detected in 1133 Intermediate Intermediate Call Service. Replace the universal Processor/ - Notify the AM Con-
(Error): writing to or reading Reagent Arm con- Reagent Arm con- intermediate reagent Software alarm via the UI trollers
Intermedi- from a permanent stor- troller failure. troller board mal- arm controller. - Perform an
ate age device (e.g. function. emergency stop
Reagent EEPROM)
Arm
CRC CRC Error detected in 1134 Start Reagent Arm Start Reagent Arm Call Service. Replace the universal Processor/ - Notify the AM Con-
(Error): writing to or reading controller failure. controller board start reagent arm con- Software alarm via the UI trollers
Start from a permanent stor- malfunction. troller. - Perform an
Reagent age device (e.g. emergency stop
Arm EEPROM)
CRC CRC Error detected in 1135 Cuvettes controller Cuvettes controller Call Service. Replace the cuvette con- Processor/ - Notify the AM Con-
(Error): writing to or reading failure. board malfunction. troller. Execute thermal Software alarm via the UI trollers
cuvette from a permanent stor- calibration for the - Perform an
age device (e.g. cuvette areas. emergency stop
EEPROM)
CRC CRC Error detected in 1136 Racks controller Racks controller Call Service. Replace the rack control- Processor/ - Notify the AM Con-
(Error): writing to or reading failure. board malfunction. ler. Execute thermal cali- Software alarm via the UI trollers
rack from a permanent stor- bration for the cuvette - Perform an
age device (e.g. areas. emergency stop
EEPROM)
CRC CRC Error detected in 1137 Optical Reading Optical Reading Call Service. Replace the ORU con- Processor/ - Notify the AM Con-
(Error): writing to or reading Units controller fail- Units controller troller. Execute thermal Software alarm via the UI trollers
ORU from a permanent stor- ure. board malfunction. calibration for the - Perform an
age device (e.g. cuvette areas. emergency stop
EEPROM)
Storage Error detected in 1140 Cuvettes controller Cuvettes controller Call Service. Refer to 1135. Processor/ - Notify the AM Con-
Write updating data on a per- failure. board malfunction. Software alarm via the UI trollers
(Fault): manent storage device - Perform an
cuvette (e.g. EEPROM) emergency stop
Storage Error detected in 1141 Racks controller Racks controller Call Service. Refer to 1136. Processor/ - Notify the AM Con-
Write updating data on a per- failure. board malfunction. Software alarm via the UI trollers
(Fault): manent storage device - Perform an
rack (e.g. EEPROM) emergency stop

Name Section
Storage Error detected in 1142 Optical Reading Optical Reading Call Service. Refer to 1137. Processor/ - Notify the AM Con-
Write updating data on a per- Units controller fail- Units controller Software alarm via the UI trollers
(Fault): manent storage device ure. board malfunction. - Perform an
ORU (e.g. EEPROM) emergency stop
Storage Error detected in 1144 Sample Arm con- Sample Arm con- Call Service. Refer to 1132. Processor/ - Notify the AM Con-
Write updating data on a per- troller failure. troller board mal- Software alarm via the UI trollers
(Fault): manent storage device function. - Perform an
Sample (e.g. EEPROM) emergency stop
Arm
Storage Error detected in 1145 Intermediate Intermediate Call Service. Refer to 1133. Processor/ - Notify the AM Con-
Write updating data on a per- Reagent Arm con- Reagent Arm con- Software alarm via the UI trollers
(Fault): manent storage device troller failure. troller board mal- - Perform an
Intermedi- (e.g. EEPROM) function. emergency stop
ate
Reagent
Arm
Storage Error detected in 1146 Start Reagent Arm Start Reagent Arm Call Service. Refer to 1134. Processor/ - Notify the AM Con-
Write updating data on a per- controller failure. controller board Software alarm via the UI trollers
(Fault): manent storage device malfunction. - Perform an
Start (e.g. EEPROM) emergency stop
Reagent
Arm

Name Section
Voltage Voltage out-of-range 1152 Sample Arm con- Sample Arm con- Call Service. The problem could be Power - Notify the AM Con-
Monitor fault detected on a controller voltage out of troller board mal- with the fuse, cabling, Manage- alarm via the UI trollers
(Fault): troller. range. function. power supply, or the ment - Perform an
Sample controller board itself. emergency stop
Arm Remove all skins and
check these items in the
order listed. If the system
allows, enter Diagnostics
> Voltages Tab to exam-
ine the voltages of the
controllers against their
limits. If a voltage is mar-
ginally out of limits,
replace the supply.
Voltage Voltage out-of-range 1153 Intermediate Intermediate Call Service. The problem could be Power - Notify the AM Con-
Monitor fault detected on a con- Reagent Arm con- Reagent Arm con- with the fuse, cabling, Manage- alarm via the UI trollers
(Fault): troller. troller voltage out of troller board mal- power supply, or the ment - Perform an
Intermedi- range. function. controller board itself. emergency stop
ate Remove all skins and
Reagent check these items in the
Arm order listed. If the system
replace the supply.

Name Section
Voltage Voltage out-of-range 1154 Start Reagent Arm Start Reagent Arm Call Service. The problem could be Power - Notify the AM Con-
Monitor fault detected on a con- controller voltage controller board with the fuse, cabling, Manage- alarm via the UI trollers
(Fault): troller. out of range. malfunction. power supply, or the ment - Perform an
Start controller board itself. emergency stop
Reagent Remove all skins and
Arm check these items in the
replace the supply.
Voltage Voltage out-of-range 1155 Cuvettes controller Cuvettes controller Call Service. The problem could be Power - Notify the AM Con-
Monitor fault detected on a con- voltage out of board malfunction. with the fuse, cabling, Manage- alarm via the UI trollers
(Fault): troller. range. power supply, or the ment - Perform an
cuvette controller board itself. emergency stop
Remove all skins and
replace the supply.

Name Section
Voltage Voltage out-of-range 1156 Racks controller Racks controller Call Service. The problem could be Power - Notify the AM Con-
Monitor fault detected on a con- voltage out of board malfunction. with the fuse, cabling, Manage- alarm via the UI trollers
(Fault): troller. range. power supply, or the ment - Perform an
rack controller board itself. emergency stop
replace the supply.
Voltage Voltage out-of-range 1157 Optical Reading Optical Reading Call Service. The problem could be Power - Notify the AM Con-
Monitor fault detected on a con- Units controller Units controller with the fuse, cabling, Manage- alarm via the UI trollers
(Fault): troller. voltage out of board malfunction. power supply, or the ment - Perform an
ORU range. controller board itself. emergency stop
replace the supply.

Name Section
FMov Automatic coordinates 1160 Arm <Arm> coordi- Arm coordinates The coordinates check
The arm cannot ini- Robotic - Notify the AM Mas-
Coor(dinat check failure nates error or CTS mismatch. tialize. fails. XYZ alarm via the UI ter
es) foot coordinates Perform a probe- Clean the metallic edge
Maint(enan error. alignment. of the rinse/clean station
ce) and try to reinitialize
If the problem per-
Autocheck again
sists call Service.
Fail - Clean all reference
points, go to diagnostics
and perform the "Coordi-
nate Adjustment" routine
FMov AM coordinates have 1165 Arm <Arm> coordi- Coordinate adjust- Service or Lab Use the diagnostics Robotic - Notify the AM Mas-
Coor(dinat never been adjusted nate adjust ment procedure not Administrator to run mode to run a coordi- XYZ alarm via the UI ter
es) not using the "Coordinate required. executed or failed. the Coordinate nates adjustment of the - Impossible to
adjusted adjustment" proce- Adjust procedure. instrument. start jobs, there-
dure. fore the instru-
ment cannot go
to ready
(ORU) Invalid emitter, detec- 1170 Invalid system con- System detected a Check system con- Check that the incuba- Reaction - Notify the AM Con-
Invalid tion, or incubator mod- figuration. hardware configu- figuration settings. tors and ORU heads are Detection alarm via the UI trollers
Configura- ule configuration ration that cannot Power off and installed. Make sure - Impossible to
tion detected, or reference support the current restart the instru- ORU and incubator start jobs, there-
channel not on system configura- ment. cables to the backplane fore the instru-
installed detection tion settings: miss- If the problem per- are secured. Otherwise, ment cannot go
module. ing or inactive sists, call Service. replace ORU module to ready
optical reading and/or incubators.
unit(s), cuvettes
incubator or CTS
module.

Name Section
Sample Probe Pre-Heater tem- 1175 Sample probe pre- Probe pre-heating The system per- Check fuse on probe, Thermal - Notify the
Probe perature defined to be heater temperature system malfunc- formed a controlled replace probe. Control alarm via the UI
Pre(- out of range for a control failure. tion. stop. Call Service. - Turn Power off
Heater) period exceeding the to the affected
Tempera- fatal error limits. heater
ture Error - Perform a con-
trolled stop
Reagent 1 Probe Pre-Heater tem- 1176 Reagent 1 probe Probe pre-heating The system per- Check fuse on probe, Thermal - Notify the
Probe perature defined to be pre-heater temper- system malfunc- formed a controlled replace probe. Control alarm via the UI
Pre(- out of range for a ature control fail- tion. stop. Call Service. - Turn Power off
Heater) period exceeding the ure. to the affected
trolled stop
Reagent 2 Probe Pre-Heater tem- 1177 Reagent 2 probe Probe pre-heating The system per- Check fuse on probe, Thermal - Notify the
Probe perature defined to be pre-heater temper- system malfunc- formed a controlled replace probe. Control alarm via the UI
trolled stop
CTS sam- Probe Pre-Heater tem- 1178 CTS sample probe Probe pre-heating The system per- CTS Sample probe is not Thermal - Notify the
ple Probe perature defined to be pre-heater temper- system malfunc- formed a controlled heated, this error will not Control alarm via the UI
Pre(- out of range for a ature control fail- tion. stop. Call Service. occur under normal con- - Turn Power off
Heater) period exceeding the ure. ditions. Contact IL if error to the affected
Tempera- fatal error limits. occurs. heater
trolled stop

Name Section
LAS sam- Probe Pre-Heater tem- 1179 LAS sample probe Probe pre-heating The system per- Error Code Reserved. Thermal - Notify the
ple Probe perature defined to be pre-heater temper- system malfunc- formed a controlled Control alarm via the UI
trolled stop
Sample Probe temperature 1180 Sample probe tem- Probe heating sys- The system per- This Sample probe is not Thermal - Notify the
Probe defined to be out of perature control tem malfunction. formed a controlled heated, this error will not Control alarm via the UI
Tempera- range for a period failure. stop. Call Service. occur under normal con- - Turn Power off
ture Error exceeding the fatal ditions. Contact IL if error to the affected
error limits. occurs. heater
- Perform a con-
trolled stop
Reagent 1 Probe temperature 1181 Reagent 1 probe Probe heating sys- The system per- Check fuse on probe, Thermal - Notify the
Probe defined to be out of temperature control tem malfunction. formed a controlled replace probe. Control alarm via the UI
Tempera- range for a period failure. stop. Call Service. - Turn Power off
ture Error exceeding the fatal to the affected
error limits. heater
- Perform a con-
trolled stop
Reagent 2 Probe temperature 1182 Reagent 2 probe Probe heating sys- The system per- Check fuse on probe, Thermal - Notify the
Probe defined to be out of temperature control tem malfunction. formed a controlled replace probe. Control alarm via the UI
- Perform a con-
trolled stop

Name Section
CTS Sam- Probe temperature 1183 CTS sample probe Probe heating sys- The system per- CTS Sample probe is not Thermal - Notify the
ple Probe defined to be out of temperature control tem malfunction. formed a controlled heated, this error will not Control alarm via the UI
Tempera- range for a period failure. stop. Call Service. occur under normal con- - Turn Power off
ture Error exceeding the fatal ditions. Contact IL if error to the affected
error limits. occurs. heater
- Perform a con-
trolled stop
LAS Sam- Probe temperature 1184 LAS sample probe Probe heating sys- The system per- Error Code Reserved. Thermal - Notify the
ple Probe defined to be out of temperature control tem malfunction. formed a controlled Control alarm via the UI
- Perform a con-
trolled stop
Clean Fluid Valve commanded 1185 Sample arm clean Clean fluid valve The system per- Perform the diagnostics Fluid - Notify the
Valve (in ON(OFF) but sensor fluid valve failure. not responding. formed an Emer- clean valve test. Movement alarm via the UI
Incorrect did not indicate gency stop: If the error is reproduc- - Perform an
State): ON(OFF) state. perform a Recov- ible, verify if the valve emergency stop
Sample ery. If the problem moves (in this case the
Arm persists call Ser- sensor is not working) or
vice. not (in this case the
valve is not working).
Clean Fluid Valve commanded 1186 Reagent arm 1 Clean fluid valve The system per- Perform the diagnostics Fluid - Notify the
Valve (in ON(OFF) but sensor clean fluid valve not responding. formed an Emer- clean valve test. Movement alarm via the UI
Incorrect did not indicate failure. gency stop: If the error is reproduc- - Perform an
Reagent ery. If the problem moves (in this case the
Arm 1 persists call Ser- sensor is not working) or

Name Section
Clean Fluid Valve commanded 1187 Reagent arm 2 Clean fluid valve The system per- Perform the diagnostics Fluid - Notify the
Valve (in ON(OFF) but sensor clean fluid valve not responding. formed an Emer- clean valve test. Movement alarm via the UI
Incorrect did not indicate failure. gency stop: If the error is reproduc- - Perform an
Reagent ery. If the problem moves (in this case the
Arm 2 persists call Ser- sensor is not working) or
Clean Pump commanded 1190 Sample clean Clean pump not The system per- Perform the diagnostics Fluid - Notify the
Pump (in ON(OFF) but sensor pump failure. responding. formed an Emer- clean pump test. Movement alarm via the UI
State): ON(OFF) state. perform a Recov- ible, verify if the pump emergency stop
Sample ery. If the problem runs (in this case the
persists call Ser- sensor is not working) or
pump is not working).
Clean Pump commanded 1191 Reagent clean Clean pump not The system per- Perform the diagnostics Fluid - Notify the
Pump (in ON(OFF) but sensor pump failure. responding. formed an Emer- clean pump test. Movement alarm via the UI
State): ON(OFF) state. perform a Recov- ible, verify if the pump emergency stop
Reagent ery. If the problem runs (in this case the
persists call Ser- sensor is not working) or
pump is not working).
Sample Pump commanded 1200 Sample rinse pump Rinse pump not The system per- Perform the diagnostics Fluid - Notify the
Rinse ON(OFF) but sensor failure. responding. formed an Emer- rinse test. Movement alarm via the UI
Pump (in did not indicate gency stop: If the error is reproduc- - Perform an
Incorrect ON(OFF) state. perform a Recov- ible, verify if the rinse emergency stop
State) ery. If the problem pump runs (in this case
persists call Ser- the sensor is not work-
vice. ing) or not (in this case
the pump is not working).

Name Section
Reagent 1 Pump commanded 1201 Reagent arm 1 Rinse pump not The system per- Perform the diagnostics Fluid - Notify the
Rinse ON(OFF) but sensor rinse pump failure. responding. formed an Emer- rinse test. Movement alarm via the UI
Reagent 2 Pump commanded 1202 Reagent arm 2 Rinse pump not The system per- Perform the diagnostics Fluid - Notify the
Rinse ON(OFF) but sensor rinse pump failure. responding. formed an Emer- rinse test. Movement alarm via the UI
LAS Sam- Pump commanded 1204 LAS sample arm Rinse pump not The system per- Error Code Reserved - Notify the
ple Rinse ON(OFF) but sensor rinse pump failure. responding. formed an Emer- alarm via the UI
Pump (in did not indicate gency stop: - Perform an
Incorrect ON(OFF) state. perform a Recov- emergency stop
State) ery. If the problem
persists call Ser-
vice.

Name Section
Waste Pump commanded 1205 Waste pump fail- Waste pump not The system per- Either the waste pump is Waste - Notify the AM Mas-
Pump (in ON(OFF) but sensor ure. responding. formed an Emer- not functional or the sen- Manage- alarm via the UI ter
Incorrect did not indicate gency stop: sors to check the state of ment - Perform an
State) ON(OFF) state. perform a Recov- the waste pump are not emergency stop
ery. If the problem functional. Enter Diag-
persists call Ser- nostics > Fluids tab to
vice. check the waste pump.
In the Waste pump sec-
tion, enter a duration of
10 seconds and press
the Start button. After the
Start button is pressed,
the operator should be
able to hear the waste
pump operating. If the
pump cannot be heard,
then remove the covers
to expose the waste
pump and repeat the
test. If the pump contin-
ues to fail, then check
both cabling and power.
If the pump is moving,
then the failure is proba-
bly in the detection sen-
sor. Make sure the
Waste pump on virtual
LED changes state
whether the pump is On
or Off.

Name Section
Coordi- Failure saving coordi- 1206 Coordinate File Invalid FTP server Call Service. Check network cables Robotic - Notify the AM Mas-
nates File nates file on the FTP Saving Failure. configuration, AM/ and connections are reli- XYZ alarm via the UI ter
Write Fail- server CM connection net- able.
ure work not working.
Ensure FTP server is
running.
ORU Failure saving ORU 1207 ORU Stored Read- Invalid FTP server Call Service. Check that the software Reaction - Notify the AM Mas-
Stored stored reading file on ing File Saving Fail- configuration, AM/ versions are correct for Detection alarm via the UI ter
Reading the FTP server ure. CM connection net- the release and that the
File Write work not working. FTP service is running
Failure on the personal com-
puter. Fix all incorrect
versions. Re-boot the
personal computer as an
attempt to restart the
FTP service.
CTS Sam- Pump commanded 1208 CTS sample arm Air pump not The system per- If the vacuum pump is on Fluid - Notify the AM Mas-
ple Air ON(OFF) but sensor air pump failure. responding. formed an Emer- too long; the instrument Movement alarm via the UI ter
Pump (in did not indicate gency stop: assumes it is not pres- - Perform an
Incorrect ON(OFF) state. perform a Recov- surizing the accumula- emergency stop
State) ery. If the problem tor.
persists call Ser- Go to the CTS Diagnos-
vice. tics screen and open the
CTS air valves.
If the CTS air pumps
runs, the problem is in
the air accumulator sen-
sor; if the pump doesn't
run, the problem is the
pump.

Name Section
CTS Failed The foot hit the wash 1209 CTS Failed to Enter The foot hit the The system per- Fluid
- Verify that the foot is - Notify the AM Mas-
to Enter station edge when the Deep Wash. wash station edge formed an Emer- properly connected to Movement alarm via the UI ter
Deep CTS probe was when the CTS gency stop: the sample arm/probe - Perform an
Wash inserted inside the probe was inserted perform a Recov- - Verify the position of emergency stop
wash station. This inside the wash sta- ery. If the problemthe sample wash station
would have caused a tion. persists call Ser- - Perform Coordinates
probe mode switch fail- vice. Adjustment procedure
ure at the end of the for sample arm
wash cycle. - Verify cap detection
sensors
Cuvette Cuvette Waste Level 1210 Cuvette waste level Cuvette waste level The system per- The feedback signal Cuvette - Notify the AM Con-
Level Sen- Sensor Not Respond- sensor failure. sensor not formed a controlled from the ultrasonic Movement alarm via the UI trollers
sor (Error) ing. responding. stop: the run has to cuvette level was not - Perform a con-
be re-started. If the detected. Ensure that all trolled stop
problem persists cables are connected
call Service. and the board has
power. Use diagnostics
(Cuvettes Tab > Waste >
Cuvette Waste Level) to
check if the level
changes with different
amount of cuvettes in the
drawer.

Name Section
Waste Waste Accumulator 1215 Unable to empty Peristaltic pump Call Service. If the waste accumulator Waste - Notify the AM Mas-
(Accumula- Full Sensor remains in internal waste res- failure. is full, waste container is Manage- alarm via the UI ter
tor Full ON state despite ervoir. Waste drain path present and full, then this ment - Perform Emer-
Sensor) cycling of Waste obstruction. alarm occurs. Or if the gency stop
Stuck Pump. Liquid sensor mal- waste accumulator is full
function. after an attempt to empty
it. Or if the waste accu-
mulator is full and the
container is not present.
In these cases, the
waste fluid sensors and
the tubing need to be
checked.
Enter Diag>Fluids tab to
check the Waste sen-
sors and accumulator
draining. If the accumu-
lator is empty, but the
LED on the sensor is
active, then there is a
problem with the sensor
or an object in front of
the sensor. If the accu-
mulator is full, set the
Waste pump duration
such as 60 seconds.
Start the pump. Ensure
that fluid is flowing
through the tube to the
waste container. If the
sensors are working and
the tubing is good, test
the waste container
presence sensor.

Name Section
Stir Power A check on the power 1220 Reagent stirring Reagent stirring Call Service. The sensor that monitors Rack Han- - Notify the AM Con-
Bad required for stirring failure. system malfunc- the power to all the stir- dling alarm via the UI trollers
returned an error tion. ring detected a failure. - Disable all stir-
Either the sensor is bad ring positions in
or the stirring circuitry diagnostics
has failed. To check, screen.
place vials with stir bars
into all of the stir loca-
tions. If all the positions
are stirring properly, then
the sensor is malfunc-
tioning. If any of the stir
positions are not stirring,
then check the reagent
stirring circuitry.
Stir Power A check on the power 1221 Reagent stirring Reagent stirring Call Service. Product under develop- Rack Han- - Notify the AM Con-
Bad: by required for stirring failure in position system malfunc- ment - Not needed in the dling alarm via the UI trollers
Position position returned an <rack tion. service manual - Disable that
error position #>, track # stirring position
<rack track #>. in diagnostics
screen.
(Cuvette) Failure during cuvette 1239 Cuvette Loader fail- Cuvette loader mal- The system per- Check for obstructions Cuvette - Notify the AM Con-
Indexing indexing detected. ure. function. The formed a controlled that would prevent the Movement alarm via the UI trollers
Failure cuvette clip may not stop: the run has to cuvette clip from drop- - Perform a con-
have fallen flat for be re-started. If the ping flat in the loader. trolled stop
pickup by the shut- problem persists Also use diagnostics to - Deschedule
tle. The cuvette call Service. verify that the cuvette and cancel jobs
strips on the clip clip presence sensor is requiring new
may not be aligned functioning. When the cuvettes
evenly or there may clip is moved into pickup
be debris on the position, the sensor is
pivot arm. read to verify that the clip
is ready.

Name Section
Clean Well Validate LLD height in 1240 Cleaning solution Air bubbles in the Perform a Clean - Perform Clean pump Fluid - Notify the AM Mas-
Not Full Clean well. If too low, low in clean well. clean solution line. prime cycle (Main- diagnostics test and ver- Movement alarm on UI ter
short sipping may Undetected clean tenance). If the ify that clean well are
occur. solution shortage. problem persists filled with clean solution
Clean pump mal- call Service. - Perform LLD test in
function. clean cup and verify that
liquid is detected
- Remove the clean bot-
tle and verify that the
instrument report the
proper alarm.
Cuvette The motor did not com- 1245 Cuvettes shuttle The motor moved The system per- Use diagnostics to verify Cuvette - Turn off power AM Con-
Shuttle plete the requested movement failure. to the left limit then formed an Emer- that the cuvette position Movement to stepper trollers
Motor - move. to the home posi- gency stop: sensor is operational motor.
Cause 3 tion at the loader perform a Recov- (color when in slot). If - Notify the
and the home posi- ery. If the problem sensor is functional, per- alarm via the UI
tion was not found. persists call Ser- form cuvette shuttle align - Perform an
vice. procedure. emergency stop
Cuvette The motor did not com- 1246 Cuvettes shuttle Incorrect # slots The system per- A slot is dirty or the shut- Cuvette - Turn off power AM Con-
Shuttle plete the requested movement failure. found. formed an Emer- tle in position slot sensor Movement to stepper trollers
Motor - move. gency stop: is dirty. Clean either slots motor.
Cause 4 perform a Recov- on the incubators or the - Notify the
ery. If the problem shuttle in position slot alarm via the UI
persists call Ser- sensor. Use diagnostics - Perform an
vice. to verify that all cuvette emergency stop
slots can be detected.
Cuvette The motor did not com- 1247 Cuvettes shuttle Home Required. A The system per- This is a software defect Processor/ - Turn off power AM Con-
Shuttle plete the requested movement failure. cuvette shuttle formed an Emer- that should be submitted Software to stepper trollers
Motor - move. operation was gency stop: to software develop- motor.
Cause 5 requested before perform a Recov- ment. - Notify the
the shuttle was ini- ery. If the problem alarm via the UI
tialized into a persists call Ser- - Perform an
known state. vice. emergency stop

Name Section
Cuvette The motor did not com- 1248 Cuvettes shuttle Cuvettes shuttle The system per- Either the processor or Processor/ - Turn off power AM Con-
Shuttle plete the requested movement failure. movement timeout. formed an Emer- software has a malfunc- Software to stepper trollers
Motor - move. Move Timeout. This gency stop: tion. Replace the cuvette motor.
Cause 6 occurs if the soft- perform a Recov- controller board and - Notify the
ware does not com- ery. If the problem repeat the failure sce- alarm via the UI
plete the move persists call Ser- nario. - Perform an
profile. vice. emergency stop
Cuvette The motor did not com- 1249 Cuvettes shuttle Cuvettes shuttle The system per- This alarm is not Cuvette - Turn off power AM Con-
Shuttle plete the requested movement failure. movement stalled. formed an Emer- enabled. Movement to stepper trollers
Motor - move. gency stop: motor.
Cause 7 perform a Recov- - Notify the
ery. If the problem alarm via the UI
persists call Ser- - Perform an
vice. emergency stop
Cuvette The motor did not com- 1250 Cuvettes shuttle Cuvettes shuttle The system per- This could be a problem Cuvette - Turn off power AM Con-
Shuttle plete the requested movement failure. movement hit unex- formed an Emer- with either the motor Movement to stepper trollers
Motor - move. pected travel limit. gency stop: step size or direction. motor.
Cause 8 perform a Recov- - Notify the
ery. If the problem alarm via the UI
Cuvette The motor did not com- 1253 Cuvettes shuttle Cuvettes shuttle The system per- General alarm to alert Cuvette - Turn off power AM Con-
Shuttle plete the requested movement failure. movement timeout. formed an Emer- there was a gripper fail- Movement to stepper trollers
Motor - move. Gripper move fail- gency stop: ure. Should be accom- motor.
Cause 11 ure. perform a Recov- panied with a detailed - Notify the
ery. If the problem alarm. alarm via the UI

Name Section
Bar Code The motor did not com- 1255 Barcode reader Barcode reader Clear obstruction This is a high level alarm Rack Han- - Turn off power AM Con-
Reader plete the requested movement failure. movement timeout. and wait for bar- that alerts that some- dling to stepper trollers
Motor - move prior to a motor Home Not Found. code reader time- thing in the reader home motor.
Cause 1 move time out (bar out to occur operation was not com- - Notify the
code). (homing of bar- pleted successfully. alarm via the UI
code). If problem Watch the reader to see
persists disable the where the failure occurs.
barcode reader in Listen for hitting an
Global Definitions obstruction. In Diagnos-
and call Service. tics > Racks section, use
the Disable Bar Code
Reader Motor button to
disable the power to the
motor. With the power
disabled, move the
reader by hand to look
for rough spots. While
checking for rough
spots, make sure that
the Track, Left Travel,
and Right Travel virtual
LEDs change state at
the appropriate time.

Name Section
Bar Code The motor did not com- 1256 Barcode reader Barcode reader Clear obstruction When moving to a posi- Rack Han- - Turn off power AM Con-
Reader plete the requested movement failure. movement timeout. and wait for bar- tion the exact number of dling to stepper trollers
Motor - move prior to a motor Incorrect Slots code reader time- slots were not detected. motor.
Cause 2 move time out (bar Found. out to occur The alarm reports the - Notify the
code). (homing of bar- number of slots alarm via the UI
code). If problem detected. If the number
persists disable the of slots was less than
barcode reader in expected, then the motor
Global Definitions either stalled or hit an
and call Service. obstruction. If the num-
ber of slots is a large
number, then false trips
may have been
detected. The false trips
can come from a bad
sensor, intermittent
cabling, or sensor to slot
alignment. In Diagnos-
tics > Racks section, use
the Disable Bar Code
motor. With power dis-
abled, move the reader
by hand to look for rough
spots. While checking for
rough spots, ensure the
Track, Left Travel, and
Right Travel virtual LEDs
change state at the
appropriate time. Also,
see if the Track LED
flickers when on a slot
location.

Name Section
Bar Code The motor did not com- 1257 Barcode reader Barcode reader Clear obstruction This alarm is produced Rack Han- - Turn off power AM Con-
Reader plete the requested movement failure. movement timeout. and wait for bar- when a command is dling to stepper trollers
Motor - move prior to a motor Home Required. code reader time- given to move the reader motor.
Cause 3 move time out (bar out to occur to a rack position prior to - Notify the
code). (homing of bar- it being homed. This sce- alarm via the UI
code). If problem nario is rare. If this
persists disable the occurs, it should be
barcode reader in entered as a complaint.
Global Definitions
and call Service.
Bar Code The motor did not com- 1258 Barcode reader Barcode reader Clear obstruction This alarm has a very Rack Han- - Turn off power AM Con-
Reader plete the requested movement failure. movement timeout. and wait for bar- low probability. Either dling to stepper trollers
Motor - move prior to a motor Move Timeout. code reader time- the hardware that motor.
Cause 4 move time out (bar out to occur changes the ramp speed - Notify the
code). (homing of bar- has a circuitry problem alarm via the UI
code). If problem or there is a software
persists disable the logic error that is loading
barcode reader in an incorrect ramp profile.
Global Definitions A solution would be to
and call Service. replace the rack control-
ler card since this will fix
either of the problems.

Name Section
Bar Code The motor did not com- 1259 Barcode reader Barcode reader Clear obstruction The alarm is reported Rack Han- - Turn off power AM Con-
Reader plete the requested movement failure. movement timeout. and wait for bar- when the reader hits an dling to stepper trollers
Motor - move prior to a motor Stalled. code reader time- object. It is detected by motor.
Cause 5 move time out (bar out to occur monitoring the encoder - Notify the
code). (homing of bar- during the move opera- alarm via the UI
code). If problem tion. The problem is
persists disable the either with hitting an
barcode reader in object or the encoder
Global Definitions feedback. In Diagnostics
and call Service. > Racks section, use the
Disable Bar Code
motor. With the power
disabled, move the
reader by hand to look
for rough spots. While
checking for rough
spots, make sure that
the Track, Left Travel,
and Right Travel virtual
LEDs change state at
the appropriate time.
Also, watch to verify that
the Encoder value
changes when the
reader is moved.

Name Section
Bar Code The motor did not com- 1260 Barcode reader Barcode reader Clear obstruction This alarm should be Rack Han- - Turn off power AM Con-
Reader plete the requested movement failure. movement timeout. and wait for bar- rare in the field. The dling to stepper trollers
Motor - move prior to a motor Unexpected Travel code reader time- most probable cause is motor.
Cause 6 move time out (bar Limit. out to occur that the motor direction - Notify the
code). (homing of bar- wiring is reversed hence alarm via the UI
code). If problem sending the motor in the
persists disable the opposite direction than
barcode reader in requested. If this prob-
Global Definitions lem occurs, check the
and call Service. wiring.
All ORUs All the ORU have been 1261 All the Optical All the ORUs have If the ORUs have Use ORU Diagnostic Reaction - Notify the AM Mas-
Disabled disabled, either manu- Reading Units are been disabled, been automatically screen to attempt to Detection alarm via the UI ter
ally or automatically. disabled. Analysis either automati- disabled, call Ser- manually enable ORUs. - Enter the Error
The instrument cannot cannot be per- cally or manually. vice. Check cabling to ORU Status
perform any tests. formed. - Automatically: When all the ORUs from backplane. Replace - If there are
ORU real-time are disabled the the ORU module. active jobs, per-
check failed system cannot perform an Emer-
- Manually: opera- form analysis. gency Stop
tor disabled ORU If this occurs during
through Diagnos- a run, the system
tics performs an Emer-
gency Stop.

Name Section
Cuvette The accumulator does 1263 Cuvettes accumu- Cuvettes accumu- The system per- Check to see if the Waste - Notify the AM Con-
Waste not return to the up lator failure. lator movement formed an Emer- cuvette waste accumula- Manage- alarm via the UI trollers
accumula- position within 2 sec- timeout. gency stop: tor is stuck in the down ment - Disable the
tor stuck onds of being emptied. perform a Recov- position. If may has got accumulator
ery. If the problem caught and cannot return solenoid
persists call Ser- to the level position to - Perform an
vice. gather more cuvettes. In Emergency
order to check the sen- Stop
sor, enter Diagnostics >
Cuvettes tab. In the
Waste section of the tab
there is a sensor named
Accumulator Up.
Remove the cuvette
waste drawer and check
that the sensor changes
state by moving the
cuvette waste accumula-
tor up and down. Also, in
Diagnostics, use the
Clear Accumulator but-
ton to verify the dump
operation of the accumu-
lator.

Name Section
ORU Tem- Temperature out of 1264 Optical reading unit Temperature out of Call Service. The heating wire could Thermal - Notify the AM Con-
perature range in a reading unit No. 1 temperature range in optical be broken, the thermistor Control alarm on UI trollers
Warning control failure. reading unit. could be shorted, or the
(ORU #1) module could require
calibration. To help trou-
bleshoot, use Diagnos-
tics > ORU Tab. If the
bly okay.

Name Section
bly okay.

Name Section
bly okay.

Name Section
bly okay.

Name Section
Incubator Temperature out of 1268 Cuvettes incubator Temperature out of Call Service. The heating wire could Thermal - Notify the AM Con-
Tempera- range in an incubator No. 1 temperature range in cuvettes be broken, the thermistor Control alarm on UI trollers
ture Warn- control failure. incubator. could be shorted, or the
ing module could require
(incubator calibration. To help trou-
#1) bleshoot, use Diagnos-
bly okay.

Name Section
Incubator Temperature out of 1269 Cuvettes incubator Temperature out of Call Service. The heating wire could Thermal - Notify the AM Con-
Tempera- range in an incubator No. 2 temperature range in cuvettes be broken, the thermistor Control alarm on UI trollers
ture Warn- control failure. incubator. could be shorted, or the
ing module could require
(incubator calibration. To help trou-
#2) bleshoot, use Diagnos-
bly okay.
Probe Probe temperature or 1270 Sample probe tem- Probe heating sys- Call Service. Verify what test(s) error Thermal - Notify the
Tempera- dispense temperature perature or dis- tem malfunction. occurs. Check test vol- Control alarm on UI
ture Warn- defined to be out of pense temperature umes especially if not an
ing warning range but out of range. IL test. Consult with
(Sample) within failure range. Applications
Probe Probe temperature dis- 1271 Reagent arm 1 Probe heating sys- Call Service. Verify what test(s) error Thermal - Notify the
Tempera- pense temperature probe temperature tem malfunction. occurs. Check test vol- Control alarm on UI
ture Warn- defined to be out of or dispense tem- umes especially if not an
ing warning range but perature out of IL test. Consult with
(Reagent within failure range. range. Applications
1)

Name Section
Probe Probe temperature dis- 1272 Reagent arm 2 Probe heating sys- Call Service. Verify on what test(s) Thermal - Notify the
Tempera- pense temperature probe temperature tem malfunction. error occurs. Check test Control alarm on UI
ture Warn- defined to be out of or dispense tem- volumes especially if not
ing warning range but perature out of an IL test. Consult with
(Reagent within failure range. range. Applications.
2)
Pre(- Probe Pre-Heater tem- 1273 Sample probe pre- Probe pre-heating Call Service. Verify on what test(s) Thermal - Notify the
Heater) perature defined to be heater temperature system malfunc- error occurs. Check test Control alarm on UI
Probe out of warning range out of range. tion. volumes especially if not
Tempera- but within failure range an IL test. Consult with
ture Warn- Applications.
ing
Pre(- Probe Pre-Heater tem- 1274 Reagent arm 1 Probe pre-heating Call Service. Verify on what test(s) Thermal - Notify the
Heater) perature defined to be probe pre-heater system malfunc- error occurs. Check test Control alarm on UI
Probe out of warning range temperature out of tion. volumes especially if not
Tempera- but within failure range range. an IL test. Consult with
ing
Pre(- Probe Pre-Heater tem- 1275 Reagent arm 2 Probe pre-heating Call Service. Verify on what test(s) Thermal - Notify the
Heater) perature defined to be probe pre-heater system malfunc- error occurs. Check test Control alarm on UI
Probe out of warning range temperature out of tion. volumes especially if not
Tempera- but within failure range range. an IL test. Consult with
ing
Reagent Reagent area tempera- 1276 Reagent area tem- Reagent cooling Call Service. Verify on what test(s) Thermal - Notify the
Temp ture defined to be out perature out of system malfunc- error occurs. Check test Control alarm on UI
Warning of warning range but range. tion. volumes especially if not
within failure range. an IL test. Consult with
Applications.

Name Section
Cuvette Cuvette shuttle tem- 1277 Cuvette shuttle Cuvette shuttle Call Service. The heating wire could Thermal - Notify the
Shuttle perature defined to be temperature out of heating system be broken, the thermistor Control alarm on UI
Temp out of warning range range. malfunction. could be shorted, or the
Warning but within failure range. module could require
tics > Cuvettes Tab. If
the temperature is fluctu-
ating and barely out of
bly okay.
(ORU) Ref Optical Reference 1278 Optical reading LED or electronic Call Service. Replace the ORU mod- Reaction - Notify the AM Con-
High or readings not within units reference failure. ule if: when the Start but- Detection alarm on UI trollers
Low expected range, possi- readings out of ton is pressed in
bly due to LED aging or range for ORU Diagnostics > ORU tab >
failure. <ORU ID>. Reference Readings
section, the DAC value is
greater than 240.
(ORU) ORU dark readings are 1279 Optical reading unit Stray light interfer- Call Service. Check for missing or Reaction - Notify the AM Con-
High Dark too high, possibly indi- <ORU ID> dark ence or electronic damaged covers that Detection alarm on UI trollers
cating excessive stray readings too high. failure. would allow light into the - Remove the
light. system. Look for possi- associated ORU
ble sources of light into module from the
the system. If covers scheduling pro-
have integrity, then cess????
replace ORU module.

Name Section
(ORU) A/D Optical readings too 1280 Optical reading LED or electronic Call Service. Replace the ORU mod- Reaction - Notify the AM Con-
readings noisy, possibly due to units readings too failure. ule. Detection alarm on UI trollers
too noisy LED aging or failure. noisy for ORU
<ORU ID>. - Create Log
Entry.
(ORU) A/D ORU amplifier and/or 1281 Optical reading unit ORU LED or elec- Call Service. Replace the ORU mod- Reaction - Notify the AM Con-
Saturated A/D converter satu- <ORU ID> readings tronic failure. ule. Detection alarm on UI trollers
rated out of range. Amplifier and/or A/ - Create Log
D converter satu- Entry.
rated.
(ORU) Math exception error 1283 Optical reading unit If the problem per- Report problem into the Reaction - Notify the AM Con-
Math (e.g. attempt to divide raw data calcula- sists call Service. complaint system. This Detection alarms through trollers
by zero, overflow, tion error. is a software defect that the UI.
result not reasonable). cannot be addressed by
the field. If possible,
monitor the operator
workflow and make sug-
gestions to change the
workflow which could
avoid the software path.

Name Section
Liquid LLD error occurred 1285 Probe <probe This alarm is Check probe condi- Try to determine if the Robotic - Notify the AM Mas-
Level during pipetting opera- name> Liquid Level reported by the tions. If the problem failure is caused by liquid XYZ alarm through ter
Detection tion. Detection error in analyzer when, persists call Ser- not detected or by a false the UI
rack position <X>, aspirating a liquid vice. positive LLD. - Complete cur-
track <YY>. from a rack con- Problems detecting liq- rent job as
tainer, one of the uid can be investigated failed, with no
following conditions performing diagnostics results if all
is detected. LLD test into rack con- determinations
- Liquid not found tainers, cuvettes and are failed. Also,
- LLD monitor fail- clean cups. if on a measure-
ure False positive LLDs can ment check,
be detected performing another mea-
diagnostics LLD test surement is per-
selecting as target loca- formed.
tion "Reference point". If an LLD failure
is during aspi-
rating any sam-
ple or material,
1. If the aspi-
rate/dispense
step is a dilution
step, the job is
descheduled
and canceled:
(continued)

Name Section
Liquid LLD error occurred 1285 (all replicates for
Level during pipetting opera- (con- the current con-
Detection tion. (continued) tinued) centration are
(continued) affected)
marked as
'failed', the job is
descheduled
and canceled. 2.
If the aspirate/
dispense step is
a predilution
step or a sam-
ple/reagent
step, the current
determination is
marked as
'failed' and its
results are
flagged.
3. If all replicate
of one concen-
tration are In
case there is not
enough liquid in
the dispense
location to per-
form the
requested mix,
the same rules
1, 2 and 3 apply.

Name Section
Dispense Dispense error 1286 Probe <probe Dispense error. Check probe condi- The system has Fluid - Notify the AM Mas-
error name> Dispense tions. If the problem detected a missing post Movement alarm through ter
error. persists call Ser- dispense rinse/clean the UI
vice. operation. - Do the same
This is not an hardware like an LLD
problem. - Create Log
Entry
Liquid LLD error in cuvette 1293 Probe <probe This alarm is Check probe condi- Try to determine if the Robotic - Notify the AM Mas-
Level name> Liquid Level reported by the tions. If the problem failure is caused by liquid XYZ alarm through ter
Detection Detection error in analyzer when, persists call Ser- not detected or by a false the UI
(Cuvette) cuvette position aspirating a liquid vice. positive LLD. - Complete the
<X>, slot <YY>. from a cuvette cell, Problems detecting liq- current job as
one of the following uid can be investigated failed, with no
conditions is performing diagnostics results if all
detected. LLD test into cuvettes. determinations
- Liquid not found False positive LLDs can are failed.
- LLD monitor fail- be detected performing
ure diagnostics LLD test
selecting as target loca-
tion "Reference point".

Name Section
Liquid LLD error in well 1294 Probe <Probe This alarm is Check probe condi- Try to determine if the Robotic - Notify the AM Mas-
Level name> Liquid Level reported by the tions. If the problem failure is caused by liquid XYZ alarm through ter
Detection Detection error in analyzer when, persists call Ser- not detected or by a false the UI
(Clean/ well position <well aspirating a liquid vice. positive LLD. - Complete the
Rinse) pos>. from a well, one of Problems detecting liq- current job as
the following condi- uid can be investigated failed, with no
tions is detected. performing diagnostics results if all
- Liquid not found LLD test into the clean determinations
- LLD monitor fail- cup. are failed.
ure False positive LLDs can - If the location
be detected performing of the liquid
diagnostics LLD test level detection
selecting as target loca- error is the
tion "Reference point". clean cup, and
the pipetting
operation is part
of a test, the
instrument per-
forms an emer-
gency stop.
Air Read Current air read for this 1295 Air read out of ORU air reading Call Service. Look for foreign obstruc- Reaction - Notify the AM Mas-
Failure - wavelength, read head range for ORU# out of range. tion in the ORU head. If Detection alarms through ter
Out Of and read channel is out <ORU ID> Chan- ORU cuvette slot is the UI
Range of range nel# <CHAN ID> clear, then insert a piece - Disable the
Wavelength# of white paper. The ORU head
<WAVE ID> Read- paper should have 4 when the instru-
ing: <ORU READ- dots of purple light. If red ment status is
ING> only, then the blue light not BUSY
is missing. If blue only,
then the red light is miss-
ing. Replace ORU mod-
ule if obstruction was not
detected.

Name Section
Invalid Invalid transmit mes- 1296 Bar code reader The system per- Bar code label format not Reaction Notify the alarm AM Con-
Transmit sage format for the bar invalid message formed an Emer- supported by the ACL Detection via the UI. Per- trollers
Message code reader. format. gency stop: TOP. form an emer-
Format perform a Recov- gency stop.
ery. If the problem
persists call Ser-
vice.
Reader Communications trans- 1297 RS232 transmit The serial port The system per- Repair / replace serial Reaction Notify the alarm AM Con-
Transmit mission hardware is hardware error. hardware is not formed an Emer- port on Command Mod- Detection via the UI. Per- trollers
Hardware not functional. functioning prop- gency stop: ule. form an emer-
erly. perform a Recov- gency stop.
ery. If the problem
persists call Ser-
vice.
Cuvette not A request was made to 1318 No cuvette strip in Either a cuvette is The system per- Use diagnostics Cuvette - Turn off power AM Con-
present to drop off a cuvette, but shuttle to drop off. really not present, formed an Emer- (Cuvettes Tab > Move Movement to stepper trollers
drop off no cuvette is detected the presence sen- gency stop: cuvettes section) to motor.
in the shuttle. sor is not function- perform a Recov- move cuvettes and verify - Notify the
ing properly (ex. ery. If the problem that the Cuvette in shut- alarm via the UI
dirty), or a cable persists call Ser- tle sensor changes state. - Perform an
has come vice. emergency stop
unplugged.
Cuvette The source position for 1323 Cuvette not present Either a scheduler The system per- This is a software defect. Cuvette - Turn off power AM Con-
source picking up a cuvette is to pickup. error or operator formed an Emer- Ask the operator or Movement to stepper trollers
empty empty. error in diagnostics. gency stop: watch the operator for motor.
perform a Recov- how they load and pro- - Notify the
ery. If the problem gram the system. After alarm via the UI
persists call Ser- determining how the - Perform an
vice. instrument is operated, emergency stop
suggest a different order
to avoid following the
same logic path in soft-
ware.

Name Section
Cuvette The destination posi- 1324 Cuvette destina- Either a scheduler The system per- This is a software defect. Cuvette - Turn off power AM Con-
destination tion for placing a tion position full. error or operator formed an Emer- Ask the operator or Movement to stepper trollers
full cuvette is occupied. error in diagnostics. gency stop: watch the operator for motor.
perform a Recov- how they load and pro- - Notify the
ery. If the problem gram the system. After alarm via the UI
persists call Ser- determining how the - Perform an
vice. instrument is operated, emergency stop
suggest a different order
to avoid following the
same logic path in soft-
ware.
Invalid The number of cuvette 1328 Invalid number of Either a module isThe system per- Ensure the PC104 dip Cuvette - Turn off power AM Con-
number of slots detected is not a cuvette slots. incorrect or the formed an Emer- switches are set to the Movement to stepper trollers
cuvette valid configuration configuration dip gency stop: proper instrument con- motor.
slots perform a Recov-
switch is set incor- figuration. - Notify the
rectly. ery. If the problem alarm via the UI
Cuvette The number of 1329 Cuvette slot found Either there are too The system per- Check cable connec- Cuvette - Turn off power AM Con-
slots found required slots was too early. many mechanical formed an Emer- tions to make sure sen- Movement to stepper trollers
too early. detected too early in slots or the sensor gency stop: sor is not noisy. In this motor.
move distance. has picked up perform a Recov- case, the move com- - Notify the
noise. ery. If the problem pleted in finding the cor- alarm via the UI
persists call Ser- rect number of slots, but - Perform an
vice. the distance traveled emergency stop
was too short.

Name Section
Gripper During initialization 1330 Gripper back sen- Either a sensor fail- The system per- Use Diagnostics Cuvette - Turn off power AM Con-
back sen- (home), the gripper sor still active. ure, cabling failure, formed an Emer- (Cuvettes Tab) to check Movement to stepper trollers
sor On attempts to move off or motor stall. gency stop: the Gripper Back sensor. motor.
the back sensor, but perform a Recov- Press the Disable Shut- - Notify the
the sensor is still ery. If the problem tle Motors button to alarm via the UI
detected or extend persists call Ser- move the shuttle freely. - Perform an
gripper operation per- vice. On the side of the shut- emergency stop
formed, but the back tle, turn the motor wheel
sensor is still detected. to move the gripper in
and out. Move the grip-
per all the way to the
back and verify that the
Gripper back sensor
changes state.
Gripper During initialization 1331 Gripper back sen- Either a sensor fail- The system per- Use Diagnostics Cuvette - Turn off power AM Con-
back sen- (home), the gripper sor not found. ure, cabling failure, formed an Emer- (Cuvettes Tab) to check Movement to stepper trollers
sor not moves off the back or motor stall. gency stop: the Gripper Back sensor. motor.
found sensor. Once detected perform a Recov- Press the Disable Shut- - Notify the
to be off the sensor, the ery. If the problem tle Motors button to alarm via the UI
motor moves towards persists call Ser- move the shuttle freely. - Perform an
the sensor to make vice. On the side of the shut- emergency stop
sure it can be detected. tle, turn the motor wheel
If the back sensor is to move the gripper in
not detected during this and out. Move the grip-
search then the alarm per all the way to the
is generated. back and verify that the
Gripper back sensor
changes state.

Name Section
Gripper for- After the gripper has 1332 Gripper forward Either a sensor fail- The system per- Use Diagnostics Cuvette - Turn off power AM Con-
ward sen- completed a retract sensor still active. ure, cabling failure, formed an Emer- (Cuvettes Tab) to check Movement to stepper trollers
sor On move the forward sen- or motor stall. gency stop: the Gripper Front sen- motor.
sor is still detected. perform a Recov- sor. Press the Disable - Notify the
ery. If the problem Shuttle Motors button to alarm via the UI
persists call Ser- move the shuttle freely. - Perform an
vice. On the side of the shut- emergency stop
tle, turn the motor wheel
to move the gripper in
per all the way out and
verify that the Gripper
front sensor changes
state.
Gripper for- Extend gripper opera- 1333 Gripper forward Either a sensor fail- The system per- Use Diagnostics Cuvette - Turn off power AM Con-
ward sen- tion did not detect the sensor not found. ure, cabling failure, formed an Emer- (Cuvettes Tab) to check Movement to stepper trollers
sor not front sensor. or motor stall. gency stop: the Gripper Front sen- motor.
found perform a Recov- sor. Press the Disable - Notify the
ery. If the problem Shuttle Motors button to alarm via the UI
persists call Ser- move the shuttle freely. - Perform an
vice. On the side of the shut- emergency stop
tle, turn the motor wheel
to move the gripper in
per all the way out and
verify that the Gripper
front sensor changes
state. If the sensor is
functional, then re-align
the shuttle as it may not
be extending far enough
to trip the sensor.

Name Section
Cuvette The accumulator is 1334 Cuvette waste tray Tray mechanically The system per- Check for obstructions in Cuvette - Notify the AM Con-
Tray Not energized to be in the did not dump. stuck or solenoid formed an Emer- the cuvette waste drawer Movement alarm via the UI trollers
Down down position to drop malfunction. gency stop: that would prevent the - Disable the
the cuvettes on the perform a Recov- tray from moving. Use accumulator
tray, but the tray is still ery. If the problem Diagnostics (Cuvettes solenoid
detected in the up posi- persists call Ser- Tab > Waste section) to - Perform an
tion. Allowed 250 ms to vice. move the tray with the Emergency
move. Clear Accumulator but- Stop
ton.
Cuvette The accumulator is 1335 Cuvette waste tray Tray mechanically The system per- Check for obstructions in Cuvette - Notify the AM Con-
Tray Not deenergized to go to not ready to receive stuck or solenoid formed an Emer- the cuvette waste drawer Movement alarm via the UI trollers
Up the up position to get cuvettes. malfunction. gency stop: that would prevent the - Disable the
more cuvettes onto the perform a Recov- tray from moving. Use accumulator
tray, but the tray is still ery. If the problem Diagnostics (Cuvettes solenoid
detected in the down persists call Ser- Tab > Waste section) to - Perform an
position. Allowed 250 vice. move the tray with the Emergency
ms to move. Clear Accumulator but- Stop
ton.

Name Section
Arm Fail- X Axis - Invalid Profile 1341 X Axis - Invalid Pro- The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ure 1 Parameter file Parameter controller reporting formed an Emer- versions are correct for XYZ via the UI. Per- ter
the alarm was sent gency stop: the release - in particular form an emer-
a velocity profile perform a Recov- the Master and Universal gency stop.
parameter(s) for ery. If the problem Arm controller that pro-
the X axis motor persists call Ser- duced the alarm. Ensure
that exceeded max- vice. that the FTP service is
imum/minimum cri- running on the personal
teria or was computer. Fix any incor-
incompatible with rect versions. Re-boot
other profile param- the personal computer in
eters. an attempt to restart the
FTP service and allow
the CM to initiate repro-
gramming of the control-
lers.
Arm Fail- Y Axis - Invalid Profile 1342 Y Axis - Invalid Pro- The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
the Y axis motor persists call Ser- duced the alarm. Ensure
lers.

Name Section
Arm Fail- Z Axis - Invalid Profile 1343 Z Axis - Invalid Pro- The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
the Z axis motor persists call Ser- duced the alarm. Ensure
lers.
Arm Fail- X Axis - Speed 1344 X Axis - Speed The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ure 4 Exceeds Profile Maxi- Exceeds Profile controller reporting formed an Emer- versions are correct for XYZ via the UI. Per- ter
mum Maximum the alarm was sent gency stop: the release - in particular form an emer-
a command to perform a Recov- the Master and Universal gency stop.
move in the X axis ery. If the problem Arm controller that pro-
at a speed that persists call Ser- duced the alarm. Ensure
would exceed the vice. that the FTP service is
maximum stored in running on the personal
the velocity profile. computer. Fix any incor-
rect versions. Re-boot
the personal computer in
an attempt to restart the
lers.

Name Section
Arm Fail- Y Axis - Speed 1345 Y Axis - Speed The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
move in the Y axis ery. If the problem Arm controller that pro-
lers.
Arm Fail- Z Axis - Speed 1346 Z Axis - Speed The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
move in the Z axis ery. If the problem Arm controller that pro-
lers.

Name Section
Arm Fail- X Axis - Cannot Pro- 1347 X Axis - Cannot The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ure 7 cess Steps Required Process Steps controller reporting formed an Emer- versions are correct for XYZ via the UI. Per- ter
Required the alarm was sent gency stop: the release - in particular form an emer-
a command to set perform a Recov- the Master and Universal gency stop.
the velocity profile ery. If the problem Arm controller that pro-
for the X axis but persists call Ser- duced the alarm. Ensure
the parameters will vice. that the FTP service is
generate a profile running on the personal
that will exceed computer. Fix any incor-
allocated memory. rect versions. Re-boot
lers.
Arm Fail- Y Axis - Cannot Pro- 1348 Y Axis - Cannot The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
for the Y axis but persists call Ser- duced the alarm. Ensure
lers.

Name Section
Arm Fail- Z Axis - Cannot Pro- 1349 Z Axis - Cannot The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
for the Z axis but persists call Ser- duced the alarm. Ensure
lers.
Arm Fail- X Axis - Selected Pro- 1350 X Axis - Selected The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ure 10 file Is Invalid Profile Is Invalid controller reporting formed an Emer- versions are correct for XYZ via the UI. Per- ter
select a particular ery. If the problem Arm controller that pro-
profile for the X axis persists call Ser- duced the alarm. Ensure
motor but the pro- vice. that the FTP service is
file does not exist. running on the personal
computer. Fix any incor-
lers.

Name Section
Arm Fail- Y Axis - Selected Pro- 1351 Y Axis - Selected The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
profile for the Y axis persists call Ser- duced the alarm. Ensure
lers.
Arm Fail- Z Axis - Selected Pro- 1352 Z Axis - Selected The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
profile for the Z axis persists call Ser- duced the alarm. Ensure
lers.

Name Section
Arm Fail- X Axis - Move Took 1353 X Axis - Move Took The universal arm The system per- Ensure that connections Robotic Notify the alarm AM Mas-
ure 13 Too Long To Complete Too Long To Com- controller reporting formed an Emer- and circuitry related to XYZ via the UI. Per- ter
plete the alarm has gency stop: the X axis step pulse are form an emer-
detected that the an perform a Recov- functioning. gency stop.
X axis move is tak- ery. If the problem
ing longer than persists call Ser- Ensure that connections
expected to com- vice. and circuitry related to
plete. the X axis verification
pulse are functioning.
Possible causes:
1. The universal Suspect defect in soft-
arm controller ware.
receives a verifica-
tion pulse from the
X axis motor cir-
cuitry for each step
pulse. The control-
ler assumes that an
X axis move is
complete when the
number of verifica-
tion pulses
received is equal to
the step pulses
sent. Therefore a
malfunction in the
step clock/step ver-
ification circuitry will
cause this alarm.
2. Software defect
especially TPU
loading complica-
tions.

Name Section
Arm Fail- Y Axis - Move Took To 1354 Y Axis - Move Took The universal arm The system per- Ensure that connections Robotic Notify the alarm AM Mas-
ure 14 Long To Complete Too Long To Com- controller reporting formed an Emer- and circuitry related to XYZ via the UI. Per- ter
plete the alarm has gency stop: the Y axis step pulse are form an emer-
Y axis move is tak- ery. If the problem
plete. the Y axis verification
Possible causes:
tion pulse from the
Y axis motor cir-
pulse. The control-
ler assumes that an
Y axis move is
complete when the
number of verifica-
tion pulses
the step pulses
sent. Therefore a
malfunction in the
cause this alarm.
2. Software defect
especially TPU
loading complica-
tions.

Name Section
Arm Fail- Z Axis - Move Took 1355 Z Axis - Move Took The universal arm The system per- Ensure that connections Robotic Notify the alarm AM Mas-
ure 15 Too Long To Complete Too Long To Com- controller reporting formed an Emer- and circuitry related to XYZ via the UI. Per- ter
plete the alarm has gency stop: the Z axis step pulse are form an emer-
Z axis move is tak- ery. If the problem
plete. the Z axis verification
Possible causes:
tion pulse from the
Z axis motor cir-
pulse. The control-
ler assumes that an
Z axis move is com-
plete when the
number of verifica-
tion pulses
the step pulses
sent. Therefore a
malfunction in the
cause this alarm.
2. Software defect
especially TPU
loading complica-
tions.

Name Section
Arm Fail- X Axis - Movement 1356 X Axis - Movement The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ure 16 Generates Too Many Generates Too controller reporting formed an Emer- versions are correct for XYZ via the UI. Per- ter
Steps Many Steps the alarm was sent gency stop: the release - in particular form an emer-
move the X axis ery. If the problem Arm controller that pro-
motor to a position persists call Ser- duced the alarm. Ensure
which would vice. that the FTP service is
require exceeding running on the personal
the number of steps computer. Fix any incor-
that can be pro- rect versions. Re-boot
cessed. the personal computer in
lers.

Name Section
Arm Fail- Y Axis - Movement 1357 Y Axis - Movement The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
move the Y axis ery. If the problem Arm controller that pro-
lers.

Name Section
Arm Fail- Z Axis - Movement 1358 Z Axis - Movement The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
move the Z axis ery. If the problem Arm controller that pro-
lers.
Arm Fail- X Axis - Invalid Limit 1359 X Axis - Invalid The universal arm The system per- Check X axis limit sen- Robotic Notify the alarm AM Mas-
ure 19 State While Homing Limit State While control reporting formed an Emer- sors for proper operation XYZ via the UI. Per- ter
Homing the alarm was gency stop: and placement. form an emer-
attempting to initial- perform a Recov- gency stop.
ize the X axis motor ery. If the problem Check for blockages or
but encountered a persists call Ser- other causes of slippage
limit sensor that did vice. in the X axis - especially
not change state as during arm initialization.
expected.
Could be caused by Possible software
slippage in the X defect.
axis, software
defect, or malfunc-
tioning or mis-
placed limit
sensor(s).

Name Section
Arm Fail- Y Axis - Invalid Limit 1360 Y Axis - Invalid The universal arm The system per- Check Y axis limit sen- Robotic Notify the alarm AM Mas-
ize the Y axis motor ery. If the problem Check for blockages or
limit sensor that did vice. in the Y axis - especially
expected.
Could be caused by Possible software
slippage in the Y defect.
axis, software
defect, or malfunc-
tioning or mis-
placed limit
sensor(s).
Arm Fail- Z Axis - Invalid Limit 1361 Z Axis - Invalid The universal arm The system per- Check Z axis limit sen- Robotic Notify the alarm AM Mas-
ize the Z axis motor ery. If the problem Check for blockages or
limit sensor that did vice. in the Z axis - especially
expected.
Could be caused by Suspect software defect.
slippage in the X
axis, software
defect, or malfunc-
tioning or mis-
placed limit
sensor(s).

Name Section
Arm Fail- X Axis - Limit Detected 1362 X Axis - Limit The universal arm The system per- Check X axis limit sen- Robotic Notify the alarm AM Mas-
ure 22 During Move Detected During control reporting formed an Emer- sors for proper operation XYZ via the UI. Per- ter
Move the alarm has gency stop: and placement. form an emer-
detected that the X perform a Recov- gency stop.
axis motor tripped a ery. If the problem Check for blockages or
travel limit sensor persists call Ser- other causes of slippage
during a move. vice. in the X axis - especially
Could be caused during arm initialization.
by:
1. slippage in the X Check for malfunctioning
axis. X axis position encoder
2. software defect and support circuits.
3. malfunctioning or
misplaced limit sen- Suspect software defect.
sor(s)
4. X axis Encoder
malfunction.
Arm Fail- Y Axis - Limit Detected 1363 Y Axis - Limit The universal arm The system per- Check Y axis limit sen- Robotic Notify the alarm AM Mas-
detected that the Y perform a Recov- gency stop.
during a move. vice. in the Y axis - especially
by:
1. slippage in the Y Check for malfunctioning
axis. Y axis position encoder
sor(s)
4. Y axis Encoder
malfunction.

Name Section
Arm Fail- Z Axis - Limit Detected 1364 Z Axis - Limit The universal arm The system per- Check Z axis limit sen- Robotic Notify the alarm AM Mas-
detected that the Z perform a Recov- gency stop.
during a move. vice. in the Z axis - especially
by:
1. slippage in the Z Check for malfunctioning
axis. Z axis position encoder
sor(s)
4. Z axis Encoder
malfunction.

Name Section
Arm Fail- X Axis - Slippage 1365 X Axis - Slippage The universal arm The system per- Check for X axis block- Robotic Notify the alarm AM Mas-
ure 25 Detected Detected control reporting formed an Emer- ages or restrictions. XYZ via the UI. Per- ter
the alarm has gency stop: form an emer-
detected that the X perform a Recov- Check X axis position gency stop.
axis motor did not ery. If the problem encoder and supporting
reach the expected persists call Ser- circuitry for malfunction.
position at the com- vice.
pletion of a move. Ensure that current ver-
Could be caused sions of master and uni-
by: versal arm controllers
1. Blockage or are compatible with the
restricted move- current revision of the
ment in the X axis. instrument.
2. Faulty X axis
position encoder.
3. X axis velocity
profile parameters
are incompatible
with current sys-
tem.

Name Section
Arm Fail- Y Axis - Slippage 1366 Y Axis - Slippage The universal arm The system per- Check for Y axis block- Robotic Notify the alarm AM Mas-
detected that the Y perform a Recov- Check Y axis position gency stop.
ment in the Y axis. instrument.
2. Faulty Y axis
position encoder.
3. Y axis velocity
profile parameters
are incompatible
with current sys-
tem.

Name Section
Arm Fail- Z Axis - Slippage 1367 Z Axis - SlippageThe universal arm The system per- Check for Z axis block- Robotic Notify the alarm AM Mas-
detected that the Z perform a Recov- Check Z axis position gency stop.
ment in the Z axis. instrument.
2. Faulty Z axis
position encoder.
3. Z axis velocity
profile parameters
are incompatible
with current sys-
tem.
Arm Fail- X Axis - Cannot Store 1368 X Axis - Cannot The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ure 28 More Ramps Store More Ramps controller reporting formed an Emer- versions are correct for XYZ via the UI. Per- ter
the alarm ran out of gency stop: the release - in particular form an emer-
memory allocated perform a Recov- the Master and Universal gency stop.
for storage of ery. If the problem Arm controller that pro-
ramps for the X axis persists call Ser- duced the alarm. Re-
motor. vice. boot the personal com-
puter in an attempt to
restart the FTP service
and allow the CM to ini-
tiate reprogramming of
the controllers.

Name Section
Arm Fail- Y Axis - Cannot Store 1369 Y Axis - Cannot The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ramps for the Y axis persists call Ser- duced the alarm. Re-
the controllers.
Arm Fail- Z Axis - Cannot Store 1370 Z Axis - Cannot The universal arm The system per- Check that the software Robotic Notify the alarm AM Mas-
ramps for the Z axis persists call Ser- duced the alarm. Re-
the controllers.

Name Section
Arm Fail- X Axis - Motor Stalled 1371 X Axis - Motor The universal arm The system per- Check for X axis block- Robotic Notify the alarm AM Mas-
ure 31 Stalled controller reporting formed an Emer- ages or restrictions. XYZ via the UI. Per- ter
the alarm is report- gency stop: form an emer-
ing that periodic perform a Recov- Check X axis position gency stop.
readings of the X ery. If the problem encoder and supporting
axis motor position persists call Ser- circuitry for malfunction.
encoder indicate vice.
that the current Ensure that current ver-
move is being sions of master and uni-
restricted or versal arm controller
blocked. software are compatible
Could be caused with the current revision
by: of the instrument.
1. Blockage or
restricted move-
ment in the X axis.
2. Faulty X axis
position encoder.
3. X axis velocity
profile parameters
are incompatible
with current sys-
tem.

Name Section
Arm Fail- Y Axis - Motor Stalled 1372 Y Axis - Motor The universal arm The system per- Check for Y axis block- Robotic Notify the alarm AM Mas-
ing that periodic perform a Recov- Check Y axis position gency stop.
readings of the Y ery. If the problem encoder and supporting
1. Blockage or
restricted move-
ment in the Y axis.
2. Faulty Y axis
position encoder.
3. Y axis velocity
profile parameters
are incompatible
with current sys-
tem.

Name Section
Arm Fail- Z Axis - Motor Stalled 1373 Z Axis - Motor The universal arm The system per- Check for Z axis block- Robotic Notify the alarm AM Mas-
ing that periodic perform a Recov- Check Z axis position gency stop.
readings of the Z ery. If the problem encoder and supporting
1. Blockage or
restricted move-
ment in the Z axis.
2. Faulty Z axis
position encoder.
3. Z axis velocity
profile parameters
are incompatible
with current sys-
tem.

Name Section
Arm Fail- X Axis - Operation Tim- 1374 X Axis - Operation The universal arm The system per- Ensure that connections Robotic Notify the alarm AM Mas-
ure 34 eout Timeout controller reporting formed an Emer- and circuitry related to XYZ via the UI. Per- ter
the alarm has gency stop: the X axis step pulse are form an emer-
detected that the X perform a Recov- functioning. gency stop.
axis motor is taking ery. If the problem
too long to com- persists call Ser- Ensure that connections
plete a move. vice. and circuitry related to
the X axis verification
Possible causes: pulse are functioning.
1. The universal
arm controller Suspect software defect.
tion pulse from the
X axis motor cir-
cuitry fro each step
pulse. The control-
ler assumes that an
X axis move is
complete when the
number of verifica-
tion pulses
the step pulses
sent. Therefore a
malfunction in the
cause this alarm.
2. Software defect
especially TPU
loading complica-
tions.

Name Section
Arm Fail- Y Axis - Operation Tim- 1375 Y Axis - Operation The universal arm The system per- Ensure that connections Robotic Notify the alarm AM Mas-
the alarm has gency stop: the Y axis step pulse are form an emer-
detected that the Y perform a Recov- functioning. gency stop.
the Y axis verification
1. The universal
tion pulse from the
Y axis motor cir-
pulse. The control-
ler assumes that an
Y axis move is
complete when the
number of verifica-
tion pulses
the step pulses
sent. Therefore a
malfunction in the
cause this alarm.
2. Software defect
especially TPU
loading complica-
tions.

Name Section
Arm Fail- Z Axis - Operation Tim- 1376 Z Axis - Operation The universal arm The system per- Ensure that connections Robotic Notify the alarm AM Mas-
the alarm has gency stop: the Z axis step pulse are form an emer-
detected that the Z perform a Recov- functioning. gency stop.
the Z axis verification
1. The universal
tion pulse from the
Z axis motor cir-
pulse. The control-
ler assumes that an
Z axis move is com-
plete when the
number of verifica-
tion pulses
the step pulses
sent. Therefore a
malfunction in the
cause this alarm.
2. Software defect
especially TPU
loading complica-
tions.

Name Section
Arm Fail- X Axis - Operation 1377 X Axis - Operation This is an internal The system per- This is an internal soft- Robotic Notify the alarm AM Mas-
ure 37 Failed Failed software error. formed an Emer- ware error XYZ via the UI. Per- ter
Cause is always gency stop: form an emer-
software defect. perform a Recov- Suspect software defect. gency stop.
Incorrect message ery. If the problem
was placed on a persists call Ser-
queue. vice.
Arm Fail- Y Axis - Operation 1378 Y Axis - Operation This is an internal The system per- This is an internal soft- Robotic Notify the alarm AM Mas-
queue. vice.
Arm Fail- Z Axis - Operation 1379 Z Axis - Operation This is an internal The system per- This is an internal soft- Robotic Notify the alarm AM Mas-
queue. vice.

Name Section
Arm Fail- Tube Release Proce- 1380 Tube Release Pro- The controller has The system per- Ensure that Z axis move- Robotic Notify the alarm AM Mas-
ure 40 dure Failed cedure Failed detected in initial- formed an Emer- ment is unrestricted. XYZ via the UI. Per- ter
ization the tube gency stop: form an emer-
(CTS Only)
release failed. perform a Recov- Ensure CTS sensors are gency stop.
The tube release ery. If the problem functioning especially
attempts to extract persists call Ser- cap detect, piercer lock,
the piercer from a vice. piercer position, and
capped tube during travel limit.
initialization by
locking the foot and Check for excessive fric-
moving the piercer tion between piercer
up until the cap latch and probe.
detect is no longer
active. Check for proper opera-
The failure can be: tion of piercer latch and
1. Faulty cap, limit, solenoid.
piercer position, or
piercer latch sen- Ensure that (if the
sors. piercer is in a cap) there
2. Restricted or is not excessive force
blocked movement required to extract the
in the Z axis. piercer from the cap.
3. Piercer latch
solenoid. Suspect software defect.
4. Excessive fric-
tion between
piercer latch and
probe.
5. Excessive force
required to extract
the piercer from the
cap.
6. Software defect.

Name Section
Arm Fail- Sensor Or Motor Fail- 1381 Sensor Or Motor The universal arm The system per- Ensure that Z axis move- Robotic Notify the alarm AM Mas-
ure 41 ure Caused Latch Off- Failure Caused controller reporting formed an Emer- ment is unrestricted. XYZ via the UI. Per- ter
set Measurement To Latch Offset Mea- the alarm has gency stop: form an emer-
Fail surement To Fail detected that the perform a Recov- Ensure CTS sensors are gency stop.
latch offset mea- ery. If the problem functioning especially
surement opera- persists call Ser- cap detect, piercer lock,
tion failed. vice. piercer position, and
This is only applica- travel limit.
ble to CTS instru-
ments. Check for excessive fric-
The failure can tion between piercer
have many causes: latch and probe.
1. Faulty cap, limit,
piercer position, or Check for proper opera-
piercer latch sen- tion of piercer latch and
sors. solenoid
2. Restricted or
blocked movement
in the Z axis.
3. Piercer latch
solenoid.
4. Excessive fric-
tion between
piercer latch and
probe.
5. Software defect.
Arm Fail- LLD Hardware Failure 1382 LLD Hardware Fail- The universal arm The system per- Check all LLD circuitry Robotic Notify the alarm AM Mas-
ure 42 ure controller reporting formed an Emer- involved with liquid level XYZ via the UI. Per- ter
the arm has gency stop: detection. In particular form an emer-
detected that the perform a Recov- ensure that the circuitry gency stop.
LLD circuitry is not ery. If the problem responsible for interrupt-
interrupting the pro- persists call Ser- ing the processor is func-
cessor at the vice. tioning properly.
required rate.

Name Section
Arm Fail- Piercer Was Not In The 1383 Piercer Was Not In The universal arm The system per- Check the piercer latch Robotic Notify the alarm AM Mas-
ure 43 Expected State The Expected State controller reporting formed an Emer- solenoid for excessive XYZ via the UI. Per- ter
the alarm was sent gency stop: friction. form an emer-
a command to ver- perform a Recov- gency stop.
ify that the piercer ery. If the problem Check the piercer spring
was in a particular persists call Ser- for proper tension.
state (CTS or Sam- vice.
ple). The verifica- Check for proper opera-
tion failed. tion of the latch solenoid
i.e. There is a mis- and drive circuitry.
match between the
state that the Mas-
ter SW expects the Suspect software defect.
Piercer to be in and
the state that the
universal arm con-
troller thinks the
piercer is in.

Name Section
Arm Fail- Z Axis - Power DAC 1384 Z Axis - Power DAC The universal arm The system per- Check that supply volt- Robotic Notify the alarm AM Mas-
ure 44 failed failed controller reporting formed an Emer- ages are functioning and XYZ via the UI. Per- ter
the alarm has gency stop: are within specifications. form an emer-
detected that DAC perform a Recov- Ensure the reference gency stop.
controlling the ery. If the problem voltage to the Z axis
amount of power to persists call Ser- DAC is within specifica-
the Z axis motor is vice. tions.
not performing If possible, ensure that
within tolerances. the Z axis power DAC is
supplying the expected
output for the applied
input data.
Replace the Z axis DAC
or the board containing
the Z axis DAC if the
DAC is not functioning
properly.
Arm Fail- Syringe Is Always Busy 1385 Syringe Is Always The universal arm The system per- Check serial connec- Robotic Notify the alarm AM Mas-
ure 45 Busy controller reporting formed an Emer- tions to the CAVRO XYZ via the UI. Per- ter
the alarm is waiting gency stop: syringe pump. form an emer-
for the CAVRO perform a Recov- gency stop.
syringe to complete ery. If the problem
an operation but it persists call Ser-
is taking too long. vice.

Name Section
(unused) Syringe Is Always Busy 1386 Syringe Is Always The universal arm The system per- Check serial connec- Robotic Notify the alarm AM Mas-
Busy controller reporting formed an Emer- tions to the CAVRO XYZ via the UI. Per- ter
the alarm sent a gency stop: syringe pump. form an emer-
command to the perform a Recov- gency stop.
CAVRO syringe to ery. If the problem
determine if it was persists call Ser-
busy but it syringe vice.
took too long to
respond.
Arm Fail- Syringe Took Too Long 1387 Syringe Took Too The universal arm The system per- Check serial connec- Robotic Notify the alarm AM Mas-
ure 47 To Respond Long To Respond controller reporting formed an Emer- tions to the CAVRO XYZ via the UI. Per- ter
the alarm is waiting gency stop: syringe pump. form an emer-
for the CAVRO perform a Recov- gency stop.
syringe to respond ery. If the problem
to a previous com- persists call Ser-
mand but it took too vice.
long.
Arm Fail- Syringe Could Not Be 1388 Syringe Could Not The universal arm The system per- Check for blockages and Robotic Notify the alarm AM Mas-
ure 48 Initialized Be Initialized controller reporting formed an Emer- loose connections XYZ via the UI. Per- ter
the alarm could not gency stop: before attempting to form an emer-
initialize the perform a Recov- reinitialize. The pump gency stop.
CAVRO syringe ery. If the problem will not accept com-
pump. persists call Ser- mands until it has been
vice. successfully initialized.
This error can only be
cleared by successfully
initializing the probe.

Name Section
Arm Fail- Syringe Does Not 1389 Syringe Does Not The universal arm The system per- Either Software defect or Robotic Notify the alarm AM Mas-
ure 49 Understand The Com- Understand The controller reporting formed an Emer- communication error. XYZ via the UI. Per- ter
mand Command the alarm received gency stop: Check syringe serial form an emer-
an error message perform a Recov- communications cables gency stop.
from the CAVRO ery. If the problem for unreliable connec-
syringe indicating persists call Ser- tions.
that the syringe did vice.
not understand the
last command sent
to it.
Arm Fail- Syringe Command 1390 Syringe Command The universal arm The system per- Either Software defect or Robotic Notify the alarm AM Mas-
ure 50 Parameter Is Invalid Parameter Is controller reporting formed an Emer- communication error. XYZ via the UI. Per- ter
Invalid the alarm received gency stop: Check syringe serial form an emer-
that the last com- vice.
mand sent to it con-
tained an invalid
parameter.
Arm Fail- Syringe Must Be Initial- 1391 Syringe Must Be The universal arm The system per- Either Software defect or Robotic Notify the alarm AM Mas-
ure 51 ized Initialized controller reporting formed an Emer- communication error. XYZ via the UI. Per- ter
the alarm received gency stop: Check syringe serial form an emer-
that it must be ini- vice.
tialized before any
further commands
can be performed.

Name Section
Arm Fail- Syringe Plunger Is 1392 Syringe Plunger Is The universal arm The system per- Check for blockages of Robotic Notify the alarm AM Mas-
ure 52 Overloaded Overloaded controller reporting formed an Emer- the syringe plunger or XYZ via the UI. Per- ter
the alarm received gency stop: excessive back pres- form an emer-
an error message perform a Recov- sure. The pump must be gency stop.
from the CAVRO ery. If the problem reinitialized before nor-
syringe indicating persists call Ser- mal operation can
that the plunger is vice. resume.
overloaded.
Arm Fail- Syringe Valve Is Over- 1393 Syringe Valve Is The universal arm The system per- Check for valve block- Robotic Notify the alarm AM Mas-
ure 53 loaded Overloaded controller reporting formed an Emer- age or excess back pres- XYZ via the UI. Per- ter
the alarm received gency stop: sure. The valve must be form an emer-
an error message perform a Recov- reinitialized before nor- gency stop.
from the CAVRO ery. If the problem mal operation can
syringe indicating persists call Ser- resume.
that the valve is vice. Continual valve overload
overloaded. errors are an indication
the valve should be
replaced.
Arm Fail- Syringe Move Is Not 1394 Syringe Move Is The universal arm The system per- This error can be caused Robotic Notify the alarm AM Mas-
ure 54 Permitted Not Permitted controller reporting formed an Emer- by a previous error con- XYZ via the UI. Per- ter
the alarm received gency stop: dition where the valve is form an emer-
an error message perform a Recov- left in bypass or through- gency stop.
from the CAVRO ery. If the problem put position.
syringe indicating persists call Ser-
that a plunger move vice. Suspect defect in soft-
is not permitted. ware.
When the valve is
in bypass or Initialization of the
throughput position syringe via diagnostics
plunger movement mode or recovery is
commands are not required.
allowed.

Name Section
Arm Fail- Syringe Error With 1395 Syringe Error With The universal arm The system per- Suspect communica- Robotic Notify the alarm AM Mas-
ure 55 Unknown Source Unknown Source controller reporting formed an Emer- tions error or software XYZ via the UI. Per- ter
the alarm received gency stop: version incompatibility. form an emer-
an error message perform a Recov- gency stop.
from the CAVRO ery. If the problem Check CAVRO syringe
syringe but it is not persists call Ser- serial connections for
a recognized pub- vice. reliability.
lished error.
Ensure that software
versions are correct for
the release - in particular
the master, and univer-
sal arm software as well
as CAVRO syringe revi-
sion.
Correct if required.
Arm Fail- Error Communicating 1396 Error Communicat- The universal arm The system per- Check CAVRO syringe Robotic Notify the alarm AM Mas-
ure 56 With The Syringe ing With The controller reporting formed an Emer- serial connections for XYZ via the UI. Per- ter
Syringe the alarm is indicat- gency stop: reliability. form an emer-
ing that either - perform a Recov- gency stop.
1. The buffer used ery. If the problem Software defect - possi-
for receiving serial persists call Ser- bly buffer must be
data from the vice. increased.
CAVRO syringe
has overflowed.
2. The control sig-
nals used for coor-
dinating serial data
transmission to the
syringe are not in
the correct state.

Name Section
Arm Fail- Syringe Hardware Mal- 1397 Syringe Hardware Not used. The system per- Replace Syringe Mod- Robotic Notify the alarm AM Mas-
ure 57 function Malfunction formed an Emer- ule. XYZ via the UI. Per- ter
gency stop: form an emer-
perform a Recov- gency stop.
ery. If the problem
persists call Ser-
vice.
Arm Fail- Cts piercer lock not 1414 Cts piercer lock not The AM has The system per- Check CTS latch sole- Robotic Notify the alarm AM Mas-
ure 74 locked locked detected that the formed an Emer- noid and drive circuitry XYZ via the UI. Per- ter
piercer latch is not gency stop: for proper operation. form an emer-
in one of it's detent perform a Recov- gency stop.
positions. ery. If the problem Check piercer spring for
persists call Ser- proper tension.
vice.
Check piercer latch for
excessive friction.

Name Section
Arm Fail- Cts probe mode switch 1415 Cts probe mode The AM attempted The system per- Check CTS latch sole- Robotic Notify the alarm AM Mas-
ure 75 failure switch failure to set the CTS formed an Emer- noid and drive circuitry XYZ via the UI. Per- ter
mode (sample or gency stop: for proper operation. form an emer-
CTS) but after veri- perform a Recov- gency stop.
fying determined ery. If the problem Check piercer spring for
that the piercer was persists call Ser- proper tension.
not in the expected vice.
mode. Check piercer latch for
excessive friction.
Possible causes:
1. CTS spring ten-
sion too light.
2. Faulty CTS posi-
tion,
or latch sensor
3. Faulty latch sole-
noid or circuitry.
CTS Sole- The CTS hardware 1416 Cannot switch CTS The sensor was not Perform a recovery. Check CTS latch sole- Robotic Notify the alarm AM Con-
noid Latch used to change the between piercing seen after perform- If the problem per- noid and drive circuitry XYZ via the UI. Per- trollers
Failure probe between pierc- and sample mode. ing the CTS mode sists, call service. for proper operation. form an emer-
ing mode and sample switch operation. gency stop.
mode failed to switch. Failure could be Check piercer spring for
sensor, spring, proper tension.
solenoid, or soft-
ware. Check piercer latch for
excessive friction.

Name Section
Location Vial Location Unreach- 1417 Location unreach- Invalid arm homing Perform Coordi- Instrument coordinates Robotic - Notify the AM Mas-
Unreach- able able by <Probe>: position or coordinates Adjustment. are closely referenced to XYZ alarm through ter
able (sam- track # nate adjustment If the problem per- the arm home position the UI
ple or <Rack>,position failure. sists, call service. sensor.
reagent) <Position>.
1. Ensure that the home
sensor for the arm that
reports the alarm is in
the proper location.
2. From diagnostics run
coordinates adjustment.
(Cuvette) Cuvette Location 1418 Location unreach- Invalid arm homing Perform Coordi- Instrument coordinates Robotic - Notify the AM Mas-
Location Unreachable able by <Probe>: position or coordinates Adjustment. are closely referenced to XYZ alarm via the UI ter
Unreach- cuvette <Cuvette nate adjustment If the problem per- the arm home position.
able Slot ID>, well <well failure. sists, call service.
position>. 1. Ensure that the home
sensor for the arm that
reports the alarm is in
the proper location.
2. From diagnostics run
coordinates adjustment.
Unex- The probe detects liq- 1419 Probe <probe The probe detects Check probe condi- Check LLD counts in - Notify alarm AM Mas-
pected Liq- uid but the measured name> unexpected liquid but the mea- tions. If the problem Diagnostics, check through the UI ter
uid Level position of the liquid is liquid level in rack sured position of persists call Ser- probe, rerun coordi- - Flag results
unexpected. position <X>, track the liquid is unex- vice. nates. with
<YY>. pected. LLD_ERROR
Unex- The probe detects liq- 1420 Probe <probe The probe detects Check probe condi- Check LLD counts in - Notify alarm AM Mas-
uid Level position of the liquid is liquid level in sured position of persists call Ser- probe, rerun coordi- - Flag results
(Cuvette) unexpected. cuvette position the liquid is unex- vice. nates. with
<X>, slot <YY>. pected. LLD_ERROR

Name Section
Unex- The probe detects liq- 1421 Probe <Probe The probe detects Check probe condi- Check LLD counts in - Notify alarm AM Mas-
uid Level position of the liquid is liquid level in well sured position of persists call Ser- probe, rerun coordi- - Flag results
(Clean/ unexpected. position <well pos>. the liquid is unex- vice. nates. with
Rinse) pected. LLD_ERROR
Pre Aspira- Invalid liquid detection: 1422 Probe <probe Invalid liquid detec- Check probe condi- Check LLD counts in - Notify alarm AM Mas-
tion Base- difference in baseline name> Pre Aspira- tion: difference in tions. If the problem Diagnostics, check through the UI ter
line Check values read before and tion Baseline baseline values persists call Ser- probe, rerun coordi- - Flag results
Failure after liquid detection is Check Failure in read before and vice. nates. with
too low. rack position <X>, after liquid detec- LLD_ERROR
track <YY>. tion is too low.
Pre Aspira- Invalid liquid detection: 1423 Probe <probe Invalid liquid detec- Check probe condi- Check LLD counts in - Notify alarm AM Mas-
(Cuvette) too low. cuvette position after liquid detec- LLD_ERROR
<X>, slot <YY>. tion is too low.
Pre Aspira- Invalid liquid detection: 1424 Probe <Probe Invalid liquid detec- Check probe condi- Check LLD counts in - Notify alarm AM Mas-
(Clear/ too low. well position <well after liquid detec- LLD_ERROR
Rinse) pos>. tion is too low.
Aspiration Invalid liquid detection: 1425 Probe <probe Invalid liquid detec- Check probe condi- Check LLD counts in - Notify alarm AM Mas-
Baseline difference in baseline name> aspiration tion: difference in tions. If the problem Diagnostics, check through the UI ter
Check Fail- values read before and baseline check fail- baseline values persists call Ser- probe, rerun coordi- - Flag results
ure (Posi- after aspiration is too ure in rack position read before and vice. nates. with
tion) high. <X>, track <YY>. after aspiration is LLD_ERROR
too high.

Name Section
Aspiration Invalid liquid detection: 1426 Probe <probe Invalid liquid detec- Check probe condi- Check LLD counts in - Notify alarm AM Mas-
Check Fail- values read before and baseline values
baseline check fail- persists call Ser- probe, rerun coordi- - Flag results
ure after aspiration is too read before and
ure in cuvette posi- vice. nates. with
(Cuvette) high. tion <X>, slot after aspiration is LLD_ERROR
<YY>. too high.
Aspiration Invalid liquid detection: 1427 Probe <Probe Invalid liquid detec- Check probe condi- Check LLD counts in - Notify alarm AM Mas-
Check Fail- values read before and baseline values
baseline check fail- persists call Ser- probe, rerun coordi- - Flag results
ure (Well) after aspiration is too read before and
ure in well position vice. nates. with
high. <well pos>. after aspiration is LLD_ERROR
too high.
Post Aspi- Invalid liquid aspira- 1428 Probe <probe The probe did not Check probe condi- Check LLD counts in - Notify alarm AM Mas-
ration tion. LLD Baseline read name> Post Aspira- stay submerged. tions. If the problem Diagnostics, check through the UI ter
Baseline after liquid level detection Baseline persists call Ser- probe, rerun coordi- - Flag results
Check Fail- tion and after liquid Check Failure in vice. nates. with
ure (Posi- aspiration is too high: rack position <X>, LLD_ERROR
tion) the probe did not stay track <YY>.
submerged.
Post Aspi- Invalid liquid aspira- 1429 Probe <probe The probe did not Check probe condi- Check LLD counts in - Notify alarm AM Mas-
ure aspiration is too high: cuvette position LLD_ERROR
(Cuvette) the probe did not stay <X>, slot <YY>.
submerged.
Post Aspi- Invalid liquid aspira- 1430 Probe <Probe The probe did not Check probe condi- Check LLD counts in - Notify alarm AM Mas-
ure (Well) aspiration is too high: well position <well LLD_ERROR
the probe did not stay pos>.
submerged.

Name Section
(Cuvette) The requested Cuvette 2040 Cuvettes strip posi- Invalid positioning The system per- Report this alarm and Processor/ - Notify the AM Con-
Invalid move is not allowed tioning failure. command. formed an Emer- backup log as a com- Software alarm through trollers
Move gency stop: plaint. This is a software the UI
perform a Recov- defect that requires cor- - Perform an
ery. rection. emergency stop
If the problem per-
sists call Service.
(Cuvette) Insufficient Liquid 2075 Insufficient liquid in This error flag is set Call Service. Verify probe alignment; Fluid - Notify the AM Mas-
Insufficient detected when mixing cuvette <Cuvette by the analyzer run Diagnostics "Coordi- Movement alarm via the UI ter
Liquid is performed in a Slot ID> well <well when, aspirating nates Adjustment" for
cuvette. position>. from a rack cuvette the probe that reported
cell, liquid is not the alarm.
found or the avail-
able liquid volume
is less than the vol-
ume to be aspi-
rated.
Schedul- The actual execution 2080 Unrecoverable Internal scheduling The system per- Report this alarm and Processor/ - Notify the AM Mas-
ing Time did not meet a critical scheduling time conflict. formed an Emer- backup log as a com- Software alarm through ter
Violation scheduling time. The violation. gency stop: plaint. This is a possible the UI
job failed and it is not perform a Recov- software defect that - Perform Emer-
possible to recover ery. requires correction. It gency Stop
If the problem per- could also be the speed
sists call Service. of the hardware.
Observe both cuvette
and arm movement for
speed.

Name Section
LIS Mes- The UDC storage is 3200 Storage of mes- Number of mes- Check communica- Ensure LIS system is Processor/ - Notify user CM
sage Stor- almost full of messages sent to LIS sages pending to tion status in both physically attached and Software through alarms
age Full sages waiting to be <%> full. be uploaded to LIS ends. If communi- powered on. If possible area.
sent to LIS. is reaching capac- cations cannot be from the LIS, verify con- - Create Log
ity. restored disable nection status. Verify Entry
them and call ser- wiring configuration
vice. according to the LIS ven-
dor specification.
LIS Mes- The UDC storage is 3201 Storage of mes- Number of mes- Check communica- Refer to 1130 Processor/ - Notify user CM
sage Stor- almost full of messages sent to LIS sages pending to tion status in both Software through alarms
age sages waiting to be overloaded. New be uploaded to LIS ends. If communi- area.
Over- sent to LIS. No more uploaded mes- has reached stor- cations cannot be - Create Log
loaded messages are sages will be age limit. restored disable Entry
accepted. rejected. them and call ser-
vice.
Upload UDC Rejected 3202 Upload message Communications Check communica- Refer to 1130 Processor/ - Notify user CM
Message Uploaded Message was rejected and are not properly tion status in both Software through alarms
Rejected therefore not sent configured or stor- ends. If communi- area.
to LIS. age of messages cations cannot be - Create Log
sent to LIS over- restored disable Entry
loaded. No more them and call ser-
messages can be vice.
accepted.

Name Section
Auto Start Auto Start could not be 3211 Auto Start failed. Possible causes The system looks Recheck all actions - Notify user CM
Failed started. are: for an opportunity listed in Operator's through UI.
- The instrument to auto start every 1 actions column, Check - Retry Auto
was in a status that minute. Certain LIS settings Start after 1
did not allow for the conditions might minute.
auto start to be initi- change without
ated. operator's interven-
- CTS Filter was not tion.
detected (for CTS Identify the cause
configuration only). among the follow-
- Enhanced clean ing and resolve:
required. - Instrument status:
- Temperatures are the auto start can-
out of range. not be initiated
- There is a ORU when the status is
disabled. Initializing, Warm-
ing Up, Error,
Emergency Stop,
Controlled Stop,
Maintenance or
Diagnostics.
- CTS Filter miss-
ing: install a new fil-
ter (Maintenance
activity).

Name Section
Auto Start Auto Start could not be 3211 (continued)
Failed started. (continued) (con-
- Temperatures are
(continued) tinued)
out of range: wait
until the tempera-
tures stabilize
(depending from
the system and
ambient condi-
tions, this might
take more than 30
minutes); if they do
not stabilize, call
Service.
- Enhanced Clean
required: perform
Enhanced Clean
for all probes
(Maintenance activ-
ity).
- ORU disabled:
call Service.
Invalid The rack button 4015 Rack button identi- Rack position key- Call Service. Check that cabling is Rack Han- - Notify the AM Con-
(Rack) But- pressed is not a valid fication failure. pad malfunction. properly seated to the dling alarm through trollers
ton code. rack LED status boards. the UI
If cabling is correct, - trace the error
replace the rack status for debug pur-
boards. pose

Name Section
Scanner Cannot communicate 4020 Barcode reader Cable discon- Call Service. Ensure that the cables Rack Han- - Notify the AM Con-
Communi- with the bar code communication fail- nected. Barcode are seated properly. To dling alarm through trollers
cations reader. ure. reader malfunction. determine if the wiring is the UI
Rack controller or correct from the reader - work without
Reader Traveling to the computer, turn off positive id
board malfunction. the instrument power,
remove the cover of the
reader, disconnect the
cable to the reader, and
attach the loopback con-
nector. After the connec-
tor is attached, restart
the instrument and enter
diagnostics. On the SW,
Covers, Racks tab,
press the Perform Loop
Back Check. If the test
has a result of Pass,
then there could be a
problem with the reader
or power to the reader. If
the result is Fail, then
check all the cabling.

3-4 Troubleshooting Procedures
Please refer to individual chapters for detailed troubleshooting procedures.

Chapter 4 Enclosure/Chassis 4-1
Chapter 4
Enclosure/Chassis
The ACL-TOP instrument is built on a base/chassis foundation to which the functional modules of the instru-
ment are precisely aligned and mounted. Enclosing the instrument are 18 internal and external urethane
skins. The chassis and the internal and external skins provide the structural support for the ACL-TOP instru-
ment. On the front panel of the instrument are two assemblies, the Sample and the Reagent doors, that pro-
vide operator access to the instrument. This chapter describes the chassis, enclosure, covers and doors for
the ACL-TOP instrument and their removal and replacement. This chapter also includes the removal/
replacement procedures for the monitor control arm.
4-1 Overview
Chassis
The chassis, as shown in Figure 4-1 "ACL-TOP Chassis", is a precision machined casting. To ensure
accuracy of the instrument, the top and bottom horizontal surfaces are machined to a very close tolerance.
In addition, to further ensure accuracy of the instrument, all functional modules, e.g., Robotic Arm Assem-
blies, Cuvette Handling System, Rack Handling System, are carefully aligned to the chassis by the use of
dowel pins in the chassis. The top horizontal surface is machined to establish a flat reference plane to which
the Cuvette Handling System and Rack Handling System are mounted. (The Cuvette Handling System is
composed of the Loader Assembly, Shuttle Assembly, Incubators #1 and #2, ORU Assembly and the
Cuvette Waste Assembly and is described in Chapter 9 Cuvette Handling System. The Rack Handling
System is composed of the Sample Assembly, Reagent Assembly and the Bar Code Reader Assembly and
is described in Chapter 11 Rack Handling.) The bottom horizontal surface of the chassis is mounted to
a urethane base that establishes the footprint (or base) of the ACL-TOP Instrument.

4 - 2 Chapter 4 Enclosure/Chassis
4-2 Physical Layout
Figure 4-1 ACL-TOP Chassis
Pylons
Rear Walls
Chassis
Base Skin
To the rear of the chassis are three aluminum sand castings, called pylons, to which the Robotic Arms are
attached. The three pylon assemblies have dowel pins to align them to the chassis to ensure their precise
location. The pylon assemblies provide the attachment and alignment of the robotic arms and the sub mod-
ules secured to the horizontal plane of the chassis. The foundation to which the entire ACL Top instrument
is built is composed of the chassis, pylon assemblies, and the base skin which establishes the instrument
footprint.

As stated, the ACL-TOP foundation is composed of the chassis and pylon assemblies installed on a base.
The foundation assembly also has two rectangular sheet metal panels mounted to the back of the pylon
assemblies that create the back wall of the ACL-TOP Instrument, as shown on Figure 4-1 "ACL-TOP Chas-
sis". The lower back wall assembly houses 2 power supplies for the instrument and is also referred to as
the Power Supply Assembly. The chassis, pylon assemblies, card cage/backplane assembly, two back wall
assemblies, along with some miscellaneous brackets, interconnection cables, and fluidic routing tubes
make up the foundation assembly to which the functional modules are attached.
Enclosure
Once the functional modules, including the Robotic Arm Assemblies, have been mounted, the external and
internal skins complete the instrument. As shown on Figure 4-2 "ACL-TOP Enclosure", there are four
external skins, and three internal skins that provide ACL-TOP structural integrity. The inner right skin and
inner left skin reinforce the right and left outer walls creating a solid foundation for the front panel assembly.
The right skin assembly, the left skin and the center skin establish the vertical references for the front panel
assembly. Once the front panel assembly is in place, the top panel is mounted to both the back wall and the
top of the front panel assembly and completes the structural integrity of the instrument. The remaining skins
are internal and are used for equipment protection and cosmetic reasons.

Figure 4-2 ACL-TOP Enclosure

Upper Skin Top Skin
Inner Left Skin (Sample Side) Center Skin
Left Skin
Sample
Door Upper Skin
Reagent Side
Inner Right
Skin
Reagent Right
Front Panel Door Skin
Sample and Reagent Doors
The Sample and Reagent doors provide operator access to the ACL-TOP instrument. Each of the doors can
be opened, closed, and locked closed. For normal operation, the doors are required to be closed and
locked. Each door has a sensor to determine whether it is open or closed and each of these sensors output
to a virtual LED on the diagnostic screen. The Diagnostic section describes the operation of the door sens-
ing during diagnostics and the Removal/Replacement section describes the removal and replacement of the
sensors.
4-3 Interconnect Diagrams
Interconnect diagrams are not applicable to this chapter.

4-4 Theory of Operation
Theory of operation is not applicable to this chapter.
4-5 Adjustments/Verification
There are no specific adjustment or verification procedures for the enclosure or chassis. Visual verification
of the proper alignment and operation by the service engineer at the end of the service visit is sufficient.
4-6 Diagnostics
Cover Status Area
The diagnostic area for the covers is the door closed indications and the door lock indications and switches.
These indications and switches are shown on the Controllers, Covers and Racks tab of the Diagnostics
screen as seen on Figure 4-3 "Diagnostics Screen, Controllers, Covers and Racks Tab". The indicators
and switches specific to the covers are described following the figure.

Figure 4-3 Diagnostics Screen, Controllers, Covers and Racks Tab
Covers Area
Figure 4-4 "Cover Status", expands the Cover area of the diagnostic window and shows there are two
LEDs indicating the door status.
The Sample cover virtual LED turns green when the sample door is closed
The Reagent cover virtual LED turns green when the reagent door is closed.

Figure 4-4 Cover Status
Virtual LEDs
Door Lock/Unlock Buttons
Sample Door Sensing
The Sample Door has a sensor located on the upper right corner of the door or the lower right corner of the
door, depending on the unit. To check the sensor operation, unlock the door (by selecting the Sample
Cover radio button and clicking the Unlock button) and open and close the door. The LED should be lit
when the door is closed and not be lit when the door is open. The sensor can also be manually pressed to
cause the LED to go on (falsely) indicating the door is closed.
NOTE: Instruments below serial number 05070377 have the sensor located in the lower right
corner of the door. Those units can be upgraded by ordering IL P/N 00027765500.
Reagent Door Sensing
The Reagent door sensor is a slot sensor, that uses a push button to break the beam. The push button is
located at the bottom right corner where the door closes. To check the sensor operation, unlock the door (by
selecting the Reagent Cover radio button and clicking the Unlock button), and open and close the door.
The LED should be lit when the door is closed and not be lit when the door is open. You can also push the
button with a finger to (falsely) indicate the door is closed.
Locking/Unlocking the Sample and Reagent Doors
The sample and reagent doors can also be individually locked and unlocked by selecting the radio button
for the appropriate door and clicking on the Lock or Unlock button.
4-7 Removal/Replacement Procedures
The following lists the steps to be performed to remove each door, panel, cover, and/or skin of the ACL-TOP
enclosure as well as the sensors on the sample and reagent covers. In addition to the enclosure items, the
removal/replacement of the Monitor Control Arm is included although it is not physically a part of the enclo-
sure.

NOTE: Removing portions of the enclosure must be performed in a specific sequence to

avoid personal injury or damage to the skins. For each removal procedure, there may be pre-
requisites that are identified and must be met before the specific item can be removed.
Sample Door Sensor Removal/Replacement
Sample Door Sensor Removal
Perform the following steps to remove the sample door sensor.

1. Open the sample door.
2. There are one of two types of sensors for the Sample door. One sensor is mounted in the lower right of
the door as shown on Figure 4-5 "Sample Door Lower Right Sensor (upgradable) ". (This sensor is
upgradable by ordering part number 0002776500.) The other type of sensor is mounted in the upper
right of the Sample door as shown in Figure 4-6 "Sample Door Upper Right Sensor (current)".

Figure 4-5 Sample Door Lower Right Sensor (upgradable)
Sensor
Figure 4-6 Sample Door Upper Right Sensor (current)
Door Sensor
3. Unplug, at connector (J2/P2) under the reagent door, the two wires that lead from the back of the sen-
sor.
4. If the instrument has the lower sensor, using a 3.0mm Allen wrench, remove the two screws holding the
sensor and remove the sensor and the wires leading to connector (J2/P2).
5. If the instrument has the upper sensor, using a 2.5mm Allen wrench, remove the two screws holding the
sensor and remove the sensor and the wires leading to connector (J2/P2).
Sample Door Sensor Replacement
To replace the Sample Door Sensor, perform the preceding removal instructions then perform the following
steps.
1. Attach the new sensor with the two screws removed and reroute the wire to the connector (J2/P2).
2. Reconnect the connector.

3. Close and open the door and verify the virtual LED on the SW, Covers and Racks tab of the Diagnostics
screen lights when the door is closed and goes out when the door is open.
Reagent Door Sensor Removal/Replacement
Reagent Door Sensor Removal
Perform the following steps to remove the reagent door sensor.

1. Open the reagent door.
2. Disconnect the two wires from the sensor as shown on Figure 4-7 "Reagent Door Sensor".
3. Using a 3.0mm Allen wrench, remove the two screws holding the sensor.
Figure 4-7 Reagent Door Sensor
Sensor Mounting
Screws
4. Remove the sensor.
Reagent Door Sensor Replacement
To replace the Reagent Door Sensor, perform the preceding removal instructions then perform the following
steps.
1. Connect the two wires to the back of the new sensor.
2. Attach the new sensor with the two screws.
3. Close and open the door and verify the virtual LED on the SW, Covers and Racks tab of the Diagnostics
screen lights when the door is closed and goes out when the door is open.
Sample Door Removal/Replacement
Removal/replacement of the sample door includes the removal of a sensor flag and a ground wire.

Chapter 4 Enclosure/Chassis 4 - 11
Sample Door Removal
Perform the following steps to remove the sample door.

2. Using a 1.5mm Allen wrench, remove the screw securing the left hinge of the sample door.as shown on
Figure 4-8 "Sample Door Hinge Attaching Screw".
Figure 4-8 Sample Door Hinge Attaching Screw
Holding Screw
3. Using a 3.0mm Allen wrench, remove the screw securing the ground wire and flag to the right hinge
assembly as shown on Figure 4-9 "Sample Door ground Wire/Flag".

Figure 4-9 Sample Door ground Wire/Flag
Ground Wire/Flag
Screw
4. Using a 2.5mm Allen wrench, remove the two screws securing the hinge and remove the lower portion
of the hinge as shown on Figure 4-10 "Sample Door Hinge".
Figure 4-10 Sample Door Hinge
Hinge Attachment
Screws
Lower Portion
of Hinge
5. Move the Sample door to a horizontal position; lift the right end off the hinge while sliding it off the left
hinge assembly.

Sample Door Replacement
To replace the sample door, perform the preceding removal instructions then install the door by performing
the removal instructions in reverse order. Note that the installation of the flag, ground wire are important and
must be as shown in Figure 4-11 "Flag/Ground Wire Installation". The small tab of flag is inserted into the
space at end of molded hinge. The (2) M3 Star Washers are to be located on both sides of the flag followed
by the ground lug, then the 3rd star washer and finally the M3x8 socket head cap screw. Also note that the
Ground wire must be parallel with flag and the Ground wire should run under the white optical sensor cable.
Figure 4-11 Flag/Ground Wire Installation
Ground Wire
Flag
Tab
Optical Sensor Cable
Reagent Door Removal/Replacement
There are no prerequisites to removing the reagent door.
Reagent Door Removal
Perform the following steps to remove the reagent door.

1. Open the Reagent Door.
2. Using a 1.5mm Allen wrench, loosen the screw on the left hinge of the door as shown in Figure 4-12
"Reagent Door Left Hinge".

Figure 4-12 Reagent Door Left Hinge
Holding Screw
3. Using a 4.0mm Allen wrench, remove the screw attaching the right hinge to the reagent door as shown
on Figure 4-13 "Reagent Door Hinge".
Figure 4-13 Reagent Door Hinge
Attachment
Screw
Removal
Pocket
4. Insert a flat tip screwdriver into the removal pocket (if necessary) to pry the hinge loose from the align-
ment pins on the reagent door.
5. Remove the hinge by sliding it to the left as shown on Figure 4-14 "Reagent Door Hinge Removal".

Figure 4-14 Reagent Door Hinge Removal
Hinge Arm
6. Move the reagent door to a horizontal position; lift the right end off the hinge while sliding the door off the
left hinge assembly.
Reagent Door Replacement
To replace the reagent door, perform the preceding removal instructions then install the door by performing
the removal instructions in reverse order. Ensure the two alignment pins for the hinge are aligned with the
hinge before attempting to move the door for insertion of the attachment screw.
Top Skin Removal/Replacement
Prerequisites: There are no items that must be removed prior to removing the top skin.
Top Skin Removal
Perform the following steps to remove the Top Skin.

1. Using a 3.0mm Allen wrench, remove the five screws (and washers) at the front and the three screws
(and washers) at the rear of the top skin as shown on Figure 4-15 "Top Skin".

Figure 4-15 Top Skin
Top Skin Screws
2. Lift the top skin and remove it from the instrument.
Top Skin Replacement
To replace the top skin, perform the preceding removal instructions then install the assembly by performing
the removal in reverse order.
Front Panel Assembly Removal/Replacement
The front panel assembly requires the removal of the top skin prior to its removal. However, there are also
a number of ribbon cables, sensor connections, and ground connections that need to be disconnected to
physically remove the front panel.
Front Panel Assembly Removal
Perform the following steps to remove the Front Panel Assembly.

1. Open both the Sample and Reagent doors of the ACL-TOP instrument.
2. Remove the top skin as described in "Top Skin Removal/Replacement".
3. Using a 4.0mm Allen wrench, remove the two screws (and washers) at the bottom left and right of the
front panel as shown on Figure 4-16 "Front Panel Lower Screws".

Figure 4-16 Front Panel Lower Screws
Front Panel Screws
4. Using a 3.0mm Allen wrench, remove the three screws (and washers) in the upper right, middle and left
of the front panel as shown on Figure 4-17 "Front Panel Upper Right Screw", Figure 4-18 "Front
Panel Center Screw", and Figure 4-19 "ACL-TOP Enclosure Upper Left Screw".
Figure 4-17 Front Panel Upper Right Screw
Attachment Screw

Figure 4-18 Front Panel Center Screw
Attachment Screw
Figure 4-19 ACL-TOP Enclosure Upper Left Screw
Attachment Screw
5. Carefully move the front panel off the unit approximately six inches and rest it vertically for disconnection
of the cables.
6. Disconnect the two ribbon cables for the Sample and Reagent keypads and the signal cable for the door
sensors and locks (labeled Safety Cover Interlock) that extend from the lower right of the panel to the
Disconnect PCB. These cables are as shown on Figure 4-20 "Front Panel Cable Connections".
NOTE: The two ribbon cable connectors have tabs on the end to lock them in place. The tabs
must be lifted from the jack before the plug can be removed. The signal cable has a lock on
the connector that must be released by pressing on the tab on the left side of the plug to
release it.

Figure 4-20 Front Panel Cable Connections
Front
Panel
Connections
7. Disconnect the ground connections from the front cover to the chassis.
Front Panel Assembly Replacement
To replace the front panel assembly, perform the preceding removal instructions then install the front panel
by performing the removal in reverse order. Note that the top skin needs to be installed following the front
panel.
Monitor Control Arm Removal/Replacement
Prerequisites: There are no items that must be removed prior to removing the monitor control arm.
Monitor Control Arm Removal
Perform the following steps to remove the Monitor Control Arm.

1. Remove the connectors for the monitor and keyboard from the monitor control arm and place the wires
on the PC or the shelf.
2. Move the mouse to the PC or the shelf.
3. Using a 6.0mm Allen wrench, remove the two screws (and washers) securing the Monitor Control Arm
as shown on Figure 4-21 "Monitor Control Arm"

Figure 4-21 Monitor Control Arm
Attachment
Screws
4. Remove the Monitor Control Arm from the instrument by pulling it away from the instrument.
CAUTION: The Monitor Control arm is heavy.
Monitor Control Arm Replacement
To replace the monitor control arm, perform the preceding removal instructions then install the assembly by
performing the removal in reverse order.
Sample Area Interior Skins Removal/Replacement
Sample Area Interior Skins Removal
Perform the following steps to remove the sample module interior skins in the order listed. (Refer to Figure
4-22 "Sample Module Interior Skins").
NOTE: Removal of the front panel assembly is not necessary.

2. Move probe housing to its highest position and foremost front position.
3. Move the arm to the leftmost position.
4. Grasp the Sample Area Module Cover at the top and pull straight up to remove it.

Figure 4-22 Sample Module Interior Skins

Sample Syringe
Pump Interior
Skin
Sample Accumulator/
Wash Station
Interior Skin
Sample Area
Module Cover
5. Grasp the Sample Syringe Pump Interior Skin at the top with two hands (one on each side of the skin)
and pull toward the front of the instrument to release the skin from its retaining flanges.
6. Disconnect the connection to the ground lug on the back of the skin as shown in Figure 4-23 "Interior
Skin Ground Lug/Snap Detent".
NOTE: The latest version of the CTS version of ACL-TOP include magnets rather than the
snap detents to hold the cover in place.
Figure 4-23 Interior Skin Ground Lug/Snap Detent
Ground Lug Snap Detent
7. Carefully remove the skin from the instrument using caution to avoid hitting the probe assembly.
8. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Sample Accumulator/
Wash Station Interior Skin.

Sample Area Interior Skins Replacement
To replace the sample area interior skins, perform the preceding removal instructions then install the module
by performing the removal in reverse order. Ensure the ground wire is attached to the Sample Syringe Pump
Interior Skin and the snap detents are properly aligned in the brackets on the rear as shown in Figure 4-24
"Brackets for Snap Detents".
Figure 4-24 Brackets for Snap Detents
Cover Holding Brackets
Inner Left Skin Removal/Replacement
Prerequisites: Prior to removing the Inner Left skin, the top panel and front panel must be removed as pre-
viously described.
Inner Left Skin Removal
Perform the following steps to remove the inner left skin.

1. Power down the ACL-TOP instrument and remove the plug from the AC Main.
2. Remove the top skin and front panel assembly.
3. Using a 3.0mm Allen wrench, remove the four screws (and washers) securing the upper skin above the
sample side robotic arm and remove the skin as shown on Figure 4-25 "Sample Side Upper Skin."
Figure 4-25 Sample Side Upper Skin.
Upper
Skin
Attachment
Screws
Attachment
Screws
4. Using a 3.0mm Allen wrench, remove the six screws (and washers) on the inside of the instrument
attaching the inner left skin to the chassis as shown on Figure 4-26 "Inner Left Skin".

Figure 4-26 Inner Left Skin
Inner Left Skin

Attachment Screws
Inner Left Skin
Attachment Screws
5. Slide the skin toward the front and the interior of the instrument and remove it from the instrument.
WARNING: Be careful the tinted window does not fall out which is
glued in place to the inner left wall.
Inner Left Skin Replacement
Install the inner left skin in reverse order of its removal followed by installing of the left skin and
the front panel assembly.
Left Skin Removal/Replacement
Prerequisites: Prior to removing the left skin, the top skin, front panel assembly, monitor control arm, and
inner left skin must be removed.
Left Skin Removal
Perform the following steps to remove the left skin.

1. Remove the top skin, front panel assembly, monitor control arm, and inner left skin.
2. Using a 3.0mm Allen wrench, remove the two screws (and washers) at the back and the two screws at
the bottom attaching the left skin to the chassis as shown on Figure 4-27 "Left Skin".

Figure 4-27 Left Skin
Attachment
Screws
3. Remove by sliding the skin sideways (away from the instrument).
Left Skin Replacement
To replace the left skin, perform the preceding removal instructions then install the skin by performing the
removal in reverse order. Note that the front panel assembly, monitor control arm and inner left skin need to
be installed following the left skin.
Reagent Area Interior Skins Removal/Replacement
Reagent Area Interior Skins Removal
Perform the following steps to remove the Reagent Area Interior Skins. See Figure 4-28 "Reagent Area
Inner Skins".
NOTE: Removal of the front panel assembly is not necessary for removal of the reagent area
interior skins.
1. Open the reagent door.
NOTE: Throughout this procedure, the arm(s) need to be manually moved (as necessary) to
ensure they are not damaged during the removal of the skins.
2. Move probe housing to its highest position and foremost front position.
3. Move the arm to the leftmost position.
4. Grasp at the top and pull straight up to remove the reagent module assembly cover.
5. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Peristaltic Pump Inte-
rior Skin.

6. Lift (straight up) and remove the peristactic pump interior skin.
Figure 4-28 Reagent Area Inner Skins
Reagent
Accumulator/
Wash Station
Interior Skin
Reagent Syringe
Pump Interior
Cover
Peristaltic
Pump
Interior
Skin
Reagent Module Assembly Cover
7. Grasp the Reagent Syringe Pump Interior Skin at the top with two hands (one on each side of the skin)
and pull toward the front of the instrument to release the skin from its retaining flanges.
8. Disconnect the connection to the ground lug on the back of the skin as shown in Figure 4-23 "Interior
Skin Ground Lug/Snap Detent".
NOTE: The latest version of the CTS version of ACL-TOP include magnets rather than the
snap detents to hold the cover in place.
Figure 4-29 Interior Skin Ground Lug/Snap Detent
Ground Lug Snap Detent
10. Using a 3.0mm Allen wrench, remove the two screws (and washers) attaching the Reagent Accumula-
tor/Wash Station Interior Skin.

Reagent Area Interior Skins Replacement
To replace the Reagent Area Interior Skins, perform the preceding removal instructions then install the skins
by performing the removal in reverse order. Ensure the ground wire is re-attached to the Reagent Syringe
Pump Interior Skin and the snap detents are properly aligned in the brackets on the rear as shown in Figure
4-30 "Brackets for Snap Detents".
Figure 4-30 Brackets for Snap Detents
Cover Holding Brackets
Inner Right Skin Removal/Replacement
Prerequisites: Prior to removing the inner right skin, the top skin, front panel assembly, and reagent area
interior skins must be removed as previously described.
Inner Right Skin Removal
Perform the following steps to remove the inner right skin.

2. Remove the top skin and front panel assembly.
3. Remove the Reagent Area Interior Skins as previously described.
4. Using a 3.0mm Allen wrench, remove the two screws in the upper left (accessible from the sample side
of the divider) and the one screw in the upper right holding the upper skin above the reagent side
robotic arm as shown on Figure 4-31 "Upper Skin Above the Reagent Side Robotic Arms".

Figure 4-31 Upper Skin Above the Reagent Side Robotic Arms
Attachment
Screws
Attachment
Screws
5. Using a 3.0mm Allen wrench, remove the four screws (and washers) on the inside of the instrument
attaching the right skin to the inner right skin as shown on Figure 4-32 "Inner Right Skin".
Figure 4-32 Inner Right Skin
Attachment
Screws
6. Slide the skin toward the interior of the instrument and remove it from the instrument.
Inner Right Skin Replacement
To replace the inner right skin, perform the preceding removal instructions then install the skin by performing
the removal in reverse order. Note that the right skin and the front panel assembly need to be installed fol-
lowing the top skin.

Right Skin Removal/Replacement
Prerequisites: Prior to removing the right skin, the top skin, front panel assembly, and reagent area interior
skins must be removed.
Right Skin Removal
Perform the following steps to remove the right skin.

2. Remove the top skin, front panel assembly, reagent area interior skins, and the inner right skin.
3. Remove all external connections on the right side of the instrument (I/O Panel Assembly) from their
respective plugs.
4. Disconnect the plug on the I/O PCB (J1/P1) for the Rinse and Clean Bottle Fluid Level Sensors as
shown on Figure 4-33 "Right Skin Removal".
Figure 4-33 Right Skin Removal
Connector
(J1/P1) for
sensors
5. Using a 3.0mm Allen wrench, remove the two screws (and washers), at the bottom, and the two screws
(and washers) at the rear attaching the right skin to the chassis as shown in Figure 4-34 "Right Skin".

Figure 4-34 Right Skin
Attachment
Screws
6. Slide the right skin away from the instrument to remove it from the instrument.
Right Skin Replacement
To replace the right skin, perform the preceding removal instructions then install the skin by performing the
removal in reverse order.
Center Skin Removal/Replacement
Prerequisites: Prior to removing the center skin, the top skin, and front panel assembly must be removed.
Center Skin Removal
Perform the following steps to remove the Center Skin.

1. Remove the top skin and front panel from the instrument.
2. Using a 4.0mm Allen wrench, remove the two screws (and washers) from the center mounting bracket
as shown in Figure 4-35 "Center Skin Attachment".
3. Remove the skin by lifting it straight up and toward the front of the instrument.

Figure 4-35 Center Skin Attachment
Attachment
Screws
Center Skin Replacement
To replace the center skin, perform the preceding removal instructions then install the new skin by
performing the removal in reverse order.
Upper Back Wall Removal/Replacement
Removal/replacement of the upper back wall is not considered to be a field service activity.
Lower Back Wall (Power Supply Assembly) Removal/Replacement
Removal/replacement of the lower back wall is not considered to be a field service activity.

Chapter 5 Processor / Software 5-1
Chapter 5
5-1 Overview:
The ACL-TOP software architecture is comprised of two modules, (1) the Control Module (CM) consisting
of the touchscreen monitor, keyboard, mouse, and the personal computer and (2) the Analytical Module
(AM) consisting of the ACL-Top instrument itself. The Control Modules primary responsibilities include
processing user input
presenting status / results
storing data
communicating with a Laboratory Information System (LIS)
printing
Note that a software version display is provided on the ACL-TOP system display by clinking on System ->
Instrument Status as shown on Figure 5-1 "System Software Version Selection".
Figure 5-1 System Software Version Selection
Clicking on the Software Version tab in the resulting screen display lists the present version of all installed
software as shown in Figure 5-2 "Software Version Tab".

5 - 2 Chapter 5 Processor / Software
Figure 5-2 Software Version Tab
The Analytical Modules responsibilities include controlling and coordinating devices in the instrument to pro-
duce results (patient, quality control, diagnostics, maintenance) as requested by the operator. Both the Con-
trol and Analytical modules include a number of software components working together to achieve the
instruments features. Figure 5-3 "Software Components" displays an overview of the components that
reside in each module. The module description provides a brief description of each component within the
module.

Figure 5-3 Software Components
Control Module
The control module resides in the personal computer and is composed of the following software compo-
nents. The function of each component is also briefly described.

Job Ordering accepts patient, QC, and calibration requests from the operator or Laboratory Infor-
mation System.
Reagent Management provides for the placement and stability of placed materials.
Data Reduction processes optical results according to the rules in the test definition to produce a
specific result.
Results Management provides access to lists of results of tests that are completed or pending
completion.
Printed Reports produces hard copies of requested information on a local or network printer.
Quality Control provides a mechanism for users to define rules to ensure samples are of high qual-
ity.
Maintenance provides a collection of actions that must be executed at different intervals to maintain
a healthy instrument.
Diagnostic Ordering enables the service engineer or customer to identify and correct an instru-
ment malfunction.
Log Management records operator and instrument actions providing an audit history and assis-
tance in troubleshooting any problems.
Alarm Management alerts the operator to an action that needs to be taken to keep the instrument
executing efficiently.
Test Definition enables a specialist to define the steps needed to perform a new test or to edit an
existing test.
Material Definition enables a specialist to define a material used in test processing.
Global Definition permits the setting of information that is used across many elements.
Database Management controls access to storing and retrieving data.
LIS Interface provides communications between the TOP personal computer and the Laboratory
Information System.
AM Interface provides communications between the TOP personal computer and the Analytical
Module (the instrument).
Analytical Module
The analytical module resides on various processors in the instrument and is composed of the following
software components. The function of each component is also briefly described.
CM Interface provides communications between the ACL-TOP personal computer and the instru-
ment (AM).
Job Processing controls job sorting and job submission.
Device Scheduling provides and coordinates the steps needed to have devices in the instrument
perform their function at the scheduled time.
Alarm Management supplies alarm information to the personal computer for user notification and
changes the instrument state based on the alarm.

Safety detects when a safety violation occurs and it places the instrument into a safe state if a vio-
lation is detected.
Rack Management controls and tracks rack insertion, bar code reading, and removal.
Cuvette Management controls cuvette status and moving cuvettes from the cuvette loader to the
cuvette waste.
Fluid Movement conducts all tasks needed to move fluid from one point to another. These tasks
include coordinate determination, aspiration, mixing, dispensing, rinsing, and cleaning.
Material Management is a database used to track the contents of both rack and cuvette materials.
Instrument Status tracks the instrument state and thereby controls what operations can be per-
formed.
Maintenance executes maintenance routines as requested by the operator.
Waste Management monitors instrument waste and changing the instrument to the appropriate
state if waste is full.
Diagnostics executes operator requested maintenance and testing actions.
Motor Control is a device control component and supplies the operations to control stepper motors.
Thermal Control is a device control component and provides either heating or cooling control to
ensure sample processing is collected at the necessary temperature.
Optical Reading is a device control component and performs data acquisition of different optical
wavelengths during the chemical reaction.
5-2 Theory of Operation/Block Diagram
The ACL-TOP processor architecture is four levels as shown in Figure 5-4 "Processor Architecture". The
hardware included in this architecture includes:
personal computer
master processor
sub-system controllers
functional controllers.
The personal computer is a Windows based, Intel Pentium class processor and provides the primary inter-
face between the operator and the ACL-Top instrument. The master processor, in the Analytical Module, is
an Intel Pentium class processor that operates in a real-time mode controlling the ACL-Top instrument. The
subsystem controller processors are Motorola 68332 processors or CAVRO processors, and are used for
Rack Handling, Cuvette handling, Optical Reading, and Fluid Movement. At present, there is one functional
controller. The functional controller is a Probe Integrated Controllers and its purpose is probe heating.

Figure 5-4 Processor Architecture
The personal computer communicates to the master processor via an Ethernet connection. The master pro-
cessor communicates to the sub-system controllers via a CAN Bus interface, which enables future expan-
sion. The probe heating controller communicates to the sub-system controller via a serial communications
interface. If the instrument contains CAVROTM robotic arms, then the probe heating controller communicates
to the rack handling controller, otherwise it communicates to the fluid movement controller.
The personal computer level uses a Windows operating system. It is responsible for user interface and does
not have any real time constraints. The master processor contains a real time operating system to ensure
timeliness when scheduling and controlling device operations. The sub-system controllers directly control
instrument devices and are able to handle interrupts from those devices on a real time basis. To ensure
proper device control, the controllers use a real time operating system. The functional controllers perform an
exact function, are typically small in code size, and do not require an operating system.
Upgrades:
All TOP software may be field upgraded to a new version. However, there is no support to downgrade the
software by going back to a previous version.

Each field upgrade is unique as new functionality may also require hardware modification. Therefore, there
is no generic procedure for software field upgrades. Field upgrades should follow the installation instructions
provided with the release media (typically a CD or DVD). Additional operations such as Export / Import will
also be contained in the installation instructions. Export / Import is also described in the Operators Manual.
WARNING: Never downgrade after a successful upgrade.
5-3 Diagnostics
There are two areas of the SW, Covers and Racks diagnostic screen that are applicable to the processor
and software. They are the Controller Status and Software Version portions as shown in Figure 5-5 "Soft-
ware, Covers and Racks Diagnostic Screen" and described below.

Figure 5-5 Software, Covers and Racks Diagnostic Screen

Controller Status
The Controller Status area, as shown on Figure 5-6 "Controller Status Area of Diagnostic Screen",
contains three virtual LEDs The Controller Status portion of the screen, displays the status of the Cuvette,
Rack, and ORU controllers. The color of the virtual LEDs can display the following states of the controller.
Green - Ready
Yellow - In process of resetting
Red - An error has been detected
Grey - Unavailable
The Reset buttons to the right of the virtual LEDs enable the cuvette controller, rack controller, or ORU con-
troller to be reset from the Ready or Error controller state.
Figure 5-6 Controller Status Area of Diagnostic Screen
Software Version
For each Software Component, the corresponding Software Version is displayed for user reference as
shown on Figure 5-7 "Software Version Area of Diagnostic Screen".

Figure 5-7 Software Version Area of Diagnostic Screen

Chapter 5 Processor / Software 5 - 11
5-4 LIS Specifications (ASTM E 1381-95 Protocol)
ASTM LLP CM STS
Revision History: (Printed: 01/Sep/2000 16:09)
Author Date Version Comment

Berenguer Torell September 1, 2000 R0.1 Initial version
Berenguer Torell February 5, 2001 R0.1.1 Minor style changes added to change from SRS to
STS.
Berenguer Torell March 23, 2001 R0.1.2 Comments from Carolina Altafulla added.
Xavier Ramirez November 26, 2001 R0.1.3 Some minor changes added after first implementation.
Nstor Silveira July 4, 2002 R0.1.4 Baud rate has been extended to match Windows
configuration.
Xavier Ramirez October 11, 2002 R 1.0 Updated diagram with a new state when the instrument
dont accept the connection
Futura data removed and redirected to apendix A
where still needs to be added the futura required
changes

Xavier Ramirez December 9, 2002 R 1.1 Added Section 3.6 with information about the pooling
performed by TOP to know the status of the
connection.
Section 4 updated with Futura mode information
Xavier Ramirez February 10, 2003 R 1.2 New socket physical layer added
Xavier Ramirez March 5, 2003 R 1.2.1 Fixed two typos
TABLE OF CONTENTS
1. Overview..................................................................... 5 - 12
2. Physical layer .............................................................. 5 - 12
3. Data link layer............................................................. 5 - 13
3.1 OVERVIEW
3.2 ESTABLISHMENT PHASE LINK CONNECTION
3.3 TRANSFER PHASE
3.4 TERMINATION PHASE LINK RELEASE
3.5 ERROR RECOVERY
3.6 CHECKING CHANNEL STATUS
3.7 RESTRICTED MESSAGE CHARACTERS
3.8 STATE DIAGRAM FOR THE INSTRUMENT
4. Appendix A Futura Compatibility mode ................. 5 - 25
1. OVERVIEW
1.1 PURPOSE
This document is intended to be a guide for implementing the protocol referred as ASTM E 1381-95 (refer-
ence R1) for the TOP device.
Also, note that TOP supports the Futura compatible mode that allows TOP to communicate with external
systems using the same protocol as Futura. See appendix A for the differences between the Futura imple-
mentation and the new implementation of the driver.
1.2 REFERENCES
Ref Description
ASTM E 1381-95 Standard specification for low-level protocol to transfer messages
R1 between clinical laboratory instruments and computer systems
Approved Oct. 10, 1995 Published January 1996
ISO 7498-1984 (E), Information Processing Systems Open Systems Interconnection
R2
Basic Reference Model
R3 ACL Futura Host Communication Message Protocol

ACL-Futura II Control Module Laboratory Information System (LIS) Interface Software

R4
Requirements ASTM Low Level Protocol (RS-232)
R5 LIS Control Module Software Functional Specification (LIS CM SFS)
2. PHYSICAL LAYER
TOP can be connected to an external system using a RS-232 serial connector or a RJ45 network connector
using sockets. These are the details of each type of connectivity.
2.1 SERIAL CONNECTION

2.1.1 OVERVIEW
This section describes those issues related to mechanical and electrical connection between the CLI and
the LIS. The topology is point-to-point, a direct connection between both devices. This section referred as
Physical layer matches the Physical layer established in the ISO Reference model for Open Systems Inter-
connection (OSI) (see reference R2).
2.1.2 CHARACTER STRUCTURE

The method of data transmission is serial-by-bit start/stop. A character is compound by the following bit sec-
tions: start bit, data bits, parity bit and stop bit(s).
The configurable bit sections are:
Bit sections Parameter Allowed values

Data bits Number of data bits coding a character 8 7
Parity bit Parity type No parity Odd Even Mark Space
Stop bit(s) Number of stop bits 1 2
The default character structure consists of one start bit, eight data bits, no parity bit, and one stop bit.
2.1.3 SPEED BAUD RATE

The data transmission rate for the instrument can be configured. The allowed values are showed below:
Baud rate 300 1200 2400 4800 9600 19200 38400

57600 115200
The default baud rate is 9600 baud.
2.1.4 INTERFACE CONNECTIONS

The serial port of the instrument is a PC-standard DB-25 (EIA/TIA 232-E) or a DB-9 (EIA/TIA 574) male con-
nector (also known as RS-232 connectors both of them).
The following are the PIN connections for a standard PC serial communications interface. Note that these
ports are wired as DTE (Data Terminal Equipment), role that corresponds to the instrument.
EIA/TIA CCITT Signal DB-9 DB-25 Used by the

Mnemonic Description
Name V.24 direction Pin Pin Instrument

TD BA 103 Out 3 2 Transmitted Data Yes

RD BB 104 In 2 3 Received Data Yes
RTS CA/CJ 105/133 Out 7 4 Request To Send Yes
CTS CB 106 In 8 5 Clear To Send Yes
DSR CC 107 In 6 6 Data Ready Set Yes
SG AB 102 - 5 7 Signal Ground Yes
DCD CF 109 In 1 8 Carrier Detect No
DTR CD 108/1, /2 Out 4 20 Data Terminal Ready Yes
RI CE 125 In 9 22 Ring Indicator No
2.1.5 SERIAL PORTS
The instrument will allow one of these serial ports: COM1, COM2, COM3 and COM4.
2.2 NETWORK CONNECTION

When top is connected to a network, it uses the TCP/IP sockets as its transport layer. TOP can act as a cli-
ent or a server depending on a configuration parameter. When TOP is configured to act as a client, you have
to specify the IP address of the server you want to connect to and the port number. When TOP is used as a
server you only have to specify the port number clients will use to connect to TOP. Only one client can be
connected to a TOP device acting as a server.
3. DATA LINK LAYER

3.1 OVERVIEW
This section covers the services described in the Data link and Transport layers, of the ISO Reference
model for Open Systems Interconnection (OSI) (see reference R2). Network services, as the ISO/OSI Ref-
erence model describes, are not required because this protocol works over a point-to-point topology.
The content for this section is a set of procedures for link connection and release, delimiting and synchro-
nizing, sequential control, error detection, and error recovery, which are briefly described below.
Link connection and release enables and disables respectively the system, for sending and receiv-
ing information.
Delimiting and synchronizing provide for data framing and frame recognition.
Sequence control maintains the sequential order of information across the connection.
Error detection senses transmission or format errors.
Error recovery attempts to recover from detected errors by retransmitting defective frames or return-
ing the link to a neutral state from otherwise unrecoverable errors.
The data link layer uses a character-oriented protocol to send messages between directly connected sys-
tems.
The data link mode of operation is one-way transfer of information with alternate supervision. Information
flows in one direction at time. Replies occur after information is sent, never at the same time. It is a simplex
stop-and-wait protocol.
There are three distinct phases in transferring of information between instrument (ACL-TOP) and the com-
puter system (HOST). In each phase one system directs the operation and is responsible for continuity of
the communication. The three phases assure the actions of the sender and the receiver are coordinated.
The three phases are establishment, transfer and termination.
3.2 ESTABLISHMENT PHASE LINK CONNECTION

3.2.1 OPERATION
The establishment phase determines the direction of the information flow and prepares the receiver to
accept the information.
The sender notifies the receiver that information is available sending an <ENQ>. The receiver responds that
it is prepared to receive transmitting an <ACK> before any information is transmitted. A receiver that cannot
immediately receive information replies to the sender with the <NAK> transmission control character.
A system, which does not have information to send, normally monitors the data link to detect the establish-
ment phase. It acts as a receiver, waiting for connections of the other system.
Sender Receiver
[Idle state]: Monitor data link() [Idle state]: Monitor data link()
[information_available AND data_link_in_neutral_state]: Send <ENQ>()
Set timer to 15 secs()
[ready_to_receive]: Send <ACK>()
[ready_to_receive]: Begin transfer phase()
[<ACK> received]: Begin transfer phase()

{OR}
{OR}
[Timeout]: Begin termination phase()
[unable_to_receive]: Send <NAK>()
Wait 10 seconds()
Enter Idle state()
3.2.2 CONTENTION
Contention takes place when both systems (Instrument and LIS host) simultaneously try to establish link
connection by transmitting an <ENQ> transmission control character.

Instrument (CLI) LIS host

[...]: Send <ENQ>()
[...]: Send <ENQ>()
[Contention]: Set timer to 1 second() [Contention]: Set timer to 20 seconds()
Monitor data link()
[...]: Send <ENQ>()
See details on how the process

continues after solving contention,
in the diagram above
The Instrument has priority to transmit information when contention occurs.
3.3 TRANSFER PHASE

3.3.1 OPERATION
During the transfer phase, the sender transmits messages to the receiver, until all messages are sent.
Messages are sent in frames.
3.3.2 FRAMES
Each frame contains a maximum of 247 characters (240 characters including message text and 7 control
characters).
Messages with a text longer than 240 characters are divided between two or more frames.
Multiple messages are never merged in a single frame or connection. Every message must begin in a new
frame.
There are two kinds of frames, the intermediate frames and the end frames. Their only difference relies on
one transmission control character, but they are semantically different.
Intermediate frame <STX> FN Text <ETB> C1 C2 <CR> <LF>
End frame <STX> FN Text <ETX> C1 C2 <CR> <LF>
A message containing 240 characters or less is sent in a single end frame.
Longer messages are sent in intermediate frames with the last part of the message sent in an end frame.
Each message is transmitted in a new connection. That means that ACL-TOP will never send two consec-
utive messages without restarting the connection with an <ENQ>.
A brief description for every part of a frame is given in the table below.

Frame part Frame part description

<STX> Start of Text transmission control character
FN Frame Number (single digit comprised in the range 0-7) See details in section Frame Num-
ber
Text Data content of Message
<ETB> End of Transmission Block transmission control character
<ETX> End of Text transmission control character
C1 Most significant character of checksum (belonging to {0-9, A-F}) See details in section
Checksum
C2 Least significant character of checksum (belonging to {0-9, A-F}) See details in section
Checksum
<CR> Carriage Return ASCII character
<LF> Line Feed ASCII character
3.3.3 FRAME NUMBER

The frame number (FN) permits the receiver to distinguish between new and retransmitted frames.
The frame number begins at 1 with the first frame of the Transfer phase. The frame number is incremented
by one for every new frame transmitted. After 7, the frame number rolls over to 0, and continues in this fash-
ion.
3.3.4 CHECKSUM
The checksum permits the receiver to detect a defective frame. The checksum is encoded as two charac-
ters.
The checksum is computed by adding the binary values of the characters, and keeping the least significant
eight bits of the result. It is an addition module 256.
The checksum is initialized to zero with the <STX> character. The checksum computation uses the FN, all
characters belonging to Text and <ETB> or <ETX>. The computation for the checksum does not include
<STX>, the checksum characters, or the trailing <CR> and <LF>.
The checksum is an integer of eight bits, and can be considered as two groups of four bits. Both groups of
four bits are converted to the ASCII characters of the hexadecimal representation, and transmitted as the
message checksum.
Example: A checksum of 89 can be represented as 01011011 in binary or 5B in hexadecimal. The check-

sum is transmitted as the ASCII character 5 followed by the ASCII character B.

Sender Receiver
Set frame number to 1 .() Set timer to 30 seconds()
Send frame()
Set timer to 15 seconds()
Check frame validity()
Set frame retransmissions to 0 .()
[valid_frame] : Send <ACK>()
Increase frame number()
Send frame()
[wrong_frame] : Send <NAK>()

Send frame()
Increase frame retransmissions()
The process continues until

all frames have been transmitted
[all_frames_transmitted] : Begin termination phase()

3.3.5 ACKNOWLEDGEMENTS
After a frame is sent, the sender stops transmitting until a reply is received (stop-and-wait protocol). The
receiver can reply to each frame in three ways.
A reply of <ACK> means the last frame was successfully received and the receiver is ready to
receive the next one. The sender must send a new frame or terminate.
A reply of <NAK> signifies the last frame was not successfully received and the receiver is prepared
to receive the frame again.
A reply of <EOT> means the last frame was successfully received and the receiver is ready to
receive the next one, but is also a request to the sender to stop transmitting. ACL-TOP will send an
<EOT> only when it wants to send a message with high priority. ACL-TOP will dismiss <EOT> until
the message is finished. Once the message is finished ACL-TOP will allow the other system to
retrieve the message.
Sender Receiver
Set frame number to 1.()
Send frame()
Set frame retransmissions to 0.()
[valid_frame AND receiver_interrupt_request] : Send <EOT>()
[sender_not_attend_the_receiver_interrupt_request] : Send frame()
Set frame retransmissions to 0.()
[valid_frame AND receiver_interrupt_re-request] : Send <EOT>()
[sender_attend_the_receiver_interrupt_request] : Begin termination phase()

3.3.6 RECEIVER INTERRUPTS

The receiver can request to the sender to stop transmitting messages by sending an <EOT>, in place of the
usual <ACK>. The sender does not have to stop transmitting after receiving the <EOT>.
If the sender chooses to ignore the <EOT>, the receiver must re-request the interrupt for the request to
remain valid.
If the receiver chooses to honor the <EOT>, it must first enter the termination phase to return the data link
to the neutral state. The original sender must not enter the establishment phase for at least 15 seconds or
until the receiver has sent a message and returned the data link to the neutral state.
ACL-TOP ignores the <EOT> until the message transmission is completed. If ACL-TOP receives and
<EOT> as an answer to the last frame, it waits 15 seconds until it goes to the establishment phase.
3.4 TERMINATION PHASE LINK RELEASE

3.4.1 OPERATION
The termination phase returns the data link to the neutral state.
The sender notifies the receiver that all messages have been sent, by sending an <EOT>, and then sets up
the data link to be in a neutral state.
Sender Receiver
Send <EOT>()
Enter idle state()
Enter idle state()
The receiver, upon receiving <EOT>, also considers the line to be in a neutral state.
3.5 ERROR RECOVERY

3.5.1 DEFECTIVE FRAMES
A receiver checks every frame to guarantee it is valid. A reply of <NAK> is transmitted for invalid frames.
Upon receiving the <NAK>, the sender retransmits the last frame with the same frame number.
A frame should be rejected because take place some of the following situations:
Any character errors are detected (parity errors, framing error).

The frame checksum does not match the checksum computed on the received frame.
The frame number is not the same as the last accepted frame or one number higher (module 8).
There are invalid characters in the message body. See section 3.6 for invalid characters
Any characters occurring before <STX> or <EOT>, or after the end of the block characters (<ETB> or
<ETX>), are ignored by the receiver when checking for frame validity.
3.5.2 RETRANSMISSIONS
Every time the sender tries to transmit a particular frame, and receives a <NAK> or any other character dif-
ferent from <ACK> or <EOT> (a <NAK> condition), a retransmission counter for the given frame is
increased. If this counter shows a single frame was sent and not accepted six times, the sender must abort
this message by proceeding to the termination phase.
3.5.3 TIME-OUTS
The sender and the receiver use timers to detect loss of coordination between them. ACL-TOP uses the
time-out specified for instruments.
3.5.3.1 ESTABLISHMENT PHASE

The sender sets a timer when transmitting the <ENQ>. A time-out occurs if a reply of an <ACK>, <NAK> or
<ENQ> is not received within 15 seconds. After a time-out, the sender enters the termination phase.
3.5.3.2 TRANSFER PHASE
Sender Receiver
Set frame number to 1 .()
Send frame()
Send frame()
The receiver is unable

Set frame retransmissions to 0 .() to communicate with the sender
[Timeout] : Begin termination phase()

The sender sets a timer when transmitting the last character of a frame. If a reply is not received within 15
seconds, a time-out occurs. After a time-out, the sender aborts the message by entering to the termination
phase.
Sender Receiver
Set frame number to 1 .()
Send frame()
[Timeout] : Discard incomplete message()

The sender is unable
to communicate with the receiver
[Timeout] : Enter idle state()
The receiver sets a timer when first entering the transfer phase or when replying to a frame. If a frame or an
<EOT> is not received within 30 seconds, a time-out occurs. After a time-out, the receiver discards the last
incomplete message and regards the line to be in the neutral state.
3.6 CHECKING CHANNEL STATUS

One of the major goals we wanted to achieve with the connectivity with external systems was to allow TOP
to know the status of the connection. The status of the connection allows users of TOP to know if there is a
physical connection or not with the LIS system, or if the connection is being rejected.
To allow this feature we have used the rules in ASTM to detect this status. This is how we did it:
When the LIS connectivity is started TOP send and <ENQ> until an <ACK> is received.
If an <ACK> is received TOP assumes the connection is established. If no messages are pending
to send an <EOT> is sent.
If a <NAK> is received TOP assumes the connection is rejected by the LIS and retries every 10
seconds as specified in the standard until the connection is accepted.
If no data is received the application assumes there is no connection with the LIS system. The
<ENQ> is sent every 15 seconds as specified in ASTM until the connection is enabled
When the connection is accepted, TOP sends and accepts any messages exchanged with the LIS.
If the connection is idle for more than 60 seconds TOP will check if the channel is still up sending
and <ENQ> and after receiving the response sends an <EOT> to finish the transmission.
3.7 RESTRICTED MESSAGE CHARACTERS

The data link protocol is designed for sending character-based message text. Some restrictions are placed
on the characters that can appear in the message content. The following characters must not appear in the
message text:
Transmission control characters Format effector control character Device control characters
<SOH>, <STX>, <ETX>, <EOT>, <ENQ>, <LF> <DC1>, <DC2>, <DC3>,
<ACK>, <DLE>, <NAK>, <SYN>, <ETB> <DC4>
The <LF> character can appear only as the last character of a frame.
3.8 STATE DIAGRAM FOR THE INSTRUMENT

Following is the state diagram for the instrument. Note that the figure is side reading and can be viewed
online by clicking on View ->Rotate View ->Clockwise or pressing Shift+Ctrl+Plus.

State diagram for the Instrument

FrameReceived [good_new_frame AND data_to_send] / IncrementFrameNumber,Send<EOT>,SetTimerTo30
FrameReceived [good_repeat_frame AND data_to_send] / Send<EOT>,SetTimerTo30
FrameReceived [bad_frame] / Send<NAK>,SetTimerTo30
Receiving
Receive<EOT>
FrameReceived [good_repeat_frame AND no_data_to_send] / Send<ACK>,SetTimerTo30
FrameReceived [good_new_frame AND no_data_to_send] / IncrementFrameNumber,Send<ACK>,SetTimerTo30

/ Shutdown
Receive<ENQ> [instument don't accept connection] / Send<NAK>

/ Startup
Receive<ENQ> [instrument_ready] / SetFrameNumberTo1,Send<ACK>,SetTimerTo30
Idle Timeout
Timeout / Send<EOT> Receive<NAK> / SetTimerTo10
DataToSend / SetFrameNumberTo1,Send<ENQ>,SetTimerTo15 Receive<ENQ> / SetTimerTo1

Connecting Sleeping
Receive<ACK> [pending_frames] / ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15
Receive<ACK> [no_pending_frames] / Send<EOT>

Receive<EOT> [interrupt_ignored] / IncrementFrameNumber,ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15
Timeout / Send<EOT> Receive<EOT> [no_pending_frames] / Send<EOT>

Sending
Receive<ACK> [pending_frames] / IncrementFrameNumber,ZeroRetryCount,BuildNextFrame,SendFrame,SetTimerTo15

<NAK> condition [RetryCount<6] / IncrementRetryCount,SendFrame,SetTimerTo15
<NAK> condition [RetryCount=6] / Send<EOT>

APPENDIX A FUTURA COMPATIBILITY MODE

The low-level protocol implementation of TOP acting in Futura mode is fully compliant with the last imple-
mentation of the Futura device.

ASTM HLP CM STS

Revision History: (Printed: 22/Jul/2004 12:06)
Author Date Version Comment

Berenguer Torell October 10, 2000 R0.1 Initial version
Berenguer Torell December 22, R0.1.1 Section 5.Transmission scenarios reorganized.
2000 Minor modifications in section 2.4.Delimiters.
Sections 4.6.Manufacturer information record and 5.2.1.
Test results delivery carried out by the instrument reworked to
accommodate the uploading of calibration mathematical
models to the LIS host.
Scenarios using Test Order record, revised to
accommodate the use of the field Instrument Specimen ID.
Diagrams belonging to Section 6.Transmission scenarios
relationships, reworked.
Berenguer Torell February 5, 2001 R0.1.2 Minor style modifications to change from SRS to STS.
Xavier Ramirez June 28, 2002 R 1.0 Document updated with TOP implementation
Francesc Fernandez July 10, 2002 R1.1 Section Demographic Data updated.
Section Sample Identification added.
Table of contents updated.
Francesc Fernandez July 29, 2002 R1.2 Updated after NTE internal review.
Xavier Ramirez July 31, 2002 R 1.2.1 Errors section updated. Some fields added to give at least the
same functionality delivered by Futura.
Francesc Fernandez August 30, 2002 R 1.2.2 Describe logic for setting ordered date and time to current
date when ordered date and time received from the LIS is
empty.
Maite Burrel September 04, R 1.3 Add changes in instrument test order autocancelation
2002 message. Section 4.1.2
Update in Header Record specification the correct ASTM
version field max length to 7.
Xavier Ramirez September 08, R 1.4 Added comments about the futura driver
2002
Xavier Ramirez October 11, 2002 R 1.5 Changes to note that error messages sent to the HOST can be
disabled
Field 012 removed in 4.5.1 Instrument uploads test result
Xavier Ramirez December 9, R 1.6 Removed an incorrect field in the sample in section 4.5.1
2002 Added Patient laboratory ID in messages coming from the
LIS. This field is still not used in TOP, but may be used in the
future
Xavier Ramirez January 7, 2003 R 1.7 Section 4.1.3 and section 4.2 removed option N from field
12 in order record. The field has also been changed from
mandatory to optional.
Xavier Ramirez January 31, 2003 R 1.8 Length of field O5 has been change to 6 characters.
Title in section 4.1.4 has been changed to a more
understandable title.
Added comment in 4.3.3 specifying that anything is required
when in a multiple host query there is not data for one of the
specimens.
Xavier Ramirez February 7, 2003 R 1.8.1 Section 2.3.3 added

Xavier Ramirez March 5, 2003 R 1.8.2 Updated 2.2.3 with the information of codepages
Updated 2.3.2 with allowed escape values and use of the local
escape delimiter
Updated 2.3.3 with the detail of the possible escaped
characters
Updated 2.3.4 with how local escape delimiter works
Section 6 added units mapping between TOP and Futura (still
not completed)
Xavier Ramirez April 8, 2003 R 1.8.3 Section 3.3 added that the consistency among values in
different fields is not checked. Added information about the
tracing system
Section 4.5. Result unit max size have changed from 50 chars
to 15 chars
Section 6 has been updated with more differences between
TOP and Futura compatible driver and the final units mapping
from TOP to Futura.
Francesc Fernandez June 17, 2003 R 1.8.4 Updated section 2.4 Patient Demographics for specifying that
Patient demographics are not updated from LIS unless
Samples are identified through Instrument Sample Id.
Xavier Ramrez June 27, 2003 R 1.8.5 Appendix A: added restriction to reject messages with t
sample id bigger than 16 characters in Futura mode
Updated section 4.5: A new flag has been added in R9 and
O26 to allow TOP to send preliminary results. Preliminary
results are tests that will be rerun by TOP.
Updated section 3.3: Notification of response when no request
is performed is also notified to TOP.
Xavier Ramrez July 2, 2003 R 1.8.6 Appendix A: Futura does not support V flag in R9
Maite Burrel July 2, 2003 R 1.8.7 Appendix A: ERRORS Add the exemption of non-validation
of H14 date field.
Xavier Ramrez July 15, 2003 R 1.8.8 Max length for Attending physician ID has changed from 30
to 14 as specified in TOP
Changed the way reruns are notified in section 4.5.1
Xavier Ramrez November 26, R 1.9 Added field Laboratory patient ID in TOP uploaded
2003 messages (section 4.4.1, 4.5.1, 4.7.2) that is uploaded by TOP
when has previously sent by the LIS host
Daniel Moncus January 27, 2004 R 1.10 Documented use of message storage by TOP (section 3.3)
Section 3.1 and 3.2 has been unified in a single one (take it
into account when consulting Revision History references)
Daniel Moncus July 22, 2004 R 1.11 Added clarifying note to section 4.3.3
Changed diagrams of section 5

TABLE OF CONTENTS
1. Overview ............................................................................1
2. Message structure and content..........................................30
3. Message transmission control...........................................35
4. Transmission scenarios.....................................................38
4.1 TOP REQUEST TEST ORDERS TO HOST ........................................................................................................39
4.2 LIS HOST INITIATED TEST ORDERS DELIVERY ............................................................................43
4.3 HOST QUERY PERFORMED BY THE INSTRUMENT .........................................................................44
4.4 INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST ..............................................................46
4.5 INSTRUMENT UPLOADS TEST RESULTS ........................................................................................................47
4.6 LIS HOST REQUEST RESULTS TO THE INSTRUMENT ......................................................................49
4.7 INSTRUMENT UPLOADS ERROR INFORMATION.............................................................................................51
5. Transmission scenarios relationships ...............................53

5.1 MANUAL OR AUTOMATIC JOB ORDERS DOWNLOADING ................................................................53
5.2 HOST-INITIATED JOB ORDERS DOWNLOADING ............................................................................................54
5.3 HOST QUERY ...............................................................................................................................................55
5.4 MANUAL OR AUTOMATIC JOB RESULTS UPLOADING ....................................................................56
6. Appendix A Futura Compatibility mode .......................57

1. OVERVIEW
1.1 PURPOSE
This document is a guide for implementing the protocol ASTM E 1394-97 for the TOP device. In this guide,
you will find detailed information of all the data that can be exchanged between TOP and laboratory infor-
mation systems (LIS).
Also, note that TOP supports the Futura compatible mode that allows TOP to communicate with external
systems using the same protocol as Futura did. See appendix A for the differences between the Futura
implementation and the new implementation of the driver included in TOP.
1.2 OVERVIEW
The implementation of the TOP protocol follows as much as possible the rules described in the ASTM stan-
dard, but some interpretation of it has been done when the standard wasnt detailed enough to complete the
implementation. This guide describes any interpretation done in the development of TOP connectivity in
order to easy the development of any interface.
1.3 REFERENCES
Ref Description
ASTM E 1394-97 Standard specification for transferring information between clinical
instruments and computer systems
R1
Approved December 10, 1997 Published March 1998

R2 ACL-Futura manual
R3 LIS Functional Specifications
2. MESSAGE STRUCTURE AND CONTENT

2.1 RECORDS
2.1.1 ORGANIZATION AND HIERARCHY OF RECORDS

Messages consist of a hierarchy of records of various types. A record can be defined as an aggregate of
fields describing one aspect of the complete message. A field can be seen as a specific attribute of a record,
which may contain aggregates of data elements further refining the basic attribute.
The hierarchy of records is composite by several levels. The record types allowed in each hierarchy level,
and the hierarchical dependencies between record types, are showed below.
Level 0 records Level 1 records Level 2 records Level 3 records Level 4 records
Message Header (H)
Comment (C)
Request Information (Q)

Comment (C)
Patient Information (P)
Comment (C)
Test Order (O)
Comment (C)
Result (R)
Comment (C)
Message Terminator (L)
Due to the he use of this hierarchical structure, some rules have been established:
A message shall be always headed by a message header record (H), and finished by a message
terminator record (L).
An order record (O) may never appear without a preceding patient information record (P).
A result record (R) may never appear without a preceding order record (O).
Comment records (C) may be inserted at any level in the hierarchy (except after a Message Ter-
minator), and it refers to the prior higher-level record.
An example of a message structure and content, according to the records hierarchy described before, is the
following:
(Level 0)MESSAGE HEADER
(Level 1) PATIENT_1
(Level 2) COMMENT_1
(Level 2) ORDER_1
(Level 3) COMMENT_1
(Level 3) RESULT_1
(Level 3) RESULT_2
(Level 4) COMMENT_1
(Level 4) COMMENT_2
.
.
.
(Level 3) RESULT_N
(Level 2) ORDER_2
(Level 3) RESULT_1
(Level 3) RESULT_2
.
.
.
(Level 3) RESULT_N
.
.
(Level 2) ORDER_N
(Level 3) RESULT_1
.
.
.
(Level 1) PATIENT_2
.
.

(Level 1) PATIENT_N
(Level 0)MESSAGE TERMINATOR
A sequence of patient information records, order records, or result records at one level, is terminated by the
appearance of a record type of the same or higher level.
2.1.2 LENGTH
The standard does not impose a maximum record length. The implementation within the IL instruments
restricts the maximum length for incoming messages to 200 KB. Outgoing messages can be of any size.
2.2 FIELDS
2.2.1 STRUCTURE
A field can be seen as a specific attribute of a record, which may contain aggregates of data elements fur-
ther refining the basic attribute. There are two kinds of aggregates within a message, the repeat field and
the component field.
Repeat field a single data element that expresses a duplication of the field definition. Each element of a
repeat field is to be treated as heaving equal priority to associated repeat fields.
Component field single data element or data elements that express a finer aggregate or extension of data
elements, which precede it.
Example: A patients name is recorded as last name, first name, and middle initial, each of which is sepa-
rated by a component delimiter.
2.2.2 LENGTHS
The standard does not impose a maximum field length, and assumes that all fields are variables in length.
The implementation within the IL instruments scope restricts the maximum field length to a concrete value
depending on the field, but never uses more characters than required by the given field value (according to
the standard).
Example: For a ten characters length field, only ten characters space will be used in the message to allow
the field content, delimiters space apart.
2.2.3 CHARACTER CODES

All data is represented as eight bit values and single-byte as defined in ISO 8859-1:1987. The eight-bit val-
ues within the range from 0 to 127 of ISO 8859-1:1987 correspond to the ASCII standard character set
(ANSI X3.4-1986). Values between 128 and 255 are undefined by this standard and are sent using the
codepage specified in the configuration of TOP. The use of different codepages allows characters from dif-
ferent cultures to be exchanged without problems. Other characters not representable using the specified
codepage are sent escaped using UTF-16 as described in Hexadecimal escaping
Allowed characters in the message: 9, 13, 32-126, 128-254

Disallowed characters in the message: 0-8, 10-12, 14-31, 127, 255
The Latin-1 character 13 is reserved as the record terminator.
2.3 DELIMITERS
2.3.1 TYPES
Delimiters are used to establish separate sections within a message. There are five different delimiters.

Record delimiter: It signals the end of any of the defined record types. It is fixed to carriage return
character Latin-1 (13) (ASCII 13).
Field delimiter: It is used to separate adjacent fields. It is configurable, and is specified in the mes-
sage header record. It shall be a single character excluding Latin-1 (13) (ASCII 13).
Repeat delimiter: Used to separate variable number of descriptors for fields containing parts of
equal members of the same set. It is configurable, and is specified in the message header record.
It shall be a single character, excluding Latin-1 (13) (ASCII 13) and the value used by the field delim-
iter.
Component delimiter: It is used to separate data elements of fields of a hierarchical or qualifier
nature. It is configurable, and is specified in the message header record. It shall be a single char-
acter, excluding Latin-1 (13) (ASCII 13), the value used by the field delimiter and the value used by
the repeat delimiter.
Escape delimiter: Used within text fields to signify special case operations. It is configurable, and is
specified in the message header record. It has a complex structure, but mainly use a single char-
acter. The chosen character shall be different from Latin-1 (13) (ASCII 13) and the field, repeat, and
component delimiter values.
2.3.2 CONSIDERATIONS
Alphanumeric characters should not be used as delimiters, according to the standard. The implementation
within the IL instruments allows the use of the following characters as delimiters. (Boundary values are also
included)
Any value from ASCII (33) to ASCII (47)
The default delimiters used within the IL instruments scope is the following set (this values can be changed
from TOP):
Record delimiter carriage returnLatin-1 (13) (ASCII 13)
Field delimiter vertical bar( | ) Latin-1 (124) (ASCII 124)
Repeat delimiter at( @ ) Latin-1 (64) (ASCII 64)
Component delimiter caret( ^ ) Latin-1 (94) (ASCII 94)
Escape delimiter backslash( \ ) Latin-1 (92) (ASCII 92)
Fields shall be identified by their position, obtained by counting field delimiters from the front of the record.
This position-sensitive identification procedure requires that when the contents of the field are null, its cor-
responding field delimiter must be included in the record to ensure that the ith field can be found by counting
(i-1) delimiters. Delimiters are not included for trailing null fields.
The following escape sequences are pre-defined.

\H\ (*)start highlighting text

\N\ (*) normal text (end highlighting)
\F\embedded field delimiter character
\S\embedded component field delimiter character
\R\embedded repeat field delimiter character
\E\embedded escape delimiter character
\Xhhhh\hexadecimal data See Hexadecimal escaping for more information
\Zcccc\Local defined escape sequences, used to send characters not representable in the config-
ured codepage. See Local escape sequence for more information.
No escape sequence contains a nested escape sequence, according to the standard.

(*) The following escaping sequences are ignored by TOP
2.3.3 HEXADECIMAL ESCAPING

The escaping of ASTM disallowed characters happens when TOP wants to send a character that is not
allowed in ASTM. Characters that can be escaped are the ASCII characters 10, 13, 127, 255. In this case,
the character will be escaped using the hexadecimal escaping. For example, if TOP wants to send the char-
acter 127 it will be escaped to \X7F\.
2.3.4 LOCAL ESCAPE SEQUENCE

Local escape sequence is used to exchange characters not representable using the configured codepage.
For example, if TOP wants to send a Japanese character (for example the Unicode character U+34C8)
using the English codepage, the character would be lost in a normal transmission because it cannot be rep-
resented in that specific codepage.
To avoid loosing any character, characters not representable in the selected codepage are escaped using
the local escape sequence. In that case, the Japanese character will be sent in four hexadecimal digits as
\Z34C8\. Also note, that many non-representable codepage characters can be added in the same escape
sequence.
2.4 DEMOGRAPHIC DATA

Given a sample, patient demographics shall never be updated from the LIS Host. Patient Demographics can
only be updated through the application unless Samples are identified through Instrument Sample ID (see
[R3] for further information).
2.5 SAMPLE IDENTIFICATION

ACL TOP instrument shall be capable to support LIS hosts that reuse Specimen ID(s). Reusing Specimen
ID(s) means that different patients can have the same Specimen Id in different periods. If this period is short
enough, for instance two consecutive days, some care is required in samples management.
Usually, these laboratories reuse their Specimen Id(s) every day, every week, or even several times in a
day. If laboratory operates in this way, it is possible to find different samples with the same Specimen Id in
the normal operation of ACL TOP. In order to support these potential situations, TOP uses the concepts
Instrument Specimen ID and Sample Life to avoid conflicts in correct samples identification.

Thus, samples can be identified from the LIS host either through the Instrument Specimen Id or the Speci-
men Id + Sample Life.
2.5.1 SPECIMEN ID
Since the Specimen ID can be reused by the LIS host for different patients, the TOP uses the concept Sam-
ple Life for determining whether new test orders shall be added to an existing sample or not.
Given a Specimen ID, test orders received from the LIS are added to the same sample if the time frame
since the sample was created till the test order was ordered (Requested/Ordered Date and Time) is < Sam-
ple Life and all patient demographic (First Name, Last Name, Birth Date, Gender, Sender ID) information is
the same.
Given a Specimen ID, test orders received from the LIS are added to a new same sample if the time frame
since the sample was created till the test order was ordered (Requested/Ordered Date and Time) is >=
Sample Life or one or more fields belonging to the patient demographic information are different.
2.5.2 INSTRUMENT SPECIMEN ID

The rules defined above section regarding the Sample Life are not applicable if the application and the LIS
Host are identifying samples by means of the Instrument Specimen ID. In this way, new test orders can be
programmed for existing expired samples.
Instrument Specimen ID is generated by the TOP and reused by the LIS Host. Through the TOP, the user
will be able to disable the usage of the Instrument Specimen ID. If disabled, the TOP will not provide to the
LIS Host any Instrument Sample ID as feedback of incoming test orders.
Instrument Specimen ID is unique within the scope of one instrument. Although in practice it is almost
impossible to reproduce, different samples might have the same Instrument Specimen ID in different instru-
ments.
If Instrument Specimen ID is used, no comparison of patient demographics shall be performed.
If Instrument Specimen ID received from the LIS does not match any Instrument Specimen Id kept by the
system, test order shall be rejected.
2.5.3 CONCLUSION
The use of the instrument Specimen ID is recommended due to the following reasons:
Instrument Specimen ID is not reused and therefore test orders are always properly assigned to the
corresponding sample.
New tests can be ordered for existing and expired Specimen Ids.
Patient demographics are not compared because Instrument Specimen Id is not reused and it
always identifies univocally a sample.
3. MESSAGE TRANSMISSION CONTROL

3.1 ERROR RECOVERY

In order to ensure proper error logging and error recovery, the next rule is followed according to the stan-
dard.
Storage Rule: Since data content is structured in hierarchical fashion, any decreasing change in the hierar-
chical level triggers storage of all data transmitted prior to said level change, and not previously saved.
An example of the prior rule application is the following.
Record # Record Type Level (level variation) Storage action
1 Message Header L0 (0)

2 Patient1 L1 (+1)
3 Order1 L2 (+1)
4 Result1 L3 (+1)
5 Order2 L2 (-1) {Save 1 4}
6 Order3 L2 (0)
7 Patient2 L1 (-1) {Save 5 6}
8 Order1 L2 (+1)
9 Comment1 L3 (+1)
10 Result1 L3 (0)
11 Comment1 L4 (+1)
12 Result2 L3 (-1) {Save 7 11}
13 Order2 L2 (-1) {Save 12}
14 Patient3 L1 (-1) {Save 13}
15 Order1 L2 (+1)
16 Result1 L3 (+1)
17 Message Terminator L0 (-3) {Save 14 16}
Note: Record # 17 is assumed as saved by virtue of the record type function
If a transmission failure occurs, transmission starts at the last record not presumed saved as outlined in sec-
tion 3.1 (Storage), but under one restriction. In order to fulfill hierarchical record level requirements, all
records necessary to reach the restart record point are repeated prior to transmitting the record where the
line failure originally occurred.
An example of required retransmissions is showed below.

Line failure at: Record Type Level (variation)Storage action Retransmission of:
1 Message Header L0 (0) 1
2 Patient1 L1 (+1) 1, 2
3 Order1 L2 (+1) 1, 2, 3
4 Result1 L3 (+1) 1, 2, 3, 4
5 Order2 L2 (-1) {Save 1 4} 1, 2, 3, 4, 5
6 Order3 L2 (0) 1, 2, 5, 6
7 Patient2 L1 (-1) {Save 5 6} 1, 2, 5, 6, 7
8 Order1 L2 (+1) 1, 7, 8
9 Comment1 L3 (+1) 1, 7, 8, 9
10 Result1 L3 (0) 1, 7, 8, 9, 10

11 Comment1 L4 (+1) 1, 7, 8, 9, 10, 11

12 Result2 L3 (-1) {Save 7 11} 1, 7, 8, 9, 10, 11, 12
13 Order2 L2 (-1) {Save 12} 1, 7, 8, 12, 13
14 Patient3 L1 (-1) {Save 13} 1, 7, 13, 14
15 Order1 L2 (+1) 1, 14, 15
16 Result1 L3 (+1) 1, 14, 15, 16
17 Message Terminator L0 (-3) {Save 14 16} 1, 14, 15, 16, 17
3.2 ERROR MESSAGES

Any error detected by TOP is traced in the UDC folder in the Windows Event Viewer in Settings\Control
Panel\Administrative Tools. If you have any problem, this is the first place you have to check to find error
information.
Optionally TOP can notify the HOST of any incorrect message received by the LIS host. Check the Report
errors to LIS check box in the HOST configuration screen in TOP if you want to activate this feature.
If error notification is active, TOP sends ASTM messages with information about the error occurred (see
Upload message Request rejected by the instrument for detailed information about the message). Top
distinguishes the syntactic and semantic errors and they are treated differently:
Syntactic errors happen when the ASTM received by TOP doesnt follow the general ASTM rules, or the
more specific rules defined by TOP. This is the list of errors TOP notifies to the LIS host:
Invalid message: The incoming message is invalid and TOP doesnt know what information is being deliv-
ered. This may happen when there are invalid characters in the message, or when an unexpected message
is received. For example, when TOP receives a response and hasnt done any request.
Invalid syntax: The incoming message has an invalid syntax, for example if the hierarchy of records is not
followed appropriately
Invalid value: The incoming message has a value that is not supported by TOP. Consistency among values
in different fields is not checked.
Missing mandatory value: The incoming message doesnt provide a value for a TOP mandatory field
Incomplete message: The incoming message was uncompleted
Semantic errors are errors that are syntactically correct, but the action cannot be executed by the instru-
ment. This is the list of semantic errors TOP notify to the LIS host:
Invalid host ID: The host ID received in the message is not the same as the one specified in TOP.
The message is discarded
Invalid instrument ID: The instrument ID received in the message is not the same as the one spec-
ified in TOP. The message is discarded
Duplicated test: A test has been received twice. The test is removed.
Invalid test: The test ordered by the LIS host is unknown to TOP. The order is removed.
Disabled or inconsistent test: The test ordered by the LIS host is disabled or is inconsistent. The
order is removed.

Invalid instrument sample id: The LIS host retrieved an invalid instrument sample id. The test is
removed.
Cancellation of pending test request could not be performed: The LIS host can cancel a previously
ordered test if this hasnt been executed yet. This message specifies the test could not be cancelled
because its execution has started. The result will be delivered to the LIS host as any other test.
LIS request not allowed: TOP doesnt allow the LIS host to perform requests for any data. If a
request from the LIS is received, the request is cancelled and no data is retrieved.
When any of the previous errors is found, TOP skips the wrong part of the message, and continues inter-
preting it as if no error existed. For extended error information for the skipped part, check the TOP commu-
nication tracing system where you will get the ASTM part of the message discarded and the reason.
These are the rules followed that describe the part of the message rejected when an error is found:
An error in a header record invalidates the whole message.
An error in a patient record invalidates all the orders below that patient in the ASTM hierarchy.
An error in a order record invalidates only that order record.
An error in a comment record invalidates only the comment record but the patient or order record is
accepted if more orders or results exist for that patient/order.
3.3 MESSAGE STORAGE

Messages that need to be uploaded to the LIS are physically persisted when the communications cannot be
performed due to hardware or software problems. This is done to avoid loosing any message even if the
application is shut down. If necessary, the user can delete all the stored messages clicking the specific but-
ton in the communications configuration screen.
This are the more specific rules implemented by TOP to manage the storage of messages:
The maximum number of messages that are allowed in the storage is 7200 messages.
Once the storage is at 75% of its capacity TOP triggers the alarm < LIS Message Storage Full> pro-
viding information of the percentage of the storage that is full. This alarm is reported during start-up
as well and every time there is a 5% increment or decrement between 75% and 100%.
Once the storage is 100% full TOP trigger the alarm < LIS Message Storage Overloaded> and no
more messages are accepted in the storage. This alarm will also be reported every time the com-
munications are restored.
Once the storage is full (100% of its capacity) the upload of any new messages will be rejected and
TOP triggers the following two alarms < Upload Message Rejected> and < LIS Message Storage
Overloaded>
4. TRANSMISSION SCENARIOS
This section details all the possible scenarios to exchange data between TOP and a LIS host.

4.1 TOP REQUEST TEST ORDERS TO HOST

This scenario takes place when the instrument, via a manual or an automatic command, launches a request
to the LIS host with the intention to download all available test orders.
4.1.1 UPLOAD MESSAGE TEST ORDER REQUEST PERFORMED BY THE INSTRUMENT

Message structure
Message header (H)
Request information (Q)
Message terminator (L)
Message Header Record
Field Comp Max. Allow

No.
Field Name Description onent Data typeLengt Req Repeat Allowed values
h
1 Record Type Identifies the record 1 String 1 Y N H
ID
2 Delimiter Defi- Define the delimiters to 1 String 4 Y N See section Delimiters for
nition be used throughout the more information
subsequent records of
the message
3 Message ID Uniquely identifies the 1 String 50 Y N
message
5 Sender Name Name or ID of the sender 1 String 14 Y N The value defined in TOP
or ID configurations
10 Receiver ID Name or ID of the 1 14 Y N The value defined in TOP
receiver configurations
12 Processing ID Indicates how this mes- 1 String 1 Y N P (Production)
sage is to be processed.
13 Version No. Version level of the cur- 1 String 7 Y N 1394-97
rent ASTM version speci-
fication.
14 Date and Date and time the mes- 1 ASTM Y N
Time of Mes- sage was generated Date
sage
Request Information Record

No. Field Name Description onent Data type Lengt Req Repeat Allowed values
h
1 Record Type ID Identifies the record 1 String 1 Y N Q
2 Sequence Defines the ith occurrence of the 1 String 1 Y N 1
Number associated record type
3 Starting Range 3 String Y N ALL
ID Number
13 Request 1 String 1 Y Y O (req. test order and demogs),
Information N (request new/edited results)
Status Codes

Message Terminator Record

No.
Field Name Description onent Data typeLengt Req Repeat Allowed values
h
1 Record Type Identifies the record 1 String 1 Y N L
ID
2 Sequence Defines the ith occur- 1 String 1 Y N 1
Number rence of the associated
record type
3 Termination Provides explanation of 1 String 1 Y N N (normal termination)
Code end of session
Example
H | @ ^ \ | <0_0> <1025080549_50> | | ACL-TOP-07 | | | | | LIS-HOST-06 | | P | 1394-97 | 20000913174650 <CR>
Q | 1 | ALL | | | | | | | | | | O@N <CR>
L | 1 | N <CR>
4.1.2 UPLOAD MESSAGE TEST ORDER REQUEST CANCELLED BY THE INSTRUMENT

The instrument can cancel the last request performed while it hasnt received any message from the LIS
host. The cancellation for the last request allows the instrument to perform another request with higher pri-
ority.
Note: Remember that only one request can be performed at the same time. The sender cannot transmit
another request until the previous one has been answered by the receiver or cancelled by the sender. TOP
will automatically cancel the request when no answer is received in 60 seconds.
Message structure
Message header (H)
Comment (C)
Message Header RecordField No.Request Information Record

h
13 Request 1 String 1 Y N A (abort last request)
Information
Status Codes

Comment Record

h
1 Record Type ID Identifies the record 1 String 1 Y N C
2 Sequence Defines the ith occurrence of the 1 String Y N 1,2,3 n
3 Comment Source Comment origination point 1 String 1 Y N I
4 Comment Text Comment id 1 String 50 N N timeout
Comment description 2 String 500 N last request has been cancelled
5 Comment Type Comment type qualifier 1 String 1 Y N P (information)
Message Terminator Record Field No. Example

Q | 1 | | | | | | | | | | | A <CR>
C | 1 | I | timeout ^ last request has been cancelled | P <CR>
L | 1 | N <CR>
4.1.3 DOWNLOAD MESSAGE TEST ORDER DELIVERY BY THE LIS HOST

Message structure
Message header (H)
Test Order (O)


h
1 Record Type ID Identifies the record 1 String 1 Y N H
2 Delimiter Define the delimiters to be used 1 String 4 Y N See section Delimiters for more
Definition throughout the subsequent information
records of the message
3 Message ID Uniquely identifies the message 1 String 50 N N
5 Sender Name or Name or ID of the sender 1 String 14 Y N The value defined in TOP
ID configurations
10 Receiver ID Name or ID of the receiver 1 14 Y N The value defined in TOP
configurations
12 Processing ID Indicates how this message is to 1 String 1 Y N P (Production)
be processed.
13 Version No. Version level of the current 1 String 7 Y N 1394-97
ASTM 1394-91 specification.
14 Date and Time of Date and time that the message 1 ASTM N N
Message was generated Date
Patient Information Record


h
1 Record Type ID Identifies the record as PIR 1 String 1 Y N P
2 Sequence Defines the ith occurrence of the 1 Numeric Y N 1,2,3 n
4 Laboratory A unique processing number 1 String 15 N N
patient ID assigned to a patient by the LAB
6 Patient Name Patient last name 1 String 20 N N
Patient first name 2 String 20 N
8 Birth date Date of birth 1 ASTM N N
Date
9 Patient Sex Sex 1 String 1 N N M (male), F (female), U
(unknown)
14 Attending Id of the attending physician 1 String 14 N N
physician ID
Test Order Record

h
1 Record Type ID Identifies the record 1 String 1 Y N O
3 Specimen ID A unique identifier for the 1 String 16 Y N
specimen assigned by the HOST
4 Instrument A unique identifier for the 1 String 30 N N
Specimen ID specimen assigned by TOP. This
must be retrieved from the LIS if
it is known.
5 Universal Test ID TOP defined Test ID 4 Numeric 6 Y Y 0 - 999999
6 Priority 1 String 1 N N S (Stat), R (normal)
7 Requested/ Date and time the order was 1 ASTM N N If empty, Requested/Ordered Date
Ordered Date and received or recorded Date and Time is set to current date and
Time Time.
12 Action code The action that needs to be taken 1 String 1 N Y A (Added in previous specimen
with the order or creates a new specimen
following the rules of the sample
life cycle),
C (Cancel a previous test request)
16 Specimen Sample type 1 String 1 Y N P (plasma)
Descriptor
26 Report Type Intention of the information 1 String 1 Y Y Q (Response to query),
contained in the record

h
1 Record Type ID Identifies the record as MTR 1 String 1 Y N L
3 Termination Provides explanation of end of 1 String 1 Y N F (last request processed)
Code session

Example
H | @ ^ \ |<0_0> <1025080549_50> | | LIS-HOST-03 | | | | | ACL-TOP-21 | | P | 1394-97 | 20000614080500 <CR>
P | 1 | | 80501 | | Anderson ^ Jim | | 19800228 | M | | | | | 542 <CR>
O | 1 | 6483 | | ^ ^ ^ 211 @ ^ ^ ^ 063 | R | 20000614043211 | | | | | A | | | | P | | | | | | | | | | Q <CR>
O | 2 | 8651 | | ^ ^ ^ 310 | S | 20000614043514 | | | | | A | | | | P | | | | | | | | | | Q <CR>
P | 2 | | | | Foster ^ Rene | | 19740717 | F | | | | | 374 <CR>
O | 1 | 0012 | | ^ ^ ^ 512 | R | 20000614044212 | | | | | A | | | | P | | | | | | | | | | Q <CR>
O | 2 | 0012 | | ^ ^. ^ 254 | R | 20000614044325 | | | | | A | | | | P | | | | | | | | | | Q <CR>
P | 3 | | | | Clinton ^ Jeremy | | 19580223 | M <CR>
O | 1 | 6537 | 310648 | ^ ^ ^ 076 | S | 20000614044212 | | | | | A | | | | P | | | | | | | | | | Q <CR>
O | 2 | 6537 | 310648 | ^ ^ ^ 098 | R | 20000614045021 | | | | | C | | | | P | | | | | | | | | | Q <CR>
O | 3 | 6912 | | ^ ^ ^ 301 @ ^ ^ ^ 357 | R | 20000614052158 | | | | | A | | | | P | | | | | | | | | | Q <CR>
P | 4 | | | | Turner ^ Jim | | 19890821 | M | | | | | 271 <CR>
O | 1 | 0509 | 479481 | ^ ^ ^ 002 | | 20000614055734 | | | | | C | | | | P | | | | | | | | | | Q <CR>
L | 1 | F <CR>
4.1.4 DOWNLOAD MESSAGE TEST ORDER RESPONSE WHEN NO DATA AVAILABLE FROM THE LIS HOST
It can happen when there is no information to download. Also note, that if the LIS host doesnt transmit any-
thing and the timeout is reached (60 seconds), the instrument will assume that the LIS host has no test
orders to program. In that case, TOP will cancel the request as specified in Upload message test order
request cancelled by the instrument.
Note: It is recommended to the LIS host implementers to always response to a request from TOP, otherwise
the communication will be stopped until the 60 seconds timeout is reached.
Message structure
Message header (H)
Message Header RecordField No.Message Terminator Record

h
3 Termination Provides explanation of end of 1 String 1 Y N I (no info from last query)
Code session
Example
H | @ ^ \ | <0_0> <1025080549_50> | | LIS-HOST-04| | | | | ACL-TOP-12 | | P | 1394-97 | 20030330033003 <CR>
L | 1 | I <CR>
4.2 LIS HOST INITIATED TEST ORDERS DELIVERY

This scenario takes place when the LIS host, decides to download all available test orders to the instrument.

4.2.1 DOWNLOAD MESSAGE LIS HOST INITIATED TEST ORDER DELIVERY

Message structure
Message header (H)
Test Order (O)

Message Header RecordField No.Patient Information Record Field No.Test Order Record

h
Specimen ID specimen assigned by TOP
6 Priority 1 String 1 N N S (Stat), R(normal)
Time Time.
12 Action code The action that needs to be taken 1 String 1 N Y A (Added in previous specimen
with the order or creates a new specimen
following the rules of the sample
life cycle),
C (Cancel a previous test request)
Descriptor
26 Report Type Intention of the information 1 String 1 Y Y O (Order record)
contained in the record
Message Terminator RecordField No. Example

H | @ ^ \ | <0_0> <1025080549_50> | | LIS-HOST-11 | | | | | ACL-TOP-09 | | P | 1394-97 | 20000715180000 <CR>
P | 1 | | | | Dillon ^ Jennifer | | 19820414 | F <CR>
O | 1 | 8201 | | ^ ^ ^ 900 | S | 20000715143243 | | | | | N | | | | P | | | | | | | | | | O <CR>
O | 2 | 8201 | | ^ ^ ^ 444 @ ^ ^ ^ 666 | R | 20000715143725 | | | | | N | | | | P | | | | | | | | | | O <CR>
P | 2 | | | | Carter ^ Rudy | | 19620121 | F | | | | | 985 <CR>
O | 1 | 5438 | 690008 | ^ ^ ^ 369 | R | 20000715143912 | | | | | A | | | | P | | | | | | | | | | O <CR>
O | 2 | 5438 | 690008 | ^ ^ ^ 963 | R | 20000715144127 | | | | | A | | | | P | | | | | | | | | | O <CR>
P | 3 | | | | Stendal ^ Jeremy | | 19321002 | M <CR>
O | 1 | 5009 | 324879 | ^ ^ ^ 209 | | 20010913215702 | | | | | C | | | | P | | | | | | | | | | O <CR>
L | 1 | N <CR>
4.3 HOST QUERY PERFORMED BY THE INSTRUMENT

This scenario is triggered when the user performs the host query functionality in the instrument. Host query
allows selective downloading of test orders, taking as input, a single Specimen ID (Sample ID) or a set of
them.

4.3.1 UPLOAD MESSAGE HOST QUERY PERFORMED BY THE INSTRUMENT

Message structure
Message header (H)
Field No.Request Information Record
Fiel Com Max. Allow

d p Leng Repeat
Field Name Description Data type Re Allowed values
No. onen th
q
t
1 Record Type ID Identifies the record 1 String 1 Y N H
2 Delimiter Defi- Define the delimiters to be used 1 String 4 Y N See section 2.3 for more informa-
nition throughout the subsequent tion
records of the message
3 Message ID Uniquely identifies the mes- 1 String 50 Y N

sage
5 Sender Name or Name or ID of the sender 1 String 14 Y N The value defined in TOP config-
ID urations
10 Receiver ID Name or ID of the receiver 1 14 Y N The value defined in TOP config-

urations
12 Processing ID Indicates how this message is 1 String 1 Y N P (Production)

to be processed.
13 Version No. Version level of the current 1 String 7 Y N 1394-97

ASTM version specification.
14 Date and Time Date and time the message was 1 ASTM Y N
of Message generated Date

h
3 Starting Range Specimen ID 2 String 16 Y Y
ID Number
Instrument specimen ID 3 String 30 N
13 Request 1 String 1 Y Y O (req. test order and demogs),
Information N (request new test orders still not
Status Codes downloaded)

Q | 1 | ^ 4243 ^ 876271 @ ^ 0434 @ ^ 0435 @ ^ 6742 ^ 878432 | | | | | | | | | | O@N <CR>
L | 1 | N <CR>

4.3.2 UPLOAD MESSAGE TEST ORDER REQUEST CANCELLED BY THE INSTRUMENT

See section Upload message test order request cancelled by the instrument for more information.
4.3.3 DOWNLOAD HOST QUERY RESPONSE FROM LIS HOST

The LIS host retrieves data for the specified sample IDs. See section Download message test order deliv-
ery by the lis host for more information. Note that if in a multiple host query, there are specimens that have
pending orders and there are others that dont, the host query response only need to retrieve the pending
specimens. TOP will assume that there are no orders for the specimens no listed in the host query
response. If multiple messages are send as response only the first will be processed and the rest will be dis-
carded.
If the LIS host doesnt have anything to answer, because it doesnt know the sample IDs or because there
are no test orders to retrieve, it must follow the same rules described in section Download message test
order response when no data available from the lis host.
4.4 INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST

This scenario takes place when the instrument receives a list of test orders from the LIS host. For every new
sample received, the instrument generates an internal sample ID (known as Instrument Specimen ID in
ASTM terminology) and sends it back to the LIS host.
Future LIS host references to these samples will be performed using both identifiers: Specimen ID and
Instrument Specimen ID. In the same way, all information sent back to the LIS host by the instrument will
be accompanied by both identifiers.
This scenario can be launched after tests orders are delivered to the instrument.
4.4.1 UPLOAD MESSAGE INSTRUMENT UPLOADS INSTRUMENT SPECIMEN ID TO LIS HOST

Message structure
Message header (H)
Test Order (O)

Note: Only one test order record will be placed under a patient information record.
Message Header RecordField No. Patient Information Record

h
1 Record Type ID Identifies the record as PIR 1 String 1 Y N P
4 Laboratory A unique processing number 1 String 15 N N
patient ID assigned to a patient by the LAB

6 Patient Name Patient last name 1 String 20 N N

Patient first name 2 String 20 N
8 Birth date Date of birth 1 ASTM N N
Date
9 Patient Sex Sex 1 String 1 N N M (male), F (female), U
(unknown)
14 Attending Id of the attending physician 1 String 14 N N
physician ID
Test Order Record

h
4 Instrument A unique identifier for the 1 String 30 Y N
Time Time.
12 Action code The action that needs to be taken 1 String 1 Y Y P (pending specimen)
with the order
Descriptor
26 Report Type Intention of the information 1 String 1 Y Y O (Order record),
contained in the record I (Pending in instrument)

P | 1 | | | | Anderson ^ Jim | | 19800228 | M | | | | | 542 <CR>
O | 1 | 6483 | 312890 | ^ ^ ^ 063 | R | 20000614043211 | | | | | P | | | | P | | | | | | | | | | O@I <CR>
P | 2 | | | | Foster ^ Rene | | 19740717 | F | | | | | 374 <CR>
O | 1 | 0012 | 312892 | ^ ^ ^ 512 | R | 20000614044212 | | | | | P | | | | P | | | | | | | | | | O@I <CR>
L | 1 | N <CR>
4.5 INSTRUMENT UPLOADS TEST RESULTS

This scenario takes place when the instrument is requested to send available test results to the LIS host.
This scenario can be executed because the action is triggered manually or automatically. This scenario can-
not be triggered by a request from the LIS host. Remember, IL instruments do not support a request mes-
sage for test results uploading.
4.5.1 UPLOAD MESSAGE TEST RESULTS DELIVERY CARRIED OUT BY THE INSTRUMENT
Message structure
Message header (H)
Test Order (O)
Result (R)

Comment (C)

Message Header RecordField No.Patient Information Record Field No. Test Order Record

h
6 Priority 1 String 1 N N S (Stat), R (normal)
7 Requested/ Date and time the order was 1 ASTM N N
Ordered Date and received or recorded Date
Time
12 Action code The action that needs to be taken 1 String 1 N N Q (mandatory when quality
with the order control)
Descriptor
26 Report Type Intention of the information 1 String 1 Y Y O (Order record),
contained in the record F (All tests results are Final or
could not be done - see R9),
P (This test triggers a rerun)
Result Record

h
1 Record Type ID Identifies the record 1 String 1 Y N R
3 Universal Test TOP defined Test ID 4 Numeric Y N 0 999999999
ID
4 Data or Observed, calculated or implied 1 String 30 N Y
Measurement result value
Value
5 Units Abbreviation of units for 1 String 15 N Y For information on specific unit
numerical results values see section 6
7 Result Abnormal Indicates the normalcy status of 1 String 2 Y N L (Below low normal),
Flags the result H (Above high normal),
N (Normal),
< (Below absolute low),
> (Above absolute high)
9 Result Status 1 String 1 Y Y F (final result),
P (preliminary result, because a
rerun has been set),
V (result validated),
X (result cannot be done)

11 Operator Operator ID for the test 1 String 30 N N

Identification performer
Operator ID for the test verifier 2 String 30 N
13 Date Time Test Date and time the instrument 1 ASTM Y N
Completed completed the test Date
14 Instrument Identifies the instrument that 1 String 14 Y N Instrument ID as specified in TOP
Identification performed this measurement
Rack id 2 String 2 Y N
Rack position 3 String 2 Y N
Comment Record

h
4 Comment Text Comment ID 1 String 50 N N
Comment description 2 String 500 N
Comment area 3 String 50 N
5 Comment Type Comment type qualifier 1 String 1 Y N I (instrument flag comment),
N (negative comment)

H | @^\ | 123 | | ACL-TOP-52 | | | | | LIS-HOST-31 | | P | 1394-97 | 20000614060520
P|1||||||||||||
O | 1 | Normal Control | <1034241923_260> | ^ ^ ^ 555 | R | | | | | | | | | | P | | | | | | | | | | O @ F
R | 1 | ^ ^ ^ 555 | 106.01 | % | | N | | F @ V | | ^ IL | | 20021211163215 | ACL-TOP-21 ^ B ^ 5
C | 1 | I | 1025 ^ reagent temperature warning ^ HW | I
C | 2 | I | 1030 ^ cuvette shuttle temp warning ^ HW | I
R | 2 | ^ ^ ^ 555 | 12.65 | sec | | N | | F @ V | | ^ IL | | 20021211163215 | ACL-TOP-21 ^ F ^ 3
R | 3 | ^ ^ ^ 555 | 0.97 | INR | | L | | F @ V | | ^IL | | 20021211163215 | ACL-TOP-21 ^ G ^ 2
C | 1 | I | 1017 ^ probe temperature warning ^ HW | I
L|1|N
4.5.2 DOWNLOAD MESSAGE TEST RESULTS DELIVERY REJECTED BY THE LIS HOST
In case there is an error in the information retrieved by the instrument to the LIS host, the LIS host cannot
retrieve any error information to the instrument
4.6 LIS HOST REQUEST RESULTS TO THE INSTRUMENT

This scenario takes place when the LIS host launches a request to the instrument, for uploading available
test results. IL instruments do not support to operate in this way, consequently, all requests for test results
received from LIS host will be rejected.
4.6.1 DOWNLOAD MESSAGE TEST RESULTS REQUEST PERFORMED BY THE LIS HOST
Message structure
Message header (H)


Message Header RecordField No.Request Information Record

h
13 Request 1 String 1 Y Y C (correction of previous values),
Information P (preliminary results),
Status Codes F (final results),
X (results cannot be done),
I (request results pending),
S (request partial results),
M (results a MIC level),
R (result previously transmitted),
A (abort last request),
N (request new/edit results),
O (request tests and demog data),
D (request demographic data only)

H | @ ^ \ | <0_0> <1025080549_50> | | LIS-HOST-05 | | | | | ACL-TOP-17 | | P | 1394-97 | 20010518123841 <CR>
Q | 1 | ALL | | | | | | | | | | I <CR>
L | 1 | N <CR>
4.6.2 UPLOAD MESSAGE REQUEST REJECTED BY THE INSTRUMENT

Message structure
Message header (H)
Comment (C)
Message Header RecordField No.Comment Record

h
4 Comment Text Comment id 1 String 50 N N invalidTransmissionInformation
Comment description 2 String 500 N Request not allowed
5 Comment Type Comment type qualifier 1 String 1 Y N N (negative result/error info)


h
3 Termination Provides explanation of end of 1 String 1 Y N Q (error in last request)
Code session
Example
C | 1 | I | invalidTransmissionInformation ^ Request not allowed | N <CR>
L | 1 | Q <CR>
4.7 INSTRUMENT UPLOADS ERROR INFORMATION

This scenario takes place when the instrument receives an invalid message from the LIS host. See Error
messages for more information on this topic.
4.7.1 UPLOAD MESSAGE ERROR INFORMATION MESSAGE (1)

This message is retrieved when there is a syntactic error, or when the host ID or instrument ID doesnt
match the values configured in TOP.
Message structure
Message header (H)
Comment (C)
Message Header RecordField No.Comment Record

h
4 Comment Text Comment id 1 String 50 N N invalidMessage
invalidSyntax
invalidValue
missingMandatoryValue
incompleteMessage
invalidTransmissionInformation


h
1 Record Type ID Identifies the record 1 String 1 Y N L
3 Termination Provides explanation of end of 1 String 1 Y N E (unknown system error)
Code session
Example
C | 1 | I | InvalidTransmissionInformation ^ Invalid host ID | N <CR>
L | 1 | E <CR>
4.7.2 UPLOAD MESSAGE ERROR INFORMATION MESSAGE (2)

This message is retrieved when there is an action that cannot be executed by the instrument.
Message structure
Message header (H)
Test Order (O)
Comment (C)
Message Header RecordField No.Patient Information Record Field No.Test Order Record

h
3 Specimen ID A unique identifier for the 1 String 16 N N
5 Universal Test ID TOP defined Test ID 4 Numeric 6 N Y 0 - 999999
7 Requested/ Date and time the order was 1 ASTM N N
Ordered Date and received or recorded Date
Time
16 Specimen Sample type 1 String 1 N N P (plasma)
Descriptor
26 Report Type Intention of the information 1 String 1 N Y O (Order record),
contained in the record X (Order cannot be done),
Y (No order/test in record)
Comment Record


h
4 Comment Text Comment id 1 String 50 N invalidDemographicData
invalidSpecimenData
invalidTestData
duplicatedTest

H | @ ^ \ | 123 | | ACL-TOP-02 | | | | | LIS-HOST-01| | P | 1394-97 | 20020421073718
P|1||||||||||||
O | 1 | 8642 | | ^ ^ ^ 1234 | R | | | | | | | | | | P | | | | | | | | | | O @ Y
C | 1 | I | invalidTestData ^ duplicated test | N
L|1|N
5. TRANSMISSION SCENARIOS RELATIONSHIPS

5.1 MANUAL OR AUTOMATIC JOB ORDERS DOWNLOADING

M a n u a l o r a u to m a tic jo b o r d e r s d o w n lo a d in g
In s tr u m e n t L IS H o s t
te s t o rd e r re q u e s t (4 .1 .1 )
T h e L IS H o s t re s p o n d s th e re q u e s t
[n o te s t o r d e r a v a ila b le ]: n o d a ta a v a ila b le ( 4 .1 .4 )
[te s t o r d e r s a v a ila b le ]: te s t o r d e r d e liv e r y ( 4 .1 .3 )
[te s t o rd e r O K ]:
s to r e r e c e iv e d o r d e r s
[in s tr u m e n t s p e c im e n t- ID a c tiv a te d ]: u p lo a d in s tr u m e n t s p e c im e n t ID ( 4 .4 .1 )
{O R }
[b a d te s t o rd e r]:
r e je c t r e c e iv e d o r d e r s
[u p lo a d e r r o r s a c tiv a te d ]: e r r o r in fo r m a tio n m e s s a g e ( 4 .7 .1 /4 .7 .2 )
T h e In s tr u m e n t c a n c e ls th e r e q u e s t
[r e q u e s t tim e o u t]: te s t o r d e r r e q u e s t c a n c e la tio n ( 4 .1 .2 )
5.2 HOST-INITIATED JOB ORDERS DOWNLOADING

Host initiated job orders downloading
Instrument LIS Host
test order delivery (4.2.1)
[test order OK]:
store received orders
[instrument speciment-ID activated]: upload instrument speciment ID (4.4.1)
[bad test order]:
reject received orders
[upload errors activated]: error information message (4.7.1/4.7.2)
5.3 HOST QUERY

H o s t q u e ry
In s tru m e n t L IS H o s t
H o s t q u e ry (4 .3 .1 )
T h e L IS H o s t re s p o n d s th e re q u e s t
[n o te s t o r d e r a v a ila b le ]: n o d a ta a v a ila b le ( 4 .1 .4 )
[te s t o r d e r s a v a ila b le ]: te s t o r d e r d e liv e r y ( 4 .1 .3 )
[te s t o rd e r O K ]:
s to r e r e c e iv e d o r d e r s
[in s tr u m e n t s p e c im e n t- ID a c tiv a te d ]: u p lo a d in s tr u m e n t s p e c im e n t ID ( 4 .4 .1 )
{O R }
[b a d te s t o rd e r]:
r e je c t r e c e iv e d o r d e r s
[u p lo a d e r r o r s a c tiv a te d ]: e r r o r in fo r m a tio n m e s s a g e ( 4 .7 .1 /4 .7 .2 )
T h e In s tr u m e n t c a n c e ls th e r e q u e s t
[r e q u e s t tim e o u t]: h o s t q u e r y c a n c e la tio n ( 4 .3 .2 )
5.4 MANUAL OR AUTOMATIC JOB RESULTS UPLOADING

M
an
ualo
rau
to
maticre
sultsu
plo
adin
g
In
stru
men
t L
ISH
os
t
te
stre
sultu
plo
ad(4
.5
.1
)
LISHost requests results
Instrument LISHost
test results request (4.6.1)
All requestsfor test resultsreceivedfromLIShost will berejected.

This instrument doesn't support tooperateinthis way.
request rejectedby instrument (4.6.2)
6. APPENDIX A FUTURA COMPATIBILITY MODE

When the communication module for TOP was designed, it was thought to ease the communication for both
new users, that can use a new protocol with extended capabilities, and old users who can reuse the old
Futura developed driver. For any information of the Futura implementation see [R2].
The Futura driver should only be used by institutions that currently have a developed driver and can reuse
it with the changes produced in this adapted version. New users should always use the new implementation
of the protocol that provides more functionality.
The Futura driver for TOP works exactly as the Futura instrument except for the following issues:
GENERAL DIFFERENCES
TOP uses the host query mechanism to request tests immediately when a rack is inserted in the
instrument. Futura did not support this feature in its original version and it has been disabled in the
new Futura driver implementation for TOP. To allow the Futura driver to work as originally, you have
to activate the automatic downloading of test orders.
The Futura documentation does not require LIS drivers to respond to all test orders requests by
TOP. Due to that, when a request is not responded in Futura compatibility mode no error message
is displayed.
DATA MAPPINGS

Futura test IDs and TOP test IDs have changed. The communication will be performed using the
new test IDs defined by TOP. Changes may be required in the LIS/driver to accommodate to these
new identifiers.
Futura result units and TOP result units have changed. Futura driver for TOP implements the
required mapping to conform as much as possible to the original Futura units. Units not supported
by Futura are sent in TOP originals format and the limitation of 6 digits detailed in the Futura doc-
umentation has been changed to 15 characters. These are the mappings performed by TOP in
Futura mode:
Top Futura/ Comment

Advance
Measured s sec
Mean Not supported
T Not supported
%T Not supported
DT delta "delta" for Delta Deriv. Algorithm
T/min ct/min
D %T delta
%T/min Not supported
mAbs Not Supported Used by Endpoint Algorithm - not available on Futura/
Advance
D mAbs mA "mA" maps to Top Final - Initial Algorithm
"delta" maps to Top Delta Derivative Algorithm. The
delta
use of the unit in this case is always mapped to mA
mAbs/min mA/min
Calculated Ratio R
INR INR
% %
Calibrated g/L g/L
mg/L Not supported
mg/dL mg/dL
ng/mL ng/mL
U/mL U/mL
IU/mL IU/mL
mU/mL Not supported
nmol/L Not supported
%vWF:Ag Not supported
User Defined Not supported
Not supported M/L equivalent to: nmol/l x 103 (never sent by TOP in
Futura mode)
Not supported g/L equivalent to: g/l x 10-6 (never sent by TOP in Futura
mode)
Statistical %CV Not supported
SD Not supported
Slope Not supported
Paired TR Not supported
%NTR Not supported
D Not supported
DN Not supported

Parallelism mean of 100% Not supported In Futura, unit label corresponds to the Unit label
selected by the user as primary unit.
mean CR aveCR
mean CR 100% Not supported
slope slope
r2 Not supported r equivalent to: (r2)1/2
y-intercept y-int
%CV of CR %CV-CR
%CV of CR Not supported
100%
Error descriptions have changed in TOP, but they will be sent using the old Futura format. Only one
comment record with all flags and errors concatenated with a + sign. The number used to indicate
the determination where the error was found has also been removed.
CHANGES IN MESSAGES
Now the patient name and last name is now separated by a component delimiter (patient record
field 6). In the original version of futura, the patient name and last name was stored in the first com-
ponent.
Specimen ID length has changed from 20 characters to 16. 16 is the maximum number of char-
acters supported by the TOP device. In case the number of characters sent by the LIS is bigger than
16 the messages is rejected.
When uploading test results Futura added the Rack ID and the Sample position in the field four in
the ASTM Order record. This field now includes the same data but the Rack ID and Sample position
has changed to the new values in TOP.
Futura supported the uploading of calibrations and checkpoints. These features have been
removed in TOP
TOP is not capable to distinguish automatically validated and manually validated results. Futura did
that sending an F or an V flag in R9 respectively. Due to that limitation in TOP, the driver of Futura
always send results with an F and V is never used.
ERRORS
Ill formed test orders messages downloaded from host are validated. If an error occurs in one mes-
sage, no error information is sent to the HOST system. These are some of the actions performed:
Fields with a maximum length longer than the value expected by TOP are truncated to the max-
imum length allowed.
Invalid date in a record makes the complete record to be invalidated and error info is sent to the
application. With the exemption of H14 which value wont be validated.
Empty order date in O7 is filled with current date.
Missing mandatory parameters are added when possible.


Chapter 6 Power Management 6-1
Chapter 6
Power Management
6-1 Overview
The Power Management consists of the +5V/+15V/-15V Power Supply, the +24V/+28V Power Supply, the
Fuse Board, and the Power Entry Module, which includes the Instrument power switch and the attach-
ment point for the line cord.

6-2 Physical Layout
Figure 6-1 "Layout of the Power Management System" shows the physical layout of the Power Management System. The +5V/+15V/-15V Power Supply is shown
in blue, the +24V/+28V Power Supply is shown in magenta, the Fuse Board is shown in green, and the Power Entry Module is shown in yellow.
Figure 6-1 Layout of the Power Management System
Power Entry
Module
Fuse Board +5V/15V/-15V Power Supply +24V/+28V Power Supply

Figure 6-2 "Interconnect Diagram for Power Management" contains the Interconnect Diagram for the Power Management.
Figure 6-2 Interconnect Diagram for Power Management

6 - 4 Chapter 6 Power Management
This section describes the operation of the four major components: the Power Entry Module, the Fuse
Board, the +5V/+15V/-15V Power Supply, and the +24V/+28V Power Supply.
Power Entry Module

The Power Entry Module includes the Instrument power switch, a Fuse Block, and the attachment point for
the line cord (see Figure 6-3 "The Power Entry Module").
Note: In Figure 6-3 "The Power Entry Module" the Right Skin of the Instrument has been removed.
Figure 6-3 The Power Entry Module
Fuse Block Attachment

Point for the
Line Cord
Instrument
Power Switch

Power Supplies
The output of the Power Entry Module goes to the primary (input) side of the +5//+15/-15 Power Supply and
to the primary (input) side of the +24V/+28V Power Supply. Both Power Supplies are located in the rear wall
of the Instrument, behind the Power Supply Covers (see Figure 6-4 "The Power Supply Covers").
Figure 6-4 The Power Supply Covers
+24V/+28V Power +5V/15V/-15V Power

Supply Cover Supply Cover
The Power Supplies are auto ranging and are compatible with a wide range of input voltages and frequen-
cies. Refer to "Electrical Requirements" for more information.
Figure 6-5 "The +5V/+15V/-15V Power Supply" shows the +5V/+15V/-15V Power Supply; Figure 6-6
"The +24V/+28V Power Supply" shows the +24V/+28V Power Supply.
Note: Figure 6-5 "The +5V/+15V/-15V Power Supply" and Figure 6-6 "The +24V/+28V Power Supply"
show Power Supplies that are in the process of being removed from the Instrument.
Figure 6-5 The +5V/+15V/-15V Power Supply

Figure 6-6 The +24V/+28V Power Supply
Fuse Boards
The secondary (output) side of the Power Supplies terminate at the Fuse Board. The Fuse Board provides
over-current protection for the modules contained within the Instrument.
"Fuse Board Diagram for the Non-CTS TOP Model (Cavro)" describes the Fuse Board for ACL TOP/
Cavro units; "Fuse Board Diagram for the CTS TOP Model" describes the Fuse Board for CTS TOP units.
The fuses on the Fuse Board are removable and can be replaced with fuses of the same rating. Spare fuses
are included on the Fuse Board and may be used to replace any fuses that have opened.
WARNING: To ensure user safety, and proper system operation,

fuses must be replaced with those that have the same rating and are
of the same type.
Fuse Board Diagram for the Non-CTS TOP Model (Cavro)
Figure 6-7 "Fuse Diagram for the ACL TOP/Cavro" contains the fuse diagram for the ACL TOP/Cavro.

Figure 6-7 Fuse Diagram for the ACL TOP/Cavro
The following table shows the secondary voltages for the ACL TOP/Cavro.
Table 6-1 Fuse Ratings and Secondary Voltages for the Non-CTS TOP Model
FUSE SIGNAL NAME RATING PART NUMBER
F1 BP_FANS_FUSE 2A/250V TIME DELAY IL #00014871705
F2 +28V_COOLING_BD 12.5A/250V SLOW BLOW** IL #00014871713
F3 +5V_LEVEL_III_CPU 4A/250V TIME DELAY IL #00014871708
F4 +24V_BACKPLANE 8A/250V TIME DELAY IL #00014871711
F6 +24V_CAVRO 8A/250V TIME DELAY IL #00014871711
F7 +24V_DC_DRIVER 8A/250V TIME DELAY IL #00014871711
F8 +5V_LEVEL_II_CPU 4A/250V TIME DELAY IL #00014871708
F18 -15V_BACKPLANE 2A/250V TIME DELAY IL #00014871705
**Current schematic and board notation refers to this value as 10A.

The following table lists the spares for the ACL-TOP board.
Table 6-2 Spare Fuses for the Non-CTS TOP Board
SPARE FUSES RATING PART NUMBER
F11, F15 2A/250V IL # 00014871705
F16 12.5A/250V** IL # 00014871713
F9, F10, F13 4A/250V IL # 00014871708
F12, F14 8A/250V IL # 00014871711
CAUTION: Use terminal block J1 along the bottom edge of the board to
check voltages. Refer to the voltage labels from the diagram above and
marked on the board in silkscreen.
Fuse Board Diagram for the CTS TOP Model
Figure 6-8 "Fuse Diagram for the CTS TOP Model" contains the fuse diagram for the CTS TOP Model of
the TOP.

Figure 6-8 Fuse Diagram for the CTS TOP Model
The following table shows the secondary voltages for the CTS TOP Model.
Table 6-3 Fuse Ratings and Secondary Voltages for the CTS TOP Model
F1 BP_FANS_FUSE 2A/250V TIME DELAY IL #00014871705
F2 +28V_COOLING_BD 12.5A/250V SLOW BLOW** IL #00014871713
F3 +5V_LEVEL_III_CPU 4A/250V TIME DELAY IL #00014871708
F6 +24V_CAVRO 8A/250V TIME DELAY IL #00014871711
F7 +24V_DC_DRIVER 8A/250V TIME DELAY IL #00014871711
F8 +5V_LEVEL_II_CPU 4A/250V TIME DELAY IL #00014871708
F18 -15V_BACKPLANE 2A/250V TIME DELAY IL #00014871705
F19 +24V_SYS_F_UA1 8A/250V TIME DELAY IL #00014871711
F20 +24V_SYS_F_UA2 8A/250V TIME DELAY IL #00014871711

Table 6-3 Fuse Ratings and Secondary Voltages for the CTS TOP Model
F21 +15V_PWR_F_UA1 2A/250V TIME DELAY IL #00014871705
F25 CAN_BUS_FUSE 2A/250V TIME DELAY IL #00014871705
The following table lists the spares for the CTS TOP board.
Table 6-4 Spare Fuses for the Non-CTS TOP Board
SPARE FUSES RATING PART NUMBER
F11, F15 2A/250V IL # 00014871705
F16 12.5A/250V** IL # 00014871713
F9, F10, F13 4A/250V IL # 00014871708
F12, F14 8A/250V IL # 00014871711
CAUTION: Use terminal block J1 along bottom edge of board to check

voltages. Refer to voltage labels from the diagram above and marked on
the board in silkscreen.
Electrical Requirements
The instrument operates correctly with electrical variations of up to 10% in an ambient temperature of 15C
to 32C (59F to 89F) with a relative humidity of 5%-85% (non-condensing). The instrument should be
placed in a position free from dust, fumes, vibrations and excessive variations in temperature. Using this
instrument at an altitude greater than 2000 meters is not recommended.
The INSTRUMENT is single phase, has current leakage of less than 500 Amps, and produces 2,049 BTU's
per hour.
In accordance with IEC 1010 safety standard, paragraph 1.4, there is no safety hazard in the temperature
range 5-40 C.
The instrument operates correctly with electrical variations of up to 10% on the nominal supply and with
supply frequencies between 47 and 63 Hz.
NOTE: The fuse board diagram and the secondary voltages for the CTS Instrument are found
are found in "Fuse Board Diagram for the CTS TOP Model".
NOTE: The fuse board diagram and the secondary voltages for the standard ACL TOP/Cavro
Instrument are found are found in ""Fuse Board Diagram for the Non-CTS TOP Model
(Cavro)".

Chapter 6 Power Management 6 - 11
CAUTION: Ensure that the supply voltage in the laboratory is compatible

with the label on the rear of the analyzer as shown in Table 6-5 "Supply
Voltages" (below).
The voltages and current values in Table 6-5 "Supply Voltages" apply to all configurations of the TOP
Instrument.
Table 6-5 Supply Voltages
Value of supply voltage for Current (A) Value as shown on the label
normal function
240V AC 10% 5A 100-240 VAC
115V AC 10% 10 A 100-240 VAC
100V AC 10% 10 A 100-240 VAC
The PC requires an input voltage between 100-240V and an amperage of 3.5A.

The monitor requires an input voltage between 100-240V and an amperage of 1.8-0.9A.
The power cord provided with the instrument is a certified cord and three-prong, double insulated, grounded
(NEMA) receptacle and plug.
Volt-Amps Specifications
This section contains the Volt-Amps specifications for all configurations of the TOP Instrument.
Volt-Amps Specifications for the TOP Analytical Module (AM)
Table 6-6 "TOP AM Volt-Amps Specifications" contains the Volt-Amps specifications for all configura-
tions of the TOP AM.
Table 6-6 TOP AM Volt-Amps Specifications
Volts AC Amps Volts/Amp Watts Frequency
100 VAC 10A 1000 VA 600 W 50/60Hz
115VAC 10A 1150 VA 600 W 50/60Hz
240VAC 5A 1200 VA 300 W 50/60 Hz

Volt-Amps Specifications for the TOP Computer Module (CM)
Table 6-7 "TOP CM Volt-Amps Specifications" contains the Volt-Amps specifications for all configura-
tions of the TOP CM.
Table 6-7 TOP CM Volt-Amps Specifications
Volts AC Amps Volts/Amp Watts Frequency
100 VAC 6A 600 VA 600 W 50/60Hz
115VAC 6A 690 VA 600 W 50/60Hz
240VAC 3A 720 VA 300 W 50/60 Hz
Volt-Amps Specifications for the TOP Monitor
Table 6-8 "TOP Monitor Volt-Amps Specifications" contains the Volt-Amps specifications for all configu-
rations of the TOP Monitor.
Table 6-8 TOP Monitor Volt-Amps Specifications
Volts DC Amps Volts/Amp Watts Frequency
12 VDC 4.16A 50 VA * 50 W 50/60Hz
NOTE: DC voltage has no phase difference so VA = Watts
6-5 Adjustments and Verifications
Verification and Adjustment of the 5Volt Rail on the ACL TOP

NOTE: ONLY the 5 volt rail is adjustment.
1. Power down the unit and open the Sample and reagent covers.
CAUTION: Instantaneous and extensive damage can result if adjustment

to the power supplies is attempted with the power on!
2. The +5V, +15V, -15V power supply is on the right hand side (facing the rear of the unit). Refer to Figure
6-9 "Power Supply Access". Remove the four mounting screws that secure the Power Supply to the
rear wall.

Figure 6-9 Power Supply Access
+5V/15V/-15V Power Supply Mounting Screws
3. Carefully pull the Power Supply away from the back wall enough to access the wire terminals.
4. Power on the Analytical Module (AM).
5. Measure the voltage across the red and black wires as shown on Figure 6-10 "+5/+15/-15V Power
Supply Wiring".
Figure 6-10 +5/+15/-15V Power Supply Wiring
Red and Black

Wires
+5V Adjustment
Potentiometer
6. Power off the AM.

7. Turn the 5V adjustment potentiometer, see Figure 6-10 "+5/+15/-15V Power Supply Wiring", turn
(clock wise to increase the voltage, counter clockwise to decrease the voltage).
8. Power up the Analytical Module (without closing the Sample and Reagent covers so the AM does not
attempt to initialize) and measure the 5 volts at the red and black wires on the supply.
9. Repeat steps 5 through 8 until the 5 volts is measured to be from 5.20 volts to 5.25 volts, adjusting the
potentiometer appropriately.
10. Secure the power supply with all mounting screws.
11. Reboot and initialize the system .

6-6 Diagnostics
The diagnostics for Power Management are on the Voltages tab. The Voltages tab contains three main areas: the ORU area, and the Controllers area, and the Arm
Controllers area. Figure 6-11 "The Voltages Tab" shows the Voltages Tab.
Figure 6-11 The Voltages Tab

ORU Area
Figure 6-12 "The ORU Area" shows the ORU area. See Testing/Correcting Voltage Errors in Chapter
10 for further information on ORU voltage.
Figure 6-12 The ORU Area
The ORU area displays voltage information for each of the four Detectors and for the Emitter. For each of
the four Detectors, the information includes the current voltage, the Lower Limit, and the Upper Limit for the
three Detectors (12V, 5V, and -12V). For the Emitter, the information consists of the current voltage, the
Lower Limit, and the Upper Limit for the 12V voltage.
NOTE: Ensure voltages are checked in the following order because voltages being incorrect
in one area could cause voltages to be incorrect in the following area.

Controllers Area
Figure 6-13 "The Controllers Area" shows the Controllers area.
Figure 6-13 The Controllers Area
The Controllers area displays voltage information for the Cuvette, Rack, and ORU Controllers. For each
Controller, the information includes the current voltage, the Lower Limit, and the Upper Limit for the four
Controller supplies (24V, 15V, 5V, and -15V).

Arm Controllers Area

Figure 6-14 "The Arm Controllers Area" shows the Arm Controllers area.
Figure 6-14 The Arm Controllers Area
The Arm Controllers area displays voltage information for the Sample Arm, Intermediate Reagent Arm, and
Start Reagent Arm. For each Arm Controller, the information includes the current voltage, the Lower Limit,
and the Upper Limit for the three Arm Controller supplies (24V, 15V, and 5V).

6-7 Removal/Replacement
Power Entry Module Removal/Replacement
Power Entry Module Removal
Refer to Chapter 4 ("Chassis and Enclosure") for details on cover removal. To remove the Power Entry Mod-
ule, the following covers must be removed: Right Skin, Inner Skin, Top Skin, Front Panel, and all four Interior
Reagent Covers. First power down the Instrument and remove the power cord.
CAUTION: Before removing the Right Skin, the Rinse Bottle, Clean Bottle,
Crossover Cables, and the fluidic waste lines must be removed.
After the covers have been removed, do the following to remove the Power Entry Module:
1. Remove the two screws that secure the Power Entry Module to the Instrument Frame (see Figure 6-15
"Power Entry Module").
Note:The Power Entry Module is mounted on the upper right side of the Instrument.
Figure 6-15 Power Entry Module
Wires Attached to
the Power Entry
Module
Mounting
Screws
2. Remove the wires attached to the rear of the Power Entry Module (see Figure 6-15 "Power Entry Mod-
ule").
3. Carefully pull the Power Entry Module from the Instrument.
Power Entry Module Installation
1. Place the Power Entry Module on the Instrument Frame as shown in Figure 6-15 "Power Entry Mod-
ule".
2. Replace the two screws shown in Figure 6-15 "Power Entry Module".
3. Re-connect the wires, in the following fashion, to the rear of the Power Entry Module
White wire to Terminal N
Black wire to Terminal L
Non-insulated wire to the remaining terminal on the Power Entry Module

4. Reconnect the power cord to the Instrument.

5. Power on the Instrument in order to verify that the Power Entry Module is working properly.
6. Reinstall the covers.
Non-adjustable Power Supply Removal/Replacement

NOTE: The Instrument has two Non-adjustable Power Supplies, the following procedure
applies to either supply.
Non-adjustable Power Supply Removal
1. Power down the Instrument.

2. Disconnect the power cord.
3. Remove the four mounting screws that secure the Power Supply to the rear wall (see Figure 6-16
"Non-Adjustable Power Supplies").
Figure 6-16 Non-Adjustable Power Supplies
+24V/+28V Power Supply +5V/+15V/-15V Power Supply
Mounting Screws Mounting Screws

4. Carefully pull the Power Supply far enough back to access the wire terminals (see Figure 6-17 "Wire
Terminals on a +5/+15/-15V Power Supply").
Figure 6-17 Wire Terminals on a +5/+15/-15V Power Supply
NOTE: The +24V/+28V Power Supply has wires connected to both ends of the unit; the +5V/
+15V/-15V Power Supply only has wires connected to one end of the unit.
5. Remove each of the wires from the Power Supply.

6. Place the Power Supply (with attached cover) on a sturdy flat surface with the cover facing up (see Fig-
ure 6-18 "The Power Supply Cover").
7. Remove the four mounting screws from the Power Supply Cover (see Figure 6-18 "The Power Supply
Cover").
8. Lift the Power Supply Cover off the Power Supply.
Figure 6-18 The Power Supply Cover
Mounting Screws for the +5V/+15V/-15V Power Supply
Non-adjustable Power Supply Installation
1. Place the new Power Supply on a sturdy, flat surface. The holes for the mounting screws should be fac-
ing upward.
2. Use the four mounting screws to secure the Power Supply Cover to the Power Supply (see Figure 6-18
"The Power Supply Cover").

3. For a +5V/+15V/-15V Power Supply, re-connect the wires in the following fashion (terminals as indi-
cated with supply installed):
Leftmost screw terminals: Blue - top terminal
Black - bottom terminal
Middle screw terminals: Black - top terminal
Brown - bottom terminal
Rightmost screw terminals: Black - top terminal
Red - bottom terminal
Three-pin connector: AC input cable
4. For the +24V/+28V Power Supply, re-connect the wires in the following fashion(terminals as indicated
with supply installed):
Left (fan) side: GND green, or green with yellow
NEW white
LINE black
Right side: Leftmost screw terminals: Black on top terminal
Yellow on bottom terminal
Rightmost screw terminals: Black on top terminal
White on bottom terminal
NOTE: The 10-pin connectors are not used on the +24V/+28V Power Supply
5. Carefully place the Power Supply into the back wall of the Instrument.
6. Fasten the four mounting screws to secure the Power Supply to the rear wall of the Instrument (see Fig-
ure 6-16 "Non-Adjustable Power Supplies").
CAUTION: Make sure the right model of Power Supply (+15V/-15V/+5V or

+24V/+28V) is installed in the correct location as shown in Figure 6-16
"Non-Adjustable Power Supplies".
Fuse Board Removal/Replacement
Fuse Board Removal
Refer to Removal/Replacement Procedures in Chapter 4 for details on cover removal. To remove the
Fuse Board, the Sample Side interior covers must be removed.
After the covers have been removed, do the following to remove the Fuse Board:
1. Power down the Instrument before removing covers.
2. Disconnect the power cord.
3. Remove all connectors and wires to the Fuse Board. (Note: The Fuse Board is located on the upper-left
portion of the Instrument rear wall.)
4. Remove the four screws that secure the Fuse Board to the rear wall of the Instrument (see Figure 6-19
"The Fuse Board").
5. Carefully pull the Fuse Board from the rear wall of the Instrument.

Figure 6-19 The Fuse Board

Mounting Screws
Note: Figure 6-19 "The Fuse Board" shows the Fuse Board for the CTS TOP. The Fuse Board for the ACL
TOP/Cavro does not have the Reagent Arm fuses, which are located on the lower right-hand side of
the Fuse Board for the CTS TOP.
Fuse Board Installation
1. Place the Fuse Board on its screw standoffs on the rear wall of the instrument.
2. Fasten the four mounting screws in their locations at the corners of the Fuse Board.
3. Fasten the wires and cables to the Fuse Board.
Be aware of the following as wires and cables are re-connectd to the Fuse Board:
The screw terminals for the Power Supply wires are not keyed. Connect the wires as follows:
+24VA White twisted with Black
+24V GNDA Black twisted with white
+28VRC Yellow twisted with Black
+28V GND Black twisted with Yellow
+5V GND Black twisted with Red
+5V Red twisted with Black
+15V GND Black twisted with Brown
+15V Brown twisted with Black
-15V GND Black twisted with Blue
-15V Blue twisted with Black
The Reagent Arm Connectors, and the Reagent Arm cables, are labeled but are not keyed. Ensure
that the Intermediate Reagent Arm cable is connected to the Intermediate Reagent Arm connector,
and the Start Reagent Arm cable to the Start Reagent Arm connector. (Note: The Reagent Arm
connectors exist only on the CTS Fuse Board.)

Chapter 7 Fluid Movement 7-1
Chapter 7
Fluid Movement
7-1 Overview
The ACL-TOP contains two distinct fluid movement systems, the Precision fluid movement system and the
Bulk fluid movement systems.
The "The Precision Fluidic Subsystem" is responsible for moving the patient samples, calibra-
tors, diluents, and reagents from rack locations to the cuvette wells.
The "The Bulk Fluidic Subsystem" provides the necessary fluids to maintain precision and accu-
racy, and to clean the probes and remove waste fluid and condensation from the instrument.
7-2 Physical Layout
Figure 7-1 "Layout of the Fluid Movement System" shows the physical layout of the Fluid Movement
System.
Figure 7-1 Layout of the Fluid Movement System

7 - 2 Chapter 7 Fluid Movement
Figure 7-2 "Fluid Movement System Interconnect Diagram" contains the Interconnect Diagram for the
Fluid Movement System. Interconnect diagrams for the robotic arms and their fluidic connections are pro-
vided in Interconnect Diagrams in Chapter 8.
Figure 7-2 Fluid Movement System Interconnect Diagram
277582
FLOPPY DRIVE
P1
00027754000
P2
P1
Speaker Battery
277587-00
277625-00
P11
J4 J8 J3 J18 J15 J6 J2 J3
Speaker Battery Mouse IDE HD Floppy SVGA CRT Keyboard COM1/2 INSTRUMENT
SIDE PANEL
Power From
J3 From Fluid
Fuse Board J9
Power Driver Board Waste
J8 Ethernet Fluid
J7 J5
From Full
PC Video Flat Panel
Backplane
J16 J14
LPT1 CAN BUS
278000 277626-00
Level 2 CPU Video

J17
COM5 SCSI EZ I/O
J12 J11 OPTOA/OPTOB
Ethernet
277624-00
To Cavro CCU9000 J14

J15 COM3/COM4
(Both) 00027758300
PC/104
J1
Clean Clean Sample Rinse

TO J3 OF 28632000 J1, J2 Pump #1 Pump #2 Pum p
X-AXIS DRIVER J8
DUAL ARM 286400 Accumulator 1 Accumulator 2 Reagent Rinse
Full Sensor Full Sensor Pump 1
CAN Bus LAS
J4 Reagent Rinse
TO J3 OF 28632000 Sample Clean Reagent
Solenoid Pump 2
X-AXIS DRIVER J7 PC/104 CAN Bus Valve
CTS ARM Valve 1
CAN Bus CTS Rinse
00027760400
00027760300
00027760700
J3 Digital I/O CTS Clean Reagent Pum p 277608

Valve Solenoid
Valve 2
Waste Pum p
Rinse Bottle #1
Warn Sensor
J2 J9 J6
277552
J1 J2 J3
Rinse Bottle #1
Fluidics Connector Board Empty Sensor
FLUIDICS
CONTROLL ER 27506000 00027760600
Fluidics LED BOARD Rinse Bottle #2
J3 J4 J5
275070 275050 Warn Sensor
J2 J1 J8
Rinse Bottle # 2
To Side Panel
277551 277518 Empty Sensor

277536
277626
14 Pin Cable To Front Panel

277519 Fluidic and Disconnect Board Clean Bottle
14 Pin Ribbon System 277621 Warn
Status LEDs and J3
Cavro Reset J1 Waste Sensor
Clean Bottle
Disconnect Board J1
J14 J25 J19 J36 Power J32 Empty
CANBUS J2
Backplane
189510-01

To maintain precision and accuracy of the system, the Precision Fluid Lines and the Sampling Probes are
filled with a working fluid, HemosIL Rinse solution, that limits the compressibility of the system fluid. The
working fluid ensures that displacements created in the Syringe Pump are precisely replicated at the probe
tip when samples are aspirated or dispensed.
NOTE: The HemosIL Rinse solution is also used by the instrument to clean the probes.
Aspirating and Dispensing

Prior to aspirating a sample, the Syringe Pump draws an air gap to create a separation zone between the
working fluid and the sample. After the sample is aspirated, the Syringe Pump draws a second air gap,
known as a transport air gap, to create a buffer between the sample and the outside environment and to
move the sample up the tube. (Moving the sample up the tube also moves the sample closer to the Probe
heater, in instruments that are equipped with a Probe Heater.)
During the dispensing of the sample, the entire transport air gap and 50% of the first air gap is dispensed
along with the sample. The remaining 50% of the first air gap (an accumulated volume in the syringe) is dis-
pensed over waste at the end of the test. When beginning a test, the Syringe Pump always starts at zero
volume.
The sizes of the air gaps can differ depending on the sample size. The air gaps for IL-approved assays are
stored in the parameter files. Users who create their own assays can define their own air gaps and generate
their own parameter files.
For customer-defined assays, the use of a Head Volume may be desired. A Head Volume allows the aspi-
ration of an additional volume of sample. (IL-defined assays do not typically use a Head Volume.)
The Precision Fluidic Subsystem

The Precision Fluidic Subsystem consists of the following components, addressing, and settings:
Table 7-1 Components of the Precision Fluidic Subsystem
Component
"Syringe Pump"
"Syringe Drive Motor"
"Syringe Pump Valve"
"Cavro Syringe Pump Settings"
"Hamilton Syringe Pump Settings"

Table 7-1 Components of the Precision Fluidic Subsystem(Continued)
Component
"Syringe Pump Addressing"
"Probes and Tubing, non-CTS, Cavro

Arms"
"Probes and Tubing, CTS"
The following subsections provide descriptions of the above listed components of the Precision Fluidic Sub-
system and their operation.
Syringe Pump
The syringe pump assemblies used on CTS and non-CTS ACL-TOP instrument types are the Cavro
XP3000, as shown in Figure 7-3 "Cavro XP3000 Syringe Pump" or the Hamilton PSD4 as shown on Fig-
ure 7-4 "Hamilton PSD4 Syringe Pump". Either assembly contains a PCB, a 24-volt DC motor, and a
pump to which a three-way Y valve, and a syringe are attached. The PCB includes a processor that receives
commands from the X-Axis Driver PCB in the CTS system using an RS-232 protocol. The processor
receives commands from the master processor in the Base TOP system and uses RS-485 protocol. The
syringe pump provides the precision fluid movement for the ACL-TOP and controls the aspiration and dis-
pensing operations in the probe.
The following descriptions of syringe pump operation apply to both the Cavro and Hamilton pumps. Differ-
ences between the two are clearly defined.
Figure 7-3 Cavro XP3000 Syringe Pump
Syringe Drive Motor
Syringe

Figure 7-4 Hamilton PSD4 Syringe Pump
Syringe Drive
Motor
Syringe
Syringe Drive Motor
The Syringe Drive Motor is a stepper motor that controls the movement of the syringe. Each time the arm is
initialized, the Syringe Drive Motor is initialized and places the syringe in the home position. The syringe is
in its home position, all the way up, when the syringe is at zero volume. When the syringe reaches zero vol-
ume, the circuit board-mounted home sensor is triggered by a flag mounted to the Syringe Plunger Holder.
Step loss in the Syringe Drive Motor is monitored by a quadrature encoder. The encoder can detect both
step loss and direction of travel. The Stepper Motor provides 30 mm travel length for the Syringe and has a
resolution of 3,000 steps. The full range of travel for the syringe is equivalent to its volume of 250uL.
Syringe
Each Syringe Pump has a syringe, a Teflon tip, and a capacity of 250uL. A portion of the syringe volume is
used to aspirate the air gap and the transport air gap as described in "Aspirating and Dispensing". Both
the Cavro and Hamilton syringes have a Kel-F Body and a Teflon Plug as shown in Figure 7-5 "Cavro
Syringe Parts" and Figure 7-6 "Hamilton Syringe Parts". As shown on the Figure, the Cavro and Hamil-
ton syringes have a different design to the syringe mounting; however their function is identical.

Figure 7-5 Cavro Syringe Parts
Teflon Tip
Plunger
Kel-F Body
Figure 7-6 Hamilton Syringe Parts
Kel-F Body
Plunger
Teflon Tip
Syringe Pump Valve
The Syringe Pump Valve is mounted to the upper front of the Syringe Pump by two Phillips pan head screws
as shown in Figure 7-7 "Syringe Pump Valve".

Figure 7-7 Syringe Pump Valve
Teflon Plug
Valve
Pan Head
Screws
The valve has three ports and each port has a -28 UNF female thread designed for a bottom seal fitting.
The plug within the pump rotates within the body to connect any 2 ports together. As shown on Figure 7-8
"Syringe Valve Ports", the upper right valve position is for the sample tubing, the upper left is for rinse input
and the lower position is for the syringe.
Figure 7-8 Syringe Valve Ports
Probe (Sample
Rinse Input Tubing)Output
Port
Syringe
Connection

The valve is turned by a stepper motor with an encoder coupled to the motor that provides positional feed-
back. Attached to the valve shaft is a flag to recognize the home position during initialization of the valve.
The valve home sensor shares a circuit board with the syringe home sensor. During initialization, the valve
spins until the flag is recognized by the home sensor. The valve is then placed in output mode in which the
syringe port is linked to the probe for sample aspiration and dispensing. Valve initialization can cause some
fluid to leak past the valve. To prevent uncontrolled fluid dispensation, the valve is only initialized by the
ACL-TOP software when the probe is over the accumulator rinse/waste location. Table 7-2 "Valve Posi-
tions for All ACL-TOP Configurations" lists the three available valve positions and their function.
Table 7-2 Valve Positions for All ACL-TOP Configurations
MODE CONNECTION FUNCTION
OUTPUT SYRINGE TO PROBE SAMPLE ASPIRATION & DISPENSE
INPUT RINSE PUMP TO SYRINGE PRIMING THE SYRINGE
BYPASS RINSE PUMP TO PROBE PRIMING
Cavro Syringe Pump Settings
On the rear panel of the Syringe Pump are two sets of jumpers and a rotary switch. The jumpers are used
to determine the communications used to communicate with the pump (RS485, RS232, baud rate) as well
as some selectable operations of the pump. The rotary switch is used to set the address of the valve.
The upper set of jumpers are Termination jumpers and should be in the position shown on Figure 7-9
"Cavro Syringe Pump Communication/Valve Jumpers". As shown on the figure, the two jumpers on the
left configure the pump for RS-485 communication if inserted. The lower jumper on the right is used to set
the Valve Mode in Normal Mode (jumper inserted) versus programming mode (without the jumper). The
fourth jumper, between pins 3 and 4 of JP4, is an extra jumper.
Figure 7-9 Cavro Syringe Pump Communication/Valve Jumpers
Pin 4 Extra Jumper

RS-485-B Pin 3
Pin 3
Pin 2
Pin 2 Valve Mode
RS-485-A Pin 1
Pin 1
JP2 JP4

The lower set of Cavro jumpers are configuration jumpers and should be in the position shown on Figure 7-
10 "Cavro Syringe Pump Lower Jumpers and Rotary Switch" to provide the functionality as identified on
the right side of the figure. The rotary address switch for the pump is also shown in Figure 7-10 "Cavro
Syringe Pump Lower Jumpers and Rotary Switch" and should be set as defined in "". As shown on the
figure, the hex number at the top of the dial indicates the address.
Figure 7-10 Cavro Syringe Pump Lower Jumpers and Rotary Switch
JP1-4 - Baud Rate (9600 Baud)
JP1-3 - EEPROM Mode (EEPROM Autostart)

JP1-2 - Protocol (OEM)
JP1-1 - Overload Detection (Enabled)
Address
Address switch
(Rotary dial)
The preceding figures show the correct placement of the jumpers for the Cavro pump. For clarification,
Table 7-3 "Jumper Settings" shows the correct settings of the Cavro Syringe Pump jumpers.
Table 7-3 Jumper Settings
JUMPER SETTING
JP1-1 OUT
JP1-2 IN
JP1-3 OUT
JP1-4 OUT
JP2- Pin1 to Pin 2 IN
JP2- Pin 3 to Pin 4 IN
JP4- Pin 1 to Pin 2 IN
JP4 - Pin 3 to Pin 4 Unused
Hamilton Syringe Pump Settings
On the rear panel of the Hamilton Syringe Pump are eight DIP switches, a set of jumpers, and a rotary
switch. The DIP switches are used to determine the communications protocol used to communicate with the
pump as well as some selectable operations of the pump. The jumpers are configuration jumpers and the
rotary switch is the address switch for the pump.

The lower set of jumpers are configuration jumpers and should be in the position shown on Figure 7-11
"Hamilton Syringe Pump Jumpers/Switches" and defined in Table 7-4 "Hamilton Configuration Jump-
ers". The rotary address switch for the pump is also shown in Figure 7-11 "Hamilton Syringe Pump
Jumpers/Switches" and should be set as defined in "Syringe Pump Addressing". Note that the center
portion of the switch has an arrow head. The arrowhead points to the address that is selected.
Figure 7-11 Hamilton Syringe Pump Jumpers/Switches
Address Selection
Address Switch
SW 1
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8
Table 7-4 Hamilton Configuration Jumpers
Pins Setting
J1 -J2 No Jumper
J3 - J4 No Jumper
J5 - J6 Jumper Inserted
J7 - J8 Jumper Inserted

Chapter 7 Fluid Movement 7 - 11
The Dip switches should be in the position shown on Figure 7-11 "Hamilton Syringe Pump Jumpers/
Switches".
Table 7-5 Hamilton DIP Switches
Switch Description Setting for ACL-

TOP
1 Syringe Overload Detection Off
2 EEPROM AutoStart/Self Test Off
3 Baud Rate 9600 or 3840Baud Off
4 Off
5 Off
6 Valve Settings Off
7 Off
8 Rs-485 Communication Termination Off
Syringe Pump Addressing
Communication between the syringe pump and the ACL-TOP is via RS-232 at 9600 baud for the Universal
arms and via RS-485 for the Cavro arms. For communication to occur, each pump is individually address-
able and must have its address set properly so the ACL-TOP can recognize it. The rotary address switch is
located on the lower rear of the syringe pump housing as shown on Figure 7-10 "Cavro Syringe Pump
Lower Jumpers and Rotary Switch". The address is properly set on all instruments prior to leaving man-
ufacturing; however, a replacement syringe pump must have its address set to properly communicate with
the ACL-TOP. Table 7-6 "Syringe Pump Addresses (CTS Instruments)" shows the syringe pump
addresses for ACL-TOP CTS units. Table 7-7 "Syringe Pump Addresses (Base TOP Instruments)"
shows the syringe pump addresses for ACL-TOP non-CTS units.
Table 7-6 Syringe Pump Addresses (CTS Instruments)
ARM LOCATION SYRINGE PUMP ADDRESS
SAMPLE 1
INTERMEDIATE REAGENT 1
START REAGENT 1
Table 7-7 Syringe Pump Addresses (Base TOP Instruments)

SAMPLE 4
INTERMEDIATE REAGENT 0
START REAGENT 4

Probes and Precision Tubing
The probes and precision tubing are responsible for contacting, acquiring, transporting, and, if the probes
are heated, heating the samples, reagents, and calibrators as they are moved from rack positions to cuvette
wells. All probes have liquid level detection (LLD) capability. The LLD capability enables the ACL-TOP sys-
tem software to perform volume tracking on reagents and diluents and to maintain the precision and accu-
racy of probe tip wetting depths and coordinate adjustments. An explanation of the LLD circuitry is provided
in Sample and Piercer LLD in Chapter 15 for CTS units and in ADRI-9 PCB in Chapter 8 for non-
CTS units.
The precision tubing connects the probe to the syringe pump valve and enables the displacements created
in the syringe pump to be transferred to the probe tip. The precision tubing is made of chemically compatible
Teflon. Leak-tight connections are maintained between the precision tubing and the sampling probes, as
well as between the precision tubing and the syringe pump valve. The precision tubing is routed in a manner
to add flexibility during arm movement and to prevent kinking and changes in tubing internal diameter.
Depending on whether the ACL-TOP is a non-CTS or a CTS instrument, there are different probes required
for each arm. The probes and tubing required by different versions are described below.
Probes and Tubing, non-CTS, Cavro Arms
The non-CTS instrument (Cavro Arms) uses three identical probes. Each probe has Liquid Level Detection
(LLD), heating, and a continuous stainless steel center with a formed tip. A pure copper tube surrounds the
steel tube to maintain thermal stability. The fitting welded to the top end of the stainless steel tube is the con-
nection for the precision tubing.
Figure 7-12 The Probe for the non-CTS instrument with Cavro Arms
A circuit board is mounted within the probe housing that can be accessed by sliding the probe cover upward.
The circuit board contains software necessary to drive the probe heater control. Values attained during cal-
ibration of the probe are stored on the probe circuit board.
Each probe has two heaters and two thermistors to regulate temperature. The Control Loop of the probe is
designed to maintain the sample temperature at 37C. There are eight discrete wires that transfer heater
and thermistor data between the Probe Circuit Board and the Probe body. For a further description of ther-
mal control of the probe, refer to Reagent Probes for Cavro Thermal Regulation in Chapter 12 and
Cavro Sample Probe Thermal Regulation in Chapter 12.

The LLD sensing for the probe is driven by a capacitance differential circuit. The LLD sensor (Alidum) is
located on the Cavro Arm Y-Axis ADRI-9 PCB. The LLD signal is carried from the probe tip to the Alidum by
a coaxial cable. The stainless steel probe tube is directly tied to the center conductor of the coaxial cable. A
0.22 Ohm resistor is hard wired between the coaxial cable center conductor and the probe body. The resis-
tor maintains the proper resistance for the Alidum's RC network to function properly. The ground plane in
the coaxial cable is tied to the isolation block at the top of the probe. If a failure in the isolation of the two
signals occurs, the probe will not perform LLD properly.
The precision tubing used on the probe has a threaded fitting on each end. The purple fitting threads onto
the probe, and the white -28 fitting threads into the right port on the syringe pump valve. The purple fitting
is meant to be torqued to 10 in-oz. Without using a torque wrench, this amount of torque can be achieved
by tightening the fitting by hand and then further tightening turn with a wrench. This torque is required to
properly preload the o-ring attached to the fitting. The O-ring provides compression to the Teflon flange as
it seals against the bottom of the valve's threaded port.
Probes and Tubing, CTS
The ACL-TOP with CTS uses two heated Reagent Probes and a non-heated Sample Probe. The Sample
Probe is assembled into the CTS Telescoping Assembly. All three probes have Liquid Level Detection (LLD)
and a continuous Stainless Steel center with a formed tip. A pure copper tube surrounds the steel tube on
the Reagent Probes to maintain thermal stability. There is a straight end at the top of the stainless steel tube
that has a rough surface finish. This straight end is the connection for the precision tubing.
A circuit board is mounted directly to the probe housing. You can access the board by sliding the cover of
the probe upwards. Due to design requirements, access to the CTS probe board is limited by protective
sheet metal covers. On both the Sample and Reagent Probes, the circuit board contains software necessary
to drive the LLD circuit. The Reagent Probe circuit boards also drive the heater control. Values attained dur-
ing calibration of the probe are stored on this circuit board.
Each Reagent Probe has two heaters and two thermistors to regulate temperature. The control loop of the
probe is designed to maintain the sample temperature at 37C. There is a 9-pin connector with eight discrete
wires that transfer heater and thermistor data between the probe circuit board and the probe body, with an
additional blue wire that carries the ground signal for the LLD circuit. For a further description of thermal con-
trol of the probe, refer to Reagent Probes for Cavro Thermal Regulation in Chapter 12.
The CTS sample probe is unique in ACL-TOP CTS instrument. There are no heaters, thermistors, or copper
jacket assembled onto the CTS Sample Probe. The Sample Probe Circuit Board does not have the heater
control software and is therefore not compatible with the heated Reagent probes.
The Liquid Level Detection (LLD) for the probe is provided by capacitance differential sensing. The LLD
sensing circuit is mounted on the probe circuit board. The LLD signal is carried to the arm controllers via the
probe flex cable. Note that the CTS probe is completely described in Chapter 15 CTS Piercer.
CTS instruments have tubing on the probe that has a compression seal. The compression connection slides
over the stainless steel tube on the probe, and the white -28 fitting threads into the right port on the 3-way
valve. The flared end of the compression connection slides over the stainless steel approximately 10 mm.
The compression band is then slid around the flare end. Once compression is on the flare, the Teflon tubing
cold flows around the roughened surface finish on the stainless steel tube. The -28 fitting should be tight-
ened by hand and then given turn with a wrench to properly seal the O-ring attached to the fitting. The O-
ring provides compression to the Teflon Flange as it seals against the bottom of the threaded valve port.

The Bulk Fluidic Subsystem

The Bulk Fluidic Subsystem consists of the following components:
Table 7-8 Components of the Bulk Fluidic Subsystem
Component
"Onboard Rinse Fluid Bottle"
"Rinse Pumps"
"Rinse and Clean Cups"
"Clean Fluid Bottle"
"Clean Pumps"
"CTS Bulk Fluids Module"
"CTS Air Flow"
The following subsections provide detailed descriptions of the components, and operation, of the Bulk Flu-
idic Subsystem.
Onboard Rinse Fluid Bottle
The ACL-TOP gets its HemosIL Rinse fluid from the Onboard Rinse Bottle on the right side of the instrument
as shown on Figure 7-13 "The Onboard Rinse Fluid Bottle". An arm-specific Rinse Pump draws the
HemosIL Rinse fluid into the ACL-TOP. The HemosIL Rinse fluid enters the system via an Aspirator inserted
into the Onboard Rinse Bottle. The fluid height in the Onboard Rinse Bottle is checked by two capacitance
sensors mounted on the inside of the right outer panel as shown on Figure 7-14 "Rinse, Clean Sensors".
Figure 7-13 The Onboard Rinse Fluid Bottle
Onboard Rinse
Fluid Bottle

Figure 7-14 Rinse, Clean Sensors
Clean Warning Clean Empty

Sensor Sensor
Rinse
Warning
Sensor
Rinse Empty
Sensor
The warning and empty sensors are monitored by the ACL-TOP system software. The LED above the waste
door indicates when the onboard rinse bottle is low or empty. When the Onboard Rinse Bottle is low, the
LED turns amber; when the Onboard Rinse Bottle is empty, the LED turns red. A warning is also sent to the
CM software that displays a red exclamation point on the Analyzer Alarm button of the Status bar.)
A low rinse bottle warning causes the instrument to enter a controlled stop where it schedules a finite num-
ber of tests that can be run prior to the instrument stopping and allowing no additional tests until the rinse
bottle is replaced. An empty rinse bottle warning causes the instrument to enter an emergency stop.
The rinse fluid performs two functions during the fluidic cycle. First, the rinse fluid washes the internal and
external surfaces of all probes that come in contact with patient samples to prevent any carryover from one
sample to another. Second, the rinse fluid acts as the working fluid for the system. The compressibility of the
rinse fluid is far less than that of air. There is a uninterrupted column of rinse fluid between the syringe and
probe tip. When sample aspiration or dispense is required, the rinse fluid acts as the medium for transferring
the fluid displacement within the syringe. Without rinse fluid, or with air bubbles in the precision tubing, the
ACL-TOP would not meet its precision and accuracy specifications. It is critical to overall performance that
priming of the fluid lines occurs on a regular basis. The fluid lines are primed each time the arms are initial-
ized and during regularly scheduled maintenance activities. See "Priming the Rinse System" and "Prim-
ing the Clean System".
Rinse Pumps
All ACL-TOP instruments have three Rinse Pumps that supply HemosIL Rinse fluid to the probes. There is
a dedicated Rinse Pump for each arm. The Rinse Pumps are contained in the Rinse Pump box that is
located under the Waste Pump Box to the left of the Waste drawer as shown on Figure 7-15 "Rinse Pump
Box Location". The Sample arm has one pump mounted in the rinse box while the Reagent arm has two
pumps mounted in the rinse box. There is a Rinse Input line leading from the Rinse Aspirator to the Rinse
Pump Box.

Figure 7-15 Rinse Pump Box Location
Waste Pump Cover
Rinse
Pump
Box
Waste Waste
Pump Drawer
NOTE: The rinse fluid should never be replaced by pouring into the onboard bottle. This
causes bubbles and/or air pockets. When a low or empty rinse bottle is removed and
replaced, the rinse system auto primes itself.
NOTE: The Rinse Aspirator is in the Onboard Rinse Fluid Bottle.
On the output side of each pump is a check valve to prevent siphoning of the rinse bottle in an error state or
during instrument service. On CTS equipped units, an additional line is included to supply rinse fluid to the
CTS Bulk Fluidic module as described in "CTS Bulk Fluids Module".
The three Rinse Pumps in the assembly are identical diaphragm pumps with 24V DC brushed motors. All
three Rinse Pumps in the Rinse Pump box are provided voltage from the same cable harness. The cable
harness terminates at a bulkhead-mounted connector on the left rear of the Rinse Pump Box. The Rinse
Pump Box is connected to the centrally located fluidic connector PCB by means of an interconnect cable.
The Rinse Pumps are not serviceable items in the ACL-TOP.
The Rinse Pumps supply the HemosIL Rinse fluid to the probes and have an average flow rate of approxi-
mately 1.02 ml/sec. To maintain fluidic precision and accuracy, the Rinse Pumps prime the precision fluid
lines on a periodic basis and during all arm Initializations. The syringe pump valve must be in bypass mode
(where the rinse pump is connected to the probe output) for the Rinse Pumps to prime the precision fluid
lines. See "Priming the Rinse System".

Rinse and Clean Cups
Rinse/Clean Cups, non-CTS
On ACL-TOP instruments with Cavro Arms, one Rinse/Clean cup is located in the Sample area and two are
located in the Reagent area. The Rinse/Clean Cup Assembly is made of chemically compatible PVC. A
drain is threaded into the bottom of the Rinse/Clean Cup to allow excess fluid to flow into the accumulator
reservoir. The Rinse/Clean Cup and the area around it should be cleaned regularly with an isopropyl alcohol
wipe.
Figure 7-16 Cavro Sample/Reagent Rinse/Clean Cups
Drain
Clean Cup Rinse Cup
Each Clean Cup has its own 24VDC solenoid valve and motor that energizes when fluid is required in the
cup. The Clean Cup is primed each time the Arms are initialized.
The Sample Probe aspirates Clean A Fluid by first performing a Liquid Level Detection on the Clean A Fluid
and then traveling down as it aspirates fluid. If the clean fluid line is not adequately primed, there is potential
for an LLD error on the clean fluid. If this error occurs, verify that there are no bubbles in the Clean aspirator
line and prime the Clean Pumps as described in "Priming the Clean System".
NOTE: It is necessary to prime the Clean Pump whenever bubbles are present in the clean
line. Refer to "Priming the Clean System".
The Rinse Cup has a flat bottom. The HemosIL Rinse Fluid is supplied by the pumps as described in "Rinse
Pumps". During rinsing, the Three-way Valve of the syringe Pump is in Bypass Mode. The diaphragm pump
is also turned on to provide flow through the Sample Probe. Fluid exits the probe tip and hits the bottom of
the Rinse Cup. The flow is redirected to rinse the outside of the probe tip. Probe tip height, relative to the
Rinse Cup, is critical to provide adequate cleaning of the probe. Height is set during the coordinate adjust
routine. The duration of the rinse routine can be configured by the user, and it must be a minimum of one
second.
NOTE: Rinse fluid should not wet the black covering of the probe. If it does, troubleshoot to
determine the source.
The alignment of the Sample Probe to the Waste Location and to the rinse/Clean Cups is controlled by the
ACL-TOP system software. The coordinates for the Waste Location and the Rinse/Clean Cups are verified
each time the Arms are initialized. The Coordinates Adjust routine should be run if an Arm Coordinates error
is reported during initialization.

NOTE: Each Sample and Reagent Probe performs its coordinates check on the metal sur-
face around the Rinse/Clean Cup. To ensure accurate coordinates checks, regular cleaning,
with an isopropyl alcohol of the Rinse/Clean Cup and the metal areas around them is recom-
mended.
Rinse/Clean Cups, CTS
On CTS ACL-TOP instruments, there is one Rinse/Clean cup in the Sample area and two in the Reagent
area. To accommodate the piercer probe, there is a well for a Deep Wash on the left of the Sample Rinse/
Clean cup as shown in Figure 7-17 "CTS Sample Rinse/Clean Cup". In the Reagent area, each Rinse/
Clean Cup has a Rinse cup on the right and a Clean cup on the left as shown in Figure 7-18 "CTS Reagent
Rinse/Clean Cup".
Figure 7-17 CTS Sample Rinse/Clean Cup
Deep Wash Rinse Cup
Figure 7-18 CTS Reagent Rinse/Clean Cup
Drain Hole
Clean Cup Rinse Cup
The Clean Cup has a flat bottom with a fill hole on the bottom. Clean A Fluid is pumped into the Clean Cup
by the Clean Pump. The Clean Cup is primed each time the Arms are initialized.
NOTE: If the clean fluid line is not adequately primed, there is potential for an LLD error on
the clean fluid. If this error occurs, verify that there are no bubbles in the clean aspirator line
then prime the Clean Pumps if necessary. See "Priming the Clean System".
Fluid level in the Clean Fluid Bottle is monitored by the ACL-TOP system software. The sample and reagent
probes aspirate Clean A Fluid from the cup by first performing a Liquid Level Detection on the fluid and then
traveling down as it aspirates the fluid.

The Deep Wash location on the left of the Rinse/Clean Cup provides a drain to the Reservoir. A filter is
installed in the Deep Wash location to collect core particles generated during closed tube sampling. The
Clean cup and Deep Wash cups need to be cleaned weekly and the filter should be changed after 5,000
pierces.
NOTE: In particularly high-volume installations, the filter should be changed more often
based on usage. After cleaning the clean cup and Deep Wash, the filter should be removed
and replaced. The filter should be removed and installed using the tool located on the left side
of the Sample Side Accumulator.
The Deep Wash process consists of an External Wash and an Internal Wash. The exterior of the CTS
Piercer Probe, and the exterior of the Sample Probe tip, are rinsed during the External Wash and the interior
of the Sample Probe is rinsed during the Internal Wash.
The External Wash is done according to the following procedure:
1. The Sample Probe, and the CTS Piercer Probe, are brought to wash depth within the Deep Wash
location.
2. The External Rinse Pump is turned on as the CTS Piercer Probe is brought down.
3. As the CTS Piercer Probe travels up, the radial rinse stream washes the entire exterior of the CTS
Piercer Probe, the interior of the CTS Piercer Probe tip, and the exterior of the Sample Probe tip.
4. Once the probe tips have cleared the radial rinse stream, the External Rinse Pump is turned off,
stopping the flow of the radial rinse stream.
NOTE: The Internal Sample Probe Rinse is not run during the External Wash to minimize the
foaming which may occur with a directed flow so deep in the filter.
During the internal wash, the interior of the sample probe is washed by a stream of rinse fluid that is sent
through the sample probe by the rinse pump.
1. The valve of the syringe pump is set to bypass mode for the rinse pump to send rinse fluid through
the sample probe.
2. Rinse fluid exits the sample probe and drains directly through the filter and into the reservoir. During
the internal wash, the flow rate of rinse fluid is 1.05 ml/second.
3. The minimum duration of the internal wash is similar to that of the non-CTS instrument configura-
tion. However, this value can not be defined in the same manner as the non-CTS instrument
because of the software timing of the operation.
Clean Fluid Bottle
The ACL-TOP gets its Clean A Fluid from the Clean Fluid Bottle on the right side of the instrument. The
Clean A Fluid is drawn into the ACL-TOP by either of the three Clean Pumps located on the Waste Accu-
mulators.
The Clean A Fluid enters the system via a chemically compatible Aspirator inserted into the Clean Fluid Bot-
tle (see Figure 7-19 "The Clean Fluid Bottle"). The fluid height in the Clean Fluid is checked by two capac-
itance sensors mounted on the inside of the right outer panel (see Figure 7-19 "The Clean Fluid Bottle").

CAUTION: Clean A Fluid contains Hydrochloric Acid and must be handled

carefully. DO NOT ALLOW CLEAN FLUID A TO COME IN CONTACT WITH
SKIN OR EYES! When handling or changing Clean Fluid Bottles, you must
wear protective eyewear, protective gloves, and protective garments.
Figure 7-19 The Clean Fluid Bottle
Clean Fluid
Bottle
Figure 7-20 Clean Fluid Sensors
Clean Warning Clean Empty

Sensor Sensor
Rinse
Warning
Sensor
Rinse Empty
Sensor
The sensors are monitored by the ACL-TOP system software. An LED as shown on Figure 7-21 "Clean
Fluid LED Indicator" indicates when the Clean Fluid Bottle is low or empty. (When the Clean Fluid Bottle
is low, the LED turns amber; when the Clean Fluid Bottle is empty, the LED turns red.) A warning is also sent
to the CM software. (The warning appears as a red exclamation point on the Analyzer Alarm button of the
Status bar.)

Figure 7-21 Clean Fluid LED Indicator
Clean Fluid LED
An empty warning will send the instrument into a controlled stop where it schedules a finite number of tests
that can be run prior to the instrument stopping tests.
Clean Pumps
The ACL-TOP uses three solenoid pumps to draw Clean A Fluid from the Clean Fluid Bottle. The Clean
Pumps are self-checking and are driven by 24 VDC solenoids with a 2 Hz pulse. There is one pump for each
clean well. The clean wells for the non-CTS sample and reagent modules, as well as the CTS reagent mod-
ule are as shown on Figure 7-22 "Clean Pumps", with the clean pump mounted just below the clean well.
Figure 7-22 Clean Pumps
Clean Well
Clean Pump
The Clean Pump for the CTS Sample module is different from the others due to the CTS requirements that
are the Deep Wash and the Deep wash filter. The Clean Pump for the CTS Sample modules is as shown in
Figure 7-23 "CTS Sample Clean Pump", with the clean pump mounted to the side of the clean well.

Figure 7-23 CTS Sample Clean Pump
CTS Sample Clean Well CTS Sample Clean Pump
The clean pumps are powered via the cable assembly for the Sample Accumulator or the Reagent Accumu-
lator, both of which plug into the Fluidic Connector Board.
The clean pump moves Clean A Fluid into a cup located at each accumulator rinse/waste station. The Clean
A Fluid wells up from the bottom of the cup on the Reagent and non-CTS Accumulator. On CTS sample
accumulators, the Clean A Fluid enters the cup from the side.)
Clean Pumps are controlled by the ACL-TOP software and when a clean is scheduled, the Clean Pump
turns on to ensure the cup is full of Clean A Fluid prior to the probe's arrival. The probe performs an LLD in
the Clean A Fluid and aspirates the desired amount of fluid. After a specified dwell time inside the probe, the
Clean A Fluid is dispensed into the waste on the Accumulator.
Clean A Fluid is used to clean the inside of a Sample Probe when additional washing of the probe is desired.
Following any use of Clean A Fluid, the probe is rinsed with Rinse Fluid to prevent Clean A Fluid from com-
ing in contact with any sample.
NOTE: No fluid other than Clean A Fluid should be run through the Clean Pumps. In the event
HemosIL Rinse Fluid is inadvertently run through the Clean Pump, the Clean Pump should
be immediately purged with Clean A Fluid. Refer to "Adjustments and Verifications" for
information on purging the Clean Pump. If Clean A fluid is not available, the Clean Pump can
be purged with De-ionized Water. If HemosIL Rinse Fluid is not immediately purged from the
Clean Pump, it will crystallize, causing permanent damage to the Clean Pump.
CTS Bulk Fluids Module
The CTS Bulk Fluids Module is located to the left of the Sample Syringe Pump (see Figure 7-24 "CTS Bulk
Fluids Module"). The module contains the Rinse pump for the CTS Deep wash and is mounted on vibration
isolators.
The Rinse Pump provides HemosIL Rinse Fluid to the Deep Wash location on the CTS Accumulator. The
pump is identical to the three rinse pumps located in the Rinse Pump Box to the right of the Reagent Module
beneath the Waste pump. The output of the Bulk Rinse Pump has a check valve to prevent siphoning of
rinse fluid through the open port of the CTS Deep Wash. Fluid is fed to the pump from a supply line routed
through the Rinse Pump Box. The supply line runs through the steel guide tube along the rear chassis of the
ACL-TOP. The output line of the pump goes through a bulkhead interconnect on the Bulk Fluidics Module
and is routed through both the drip tray on the Syringe Pump and the right support bracket of the Sample
Accumulator.

Figure 7-24 CTS Bulk Fluids Module
Rinse Pump
Fluidics
Module
Air Pump/Air Cylinder
The Air Pump, as shown on Figure 7-25 "CTS Air Pump/Cylinder" is mounted on the rear of the instru-
ment behind the Sample module. The Air pump maintains the pressure in the air cylinder. The output of the
air pump leads directly to the air cylinder mounted to the side of the left pylon support (see Figure 7-25
"CTS Air Pump/Cylinder"). The air cylinder is connected via black polyurethane tubing to the Sample Arm
Air Valve that is used to aid in cleaning the rinse liquid from the piercer and piercer probe as stated below.
Figure 7-25 CTS Air Pump/Cylinder
Air Pump
Air Cylinder

Air Pump
The two valves on the CTS Z-axis assembly release air from the cylinder and direct the air flow to the CTS
probe foot or to the area between the CTS piercer and sample probes during cleaning. The air flow to the
probe purges any residual fluid from the circular area between the Sample and Piercer Probe after a Deep
Wash. The air flow to the foot removes any droplets that might be on the foot. The Air Pump is a 24V N86-
style diaphragm pump and is integral to the functioning of closed tube sampling, because it maintains the
clear vent path needed during aspiration in closed tubes. The Air Pump pressurizes the air cylinder to 26
psig (179 kPa, 1.8 bar). Pressure is held in the cylinder by the two valves mounted on the CTS Z-axis
assembly. The pressure in the closed system is monitored and controlled by a pressure transducer mounted
next to the air clinder as shown in Figure 7-26 "Air Pressure Transducer". The sensor/switch is a digital
switch, as shown on that triggers the ACL-TOP software to start and stop the Air Pump. The Air Pump is
capable of charging the air cylinder in 7-10 seconds. The output of the air pump has a diaphragm check
valve to prevent backflow of air into the pump. Care should be taken during servicing of all air lines to ensure
airtight connections. Tube connections must be made with properly cut tubing to maintain the pressure
capabilities of the barb fittings. Cable ties are applied to each barb fitting to provide an additional safety mar-
gin to the fittings.
Figure 7-26 Air Pressure Transducer
The two valves located on the CTS Z-axis Assembly direct air flow to the CTS probe foot and to the area
between the Sample Probe and the CTS Piercer Probe. The output of the air cylinder is connected to the
CTS air valve using polyurethane tubing that is routed through the steel tubing guide and into the Common
(COM) port on the front valve (Accumulator Valve). The Normally Closed (N/C) port is routed down to the
CTS probe foot. The Normally Open (N/O) port is connected to the N/C port on the rear (Air Pressure) Valve.
The N/C port on the rear valve maintains the air pressure for the air cylinder. The rear valve N/O port is left
open to act as an atmospheric vent during closed tube aspirations. The COM port on the rear valve leads to
the CTS probe port and provides the air flow to clear the circular opening between the probes. Proper tubing
connections should be performed based on the fluidic diagram as shown in Figure 7-29 "CTS ACL-TOP
Fluidic Diagram".
CAUTION: The pneumatic system is pressurized to 26 psig (179 kPa, 1.8

bar). Use caution when disconnecting air lines. Bleed down the system
using Diagnostics before servicing.

CTS Air Flow
When the CTS Piercer Probe performs a Deep Wash, there is usually a small volume of fluid that gets
trapped between the Sample Probe and the CTS Piercer Probe. Due to capillary action, the fluid will propa-
gate up some portion of the interior of the CTS Piercer Probe. The area filled with fluid is also the pathway
for the atmospheric vent of the piercing probe and can create a blockage in the tube so the air pressure dif-
ferentials cannot travel freely through the CTS Piercer Probe.
The CTS Piercer Probe pierces a closed tube to aspirate sample volume without the need of removing caps.
After the top of the tube is pierced, the Sample Probe (located within the piercing probe) telescopes out sev-
eral millimeters to contact the sample and perform a Liquid Level Detection (LLD). The CTS Piercer Probe
maintains the opening in the rubber seal as the two probes move down. Once an LLD has occurred, the
Syringe Pump aspirates sample into the Sample Probe. If a clear vent path does not exist through the CTS
Piercer Probe and up to the rear valve on the CTS Z-axis, then the internal pressure of the sample tube will
not be at atmospheric pressure and the aspiration of sample will occur at other than atmospheric pressure.
A tube pressure above atmospheric leads to over aspiration; a partial vacuum leads to under aspiration. The
clear vent path allows the immediate pressure equalization inside the sample tube and maintains precision
and accuracy results for the ACL-TOP CTS.
The air purge system on the CTS Piercer Probe releases a short burst of high pressure air (26 psig at initial
release), which clears excess fluid from the circular area between the Sample Probe and the CTS Piercer
Probe. This operation occurs immediately after the Deep Wash routine on the CTS Piercer Probe. In addi-
tion, the air purge system supplies a short burst of air through the probe foot to the outside of the piercer tip.
This removes any residual rinse fluid that may remain after the Deep Wash.
PCB Descriptions
The following are high-level descriptions of the PCBs in the Fluid Handling System.Figure 7-27 "Location
of Fluidics Controller/Connector PCBs" and Figure 7-28 "Fluidic LED PCB" shows where the Fluidics
PCBs are located within the instrument. Note that the Fluidics Controller Board and the Fluidics Driver/Con-
nector Board are ordered as one assembly.
Figure 7-27 Location of Fluidics Controller/Connector PCBs
Fluidics Controller,
Driver/Connector
PCBs
(under cover)

Figure 7-28 Fluidic LED PCB
Fluidic LED PCB
Fluidic Controller PCB
Interfaces directly to the PC104 board and the Fluidics Driver/Connector Board.
Provides Address and Data decoding from the PC104 board and translates to Digital I/O to the Flu-
idic Driver/ Connector Board.
Mounted under the Fluidics Controller PCB. (The cover protecting the PCBs from any fluid must be
removed to access the Fluidic Controller or Fluidics Driver/Connector PCBs.)
Fluidics Driver/Connector PCB
Interfaces to the Fluidic controller board to provide control of all fluidic pumps and solenoid valves.
Provides sensor inputs for the liquid sensors: rinse, clean, and liquid waste in the internal accu-
mulators and external liquid waste bottle.
Provides solenoid power to cover interlocks, Sample and Reagent front cover sensors, and emer-
gency stop button.
Mounted on top of the Fluidics Controller PCB. (The cover protecting the PCBs from any fluid must
be removed to access the Fluidic Controller or Fluidics Driver/Connector PCBs.)
Fluidic LED PCB
Provides a visual indication of the liquid level status of Clean, Rinse and liquid waste.
Provides Visual indication of waste cuvette height.
This board is mounted to the front panel behind the Fluidic Indicator panel.
Fluidics Diagrams for the TOP Instrument

The following are the Fluidics Diagrams for the ACL-TOP instrument. (See Figure 7-29 "CTS ACL-TOP
Fluidic Diagram" and Figure 7-30 "Non-CTS Fluidic Diagram".

Figure 7-29 CTS ACL-TOP Fluidic Diagram

Figure 7-30 Non-CTS Fluidic Diagram

Syringe Pump Addressing and Jumpers

The address and jumpers on a Syringe Pump must be set properly so the ACL-TOP instrument can com-
municate with the pump. The address is set by turning the rotary switch with a small, flat-blade screwdriver.
The jumpers are set by inserting or removing the jumpers as necessary to connect the pins. (A description
of the address setting and jumper settings in provided in "Cavro Syringe Pump Settings" and "Hamilton
Syringe Pump Settings".)
Table 7-9 "Syringe Pump Addresses for CTS Instruments" lists the Syringe Pump Addresses for ACL-
TOP instruments equipped with Universal Arms, including CTS Models.
Table 7-10 "Syringe Pump Addresses non-CTS Instruments" lists the Syringe Pump Addresses for
ACL-TOP instruments equipped with Cavro Arms.
Table 7-9 Syringe Pump Addresses for CTS Instruments
Sample 1
Intermediate Reagent 1
Start Reagent 1
Table 7-10 Syringe Pump Addresses non-CTS Instruments
Sample 4
Intermediate Reagent 0
Start Reagent 4
Table 7-11 "Syringe Pump Jumper Settings"shows the correct settings of Cavro Syringe Pump jumpers.
Table 7-11 Syringe Pump Jumper Settings
JUMPER SETTING
J1-1 OUT
J1-2 IN
J1-3 OUT
J1-4 OUT
J2-1 IN
J2-2 IN
J4-1 IN

Priming the Rinse System

Priming of the Rinse system can be done in one of three ways.
1. Initialize all Arms
Click the Initialize All Arms button on the Probes tab of the Diagnostic screen.
2. Running the Rinse Pump
Select the appropriate arm in the Select portion of the Fluids diagnostic screen.
Enter a duration of 10 seconds.
Press the Start button in the (Rinse) lower left portion of the Probe screen.
Continue the above until the fluid coming into the rinse cup flows in a steady stream.
3. Execute Automatic Fluidic Line Priming Cycle from the ACL-TOP applications maintenance
screen.
Initiate the ACL-TOP application.
Open the Maintenance screen.
Click on System --> Maintenance.
Click on the box preceding Automatic Fluidic Line Priming Cycle
Click on the Run icon as shown on Figure 7-31 "Maintenance Screen Run Button".
Figure 7-31 Maintenance Screen Run Button
Priming the Clean System

Priming of the Clean system can be done in one of three ways.
1. Initialize all Arms
Click the Initialize All Arms button on the Probes tab of the Diagnostic screen.
2. Running the Clean Pump
Select the appropriate arm in the Select portion of the Fluids diagnostic screen.
Enter a duration of 10 seconds.
Press the Start button.
Continue the above until the fluid coming into the clean cup flows in a steady stream.
3. Execute Automatic Fluidic Line Priming Cycle from the ACL-TOP applications maintenance
screen.
Initiate the ACL-TOP application.
Open the Maintenance screen.
Click on System --> Maintenance.
Click on the box preceding Automatic Fluidic Line Priming Cycle

Click on the Run icon as shown on Figure 7-32 "Maintenance Screen Run Button".
Figure 7-32 Maintenance Screen Run Button
Performing the Rinse Flow Rate Test

The Flow Rate Test is used to determine if the rinse fluidics are functioning properly. Perform the following
steps to execute the test.
1. Open the Probes tab of the Diagnostic screen.
2. Select the arm to be adjusted from the drop down Probe: selection box as shown in Figure 7-33
"Arm Selection".
Figure 7-33 Arm Selection
3. Click on the Flow Rate Test button in the Rinse portion of the screen (lower left) as shown in Fig-
ure 7-34 "Flow Rate Test Buttons".
Figure 7-34 Flow Rate Test Buttons
4. Based on the arm selected, the system displays a message stating where to place a graduated con-
tainer. The locations are:
Sample Arm: Sample Track 6, Position 5

Reagent Arm 1: Reagent Track 3, Position 3
5. Place the graduated container in the indicated position.

6. Select the number of seconds for the pump to run (5 seconds) in the Duration: box in the (lower
left) of the Probes tab as shown on Figure 7-34 "Flow Rate Test Buttons".
7. NOTE: If necessary, the Stop button can be clicked on to discontinue the test.
8. Click the Start button in the Rinse area of the screen.
9. After the probe has dispensed Rinse solution into the graduated container for the set length of time,
measure the volume of solution in the graduated beaker. The flow rate must be as shown in Table
7-12 "Rate Flow Measurements".
Table 7-12 Rate Flow Measurements
Base Top CTS
Volume After 5 Seconds Flow Rate Volume After 5 Seconds Flow Rate
5.150.5ml (4.65 to 5.65ml) 1.03ml/sec 5.581.04ml (4.54 to 6.61ml) 1.12 ml/sec
(0.10ml) (0.20ml)
If the flow rate is too low, i.e., not enough Rinse is deposited in the beaker; check the fluidic rinse tubes for
any restrictions and the rinse pump for proper operation. If the flow rate is too high, check the rinse pump
and check valves.
Verifying the Fluidics after Repair or Replacement

The flowchart in Figure 7-35 "Flowchart for Fluidic Functional Test" shows the functional tests after the
repair or replacement of any Fluid System component.

Figure 7-35 Flowchart for Fluidic Functional Test
Replace/Repair
Replace/Repair
Replace Probe Replace Syringes Accumulator,
Replace Probes Pumps or Valves
Rinse Tubing and tubing Tubing or Valves
Perform the
Perform the
Perform Coordinates Adjustment Rinse Flow Rate
Clean Pump Test
Test
Perform the LLD Verify that the

test inside a Virtual LED for
cuvette (100 ul) the Sample Clean
and inside a cup Pump is on
(200 ul)
Verify that the

Visually verify
Virtual LED for
alignment by
the Waste Pump
moving material
is on
to several
locations with the
Move function.
Verify that the
Virtual LEDs for
the Waste
Sensors are all
off
Perform the Flow
Rate Test
Fluidic Precision
Test
Adjusting the CTS Air Pressure

The air purge system on the CTS Piercer Probe releases a short burst of high pressure air (24 psig at initial
release), which clears excess fluid from the circular area between the Sample Probe and the CTS Piercer
Probe. This operation occurs immediately after the Deep Wash routine on the CTS Piercer Probe. In addi-
tion, the air purge system supplies a short burst of air through the probe foot to the outside of the piercer tip.
This removes any residual rinse fluid that may remain after the Deep Wash. This air pressure is maintained
at 26psig via a transducer located next to the air cylinder.
The transducer is used to set the air pressure and is adjusted using the following steps.
Verify the Pressure Sensor Set Points using the chart below to navigate the sensor keys as shown on Fig-
ure 7-36 "Sensor Keys" to set the pump to turn on at 22psig and turn off at 24psig.

Figure 7-36 Sensor Keys
Sensor Keys
Confirm or set the following:

"Press and hold the 'SET' button for > 2 seconds.
"Verify/Set pressure to 'PSI'
"Press 'SET'.
"Verify/Set OVT1 to 'InC'
"Press 'SET'.
"Verify/Set OVT2 to '2nO'
"Press 'SET'.
"Verify/Set Response Time to '24'
"Press 'SET'.
"Verify/Set mode to 'mAn' (where the m is displayed as an n with a line over it due to the limi-
tations of the display)
"Press 'SET'.
"Verify/Set P_1 to '24'
"Press 'SET'.
"Verify/Set P_2 to '22'
"Press 'SET'.
"Verify/Set N_3 to '0'
"Press 'SET'.
"Verify/Set N_4 to '0'
"Press 'SET' to end the settings.

7-6 Diagnostics
The diagnostics for the Fluid Movement System are on the Fluids tab. The Fluids tab contains seven main
areas:
"Clean Sensors Area",
"Clean Pump Area",
"Stirring Area",
"Waste Sensors Area",
"Shipping Preparation Area",
"Waste Pump Area",
"Fluid Precision Test Area".
Figure 7-37 "Fluids Tab" shows the entire Fluids tab.

Figure 7-37 Fluids Tab

Clean Sensors Area

The Clean Sensors area contains virtual LEDs for the cleaning-related valves and pumps in the Fluid Move-
ment System. When a specific pump or valve is in use, the corresponding virtual LED turns green. Figure
7-38 "Clean Sensors Area" shows the Clean Sensors area.
Figure 7-38 Clean Sensors Area
Clean Pump Area

The Clean Pump area enables the testing the Sample and Reagent Probes and opening of the cleaning
related valves. (Note: A valve is opened to test it.) Figure 7-39 "Clean Pump Area" shows the Clean Pump
area. The descriptions below the figure describe each of the buttons and indicators.
Figure 7-39 Clean Pump Area
Select Pull-down
List
The Select Pull-down List
Use the Select pull-down list to select a valve to test, or a probe to clean. The Select pull-down list contains
the following options:
Sample arm Select this option to open the Sample valve or clean the Sample Probe.
Intermediate Reagent arm Select this option to open the Reagent 1 valve or clean the Reagent
1 Probe.
Start Reagent arm Select this option to open the Reagent 2 valve or clean the Reagent 2 Probe.

The Set Valve Button
The Set Valve button test the opening of the selected valve. When the Set Valve button is clicked, the
valve selected from the Select pull-down is opened and the corresponding virtual LED turns green (see Fig-
ure 7-38 "Clean Sensors Area").
NOTE: This action does not close the valve; the valve remains open, and the virtual LED
remains green, until the Clean Pump utility is run.
The Duration Selection Field and the Start and Stop Buttons
The Duration box determines the length of time (in seconds) the selected pump runs. For example, with
Sample arm selected in the Select pull-down list, select 60 in the Duration field to run the Sample Pump
for 60 seconds.
The Start button is clicked to start the selected pump. The pump runs until the end of the duration time
unless the Stop button is clicked, in which case, the pump immediately stops.
Stirring Area
The Reagent Module contains stirrers for position 1 and 2 in each of the six Reagent Tracks. The Stirring
Area contains an LED that, when red, indicates that none of the stirrer positions are working and indicates
a problem with the voltage to the stirrers or the Reagent module. The Stirring Area also contains a a check-
box for each stirrer position. A checked box indicates that a material requiring stirring is to be placed in that
position. Unchecking a box the indicates that a material not requiring stirring is to be placed in that position.
Figure 7-40 "Stirring Area" shows the Stirring area.
Figure 7-40 Stirring Area
Unchecking or checking a box and clicking the Save button causes the system to save the status for each
of the positions and continues into normal ACL-TOP operation. A stirring error alarm is displayed by the sys-
tem if a material requiring stirring is placed in a position in which the box is not checked or, by placing a
material not requiring stirring into a position where the box is checked.

Waste Pump Area

The Waste Pump area contains a Waste pump on LED that turns green when the Waste Pump is running,
a Start button to start the pump, a Stop button to stop the pump, and a setting to determine how long
the pump runs. Figure 7-41 "Waste Pump Area" shows the Waste Pump area.
Figure 7-41 Waste Pump Area
The Duration box determines the length of time (in seconds) the Waste Pump runs. The Start button starts
the Waste Pump. The pump runs for the time specified unless the Stop button is clicked to immediately
stop the pump.
The automatic activation of the Waste Pump is disabled upon opening the Fluids Diagnostic screen; it is re-
enabled upon exiting the screen and when the Fluid Precision Test is started.
Waste Sensors Area

The Waste Sensors area contains virtual LEDs that are green when the Sample Accumulator, Reagent
Accumulator, or the Waste Container is below the warning level. The sensor turns yellow when the container
reaches the warning level and turns red when the container is full. Figure 7-42 "Waste Sensors Area"
shows the Waste Sensors area.
Figure 7-42 Waste Sensors Area
Shipping Preparation Area

The Shipping Preparation area contains a utility for performing a Decontamination Shutdown. The virtual
LED, Status, in this area turns amber when the decontamination is process, green when the decontamina-
tion is successfully completed, and red when there was a problem during the decontamination. Figure 7-43
"Shipping Preparation Area" shows the Shipping Preparation area of the Fluids screen.

Figure 7-43 Shipping Preparation Area
The Start button initiates the Decontamination Shutdown.

The Stop button stops a Decontamination Shutdown in progress.
The Decontamination Shutdown does the following:
Clears all cuvettes
Disables the bar code reader motor
Disables all heaters
Runs each probe line dry
Runs each clean line dry
Empties each syringe
Empties the waste accumulator
To avoid unintentional shipping preparation, the user is prompted to confirm the request to start shipping
preparation and is prompted to disconnect the rinse and clean bottle.
Fluid Precision Test Area

The Fluid Precision Test area contains a utility for performing a test in which the instrument calculates the
mean of 25 ORU readings at 405nm for 6 dilutions of optical control fluid with factor diluent. For each dilu-
tion, four replicates are prepared and measured and one reading is collected from each of the 4 ORU chan-
nels. Figure 7-44 "Fluid Precision Test Area" shows the Fluid Precision Test area.
Figure 7-44 Fluid Precision Test Area
The probe used to perform the test is selected in the Probe box and, for both factor diluent and optical con-
trol, the head volume, air gap, and transport air gap can be specified.

When the Precision Fluid test is initiated, a prompt is displayed to place a set of materials in the positions
described below, and to Confirm (OK) or to Reject (Cancel) the start of the procedure. Depending upon the
Probe selected, material should be placed in the position as shown in Table 7-13 "Precision Fluid Test
Materials".
Table 7-13 Precision Fluid Test Materials
Probe Selection Material Position
Sample Arm Factor Diluent in track D2 position 1; Optical Control in

track D2 position 2.
Reagent Arm 1 Factor Diluent in track R1 position 1; Optical Control in

track R1 position 2.
Reagent Arm 2 Factor Diluent in track R5 position 1; Optical Control in

track R5 position 2.
The instrument does not start the procedure if any of the following conditions are true:
The selected probe is not initialized and ready to move.
The cuvette shuttle is not initialized and ready to move.
Any of the 4 ORU's are disabled.
Cuvettes are not present in the loader area.
When the procedure starts, four cuvettes are moved from the Cuvette Loader into the positions described in
the following list, depending on the selected probe:
Sample Arm Incubator 1 slots 1, 2, 3 and 4
Reagent Arm 1 Incubator 2 slots 1, 2, 3 and 4
Reagent Arm 2 ORU 1, 2, 3 and 4
The selected probe aspirates and then dispenses the Factor Diluent to each cell of the loaded cuvettes. At
the end of the dispensation in the last cuvette, a rinse cycle (one second) of the probe is executed. Upon
completion of the rinse, the selected probe aspirates and then dispenses the Optical Control to each cell of
the loaded cuvettes. At the end of every dispensation, a mix (60% of volume) followed by a rinse (one sec-
ond) is executed.
When all materials have been dispensed for all the replicates, for each dilution the cuvette is moved to the
ORU, unless it is already at the ORU based on the arm selected.
Before starting ORU readings, a 15-second delay is performed.
The instrument executes 25 ORU readings for each cell of both cuvettes and calculates the mean for each
cell.
When the ORU readings have been executed, the cuvette is moved to the cuvette waste.
The procedure is then repeated for the other concentrations of Optical Fluid and Factor Diluent.
At the end of the procedure, the instrument displays the absolute absorbance for all replicates and all dilu-
tions with a mean, SD, CV with regression statistics, slope intercept and R^2.
Absolute absorbance for all dilutions and replicates is compared to a predefined range; all values out of
range are displayed in red.

The user can select the dilution they want to test or repeat. All six dilutions must be performed to pass
regression analysis but P6 A specifications should always pass. If not, corrective action must be taken.
For each dilution, mean, Standard deviation (SD) and %CV of absolute absorbance of all replicates are cal-
culated and displayed. Values out of range are displayed in red.
The following table specifies the upper limits for SD and %CV for the various dilutions of Optical Fluid and
diluent.
Table 7-14 Upper Limits for SD and %CV
Dilution SD %CV
100% 0.01 1.0
75% 0.008 1.1
50% 0.006 1.1
25% 0.005 2.7
12.5% 0.005 4.6
6.25% 0.005 8.3
To ensure the proper amount of each material has been placed on the instrument for testing all cells of the
ORU, the procedure terminates if a liquid level detection failure is detected.

7-7 Removal and Replacement
Cavro Syringe Pump Assembly Removal/Replacement
CTS Sample Cavro Syringe Pump Removal
CAUTION: Ensure the instrument is powered OFF before you perform the
following procedure.
1. Remove the Sample Area interior skins as described in Sample Area Interior Skins Removal/
Replacement in Chapter 4.
2. Move the Probe serviced by the Syringe Pump over the Rinse Cup. (This ensures that any fluid that
drips out of the Probe will drip into the Rinse Cup.)
3. Remove the aspirator from the Rinse bottle. Unscrew and remove the precision (probe) tubing from
the Syringe Pump Valve (see Figure 7-45 "Sample Cavro Syringe Pump Assembly"). (Fluid will
drain from the probe.)
Figure 7-45 Sample Cavro Syringe Pump Assembly
Mounting
Screws
Rinse Tubing
Barbed
Fitting Precision
(Probe)
Tubing
4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-45 "Sample Cavro Syringe
Pump Assembly").
CAUTION: Do not unscrew the barbed fitting on the Rinse tubing line of
the Syringe Pump Valve. The barbed fitting is torqued to a precise
specification. If the torque is changed, it could cause the Syringe Pump to
malfunction.

5. Using a tubing cutter, trim the rinse tubing by 1/4. (This removes the part of the line that was
stretched over the barbed fitting.)
6. Move the probe to the side so it will not be damaged when removing the pump assembly.
7. Unscrew and disconnect the front fluidic fitting on the top of the CTS Bulk Fluid Assembly, labelled
Rinse Input. See Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly". (This is neces-
sary to obtain clearance to slide out the CTS Bulk Fluidics Assembly.)
8. Loosen the three captive mounting screws securing the CTS Bulk Fluidics Assembly to the Sample
Arm, as shown on Figure 7-69 "CTS Fluidics Mounting", and slide the module out only far enough
to access the two screws securing the top front of the syringe pump.
9. While holding the Syringe Pump Asssembly from the bottom, remove the two screws that hold the
front of the syringe pump and remove the pump from the mounting bracket..
Figure 7-46 CTS Fluidics Mounting (Cavro)
Mounting
Screws

10. Remove the syringe pump cable from the 15 pin electrical connector on the back of syringe pump as
shown on Figure 7-47 "Cavro Syringe Pump Back".
Figure 7-47 Cavro Syringe Pump Back
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
11. Carefully remove the syringe pump from the instrument.

12. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate from
the pump.
CTS Sample Cavro Syringe Pump Installation
See Figure 7-48 "Cavro Syringe Pump Back" for steps 1 through 4.
1. Ensure that the Syringe Pump address is set to an address of 1. The Syringe Pump address is speci-
fied with the address switch (rotary) at the rear of the Syringe Pump. Refer to "Cavro Syringe Pump
Settings" for more information on the proper settings for Syringe Pump addresses.

Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
2. Ensure that the Syringe Pump jumpers are at the proper settings. Refer to "Cavro Syringe Pump
Settings" for more information on the proper settings for Syringe Pump jumpers.
3. Attach the drip plate to the bottom of the pump using the screws previously removed.
4. Re-connect the 15-pin electrical connector(s) to the back of the Syringe Pump(s).
5. Slide the CTS Bulk Fluid Assembly toward the front of the instrument and engage the pin on the rear
bracket in the Syringe pump so the front bracket openings align with the screw holes.
6. Insert, and tighten, the two mounting screws that fasten the front of the Syringe Pump Assembly to the
CTS Bulk Fluid Assembly.
7. Slide the CTS Bulk Fluid Assembly toward the rear of the instrument and tighten the three mounting
screws as shown on Figure 7-49 "Cavro Syringe Pump Assembly".
Figure 7-49 Cavro Syringe Pump Assembly
Mounting
Screws
Rinse Tubing
Barbed
Fitting Precision
(Probe)
Tubing

8. Attach the Rinse Input Tube to the CTS Bulk Fluid Assembly, labelled Rinse Input.
9. Carefully attach the Rinse tubing to the barbed fitting ensuring it is pushed all the way on the fitting
(see Figure 7-49 "Cavro Syringe Pump Assembly").
10. Screw the Probe tubing onto the Syringe Pump Valve (see Figure 7-49 "Cavro Syringe Pump
Assembly").
11. Re-install the Sample Area interior skins.
Base TOP Sample Arm Cavro Syringe Pump Removal
2. Move the Probe(s) serviced by the Syringe Pump over the Rinse Cup. (This ensures that any fluid that
3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-50 "Cavro Sam-
ple Arm Syringe Pump Tubing"). (Fluid will drain from the probe.)
4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-50 "Cavro Sample Arm Syringe
Pump Tubing").
NOTE: Do not unscrew the barbed fitting on the Rinse tubing line of the Syringe Pump Valve.
The barbed fitting is torqued to a precise specification. If the torque is changed, it could cause
the Syringe Pump to malfunction.
Figure 7-50 Cavro Sample Arm Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6. Move the arms to the side so they will not be damaged when removing the pump assembly.

7. While holding the pump assembly by the bottom, remove the four mounting screws securing the
syringe pump mounting bracket to the standoffs from the Reagent Arm, as shown on Figure 7-51
"Cavro Sample Arm Pump Assembly Mounting".
Figure 7-51 Cavro Sample Arm Pump Assembly Mounting
Mounting
Mounting Screws
Screws
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)

the pump.
Base TOP Cavro Sample Syringe Pump Installation
1. Ensure that the Syringe Pump address is properly set. Refer to "Cavro Syringe Pump Settings" for
more information on the proper settings for Syringe Pump addresses. The Syringe Pump address is
specified with the address switch (rotary) at the rear of the Syringe Pump.
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
5. Engage the pin on the rear bracket in the Syringe pump so that the front bracket openings align with
the screw holes.
6. Insert, and tighten, the two mounting screws that secure the front of the Syringe Pump Assembly

7. Insert the screws and fasten the mounting bracket to the standoffs as shown on Figure 7-54 "Sample
Arm Cavro Pump Assembly Mounting".
Figure 7-54 Sample Arm Cavro Pump Assembly Mounting
Mounting
Mounting Screws
Screws
8. Ensure the rinse supply tube(s) is routed through the mounting bracket as shown on the figure and
attach it to the syringe pump valve(s) (upper left port) by carefully pressing it onto the barbed fitting.
(See Figure 7-55 "Sample Arm Cavro Syringe Pump Tubing".)
9. Screw the Probe tubing onto the Syringe Pump Valve(s) (see Figure 7-55 "Sample Arm Cavro
Syringe Pump Tubing").
Figure 7-55 Sample Arm Cavro Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing

Reagent Cavro Syringe Pump Removal
1. Remove the Reagent Area interior skins as described in Reagent Area Interior Skins Removal/
2. Move the Probes over the Rinse Cups. (This ensures that any fluid that drips out of the Probes will
drip into the Rinse Cup.)
NOTE: If removing both Reagent Syringe Pumps, ensure the tubes that are connected to
Pump R1 and those connected to Pump R2 are identified. This can be done by placing a
small mark on the tubes for one Syringe Pumps (R1 or R2). (It is recommended that the mark
be made with a soft-tip marking pen.) When re-connecting the tubes, ensure the tubes are
connected to the proper pumps.
3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-56 "Reagent
Cavro Syringe Pump Tubing"). (Fluid will drain from the probe.)
4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-56 "Reagent Cavro Syringe
Pump Tubing").
Figure 7-56 Reagent Cavro Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6. .Move the probes to the side so they will not be damaged when removing the pump assembly.

7. Loosen the three captive mounting screws securing the syringe pumps to the Reagent Arm, as shown
on Figure 7-57 "Reagent Arm Cavro Pump Assembly Mounting".
Figure 7-57 Reagent Arm Cavro Pump Assembly Mounting
Mounting
Screws
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)

the pump.
Reagent Cavro Syringe Pump Installation
1. Ensure that the Syringe Pump address is properly set. Refer to "Cavro Syringe Pump Settings" for
more information on the proper settings for Syringe Pump addresses. The Syringe Pump address is
specified with the address switch (rotary) at the rear of the Syringe Pump.
Jumpers
15 Pin Electrical
Connector
Jumpers
Address Switch
(Rotary)
NOTE: If installing both Reagent Syringe Pumps, ensure the 15-pin connector with two extra
wires (black twisted with blue) is connected to the R2 (rightmost) Syringe Pump.
the pump screw holes.
6. Insert, and tighten, the two mounting screws that secure the front of the Syringe Pump Assembly.

7. Slide the mounting bracket toward the rear of the instrument and tighten the three mounting screws as
shown on Figure 7-60 "Reagent Arm Cavro Pump Assembly Mounting".
Figure 7-60 Reagent Arm Cavro Pump Assembly Mounting
Mounting
Screws
8. Ensure the rinse supply tubes are routed through the mounting bracket as shown on the figure and
attach them to the syringe pump valve(s) (upper left port) by carefully pressing them onto the barbed
fitting. (See Figure 7-61 "Reagent Cavro Syringe Pump Tubing".)
9. Screw the Probe tubing onto the Syringe Pump Valves (see Figure 7-61 "Reagent Cavro Syringe
Pump Tubing").
Figure 7-61 Reagent Cavro Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
10. Re-install the Reagent Area interior skins.

Cavro Syringe Tip Removal/Replacement
Cavro Syringe Tip Removal
1. Remove the Sample Area or Reagent Area interior skins as described in Sample Area Interior
Skins Removal/Replacement in Chapter 4 or Reagent Area Interior Skins Removal/Replace-
ment in Chapter 4.
Reference Figure 7-62 "Removing the Cavro Syringe" for steps 3 through 8.
3. Unscrew and remove the probe tubing from the Syringe Pump Valve. (Fluid will drain from the probe.)
4. Carefully pull the Rinse tubing from the barbed fitting.
6. Loosen the Thumbscrew at the bottom of the Syringe Tube.
7. Slide the Thumbscrew Block Assembly down to the Syringe Pump Bottom Plate.
8. Unscrew the Syringe Glass Screw.
Figure 7-62 Removing the Cavro Syringe
Probe Tubing
Rinse Tubing
Barbed Fitting
Syringe Glass
Screw
Syringe
Thumbwheel

9. Remove the glass tube containing the Syringe.

10. Pull the metal plunger from the glass tube.
11. Using pliers, pull the Teflon syringe tip from the metal plunger (see Figure 7-63 "Cavro Syringe Tip
Removal").
Figure 7-63 Cavro Syringe Tip Removal
Teflon Tip
Plunger
Glass Tube
Cavro Syringe Tip Installation
See Figure 7-64 "Cavro Syringe Tip Installation" for steps 1 through 5.
1. With the open side of the Teflon tip facing up, slide the Teflon tip into the ISE slot on the installation
block.
2. Place the rubber o-ring on the tip of the metal plunger.
3. Insert the end of the plunger with the rubber o-ring into the ISE slot of the installation block. (Push
the plunger in so that the Teflon tip snaps onto the tip of the metal plunger.)
4. Remove the plunger from the ISE slot, rinse it with 70% isopropyl alcohol and then rinse with DiH2O.
5. Insert the plunger, with the Teflon tip attached, into the Syringe glass tube.

Figure 7-64 Cavro Syringe Tip Installation

Teflon Tip
Syringe Tip Plunger
Installation
Tool Syringe
Glass Tube
O-Ring
See Figure 7-65 "Cavro Syringe Valve Assembly/Tubing" for steps 6 through 12.
6. Screw the Syringe Glass tube onto the Syringe Pump Valve.
7. Raise the thumbscrew block so that the metal knob at the bottom of the syringe plunger seats in the
thumbscrew block.
8. Tighten the thumbwheel until it is finger-tight.
9. Use pliers to tighten the thumbwheel an additional 1/4 turn (ensure it is tightened ONLY 1/4 turn) to
ensure tightness.
10. Attach the Rinse tubing to the barbed fitting.
11. Screw the Probe tubing onto the Syringe Pump Valve.
Figure 7-65 Cavro Syringe Valve Assembly/Tubing
Probe Tubing
Rinse Tubing
Barbed Fitting
Syringe Pump
Valve Syringe Glass
Screw
Thumbwheel
12. Install the Reagent or Sample area interior skins.

Cavro Syringe Valve Removal/Replacement
Cavro Syringe Valve Removal
1. Remove the Sample or Reagent area interior skins as described in Sample Area Interior Skins
Removal/Replacement in Chapter 4 or Reagent Area Interior Skins Removal/Replacement in
Chapter 4.
See Figure 7-66 "Cavro Syringe Removal" for steps 2 through 11.
Figure 7-66 Cavro Syringe Removal
Rinse Tubing Probe Tubing
Barbed Fitting
Phillips Screws
Syringe Glass Syringe Glass

Tube Screw
Thumbscrew
7. Slide the Thumbscrew Block Assembly down to the Syringe Pump Bottom Plate.
8. Unscrew the Syringe Glass Screw.

9. Remove the glass tube containing the Syringe.

10. Remove the two Phillips screws on the Syringe.
11. Gently pull the Valve from the front face of the Syringe Pump Assembly.
Cavro Syringe Valve Installation
1. Mount the Syringe Valve on the front face of the Syringe Pump Assembly.
See Figure 7-67 "Cavro Syringe Installation" for steps 2 through 8.
2. Fasten the two Phillips screws that secure the Syringe Valve.
Figure 7-67 Cavro Syringe Installation
Barbed Fitting
Phillips Screws
Syringe Glass Syringe Glass

Tube Screw
Thumbscrew
4. Raise the thumbscrew block so that the metal knob at the bottom of the syringe plunger seats in the
thumbscrew block.
5. Tighten the thumbscrew until it is finger-tight.
6. Use pliers to tighten the thumbscrew an additional 1/4 turn (ONLY 1/4 turn) to ensure tightness.
9. Install the sample or Reagent area interior skins.

Hamilton Syringe Pump Assembly Removal/Replacement
CTS Sample Hamilton Syringe Pump Removal
3. Remove the aspirator from the Rinse bottle. Unscrew and remove the precision (probe) tubing from
the Syringe Pump Valve (see Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly").
(Fluid will drain from the probe.)
Figure 7-68 Hamilton CTS Sample Syringe Pump Assembly
Mounting Screws
Rinse Rinse Tubing

Input
Fitting Barbed
Precision
Fitting
(Probe)
Tubing
4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-68 "Hamilton CTS Sample
Syringe Pump Assembly").

6. Move the probe to the side so it will not be damaged when removing the pump assembly.
7. Unscrew and disconnect the front fluidic fitting on the top of the CTS Bulk Fluid Assembly, labelled
Rinse Input. See Figure 7-68 "Hamilton CTS Sample Syringe Pump Assembly". (This is neces-
sary to obtain clearance to slide out the CTS Bulk Fluidics Assembly.)
8. Loosen the three captive mounting screws securing the CTS Bulk Fluidics Assembly to the Sample
Arm, as shown on Figure 7-69 "CTS Fluidics Mounting", and slide the module out only far enough
to access the two screws securing the top front of the syringe pump.
Figure 7-69 CTS Fluidics Mounting
Syringe
Pump
Mounting
Rinse Screws
Input
Fitting
Mounting
Screws

shown on Figure 7-70 "Hamilton Syringe Pump Back".
Figure 7-70 Hamilton Syringe Pump Back
Address Selection
(shown at 0)
Address Switch
15 Pin Electrical SW 1
Connector
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8

the pump.
CTS Sample Hamilton Syringe Pump Installation
See Figure 7-71 "Hamilton Syringe Pump Back" for steps 1 through 4.
1. Ensure that the Syringe Pump address is set to an address of 1. The Syringe Pump address is speci-
fied with the address switch (rotary) at the rear of the Syringe Pump. The arrow on the center dial of
the switch indicates the address setting. Refer to "Hamilton Syringe Pump Settings" for more infor-
mation on the proper settings for Syringe Pump addresses.

Address Selection
(shown at 0)
Address Switch
15 Pin Electrical SW 1
Connector DIP Switches
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8
2. Ensure the Configuration jumpers are at the proper settings. Refer to "Hamilton Syringe Pump Set-
tings" for more information on the proper jumper settings.
3. Set the DIP switches for the pump as stated in "Hamilton Syringe Pump Settings".
6. Slide the CTS Bulk Fluid Assembly toward the front of the instrument and engage the pin on the rear
bracket in the Syringe pump so the front bracket openings align with the screw holes.
7. Insert, and tighten, the two mounting screws that fasten the front of the Syringe Pump Assembly to the
CTS Bulk Fluid Assembly.

8. Slide the CTS Bulk Fluid Assembly toward the rear of the instrument and tighten the three mounting
screws as shown on Figure 7-72 "Hamilton Syringe Pump Assembly Mounting".
NOTE: Use caution to ensure the Rinse Input tube is routed across the top of the assembly,
is inside the rear bracket, and does not get damaged.
Figure 7-72 Hamilton Syringe Pump Assembly Mounting

Mounting Screws
Rinse Rinse Tubing

Input
Fitting Barbed
Precision
Fitting
(Probe)
Tubing
9. Attach the Rinse Input Tube to the CTS Bulk Fluid Assembly, labelled Rinse Input.
10. Carefully attach the Rinse tubing to the barbed fitting ensuring it is pushed all the way on the fitting
(see Figure 7-72 "Hamilton Syringe Pump Assembly Mounting").
11. Screw the Probe tubing onto the Syringe Pump Valve (see Figure 7-72 "Hamilton Syringe Pump
Assembly Mounting").
Base TOP Hamilton Sample Arm Syringe Pump Removal

3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-73 "Hamilton
Sample Arm Syringe Pump Tubing"). (Fluid will drain from the probe.)
4. Carefully pull the Rinse tubing from the barbed fitting (see Figure 7-73 "Hamilton Sample Arm
Figure 7-73 Hamilton Sample Arm Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6. Move the arm to the side so they will not be damaged when removing the pump assembly.

7. While holding the pump assembly by the bottom, remove the four mounting screws securing the
syringe pump mounting bracket to the standoffs from the Reagent Arm, as shown on Figure 7-74
"Hamilton Sample Arm Pump Assembly Mounting".
Figure 7-74 Hamilton Sample Arm Pump Assembly Mounting
Mounting
Screws Mounting
Screws
front of the syringe pump and remove the pump from the mounting bracket.
Address Selection
Address Switch
15 Pin Electrical
Connector SW 1
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8

the pump.

Base TOP Hamilton Sample Syringe Pump Installation
1. Ensure that the Syringe Pump address is properly set. Refer to "Hamilton Syringe Pump Settings"
for more information on the proper settings for Syringe Pump addresses. The Syringe Pump address
is specified with the address switch (rotary) at the rear of the Syringe Pump.
Address Selection
(shown at 0)
Address Switch
SW 1
15-Pin
Electrical
Connector
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8
2. Ensure that the Syringe Pump jumpers are at the proper settings. Refer to "Hamilton Syringe Pump
Settings" for more information on the proper settings.
3. Set the DIP switches for the pump as stated in "Hamilton Syringe Pump Settings".
the screw holes.
7. Insert, and tighten, the two mounting screws that secure the front of the Syringe Pump Assembly
8. Insert the screws and fasten the mounting bracket to the standoffs as shown on Figure 7-77 "Hamil-
ton Sample Arm Pump Assembly Mounting".

Figure 7-77 Hamilton Sample Arm Pump Assembly Mounting
Mounting
Screws Mounting
Screws
9. Ensure the rinse supply tube(s) is routed through the mounting bracket as shown on Figure 7-77
"Hamilton Sample Arm Pump Assembly Mounting"and attach it to the syringe pump valve(s)
(upper left port) by carefully pressing it onto the barbed fitting. (See Figure 7-78 "Hamilton Sample
Arm Syringe Pump Tubing".)
10. Screw the Probe tubing onto the Syringe Pump Valve(s) (see Figure 7-78 "Hamilton Sample Arm
Figure 7-78 Hamilton Sample Arm Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing

Reagent Hamilton Syringe Pump Removal
1. Remove the Reagent Area interior skins as described in Reagent Area Interior Skins Removal/
NOTE: If removing both Reagent Syringe Pumps, ensure the tubes that are connected to
Pump R1 and those connected to Pump R2 are identified. This can be done by placing a
small mark on the tubes for one Syringe Pumps (R1 or R2). (It is recommended that the mark
be made with a soft-tip marking pen.) When re-connecting the tubes, ensure the tubes are
3. Unscrew and remove the probe tubing from the Syringe Pump Valve(s) (see Figure 7-79 "Hamilton
Reagent Syringe Pump Tubing"). (Fluid will drain from the probe.)
4. Carefully pull the Rinse tubing from the barbed fitting(s) (see Figure 7-79 "Hamilton Reagent
5. Using a tubing cutter, trim the rinse tubing(s) by 1/4. (This removes the part of the line that was

Figure 7-79 Hamilton Reagent Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
6. Move the probes to the side so they will not be damaged when removing the pump assembly.
7. Loosen the three captive mounting screws securing the syringe pump(s) to the Reagent Arm, as
shown on Figure 7-80 "Reagent Arm Hamilton Pump Assembly Mounting" and slide the module
forward enough to access the two screws securing the top front of the pump.
Figure 7-80 Reagent Arm Hamilton Pump Assembly Mounting
Mounting
Screws

Address Selection
Address Switch
SW 1 DIP Switches
15-Pin
Electrical
Connector
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8

11. Remove the screws on the bottom of the pump holding the drip plate and remove the drip plate.
Reagent Hamilton Syringe Pump Installation
1. Ensure that the Syringe Pump address is properly set. Refer to "Hamilton Syringe Pump Settings"
for more information on the proper settings for Syringe Pump addresses. The Syringe Pump address
is specified with the address switch (rotary) at the rear of the Syringe Pump.

Address Selection
Address Switch
SW 1 DIP Switches
15-Pin
Electrical
Connector
SW 8
J1 - J2
Configuration
J3 - J4 Jumpers
J5 - J6
J7 - J8
2. Ensure that the Syringe Pump jumpers are at the proper settings. Refer to "Hamilton Syringe Pump
3. Set the DIP switches for the pump(s) as stated in "Hamilton Syringe Pump Settings".
4. Attach the drip plate to the bottom of the pump(s) using the screws previously removed.
CAUTION: If installing both Reagent Syringe Pumps, ensure the 15-pin

connector with two extra wires (black twisted with blue) is connected to
the R2 (rightmost) Syringe Pump.
the pump screw holes.
7. Insert, and tighten, the two mounting screws that fasten the front of the Syringe Pump Assembly.

8. Slide the mounting bracket toward the rear of the instrument and tighten the three mounting screws as
shown on Figure 7-83 "Reagent Arm Hamilton Pump Assembly Mounting".
Figure 7-83 Reagent Arm Hamilton Pump Assembly Mounting
Mounting
Screws
9. Ensure the rinse supply tube(s) is routed through the mounting bracket as shown and attach it to the
syringe pump valve(s) (upper left port) by carefully pressing it onto the barbed fitting. (See Figure 7-
84 "Reagent Hamilton Syringe Pump Tubing".)
10. Screw the Probe tubing onto the Syringe Pump Valve(s) (see Figure 7-84 "Reagent Hamilton

Figure 7-84 Reagent Hamilton Syringe Pump Tubing
Rinse Tubing
Precision
(Probe)
Tubing
11. Re-install the Reagent Area interior skins.
Hamilton Syringe Tip Removal/Replacement
Hamilton Syringe Tip Removal
1. Remove the Sample Area or Reagent Area interior skins as described in Sample Area Interior
Skins Removal/Replacement in Chapter 4 or Reagent Area Interior Skins Removal/Replace-
ment in Chapter 4.
Reference Figure 7-85 "Removing the Hamilton Syringe" for steps 3 through 8.

7. Raise the plunger within the syringe.
8. Unscrew and remove the Syringe.
Figure 7-85 Removing the Hamilton Syringe
Barbed Fitting
Syringe
Screw
Connection
Syringe
Thumbwheel
9. Pull the metal plunger from the glass tube.

10. Using pliers, pull the Teflon syringe tip from the metal plunger (see Figure 7-86 "Hamilton Syringe
Tip Removal").

Figure 7-86 Hamilton Syringe Tip Removal
Teflon Tip
Plunger
Glass Tube
Hamilton Syringe Tip Installation
See Figure 7-87 "Hamilton Syringe Tip Installation" for steps 1 through 5.
1. With the open side of the Teflon tip facing up, slide the Teflon tip into the ISE slot on the installation
block.
2. Place the rubber o-ring on the tip of the metal plunger.
3. Insert the end of the plunger with the rubber o-ring into the ISE slot of the installation block. (Push
the plunger in so that the Teflon tip snaps onto the tip of the metal plunger.)
4. Remove the plunger from the ISE slot, rinse it with reagent-grade alcohol and then rinse with DiH2O.
5. Insert the plunger, with the Teflon tip attached, into the Syringe glass tube.

Figure 7-87 Hamilton Syringe Tip Installation

Syringe Tip
Installation
Tool
Plunger
Teflon Tip
Syringe
Glass Tube
O-Ring
See Figure 7-88 "Hamilton Syringe Valve Assembly/Tubing" for steps 6 through 12.
7. Manually lower the plunger so the metal knob at the bottom of the syringe plunger seats in the thumb-
wheel block.
9. Use pliers to tighten the thumbwheel an additional 1/4 turn (ensure it is tightened ONLY 1/4 turn) to
ensure tightness.

Figure 7-88 Hamilton Syringe Valve Assembly/Tubing
Barbed Fitting
Syringe Pump
Valve
Syringe Glass
Tube
Thumbwheel
12. Install the Reagent or Sample area interior skins.
Hamilton Syringe Valve Removal/Replacement
Hamilton Syringe Valve Removal
1. Remove the Sample or Reagent area interior skins as described in Sample Area Interior Skins
Chapter 4.
See Figure 7-89 "Hamilton Pump Syringe Removal" for steps 2 through 10.

6. Loosen the Thumbwheel at the bottom of the Syringe Tube.
7. Raise the Syringe Plunger.
8. Unscrew and remove the Syringe glass tube.
9. Remove the two Phillips screws on the Syringe.
10. Gently pull the Syringe Pump Valve from the front face of the Syringe Pump Assembly.
Figure 7-89 Hamilton Pump Syringe Removal
Barbed Fitting
Syringe Pump
Valve Phillips Screws
Syringe Glass
Tube
Thumbwheel
Hamilton Syringe Valve Installation
See Figure 7-90 "Hamilton Syringe Installation" for steps 1 through 8.

1. Mount the Syringe Valve on the front face of the Syringe Pump Assembly.
2. Fasten the two Phillips screws that secure the Syringe Valve.

Figure 7-90 Hamilton Syringe Installation
Barbed Fitting
Syringe Pump
Valve Phillips Screws
Syringe Glass
Tube
Thumbwheel
4. Lower the syringe plunger so the metal knob at the bottom of the syringe plunger seats in the thumb-
wheel block.
6. Use pliers to tighten the thumbwheel an additional 1/4 turn to ensure tightness.
9. Install the sample or Reagent area interior skins.
Rinse Pump Removal/Replacement
Rinse Pump Removal
1. Remove the Waste Pump as described in Waste Pump Removal in Chapter 13.
NOTE: It is not necessary to completely remove the Waste Pump from the instrument. The
connections to the accumulators can be left on the pump and the pump placed on to of the
reagent accumulator during removal of the Rinse Pump Assembly.
1. Verify that all tubes are clearly marked to ensure proper placement in the installation.
2. Disconnect the tubing and Fluidics cable from the connectors at the top of Rinse Pump Box as shown
on "Rinse Box Connections".
NOTE: The CTS fitting, as identified in the figure, has a red cap on it in a non-CTS unit.

Figure 7-91 Rinse Box Connections
CTS Fitting
3. Remove the two captive screws that secure the Runse pump to the cover as shown on Figure 7-92
"Rinse Pump Screws".
Figure 7-92 Rinse Pump Screws
Retaining Screws
4. Lift and remove the Rinse Pump Assembly out of the cover and the instrument.
Rinse Pump Installation
1. Lower the Rinse Pump assembly into the cover and tighten its two captive screws as shown on Fig-
ure 7-93 "Rinse Pump Retaining Screws".
NOTE: Ensure all tubing and cabling are within the cover and the Bracket for the Rinse Pump
Connector is outside the Rinse Pump cover as shown in Figure 7-93 "Rinse Pump Retain-
ing Screws".

Figure 7-93 Rinse Pump Retaining Screws

Retaining Screws
Captive Screws
Rinse Pump
Connector
2. Connect the Rinse Pump cable to the Rinse Pump connector.

3. Connect the tubing to the top mounted Rinse Box fittings based on the labeling on the tubing, i.e.,
Sample to Sample, R1 to INTERMED., R2 to START, Rinse Input to Rinse Input, and CTS to CTS.
4. Replace the Waste Pump as described in Waste Pump Installation in Chapter 13.
Precision Tubing Removal/Replacement
Precision Tubing Removal
CAUTION: Ensure that the instrument is powered OFF before you perform
the following procedure.
1. Remove the sample or Reagent area interior skins as described in Sample Area Interior Skins
Chapter 4.
3. Unscrew and remove the probe tubing from the Syringe Pump Valve (see Figure 7-94 "The Probe
Tubing"). (Fluid will drain from the probe.)

Figure 7-94 The Probe Tubing
Probe Tubing
Rinse Tubing
4. depending on whether the tubing is being changed for a CTS Sample Arm, non-CTS Sample Arm,
Intermediate Arm or Start Arm, remove the Phillips screws securing the Strain Relief Bracket for the
probe tubing as shown in:
Figure 7-95 "Precision Tubing Strain Relief on CTS Sample Arm".
Figure 7-96 "Precision Tubing Strain Relief on Base TOP Sample Arm"
Figure 7-97 "Precision Tubing Strain Relief on Intermediate (R1) Arm"
Figure 7-98 "Precision Tubing Strain Relief on Start (R2) Arm"
Figure 7-95 Precision Tubing Strain Relief on CTS Sample Arm

Figure 7-96 Precision Tubing Strain Relief on Base TOP Sample Arm
Strain Relief
Bracket
Figure 7-97 Precision Tubing Strain Relief on Intermediate (R1) Arm
Strain Relief Bracket

Figure 7-98 Precision Tubing Strain Relief on Start (R2) Arm
5. Move the Probe down in the Z direction until the Probe tip touches the Sample (or Reagent) Plate.
6. Slide the Probe Cover up the Z-Drive Rack until the Probe Cover is above the Probe.
7. Using a 1.5 mm Allen Wrench, loosen the two set screws on the Probe.
8. Slide the Z-Rack up until the Probe tubing and the purple fitting are exposed.
9. Unscrew the purple fitting from the probe.
10. Pull the tubing out of the machine.
Precision Tubing Installation
1. If you are installing the precision tubing on a CTS Sample Arm,

a. Route the precision tubing through the corrugated plastic sleeve for the fluid line.
b. Attach the ends of the precision tubing to the appropriate connectors on the Syringe Pump.
c. Dress the tubing as shown in Figure 7-99 "Dressing the Tubing on CTS Sample Arm".
d. Install the Sample Area interior skins.
2. If you are installing the precision tubing on a Reagent Arm, or on a Cavro or Sample Arm,
a. Route the precision tubing through their stainless steel conduits.
b. Attach the ends of the precision tubing to the appropriate connectors on the Syringe Pump and the
probe.
c. Dress the tubing as shown in the appropriate figure below.
d. Install the Sample or Reagent area interior skins.

3. To allow the probes a full range of motion in all three planes (X, Y, and Z), the precision tubing must
be routed as shown in the following figures.
NOTE: For the probes to function properly, the tubing must be routed through the Strain
Relief Brackets exactly as shown. For each tube, there must be a sufficient service loop to
allow unimpeded Z-Axis movement in all positions.
Figure 7-99 "Dressing the Tubing on CTS Sample Arm"

Figure 7-100 "Dressing the Tubing on Base TOP Sample Arm"
Figure 7-101 "Dressing the Tubing on Intermediate (R1) Arm"
Figure 7-102 "Dressing the Tubing on Start (R2) Arm"
Figure 7-99 Dressing the Tubing on CTS Sample Arm

Figure 7-100 Dressing the Tubing on Base TOP Sample Arm

Figure 7-101 Dressing the Tubing on Intermediate (R1) Arm
Figure 7-102 Dressing the Tubing on Start (R2) Arm

Chapter 8 Robotic XYZ Arms 8-1
Chapter 8
Robotic XYZ Arms
8-1 Overview:
The ACL-TOP uses three XYZ robot arms for the movement of fluids during analysis. One robot arm assem-
bly is mounted on the sample side of the instrument and is referred to as the Sample Arm. The other robot
arm assembly contains two reagent arms, and is on the reagent side of the instrument. The reagent arms
are the left reagent arm, or Intermediate Reagent Arm, and the right reagent arm, or Start Reagent Arm.
The robotic arms of the ACL-TOP system allow the probes to move in the X (left to right), Y (front to back)
and Z (up and down) direction as shown on Figure 8-1 "XYZ Axes"
Figure 8-1 XYZ Axes
X Axis
Y
Axis
Z
Axis
CAUTION: When manually moving the XYZ arms, grasp the arms as close
to the rear of the instrument as possible. Damage may result if arm is
moved improperly.

8 - 2 Chapter 8 Robotic XYZ Arms
The arms installed on an ACL-TOP and the probes associated with the arms differ depending on the instru-
ment configuration as shown on Table 8-1 "Robotic Arm/Probe Configurations".
Table 8-1 Robotic Arm/Probe Configurations
Arms Probes
Instrument Type Sample Reagent Sample Probe Left Reagent Right Reagent
Arm Arm Probe Probe
ACL-TOP with Cavro
Arms Cavro Cavro Heated Heated* Heated*
(000028000)
ACL-TOP Closed
IL Piercer (Non-
Top System CTS Heated* Heated*
Double Heated)
(0000280020)
* Note that the heated probes used with the Cavro arms and the heated probes used with the CTS Sample
arms are not compatible.
8-2 Physical Layout
Figure 8-2 "Layout of the Robotic XYZ Arms" shows the physical layout of the Robotic XYZ Arm Assem-
blies including the sample and reagent arms as well a the X-Axis Assembly on which they move.
Figure 8-2 Layout of the Robotic XYZ Arms
Sample Arm Left Reagent Arm Right Reagent Arm

The Interconnect Diagrams for the CTS, Cavro, and IL Double Arms differ in both the PCBs used and the
input requirements for the arm due to the different type of arms and probes used within the arms. Figures 8-
3 through 8-6 show the interconnect diagrams for the following arms:
Closed Tube Sampling (CTS) Arm (Figure 8-3 "Interconnect Diagram - CTS/IL Double Sample
Arm")
Reagent IL Double Arm (Figure 8-4 "Interconnect Diagram - CTS/IL Double Reagent Arm")
Sample Cavro Arm (Figure 8-5 "Interconnect Diagram - Sample-side Cavro Arm")
Reagent Cavro Arm (Figure 8-6 "Interconnect Diagram - Reagent-side Cavro Arms")

Figure 8-3 Interconnect Diagram - CTS/IL Double Sample Arm
Figure 8-4 Interconnect Diagram - CTS/IL Double Reagent Arm

J J J
3 5 6 J
J11 9
J
4
J13
J10 J14
J12 J
7
J15
J J J
J16 8
2 1
J
J 3
J
4
3
J
J J
1
3 1
J
J
4 J J J
3
5 5 2
J J J
1 1 J J 4
J J J 6 6 J
5 5 2 J J
8
7 2
J
J J 4
6
J 6
J
J 2 8
J
7
7
J J
8 2 J
J 5
1
J J J
J 3
J 8 2 J 7
1 5 J
J
6
J 9
J 3 J
7 4
J
J
6
9
J
4

Figure 8-5 Interconnect Diagram - Sample-side Cavro Arm
XP3000
Diluter
Pum p
27756500
J1 +24V OUT MODULO 1
Y-AXIS 00027763300
To Sample Probe
J21 RS 485 Diluter ALIDUM
From Fuse Board J5 MODULO 1

Z-AXIS
00027751100 +24V IN
J2 ADRI-9
Cavro Arm Module
J7 Diagnostic s CCU9000 Cavro Single Arm Module
To LEVEL 2 CPU (278000) CCU9000
J14 00027758300 232 External
J15
PC MODULO 1
Y-AXIS
232 Aux
J16
Devic e MODULO 1 ALIDUM
X-AXIS MODULO 1
J17 RS 485 / 422
EXT Z-AXIS
ADRI-9
Figure 8-6 Interconnect Diagram - Reagent-side Cavro Arms
XP3000 XP3000
Diluter Diluter
Pum p Pum p
27756500
J1 +24V OUT MODULO 1
Y-AXIS 00027763300 To
J21 RS 485 Diluter MODULO 1 Reagent 1 Probe
ALIDUM
X-AXIS MODULO 1
From Fuse Board J5
00027751100 Z-AXIS
J2 +24V IN ADRI-9
Cavro Arm Module Cavro Dual Arm Module

J7 Diagnostic s
CCU9000
To LEVEL 2 CPU (278000) CCU9000
J14 00027758300
J15 232 External PC
MODULO 1
00027763300 To
Y-AXIS
J16 232 Aux Reagent 2 Probe
Devic e MODULO 1 ALIDUM
X-AXIS
J17 RS 485 / 422 MODULO 1
EXT Z-AXIS
ADRI-9

Cavro Arms (Used on ACL-TOP model 0000280000)

Each Cavro arm is a robot controlled by three stepper motors with step loss (slippage) detection capability.
The stepper motors control probe movement in the X, Y, and Z direction. Communication with the Cavro
arms is via RS-232 from the ACL-TOP master processor that controls the positioning of the arms and
probes. Hardware and software errors encountered by the arm are communicated to the operator via the
ACL-TOP error log.
Figure 8-7 ACL-TOP with Cavro Arms
Cavro Reagent Arms

Cavro Sample Arm
X-Axis Assembly
The main structural member for the X-Axis Assembly is the X-Frame, as shown on Figure 8-8 "X Frame",
that is mounted to the ACL-TOP pylons through vibration isolators. Each X-Axis Assembly (Sample and
Reagent) is mounted with four vibration isolators. Examples of the vibration isolators are shown in Figure 8-
9 "Vibration Isolators". In the figure, the four vibration isolators in the middle of the instrument are shown.
The two isolators on the right are for the Reagent Arm Assembly and the two on the left are for the Sample
Arm Assembly.
The X-Frame is made of a machined aluminum extrusion and attached to it are:
two guide rails,
the X-Axis Stepper Motor,
X-Axis Idler Pulley/Encoder Assembly,
and the CCU PCB.

Figure 8-8 X Frame
X Frame
Figure 8-9 Vibration Isolators

Sample Arm Reagent
Right Left
Vibration Vibration
Isolators Isolators
The Y Axis assembly is attached to the X Axis guide rails (X Rails) by three rollers creating a carriage
assembly that rides along the rails. The drive belt attached to the X axis motor pulley provide the X axis
movement for the carriage. The rollers are adjusted by the OEM supplier and should not be adjusted in the
field. Figure 8-10 "X Axis Rollers and Drive Belt" shows two of the three rollers (there are two rollers on
the front of the carriage), the X-Rails on which the rollers ride, and the drive belt and its attachment to the
arm to move the arm in the X direction. On the left end of the X axis assembly is the X Axis Stepper Motor
(drive motor), with its attached encoder, that powers the drive belt.
Figure 8-10 X Axis Rollers and Drive Belt
X Frame
X Axis
Drive Belt
X Rails
Drive Belt
Rollers Carriage Attachment
Y Axis Assembly

The X-Axis Stepper Motor is attached to the underside of the X-Frame Extrusion. The encoder disk for the
motor is located under the drive pulley mounted on the upper side of the X-Frame Extrusion, and is read by
a slotted optical sensor. Figure 8-11 "Motor, drive belt and encoder" shows the motor. the drive pulley,
the encoder, and the optical sensor for the encoder.
Figure 8-11 Motor, drive belt and encoder
Drive Pulley
Encoder
Disk
Optical Sensor
Drive Belt
For the X-Axis Assembly on the Reagent side, the two arms require two motors and two drive belts. The lay-
out of these motors and belts are as shown on Figure 8-12 "X Axis Motors - Reagent Side".
Figure 8-12 X Axis Motors - Reagent Side
R1 (Left Arm) Motor
R2 (Right Arm) Motor

Figure 8-13 X Axis Belts - Reagent Side
R1 (Left Arm) Belt
R2 (Right Arm) Belt
Y-Axis Assembly
The Y-Axis Assembly attaches to the X-Axis Assembly by the three rollers that allow it to move along the X
axis. Figure 8-14 "Y Axis Assembly" depicts the parts of the Y-Axis Assembly. As shown in the figure, the
Y-Axis Assembly has 2 guide rails and the Z carriage assembly attaches to the guide rails with three rollers.
The rollers are adjusted by the OEM supplier and should not be adjusted in the field. Driven by the Y drive
belt and guided by the guide rails, the Z carriage rides along a square shaft that runs the length of the Y axis.
The square shaft should never be lubricated or greased in any way.
The Y drive belt is rotated through a set of tandem pulleys that enables the motor to reside on the top of the
Y-Axis Assembly while powering the belt on the bottom of the assembly.
Figure 8-14 Y Axis Assembly
Z Axis Drive Belt Roller Z Carriage Y Drive Belt
Guide Rail
Tandem Pulleys
Square Shaft

Chapter 8 Robotic XYZ Arms 8 - 11
As shown on Figure 8-15 "Y Axis Stepper Motor", the Y Axis Stepper Motor is mounted on top of the Y-
Axis Extrusion. The encoder for the motor is mounted to the motor shaft on top of the drive pulley. The
encoder disk is read by a slotted optical sensor. A set of tandem pulleys redirects the motion of the Y-Motor
to the Y-Axis drive belt as previously shown above in Figure 8-14 "Y Axis Assembly".
Figure 8-15 Y Axis Stepper Motor
Z Axis Encoder Y Axis Motor

Z Axis Motor
Z Axis Drive Belt
Z-Axis Assembly
The Z-Axis Assembly attaches to and moves along the Y-Axis Assembly via the three rollers and rides along
the square shaft. The square shaft is driven by the Z axis motor and drive belt and turns a pinion gear inside
the aluminum block of the Z-Axis Assembly. The pinion gear teeth engage the teeth on the Z-Rack Drive that
provides the Z axis (up and down) motion of the probe. As shown on Figure 8-16 "Z Axis Motor, Pulley
and Encoder". the Z Axis Stepper Motor is mounted to the Y Axis Extrusion. The encoder for the motor is
mounted to the motor shaft and is directly in front of the drive pulley. The encoder disk is read by a slotted
optical sensor. A short closed loop belt drives a pulley rigidly mounted to the square shaft that runs along
the Y axis.
Figure 8-16 Z Axis Motor, Pulley and Encoder
Z axis Motor
Z axis Encoder
Z axis Drive Belt
Square Shaft
that drives the
Z-Axis Assembly

Figure 8-17 "Z-Axis Assembly" depicts the Z-Axis Assembly. As shown, the Z Rack mounting hole pro-
vides the alignment of the teeth in the Z Rack to engage the square shaft that drives the rack and probe up
and down.
Figure 8-17 Z-Axis Assembly
Z-Axis Assembly
Y axis Drive Belt Z Rack Mounting

Hole
Square Shaft
Properly cleaning the Z Axis Assembly with an isopropyl alcohol wipe on a regular basis is recommended.
The square shaft should never be lubricated or greased in any way.
Arm Initialization
On a Cavro arm, each of the three axes (X, Y, and Z) have sensors to indicate the arm has properly moved
to the designated home position on that axis. The X and Y home sensors are the slotted optical travel limit
sensors (see "X, Y, Z Travel Limit Sensors" below) that are interrupted by a flag attached to each axis
assembly. The Z axis home sensor is a capacitive sensor tied to the Liquid Level Detection (LLD) circuit in
the probe. When an electrical contact is made between the probe bracket and collar on the arm, the probe
is considered home. The home positions are as shown in Table 8-2 "Cavro X, Y, Z Home Positions".
Table 8-2 Cavro X, Y, Z Home Positions
Table 8-3
Arm/ Axis Home Position
All Z Up
Sample arm X Rear, right side of the Sam-
ple Area
Left Reagent arm X Rear, left side of the
Reagent Area
Right Reagent X Rear, right side of the
arm Reagent Area

During the Initialization sequence, the Z axis initialization occurs first. This is done to raise the probe and
prevent damage to it when moving the probe along the X and Y axes. The probe initialization routine
involves raising the probe until it triggers the LLD circuit by a metal tab on the probe contacting a steel ring
on the Z-Axis Assembly. Once the LLD circuit is triggered, the probe is considered home and the probe is
moved down several steps to offset it from the sensor. During normal operation, the software only enables
the probe to be raised to the upper limit minus the offset to avoid false indications by the LLD circuit.
When all three arms have initialized, the ACL-TOP runs a coordinates check on the metal openings around
the rinse/clean stations. This action is performed each time the ACL-TOP is initialized to verify that no
changes have occurred to the probe tip positions since the last coordinates check. If an error occurs during
this check, the operator is prompted to run the coordinates adjustment routine in the Diagnostics Menu.
X, Y, Z Travel Limit Sensors
Both the X and Y axes have travel limit flags and sensors used to sense the limits of the carriage travel and
avoid any damage to the equipment in case of an error. These sensors are slotted optical sensors whose
sensing is interrupted by the flag which goes between the two halves of the sensor. The X limit flags are
mounted on the X-Axis Assembly and the sensor is mounted on one of the boards that travel along the X
axis with the arm as shown in Figure 8-18 "X Limit Flags and Travel Limit Sensors".
Figure 8-18 X Limit Flags and Travel Limit Sensors
Slotted Sensors
Sensor
Flag
Flags
Left Flag/Sensor Right Flag/Sensor
The Y limit flag is mounted on the rear of the Z carriage and the limit sensor is mounted on the Y-Axis
Assembly as shown on Figure 8-19 "Y Limit Flag and Travel Limit Sensor", There is no travel limit sensor
on the front of the Y-Axis Assembly. This limit is controlled by the software tracking of the encoder output
and ensuring the count never reaches a point indicating the arm has passed its limit.

Figure 8-19 Y Limit Flag and Travel Limit Sensor
Sensor
To Be Added.
Flag
For the X and Y axes, if the arm exceeds normal system travel range, the flag blocks the slotted travel limit
sensor. This sensor indication is communicated to the software that stops the arm movement prior to it hit-
ting its rubber stop.
Limiting travel for the Z axis is managed by the software monitoring of the Stepper Motor Encoder.
Communications
Communication with the Cavro arm is through RS232 communication between the master processor in the
right rear of the ACL-TOP and the Cavro Central Control Unit (CCU) located below the X-rails. The Cavro
CCU sends commands to the Cavro devices and completion messages are sent back to the master proces-
sor. There is one CCU for the Sample arm and one CCU that controls both Reagent Arms as shown on the
Interconnect diagrams. The communication cable for the arms goes from connector J15 on the CCU to con-
nector J14 on the Level2 CPU (Master Processor).
CCU PCB
The Central Control Unit (CCU) PCB is mounted below the X-Axis Assembly on four standoffs, as shown on
Figure 8-20 "Central Control Unit (CCU) for Cavro Arms" and controls communication between the
Cavro arms and the Master Processor in the right rear of the instrument. The electronics that drive the X-
Axis motor(s) are located on the CCU and communication to the syringe pumps is routed through the CCU
PCB to the master processor. The syringe pump communication cable plugs into J21 on the right side of the
CCU, 24V power for the syringe pumps plugs into J1 on the CCU, and 24V power for the arms plugs into J2
on the CCU.

Figure 8-20 Central Control Unit (CCU) for Cavro Arms
LEDs
CCU Board
As shown on the figure, there are four LEDs on the CCU PCB to help identify error states of the arm. The
LEDs blink slowly if the arms are functioning properly. If the LEDs blink quickly (twice per second) there is a
problem with step loss (slippage). If the LEDs are on constantly, there is a problem with the arm hardware.
ADRI-9 PCB
The ACL-TOP contains two ADRI-9 PCBs, one for the Sample Arm and one for the Reagent Arms. The
ADRI-9 PCB contains the motor drivers for the Y and Z axes, the end of limit sensors for the X axis, and the
liquid level sensing circuit that is contained within a metal casing and is referred to as the Alidum. The Ali-
dum is connected to the probe via a coaxial cable. The Alidum sensitivity can be varied by changing a dip
switch setting on the ADRI-9 PCB. The sensitivity of the Alidum is set and verified during manufacture and
should not be modified in the field.
The ADRI 9 PCB consists of two PCBs stacked one atop the other and located on the traveling Y-Axis as
shown on Figure 8-21 "ADRI-9 PCBs". (Note that the PCB is shown from the back. The PCBs are not vis-
ible from the front of the instrument as they are behind the Y and Z Axis Stepper Motors.) The ADRI-9 PCB
has a series of dip switches that allow the arm position (Sample, Left Reagent, Right Reagent) to be defined
and the sensitivity of the LLD circuit to be selected. The dip switches not meant to be changed in the field.
The switches are shown in Figure 8-22 "ADRI 9 Dip Switches", and their settings are shown in Table 8-4
"Cavro ADRI-9 Dip Switch Settings", for verification purposes.
NOTE: There is an extra ADRI-9 board on the Sample side X-Axis Assembly that is required
for software checking.

Figure 8-21 ADRI-9 PCBs
Figure 8-22 ADRI 9 Dip Switches
S4 S3 S2
S1
For reference purposes, the configuration of the dip switch settings are shown in Table 8-4 "Cavro ADRI-9
Dip Switch Settings".
Table 8-4 Cavro ADRI-9 Dip Switch Settings
Table 8-5
S1 S2 S3 S4
Sample Arm On On Off On

Reagent 1 Arm On On On Off
Reagent 2 Arm On On Off On

Table 8-5
Sensitivity Standard N/A N/A Off N/A

Sensitivity High N/A N/A On On
Sensitivity Very High N/A N/A On On
If LLD issues arise and are not isolated to the sampling probe or coaxial cable connection, the resistance of
the Alidum should be measured to ensure that the RC network of the Alidum is functioning properly. Refer
to "Alidum Resistance Check" for measuring the resistance of the Alidum.
Probe Interconnect PCB
The probe interconnect PCB is located on the Y-Axis carriage. The PCB is an interconnect PCB that
reduces the white flex cable down to the orange flex cable that leads to the probe. The probe interconnect
PCB has two strain relief brackets mounted to it to prevent damage to the two flex cables. When servicing
the probe interconnect PCB, care should be taken to reinstall the strain relief brackets and manually verify
that there are no interferences between the flex cable and Y-Axis covers.
DC Driver Board
The DC Driver board is part of the thermal control system that regulates the temperature of up to three
probes in the ACL TOP system. It provides variable DC voltages for driving two heaters on each of the three
probes. One DC driver board accommodates all three probes on an instrument.
The circuit consists of six Buck regulator circuits, one for each heater. The Buck regulator uses an FET, an
inductor, a capacitor, and a schottky diode.
When the FET is turned on, the full voltage is present across the coil but falls exponentially while the current
in the inductor decreases to discharge the capacitor to ground. When the FET is turned off, the voltage
across the inductor becomes reversed in polarity to maintain the current flow to the capacitor. The reversed
voltage is now conducted through the diode, thus offering the FET protection. Unless the FET is turned on
again, the current in the inductor diminishes and the voltage charges back to +24V.
The DC voltage is derived from a 30KHZ pulse train. To maintain any given voltage output, the duty cycle of
the 30KHz is varied with the voltage output directly proportional to the duty cycle, i.e., an increased duty
cycle offers higher voltage. For example: with a circuit powered from +24V and the 30KHz at a 50% duty
cycle, the output from the buck regulator circuit is 12V.
The power capacity of each Buck regulator is limited to the current capability of the coil which is
1.5A. With each heater at 32 ohms, the maximum current draw per heater does not exceed 0.75A.
Heater Probe PCB
The heater Probe PCB is located within the probe, as shown on Figure 8-23 "Heater Probe PCB", and pro-
vides control of the two heaters within the probes. The probe fuses are protective measures that prevent
overheating and burning in the probe. If a fuse blows under normal operation, it indicates a problem with the
probe and the probe should be replaced. When a probe fuse is blown a thermal warning is generated and
the red LED on the fuse PCB goes on. If the fuse blows because of a problem other then normal operation,
the fuse can be removed and replaced with tweezers.

Figure 8-23 Heater Probe PCB
Probe Heater
Board
Probe Fuse
CTS Sample Arm (Used on ACL-TOP model 0000280020)

The CTS Sample arm is a robot controlled by three stepper motors with step loss (slippage) detection
capability. The stepper motors control motion in the X, Y, and Z axis. Communication with the CTS Sample
arm is via Can-bus from the ACL-TOP master processor. The ACL-TOP system software controls the posi-
tioning of the arms and hardware and software errors encountered by the arm are communicated to the
operator via the ACL-TOP error log.
Figure 8-24 ACL-TOP CTS with CTS Sample and IL Double Arms
Reagent
IL Double Arm
CTS Sample
Arm
X-Axis Assembly
The main structural member for the X-Axis of the arm is the X-Frame, as shown on Figure 8-8 "X Frame",
that is mounted to the three pylons on the ACL-TOP chassis. The X-Frame is made of extruded aluminum
and designed to accept the additional loading created by closed tube sampling (CTS). Attached to the X-
Frame are:
two rails
X-Axis Stepper Motor/encoder assembly

X-Axis idler pulley

X-Axis PCB.
Figure 8-25 X-Axis Assembly
X Axis Assembly
The X-Carriage is attached to the X-Axis bearing rails by two bearing blocks and the drive belt that provides
the X axis movement for the Y-Axis Assembly. The bearing blocks are fixed and are not field adjustable. Fig-
ure 8-26 "X Axis Drive Belt (Sample Side)" shows the rails and the drive belt.
Figure 8-26 X Axis Drive Belt (Sample Side)
X Axis Rails
Drive
Pulley
X Drive Belt
On the right end of the X-Axis Assembly is the X axis stepper motor (drive motor), with its attached encoder,
that powers the X Axis Stepper Motor(s) and is attached to the underside of the X-Frame. The encoder disk
for the motor is mounted to the motor shaft on the rear of the motor casing. As opposed to the other encod-
ers that are visible, the Y Axis motor encoder is enclosed and not visible. The encoder disk is read by an
optical sensor.

Figure 8-27 X Axis Drive Motor

End of Limit
Travel Sensor
X Axis
Frame
X Axis Motor
X Axis Motor
Encoder
The Reagent X-Axis Assembly supports two arms and requires separate motors and drive belts for each
arm. While each assembly can travel the length of the X axis, the software controls the arms and ensures
there is no collisions between them. Note that there are also flags on each arm and sensors on the other
arm, as described in "CCU PCB", that protect them from collision in the event of a failure in the software or
hardware. Figure 8-28 "Reagent Side Drive Belts" shows the X axis drive belts while Figure 8-29
"Reagent Side X Axis Motors" shows the X axis motors.
Figure 8-28 Reagent Side Drive Belts
R2 (Right) Drive Belt R1 (Left)

Drive Belt

Figure 8-29 Reagent Side X Axis Motors

Reagent Side
X Axis Motors
Y-Axis Assembly
The Y-Axis Assembly mounts to the X carriage. The main structural member of the Y-Axis Assembly is the
Y frame that is made of extruded aluminum and designed to minimize deflection during sample acquisition.
The Y-Axis Assembly has a single bearing rail running the length of the extrusion and the Z carriage
attaches to the bearing rail with one bearing block and the Y drive belt as shown on Figure 8-30 "Y-Axis
Assembly".
Figure 8-30 Y-Axis Assembly
Y Axis Drive Pulley
Y Axis
Drive Motor Y Axis Drive Belt

The Y Axis Stepper Motor is mounted on the top of the Y Axis Extrusion in front of the Y Axis PCB stack.
The encoder disk for the motor is mounted to the motor shaft on the rear (top) of the motor casing. As
opposed to the other encoders that are visible, the Y Axis motor encoder is enclosed and not visible. The
encoder disk is read by an optical sensor. The motor shaft passes through the Y-Axis Assembly and is
attached to a drive pulley that powers the Y drive belt. The Y drive belt moves the Z-Axis Assembly forward
and backward on the arm as shown on Figure 8-32 "Y Axis Drive Belt".
Figure 8-31 Y Axis Stepper Motor
Y Axis
Stepper
Motor
Figure 8-32 Y Axis Drive Belt
Front Pulley
Y Axis
Drive Belt
Drive Motor
Drive Pulley

Z-Axis Assembly
The Z-Axis Assembly attaches through the Y Axis carriage. The Z-Axis Assembly include the mounting bulk-
head, Z axis motor/encoder assembly, bushings and Z axis circuit PCB. A pinion gear is attached to the Z
motor shaft to drive the Z-Rack. The CTS Sample arm differs due to the additional requirements of the CTS
Piercer. These requirements include:
accommodation of the Brake Rack that is used on the CTS Piercer
increased torque for the Z drive motor to enable the piercing of the top of the sample
additional air and cleaner controls to ensure proper cleaning of the piercer probe.
Cleaning the Z-Rack with an isopropyl alcohol wipe on a regular basis is recommended.
The Z Axis Stepper Motor travels with the Z-Axis Assembly as shown on Figure 8-35 "Z Axis Controller
PCB". The encoder disk for the motor is mounted to the motor shaft on the rear of the motor casing. As
opposed to the other encoders that are visible, the Z axis motor encoder is enclosed and not visible. The
encoder disk is read by an optical sensor.
Figure 8-33 Z-Axis Assembly
Z-Axis
Assembly Z Axis
(Bottom Motor
View)
Z Drive
Rack
For the CTS Piercer Arm, a number of changes are made as shown on Figure 8-34 "CTS Piercer Z-Axis
Assembly". The bottom of the Z-Axis Assembly is modified to accommodate the Brake Rack and additional
hardware (and circuitry) that is used to lock the Brake Rack, and CTS Piercer Foot, when a cap is detected
on the sample. The motor assembly is also modified with a gearbox used to increase the torque of the motor
(by a factor of almost 4 to 1) to accommodate the piercer action. In addition, there are two solenoid valves
added to an extension of the Z-Axis Assembly to accommodate requirement for the additional air and fluid
needs in cleaning of the CTS Piercer.

Figure 8-34 CTS Piercer Z-Axis Assembly
Piercer Air & Fluid

Solenoid Valves
Gear Box
Brake Rack Opening
As shown in Figure 8-35 "Z Axis Controller PCB", the Z Axis controller PCB, which is enclosed in a cas-
ing, also travels with the Z-Axis Assembly. The figure also shows the top portion of the Z-Axis Assembly.
Figure 8-35 Z Axis Controller PCB
Z Axis
Controller
PCB
Z-Axis
Assembly
(Top View)
Arm Initialization
On a CTS Sample Arm, each of the three axes (X, Y, and Z) have a home sensor to indicate the arm has
properly moved to the home position on that axis. The X and Y home sensors are the slotted optical travel
limit sensors (see "X, Y, Z Travel Limit Sensors" below) that are interrupted by a flag attached to each axis
assembly. The Z home sensor is a capacitive sensor tied to the Liquid Level Detection (LLD) circuit in the
probe. When an electrical contact is made between the probe bracket and collar on the arm, the probe is
considered home. The home positions are as shown in Table 8-2 "Cavro X, Y, Z Home Positions".

Table 8-6 CTS Sample and IL Double Arm X, Y, Z Home Positions

Table 8-7
Arm/ Axis Home Position
All Z Up
Sample X Rear, right side of the Sample
Area
Left (R1) Reagent X Rear, left side of the Reagent
Arm Area
Right (R2) Reagent X Rear, right side of the Reagent
Arm Area
During the Initialization sequence, the Z-Axis initialization occurs first. This is done to raise the probe and
prevent damage to it when moving the probe along the X and Y axes. The probe initialization routine
involves raising the probe until it triggers the LLD circuit by a metal tab on the probe contacting a steel ring
on the Z-Axis. Once the LLD circuit is triggered, the probe is considered home and the probe is moved down
several steps to offset it from the sensor. During normal operation, the software only enables the probe to
be raised to the upper limit minus the offset to avoid false indications by the LLD circuit.
The X and Y axes also have an travel limit flags and sensors in both the X and Y directions. The sensors are
slotted optical sensors that sense the flag on the arm. The X limit flag are mounted on the assembly and the
sensors are mounted on each side of the Y Driver Board that travel along the X axis with the arm as shown
in Figure 8-18 "X Limit Flags and Travel Limit Sensors".
Figure 8-36 CTS Sample and/or IL Double Arm X Flag and Travel Limit Sensors
Left Side Travel Limit Flag
Travel Limit Sensors
Right
Side
Travel
Limit
Flag

For the Reagent Arms, in addition to the left and right travel limit sensors and flags on the X-Axis Assembly,
there are also limit flags and sensors that ensure there is no collision between the two reagent arms. These
flags and sensors are mounted on the traveling board stacks on the arms as shown in Figure 8-37 "Flags
and Sensors Between Reagent Arms". As shown in the figure, the flags and sensors are duplicated with
two flags and two sensors.
Figure 8-37 Flags and Sensors Between Reagent Arms
X Travel Limit X Travel Limit

Flag Sensor
X Travel Limit X Travel Limit

Sensor Flag
There is one flag and sensor located on both the rear and front of the Y-Axis Assembly. The Y flag is
mounted on the front and rear of the travelling Z-Axis Assembly with the limit sensors mounted on the Y-Axis
Assembly as shown on Figure 8-19 "Y Limit Flag and Travel Limit Sensor".
Figure 8-38 CTS Sample and/or IL Double Arm Y Flags and End of Limit Sensors
Front of Arm Flags Rear of Arm

Sensors

CTS Probe Initialization
The CTS probe initialization is more complex. Home for the probe is similar to other probes, but several
more initialization steps are performed to prepare the CTS probe to run samples. For more information
regarding the initialization routing of the CTS probe see Chapter 15 CTS Piercer.
In addition to the home sensors, the X and Y axes also have travel limit sensors. These sensors functions
the same as the home sensor (and, in fact are used as the sensors for the home position). In the event the
arm exceeds its normal system operating range, the travel limit sensor stops the movement prior to the
assembly hitting its rubber bumper stop. Over travel in the Z-Axis is controlled by software monitoring of the
Stepper Motor and encoder.
When all three arms have initialized, the ACL-TOP runs a coordinates check on the metal openings around
the rinse/clean stations. This action is performed each time the ACL-TOP is initialized to verify that no
changes have happened to the probe tip positions since the last coordinates check. If an error occurs during
this check, the operator prompted to run the coordinates adjust routine in the Diagnostics Menu.
Communications
Communication with the CTS Sample and/or IL Double Arm is through the Can-Bus for the communication
between the master processor in the right rear of the ACL-TOP and the X-Axis Controller PCB. The X-Axis
controller sends commands to the different axes through the white flex cables and completion messages
back to the master processor. The communication cable for the sample arm goes directly from the master
processor to the connector on the sample X-Axis Controller PCB. The communication cable for the reagent
arm goes from the master processor to reagent connector on the reagent arm X-Axis Controller PCB.
PCBs
There are four PCBs that provide control for the CTS Sample and/or IL Double Arms. They are the XYZ
Controller PCB, X Axis Driver PCB, Y Axis Driver PCB, and Z Axis Controller PCB. The interconnections for
these PCBs are shown in 8-3 "Interconnect Diagrams", and their location within the instrument is shown
in Figure 8-39 "CTS Sample and/or IL Double Arm PCB Locations". The following paragraphs describe
the operation of the PCBs.

Figure 8-39 CTS Sample and/or IL Double Arm PCB Locations
XYZ Controller PCB
Y Driver PCB
Z Axis Controller PCB (under cover) X Axis Driver PCB
XYZ Controller PCB
The XY Z Controller PCB, as shown on Figure 8-40 "XYZ Controller Interface PCB, Y-Driver PCB", is the
top PCB of the two PCBs located on the back of the CTS Sample and/or IL Double Arm. It controls all pro-
cessing operations pertaining to the single arm to which it is attached. This PCB contains control circuitry for
all three axes of motion for the arm. Due to the level of resources required to control the arm, there is one
PCB for each Sample and Reagent arm. The PCB contains circuitry to provide for the following functions:
stepper motor drive signals, motion encoders, DIO, voltage monitoring, Liquid Level Detection (LLD),
EEPROM, SPI communications, CAN communications, and RS232 communications.
Y Driver PCB
The Y Driver PCB, as shown on Figure 8-40 "XYZ Controller Interface PCB, Y-Driver PCB", is the bottom
PCB provides of the two PCBs located on the back of the CTS Sample and/or IL Double Arm. It provides Y
axis stepper motor control and Probe DC heating. One PCB accommodates one arm in a two arm assembly.
The Y Driver PCB interfaces directly with the CPU controller to provide software controlled motion and Y
axis positioning. It provides an interface for a motion encoder and interfaces both Phase A and Phase B to
the controller. It provides an interface to the heated probe PCB and provides proportional pulse width mod-
ulated DC heating for two heaters on the probe boards. The Y Driver PCB also provides interconnection for
Y End of travel and Home detection sensors. The X travel limit sensors are directly mounted to the PCB.

Figure 8-40 XYZ Controller Interface PCB, Y-Driver PCB
XYZ
Controller
PCB
Y Driver PCB
X Travel
Limit Sensor
X Axis Driver PCB
The X Axis Driver PCB is mounted below the X-Axis Assembly on five standoffs, as shown on Figure 8-41
"X Axis Driver PCB". It interfaces and drives the X stepper motor for the arm and provides the interface for
the encoders of those stepper motors. If installed on the Reagent assembly, the PCB provides the interface,
drive circuitry, and encoder interface for both arms. The PCB provides CTS capability for the right arm. The
X Driver directly interfaces with the Level III CPU to provide software controlled motion and module position-
ing.
The X Driver PCB drives, using logic FETs, the two solenoid valves located on the Z-Axis Assembly, used
during CTS operation. It interfaces the air pump and fluid pump on the Z-Axis Assembly and provides the
interface for the air pressure sensor.
The X Driver PCB provides the Can Bus interface to the Level II CPU (Master Processor) and two RS232
connections for communication with the diluter pumps.

Figure 8-41 X Axis Driver PCB
LEDs
The Can Bus interface splits to both arms while the RS232 ports are specific to one arm. The RS232 con-
nections also provides the +24V power for two syringe pumps.
As shown on the figure, there are four LEDs on the CCU PCB to help identify error states of the arm. The
LEDs blink slowly if the arms are functioning properly. If the LEDs blink quickly (twice per second) there is a
problem with step loss (slippage). If the LEDs are on constantly, there is a problem with the arm hardware.
Z Axis Controller PCB
The Z Axis Controller PCB is located on the Z axis carriage. The PCB is an interconnect PCB that reduces
the white flex cable down to the orange flex cable that leads to the probe. The PCB contains connectors for
the valves and sensors required for Z home sensing and by CTS equipped arms. The Z Driver PCB is uti-
lized on each of the arms contained in the CTS instrument. This PCB is responsible for signal buffering,
probe RS485 translation for SPI, open-collector sensors, motor encoder, PWM solenoid driving, MOSFET
control, as well as stepper motor control with adjustable power control. The PCB moves with the Z carriage
assembly along the Y axis of the instrument during typical operation.

Figure 8-42 Z-Axis Controller PCB
J8 J9
J5
J1
J3 J4
J2
The Z-Axis Controller PCB has a strain relief cover made of PVC that attaches to the top of the PCB. The
PVC cover provides strain relief to the two flex cables and manages the cable harnesses that route between
the Z-Axis Controller PCB and the probe below. When servicing the Z-Axis Controller PCB, care should be
taken to reinstall the strain relief brackets and manually verify that there are no interferences between the
cable and Y-Axis components.
Probe Alignment and Coordinates Adjustment

Each arm requires knowledge of a set of target locations (e.g. rack containers, cuvette cells, clean / rinse
stations), and each location is defined by X and Y axis coordinate positions as well as 3 Z axis coordinate
positions (Zmax, Zsearch, Zposition). Originally, the coordinate positions are obtained from the CAD model
of the instrument; however, due to mechanical tolerances, the physical geometry of each instrument is dif-
ferent from the one defined by the CAD model due to manufacturing and assembly tolerances, as well as
from mishandling, for example, a bent probe.
It requires 3 reference points to provide the 3-D transformation from the CAD coordinates to the coordinates
of the specific instrument. By knowing how 3 reference points have moved, it can be calculated how all other
points have moved. The system starts with a 3-D CAD model of the ACL-TOP system that is the golden
model and provides the coordinates of all reference points and targets, referred to as master reference
coordinates and master target coordinates. These master coordinates serve as the basis for all proce-
dures performed on the AM.
The Probe Alignment procedure consists of measuring the position of a set of reference points using the
probe Liquid Level Detection (LLD) capability.

The Coordinates Adjustment procedure is a method used by the software to adjust the CAD coordinates
of all positions reachable by the arms to account for variances in the actual instrument geometry. (The flow-
chart of the Coordinate Adjustment procedure is included in the "Probe and Arm Initialization Flow-
charts" section of this chapter.)
The coordinate adjustment starts by locating reference points, using the master reference coordinates from
the CAD model, and establishing correlations, or offsets, to those reference points for the instrument. The
correlation calculation results in a transform matrix, that, once established, is used to calculate actual coor-
dinates of all targets and the difference for any specific point. The actual reference point coordinates are
saved in a file, to enable the instrument to adjust the coordinates at every startup without measuring refer-
ence points every time.
To minimize the number of points required to adjust the coordinates, target locations are grouped together
into modules. A module is defined as a set of mechanical components that maintain their 3-D relationship
throughout the systems lifetime, from assembly to years of operation. For example, the clean, waste, and
rinse wells are built into a single mold. ORUs 1 to 4 share the same base. A module is characterized in 3-D
by 3 reference points.
Reference Point Positions
The diagrams in this section show the reference point positions for each configuration of the TOP Instru-
ment.
Figure 8-43 "Reference Point Positions for Base TOP Instruments (Cavro Arms)" shows the reference
point positions for Base TOP Instruments with Cavro Arms.
Figure 8-44 "Reference Point Positions for CTS Instruments" shows the reference point positions for
CTS Instruments.

Figure 8-43 Reference Point Positions for Base TOP Instruments (Cavro Arms)
Shuttle
Home
Shuttle Mechanism Zone
S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S R 1 1 R 1 1
l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l 2 2 2 2
R R R R R
o o o o o o o o o o o o o o o o o o o o o o Ro o o o o o o o o o o o o o o o o o 3 3 3 3
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t 4 4 4 4
R
# # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # #
1 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ORU #1 ORU #2 ORU #3 ORU #4
0 R 0 1 2 3 4 R R
Cuvette Indexer CTS Hold Area INCUBATOR #1 INCUBATOR #2
Sample Station Reagent#1 Station Reagent#2 Station

R R R
Cuvette Pivot Arm
PC PW PR PC PW PR PC PW PR
R R R R R R
1 1 1 2 2 2 3 3 3
Clean Waste Rinse Clean Waste Rinse Clean Waste Rinse

CUVETTE
1 1 1 1 1 1 1 1 1 1 1 1 WASTE
1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 R R R
R
3 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 2 2
4 4 4 4 4 4 4 4 4 4 4 4
3 3 3 3 3 3 3 3 3
5 5 5 5 5 5 5 5 5 5 5 5
Cuvette Load
6 6 6 6 6 6 6 6 6 6 6 6 4 4 4
4 4 4 4 4 4
7 7 7 7 7 7 7 7 7 7 7 7 5 5 5
8 8 8 8 8 8 8 8 8 8 8 8 6 6 6
R
5 5 5 5 5 5
R
9 9 9 9 9 9 9 9 9 9 9 9 R 7 R 7 7 R R R
1 1 1 1 1 1 1
B 1 6 16 16 6 6 6
1 8 8 1 8
0 0 0 0 0 0 0 0 C
0 0 0 0
S S S
S1 S2 S3 S4 S5 S6 S7 S8 S9 10 11 12 D1 D2 - D3 R1 R2 R3 R4 R5 R6
H
Reagent Arm #1
O Zone- Logical
M Arm #2 Reagent Arm #2 Zone -
Logical Arm #3
Sample Arm Zone - Logical Arm #1 E
R Reference point
Barcode Reader Module ( BC ) Zone
Figure 8-44 Reference Point Positions for CTS Instruments
Shuttle
Home
Shuttle Mechanism Zone
S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S R 1 1 R 1 1
l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l 2 2 2 2
R R R R R
o o o o o o o o o o o o o o o o o o o o o o Ro o o o o o o o o o o o o o o o o o 3 3 3 3
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t 4 4 4 4
R
# # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # #
1 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ORU #1 ORU #2 ORU #3 ORU #4
0 R 0 1 2 3 4 R R
Cuvette Indexer CTS Hold Area INCUBATOR #1 INCUBATOR #2

Sample Station
R Reagent#1 Station Reagent#2 Station
Cuvette Pivot Arm R R
waste PC PW PR
PC1 R PC PW PR
wash R R R
3 3 3
R
2 2 2
R
Clean Waste Rinse Clean Waste Rinse
Clean CUVETTE
1 1 1 1 1 1 1 1 1 1 1 1 WASTE
1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 R R R
R
3 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 2 2
4 4 4 4 4 4 4 4 4 4 4 4
3 3 3 3 3 3 3 3 3
5 5 5 5 5 5 5 5 5 5 5 5
Cuvette Load
6 6 6 6 6 6 6 6 6 6 6 6 4 4 4
4 4 4 4 4 4
7 7 7 7 7 7 7 7 7 7 7 7 5 5 5
8 8 8 8 8 8 8 8 8 8 8 8 6 6 6
5 5 5 5 5 5
R R
9 9 9 9 9 9 9 9 9 9 9 9 R 7 R 7 7 R R R
1
B 6 6 6 6 6 6
1 1 1 1 1 1 1 1 1 1 1 8 8 8
0 0 0 0 0 0 0 0 0 0 0 0 C
S S S
S1 S2 S3 S4 S5 S6 S7 S8 S9 10 11 12 D1 D2 - D3 R1 R2 R3 R4 R5 R6
H
Reagent Arm #1
O Zone- Logical
M Arm #2 Reagent Arm #2 Zone -
Logical Arm #3
Sample Arm Zone - Logical Arm #1 E R Reference point
Barcode Reader Module ( BC ) Zone

Reference Point Search
The adjustment operates on the premise that reference screws are, by definition, circular. The probe diam-
eter is slightly narrower at the tip than the base and may come in contact from the side and cause a false
detection. Also, the probe is not necessarily perfectly aligned vertically or, a droplet may lie at the tip of the
probe. To alleviate these differences, 2 consecutive contacts are made for each point searched. If there is
a substantial height difference between the two contacts, the first contact is rejected. If a droplet is present,
it is dissipated on the first contact and cause the second contact to fail, and the scan resumes as if no con-
tact was made.
Figure 8-45 Reference Screw Detection
2
1
Measurement of the Reference Screw Position
The nominal position of reference screws is the center of the screw head. The probe has to measure the
position of three points on the external circumference of the head and calculate the coordinates of the cen-
ter. Because the edges of the screw head are not vertical, to measure the Z coordinate of the screw head,
the probe has to touch the highest part of the head after the X and Y coordinates of the center have been
calculated.
The following describes the procedure used to measure the coordinates of a reference screw.
1. Set the start position
a. For the first screw in the module, the start searching position is set as follows:
XStartSearch: Xcad ScrewRadius / 2

YStartSearch: Ycad
(We don't start at the coordinates of the center of the screw head to avoid the hole)
b. The LLD start and end position for the first screws are set as follows:
ZStartLld = 9.75mm above Zcad

ZEndLld = 2.75mm above Zcad
These values are very conservative to avoid hitting the rack area plate.
c. For the second and third screws of each module, the start position is adjusted taking into account the
measured position of the first screw; in this way the instrument is able to touch the second and third
screw at the first attempt
2. Touch the screw head
a. The probe performs LLDs until the screw is touched. The size of searching area is 20.88mm on X
and 11mm on Y.

b. If the screw is not found, the instrument performs another attempt updating the LLD start and end
position as follows:

ZEndLld = 3.25mm below Zcad
c. If the screw is not found, the instrument performs another attempt updating the LLD start and end
position as follows:
ZEndLld = 5.5mm below Zcad
If the screw is not found, the procedure is aborted and an error condition is reported.
3. Measure the X and Y coordinates of the screw center.
a. Starting from the position where the screw was touched the first time, the probe measures the posi-
tion of three points on the external circumference of the screw head.
b. The X and Y coordinates of the center are calculated based on the three measured points.
4. Measure Z coordinate
a. Once the X and Y coordinates of the center are known, the probe scans the screw head to measure
the screw height, keeping track of the highest point touched.
b. To achieve the maximum accuracy and avoid outliers, the height of the screw is measured three
times, and the lowest result is used as measured screw height.
NOTE:The third screw in the incubator, ORU and holding area modules
are too close to the indexer assemblies for running the entire
measurement procedure. For these screws, only the Z coordinate is
measured.
Z and Y coordinates are calculated as follows:
XLastScrewmeas XFirstScrewmeas + (XLastScrewcad - XFirstScrewcad)
YLastScrewmeas YFirstScrewmeas + (YLastScrewcad - YFirstScrewcad)
Waste stations Reagent and Cavro Arm Sample Probes
Three reference points are measured on the metallic contour of the waste station: two reference points at
the extremities of the X-axis and one reference point on the extremity of the Y-axis. For each reference
point, X, Y, and Z coordinates are recorded. Each Z coordinate is found by lowering the probe until it meets
the contour surface of the station. As with screws, for each of the 3 points, 2 successive contacts must be
made to determine a point.
Due to the unconventional shape of the waste station, it is considered a rectangle when searching. There-
fore, the locating procedure starts by moving the probe to the center of the station, and then moving along
the Y-axis (1) until the top edge is found. This is the largest linear edge of the station and reduces the pos-
sibility of hitting the circular edge. Knowing the dimension of the station, the probe can be positioned at the
center (relative to the Y axis) of the station and then moved along the X-axis to find both edges (2 & 3).
Only Y and Z coordinates can be measured for the first reference point, while only X and Z can be measured
for second and third point. The non-measured coordinates are calculated as follows:

X1measured = (X2measured + X3measured) / 2

Y2measured = Y1measured + (Y2cad - Y1cad)
Y3measured = Y2meas
Figure 8-46 Well Area Cutout Reference Points for Non-CTS Probes
1
R 2 R R 3
X R R R R R R
Waste Stations CTS Sample Arm Sample Probes
The sample area waste station reference points on CTS Sample Arm instruments are in different positions,
because the sneeze guard makes the left edge unreachable. Also, the sample probe could have the CTS
piercer, and the system must be sure to touch the reference surface with the sample probe tip rather than
with the piercer. Therefore, the process starts by moving the probe along the Y-axis until the bottom edge
(1) and the top edge (2) are found. Knowing the dimension of the station, the probe can be positioned at the
center (relative to the Y axis) of the station and then moved along the X-axis to find the right edge (3).
Only Y and Z coordinates are measured for the first two reference points, while only X and Z are measured
for the third point. The non-measured coordinates are calculated as follows:
X1measured = X3measured + (X1cad - X3cad)

X2measured = X1measured
Y3measured = (Y1measured + Y2measured) / 2
Figure 8-47 Well Area Cutout Reference Points for CTS Probes
2
R R R
X
R R R
R R R 3
Y 1
Air gaps
To reduce the formation of droplets below the probe tip, at the beginning of the alignment procedure, the
syringe is initialized and a 250 milliliter air gap is aspirated. The air gap is removed and aspirated again
when the probe moves to the next module; to avoid the formation of air bubbles, before removing the air gap
the probe is filled with rinse liquid by running the rinse pump.
Coordinates File
When the probe alignment procedure is successfully completed (i.e., the probe has measured all reference
points) the measured coordinates are saved in a file.

The file name and path are: C:\Program Files\IL\ACL-TOP\AMSw\FTPBoot\Coordinates\XX-XX-XX-XX-XX-

XX-coor.dat where XX-XX-XX-XX-XX-XX is the MAC address of the master PCB Ethernet network adapter.
The file has a header section and a data section.
The header section contains the:
Cyclic Redundancy Check (CRC) of the data section, to detect data corruption
File version, to be sure that the file is compatible with the software running on the instrument.
The data section contains the measured coordinates of the reference points for all probes.
The file is read at startup and after each recovery operation after an emergency stop. If the file is not
present, or the file version doesn't match with the software running on the instrument, or no data is written
for one or more probes, an alarm is reported and the instrument status is set to error.
Coordinate Calculation and Check
After power up, the coordinates of each target location are calculated, to adjust the CAD coordinates based
on the latest measurement. This calculation does not require any mechanical movement, but requires
access to the measured coordinates of each reference point, as well as the CAD reference point coordi-
nates. The measured coordinates are read from the coordinates file and the CAD coordinates are hard
coded in the software running on the master PCB.
With this information, the transform matrix for each module is calculated, and all target location coordinates
are adjusted according to the transform matrix. After all target coordinates are adjusted, an alignment check
is performed to ensure that the last coordinates adjustment is still accurate. The alignment check involves
measuring the coordinates of reference points in the waste module and comparing these coordinates with
the last measured coordinates read from the coordinate file. If the expected and measured coordinates are
not within tolerance, then the alignment check fails, and the probe must be re-aligned. The instrument can-
not run jobs until the probe alignment is performed.
CTS Instruments Alignment of Piercer Probe Foot to the Wash Station
CTS instruments must be able to insert the foot into the wash station during wash and priming operations.
The mechanical tolerances between sample probe and external surface of the foot make collisions between
the foot and edge of wash station possible even if the probe is aligned. For this reason, the piercing probe
has to align the foot inside the wash station, overwriting the adjusted X and Y coordinates of the wash sta-
tion with the coordinates measured during the foot alignment.
Since both wash station edge and foot are made by non-conductive materials, the instrument uses the cap
detection mechanism instead of the liquid level detection.
The foot alignment is executed:
During the probe mechanical initialization (at startup and via diagnostics)
After the arm homing performing the Maintenance Routine Clean
At the end of the probe alignment procedure
The foot alignment procedure is not executed if the measured coordinates of the wash station reference
points are not available.
The following list describes the alignment procedure:

1. Set start and cap detection positions.

XStartSearch: Adjusted X coordinate of the wash station
YStartSearch: Adjusted Y coordinate of the wash station
The cap detection start and end position are defined as follows:
zStart: the bottom face of the foot 6mm is above the measured Z coordinate of the wash reference
points
zEnd: the bottom face of the foot 3mm below the measured Z coordinate of the wash reference
points
2. Insert the foot inside the wash station.
The probe performs cap detections until no surface is detected below the foot. The size of searching area is
5mm on both X and Y axes.
3. Measure position of the left and right edges.
a. The probe moves on the X axis to detect the wash station edge on the left and on the right of the
position found by the previous step.
b. The probe is then moved on the X axis to the middle position between the two edges. (Note: This
position maybe still be inaccurate, because the start search position could be far from the center on
both axes.)
4. Measure the position of the top and bottom edges.
a. The probe moves on the Y axis to detect the wash station edge and on the bottom of the position
found by the previous step.
b. The probe is then moved on the Y axis to the middle position between the two edges.
5. Measure the position of left and right edges.
a. The probe moves on the X axis to detect the wash station edge on the left and on the right of the
position found by the previous step.
b. The probe is then moved on the X axis to the middle position between the two edges.
6. Update the coordinates.
a. The position of the probe at the end of the previous step defines the measured X-Y position of the
wash station.
b. The X and Y adjusted coordinates of the wash station are replaced by the X and Y coordinate of the
current position of the probe.
The foot alignment procedure fails if any of the following conditions exist:
The measured coordinates of the wash station reference points are not available.
The foot cannot be inserted into the wash station (the cap detection always reports surface found).
The edges are not found (Moving toward the edges, the cap detection never reports surface
found).
When the procedure fails, the instrument reports the alarm Coordinates check failure.
The following probe errors are corrected by the foot alignment procedure:
Probe not accurately inserted into the Probe body
Probe Bent

The following arm errors are corrected by the foot alignment procedure:
The circuit PCB with the home flag has a high tolerance due to large fixing holes.
The home flag is bent.
The arms have a certain weight that can cause them to tilt around the X axis, towards the racks.
The following errors are not correctable by the foot alignment procedure:
Mechanical assembly errors
Component does not meet the size and assembly specifications (Transform matrix corruption,
adjustment failure).
Improper installation of the component to the chassis.
Probe pipetter not accurately inserted into probe body (Probe cannot reach the reference
point).
Reference screw is not completely tightened.
Reference screw is not grounded.
Arm motor slippage that may go unnoticed by the Cavro software. (Note: The CTS Sample arm
controller monitors the motor slippage but a small amount of slippage is tolerated.)
LLD is not functional. This will generate software exception when the arm slowly makes contact with
the reference point: Steps loss on Z axis - cavro error 22 (cavro arms), Slippage on Z Axis (CTS
Sample Arms).
LLD falsely triggers. (Transform matrix corruption or alignment procedure failure.)
Mechanical modules not grounded (alignment procedure failure).
Arms not at 90 degrees.

Probe and Arm Initialization Flowcharts

This section contains flowcharts of the Probe and Arm initialization procedures.
Probe and Arm Initialization on CTS Sample and/or IL Double Arm
Figure 8-48 "CTS Sample and/or IL Double Arm Initialization" is the flowchart for CTS Sample and/or IL
Double Arm initialization.
Figure 8-48 CTS Sample and/or IL Double Arm Initialization
Figure 8-49 "Probe Initialization for CTS Sample Arms" is the flowchart for the initialization of probes on
CTS Sample Arms.

Figure 8-49 Probe Initialization for CTS Sample Arms

Probe and Arm Initialization on CTS Sample Arms
Figure 8-50 "Probe Initialization for CTS Sample Arms" is the flowchart for the initialization of probes on
CTS Sample Arms.
Figure 8-50 Probe Initialization for CTS Sample Arms

IL Double Arm Homing Procedure Flowchart
Figure 8-51 "IL Double Arm Homing Procedure" contains the flowchart for the IL Double Arm Homing
Procedure. Note that the Home sensor referenced in the procedure is the travel limit sensor for the direction
in which the arm home position is located.
Figure 8-51 IL Double Arm Homing Procedure

Probe and Arm Initialization on Cavro Arms
Figure 8-52 "Probe Initialization for Cavro Arms" is the flowchart for the initialization of probes on Cavro
Arms.
Figure 8-52 Probe Initialization for Cavro Arms

Coordinates Checking Procedure Flowchart
Figure 8-53 "Coordinates Checking Procedure" contains the flowchart for the Coordinates Checking
Procedure.
Figure 8-53 Coordinates Checking Procedure

Tube Release Procedure Flowchart
Figure 8-54 "Tube Release Procedure" contains the flowchart for the Tube Release Procedure.
Figure 8-54 Tube Release Procedure

Verifying a CTS Arm or a Universal Dual Arm

1. Initialize all arms on the Instrument. Refer to "Diagnostics" for details.
2. Upon successful initialization of the arms, perform a coordinates adjustment for each arm on the instru-
ment. Refer to "Coordinate Adjust".
3. Perform an LLD check for all arms. See "Probe LLD Error Troubleshooting".
Alidum Resistance Check

1. Disconnect the coaxial cable from the arm.
2. Measure the resistance between the center pin and the outside case of the coaxial cable.
3. The proper resistance is 7500 ohms +/- 1000 ohms.
4. If the resistance is more than expected or infinite, the Alidum assembly should be replaced.
8-6 Diagnostics
Probes Tab of Diagnostic Screen

The diagnostics for the XYZ Robotic Arms are on the Probes tab as shown on Figure 8-55 "The Probes
Tab". The Probes tab contains five main areas: the Temperature log area, the LLD area, the Rinse area,
the Clean area, and the Move area. In addition to the five main areas, the Probes tab contains six high-level
functions for the XYZ Robotic Arms. The six functions are
"Initialize All Arms"
"Home All Arms"
"Disable Sample Arm"
"Disable Reagent Arms"
"Coordinate Adjust"
"Set Valve"

Figure 8-55 The Probes Tab

Initialize All Arms
The Initialize All Arms button consists of homing the arm, moving it to the wash/clean station, priming the
rinse, and priming the clean. The arms cannot be initialized individually due to the risk of collisions and leak-
age.
The Arm Status field shows the initialization state for the arms. The possible values in this field are
Unknown, Not initialized, Initialization in progress, Busy, Error, and Ready.
In the event of an error, the possible causes are displayed in the Alarms section. With the exception of the
Initialize All Arms command, commands involving arm movements sent to an arm that is not initialized are
ignored to avoid generation of error conditions.
Home All Arms
The Home All Arms button sends all arms to their home positions. Selecting this button causes the arms
to go to their home positions without initializing them. Refer to "Arm Initialization" for a detailed description
of the home position for each Robotic Arm.
Disable Sample Arm
The Disable Sample Arm button disables, i.e., powers off, the Sample Arm. When the Sample Arm is dis-
abled, it can be moved by hand. This allows access to the left (Sample) side of the instrument.
Disable Reagent Arms
The Disable Reagent Arms button disables, i.e., powers off, the Reagent Arm. When the Reagent Arm
is disabled, it can be moved by hand. This allows access to the right (Reagent) side of the instrument.
Coordinate Adjust
The Coordinate Adjust button initiates a complete probe coordinates adjustment. The probe to be
adjusted is selected from the Probe pull-down list.
NOTE: Before the Coordinate Adjustment is performed, all interior covers must be removed
from the Sample and Reagent modules. See Sample Area Interior Skins Removal in
Chapter 4 and Reagent Area Interior Skins Removal in Chapter 4 for instructions on
removing the covers.
The Coordinate Adjust is typically performed when the probe needs to be adjusted for the first time, or after
a mechanical repair. If there are racks in the modules, or the bar code reader is not home, the Coordinate
Adjust cannot be performed and the operator is notified. During the adjustment, the bar code reader cannot
be moved by either the Analytical Module or Control Module track buttons until the operation is finished.
When a probe is selected from the Probe pull-down list, the screen displays the steps lost on the Arm since
the last initialization and the steps lost since the Instrument Startup. This information is shown for the X, Y,
and A axes.It is possible that a high number of Z steps will show as being lost (typical error values are 40-
44 step lost). The number of steps lost during a positive calibration test is 1 or 2 maximum.

Set Valve
The Set Valve button sets the pump valve for the selected Probe to Input, Output, or Bypass based on
the corresponding radio button. The probe to be used is selected from the Probe pull-down list. This button
is used to test the valve to ensure it switched positions correctly.
LLD Area
The LLD area of the Probes tab, as shown on Figure 8-56 "LLD Area of Probes Tab", is used to investi-
gate problems with Liquid Level Detection and as an alternative method for performing alignment checks.
When the Start button in this area is clicked, the system performs an LLD on the container (Bottle type)
that is in the location specified by the Module, Slot, and Position pull-downs in the LLD area.
Figure 8-56 LLD Area of Probes Tab
The Mode pull-down selections specify the conditions for stopping the LLD. The modes and when they
cause a stop are:
Stop on failure - The LLD stops upon detection of any failure.
Stop always - The LLD stops after one cycle.
Dont stop - The LLD stops upon completion of the number of cycles specified in the #cycles box.
The number of LLD cycles is determined by the #Cycles entry. If Stop always is selected as the mode, the
number of cycles is set to one.
The Stop button is used to stop an LLD in progress.
The number of successful LLDs is displayed in the Passes field; the number of failed LLDs is displayed in
the Failures field. Table 8-8 "LLD Module, Slot, and Position Settings" shows the Module, Slot, and Posi-
tion values that are available for each Arm.
Table 8-8 LLD Module, Slot, and Position Settings
Arm Module Track/Slot Position
Sample Sample Rack S1-S12 1-10
Diluent Rack D1-D2 1-8
CTS 2-14 1-4
Incubator 1 1-8 1-4

Table 8-8 LLD Module, Slot, and Position Settings
Clean 1 1
Reagent Arm 1 Diluent Rack D3 1-8
Reagent Rack R1-R4 1-6
Incubator 2 1-8 1-4
Clean 1 1
Reagent Arm 2 Reagent Rack R3-R6 1-6
ORU 1-4 1-4
Clean 1 1
Rinse Area
The Rinse area of the Probes diagnostic screen, as shown on Figure 8-57 "The Rinse Area", is used to
start and stop a probe rinse and to specify the duration of a probe rinse. The virtual LED labeled Pump
turns green when the rinse pump is running and the rinse is in progress.
Figure 8-57 The Rinse Area
The Duration field specifies the length of time (in seconds) of the rinse cycle. Select the Start button to
start the pump rinse; select the Stop button to stop a pump rinse cycle in progress.
The Flow Rate Test is used to determine if the rinse pumps are functioning properly and to detect any kinks
in the tubing between the rinse pumps and the probes. The Start button control the start of the test. The
Stop button can be used to stop a test in progress.
When the test is started, the selected probe is moved to a predefined XY position and to the maximum
height to allow the placement of a graduated container beneath the probe. The positions XY where each
probe shall be moved are the following:

Sample ArmSample Track 6, Position 5

Reagent Arm 1Reagent Track 3, Position 3
Reagent Arm 2Reagent Track 3, Position 3
If there is another probe in the same area it will be homed.
Once the container has been placed beneath the probe, the Start button in the Rinse area is clicked to run
the rinse pump for the specified duration. When the Flow Rate Test is performed, the Rinse Test runs the
rinse pump without moving the probe to the rinse station. The Stop button is clicked on to discontinue the
test. The volume mean must be 5.10mL (-0.3mL /=0.5mL). The flow rate mean must be 1.03 mL/ sec(-.06mL
// =0.10mL). Measurements should be taken using a graduated container.
Clean Area
The Clean portion of the Probe diagnostic screen, as shown on Figure 8-58 "The Clean Area", causes the
system a to run a Probe Clean cycle. A Probe Clean cycle consists of
filling the Clean Cup
aspirating the Clean-A fluid
dispensing the Clean-A Fluid into the Waste Fluid Accumulator
and rinsing the Probe.
Figure 8-58 The Clean Area
When the Start button is clicked on, the system performs a Clean Cycle in the specified location for the
selected Arm. (The location is specified with the Module, Slot, and Position pull-downs.) Table 8-9 "Select-
able Cleaning Locations" lists the Modules, slots, and positions that can be selected for each arm.

Table 8-9 Selectable Cleaning Locations
Arm Module Slot Position
Sample Diluent Rack D1-D2 1-8
Clean 1 1
Clean 1 1
Clean 1 1
The following fields can be used to specify additional parameters for the Clean Cycle:
Hold Time The Clean Hold duration in seconds.
Volume The Clean Volume in uL.
Enable agitation Click this box to enable Clean Agitation.
Air gap The first air gap in uL.
Transport Air gap The Transport air gap in uL.
The Stop button stops a Clean Cycle in progress.
Move Area
The Move area, as shown on Figure 8-59 "The Move Area", is used to move material from one position to
another.
The Source and Target locations for the material are selected from the respective pull-down lists (Module,
Slot, and Position). The #Cycle field is used to specify the number of repetitions for the move activity. The
Start button initiates the movement of material. The Stop button stops the movement after the current move
cycle is completed.
NOTE: The Emergency Stop button stops the current movement.

Figure 8-59 The Move Area
Table 8-10 "Allowable Source and Destination Positions" shows the allowable source and destination
positions for each arm.
Table 8-10 Allowable Source and Destination Positions
Sample Arm Sample Rack S1-S12 1-10
Diluent Rack D1-D2 1-8
Predilution Area 2-14 1-4
Incubator 1 1-8 1-4
Reagent Arm 1 Diluent Rack D3 1-8
Reagent Rack R1-r4 1-6
Incubator 2 1-8 1-4
ORU 1-4
Use the following fields to specify additional parameters for moves:

Volume The Volume of material to be moved (in uL).
Air gap The first air gap in uL.

Transport Air gap The Transport air gap in uL.

Head The Head Volume (in uL) for the material move.
Probe Troubleshooting
The flowchart in Figure 8-60 "Probe Troubleshooting Flowchart" is to be used for performing functional
tests after replacing, or repairing, a Probe component.
NOTE: If repairs are made to a specific component, follow the maintenance guidelines for the
component. After a repair, leave the instrument initialized and in the READY state.

Figure 8-60 Probe Troubleshooting Flowchart

Probe LLD Error Troubleshooting
This procedure is to investigate major problem with the LLD system. In the case of minor problems with the
LLD system, such as liquid level detection errors in specific areas or specific containers, it's recommended
to use the specific LLD test in the service program (see Figure 8-61 "LLD Diagnostics") to reproduce the
error conditions.
Figure 8-61 LLD Diagnostics
Cavro Probe Troubleshooting
The first check has to be done using a digital multi-meter device (DVM) set on the Ohm measurement.
1. Connect the DVM probe on the test point as shown in Figure 8-62 "DVM Probe Connections" (GND /
SIGNAL). These are the 2 test points of the LLD coaxial cable that connect the probe to the LLD board
inside the arm movement assembly.
Figure 8-62 DVM Probe Connections
Signal
Ground
2. A value in the range 5KOhm to 8KOhm is in the working range. A lower value (typically 200-300 Ohm),
indicates a problem in the probe, coaxial cable or the assembly.
3. Check the following (see Figure 8-63 "Probe Visual Inspection"):
The tubing connector bar must be straight. If the tubing connector bar (at signal level) is bent, once
the probe is assembled, the bar touches the Z-rod assembly (at GND level). This causes a short cir-
cuit in the LLD system.

The hole in the probe assembly that is the housing for the Z-rod assembly must be dry. Any liquid
drop, however small, may generate random or persistent short circuits between the Z-rod assembly
(at GND level) and the tubing connector bar (at signal level).
Figure 8-63 Probe Visual Inspection
Housing for Tubing

Z-Rod Connector
Assembly
Bar
Universal Arm Diagnostic Screen

The diagnostics for the CTS Sample and/or IL Double Arms are on the Universal Arm tab as shown on Fig-
ure 8-64 "Diagnostic Screen - Universal Arm". The Probes tab contains four main areas: the "Sensors
Area", the "Intermediate Arm Area" area, the "Start Arm Area" area, and the "ZDAC Check" area. Each
of these areas are described following the figure.

Figure 8-64 Diagnostic Screen - Universal Arm

Sample Arm Area
The Sample Area of the Universal Arm Dignostic screen consists of a Sensors, Encoder Limits, Encoder,
and LLD Frequency Area. Each of these area are described below.
Sensors Area
The sensors area includes virtual LEDs for five sensors, as listed and described below.
X Home - When red, this virtual LED indicates the Arm is in the home position on the X Axis, to the far right
of the Sample area, and has caused the Home sensor to be interupted. The LED is green when the limit
switch is not interrupted.
Y Home - When red, this virtual LED indicates the Arm is in the home position on the Y Axis, to the extreme
rear of the Sample area, and has caused the Home sensor to be interupted. The LED is green when the limit
Y Limit -When red, this virtual LED indicates the Arm is at the limit of the Y Axis, the extreme front of the
Sample area, and has caused the limit sensor to be interupted. The LED is green when the limit switch is
not interrupted.
Z Home - When red, this virtual LED indicates the Arm is at the Home position on the Z Axis, all the way up,
as indicated by the encoder value.
Encoder Limits
There are encoder limits that can be set for the X, Y, and Z Motors using the UP and DOWN arrows to the
right of the entry box. These limits determine the amount of slippage the arm is permitted during one oper-
ation, before causing an error. Any number between 1 and 9999 can be entered; however, the suggested
settings are: X Motor: 4, Y Motor: 4, Z Motor: 30. The Set button at the bottom of the area causes the limits
that have been entered in the input boxes to be stored in the system for use in error checking.
Encoder
The Encoder area displays the current encoder counts for the X, Y, and Z Arms. These counts indicate the
location of the arm and should be at maximum value when the arm is at its limits. Typical values for each
are are as follow:
X: Arm all the way to the right: approx. -500, Arm all the way to the left: approx. 16500.
Y: Arm all the way to the front: approx. 14200, Arm all the way to the back:approx. 0.
Z: Arm all the way to the top:approx. -7500, Arm all the way to the bottom: approx. 23400.
LLD Frequency
The LLD Frequency displays the frequency count of the Liquid Level Detection circuit. The LLD frequency
can be used to check the LLD circuit. With no contact, the Sample Arm should be about 900 counts when
the probe is not in contact with anything and 0 when touching a coordinate screw.

Intermediate Arm Area
The Intermediate Arm Area of the Universal Arm Dignostic screen consists of a Sensors, Encoder Limits,
Encoder, and LLD Frequency Area. Each of these area are described below.
Sensors Area
X Home - When red, this virtual LED indicates the Arm is in the home position on the X Axis, to the far left
of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit
rear of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit
Reagent area, and has caused the limit sensor to be interupted.The LED is green when the limit switch is
not interrupted.
Encoder Limits
Encoder
are are as follow:
LLD Frequency
can be used to check the LLD circuit. The Intermediate Arm should be about 900 counts when the probe is
not in contact with anything and 0 when touching a coordinate screw.

Start Arm Area
The Start Arm area of the Universal Arm Dignostic screen consists of a Sensors, Encoder Limits, Encoder,
and LLD Frequency Area. Each of these area are described below.
Sensors Area
X Home - When red, this virtual LED indicates the Arm is in the home position on the X Axis, to the far right
of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit
rear of the Reagent area, and has caused the Home sensor to be interupted.The LED is green when the limit
Reagent area, and has caused the limit switch to be interupted. The LED is green when the limit switch is
not interrupted.
Encoder Limits
Encoder
are are as follow:
LLD Frequency
can be used to check the LLD circuit. The Start Arm should be about 900 counts when the probe is not in
contact with anything and 0 when touching a coordinate screw.
ZDAC Check
The ZDAC (Z Digital to Analog Converter) portion of the screen is not used at present..

8-7 Removal/Replacement Procedures
CTS Arm (283777-00) Removal/Replacement
Closed Tube Sample (CTS) Arm Removal
CAUTION: Ensure that the instrument is powered OFF before you perform
1. Remove the Top Skin, Center Skin, Upper Skin (sample side), Inner Left Skin, and the interior Sample
Skins as described in Chapter 4 Enclosure/Chassis.
2. Remove the Telescoping CTS Assembly as described in Piercer Probe Removal/Installation in
Chapter 15.
3. Disconnect the rinse bottle coupling from the Fluidic I/O panel.(This should be done prior to any servic-
ing of the fluid system. It prevents leaks and siphoning.)
4. Disconnect the fluid pump sensor cable from the 6-pin connector on the side of Bulk Fluidic Assembly.
(See Figure 8-65 "CTS Bulk Fluid Connections".)
5. Disconnect the rinse input and output fittings from the CTS Bulk Fluidic Assembly as shown on Figure
8-65 "CTS Bulk Fluid Connections"
Figure 8-65 CTS Bulk Fluid Connections
Rinse Input &

Sensor Cable
Output
6 Pin Connector
Connectors

6. Disconnect the following cables from the X Axis Driver PCB. (See Figure 8-66 "Sample CTS X Axis
Driver Cable Connections").
4-pin cable (286526-00) on J7 to the syringe pump
6-pin cable on J11 from the bulk fluid assembly
4-pin cable (286519-02) on J3 to the PC104 Board
14-pin power distribution cable (286539-01) on J9 from the fuse board.
5-pin cable (286514-00) on J13 from the air pump sensor.
Figure 8-66 Sample CTS X Axis Driver Cable Connections
J9
J11
J13 J3
J5
J7
LED Front of Board LED

7. Unscrew and remove the precision (probe) tubing from the Syringe Pump Valve (see Figure 8-67
"Syringe Pump Tubing"). (Fluid will drain from the probe.)
8. Carefully pull the Rinse tubing from the barbed fitting (see Figure 8-67 "Syringe Pump Tubing").
malfunction.

Figure 8-67 Syringe Pump Tubing
Precision
(Probe)
Rinse Tubing
Tubing
9. Using a tubing cutter, trim the rinse line by 1/4. (This removes the part of the line that was stretched
over the barbed fitting.) Move the rinse line from the interior of the Bulk Fluidics Assembly to enable the
removal of the assembly.
10. Loosen the three captive mounting screws securing the syringe pump and Bulk Fluidics Assembly to
the Sample Arm and slide the module out as shown on Figure 8-68 "CTS Fluidics Mounting".
Figure 8-68 CTS Fluidics Mounting
Mounting
Screws

11. Remove the syringe pump cable from the 15 pin electrical connector on back of syringe pump as
shown on Figure 8-69 "Syringe Pump Cable".
Figure 8-69 Syringe Pump Cable
Rear of Syringe Pump
Syringe Pump Cable
12. Remove the end of the polyurethane tubing coming from the top of tube guide to the right angle fitting
on the air Sample arm valve assembly. Pull the tubing through the grommet on the top of the air valve
bracket as shown on Figure 8-70 "Air Tubing to Arm".
Figure 8-70 Air Tubing to Arm
Air Valve
Bracket
Grommet
Air Line
Connection
13. Using a 5mm Allen wrench, remove the four mounting screws as shown on for the CTS Arm Assembly
and lift and remove the CTS Arm Assembly from the left and center pylons.

Figure 8-71 CTS Arm Assembly Mounting Screws
Mounting Screws
Closed Tube Sample (CTS) Arm Installation
1. Mount CTS arm assembly on the left and center pylons. Ensure the arm assembly is aligned with the
alignment pins on the pylon.

2. Insert and secure the four mounting screws securing the assembly using a 5mm Allen wrench as shown
on Figure 8-72 "CTS Arm Assembly Mounting Screws"
Figure 8-72 CTS Arm Assembly Mounting Screws
Mounting Screws
3. Connect the following cables to the X Axis Driver PCB (see Figure 8-73 "CTS X Axis Driver PCB
Cable Connections":
NOTE: All cables connected to the x-axis driver PCB should be routed toward the rear of the
PCB to allow room for tubing connections to the bulk fluidics module.
5-pin cable (286514-00) from the fluid pressure sensor to J13

4-pin cable (286526-00) from the syringe pump to J7
6-pin cable (286547-00) from the bulkhead and air pressure pump to J11
4-pin cable (286519-01) from the PC104 board to J3
14-pin power distribution cable (286539-02) from the fuse board to J9.

Figure 8-73 CTS X Axis Driver PCB Cable Connections
J11
J13 J3
J7
(Front of Board)
LEDs
4. Ensure the pump address on the Syringe Pump Housing is set to 1 as described in Syringe Pump
Addressing and Jumpers in Chapter 7.
5. Attach the Syringe Pump Cable (286525-00) to the back of the Syringe Pump as shown on Figure 8-74
"Syringe Pump Cable" and secure the pump with the two 4-40 x 1/4 screws and flat washers.
Syringe Pump Cable
6. Install the Sample Syringe Pump on the CTS Bulk Fluids Module. Refer to CTS Sample Cavro
Syringe Pump Installation in Chapter 7 or CTS Sample Hamilton Syringe Pump Installation in
Chapter 7. Do not fully tighten the screws yet. Tubing routing must be done before securing the Pump
to the module.

7. Mount the CTS Fluidics Module to the Arm Assembly using the three screws as shown on Figure 8-75
"CTS Fluidics Module Mounting".
Figure 8-75 CTS Fluidics Module Mounting
Mounting
Screws
Screws
8. See Figure 8-76 "Syringe Pump Tubing". Attach the precision tubing to the sample syringe pump
valve (upper right port).
Route the rinse supply tube through the Bulk Fluidic assembly as shown on the above figure and attach
it to the sample syringe pump valve (upper left port) by carefully pressing it onto the barbed fitting.
Tighten the two screws securing the syringe pump.
Figure 8-76 Syringe Pump Tubing
Precision
(Probe)
Rinse Tubing
Tubing

9. Install the CTS rinse input and rinse output fittings to the top of the CTS Bulk Fluidics Module as shown
on Figure 8-77 "Rinse Input/Output Fittings".
Figure 8-77 Rinse Input/Output Fittings
Rinse Input &

Output Sensor Cable
Connectors Connector
10. Connect the rinse bottle coupling to the Fluidic I/O panel.
11. Connect air pump sensor cable ((286547-00)) to the connector on the side of Bulk Fluidic Assembly
(see Figure 8-77 "Rinse Input/Output Fittings".
12. Pull the polyurethane tubing through the grommet on the top of the air valve bracket as shown on Fig-
ure 8-78 "Connecting the Air Tubing to the Arm". Connect the end of the tubing to the right angle
fitting on the air Sample arm valve assembly.
Figure 8-78 Connecting the Air Tubing to the Arm
Air Valve
Bracket
Grommet
Air Line
Connection
13. Install the Telescoping CTS Assembly as described in Telescoping CTS Assembly Installation in
Chapter 15.
14. Verify the CTS Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is
run as part of the verification.
15. Reinstall the instrument skins.

Reagent IL Double Arm Removal/Replacement
Reagent IL Double Arm Removal
1. Remove the Top Skin, Center Skin, Inner Right Skin, and the Reagent area inner skins as described in
Removal/Replacement Procedures in Chapter 8.
2. Move both reagent probes over the Rinse Cups. (This ensures that any fluid that drips out of the Probes
drips into the Rinse Cup.)
3. Disconnect the rinse bottle coupling from the Fluidic I/O panel.(This should be done prior to any servic-
ing of the fluid system. It prevents leaks and siphoning.)
CAUTION: When removing Reagent Syringe Pumps, ensure the tubes

connected to Pump R1 and the tubes connected to Pump R2 are
identified. This can be done by placing a small mark on the tubes for one
Syringe Pump (R1 or R2). (It is recommended that the mark be made with a
soft-tip marking pen.) When re-connecting the tubes, ensure the tubes are
4. Unscrew and remove the probe tubing from the Syringe Pump Valves (see Figure 8-79 "Reagent
Syringe Pumps"). (Fluid will drain from the probe.)
5. Carefully pull the Rinse tubing from the barbed fitting on each valve (see Figure 8-79 "Reagent
Syringe Pumps").
malfunction.

Figure 8-79 Reagent Syringe Pumps
Rinse Tubing
Connectors
Precision
Tubing
Connection
6. Using a tubing cutter, trim the rinse line by 1/4. (This removes the part of the line that was stretched
over the barbed fitting.)
7. Disconnect the Fluidic Dispense cable between the syringe pump for Reagent Arm 2 and the ORU.
8. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probes and
remove the probe from the Z-rack on each arm.
9. Remove the flex cable from the Probe PCB on each arm.
10. Remove the purple fittings of the probe tubing from the stainless steel fittings at the top of the probes
Support the stainless steel support tube while disconnecting the tubing to ensure it doesnt bend.
11. Disconnect the following cables from the X-axis driver PCB. (See Figure 8-80 "Reagent IL Double
Arms X Axis Driver PCB Cabling"
4-pin cable (286525-00) on J7 to the Right Arm syringe pump
4-pin cable (286525-00) on J8 to the Left Arm syringe pump
5-pin cable (286535-00) on J5 to the Right Arm X Axis Stepper Motor Encoder
5-pin cable (286535-00) on J6 to the Left Arm X Axis Stepper Motor Encoder
4-pin cable (286519-01) on J3 to the PC104 Board

Figure 8-80 Reagent IL Double Arms X Axis Driver PCB Cabling
J3
J14
J6 J5
J7

12. For each of the two heated probes (IL P/N 283950-00):
a. Lift the Sample Probe cover from the probe housing.
b. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probe and
remove the Probe from the Z-rack.
c. Remove the flex cable from the Probe PCB.
13. Using a 5mm Allen wrench, remove the four mounting screws as shown on Figure 8-81 "Reagent IL
Double Arm Assembly Mounting Screws" for the Reagent IL Double Arm Assembly and lift and
remove the assembly from the right and center pylons.

Figure 8-81 Reagent IL Double Arm Assembly Mounting Screws
Mounting Screws
Reagent IL Double Arm Installation
1. Mount the Reagent Arm Assembly on the right and center pylons. Ensure the arm assembly is aligned
with the alignment pins on the pylon.
2. Insert and secure the four screws securing the assembly using a 5mm Allen wrench as shown on Fig-
ure 8-72 "CTS Arm Assembly Mounting Screws"
Figure 8-82 Reagent IL Double Arm Assembly Mounting Screws
Mounting Screws
3. Connect the following cables to the X-axis driver PCB.(See Figure 8-83 "Reagent IL Double Arms X
Axis Driver PCB Cabling")

4-pin cable (286525-00) on J7 from the Right Arm syringe pump

4-pin cable (286525-00) on J8 from the Left Arm syringe pump
5-pin cable (286535-00) on J5 from the Right Arm X Axis Stepper Motor Encoder
5-pin cable (286535-00) on J6 from the Left Arm X Axis Stepper Motor Encoder
4-pin cable (286519-01) on J3 from the PC104 Board
Figure 8-83 Reagent IL Double Arms X Axis Driver PCB Cabling
J3
J6 J5
J8 J7

4. Attach the Syringe Pump Cable (286525-00) to the back of the Syringe Pumps as shown on Figure 8-84
"Syringe Pump Cable" and secure the pump with the two 4-40 x 1/4 screws and flat washers.
CAUTION: Ensure the 15-pin connector with two extra wires (black twisted
with blue) is connected to the R2 Syringe Pump.

Syringe Pump Cable
5. Mount the syringe pump assembly on the arm as shown on Figure 8-85 "Reagent Arm Pump Assem-
bly Mounting". Do not tighten screws yet. Tubing routing must be done prior to securing the pump to
the arm.
Figure 8-85 Reagent Arm Pump Assembly Mounting
Mounting
Screws
6. See Figure 8-76 "Syringe Pump Tubing". Attach the precision tubing to both syringe pump valves
(upper right port).
Route the rinse supply tubes through the mounting bracket as shown on the figure and attach it to the
syringe pump valves (upper left port) by carefully pressing it onto the barbed fitting. Ensure it is fully
seated on the fitting.
7. Tighten the two screws securing the syringe pump.

Figure 8-86 Reagent Syringe Pump Tubing

Rinse Tubing
Precision
(Probe)
Tubing
8. Connect the fluidic dispense cable between the syringe pump for reagent arm 2 and the ORU.
9. Connect the rinse bottle coupling to the Fluidic I/O panel.
10. For each of the two heated probes (IL P/N 283950-00):
a. Lift the Probe cover from the probe housing.
b. Insert the Probe on the Z-rack.
c. Use a 1.5mm Allen wrench to tighten the screws on the rear and upper left side of the probe.
d. Connect the flex cable to the Probe PCB.
11. Screw the purple fitting of probe tubing to the stainless steel fitting at the top of the probe as shown on
Figure 8-97 "Probe Top". Hand tighten and then tighten one quarter turn with pliers. Support the stain-
less steel support tube while connecting the tubing to ensure it doesnt bend.
Figure 8-87 Probe Top
Stainless Steel
Probe Tubing Fitting
12. Verify the Reagent Arms as described in "Adjustments and Verifications". Ensure coordinate adjust
is run as part of the verification.

Cavro Sample Arm Removal/Replacement
Cavro Sample Arm Removal
1. Remove the Top Skin, Center Skin, Upper Skin (sample side), Inner Left Skin, and the Sample Area
interior skins as described in Removal/Replacement Procedures in Chapter 8.
2. Lift the Sample Probe cover from the probe housing.
3. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probe and remove
the Sample Probe from the Z-rack.
4. Remove the flex cable from the Sample Probe PCB.
5. Use a Phillips head screwdriver to loosen the cable clamp holding the LLD coaxial cable to the Sample
Arm as shown on Figure 8-88 "Cable Clamp on Arm"
Figure 8-88 Cable Clamp on Arm
6. Detach the end of the LLD coaxial cable from its connection in the arm and remove the cable from the
cable clamp.
7. Remove the purple fitting of the probe tubing from the stainless steel fitting at the top of the probe as
shown on Figure 8-89 "Probe Top". Support the stainless steel support tube while disconnecting the
tubing to ensure it doesnt bend.

Stainless Steel
8. Disconnect the following cables to the CCU-9000 PCB. (See Figure 8-90 "CCU Connections"):
P15 from connector J15 (RS232 cable).
P1 from connector J1 (Cable from the syringe pump).
P2 from connector J2 (Cavro power cable).)
Figure 8-90 CCU Connections
J2
(Fuse Board) J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
9. Remove the Sample flex cable from the DC Driver PCB as shown on Figure 8-91 "DC Driver PCB
Connections".

Figure 8-91 DC Driver PCB Connections
Sample
Arm Cable
10. Using a 5mm Allen wrench, remove the front left mounting screw and the 277588-00 cable (GND) as
shown on Figure 8-92 "Ground Cable Connection".
Figure 8-92 Ground Cable Connection
Mounting
Screw
Ground
Cable
11. Using a 5mm Allen wrench, remove the rear left mounting screw and the two mounting screws on the
right end of the Cavro Sample Arm Assembly.
12. Lift and remove the Cavro Sample Arm Assembly from the pylons.
Cavro Sample Arm Installation
1. If not mounted on the arm assembly, install the Sample Syringe Pump on the arm before mounting the
arm. Refer to Cavro Syringe Pump Assembly Removal/Replacement in Chapter 7.
2. Mount the Cavro Sample Arm Assembly on the vibration isolators atop the left and center pylon assem-
blies.
3. Using a 5mm Allen Wrench, insert and tighten the two right and the rear left mounting screws for the
assembly. (The left mounting screws are shown on Figure 8-93 "Ground Wire and Mounting
Screw".)
4. Attach the end of the ground cable to the front left mounting screw as shown in Figure 8-93 "Ground
Wire and Mounting Screw" with a star washer above and below the ground connector.

Figure 8-93 Ground Wire and Mounting Screw
Mounting
Screws
Ground
Wire
5. Connect the following cables to the CCU 9000 PCB. (See Figure 8-94 "CCU Connections".)
P15 of the 277583-00 Cable Assembly (RS232) to J15
P1 from the syringe pump to J1
P2 of the Cavro power cable to J2
J2
(Fuse Board) J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
6. Connect the Sample Arm flex cable to the sample-side probe connector of the DC Driver PCB as shown
in Figure 8-95 "DC Driver PCB Connections".

Sample
Arm
Cable
7. Insert the Sample probe onto the arm by sliding it on the Z Drive Rack. Orient the PCB of the Sample
probe so that if faces to the right side of the Instrument as shown on Figure 8-96 "Heater Probe PCB
and Heater Cable Routing".
CAUTION: Always hold the Probe by the Upper Housing. To prevent

Thermistor damage, never handle the Probe by the black tube.
8. Attach the flex cable to the probe as shown in Figure 8-96 "Heater Probe PCB and Heater Cable
Routing" so it will come out of the bottom of the probe cover.
Figure 8-96 Heater Probe PCB and Heater Cable Routing
9. Slide the probe tubing (with the purple tip) through the top of the probe cover.

10. Screw the purple fitting of probe tubing to the stainless steel fitting at the top of the probe as shown on
Figure 8-97 "Probe Top". Hand tighten and then tighten one quarter turn with pliers. Support the stain-
less steel support tube while connecting the tubing to ensure it doesnt bend.
Stainless Steel
11. Loosen the screw holding the cable clamp on the side of the arm as shown in Figure 8-98 "Coax
Cable Connection to Arm". Place the coaxial cable through the clamp cable and through the hole in
the arm cover.
Figure 8-98 Coax Cable Connection to Arm
12. Slide the cable along the arm in the channel just above the bottom of the arm cover and attach it to the
connector of the co-axial cable from the alidum.
13. Remove any slack in the portion of the cable in the arm cover and tighten the cable clamp to hold the
cable in place on the arm.
14. Pull the excess probe tubing from above the arm while lightly pushing the probe onto the Z-rack until it
bottoms out. Use a 1.5mm Allen wrench to remove the two set screws (one at the rear and one in upper
left side of the probe housing) and apply a small amount of thread lock (P/N C311-0132-001) on at least
four of the threads. Re-insert and tighten both set screws to secure the probe to the Z Drive Rack.
15. Slide the probe cover over the probe housing. Ensure the green wire on the probe is positioned in the
notch located on the top front surface of the housing. Ensure the flex cable leading to the probe PCB is
folded and exits from the bottom of the probe cover and the cable routing is as shown on Figure 8-99
"Flex Cable to Probe Assembly".

Figure 8-99 Flex Cable to Probe Assembly
Probe Cable
Routing
16. Verify the Sample Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is
Cavro Reagent Arm Assembly Removal/Replacement
Cavro Reagent Arm Assembly Removal
1. Remove the Top Skin, Center Skin, Upper Skin (Reagent side), Inner Right Skin, and the interior
Reagent Module skins as described in Removal/Replacement Procedures in Chapter 4.
2. Lift the probe cover from the probe housings on both arms.
3. Use a 1.5mm Allen wrench to loosen the screws on the rear and upper left side of the probe and remove
the Sample Probe from the Z-rack.
4. Remove the flex cable from the Sample Probe PCB.
5. Use a Phillips head screwdriver to loosen the cable clamp holding the LLD coaxial cable to the Sample
Arm as shown on Figure 8-88 "Cable Clamp on Arm"

Figure 8-100 Cable Clamps
Left Reagent Arm (R1) Clamp Right Reagent Arm (R2) Clamp
6. Detach the end of the LLD coaxial cables from their connection in the arms and remove the cable from
the cable clamp.
7. Remove the purple fittings of the probe tubing from the stainless steel fittings at the top of the probes.
8. Remove the flex cable from the probes.
9. Disconnect the following cables to the CCU-9000 PCB. (See Figure 8-101 "CCU Connections"):
P15 from connector J15 (RS232 cable.)
P1 from connector J1 (Cable from the syringe pump.)
P2 from connector J2 (Cavro power cable.)
J2
(Fuse Board) J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
10. Remove both Reagent flex cables from the DC Driver PCB as shown on Figure 8-102 "DC Driver
PCB Connections".

Reagent
Arm 2
Reagent
Arm 1
11. Using a 5mm Allen wrench, remove the front right mounting screw and the 277588-00 cable (GND).
Figure 8-103 Ground Cable Connection
Front
Mounting
Screw
Rear
Mounting
Ground Screw
Cable
12. Using a 5mm Allen wrench, remove the rear left mounting screw and the two mounting screws on the
left end of the Cavro Reagent Arm Assembly.
13. Lift and remove the Reagent arm assembly from the pylons.
Cavro Reagent Arm Assembly Installation
1. If not mounted on the arm assembly, install the Reagent Syringe Pumps on the arm before mounting the
arm. Refer to Reagent Cavro Syringe Pump Installation in Chapter 7 or Reagent Hamilton
Syringe Pump Installation in Chapter 7.
2. Mount the Cavro Reagent Arm assembly to the right and center pylon assemblies atop the vibration iso-
lators.

3. Using a 5mm Allen Wrench, insert and tighten the two right and the rear right mounting screws for the
assembly. (Right mounting screws are shown on Figure 8-104 "Cavro Reagent Ground Wire, Mount-
ing Screws".
4. Attach the end of the ground cable to the front left mounting screw as shown in Figure 8-104 "Cavro
Reagent Ground Wire, Mounting Screws" with a star washer above and below the ground connector.
Figure 8-104 Cavro Reagent Ground Wire, Mounting Screws
Reagent Ground Wire

Mounting
Screws
5. Connect the following cables to the CCU 9000 PCB (see Figure 8-105 "CCU Connections"):
Connect P15 of the 277583-00 Cable Assembly (RS232) to J15
Attach P1 from the syringe pumps to J1
Connect P2 of the 277511-00 Cavro Power Cable to J2

J2
(Fuse Board) J15
(Control
Board
-RS232)
J1
(Pump)
(Front of Board)
6. Connect the reagent flex cables to the reagent probe connector of the DC Driver PCB as shown in Fig-
ure 8-106 "DC Driver PCB Connections".
NOTE: Do not cross the cables. This means the R1 cable goes on the board connector
labeled R2 and vice versa.
Reagent
Arm 2
Reagent
Arm 1
Sample
Arm

CAUTION: Always hold the Probe by the Upper Housing. To Prevent

Thermistor damage, never handle the Probe by the black tube.
7. Insert the Reagent probes on each of the arms by sliding it on to the Z Drive Rack. Orient the PCB of the
probe so that if faces to the right side of the Instrument as shown on Figure 8-107 "Probe Orienta-
tion".
Figure 8-107 Probe Orientation
8. For the right arm:

Insert the probe tubing through the top of the probe cover. Support the stainless steel support tube
while connecting the tubing to ensure it doesnt bend.
Screw the purple fitting of the probe tubing to the stainless steel fitting at the top of the probe as
shown on Figure 8-97 "Probe Top". Hand tighten and then tighten with pliers one quarter turn.
Figure 8-108 Probe Top Connections

Clamp Screw
Cable Clamp
LLD
Sensing Cable

Connect the flex cable to the probe as shown in Figure 8-96 "Heater Probe PCB and Heater
Cable Routing" so it will exit the bottom of the probe housing.
Figure 8-109 R2 Heater Probe PCB and Cable Routing
Remove the screw holding the cable clamp on the side of the arm as shown in Figure 8-110 "Coax
Cable Connection to R2". Place the coaxial cable through the clamp cable and through the hole in
the arm cover.
Figure 8-110 Coax Cable Connection to R2
Slide the cable along the arm in the channel just above the bottom of the arm cover and attach it to
the connector of the co-axial cable from the alidum.
Tighten the cable clamp to hold the cable in place on the arm.
Pull the excess probe tubing from above the arm while lightly pushing the probe into the Z-rack until
it bottoms out. Use a 1.5mm Allen wrench to remove the two set screws (one at the rear and one in
upper left side of the probe housing) and apply a small amount of thread lock (P/N C311-0132-001)
on at least four of the threads. Tighten both set screws to secure the probe to the Z Drive Rack.
Slide the probe cover over the probe housing. Ensure the green wire on the probe is positioned in
the notch located on the top front surface of the housing. Ensure the flex cable leading to the probe
PCB is folded and exits from the bottom of the probe cover and the cable routing is as shown on Fig-
ure 8-111 "R2 Flex Cable to Probe Assembly".

Figure 8-111 R2 Flex Cable to Probe Assembly
Flex Cable Exits

From Bottom of
Probe Cover
For the left arm:

Insert the probe tubing through the top of the probe cover. Support the stainless steel support tube
while connecting the tubing to ensure it doesnt bend.
Screw the purple fitting of probe tubing to the stainless steel fitting at the top of the probe as shown
on Figure 8-112 "Probe Top". Hand tighten and then tighten with pliers one quarter turn.
Fitting for
Probe Tubing
Feed the flex cable through the cable guide on top of the probe cover, over the top of the probe
heater board as shown on Figure 8-113 "Flex Cable Routing for Left Reagent Arm", and connect
it to the probe heater board. Slide the probe cover over the probe housing. Ensure the green wire on
the probe is positioned in the notch located on the top front surface of the housing. The resulting
cable routing should look as shown on Figure 8-114 "Left Reagent Arm Flex Cable".

Figure 8-113 Flex Cable Routing for Left Reagent Arm
Cable Guide
Figure 8-114 Left Reagent Arm Flex Cable
Remove the screw holding the cable bracket on the top of the probe as shown on Figure 8-115
"Cable Bracket Screw".
Figure 8-115 Cable Bracket Screw
Cable Bracket Screw
Cable Bracket
Place the LLD coaxial cable in the bracket channel so that it exits the under the bracket as shown
in Figure 8-116 "Reagent Left Arm LLD Cable". Reinsert and tighten the cable bracket screw.

Figure 8-116 Reagent Left Arm LLD Cable
Remove the screw holding the cable clamp on the side of the arm as shown in Figure 8-98 "Coax
Cable Connection to Arm". Place the coaxial cable through the clamp and through the hole in the
arm cover.
Figure 8-117 Coax Cable Connection to Left Reagent Arm
LLD Coaxial Cable Clamp

Cable
Slide the cable along the arm in the channel just above the bottom of the arm cover and attach it to
the connector of the co-axial cable from the alidum.
Remove any excess cable in the channel of the arm cover and tighten the cable clamp to hold the
cable in place on the arm.
Pull the excess probe tubing from above the arm while lightly pushing the probe into the Z-rack until
it bottoms out. Use a 1.5mm Allen wrench to remove the two set screws (one at the rear and one in
upper left side of the probe housing) and apply a small amount of thread lock (P/N C311-0132-001)
on at least four of the threads. Re-insert and tighten both set screws to secure the probe to the Z
Drive Rack.
9. Verify the Reagent Arm as described in "Adjustments and Verifications". Ensure coordinate adjust is

Individual Cavro Arm Removal/Replacement
CAUTION: Ensure the instrument is powered OFF before performing the

To access the individual Cavro arms follow steps 1-7 of "Cavro Sample Arm Removal" for the Sample side
or steps 1-8 of "Cavro Reagent Arm Assembly Removal" for the Reagent side.
Individual Cavro Arm Removal
1. Remove the Z rack, insulation block and Probe assembly.

2. Remove the ADRI-9 board. (See "ADRI-9 Board Removal".)
3. Remove the front ADRI-9 bracket by removing the two 2.5mm Front Bracket screws. (See Figure 8-118
"Removing the Arm".)
Figure 8-118 Removing the Arm
Front Bracket Screws
Hex Screws
4. Remove the three hex screws holding the arm on to the X-slide. Remove the arm.
Individual Cavro Arm Installation
1. Install the new arm by following these directions in reverse order (Step 5 through Step 1).
2. follow steps 6-17 of "Cavro Sample Arm Installation" for the Sample side or steps 6-10 of "Cavro
Reagent Arm Assembly Installation" for the Reagent side.

Cavro Arm Insulation Block/Cable Assembly Removal/Replacement

Insulation Block/Cable Assembly Removal
1. Remove the plastic cable binder underneath the arm(s) holding the coax cable.
NOTE: Use a small wire cutter to remove the plastic cable binder. A new cable binder is
included with each replacement insulation block assembly.
2. Push the coax cable through the back-end of the arm(s) until the gold connector is visible, as shown in
Figure 8-119 "ALIDUM Coax Cable", to locate the coax cable connector.
Figure 8-119 ALIDUM Coax Cable
Gold Coax Connector
3. Disconnect the coax cable by gently sliding back the releasing cover on the insulation block side of the
gold connector. This will release the cable from the ALIDUM cable.
4. To remove the insulation block assembly, carefully pull the coax cable forward through the arm.
Insulation Block/Cable Assembly
1. Install the new insulation block and feed the cable from the front of the arm through the hole in the arm
mounting block.
2. Attach the gold connector to the matching connector on the coax cable. Be sure that the connector is
firmly seated.
3. Adjust the ALIDUM coax cable until all of the slack is removed from behind the arm(s).

CAUTION: Ensure the Alidum coax cable is not twisted or kinked.

4. Fasten the coax cable to the arm using a new plastic cable binder.
Cavro Arm Flex Cable Removal/Replacement

Cavro Arm Flex Cable Removal
1. Remove the ADRI-9 board cover.

2. Disconnect the flex cable from the ADRI-9 board by holding the connector at its ends and gently pull
straight upward.
3. Open the flex cable clamp located underneath the flex cable guide (located just right of the CCU-9000).
4. Remove the four screws which hold the CCU-9000 board in place.
5. Lower the CCU-9000 board approximately 2 cm.
6. Disconnect the flex cable from the CCU-9000 board.
Cavro Arm Flex Cable Installation
1. Remove old cable noting how it is routed over and under the flex cable supports.
2. Inspect the new flex cable ensuring that the foam protective strip is attached to the ADRI-9 end of the
cable. (See Figure 8-120 "Installing the Flex Cable".)
Figure 8-120 Installing the Flex Cable
Protective Strip Flex Cable Connector
ADRI-9 Board
Flex Cable Channel

3. Connect the end of the flex cable with the foam protective strip to the ADRI-9 board. (See Figure 2.)
4. Run the flex cable through the flex cable channel and flex cable clamp.
5. Carefully push the connector of the flex cable onto its appropriate base on the CCU-9000 board.
6. Reattach the CCU 9000 board to the X-frame using all four allen screws.
7. Close the flex cable clamp.
CAUTION: Ensure the flex cable is not twisted or kinked and is lying flat in
the flex cable channel.
8. Reattach the ADRI-9 board cover.
Cavro Arm Y- and Z-axis Optical Sensor Removal/Replacement

Y- and Z-axis Optical Sensor Removal

2. Remove the screw holding the Y-/Z-axis slotted optical sensor in place. (See Figure 8-121 "Slotted
Optical Sensors".)
Figure 8-121 Slotted Optical Sensors
Z-Axis Mounting Screws
Z-Axis Slotted Optical Sensor
Encoder Wheel
Y-Axis Mounting Screws
Z-Axis Slotted Optical Sensor
3. Using wire cutters, cut the plastic cable binders holding the optical sensor wires in place.

4. Loosen the ALIDUM bracket.

5. Disconnect the slotted optical sensor connector from its base on the ADRI-9 board.
Y- and Z-axis Optical Sensor Installation
1. Run the wires of the new slotted optical sensor under the ALIDUM bracket.
2. Attach the connector of the new slotted optical sensor to its base on the ADRI-9 board.
3. Tighten the ALIDUM bracket.
4. Attach the new slotted optical sensor.
5. Replace all three cable binders ensuring that all the cables are bound together. Space the cable binders
approximately 2 cm apart.
6. Reattach the ADRI-9 board cover.
Cavro Arm X-Axis Optical (SLD) Sensor Removal/Replacement

X-Axis Optical (SLD) Sensor Removal
1. Move the arm(s) to the center.

2. Remove the allen screw from the optical sensor block that is to be replaced. (See Figure 8-122 "Opti-
cal Switch Block".)
Figure 8-122 Optical Switch Block
Slotted Optical Switches
Optical Switch Block
3. Remove the four screws that hold the CCU-9000 board in place.
4. Cut the plastic cable binders (using small wire cutters) that hold the slotted optical sensor wires in place.

5. Unplug the slotted optical sensor connector from its base on the CCU-9000 board.
6. Pull the optical sensor block and the slotted optical sensor away from the X-frame.
7. Remove the allen screw holding the slotted optical sensor to the optical sensor block.
X-Axis Optical (SLD) Sensor Installation
1. Attach the new slotted optical sensor to the optical sensor block.
2. Feed the wires of the slotted optical sensor through the hole in the top of the X-frame. (Located by the X-
axis motors.)
3. Guide the optical sensor block back into its original position.
4. Attach the optical sensor connector into the appropriate connection on the CCU- 9000 board.
5. Secure the loose wires of the optical sensor (using the plastic wire binders included) with the other wires
underneath the X-frame.
6. Reinstall the CCU-9000 board.
CAUTION: Ensure no wires or cables leading to the Cavro Arm unit are
creased or twisted. Ensure the slotted optical sensor is not touching the
encoder wheel.
7. Reinstall the optical sensor block.
Cavro Arm ALIDUM Removal/Replacement

ALIDUM Removal

2. Remove the ALIDUM bracket.
NOTE: Notice how the optical sensor wires run underneath the ALIDUM bracket.
3. Carefully unseat the ALIDUM from the ADRI-9 board.
NOTE: Only Lift up on the ALIDUM until the pins are free from the ADRI-9 board.
4. Trace the coax wire from the ALIDUM to the gold connector.

5. Disconnect the ALIDUM from the coax cable by separating the gold connectors. (See Figure 8-123
"ALIDUM Coax Cable".)
Figure 8-123 ALIDUM Coax Cable
Gold Coax Connector
6. Discard the old ALIDUM.
ALIDUM Installation
Install the ALIDUM by following the "ALIDUM Removal" directions in reverse order (Step 5 through Step 1).

Cavro Arm ADRI-9 Board Removal/Replacement

ADRI-9 Board Removal

2. Disconnect all cables from the ADRI-9 board (See Figure 8-124 "Diagram of the ADRI-9 Board").
NOTE: Document where the cables connect to the ADRI-9 board. Remember to disconnect
the ALIDUM cable.
Figure 8-124 Diagram of the ADRI-9 Board
3. Remove the four hexagon spacers from the ADRI-9 board.

4. Remove the ADRI-9 board.
NOTE: Do not try to lift the ADRI-9 board straight up. Turn the board a little to the left or right
and then lift.

ADRI-9 Board Installation
1. Install the new ADRI-9 board by following the "ADRI-9 Board Removal" directions in reverse order
(Step 4 through Step 1).
CAUTION: Ensure the red SW 1-4 switches on the new ADRI-9 board are
set in the same positions as on the ADRI-9 board that was removed. The
arms will not function properly if the switches are set in the wrong
position. (See Figure 8-125 "SW Switches".)
Figure 8-125 SW Switches
CCU-9000 Board Removal/Replacement

CCU-9000 Board Removal
1. Remove the four screws holding the CCU-9000 board to the X-frame. Unplug all wires connected to the
CCU-9000 board.
NOTE: Document where the connectors plug into the CCU-9000 board. (See Figure 8-126
"CCU-9000 Board Diagram").
2. Remove the old CCU-9000 board.

3. Place the new CCU-9000 board and reinstall the four mounting screws. Connect all wires to their appro-
priate connections.

Figure 8-126 CCU-9000 Board Diagram

CAVRO Arm Belt Removal/Replacement
CAVRO Arm X-Axis Belt Removal
1. Loosen the Tensioner screw (as shown in Figure 8-127 "Tensioner Screw Location"), of the belt that
is to be removed, until it is allowed to slack. These screws are located on the underside of the X-Axis
chassis on the right-hand side, near the Pylon mounts.
Figure 8-127 Tensioner Screw Location
Tensioner Screws
2. Remove the Z rack, insulation block and Probe assembly.

3. Remove the ADRI-9 board. (See Replacing the ADRI-9 Board on Page 8.)
4. Remove the front ADRI-9 bracket by removing its two 2.5mm screws. (See Figure 8.)

5. Remove the two belt bracket screws (connecting the belt bracket to the Y-Axis carriage) as shown in
Figure 8-128 "Belt Bracket Screw Location".
Figure 8-128 Belt Bracket Screw Location
Belt Bracket Screws
6. Pull the bracket clear of the carriage and loosen the screw on the belt clamp to release the belt.
CAVRO Arm X-Axis Belt Installation
1. Feed the drive belt over the pulleys of the tensioner and motor pulley.
2. Ensure the belt is inserted straight in the belt clamp and close the belt by tightening clamp screws.
3. Secure the belt bracket to the carriage by replacing the two belt bracket screws as shown in Figure 8-
128 "Belt Bracket Screw Location".
4. Verify that both belt tensioners' hold down screws are finger tight at this time and that all excess belt
slack is removed by adjusting the tensioning screws. Do not over tighten the belt!
5. Tension the belt by pulling the pulley toward the end plate and tightening the tensioning screw until slack
is entirely removed from belt. Tighten screw with torque driver to 20 in/lbs.

CAVRO Arm Y-Axis Belt Removal
NOTE: A mirror may be helpful for Y-Axis arm servicing.

1. Loosen the tensioning screw (as shown in Figure 8-129 "Y-Axis Tensioning Screws") until the belt is
slack.
Figure 8-129 Y-Axis Tensioning Screws
Tensioning Screws
2. Remove the screw on the belt clamp (as shown in Figure 8-130 "Y-Axis Belt Clamp") to release the
belt.
Figure 8-130 Y-Axis Belt Clamp
Belt Clamp
Screw
3. Remove the belt from the tensioner and motor pulleys.
CAVRO Arm Y-Axis Belt Installation
1. Feed drive belt, through the tensioner and motor pulley.

2. Ensure the belt is inserted straight in the belt clamp and close the belt by tightening the belt clamp screw
as shown in Figure 8-129 "Y-Axis Tensioning Screws".
3. Tension the belt by pushing the pulley toward the end plate. Do not over tighten the belt!
4. Tighten tensioning screw.


Chapter 9 Cuvette Handling System 9-1
Chapter 9
9-1 Overview
The Cuvette Handling System transports and handles four-well cuvettes within the ACL-TOP Instrument for
blood chemistry analysis.
The Cuvette Handling System consists of six basic sub-modules:
The Cuvette Loader Assembly
The Cuvette Shuttle Assembly
The Hold/Incubator #2 Assembly
The Incubator #1 Assembly
The Optical Reading Unit (ORU) Assembly
A four-well cuvette is moved sequentially from the Cuvette Loader to either the CTS Hold/Incubator #2
(depending on the type of analysis). Then the cuvette may be moved to Incubator #1 (again, depending on
the type of analysis). From the Hold or Incubator, the cuvette is moved to the ORU, where the analysis takes
place. When analysis is complete, the cuvette is moved to the Waste Shelf for disposal. Movement of the
cuvettes to the various stations is accomplished by the Cuvette Shuttle Assembly.

9-2 Physical Layout
Figure 9-1 "Layout of the Cuvette Handling System" shows the physical layout of the Cuvette Handling System.
Figure 9-1 Layout of the Cuvette Handling System
SHUTTLE ASSY
LOADER ASSY
CTS HOLD/INCUBATOR #2 ASSY
CHS CONTROLLER CARD

LEFT POSITION
INCUBATOR #1 ASSY
CUVETTE WASTE
OPTICAL READ UNIT ASSY SHELF ASSY

Figure 9-2 "Interconnect Diagram for the Cuvette Handling System" contains the Interconnect Diagram for the Cuvette Handling System.
Figure 9-2 Interconnect Diagram for the Cuvette Handling System

9 - 4 Chapter 9 Cuvette Handling System
Cuvette Shuttle Assembly

The Cuvette Shuttle Assembly transports one four-well cuvette at a time to the various submodules of the
Cuvette Handling System. Figure 9-3 "The Cuvette Shuttle Assembly" shows the Cuvette Shuttle
Assembly.
Figure 9-3 The Cuvette Shuttle Assembly
Cuvette Shuttle
Assembly

The Cuvette Shuttle Assembly consists of several subassemblies, including the following: the Gripper
Assembly, the Solenoid Assembly and the Shuttle Pivot Assembly.
Gripper Assembly
The Gripper Assembly is the mechanism that grabs and releases a single cuvette within the Cuvette Shuttle
Assembly. The Gripper slides front to back within the Cuvette Shuttle Assembly via a DC stepper motor. The
movement of the Gripper Assembly is limit controlled by front and rear slotted sensors. The rear sensor is a
static location (end stop) and is located inside the Cuvette Shuttle Assembly (not visible from the outside);
the front sensor is an adjustable position. (Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replace-
ment" for information on making adjustments.) Figure 9-4 "The Gripper Assembly" shows the Gripper
Assembly.
Figure 9-4 The Gripper Assembly
Gripper Assembly
Solenoid Assembly
The Solenoid Assembly works in conjunction with the Gripper Assembly to allow the Gripper Arm (part of
the Gripper Assembly) to grab and release a cuvette. The Solenoid Assembly is non-adjustable and con-
sists of a wheel that slides on a linear rail, allowing the Gripper Assembly (when fully extended forward) to
be "open" and release a cuvette. Conversely, when the Gripper Assembly is fully extended forward, and the
solenoid is fired (also extended forward), the Gripper Arm returns to its default position of "closed", and
grabs a cuvette. Figure 9-5 "The Solenoid Assembly" shows the Solenoid Assembly.
When the solenoid is in the default position, and the Gripper Assembly is forward of the solenoid wheel (fully
extended), the Gripper is open. When the solenoid is in the default position, and the Gripper Assembly is
behind the solenoid wheel (not extended), the Gripper is closed.

Note: The default position for the solenoid is not extended (i.e., solenoid not fired). Figure 9-5 "The
Solenoid Assembly" shows the solenoid in the default position.
Figure 9-5 The Solenoid Assembly
Linear Rail
Solenoid
Wheel
Solenoid
Assembly
Shuttle Pivot
Assembly
Shuttle Pivot Assembly
The Shuttle Pivot Assembly is used in coordination with the Shuttle Alignment Tool to adjust the Cuvette
Handling Plane. The Cuvette Handling Plane is an imaginary horizontal plane which is defined by the bottom
surface of the cuvette and extends from the Loader to the Cuvette Waste Assembly. The Cuvette Handling
Plane must be adjusted to allow the Shuttle Assembly to pick and place cuvettes accurately.
Figure 9-6 "The Shuttle Pivot Assembly and the Shuttle Alignment Tool" shows the Shuttle Pivot
Assembly and the Shuttle Alignment Tool.
The Shuttle Pivot Assembly consists of two adjustment (set) screws as shown in Figure 9-6 "The Shuttle
Pivot Assembly and the Shuttle Alignment Tool". These set screws are used to adjust the tilt and "Z"
height of the Shuttle Assembly. Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replacement" for infor-
mation on using the Shuttle Pivot Assembly to adjust the Cuvette Handling Plane.

Note: The "X" and "Y" axes must also be adjusted to allow the Gripper Assembly to pick and place
cuvettes accurately. Refer to "X Adjustment" to adjust the "X" axis and to "Y Adjustment" to
adjust the "Y" axis.
Figure 9-6 The Shuttle Pivot Assembly and the Shuttle Alignment Tool
Adjustment Screws
Shuttle Align-
ment Tool
In addition to the three main subassemblies, the Shuttle Assembly has thermal control. For more informa-
tion on thermal control in the Shuttle Assembly, refer to Chapter 12 (Thermal Control).
Cuvette Loader Assembly

The Cuvette Loader Assembly is made up of two main subassemblies: the Transport Deck Assembly and
the Indexer Assembly. Using the two Transport Belts, the Transport Deck Assembly moves cuvette clips
forward to the Indexer Assembly. The Indexer Assembly then aligns a clip of cuvettes to the number one
position of the Indexer. When a cuvette clip is aligned, the Gripper Assembly grabs the individual cuvette in
the number one position of the Indexer. Figure 9-7 "The Cuvette Loader Assembly" shows the Cuvette
Loader Assembly.

Figure 9-7 The Cuvette Loader Assembly
Indexer
Assembly Loader Shown in
Number One Position
of the Indexer
Transport Deck
Assembly
Transport Belts
Transport Deck Assembly
The Transport Deck Assembly consists of a parallel belt system, which is actuated by a DC gear head motor
combination that uses a drive belt. The DC motor works in conjunction with the following reflective sensors,
which are shown in Figure 9-8 "The Transport Deck Sensors":
The forward sensor is used as the load position to the Indexer Assembly. This sensor recognizes
the presence of a cuvette clip so that the Indexer Rotating Platform may be prepared with a new clip
every ten cuvettes.
The reflective sensor at the number three cuvette clip position is used to generate a User warning
when only two cuvette clips (20 cuvettes) remain in the Cuvette Loader Assembly. When this con-
dition occurs, the operator must load more cuvette clips before the Instrument goes into a "con-
trolled stop" (standy mode). (Refer to the Operators Manual for more information on controlled
stops.)

Figure 9-8 The Transport Deck Sensors

Front Sensor (#1 cuvette
clip position)
Rear Sensor (#3 cuvette

clip position)
Indexer Assembly
The Indexer Assembly is comprised of a Lead Screw Assembly that works in conjunction with a rotating plat-
form. Within the Lead Screw Assembly, a Cuvette Pusher Assembly aids in indexing individual cuvettes to
the number one position (pick-up position) of the Loader Assembly.
Figure 9-9 The Indexer Assembly
Pick-up Position
for Cuvettes
Rotating
Platform
Pusher
Assembly
Components of
the Lead Screw
Assembly

Pusher Assembly
The Pusher Assembly (Figure 9-9 "The Indexer Assembly") utilizes a compression spring and a slotted
sensor to index, or push, the cuvettes in the "X" direction, so that the rightmost cuvette is always pushed
against the inside right surface of the Indexer. The spring within the Pusher Assembly ensures that there is
enough force against the cuvette so that it is in the correct position for the Gripper to grab. The sensor
mounted within the Pusher Assembly indicates whether the Pusher Assembly should engage the Lead
Screw to apply pressure to the cuvette (i.e., index the cuvettes to the pickup position).
The Lead Screw/Pusher Assembly also utilizes limit sensors at either end of the Lead Screw Assembly.
Both limit sensors are of the slotted sensor type that control the beginning and end travel of the Lead Screw/
Pusher Assembly. All movement of the Lead Screw Assembly is created using a DC gear head motor com-
bination that also uses a drive belt. (All movement of the Lead Screw Assembly is in the 'X' direction.)
The other component that works in conjunction with the Lead Screw Assembly is the Cuvette Rotating Plat-
form (Figure 9-10 "The Cuvette Rotating Platform (in Horizontal Down Position)"). This platform is the
method by which cuvette clips are transferred from the vertical position (transport deck position) to the hor-
izontal position (Indexer position).
Figure 9-10 The Cuvette Rotating Platform (in Horizontal Down Position)
Flexible O-ring
Belt
The Cuvette Rotating Platform is actuated by a DC gear head motor combination via a flexible O-ring belt.
The Cuvette Rotating Platform has two limit switches of the slotted sensor type. These sensors are used to
indicate the two positions of the Cuvette Rotating Platform (vertical and horizontal):
Vertical upright position The position in which the Cuvette Rotating Platform picks up a cuvette
clip from the Transport Deck.
Horizontal down position This position allows horizontal cuvette indexing by the Lead Screw
Assembly.

Chapter 9 Cuvette Handling System 9 - 11
CTS Hold and Incubator #2 Assembly

The CTS Hold/Incubator #2 Assembly is a 14-slot unheated incubator that is used to hold cuvettes during
dilution. Figure 9-11 "The Incubators and the Cuvette Indexer Assemblies" shows the CTS Hold Incu-
bator #2 Assembly.
The Cuvette Indexer Assemblies are mounted on top of the CTS Hold/Incubator #2 Assembly. Each Cuvette
Indexer Assembly is an alignment mechanism that is used to accurately and consistently position cuvettes
within the CTS Hold/Incubator #2. Figure 9-11 "The Incubators and the Cuvette Indexer Assemblies"
shows the Cuvette Indexer Assembly for the CTS Hold/Incubator #2.
Figure 9-11 The Incubators and the Cuvette Indexer Assemblies
CTS Hold/Incubator #2
Assembly
Cuvette Indexer
Assembly
Incubator #1 Assembly
Cuvette Indexer Assembly
CTS Incubator #1 Assembly

The CTS Incubator #1 Assembly (PN 288168-00) is an 8-slot heated incubator. Figure 9-11 "The Incuba-
tors and the Cuvette Indexer Assemblies" shows the CTS Incubator #1 Assembly.
The CTS Incubator #1 is thermal controlled. For more information on thermal control in the CTS Incubator
#1, refer to Chapter 12 (Thermal Control).
As with the CTS Hold/Incubator #2, the Cuvette Indexer Assemblies are mounted on top of the CTS Incu-
bator #1 Assembly. The Cuvette Indexer Assembly is an alignment mechanism that is used to accurately
and consistently position cuvettes within the CTS Incubator #1. Figure 9-11 "The Incubators and the
Cuvette Indexer Assemblies" shows the Cuvette Indexer Assembly for the CTS Incubator #1.
Optical Read Unit (ORU) Assembly

The ORU assembly is the analytical module of the Instrument, where chemical reactions take place and are
analyzed for patient results. The ORU is made up of four Reader Head Subassemblies, an Emitter Subas-
sembly, an Emitter Board, and a Fiber Bundle Subassembly. Figure 9-12 "The ORU Assembly" shows the
ORU Assembly.

Figure 9-12 The ORU Assembly
Reader Head Assemblies
Cuvette Indexer Assemblies
Each Reader Head has a Cuvette Indexer Assembly mounted to the top of it. The Cuvette Indexer Assem-
bly performs the same function for each Reader Head that it performs for the incubators: it accurately
locates and retains each cuvette within each Reader Assembly for repeatable Cuvette Shuttle picking and
placing.
Each ORU includes an Emitter Subassembly, a Fiber Bundle Subassembly, and four Reader Head
Subassemblies. Figure 9-13 "ORU Subassemblies" shows all of the subassemblies of the ORU.
Figure 9-13 ORU Subassemblies
Emitter Board Reader Head

Emitter
Subassemblies Fiber Subassembly
Subassembly
Reader Head Subassemblies
Each Reader Head Subassembly is thermal controlled. For more information on thermal control in the
Reader Head Subassemblies, refer to Chapter 12 (Thermal Control).
Each Reader Head Subassembly has a detector PCB that uses 4 detector diodes to capture reactions over
time. Each detector PCB has four channels (diodes), one for each well of the cuvette.

Emitter Subassembly and Fiber Bundle Subassembly
The Emitter Assembly is mounted at the bottom of the ORU as shown in Figure 9-13 "ORU Subassem-
blies". This subassembly produces the 405nm and 660nm light sources that are used to analyze the reac-
tion.
The Fiber Bundle Subassembly is the mechanism that transfers both light sources to all four channels in
each Reader Head Assembly. Through the use of plastic fiber optic cable, the 405nm and 660nm wave-
lengths are generated at the Emitter and passed through an integrating rod located within the Fiber Bundle
Subassembly, thus creating uniform light. The light source is then passed through each Reader Head Sub-
assembly.
Within each Reader Head Subassembly, the light source is collimated in each of the four channels (via a
collimating lens). The light source is then passed through each of the four windows of the cuvette, where
the reaction takes place. Once passed through the optical window of the cuvette, each of the four detector
diodes senses the reaction and reports the data back to the master controller for processing.
Sensors in the Cuvette Handling System
Cuvette Loader Sensors and How They Work
When there is no cuvette in the pick-up position for cuvettes, and there is no cuvette clip on the Loader Plat-
form, the pivot table moves into the vertical position and gets the cuvette strip in the number one cuvette clip
position on the Transport Deck. The Pivot Arm Down Sensor is a slotted sensor that detects when the pivot
table is in the horizontal position. When the pivot table is in the horizontal position, and there is no cuvette
in the pick-up position for cuvettes, the TOP software directs the pivot table to become vertical and get a
cuvette clip from the number one cuvette clip position.
Note: The Front Sensor on the Transport Deck detects when the pivot table is in the horizontal position (see
"Transport Deck Assembly"). The Cuvette in-slot sensor detects the presence of a cuvette in the
pick-up position for cuvettes (see "Cuvette In Slot Sensor").
Cuvette Shuttle Sensors and How They Work
Shuttle Limit Sensors
The shuttle limits sensors are located on pylons at each end of the shuttle travel. The sensors are T type
slotted sensors; the shuttle has a flag that enters each slot. Refer to "Cuvette Shuttle Y-Axis Motor
Removal/Replacement" for information on making adjustments.

Figure 9-14 The Left and Right End-of-limit Sensors
Left End-of-Limit Sensor (on left Right End-of-Limit Sensor

side of chassis) (on right side of chassis)
Gripper Limit Sensors
The gripper front and back T type sensors are enabled as the gripper moves forward (front sensor) and back
(back sensor). Only the Gripper Front sensor (also known as the Cuvette Y-Axis Front Sensor) is adjustable.
Refer to "Cuvette Shuttle Y-Axis Motor Removal/Replacement" for information on making adjustments.
Figure 9-15 "Sensors on the Front of the Cuvette Shuttle" shows the location of the gripper front sensor.
(Note: The Gripper Back sensor, also known as the Cuvette Y-Axis Rear Sensor, is located on the back side
of the Cuvette Shuttle Assembly and is shown in Figure 9-16 "Sensors on the Rear of the Cuvette Shut-
tle".)
Figure 9-15 Sensors on the Front of the Cuvette Shuttle
Cuvette In Slot Sensor
Gripper Front Sensor
Shuttle Position Sensor

Figure 9-16 Sensors on the Rear of the Cuvette Shuttle
Gripper Back Sensor
Cuvette In Slot Sensor
The cuvette in slot sensor is a reflective type sensor that is triggered when a cuvette in a slot is detected as
the shuttle passes in front of that slot. Figure 9-15 "Sensors on the Front of the Cuvette Shuttle" shows
the location of the Cuvette in Slot Sensor.
Shuttle Position Sensor
The Shuttle Position Sensor (also known as the Shuttle Position X-Axis Sensor) is a slotted sensor that
detects the X-Axis alignment of cuvette slots relative to the Cuvette Shuttle. In order to move a cuvette into
a slot, it is critical that the slot be properly aligned to the Cuvette Shuttle. Figure 9-15 "Sensors on the
Front of the Cuvette Shuttle" shows the location of the Shuttle Position Sensor. Refer to "Cuvette Shuttle
Y-Axis Motor Removal/Replacement" for information on making adjustments to sensors.
Refer to Diagnostics later in this section for additional information on the Cuvette Shuttle sensors and their
associated virtual LEDs.
Cuvette in Shuttle Sensor
The cuvette in shuttle sensor is a reflective sensor that is enabled when a cuvette is detected in the shuttle.
This sensor is located on the Cuvette Shuttle PCB about half of the way back.
Board Descriptions
This section provides high-level descriptions of the PCBs in the Cuvette Handling System.

Cuvette Loader PCB
Located on the underside of the Cuvette Loader.

Provides ability to transport cuvettes to pivot arm and to the Cuvette Shuttle.
Interfaces to the Controller board to Provides the Drive capability to operate DC motors.
Interfaces to optical sensors for positional feedback.
Provides interface to reflective sensors for cuvette sensing.
Cuvette Shuttle Y-Axis PCB
Located on the side of the Shuttle Assembly, under the Y-Axis PCB Cover.
Provides the electrical interface to the mechanical shuttle assembly; enables the capability to trans-
port cuvette strips from the Loading location to Incubator, ORU and Waste locations within the ACL
TOP system.
Interfaces the controller signals to drive a Stepper motor, fire a solenoid, and power a heater.
Provides sensor signals to the controller from optical and reflective sensors (i.e., Gripper forward
sensor, Gripper Reverse Sensor, Module Position Sensor, Cuvette in Module Sensor and Cuvette
in Shuttle Sensor).
Includes a 12-bit Analog-to-Digital converter for thermal measurements; sends serial SPI Data to
the controller.
Cuvette Handling/Rack Handling X-Axis PCB
Located on the floor of the chassis on the right hand side, under the plastic shield.
Provides the electrical interface to the mechanical shuttle assembly; enables the capability to trans-
port cuvette strips from the Loading location to Incubator, ORU and Waste locations within the ACL
TOP system.
Provides the ability to move the Rack Barcode Scanner Assembly to sample and reagent positions
for Rack loading.
Offers re-buffering of digital signals that feed through the board to, and from, the Cuvette Handling
Y-Axis PCB and the Remote Traveling Interface PCB (RS-232 feed through only).
Includes Inputs for end-of-travel optical sensors for both Cuvette Handling and Rack Handling Sub-
systems,
Supports a quadrature motor encoder interface used by the Rack handling Subsystem.
ORU Interface PCB
Located on the bottom of the ORU Cradle Assembly.

Interfaces with the ORU Controller board to interconnect with four detector boards and provide ther-
mal regulation for each of the ORU heads.

Accepts four 30HZ pulse width modulated signals from the controller to proportionally control the
heating element on each ORU head utilizing FET drivers.
A multiplexer on-board selects which ORU Head temperature is to be read.
An on-board 12-bit ADC is used to convert the temperature signal from the thermistor to digital data
which is interpreted by the ORU controller.
Serves as a pass through for the Digital signals that interconnect the four detector boards.
ORU Detector PCB
Located inside each ORU.

Measures the amount of light that is emitted through patient samples during chemical reactions.
Has four channels for analytical purposes and a reference channel that measures the raw light
source.
Utilizes a 16-bit ADC to provide analytical data to the ORU controller with high accuracy.
For stability and noise immunity, voltages are re-regulated and filtered on-board.
For signal integrity, digital signals are buffered entering and leaving the board.
ORU Emitter PCB
The ORU Emitter PCB is a part of the Emitter Assy, located on the ORU Cradle Assy.
Generates the 405 and 660 wavelengths that are emitted through the samples.
Has a programmable DAC which is used to regulate the power in the LED and maintain consistent
power output on each LED (Closed Loop Control).
Includes a hardware timer circuit as a safety device. (In the unlikely event of a software failure, the
LED's are shut off to prevent burnout.)
The operation of the Cuvette Handling System can is verified by successfully moving cuvettes from the
Cuvette Loader to every position in the system (i.e., CTS Hold/Incubator #2, Incubator #1, ORU, and
Cuvette Waste Container). To do this, use the following steps:
1. Ensure that at least two cuvette strips are in the Transport Deck.
2. Click on the Cuvettes tab in Diagnostics.
3. Use the "Move Cuvettes" function to move 11 cuvettes from the Cuvette Loader to every position in the
system (i.e., CTS Hold/Incubator #2, Incubator #1, ORU, and Cuvette Waste Container). (Note: Enter
11 in the Number of cuvettes field.
The "Move Cuvettes" function is in the Move Cuvette(s) Area of the Cuvettes Diagnostics tab. Refer to
"Move" for information on using the "Move Cuvettes" function.

9-6 Diagnostics
The diagnostics for the Cuvette Handling System are on the Cuvettes tab. The Cuvettes tab contains three main areas: the Shuttle area, the Waste area, and the
Loader area. Figure 9-17 "The Cuvettes Tab" shows the Cuvettes tab.
Figure 9-17 The Cuvettes Tab

Shuttle Area
Figure 9-18 "The Shuttle Area" shows the Shuttle area.
Figure 9-18 The Shuttle Area
Disable Shuttle Motors Button
The Shuttle motors are disabled by selecting the "Disable Shuttle Motors" button. When the Shuttle motors
are disabled, the "Move Cuvettes" and "Clear All Cuvettes" functions are disabled. The Shuttle motors must
be disabled when the Cuvette Shuttle is to be moved by hand to check the shuttle sensors or to remove
jammed cuvettes. The "Initialize Shuttle" button re-enables the Shuttle motors.
Initialize Shuttle Button
The Cuvette Shuttle is initialized by selecting the "Initialize Shuttle" button. Initialization enables the Shuttle
motors, checks the location of the cuvette slot positions, scans the slots for cuvettes, and positions the Shut-
tle to pick up a new cuvette from the Cuvette Loader. The shuttle status is displayed and includes the follow-
ing: Unknown (during system initialization), Ready, Not Initialized, Initializing, Error, and Busy.
Initialization must be performed after clearing jammed cuvettes.
Note: The Shuttle motors cannot be disabled during Shuttle Initialization.

Cuvette Shuttle Temperature Area
The Cuvette shuttle temperature Area displays the current temperature of the Cuvette Shuttle in the Current
value field and the lower, and upper, temperature limits in the Lower limit and Upper limit fields.
Move Cuvette(s) Area
The functions in the Move Cuvette(s) area may be used to move, extend, grab, or pull back cuvettes. The
functions in this area are useful for fixing problems related to cuvette jamming. After clearing and repairing
a cuvette jam, the positions that caused the jam should be exorcized. The Start button initiates all of these
cuvette operations.
Move
The user can move cuvettes through any and all slots on the instrument. Both the direction and reuse of the
same cuvette are options.
The requested operation is not executed if the Shuttle is not initialized, the Gripper is extended, or the num-
ber of cuvettes to be moved is greater than zero and there is a cuvette in the shuttle.
The user can select the module(s), and position in the modules, to which the cuvette is moved. The user can
select multiple positions, or all positions, in each module.
The selectable modules and positions are as follows:
Table 9-1 Selectable Modules and Positions
Module Position
Loader Not Applicable
Hold Area Positions 1-14
Incubator 2 Positions 1-8
ORU Positions 1-4
Waste Not Applicable
If the Cuvette Waste module is not selected, the cuvette is moved through each selected position and stop
at the last selected module and position, and the number of cuvettes can be set to any value from 1 through
99.
If the Cuvette Loader module is not selected, the number of cuvettes field can be set to any value from 1
through 99.
Note: Shuttle motors can not be disabled when a move is in progress.
Extend
The Extend operation moves the gripper on the cuvette shuttle into the position where it can pick up the
cuvette in the slot.

Note: This operation is not executed if a cuvette is present in the cuvette shuttle and the shuttle is at the
Cuvette Pick-up position, or there is a cuvette in the slot in front of the shuttle.
Note: It is not necessary for there to be a cuvette in the slot that is specified for this command. If the extend
operation is started, the gripper extends to its pick-up cuvette position and then retract into the
Cuvette Shuttle.
Grab
The Grab operation extends the gripper and closes the gripper's jaws. A cuvette is not required in the
selected grab position. If the grab operation is started and the gripper is already extended, the jaws are just
closed. If the grab operation is started and the gripper is not extended, the gripper is extended and then the
jaws are closed.
Pullback
In the Pullback operation, the Gripper is extended, the jaws are closed, and the Gripper pulls back to move
the cuvette into the Shuttle. It is recommended (but not required) that there be a cuvette in the slot that has
been selected for the Pullback operation. If the pullback operation is started, the Extend and Grab opera-
tions is performed, and then the Gripper pulls the cuvette into the shuttle. If the shuttle is in the Waste posi-
tion, the cuvette is released when the Pullback operation is executed.
Clear All Cuvettes
Selecting the "Clear all Cuvettes" button transfers all cuvettes in CTS Hold/Incubator #2, all cuvettes in Incu-
bator #1, and all cuvettes in the ORU to the Cuvette Waste Assembly.
Sensors Area
The Sensors Area contains virtual LEDs for all of the sensors in the Cuvette Handling System. When the
sensor is enabled, the corresponding virtual LED turns green.
The state of each of the following sensors is shown in the Sensor Area of the Cuvettes tab:
Shuttle left limit and Shuttle right limit These sensors are mounted on the Right and Left Outer
Pylons at each end of the Shuttle Travel. The virtual LEDs for these sensors turn green when the
Cuvette Shuttle reaches its left or right limit.
Gripper front and Gripper back The Gripper Front sensor is enabled as the Gripper moves for-
ward. The Gripper Back sensor is enabled as the Gripper moves backward. The virtual LED's for
the gripper front and gripper back sensors turn green when the front or back limit is reached.
Cuvette in slot The Cuvette in slot sensor is enabled when a cuvette placed into a slot is detected
as the shuttle passes in front of that slot. The virtual LED for the cuvette in slot sensor turns green
when a cuvette is detected in a slot.
Cuvette in shuttle The Cuvette in shuttle sensor is enabled when a cuvette is detected inside the
Shuttle. The virtual LED for the Cuvette in shuttle sensor turns green when a cuvette is detected
inside the shuttle.
Shuttle position The shuttle position sensor is a slot sensor that detects if a slot is correctly
aligned to allow a cuvette to be moved into the slot. The virtual LED for the Shuttle position sensor
turns green when a correctly aligned slot is detected.

Waste Area
The Waste Area contains buttons that control the operation of the Waste Shelf (Accumulator), virtual LEDs
that indicate the status of the Waste Assembly, and Sensors for the Waste Assembly. Figure 9-19 "The
Waste Area" shows the Waste area.
Figure 9-19 The Waste Area
Start, Stop, and Clear Accumulator Buttons
Select the Stop button to turn off the Ultrasonic sensor for the Waste Shelf. The Ultrasonic sensor is turned
off to make adjustments or to pull out the Waste Drawer, etc.
Select the Start button to turn on the Ultrasonic sensor for the Waste Shelf. This makes the Waste Shelf
resume its normal operation (i.e., dumping waste cuvettes into the Waste Drawer).
Select the Clear Accumulator button to rotate the Waste Shelf to the "down" position. When the Waste Shelf
is in the "down" position, the shelf is tilted to allow any cuvettes on the shelf to drop into the Waste Con-
tainer.
Virtual LEDs
The upper-left portion of the Waste Area contains virtual LEDs for all of the sensors in the Waste Assembly.
When the sensor is enabled, the virtual LED turns green.
The state of each of the following sensors is shown in the Waste Area of the Cuvettes tab:
Cuvette waste inserted This sensor indicates whether the Waste Container is inserted or
removed. The virtual LED for this sensor turns green when the Waste Container is inserted and red
when the Waste Container is removed.
Cuvette waste door This sensor indicates whether the Waste Door is open or closed. The virtual
LED for this sensor turns green when the Waste Door is opened.
Accumulator up This sensor indicates when the Accumulator is in the "up" position. (When the
Accumulator is in the "up" position, the shelf is horizontal and can hold cuvettes. When the Accu-
mulator is in the "down" position, the shelf is tilted down and any cuvettes on the shelf are dumped
into the Waste Container.)

Other Sensors in the Waste Area
The Cuvette waste level field indicates the height of the waste cuvettes in the Waste Container. The Waste
full limit field indicates the maximum allowable height of waste cuvettes in the Waste Container. When the
waste cuvettes reach the height specified in the Waste warning limit field, a user warning is sent to the
computer screen. When the waste cuvettes reach the height specified in the Waste full limit field, the
Instrument goes into a controlled stop (standby mode). Refer to the Operators Manual for more informa-
tion on controlled stops.
Loader Area
Figure 9-20 "The Loader Area" shows the Loader area.
Figure 9-20 The Loader Area
Initialize Loader
The Loader is initialized by clicking the Initialize Loader button. Loader initialization consists of the follow-
ing:
1. The Transport Deck Belts are turned on until cuvette clips are transferred to the Index Pickup Position
(i.e., frontmost position on the Transport Deck).
2. The Pivot Table moves from vertical to horizontal (i.e., rotates one cuvette clip to the Index position).
3. The Indexer Assembly pushes the cuvette clip against Shuttle Pick-up Position Number One.
When the Loader has finished initializing, the status message Ready displays as shown in Figure 9-20
"The Loader Area".
Move Indexer (Left)
Move the Indexer Assembly (in the Cuvette Loader Assembly) all the way to the left by clicking the Move
Indexer (Left) button.

Move Indexer (Right)
Move the Indexer Assembly (in the Cuvette Loader Assembly) all the way to the right by clicking the Move
Indexer (Right) button. If there is a cuvette strip on the Loader, it is indexed to the Number One position,
where it can be picked up by the Cuvette Shuttle.
Up Pivot Arm
Move the Pivot Arm (for the Pivot Table) into the vertical position by clicking the Up Pivot Arm button.
Down Pivot Arm
Move the Pivot Arm (for the Pivot Table) into the horizontal position by clicking the Down Pivot Arm button.
Virtual LEDs in the Loader Area
The Loader Area contains virtual LEDs for all of the sensors in the Loader Assembly. When the sensor is
enabled, the corresponding virtual LED turns green.
The state of each of the following sensors is shown in the Loader Area of the Cuvettes tab:
Push cuvette The Push Cuvette sensor is located in the Pusher Assembly. The virtual LED for
this sensor turns green when the Pusher Assembly is engaged (i.e., pushing a cuvette strip).
Low This is the rear sensor on the Transport Deck (see Figure 9-8 "The Transport Deck Sen-
sors"). The virtual LED for this sensor turns green when the Loader is low on cuvette strips (i.e.,
when three, or fewer, cuvette strips are left on the Transport Deck).
Empty This is the front sensor on the Transport Deck (see Figure 9-8 "The Transport Deck Sen-
sors"). The virtual LED for this sensor turns red when there are no cuvette strips remaining in the
Loader.
Pivot arm up This sensor is located in the Pivot Table. The virtual LED for this sensor turns green
when the Pivot Table is in the vertical position.
Pivot arm down This sensor is located in the Pivot Table. The virtual LED for this sensor turns
green when the Pivot Table is in the horizontal position.
Indexer left limit The virtual LED for this sensor turns green when the Indexer is in its leftmost
position. (This occurs when the Loader is full.)
Indexer right limit The virtual LED for this sensor turns green when the Indexer is in its rightmost
position. (This occurs when the Loader is empty.)

Cuvette Shuttle and Loader Functional Checks

Use the flowchart in Figure 9-21 "Cuvette Shuttle and Loader Troubleshooting Flowchart" for perform-
ing functional tests after a component in the Cuvette Handling System is replaced or repaired. Aside from
mechanical errors, Shuttle errors can occur as a result of the following:
Improper placement of cuvettes by the Loader
Obstructions in the cuvette path
Faulty index bars
Faulty cuvette clips
NOTE: If repairs are made to a specific component, follow the maintenance guidelines for the component.
After a repair, leave the instrument initialized and in the READY state.
Figure 9-21 Cuvette Shuttle and Loader Troubleshooting Flowchart

Cuvette Loader Assembly Removal/Replacement
Cuvette Loader Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Loader Assembly
the following covers must be removed: Left Skin, Inner Left Skin, Upper Skin (Sample Side), Sample
Syringe Cover, Sample/Accumulator Wash/Rinse Cover, Top Skin, Front Panel, and Sample Side Robotic
Arm Cover.
After the covers have been removed, do the following to remove the Loader Assembly:
1. Remove the cable J1 from P1 of the Loader PCB.
2. Remove the four screws shown in Figure 9-22 "The Cuvette Loader Assembly (seen from above
and behind)", and remove the module from the Instrument. Please remember that the Loader mounting
hardware is NOT captive.
Figure 9-22 The Cuvette Loader Assembly (seen from above and behind)
Screw Locations
Loader Assembly Installation
1. Position the Loader Assembly using the alignment pin to ensure proper location.
2. Reinstall the mounting hardware previously removed.
3. Reconnect the cable J1 to P1 of the Loader PCB.
CTS Hold/Incubator #2 Removal/Replacement
NOTE:There is an error in the software that misidentifies the Incubators.

Incubator 1 in the SW refers to Incubator 2 hardware. Incubator 2 in the
SW refers to Incubator 1 hardware.

CTS Hold/Incubator #2 Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the CTS Hold/Incubator
#2 Assembly, the following covers must be removed: Sample Syringe Cover, Sample Accumulator/Wash
Rinse Cover, and the Sample Module Cover.
After the covers have been removed, do the following to remove the CTS Hold/Incubator #2:
1. Loosen the four captive screws shown and remove the CTS Hold/Incubator #2 from the Instrument.
(Note: The Captive screws are painted orange as shown in Figure 9-23 "Captive Screws on the CTS
Hold/Incubator #2".)
2. Remove the cable P1 from J1 of the Incubator Heating PCB.
Figure 9-23 Captive Screws on the CTS Hold/Incubator #2
Screw Locations
CTS Hold/Incubator #2 Installation
1. Reconnect cable P1 to J1 of the Heating PCB.

2. Position the assembly using the alignment pin to ensure proper location. (Note: The alignment pin is
on the chassis.)
3. Tighten the four captive screws.
4. Refer to Inputting Thermal Coefficients using ThermalCal in Chapter 12 to enter the coefficients
of the replacement unit.
Incubator #1 Removal/Replacement
NOTE:There is an error in the software that misidentifies the Incubators.

Incubator 1 in the SW refers to Incubator 2 hardware. Incubator 2 in the
SW refers to Incubator 1 hardware.
Incubator #1 Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Incubator #1 Assem-
bly, the following covers must be removed: Reagent Syringe Cover, Reagent Accumulator/Wash Rinse
Cover, Reagent Module Cover, and Peristaltic Pump Cover.
After the covers have been removed, do the following to remove the Incubator #1 Assembly:

1. Loosen the four captive screws shown and remove the assembly from the unit.
2. Remove the cable P1 from J1 of the Incubator Heating PCB.
Incubator #1 Installation
1. Reconnect the cable P1 to J1 of the Incubator Heating PCB.

2. Position the assembly using the alignment pin to ensure proper location. (Note: The alignment pin is
on the chassis.)
3. Tighten the four captive screws. (Note: The Captive screws are painted orange as shown in Figure 9-
24 "Captive Screws on the Incubator #1".)
4. Refer to Inputting Thermal Coefficients using ThermalCal in Chapter 12 to enter the coefficients
of the replacement unit.
Figure 9-24 Captive Screws on the Incubator #1
Screw Locations
Optical Reading Units Cradle Assembly

Refer to Removing the ORU Assembly in Chapter 10 for details and instructions on ORU removal.
Cuvette Shuttle Assembly Removal/Replacement
Cuvette Shuttle Assembly Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Cuvette Shuttle
Assembly, the following covers must be removed: Sample Syringe Cover and Sample Accumulator/Wash
Rinse Cover.

CAUTION: Ensure that the Instrument is powered OFF before performing

After the covers have been removed, do the following to remove the Cuvette Shuttle Assembly:
1. Position the Cuvette Shuttle Assembly so that it is between the Loader Assembly and the CTS Hold/
Incubator #2. (Note: Ensure that the X-Axis sensor (i.e., position sensor) is not between a position
flag.)
2. Remove the mounting screw, flat washer, and lock washer from the Mounting Bracket (see Figure 9-25
"The Mounting Bracket").
Figure 9-25 The Mounting Bracket
Mounting Screw
Mounting Bracket
3. Carefully remove the Cuvette Shuttle Assembly from the mounting bracket so not to damage the posi-
tion sensor. (It is recommended to slide the Cuvette Shuttle Assembly to the left before pulling it out of
the Instrument.)
4. Remove the Shuttle Lower Strain Relief Bracket (see Figure 9-26 "The Y-Axis Adjustment and Lock-
ing Screws").
5. Remove the cable from connector J6 (see Figure 9-26 "The Y-Axis Adjustment and Locking
Screws").

Figure 9-26 The Y-Axis Adjustment and Locking Screws
J6 Connector
The Orange Thumbscrews
Cuvette Shuttle Assembly Installation
1. Connect cable P6 to connector J6 of the X-axis PCB.

2. Replace the Shuttle Lower Strain Relief Bracket.
3. Carefully position the Cuvette Shuttle Assembly on the bracket using the alignment pins taking care so
as not to damage the position sensor.
4. Replace and tighten the mounting screw, flat washer, and lock washer on the Mounting Bracket.
5. Align the Cuvette Shuttle as described in "Cuvette Shuttle Y-Axis Motor Removal/Replacement".
6. Verify the operation of the Cuvette Shuttle by moving 11 cuvettes from the Cuvette Loader to every posi-
tion in the system (i.e., CTS Hold Incubator #2, Incubator #1, ORU, and Cuvette Waste Container).
Refer to "Adjustments/Verification" for information on how to do this.
Cuvette Shuttle Y-Axis Motor Removal/Replacement

Y-Axis Motor Removal
1. Remove the Shuttle Assembly from the ACL-TOP instrument as described in "Cuvette Shuttle Assem-
bly Removal".

2. Remove the Y-Axis PCB Cover by removing the four cover screws as shown in Figure 9-27 "Y-Axis
PCB Cover".
Figure 9-27 Y-Axis PCB Cover
Cover screws
Cover Y-Axis
PCB
3. Disconnect all cables from the Y-Axis PCB.

4. Remove the four standoffs and remove the Y-Axis PCB. (See Figure 9-28 "Y-Axis PCB").
Figure 9-28 Y-Axis PCB
Standoffs
Y-Axis PCB
5. Remove the Motor and Shuttle Heater cables from the cable clamp on the bottom of the shuttle assem-
bly, as shown on Figure 9-29 "Cables and Cable Clamp", and remove the cable ties.

Figure 9-29 Cables and Cable Clamp
Motor Cable Cable Clamp
Drive Belt
Shuttle Heater
Cable
6. Move the Shuttle Heater cable back through the motor bracket and clear of the assembly.
7. Loosen the two socket head bracket mounting screws as shown on Figure 9-30 "Motor Bracket
Mounting Screws".
8. Decrease the tension in the belt until it is slack by loosening the two adjustment screws on the Y-Axis
Motor Bracket, as shown on Figure 9-30 "Motor Bracket Mounting Screws".
9. Remove the two Bracket Mounting screws and remove the Y-Axis Motor/Pulley Assy.
Figure 9-30 Motor Bracket Mounting Screws
Bracket Mounting Screws
Tension Adjustment Set Screws
Y-Axis Motor Installation
1. Place the new Y-Axis Motor/Pulley Assy (P/N 281855-00) on the Shuttle Assembly and finger-tighten
the bracket mounting screws as shown in Figure 9-30 "Motor Bracket Mounting Screws".

2. Place the drive belt on the motor pulley and turn the tension adjustment set screws until their top is even
with the "ears" on the motor bracket.
3. Route the motor and heater cables through the cable clamp on the bottom of the Shuttle Assembly (See
Figure 9-31 "Cables and Cable Clamp").
Figure 9-31 Cables and Cable Clamp
Motor Cable Cable Clamp
Drive Belt
Shuttle Heater
Cable
4. Route the Shuttle Heater cable through the opening in the motor bracket (See Figure 9-31 "Cables and
Cable Clamp").
5. Ensure the cables are positioned as shown in Figure 9-32 "Cable Routing" before installing the Y-Axis
Shuttle PCB.
Figure 9-32 Cable Routing

6. Place the new Y-Axis PCB (P/N 276140-00) on the four standoffs and plug all cables into the PCB as
shown on Figure 9-28 "Y-Axis PCB".
Figure 9-33 Y-Axis PCB
Standoffs
Y-Axis PCB
7. Secure the motor cable and the Shuttle Heater cable with cable ties as shown on Figure 9-34 "Com-
pleted Assembly".
8. Secure the Y-Axis PCB Cover by re-installing the four cover screws as shown on Figure 9-34 "Com-
pleted Assembly".
Figure 9-34 Completed Assembly
Cable Ties
Cover Screws
9. Install and align the Cuvette Shuttle as described in "Cuvette Shuttle Y-Axis Motor Removal/
Replacement".
10. Verify the operation of the Cuvette Shuttle as described in "Cuvette Shuttle and Loader Functional
Checks".
Cuvette Shuttle Solenoid Removal/Replacement

1. Remove the Shuttle Assembly from the ACL-TOP instrument as described in "Cuvette Shuttle Assem-
bly Removal"
2.

3.
Aligning the Cuvette Shuttle

The Cuvette Shuttle must be aligned after it is removed or replaced. This section describes how to align the
Cuvette Shuttle.
1. "Cuvette Shuttle Alignment Check"
2. "Z Height and Tilt Check"
3. "Y Adjustment"
4. "X Adjustment"
NOTE:A Cuvette Shuttle Alignment Check must be performed before any

of the other tasks.
Cuvette Shuttle Alignment Check
1. With the Instrument powered on, select the Cuvettes tab in Diagnostics.
2. Select the Disable Shuttle Motors button.
3. Do the following to check the Left Limit Sensor of the Cuvette Shuttle Assembly:
a) Manually move the Cuvette Shuttle Assembly all the way to the leftmost end of the Shuttle Travel.
(When the Cuvette Shuttle reaches the leftmost end of the Shuttle Travel, the virtual LED for
Shuttle Left Limit should turn green.)
b) If the virtual LED for Shuttle Left Limit does not turn green, adjust the sensor bracket up or down.
c) Repeat steps a and b (above) until the virtual LED for Shuttle Left Limit turns green.
4. Repeat steps a through c (above) for the Right Limit Sensor of the Cuvette Shuttle Assembly.
Figure 9-35 The Left and Right End-of-limit Sensors
Left End-of-Limit Sensor (on left Right End-of-Limit Sensor

side of chassis) (on right side of chassis)
5. Do the following to check the Shuttle Alignment Tool:

a) Position the Cuvette Shuttle Assembly in front of the Shuttle Alignment Tool. (The location of the
Shuttle Alignment Tool is shown in Figure 9-36 "Location of the Shuttle Alignment Tool".)
b) Loosen the orange thumbscrews on the Shuttle Alignment Tool and insert the Shuttle Alignment
Tool into the Cuvette Shuttle Assembly.
c) If the Shuttle Alignment Tool can not be smoothly inserted into the Cuvette Shuttle Assembly, per-
form the Z Height and Tilt Check (see "Z Height and Tilt Check").
Figure 9-36 Location of the Shuttle Alignment Tool
Z Height and Tilt
Adjustment Screws
Z height and Tilt Locking

Screws
Shuttle Alignment Tool
Orange Thumbscrews
Z Height and Tilt Check
1. Power off the Instrument.

2. Orient the Cuvette Shuttle Assembly so that the front face of the Shuttle is directly in front of the Align-
ment Tool shown in Figure 9-36 "Location of the Shuttle Alignment Tool".
3. Loosen the orange thumbscrews on the Alignment Tool and attempt to insert the dowel pin (located in
the center of the Alignment Tool) into the front face of the Shuttle Assembly.
4. If the dowel pin does not fit smoothly into the front face of the Shuttle Assembly, do the following:
a) Loosen the Z Height and Tilt Locking Screws (see Figure 9-36 "Location of the Shuttle Align-
ment Tool").
b) Adjust the Z Height and tilt by turning the Z Height and Tilt Adjustment Screws (see Figure 9-36
"Location of the Shuttle Alignment Tool"). The alignment is correct when 1) the dowel fits
smoothly into the front face of the Shuttle Assembly and 2) the front face of the Alignment Tool is
completely flush (perpendicular) with the mating face on the front of the Cuvette Shuttle Assembly.
c) Tighten the Z Height and Tilt Locking Screws to secure the adjustment.
5. With the Z Height and Tilt Locking Screws tightened, re-check the adjustment as follows
1) The dowel should fit smoothly into the front face of the Shuttle Assembly.
2) The front face of the Alignment Tool should be completely flush (perpendicular) with the mating
face on the front of the Cuvette Shuttle Assembly. (The Alignment Tool surface should not be
tilted against the front surface of the Cuvette Shuttle.)
6. If the adjustment is not correct, repeat step 4 and step 5.

NOTE:Ensure that each Z Height and Tilt Locking Screw has a lock
washer, and a flat washer, assembled to it.
Figure 9-37 The Z Height and Tilt Adjustments
Z Height and Tilt Adjustment Screws
Z Height and Tilt Locking Screws
Y Adjustment
NOTE:The following procedure should be performed with the Instrument

powered on.
1. Orient the Cuvette Shuttle Assembly so that the front face of the Shuttle is directly in front of the Cuvette
Pick-up position on the Loader.
2. Loosen the Y-Axis Sensor Adjustment screw (see Figure 9-39 "The Y-Axis Adjustment and Locking
Screws").
3. Turn the Turning Wheel until the front face of the Gripper Assembly is flush with the front face of a
cuvette located at the Cuvette Pick-up position on the Loader Assembly. (The Turning Wheel is shown
in Figure 9-38 "The Y-Axis LED and the Turning Wheel".)
4. Turn the Y-Axis Sensor Adjustment screw until the Y-Axis LED comes on with the Gripper Assembly just
touching the front face of the Cuvette at the Cuvette Pick-up position. (The Y-Axis Sensor Adjustment
screw is shown in Figure 9-39 "The Y-Axis Adjustment and Locking Screws". The Y-Axis LED is
shown in Figure 9-38 "The Y-Axis LED and the Turning Wheel".)
Note:Turning the Y-Axis Sensor Adjustment screw in a counterclockwise direction moves the
Y-Axis Sensor towards the front of the Instrument.
5. After the alignment of the Y-Axis Sensor has been set, tighten the Y-Axis Adjustment Locking screw to
secure the adjustment. (The Y-Axis Adjustment Locking screw is shown in Figure 9-39 "The Y-Axis
Adjustment and Locking Screws".)
NOTE:Ensure that the Y-Axis Sensor Adjustment Screw has a lock

washer, and a flat washer, assembled to it.

6. When the Y-Axis Sensor is properly adjusted, slight turns of the Y-Axis Sensor Adjustment screw makes
the LED go on and off. If the adjustment is not correct, repeat step 4 and step 5.
Figure 9-38 The Y-Axis LED and the Turning Wheel
Y-Axis LED Turning Wheel

Figure 9-39 The Y-Axis Adjustment and Locking Screws
Y-Axis Sensor Adjustment

Screw
Y-Axis Adjustment Locking

Screw
X Adjustment
NOTE:The following procedure should be performed with the Instrument

powered on.
1. Place a cuvette into the first slot of CTS Hold/Incubator #2.
2. Orient the Cuvette Shuttle so that the Gripper Assembly is directly in front of the cuvette in the first slot
of CTS Hold/Incubator #2.
3. Align the center of the Gripper Assembly to the center of the cuvette in the first slot of CTS Hold/Incuba-
tor #2.

4. Extend the Gripper Assembly until its front surface touches the front surface of the cuvette.
5. Do the following to establish where the X-Axis Sensor LED illuminates with respect to the Gripper
Assembly:
a) Turn the X-Axis Sensor Adjustment Screw clockwise, or counterclockwise, until the X-Axis LED
goes on. (The X-Axis Adjustment Screw is shown in Figure 9-40 "The X-Axis Adjustment and
Locking Screws"; the X-Axis LED is shown in Figure 9-41 "LEDs on the Cuvette Shuttle
Assembly".)
b) When the X-Axis LED goes on, note how far off center the Gripper Assembly is to the center of the
cuvette. (Turning the X-Axis Adjustment Screw clockwise moves the Sensor towards the right;
turning the X-Axis Adjustment Screw counterclockwise moves the Sensor towards the left.)
NOTE:Because the sensor is seeing two edges of a slot, the LED only
stays on when in the zone of the slot. This means that if the shuttle
moves in the X direction, from one side of the Instrument to the other,
the LED illuminates for a certain distance and then shut off. This is
because the sensor is off until it sees the first edge, then illuminates for
the width of the slot (.50 mm), then shuts off after it sees the other edge.
Knowing this, we need to establish where the other edge of the slot turns
off the LED, and then note how far off center the Gripper Assembly is in
relation to the center of the cuvette. These two distances need to be
equal.
6. Turn the X-Axis Sensor Adjustment Screw until the two distances (see above NOTE) appear to be
equal.
7. When an equal spacing has been established, tighten the X-Axis Adjustment Screw.
NOTE:Ensure that the X-Axis Adjustment Screw has a lock washer, and
a flat washer, assembled to it.

Figure 9-40 The X-Axis Adjustment and Locking Screws
X-Axis Sensor Adjustment

Screw (Located behind the
Locking Screw)
X-Axis Adjustment Locking

Screw
Figure 9-41 LEDs on the Cuvette Shuttle Assembly
Cuvette In-slot
Sensor LED
Y-Axis LED
X-Axis LED
After the X-Axis Sensor Adjustment is performed, do the following to verify proper alignment of both the X-
and Y-Axis adjustments:
1. Power on the Instrument and select the Cuvettes tab from the Diagnostics menu.
2. Initialize the Cuvette Shuttle by clicking on the Initialize Shuttle button on the Cuvettes tab.
3. Fill the Transport Deck with at least three cuvette clips.
4. Using the Move Cuvettes function, move 25 cuvettes in the following fashion:
a) From the Loader to the respective first slots of the CTS Hold Area, Incubator #2, Incubator #1, and
the ORU.
b) From the first slot of the ORU to Waste.

NOTE:When the Cuvette Shuttle picks and places the cuvette, note
where the Gripper Arm is placed within the cuvette well. The Gripper Arm
should be in the center. The Gripper Arm should not hit the right inner
side wall of the cuvette. If the Gripper Arm hits the right inner side wall of
the cuvette, it is not be able to properly pick and place the cuvettes.
5. If the Gripper Arm does not pick cuvettes at all, or if it fails to pick and place smoothly within the cuvette
well, re-adjust the X-Axis alignment.
6. If the Gripper Arm appears to be in the center but still does not pick cuvettes, re-adjust the Y-Axis align-
ment.
7. If there is a gap between the cuvette front face and the Gripper front face, re-adjust the Y-Axis align-
ment.


Chapter 10 Reaction Detection 10 - 1
Chapter 10
Reaction Detection
10-1 Overview
The ACL-TOP Reaction Detection subsystem measures turbidity (opaqueness) of the cuvette well during a
clotting reaction. The Emitter PCB produces light that travels from the Emitter PCB via the Optical paths,
through the cuvette wells, and onto the detector chips on the Detector PCB. At power up, electrical currents
through the red and the blue LEDs are automatically adjusted so that the reference detector (on the Detector
PCB) sees a pre-determined amount of light energy from each LED. These two light levels are maintained
by automatic adjustment of the Emitter PCB by the Optical Reading Unit (ORU) Controller.
When a reaction occurs in a cuvette well, the cuvette well becomes more cloudy and less light is allowed to
reach the detector chip.
The Reaction Detection subsystem consists of five functional components:

ORU controller
Emitter PCB
Optical Paths
Detector PCB
Thermal regulation
NOTE: Please refer to Physical Layout in Chapter 9 for the physical layout aspects of
reaction detection and to Theory of Operation/Block Diagram in Chapter 5 for informa-
tion on the Level II CPU, controller PCBs, and their associated software.
ORU Controller PCB

The ORU Controller has four primary functions:
It pulses the two light sources on the Emitter PCB at 40 Hertz, with the blue light having a 10% duty
cycle and the red light having a 25% duty cycle.
It retrieves data from the Detector PCB.
It provides thermal regulation to the ORU heads.
It monitors the 12V supply on the Emitter PCB.

10 - 2 Chapter 10 Reaction Detection
The ORU Controller PCB is located in the card cage in the middle front of the instrument between the Sam-
ple and Reagent modules. It is the rightmost PCB of the three PCBs in the module.
Emitter PCB
The Emitter PCB powers the red and blue LEDs that are the light source for reaction detection. The Emitter
PCB also sends an analog signal back to the ORU Controller for monitoring purposes. Upon power up, there
is a beam of magenta light (combination of red and blue) passing across each cuvette channel of each ORU
head.
The Emitter PCB is located on the right end of the ORU Assembly.
Optical paths
There are two parts to the ACL-TOP optical path, the optical fiber path and the reference path. The optical
fibers, or fiber assembly, consists of two collecting rods, one integrating rod, and 19 individual fibers of var-
ious lengths. The two collecting rods gather light from the red and blue sources while the integrating rod
combines the two wavelengths. The 19 individual fibers distribute the combined light to all channels of the
ORU heads, the reference channel, and two spares. Obstructions, pinching, and tight bends of the fibers
impede the light propagation.
The Reference path is an acrylic rod that directs light from the reference optical fiber to the reference detec-
tor chip on the Detector PCB. The output of the reference path is used for automatic adjustment of the Emit-
ter PCB by the Optical Reading Controller.
Detector PCB
Light passing through the reaction cuvette well enters the detector chips on the Detector PCB. The corre-
sponding signals are conditioned and converted to digital format for the controller to process. Each ORU
head has a detector PCB mounted within the head.
ORU Light Generation, Flow and Sensing

Figure 10-1 "ORU Light Path" shows a simplified version of the generation and flow of the light in the ORU
that is used to sense reactions in the cuvettes. Note that the description does not include the reference
channel, the optical and voltage feedbacks and various checking circuits that are used to ensure the accu-
racy of the ORU. As shown in the figure, the generation of the light for the ORU begins with the Emitter PCB
supplying voltage to the LEDs in the Emitter Block. (There are four LEDs for each of the two light sources in
the Emitter Block. Each set of four LEDS are enclosed as a single light source.) The LED light outputs are
filtered and focused within the Emitter Block and enter the large and small fiber bundles as red and blue
light, i.e., wavelength of 405, and 671nm respectively). The large fiber bundle is used to transmit the Blue
light while the small fiber bundle is used to transmit the red light. The two colored light sources enter a col-
lecting rod and are combined into a magenta light in an integrating rod. From the integrating rod, the light
separates into the fibers for each ORU head and is delivered through the optical fibers to the ORU head
where it is used to detect reactions. After passing through the cuvette wells in the ORU head, the light is
focused by lenses on the other side of the head and sensed by a sensor within the head. The output of the
sensor is converted to a proportionate voltage output and used by the detector PCB to determine the reac-
tion.

Figure 10-1 ORU Light Path

Thermal Regulation
Logic signals from the ORU Controller enable/disable the Field Effect Transistors (FETs) to turn on or off
power to the heating pads in the ORU heads. The FETs are located on the ORU Interface PCB. Also, there
is a thermal cut-off switch mounted on each ORU head to prevent run-away temperatures. Refer to Optical
Reading Unit (ORU) Cradle Thermal Regulation in Chapter 12 for a description of thermal elements.
Interconnect Diagram
Figure 10-2 "Reaction Detection Block Diagram/Interconnections" shows the data flow throughout the
components of the Optical reading Unit.

Figure 10-2 Reaction Detection Block Diagram/Interconnections

10-3 Adjustments/Verifications
Verification of the ORU assembly is accomplished through use of the verification procedures described in
the following pages. The procedures are based on and use the diagnostic capabilities built into the ACL-
TOP instrument.
Adjustments to the ORU assembly are included within the verification procedures that follow.
Verifying the ORU

Following is the procedure to test/verify the ORU with references to the other, more detailed procedures for
testing/verifying individual ORU areas. Figure 10-3 "Overall ORU Verification" shows the overall flow of
the procedure. There are two symbols used in the flowcharts to aid in navigation. The symbols and their
meaning are as follow:
...Indicates a link to another flowchart
Indicates an entry from one or more other flowcharts
NOTE: The flowchart is meant to be a guide and the written, step-by-step procedure following
the flowchart includes all actions required.

Figure 10-3 Overall ORU Verification
1. Open the General Log File for the instrument to verify the ORU error. (Click on System -> General Log
List.
2. Power up the instrument and place it in Diagnostic mode. (Click on System ! Diagnostics.

3. Open the Voltage tab in the diagnostics window as shown in Figure 10-4 "Voltage Tab in Diagnostics Window".
Figure 10-4 Voltage Tab in Diagnostics Window
ORU Voltages
ORU Controller
Voltages
Emitter Voltages

4. Check the ORU Controller, Emitter and ORU voltages as shown in Figure 10-4 "Voltage Tab in Diag-
nostics Window" and verify that they are all within the limits shown on the screen. (Out of Limit read-
ings are displayed in red.)
5. If any voltage is not within limits, refer to "Testing/Correcting Voltage Errors".
6. Open the ORU tab in the diagnostics window as shown on Figure 10-5 "ORU Tab of Diagnostic
Screen".

Figure 10-5 ORU Tab of Diagnostic Screen

7. Verify that ORUs 1-4 are enabled (Green LED) as indicated on Figure 10-6 "ORUs Enabled Indica-
tors Portion of Diagnostic Screen".
Figure 10-6 ORUs Enabled Indicators Portion of Diagnostic Screen
8. If all four LEDs are not lit, refer to "Enabling ORUs".

9. Ensure all ACL-TOP covers are installed and the sample and reagent doors are closed.
10. Within the Dark Readings area of the screen as shown on Figure 10-7 "Dark Readings Portion of
Diagnostic Screen", click on the Start button to test the ORU dark readings and, after approximately
one minute, click on the Stop button to end the test. Ensure the test is stopped before proceeding with
any other tests. Verify the dark readings on each channel of each ORU are below the limit indicated on
the screen. If any readings are not below the limit, refer to "Testing/Correcting Dark Readings".
Figure 10-7 Dark Readings Portion of Diagnostic Screen
Limit
(Maximum Value)
11. Click on the Start button in the Reference Reading portion of the diagnostic screen as shown on Figure
10-8 "Reference Readings Portion of Diagnostic Screen". Check Min. /Max. Reference readings
and ensure that they are within the limits specified on the screen. Most important, check Min. DAC and
Max. DAC readings for both blue and red and verify that they are between 35 -235. Click on the Stop
button before proceeding with the next test. If any readings are not within the limits, refer to "Tuning
ORU Optics".
Figure 10-8 Reference Readings Portion of Diagnostic Screen

12. Using the ORU selection buttons as shown on Figure 10-9 "Optical Readings Portion of Diagnostic
Screen", select each ORU individually, press the Start button, and check the value of the mean air opti-
cal blanking (Air column) and ensure that they are within the limits specified on the screen. (The Air
reading indicates the values when there is nothing in the cuvette well - except air. Ensure readings for
Red - 671 and Blue - 405 on all 4 ORU heads are checked. Press the Stop button before proceeding
with each ORU test. If any readings are not within limits, refer to "Testing/Correcting Optical Blank-
ing Errors".
Figure 10-9 Optical Readings Portion of Diagnostic Screen
13. Check all cables and cable connections to the ORU and verify they have not been damaged or subject
to spillage. If they have been damaged in any way, replace them.
NOTE: If the cables are to be replaced, be sure to check the board connectors to ensure they are not
damaged or have spillage affecting their operation.
14. Check that the temperature readings of all four ORUs are within the upper and lower limits as specified
in the temperature portion of the diagnostic screen (see Figure 10-10 "Temperature Portion of Diag-
nostic Screen"). At this time, temperature controls are not replaceable items. Therefore, if the readings
are not within specifications, replace the ORU as described in "Removing/Replacing the ORU
Assembly" and "Installing the ORU Assembly".
Figure 10-10 Temperature Portion of Diagnostic Screen

15. Clean the ORU heads, using a dry cotton swab, and wipe the channel of the ORU head from the front
of the instrument to the back. Continue cleaning with clean swabs until the swab being used comes out
completely clean.
16. Perform a coordinate adjust as described in Diagnostics in Chapter 8.
17. At this point, all diagnostic tests on the ORU have passed. Perform the Air Blanking for all ORUs to
reset the reference point as stated in the following steps.
18. Click on the Start Air Blanking for all ORUs button, in the Optical readings portion of the diagnostic
screen as shown in Figure 10-11 "Air Blanking of All ORUs".
Figure 10-11 Air Blanking of All ORUs
Air Blanking for

all ORUs button
19. Upon completion of the Air Blanking (approximately 5 minutes), a message box is displayed showing
the readings for each channel. Verify all readings are between 500000 and 1200000. If not, replace the
ORU as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assem-
bly".
20. Click on the Start Factor Diluent Blanking for all ORUs button, in the Optical readings portion of the
diagnostic screen as shown in Figure 10-12 "Factor Diluent Blanking for all ORUs".
NOTE: A prompt is displayed to place a vial in position 1 of Rack R5 filled with 10mL of Factor
Diluent to perform the Factor Diluent Blanking.

Figure 10-12 Factor Diluent Blanking for all ORUs
Factor Diluent Blanking

for all ORUs button
21. Upon completion of the Factor Diluent Blanking (approximately 30 minutes), a message box is dis-
played showing the readings for each channel. Verify all readings are between 500000 and 1200000. If
so, the ORU is working properly. Verify the system operation by monitoring the customer application.
22. If the Factor Diluent Blanking is not within the limits, once again clean the ORU heads with a clean dry
cotton swab and wipe the channel of the ORU heads from the front of the instrument to the back. Con-
tinue cleaning with clean swabs until the swab being used comes out completely clean.
23. Inspect the probe and, if necessary, clean or replace the probe.
24. Perform a coordinate adjust as described in Diagnostics in Chapter 8.
25. Perform the Factor Diluent Blanking again and verify all readings are between 500000 and 1200000. If
so, verify the system operation by monitoring the customer application.
26. If not, replace the ORU as described in "Removing/Replacing the ORU Assembly" and "Installing
the ORU Assembly".
Testing/Correcting Voltage Errors

Figure 10-13 "Testing/Correcting Voltage Errors" shows the overall flow of the procedure for testing/cor-
recting voltage errors.

Figure 10-13 Testing/Correcting Voltage Errors

N
NOTE:Ensure voltages are checked in the following order because
voltages being incorrect in one area could cause voltages to be incorrect
in the following area.
1. Check the ORU controller voltages on the Voltage tab of the diagnostic screen as shown in Figure 10-
14 "ORU Controller Voltages".
Figure 10-14 ORU Controller Voltages
2. Are the voltages within limits? If not, continue with step 3. If the voltages are within limits, go to step 8.
3. Check the voltages on the Fuse PCB, using a meter.
4. If the voltages are okay on the fuse board, replace the ORU controller PCB (as part of the ORU Assem-
bly) as described in "Removing/Replacing the ORU Assembly" and "Installing the ORU Assem-
bly".
5. If the voltages on the Fuse PCB are not correct, check the power supply output voltages using a meter.
6. If the power supply output voltages are okay, replace the Fuse PCB as described in Fuse Board
Removal/Replacement in Chapter 6.
7. If the power supply voltages are NOT okay, replace the power supply as described in Non-adjustable
Power Supply Removal/Replacement in Chapter 6.
8. Check the Emitter voltage on the Voltage tab of the diagnostic screen as shown in Figure 10-15 "Emit-
ter Voltage Display".
Figure 10-15 Emitter Voltage Display
9. If the Emitter voltages are within limits, go to step 11.

10. If the Emitter voltages are not within limits, replace the ORU Assembly as described in "Removing/
Replacing the ORU Assembly" and "Installing the ORU Assembly".
11. Check the cabling and cable seating to the ORU, specifically the cabling to the Emitter Board.
12. If the cabling is okay and all cables are properly seated, replace the Emitter Assembly as described in
"Removing/Installing the Emitter Assembly".
13. If the cabling is not okay, reseat any cables that need seating and/or replace all ORU cables.
14. Go to the procedure "Verifying the ORU" to verify the ORU operation as described in that procedure.

Enabling ORUs
The overall flow of the procedure for enabling ORUs is shown in Figure 10-16 "Enabling ORUs Flow-
chart".

Figure 10-16 Enabling ORUs Flowchart
Enabling ORUs
Re-enable ORU in
Diagnostic mode.
Can ORU be
re-enabled No
Replace ORU
Yes
I
Change to
Operating Mode
Reinitialization No
OK?
Review Error log,
check for
extraordinary light.
Yes
Clean head.
Verify System
Change to
Operating Mode
Reinitialize
OK? Yes
I
No
Verify ORU
Replace ORU
1. If all four ORU Enabled LEDs are not lit, click on any box without a check mark as shown in Figure 10-
17 "ORU Enabling Portion of Diagnostic Screen" and click on the Save button. Verify that the green
LED light indicating the ORU is enabled becomes lit.
2. If all ORUs cannot be enabled, check the log file in an attempt to determine what disabled the ORU,
verify the items in the Testing/Verifying the ORU procedure and correct as necessary, recognizing that
an ORU can be disabled by problems with the temperature, reference output, dark readings, voltages,
or air readings. If checking and correcting any problem in these areas does not allow the ORU to be
enabled, replace the ORU Assembly as described in "Removing/Replacing the ORU Assembly" and
"Installing the ORU Assembly".

Figure 10-17 ORU Enabling Portion of Diagnostic Screen
3. If all ORUs can be enabled, place the instrument in user mode by clicking on one of the three buttons
(Sample, Reagent, and Diluent) in the upper right of the window as shown in Figure 10-18 "Sample,
Reagent, Diluent Buttons".
Figure 10-18 Sample, Reagent, Diluent Buttons
4. Was an error displayed? (During conversion to user mode, the instrument is re-initialized and checks
are made to ensure it is in proper operating condition.)
5. If an error was detected, review the error log to determine what error was detected and use the proce-
dures in "Verifying the ORU" to analyze the error. Also, check the unit to ensure there is not excessive
light on the instrument (if so, move the instrument or shield it from the light), and clean the heads by
using a dry cotton swab and wiping the channel of the ORU head from the front of the instrument to the
back. Continue cleaning with clean swabs until the swab being used comes out completely clean.
6. Place the instrument in diagnostic mode and then back in user mode by clicking on one of the three but-
tons (Sample, Reagent, and Diluent) in the upper right of the window as shown in Figure 10-18 "Sam-
ple, Reagent, Diluent Buttons" to re-initialize it.
7. Was an error displayed? If not, return to the "Verifying the ORU" and check the remaining diagnostic
readings bearing in mind that the ORU was disabled by the system by one of the following:
Air reading went below the low limit.
Air reading went above the high limit.
The difference between the current air reading and the stored air reading was higher than the limit.
A detector voltage error was detected by the ORU.
8. If an error was displayed, replace the ORU Assembly as described in "Removing/Replacing the ORU
Testing/Correcting Dark Readings

Figure 10-19 "Testing/Correcting Dark Readings Flowchart" shows the overall flow of the procedure for
Testing/Correcting Dark Readings.

Figure 10-19 Testing/Correcting Dark Readings Flowchart
Testing/Correcting Dark Readings
Does instrument
have extraordinary Yes
light?
Move equipment
out of the light or
shield it from light.
No
Good grounding
connections on ORU No
heads?
Verify ground
connections.
Yes
Check remainder of ORU

diagnostic readings.
Correct as necessary.
Problem
resolved? No
Yes Replace ORU
Verify operation
1. Check the environment for excessive light, for example, bright sunlight shining directly on the unit.
2. If the light is excessive, either move the unit or shield the unit from the excessive light. Repeat the test-
ing by clicking on the Start button to test the ORU dark readings and, after approximately one minute,
click on the Stop button to end the test. Ensure the test is stopped before proceeding with any other
tests.
3. If all dark readings on each channel of each ORU, as shown on Figure 10-20 "Dark Readings Portion
of Diagnostic Screen", are now below the limit, the problem has been corrected and all steps of "Ver-
ifying the ORU" should be performed to verify the ORU operation. If any reading is not below the limit,
continue to step 4.

Figure 10-20 Dark Readings Portion of Diagnostic Screen
4. Remove the ORU as described in "Removing/Replacing the ORU Assembly".

5. Check the grounding on each of the four ORU heads by using a digital multimeter to measure the resis-
tance between the ground wire as shown in Figure 10-21 "ORU Head Ground Connections" and
anywhere on the ORU chassis plate. Resistance should be less than 0.5 ohms.
Figure 10-21 ORU Head Ground Connections
Ground connections for ORU heads

ORU Chassis Plate
6. If any ground readings are higher than 0.5 ohms, tighten the ground screws and verify the connection
until the resistance is within limits.
7. Check the remainder of the ORU diagnostic screen readings as described in "Verifying the ORU" and
follow the procedure for correcting the problem.
8. If all other readings are within specification and the ground connections were the proper resistance,
replace the ORU as described in "Removing/Replacing the ORU Assembly" and "Installing the
ORU Assembly".
9. Verify the operation of the instrument by monitoring the user application.

Testing/Correcting Optical Blanking Errors

Figure 10-22 "Testing/Correcting Optical Blanking Errors" shows the overall flow of the procedure.
Figure 10-22 Testing/Correcting Optical Blanking Errors
Testing /Correcting Optical

Blanking Errors
E Are they cracked,

scratched, Yes
damaged?
Spillage?
G
Clean ORU heads Replace ORU.
No
Problem
Corrected? Yes
I
No Tune ORU Optics.
Verify ORU
Remove the ORU
Connect the ORU via the Readings Okay

extended cables. Now? Yes
I
No
Inspect unit cables for Verify ORU.
damage, dirt and spills .
Replace Emitter
Block Assembly .
Damage, dirt,
or spill? Yes
Min./Max.
No Clean or Replace Reference
cables as needed. Readings Okay No
Now?
Power up instrument in
Diagnostic Mode.
G
Yes
Replace ORU.
I
Remove/check and, if
Verify ORU.
necessary, clean Fiber
Bundle Ends (at ORU end).
1. Using a dry cotton swab, clean the ORU heads by wiping the channel of the ORU head from the front of
the instrument to the back. Continue cleaning with clean swabs until the swab being used comes out
completely clean.
2. Recheck the value of the mean air optical blanking as described in the Optical blankings portion of
"Verifying the ORU".

3. If the readings are now within specifications, the problem has been corrected and all steps of the "Veri-
fying the ORU" procedure should be performed to verify the ORU operation.
4. If the readings are still not within specifications, the ORU should be removed as described in "Remov-
ing/Replacing the ORU Assembly" and the optics should be tuned as described in the "Tuning ORU
Optics" procedure.
5. If the readings are now within specifications, the problem has been corrected and all steps of the "Veri-
fying the ORU" should be performed to verify the ORU operation.
6. If the readings are still not within specification, the ORU assembly should be replaced as described in
"Removing/Replacing the ORU Assembly" and "Installing the ORU Assembly".
Temperature Troubleshooting
1. Check that the temperature readings for all four ORUs are within the upper and lower limits as specified
in the temperature portion of the diagnostic screen Figure 10-23 "Temperature Portion of Diagnostic
Screen"
Figure 10-23 Temperature Portion of Diagnostic Screen
2. At this time, temperature controls are not replaceable items. Therefore, if the readings are not within
specifications, replace the failing unit as described in the procedure identified in the following table.
Table 10-1 Temperature Repair Procedures
Unit with Temperature Procedure

outside range
Incubator # 1 Incubator #1 Removal/Replacement in Chapter 9
Incubator # 2 CTS Hold/Incubator #2 Removal/Replacement in

Chapter 9
ORU # 1 through # 4 "Removing/Replacing the ORU Assembly"

10-4 Diagnostics
ORU Diagnostics Tab

As shown on Figure 10-24 "ORU Diagnostic Tab", the ORU tab contains four main areas:
The Optical Blanking area
The Temperatures area
The Reference Readings area
The Dark Readings area.

Figure 10-24 ORU Diagnostic Tab
Temperature Area
Optical Blanking Area
Dark Readings Area

Reference Reading Area

Optical Blanking Area
The ORU optical blanking tests the output values of the ORU with air, i.e. an empty ORU, and with a cuvette
containing Factor Diluent whose opacity is known. Using these outputs, the system measures and stores the
results which are factored into measurements taken when the instrument is in non-diagnostic mode. As
shown on Figure 10-25 "Optical Blanking Area of ORU Diagnostic Screen", the Optical Blanking area
contains the following:
ORU selection
ORU status
Optical blankings
Figure 10-25 Optical Blanking Area of ORU Diagnostic Screen
ORU Selection
ORU Status
ORU Selection
The ORU Selection buttons enable the selection of an individual ORU for testing. Clicking one of the radio
buttons, followed by the Start button to the right, initiates the optical blanking of the selected ORU. Clicking
the Start Air Blanking button or Start Factor Diluent Blanking button causes Air or Factor Diluent blank-
ing to be performed on the selected ORU
NOTE: Reference readings tests cannot be executed while performing the optical reading
tests.
ORU Status
Each ORU can be enabled or disabled using the Enable buttons in the middle right of the diagnostic screen
area.
The instrument automatically disables an ORU when one of the following conditions is detected for any of
the ORUs 4 channels:
The current air reading is lower than the air reading low limit

The current air reading is higher than the air reading high limit
The difference between the current air reading and the stored air reading is greater than the air
reading drift limit
A detector voltage error is reported by the ORU.
The air reading low limit is 500,000; the air reading high limit is 1,200,000; the air reading drift limit is 6%.
In normal operation, current air readings are automatically executed at the end of the cuvette shuttle
mechanical initialization and every time a cuvette is removed from an ORU. Current air readings are not
executed if the instrument status is DIAGNOSTICS, to avoid conflict with diagnostics tests. If the instrument
status is BUSY or CONTROLLED STOP, automatic requests to disable ORUs are processed when the
RUN session is completed. Cuvettes still to be scheduled are not sent to ORUs waiting to be disabled.
Results from ORU channels where the previous air reading was invalid (value out of range or drift detected)
are flagged. When the instrument status is DIAGNOSTICS, ORUs are not automatically disabled and an
alarm is displayed.
If stored air readings are not available for an existing and enabled ORU (they have never been stored or the
file cannot be read at startup), an alarm is displayed to ask the user to perform the Air Blanking and the
instrument status is changed to ERROR to prevent the user from running any tests.
NOTE: Reference readings tests cannot be performed while performing blanking.
Optical Blanking
Optical blanking can be started and stopped for each wavelength and analytical channel for the selected
ORU. If the ORU selection is changed, all displayed values are reset to zero. Once blanking is started, the
values currently displayed on the screen are set to zero. The readings are based on 25 acquisitions or until
the test is stopped.
For each wavelength (405, 671), and for each channel (1-4), the following data are displayed as shown on
Figure 10-25 "Optical Blanking Area of ORU Diagnostic Screen":
Mean (%T)
CV (%CV)
Absolute Absorbance (mAbs)
Stored DiH20 Reading (Factor Diluent)
Stored Air Reading (Air)

Lower and upper limits for air readings, which are valid for all ORUs, channels, and wavelengths are dis-
played for reference.
ORU Air Calibration
Air Blanking is performed on a selected ORU by clicking on the desired ORU radio button and clicking the
Start Air Blanking button, or on all the ORUs by clicking the Start Air Blanking for all ORU's button.
The instrument calculates the mean of 1000 readings for the ORU channel and wavelengths.
Each ORU generates eight Air Reading values, one for each wavelength and one for each of the four chan-
nels.

The currently stored Air Readings values are shown in the Optical Blanking display. When the newly
acquired Air Readings values are available, they can be accepted or not. If they are not accepted, the cur-
rently stored Air Readings values continue to be used. If the new Air Readings values are accepted, they
replace the currently stored values.
The air reading low limit is 500,000; the air reading high limit is 1,200,000; the air reading drift limit is 6%.
ORU Factor Diluent Calibration is performed on a selected ORU by enabling the desired ORU radio button
(in the Optical Readings portion of the screen) and clicking the Start Factor Diluent Blanking button, or the
Factor Diluent Blanking can be performed on all the ORUs by clicking the Start Factor Diluent Blanking
for all ORU's button. The instrument calculates the mean of the readings for each ORU, for all channels and
wavelengths, using 10 cuvettes filled with Factor Diluent. For each head/channel/wavelength, after having
calculated the mean of the replicates, the replicate having the maximum distance from the mean is dis-
carded. The mean is then recalculated using the remaining 9 replicates.
When Factor Diluent Blanking has been initiated, a prompt is provided to the user to place a vial in position
1 of rack R5 filled with 10mL of Factor Diluent, and to Confirm (OK) or to Reject (Cancel) the start of the
procedure. Each cuvette is automatically placed in the first selected ORU. Each cell of the cuvette is filled
from the placed Factor Diluent using the following parameters.
Volume 200ml
Air gap 15ml
Transport Air gap 10ml
To remove air bubbles in the cuvette, a 70% mix is performed after each dispensation. A 10 second delay is
then enacted before starting ORU readings after the last dispensation and/or after moving a cuvette into the
next ORU. Each ORU generates eight Factor Diluent reading values, one for each wavelength and one for
each of the four channels. Each value is the mean of 100 readings. If the All ORUs button was selected,
the cuvette is then moved into each of the other selected ORUs. When a cuvette has been used by all the
selected ORUs, it is moved to the cuvette waste and a new cuvette is loaded, until the proper number of
cuvettes have been used.
For each ORU, channel, and wavelength, the instrument calculates the mean of the values read from each
cuvette. These values are the new Factor Diluent Readings that can be accepted or rejected. If rejected, the
currently stored Factor Diluent Readings values continue to be used. If accepted, the new Factor Diluent
Readings values replace the currently stored values.
Temperatures Area
As shown on Figure 10-27 "Reference Readings Portion of Diagnostic Screen", the temperature, lower
limit, and upper limit are displayed for each ORU head and both incubators. Refer to Optical Reading Unit
(ORU) Cradle Thermal Regulation in Chapter 12 for detailed information on the thermal elements in the
instrument.

Figure 10-26 Temperature Area of ORU Diagnostic Screen
Reference Readings Area
The reference channel readings come from one ORU (ORU #1, the leftmost ORU). The reference readings
are used with the analytical channels. The user has the ability to start and stop reference readings. For the
Blue 405 wavelength, Red 671 wavelength, and for Dark, the following values are displayed after being ini-
tialized when the Reference Reading test starts, as shown on Figure 10-27 "Reference Readings Portion
of Diagnostic Screen".
Minimum (Min.) reference reading
Maximum (Max.) reference reading
Lower Limit
Upper Limit
Figure 10-27 Reference Readings Portion of Diagnostic Screen
For each wavelength, the following values are displayed for the DAC after being initialized when the Refer-
ence Reading test starts.
Minimum DAC value (Min. DAC)
Maximum DAC value (Max. DAC)
NOTE: Blanking cannot be performed while performing reference readings tests.
NOTE: Blanking and reference reading tests are automatically stopped if the user starts the
Fluid Precision Test.

Dark Readings
The Dark Reading is the reading of the analytical channel without the emitter and is displayed as shown on
Figure 10-28 "Dark Readings.". This reading indicates the electronics (dark current) and stray light effect
on the ORU light readings. Dark readings can be started and stopped for all enabled ORUs. When started,
the maximum readings are reset to zero. The maximum dark reading are updated for each ORU and each
channel until the test is stopped. The upper dark limit, valid for all the channels and all the ORUs, and dis-
played as Limit, is displayed for reference
Figure 10-28 Dark Readings.
Linearity Test Tab

The linearity diagnostic, as shown on Figure 10-29 "ORU Linearity Diagnostic" is being refined for field
use and is currently only for Research and Development use.

Figure 10-29 ORU Linearity Diagnostic

Removing/Replacing the ORU Assembly
Removing the ORU Assembly
1. Turn off power to the ACL-TOP instrument.

2. To enable the removal the Optical Reading Units Cradle Assembly, remove the Reagent Syringe Cover,
Reagent Accumulator/Wash Rinse Cover, Reagent Rack Cover, as described in Removal/Replace-
ment Procedures in Chapter 4.
3. Place a table or cart that is approximately the same height as the Instrument base in front of the instru-
ment.
4. Loosen the four captive retaining screws securing the ORU module as shown on Figure 10-30 "ORU
Retaining Screws".
Figure 10-30 ORU Retaining Screws
ORU Retaining Screws
NOTE: In the following steps that disconnect cables from the ORU, the cables are only to be
disconnected from the ORU cradle assembly. They are not to be removed from the ACL-TOP
instrument.
5. Lift the ORU module and disconnect the ribbon cables from J1 and J2 of the ORU Interface PCB as
shown in Figure 10-31 "ORU Cable Connections".

Figure 10-31 ORU Cable Connections
J1
J1
J2 J3
ORU Interface PCB Emitter PCB
6. Remove the ribbon cable from J1 of the Emitter PCB as shown on Figure 10-31 "ORU Cable Connec-
tions".
7. Remove the Power cable from J3 of the ORU Interface PCB as shown on Figure 10-31 "ORU Cable
Connections".
8. Remove the ORU Assembly from the instrument and place it on the table or cart in front of the instru-
ment.
9. If you are connecting the ORU to the extended cables for testing, perform the procedure "Connecting
the ORU for Testing".
Installing the ORU Assembly

1. If not previously checked, check the ORU cables for damage, dirt, and spills that may compromise their
operation. If damaged, replace the cables.
2. If installing a new ORU, write down the ORU Thermal Coefficient figures from the calibration sticker on
the bottom cover of the replacement ORU as shown on Figure 10-32 "Calibration Offsets".
NOTE: These figures are used in step 8 to enter the coefficients for the new ORU.

Figure 10-32 Calibration Offsets
3. If re-installing the ORU Assembly after tuning the ORU optics, remove the ORU extended cables and
attach the original cables to the Backplane PCB as follow:
Remove the extended cable from J17 of the ORU Interface PCB to J1 of the Emitter PCB.
Remove the extended cable from J15 of the Backplane PCB to J1 of the ORU Interface PCB.
Remove the extended cable from J16 of the Backplane PCB to J2 of the ORU Interface PCB.
Remove the extended power cable connected to J3 of the ORU Interface PCB.
Attach the original signal cable to J15 of the Backplane PCB
Attach the original signal cable to J16 of the Backplane PCB
Attach the original signal cable to J17 of the ORU Interface PCB
4. Place the ORU into the instrument while re-attaching the cables to the ORU, as shown on Figure 10-33
"ORU Backplane PCB Connections" and Figure 10-34 "ORU Cable Connections" as follow:
Attach the signal cable from J15 of the Backplane PCB to J1 of the ORU Interface PCB
Attach the signal cable from J16 of the Backplane PCB to J2 of the ORU Interface PCB
Attach the signal cable from J17 of the ORU Interface PCB to J1 of the Emitter PCB
Attach the power cable to J3 on the ORU Interface PCB

Figure 10-33 ORU Backplane PCB Connections
J15 J16
J17
Figure 10-34 ORU Cable Connections
J1 J1
J2 J3
ORU Interface PCB
Emitter PCB
5. Tighten the four screws securing the ORU in the instrument as shown in Figure 10-34 "ORU Cable
Connections".

Figure 10-35 ORU Retaining Screws
ORU Retaining Screws
6. Re-install the instrument covers as described in Removal/Replacement Procedures in Chapter 4.

7. Apply power to the ACL-TOP instrument and enter the ORU diagnostics screen.
8. If a new ORU is being installed, enter the thermal coefficients for the ORU as described in Inputting
Thermal Coefficients using ThermalCal in Chapter 12.
9. Verify the operation of the ORU by performing all checks in "Verifying the ORU".
10. Remove the inner covers of the Reagent area. (Reagent Syringe Cover, Reagent Accumulator/Wash
Rinse Cover, and Reagent Rack Cover as described in Removal/Replacement Procedures in
Chapter 4.)
11. Perform a coordinates check on both reagent arms as described in Diagnostics in Chapter 8.
12. Perform the air blankings and factor diluent blankings as described in "Verifying the ORU".
13. Re-install the inner covers of the Reagent area.
Removing/Installing the Emitter Assembly
Removing the Emitter Assembly
1. Turn off power to the ACL-TOP instrument.

2. Loosen the small fiber bundles set screw as shown in Figure 10-36 "Fiber Bundle Disconnect".
3. Remove the small fiber optic bundle from the emitter block.
CAUTION: Do not twist the fiber optic bundle as it can damage the fibers.
4. Loosen the two large fiber bundle holder set screws as shown on Figure 10-36 "Fiber Bundle Discon-
nect".
Figure 10-36 Fiber Bundle Disconnect

Small fiber bundle

set screw
Large fiber bundle

holder set
screws
5. Carefully pull to remove the large fiber bundle from the emitter block.
6. If this procedure was entered from the ORU test procedure, remove the extended cable connected to
J1 of the Emitter PCB.
7. Using a 3mm Allen wrench, remove the two screws securing the emitter head assembly as shown on
Figure 10-37 "Emitter Head Attachment Screws" and lift the emitter head from the ORU cradle
assembly.

Figure 10-37 Emitter Head Attachment Screws
Allen head
screws securing
emitter head.
Set screw
securing small
fiber bundle
8. Using a 1.5mm Allen wrench, verify the set screw securing the small fiber bundle is in the new Emitter
Assembly and loosen it to enable the insertion of the small fiber bundle.
9. Place the new Emitter Assembly and secure it using the two Allen screws. Do not fully tighten the Allen
screws at this time.
10. Attach the extended cable to J1 of the Emitter PCB.
11. Insert both fiber bundles completely into the emitter head.
12. Tighten the two Allen screws on the Emitter Block assembly.
14. Slowly slide the large optic bundle out of the emitter head while watching the DAC readings being dis-
played on the diagnostic screen. (Move the optic bundle in small increments and pause to allow the
DAC readings to stabilize for each movement.)
15. Adjust the position of the large fiber bundle until the DAC readings are minimized. Adjust the small fiber
bundle to further minimize the reading. Adjust until the DAC Readings are minimal but not below 35 (the
signal is maximized). When the readings are at their lowest and acceptable (between 35 235), using a
1.5mm Allen wrench, secure the small fiber bundle with the fiber bundle set screw in the emitter head
and the large fiber bundle with the two set screws in the fiber bundle holder.
16. Re-install the ORU as described in "Installing the ORU Assembly" and perform all verifications as
directed in that procedure.
Connecting the ORU for Testing

NOTE: All cable connectors are keyed.

Refer to Figure 10-38 "Backplane Connectors" and Figure 10-39 "ORU Cable Connections" for steps
1 through 3.
1. Remove the ORU emitter ribbon cable from J17 of backplane PCB,. Connect the extended ribbon
cable (PN 277667-00) from the kit to J17 (note that the key for the cable is facing toward the front of
the instrument) and connect the other end to J1 on the Emitter PCB.
2. Remove the ORU signal cable from J16 of backplane PCB. Connect the extended ribbon cable (PN
277668-01) from the kit to J16 and connect the other end to J2 on the ORU Interface PCB.
3. Remove the ORU signal cable from J15 of backplane PCB. Connect the extended ribbon cable (PN
277668-02) from the kit to J15 and connect the other end to J1 on the ORU Interface PCB.
Figure 10-38 Backplane Connectors
J15
J16
J17

Figure 10-39 ORU Cable

Connections
J1 J1
J2 J3
ORU Interface PCB
Emitter PCB
4. Connect the male end of the Power cable in the kit (PN 277666-00) to the power cable removed from J3
on the ORU Interface PCB as shown on Figure 10-40 "Power Cable Connection"
5. Connect the other end of the Power Cable to J3 on the ORU Interface PCB as shown on Figure 10-39
"ORU Cable Connections".

Figure 10-40 Power Cable Connection
Extended
Original ORU power cable
power cable (male end)
6. Place the ORU upside down and on a stable surface as shown in Figure 10-41 "ORU Positioned For
Testing".
Figure 10-41 ORU Positioned For Testing
7. Power up instrument in the diagnostics mode only. (It will automatically come up in diagnostic mode
because the reagent door is open.)
CAUTION: Do not power unit up in the normal operating mode as damage to

the instrument could result.
8. Refer to the procedure "Tuning ORU Optics".

Tuning the ORU Optics

Figure 10-42 "Tuning ORU Optics" shows the overall flow of the procedure for tuning the ORU optics.
Figure 10-42 Tuning ORU Optics

Tuning ORU Optics

NOTE: It is assumed the ORU has been removed from the unit as described in the procedure
"Removing/Replacing the ORU Assembly"and connected to the instrument with the
extended cables as described in the procedure "Connecting the ORU for Testing". If not,
perform these procedures before proceeding.
1. Ensure power to the system is OFF.

2. Check to determine if the serial number of the ACL-TOP instrument is below 05080387. If so, the instru-
ment was not initially built with the bracket and cover that allows the optics to be tuned.
NOTE: This procedure assumes the new ORU fiber bundle bracket and bottom cover of the
ORU has been installed (as shown in Figure 10-43 "Fiber Bundle Set Screws" and recog-
nized by the fiber bundle holder for the large fiber bundle and the curved cover that allows
adjustment). If not, perform the procedure "Installing the ORU Optics Alignment Kit (PN
280033-00)".
3. Using a 1.5mm Allen wrench, loosen the two set screws, as shown on Figure 10-43 "Fiber Bundle Set
Screws", on the large fiber bundle holder securing the large fiber bundle.
Figure 10-43 Fiber Bundle Set Screws
Fiber
Large fiber bundle Bundle
holder set screws. Holder
4. Using a 1.5mm Allen wrench, loosen the set screw that locks the small fiber bundle in place as shown
on Figure 10-44 "Fiber Bundle Disconnect".

Small fiber
bundle
Large fiber
bundle
5. Carefully pull to remove the large and small fiber bundles from the emitter blocks.
6. Inspect the ends of the optic fiber bundles for damage (cracking, scratching, fluid leakage) dirt, dust and
contaminants. If dirty or dusty, gently clean the ends of both the large and small fiber bundles, as shown
in Figure 10-45 "Fiber Bundle Ends", with a clean, dry cotton swab. If the optics show damage or
signs of leakage, replace the ORU as described in the procedure "Removing/Replacing the ORU
Figure 10-45 Fiber Bundle Ends
Small Fiber
Bundle
Large
Fiber
Bundle
7. Insert both fiber bundles all the way into the emitter head.

CAUTION: With power applied, there are potentially harmful voltages

available in the ORU. Do not touch anything other than the fiber bundle.
9. Slowly slide the large optic bundle out of the emitter head while watching the DAC readings being dis-
played on the diagnostic screen. (Move the optic bundle in small increments and pause to allow the
DAC readings to stabilize for each movement.)
10. Adjust the position of the large fiber bundle until the DAC readings are minimized. Adjust the small fiber
bundle to further minimize the reading. Adjust until the DAC Readings are minimal but not below 35 (the
signal is maximized). When the readings are at their lowest and acceptable (between 35 235), using a
1.5mm Allen wrench, secure the small fiber bundle with the fiber bundle set screw in the emitter head
and the large fiber bundle with the two set screws in the fiber bundle holder.
11. If the DAC readings are now acceptable, the adjusting and cleaning of the optical components has cor-
rected the problem and the instrument should be powered off, the extended cables should be removed
and the ORU re-installed as described in "Installing the ORU Assembly".
12. If the DAC readings are still too high (above 235), the adjusting and cleaning of the optical components
has not corrected the problem, the instrument should be powered off, and the Emitter Assembly should
be replaced as described in "Removing/Installing the Emitter Assembly".
Installing the ORU Optics Alignment Kit (PN 280033-00)

NOTE: The following assumes that the ORU has been removed from the instrument. If not,
use the removal steps in "Removing/Replacing the ORU Assembly" to remove the ORU
from the instrument.
1. Remove the four screws securing the cover on the bottom of the ORU as shown in Figure 10-46 "ORU
Cover Attachment Screws " and remove the cover.

Figure 10-46 ORU Cover Attachment Screws
ORU Cover
Screws
2. Remove the set screw for the large fiber optic bundle as shown in Figure 10-47 "Fiber Bundle Discon-
nect". (The new fiber bundle holder will be used to secure the large fiber bundle.)
3. Loosen the set screw for the small fiber bundle as shown in Figure 10-47 "Fiber Bundle Disconnect".
Small fiber bundle

Small fiber
bundle set
screw.
Large fiber
bundle set
screw
Large fiber bundle
4. Carefully pull to remove the large and small fiber bundles from the emitter block.
CAUTION: Do not twist the fiber optic bundle as it may damage the fibers.
5. Remove the center cover standoff and the screw securing the ORU Interface PCB as shown in Figure
Figure 10-48 "Cover Hardware Removal"

Figure 10-48 Cover Hardware Removal
Center
Cover ORU Interface Board
Standoff Retaining Screw
6. Using a 2.5mm Allen wrench, install the bracket, as shown in Figure 10-49 "Bracket Mounting", using
the two M3x6 screws included in the kit.
Figure 10-49 Bracket Mounting
Bracket Attachment
Screws
7. Insert the Large Fiber Bundle through the opening in the bracket and into the opening on the emitter
block. Ensure all fiber optic cables are within the standoffs for the cover.
CAUTION: Do not twist the fiber optic bundle as it may damage the fibers.

8. Insert the Small Fiber Bundle into the Emitter Block.

9. Attach the new cover as shown in Figure 10-50 "New Cover Attachment".
Figure 10-50 New Cover Attachment
Cover
retaining
screws
11. Return to the procedure "Tuning ORU Optics" to properly adjust the focal lengths of the optical fiber
bundles.

Chapter 11 Rack Handling 11 - 1
Chapter 11
Rack Handling
11-1 Overview
The Rack Handling System is responsible for recording, storing and handling of patient samples as well as
recording, storing and handling of ACL-TOP Diluent and Reagent chemistries.

11 - 2 Chapter 11 Rack Handling
11-2 Physical Layout
Figure 11-1 "Rack Handling System.", the Rack Handling System is made up of three modules/assem-
blies, the Sample Module, the Reagent Module, and the Bar Code Reader assembly. The Sample Module
is responsible for the storing and handling of patient samples and diluents and sensing the presence or
absence of racks in the module. The Reagent Module is responsible for the storing and handling of reagents
and diluents and sensing the presence or absence of racks in the module. The Bar Code Reader assembly
is responsible for allowing access to only one sample or reagent rack at a time and reading the bar code
labels on all racks/vials that are inserted or removed from either the sample or reagent modules.
Figure 11-1 Rack Handling System.

Figure 11-2 "Rack Handling Interconnections" shows the interconnections between the various elements in the Rack Handling System.
Figure 11-2 Rack Handling Interconnections

Sample Module Assembly

The Sample Module is responsible for the storing and handling of patient samples and diluents and sensing
the presence or absence of racks in the module. The sample holding area accommodates a maximum of 12
sample racks and two diluent racks. Each sample rack accommodates 10 sample vials providing a total
capacity of 120 samples. Each diluent rack accommodates eight diluent vials providing a total capacity of 16
diluents. Figure 11-3 "Sample Module (CTS)" shows a fully loaded sample module.
Figure 11-3 Sample Module (CTS)
Diluent Racks
Sample Racks
Sample racks are inserted from the front of the instrument. As each rack is inserted (or removed) the bar
code reader reads all bar code labels on the sample rack as explained in the Bar Code Reader Assembly
section. Each rack has a protrusion on the rear that, when a rack is fully inserted, trips a sensor on a Sample
Presence PCB located on the back of the sample module. Tripping the sensor on the Sample Presence
PCB indicates to the system that a sample rack is present in the position and is indicated to the operator by
the lighting of an LED on the keypad located below the sample rack location. The LEDs for the samples are
labeled S1 through S12 corresponding to the 12 sample rack positions. The Sample PCB, along with the
LED indications to the operator, is shown on Figure 11-5 "Sample Rack Sensing Indications (all posi-
tions filled)".
NOTE:Special CTS racks are used for cap piercing; these rack are
identified by labels having "CTS" in bold on the front of the rack.

Figure 11-4 Sample Racks
CTS
NON CTS
NOTE: Standard and CTS Sample Racks are not interchangeable.
Figure 11-5 Sample Rack Sensing Indications (all positions filled)
The diluent racks are physically different from the sample racks and accommodate 4ml, 8ml, 10ml, 15ml,
20ml, and 30ml vial sizes. The various sizes are accommodated by the addition of vial adapters. The diluent
racks, like the sample racks, have a protrusion on the rear that is used to trip a sensor on the Sample PCB.
Tripping the sensor indicates to the system that a diluent rack is present in the position and is indicated to
the operator by the lighting of an LED on the keypad located below the sample rack location. The LEDs for
the diluents are labeled D1 and D2 corresponding to the diluent rack positions.
Sample Presence PCB
The Sample Presence PCB is mounted on the rear of the Sample module and is used to sense, and indicate
to the instrument and the operator, the presence of sample racks and diluent racks. The PCB contains 14
sensors, 12 for the sample racks and two for the diluent racks. The sensors for the sample racks are optical
sensors whose beam is broken by the protrusion (flag) on the rear of the sample or diluent racks. The out-
puts of the sensors are fed through a ribbon cable that goes to the backplane PCB and then to the Rack
Controller PCB. Figure 11-6 "Sample Presence PCB" shows a Sample Presence PCB mounted on the
rear of the Sample assembly.

Figure 11-6 Sample Presence PCB
Sample Presence PCB
Sample Flag
The sample module includes a sample flag for the bar code reader. This flag is a precisely machined cut
piece of sheet metal, mounted with alignment pins, on the front underside of the sample plate as shown on
Figure 11-7 "Sample Flag ". The flag has cutouts (slots) that coincide to each sample and diluent rack posi-
tion. Using an optical sensor mounted on the RTI PCB on the bar code reader assembly, the slots in the flag
allow the curtain opening and bar code reader to be positioned at the correct rack position. In this manner,
the rack can be inserted and bar code reading can occur during loading and unloading of the sample or dilu-
ent rack. Located at the bottom right corner of the Sample flag is an additional slot used for the Bar Code
Reader to establish its home position when initializing or returning from a prompted task.
Figure 11-7 Sample Flag
Sample Flag

Reagent Module
The Reagent Module is responsible for the storing and handling of reagents and diluents and sensing the
presence or absence of racks in the module. The reagent holding area accommodates a maximum of six
reagent racks and one diluent rack labeled R1 through R6 and D3 respectively. The reagent rack accommo-
dates six reagent vials providing a total capacity of 36 reagent vials. Each diluent rack accommodates eight
diluent vials providing a total capacity of eight diluents. The reagent module accommodates stirring posi-
tions in each reagent rack. Only stirring is available at position 1 and 2 (the two rear positions) of each rack.
Figure 11-8 "Reagent Module" shows a fully loaded reagent module with the locations of the reagent racks
and diluent rack identified.
Figure 11-8 Reagent Module
D3 R1 R3 R4 R5 R6
R2
Reagent and diluent racks are inserted from the front of the instrument, similar to the sample and diluent
racks. Each rack has a protrusion on the rear that, when a rack is fully inserted, trips a sensor on a Reagent
Presence PCB located on the back of the reagent module. Tripping the sensor on the Reagent Presence
PCB indicates to the system that a reagent rack is present in the position and is indicated to the operator by
the lighting of an LED on the keypad located below the reagent rack location. The LEDs for the reagent
racks are labeled D3, R1 through R6 corresponding to the diluent and six reagent rack positions. The
Reagent PCB, along with the LED indications to the operator, is shown on Figure 11-9 "Reagent Rack
Sensing Indicators". The Reagent Module is the same for CTS and non CTS models.

Figure 11-9 Reagent Rack Sensing Indicators
Reagent Presence PCB
The Reagent Presence PCB is mounted on the rear of the reagent module and is used to sense, and indi-
cate to the instrument and the operator, the presence of reagent and diluent racks. The PCB contains seven
sensors, six for the reagent racks and one for the diluent rack. The sensors for the reagent and diluent racks
are optical sensors whose beam is broken by the protrusion (flag) on the rear of the reagent or diluent racks.
The outputs of the switches are fed through a ribbon cable that goes to the backplane PCB and then to the
Rack Controller PCB. Figure 11-10 "Reagent Presence PCB " shows a Reagent Presence PCB mounted
on the rear of the Reagent assembly.
Figure 11-10 Reagent Presence PCB

Reagent Mounting Plate
The Reagent Module mounting plate provides stirring for the two rear positions in each reagent rack. In addi-
tion, the Reagent Module mounting plate is cooled to maintain the temperature of the fluid inside the vials at
15 degrees C plus or minus 3 degrees C.
The stirring of the reagent positions is accomplished by stirring transformers on the Magnetic Stirrer
Assembly on the bottom of the reagent module as shown on Figure 11-11 "Reagent Mounting Plate Stir-
rers and Heat Sink". The transformers cause the metal stirrers in the vials to revolve and stir the fluid. In
normal operation, the transformers are always supplied power. In normal operation, if a reagent container
that does not require stirring is placed in these positions, the system indicates an Placement Error alarm to
the operator or, in diagnostic mode, lights the stirring LED on the Fluids diagnostic tab.
Figure 11-11 Reagent Mounting Plate Stirrers and Heat Sink
Stirrers
Heat Sink
Reagent
Flag
Reagent Cooling with Fan Speed Controller PCB
Control of the Thermal Electric Coolers is performed by the Reagent Cooling with Fan Speed Controller
PCB mounted on the right side of the reagent module as shown in Figure 11-12 "Reagent Cooling with
Fan Speed Controller PCB". This PCB provides power to the Coolers when cooling is required as indi-
cated by a thermal sensor (via a thermistor) located on the mounting plate. In addition to supplying power to
the coolers when cooling is required, the PCB also controls the speed of the five reagent cooling fans based
on input from the sensor. The PCB also monitors the temperature of the mounting plate and generates a sig-
nal causing a System temperature out-of-range indication if the temperature goes outside its range of 15
degrees C plus or minus 3 degrees C.
NOTE: Units below S/N 05070377 do not have speed control. Kit P/N 294113-00 can be used to upgrade.
NOTE: Thermistors are sealed. Units below S/N 05110442 do not have sealed thermistors. Kit P/N 277559-
01 can be used to upgrade.

Figure 11-12 Reagent Cooling with Fan Speed Controller PCB
Reagent Flag
The reagent module includes a flag for the bar code reader. This flag, which consists of a precisely cut piece
of sheet metal, is mounted, with alignment pins, on the front underside of the reagent plate as shown on Fig-
ure 11-13 "Reagent Flag". The flag has precision cutouts (slots) that coincide to each sample and diluent
rack position. Using an optical sensor mounted on the RTI PCB on the bar code reader assembly, the slots
in the flag allow the curtain opening and bar code reader to position at the correct rack position for reagent
loading and unloading.
Figure 11-13 Reagent Flag
Flag

Bar Code Reader Assembly

The Bar Code Reader assembly, as shown on Figure 11-14 "Bar Code Reader Assembly", allows access
to only one sample or reagent rack at a time and reads the bar code labels on all racks that are inserted or
removed from either the sample or reagent modules. The Bar Code Reader Assembly reads bar code labels
on sample tubes and ACL-TOP reagent bottles when they are inserted into and removed from the ACL-TOP
Sample, Reagent and Diluent racks. The ACL-TOP uses a traveling bar code reader that travels along the
front of the instrument and aligns itself with the rack being inserted. By use of a curtain material that limits
access to the rack where the bar code reader is positioned, the bar code reader also ensures access to one
rack at a time and ensures system integrity and security.
Figure 11-14 Bar Code Reader Assembly
To provide its travel, the bar code reader is mounted on a carriage that slides within a rail across the front
of the Sample and Reagent modules of the instrument. The movement is provided by the Bar Code Drive
Motor and the Bar Code Drive Belt as described below. Upon being directed to a specific rack location, the
bar code reader travels to that location where the curtain opening only allows access to the specific rack
location selected. Included within the bar code reader assembly is an RTI PCB, as described below, con-
taining the sensor for the racks.
Rack Insertion
1. A position is selected for the Bar Code Reader using either the Sample or Reagent Touch pads.
2. The Bar Code Reader moves to the selected position.
3. The Bar Code Reader reads all of the position labels and must read them all in order starting from
position1. In between each position label there is a "0" label that informs the Analytical Module if that
position is occupied. If the occupied position has a bar code label it is read at this time. If there is no bar
code label a question mark is displayed on that position in the appropriate detail section. The last label
read from the rack is the rack identifier label. Sample rack identifier labels also specify if the rack is a
CTS rack.
4. The flag on the end of the rack interrupts a sensor on the presence printed circuit board. If any of these
labels are not read or read out of sequence the TOP reports an alarm.

Rack Removal
1. A position is selected for the Bar Code Reader using either the Sample or Reagent Touch pads.
2. Removing the rack from the instrument causes the flag to be removed from the sensor of the Presence
printed circuit board.
3. The Analytical Module reads the identifier label and then all of the position labels from the highest posi-
tion down. The rack must be completely removed from the unit.
Remote Travel Interface PCB
The rack sensor for the bar code reader is on the Remote Travel Interface (RTI) PCB. The RTI PCB is
attached to the moving bar code reader as a traveling PCB that has a slotted, vertically mounted optical sen-
sor mounted to it as shown on Figure 11-15 "RTI PCB". This sensor uses the slots on the Sample and
Reagent Flags (sheet metal flags mounted to the bottom front of the Sample and Reagent modules) which
is a slotted piece of sheet metal, previously discussed in the Sample Flag and Reagent Flag sections. This
sensor optically senses each slot on both the sample and reagent flags as it passes by them. These slots,
on both the sample and reagent flags, coincide with each rack location on the sample and reagent modules.
Output from the sensor is provided to the X Axis PCB which drives the bar code reader motor.
Figure 11-15 RTI PCB
Optical
Sensor
RTI PCB
Tabs for Travel Limit
Bar Code Reader Travel Limit Sensors
Mounted to the curtain brackets at the left end of the sample module and the right end of the reagent module
are vertically mounted sensors that establish the travel limits of the Bar Code Reader assembly. The tabs
that are sensed by these sensors are shown on Figure 11-15 "RTI PCB" and are metal tabs that protrude
from the RTI PCB mounting bracket. These tabs block the light source for the limit sensor mounted on the
curtain bracket as shown on Figure 11-16 "Bar Code Reader Travel Limit Sensor", when the reader
reaches the limit of its travel and stop the reader from moving any further in that direction. Output from the
sensors is provided to the X Axis PCB which drives the bar code reader motor.

Figure 11-16 Bar Code Reader Travel Limit Sensor
Travel Limit Sensor
Bar Code Reader Drive Motor
The bar code reader drive motor is located on the right side of the bar code reader assembly and is attached
to the support plate of the bar code reader. The motor is a quick start/stop two phase motor driven from the
X Axis PCB. The motor moves the bar code reader via a drive belt that prevents slippage. Each end of the
belt is attached to the bar code reader assembly via screws.
Bar Code Reader Encoder
The bar code reader encoder is located in the left side of the bar code reader assembly and is attached to
the support plate of the bar code reader. It also acts as the left pulley for the bar code reader drive belt. The
encoder functions as a counter and is used by the X Axis PCB to determine the slot location of the bar code
reader at any given time.
Bar Code Reader Curtain
The curtain in front of the Sample and Reagent modules is mounted on two spring loaded spools at the right
and left sides of the bar code reader assembly. The curtain is made up of two pieces, each piece being
wrapped upon the left or right spool and is made of teflon coated fabric.
There are no adjustment procedures for the Rack Handling Assembly.

Upon completion of any replacement or modification to the instrument, the operation of the instrument
should be completely verified. The extent of the verification depends on the severity, complexity, and/or fre-
quency along with the individual situation. The minimum verification after servicing the Rack Handling sys-
tem is to insert and remove sample, diluent, and reagent racks with barcoded tubes, cups, and vials and
verify the system reads the labels correctly and the racks fit properly without interference.

11-6 Diagnostics
Rack Handling Diagnostics

Figure 11-17 "SW, Covers, and Racks Diagnostic Screen" shows the diagnostic screen that includes the
Rack Handling Diagnostic area. The area specific to Rack handling is identified and broken out in the follow-
ing paragraphs to describe the area.

Figure 11-17 SW, Covers, and Racks Diagnostic Screen
Rack Handling
Area

Racks area
The Left Travel and virtual LEDs, as shown on Figure 11-18 "Racks Area of Diagnostic Screen", turn
green when the bar code reader is moved to its leftmost position. The Right Travel virtual LED turns green
when the bar code reader is moved to its rightmost position. To verify these sensors, click the Disable Bar
Code Reader Motor button and manually move the bar code reader to it left and rightmost positions. As the
reader is moved, the Track virtual LED turns green when the reader passes over a track position. Clicking
the Initialize Bar Code Reader Motor button restarts the bar code reader motor and moves the reader back
to its home position.
Figure 11-18 Racks Area of Diagnostic Screen
Encoder Value
The encoder value of the motor is displayed in the rack area. The encoder is zeroed when moved to the
home position and changes value when the reader is moved to different rack positions.
When this screen is closed, if the reader motor was manually disabled it needs to be reinitialized.
Perform Loop Back Check
A serial port loop back check with a Pass/Fail status enables the communication to the bar code reader to
be tested. To perform the check, remove the cover of the bar code reader, remove the cable to the reader,
attach a serial port loopback connector, and click on the Perform Loop Back Check to initiate the check. A
portable computer with a serial port and reader diagnostics software can also be used to check the reader.

Track Buttons
Track buttons do not have a diagnostic test. If the track buttons on the Analytical Module do not function, the
user has the ability to move to the track positions using the virtual buttons on the Control Module. If the Con-
trol Module buttons are operational, the track buttons on the AM have a failure.
Bar Code Label Reading and Rack Detection
Reading bar code labels and detecting rack insertions do not have a diagnostic test. The reading of labels
and rack presence is a normal instrument operation. To test the reading of labels, a rack should be inserted
into a slot while the appropriate rack detail screen is displayed. The rack should be displayed when the rack
presence is detected.
Reagent temperatures
The reagent block actual temperature, lower limit, and upper limit are displayed as shown on Figure 11-19
"Reagent Temperature Area of Diagnostic Screen".
Figure 11-19 Reagent Temperature Area of Diagnostic Screen
Stirrers
The Stirrer status is accessible under the Fluids tab as shown on Figure 11-20 "Stirring Screen"
Figure 11-20 Stirring Screen

The following provides removal/replacement procedures for the Sample and Reagent Module Assemblies
as well as the Bar Code Reader Assembly. Each replaceable part within those assemblies is described in a
removal /replacement procedure.
Sample Module Assembly Removal/Replacement
Sample Module Assembly Removal (Both CTS and non-CTS models)
Perform the following steps to remove the sample module assembly. (See Figure 11-21 "Sample Assem-
bly Removal".
1. To remove the Sample Module Assembly, the sample area interior skins must be removed as described
in Sample Area Interior Skins Removal/Replacement in Chapter 4.
2. It is suggested that the Front Panel Assembly be removed for easier access as described in Front
Panel Assembly Removal/Replacement in Chapter 4.
3. Move the bar code reader to the far right of its travel.
NOTE: Failure to move the bar code reader to the far right of its travel can result in damage
to the bar code reader assembly and the sample module flag.
4. Using an Allen wrench, loosen the four orange colored cap-head screws on the sides of the Sample
Module Assembly. (The screws are captive and should not be removed.)
5. Remove the ribbon cable located on the top of the Sample Presence PCB at connector P1.
6. Lift and remove the Sample Assembly. Lift the left side of the assembly higher to help slide the sample
flag out.

Figure 11-21 Sample Assembly Removal
Sample Module
Mounting
Screws
CTS
Sample Module
Mounting
Screws
Non-CTS
Sample Module Assembly Installation
To replace the Sample Assembly, perform the preceding removal instructions then install the assembly by
performing the removal in reverse order making sure that the sample module is correctly seated on the
chassis alignment pins.
Sample Presence PCB Removal/Replacement
Sample Presence PCB Removal
Perform the following steps to remove the Sample PCB.

1. Remove the Sample Module Assembly as shown in the previous procedure.
2. Remove the eight Phillips Head screws and washers securing the Sample Presence PCB to the Sample
Module as shown on Figure 11-22 "Sample Presence PCB".
3. Lift and remove the Sample PCB.

Figure 11-22 Sample Presence PCB
Sample Presence PCB
Sample Presence PCB Installation
To replace the Sample PCB, perform the preceding removal instructions then install the PCB by performing
Sample Flag Removal/Replacement
Sample Flag Removal
Perform the following steps to remove the Sample Flag.

1. To remove the Sample Flag, the Sample Module must be removed as previously described.
2. Remove the four Phillips head screws holding the Sample Flag as shown in Figure 11-23 "Sample
Flag". (Note the alignment pins on the Sample Module and their orientation with the alignment holes in
the Sample Flag.)
3. Remove the Sample Flag.

Figure 11-23 Sample Flag

Alignment Pins
Attachment Screws
Sample Flag Installation
To replace the Sample Flag, perform the preceding removal instructions, ensuring the alignment pins are in
their respective holes, then install the flag by performing the removal in reverse order. After installing the
Sample Flag, manually move the barcode reader assembly to ensure the slotted sensor on the RTI PCB
clears the Sample Flag.
Reagent Module Removal/Replacement
Reagent Module Removal
Perform the following steps to remove the Reagent Module Assembly.

1. Remove the reagent area interior skins as described in Reagent Area Interior Skins Removal/
2. Move the bar code reader to the far left of its travel.
NOTE: Failure to move the bar code reader to the far left of its travel can result in damage to
the bar code reader assembly.
3. Loosen the four orange Phillips Head screws on the sides of the reagent module as shown onFigure 11-
24 "Reagent Module Screws (Left Side)"and Figure 11-25 "Reagent Module Screws (Right Side)".
(The screws are captive and should not be removed.)
4. Remove the cable (J1) located on the top rear of the reagent module (on the reagent presence PCB).

Figure 11-24 Reagent Module Screws (Left Side)
Mounting
Screws
(Left Side)
Figure 11-25 Reagent Module Screws (Right Side)
Mounting
Screws
(Right Side)
5. Remove the cables for the fans in the lower right of the Reagent Cooling with Fan Speed Controller PCB
(J4, J5, J6, J7, and J8) as shown on Figure 11-26 "Reagent Cooling with Fan Speed Controller PCB
Mounting".
6. Disconnect the five ground wires that connect to chassis ground.
7. Disconnect J1 (as shown on Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB") on
the Reagent Cooling with Fan Speed Controller PCB.

8. Disconnect the Power In cable (J3) (as shown on Figure 11-27 "Reagent Cooling with Fan Speed
Controller PCB") on the Reagent Cooling with Fan Speed Controller PCB.
Figure 11-26 Reagent Cooling with Fan Speed Controller PCB Mounting
J1
J3 See below.
9. Disconnect the fan outputs (J4, J5, J6, J7, J8) on the Reagent Cooling with Fan Speed Controller PCB
as shown in Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB". (Note that the fan out-
puts can be attached to any fan even though they are labeled as attaching to a specific fan.)
J1
J4
J8
J9
J3 J5
J2 J6 J7
10. Remove the drain tube connecting the reagent module to the waste pump at the waste pump connec-
tion. Tube can be removed by pulling while twisting.
11. Carefully lift and remove the reagent module.

Reagent Module Installation
To replace the reagent module, first write down the ORU Thermal Coefficient figures from the calibration
sticker on the bottom cover of the replacement ORU. Then perform the preceding removal instructions and
install the module by performing the removal in reverse order. Ensure all fan and ground connections are
reconnected. Failure to do so results in overheating of the TEC. Perform the procedure Inputting Thermal
Coefficients using ThermalCal in Chapter 12 to enter the coefficients of the replacement unit
Reagent Drain Tube Removal/Replacement

ACL-TOP Units with serial numbers above XXX use the new style drain tube. Instruemnts with SN below
06030563 were manufactured with the old style drain tube and should be upgraded.
Refer to "Reagent Module Removal/Replacement" for instructions on removing and installing the
Reagent Module.
Reagent Module Tubing Removal
1. Remove the Reagent Module as specified in Reagent Module Removal/Replacement in Chapter 11 of

the ACL TOP Service Manual.
2. Flip the Reagent module over to expose the tubing and remove each end from its barb fitting as shown
in Figure 11-28 "Barb Fittings".
Figure 11-28 Barb Fittings
Barb Fitting Barb Fitting
3. Pull the old tubing out of the clamps and discard it.
4. Remove the single cable clamp on the Reagent Flag side of the assembly.
NOTE: The screws holding the clamps to the coupler plate may be loosened to ease removal of the tubing.

Reagent Module Tubing Installation
1. Replace the cable clamp on the Reagent Flag side of the assembly with a double clamp configuration as
shown in Figure 11-29 "Double Clamp Assembly".
Figure 11-29 Double Clamp Assembly
Short End
Top Clamp
Bottom Clamp Long End
2. Connect the center tube (the 19mm tube at the "Y" base) to the barb fitting on the Reagent Flag side of
the assembly.
3. Run the longer end of the tubing through the bottom clamp on the Reagent Flag side of the assembly.
4. Run the tube through the two clamps on the Magnetic Stirrer Board.
5. Insert the longer tube end of the new drain tubing assembly into the barb fitting closest to the Magnetic
Stirrer Board (see Figure 11-30 "Reagent Cooler").
Figure 11-30 Reagent Cooler
Y Base TEC Cable Double Clamp Short End
Stirrer Board Single Clamp Long End

6. Run the shorter end of the tubing through the top of the double clamp
7. Attach one Cable Clamp as shown in Figure 11-31 "Secured Tubing" and route the tubing through it.
8. Attach two Tie Wraps around black wire and both loops of the TEC Cable as shown in Figure 11-31
"Secured Tubing".
Figure 11-31 Secured Tubing
Cable Clamp
Tie Wrap Tie Wrap
9. Reinstall the Reagent Module as specified in Reagent Module Removal/Replacement in Chapter 11 of

the ACL-TOP Service Manual.
Reagent Presence PCB Removal/Replacement
Reagent Presence PCB Removal
Perform the following steps to remove the Reagent Presence PCB.

1. Remove the Reagent Module as shown in the previous procedure.
2. Remove the eight Phillips head screws and washers securing the Reagent Presence PCB to the
Reagent Module as shown on Figure 11-32 "Reagent Presence PCB".
3. Lift and remove the Reagent Presence PCB.
Figure 11-32 Reagent Presence PCB

Reagent Presence PCB Installation
To replace the reagent PCB, perform the preceding removal instructions then install the PCB by performing
Reagent Cooling with Fan Speed Controller PCB Removal/Replacement
Reagent Cooling with Fan Speed Controller PCB Removal
Perform the following steps to remove the Reagent Cooling with Fan Speed Controller PCB.
1. Remove the Reagent Module as described in "Reagent Module Removal/Replacement".
2. Disconnect the remaining connectors on the PCB (TEC output (J2) and the reagent cooling thermistor
(J9) connectors as shown on Figure 11-27 "Reagent Cooling with Fan Speed Controller PCB").
3. Remove the four Phillips Head screws and washers securing the Reagent Cooling with Fan Speed Con-
troller PCB to the Reagent Module as shown on Figure 11-33 "Reagent Cooling with Fan Speed
Controller PCB".
Mounting Screws

4. Lift and remove the Reagent Cooling with Fan Speed Controller PCB.
Reagent Cooling with Fan Speed Controller PCB Installation
To replace the Reagent Cooling with Fan Speed Controller PCB, perform the preceding removal instructions
then install the PCB by performing the removal in reverse order. (Note that the fan outputs (J4, J5, J6, J7,
J8) can be attached to any fan even though they are labeled as attaching to a specific fan.)
Reagent Flag Removal/Replacement
Reagent Flag Removal
Perform the following steps to remove the Reagent Flag.

1. To remove the Reagent Flag, the Reagent Module must be removed as described in "Reagent Module
Removal/Replacement".

2. Using an Allen wrench, remove the five cap head screws holding the Reagent Flag as shown in Figure
11-34 "Reagent Flag".
NOTE: When disassembling the Reagent Flag, a flexible drip shield and backing plate also
comes off. Note the orientation of these parts for reassembly.
3. Remove the Reagent Flag.

Figure 11-34 Reagent Flag
Mounting Screws
Reagent Flag
Reagent Flag Installation
To replace the Reagent Flag, perform the preceding removal instructions then install the flag by performing
the removal in reverse order making sure the flag is aligned on the three flag alignment pins before inserting
any screws.
Bar Code Reader Assembly Removal/Replacement
Bar Code Reader Assembly Removal
Perform the following steps to remove the Bar Code Reader Assembly.
1. Remove the top and front cover as described in Section 4, Enclosures/Chassis.
2. Remove the Sample and Reagent Area interior covers as previously described in this section.
NOTE: When removing/installing the bar code reader assembly, the bar code reader must be
in its home position. The bar code reader home position is when the left edge of the bar code
readers white cover is even with the left edge of the reagent module. In its home position, the
slotted sensor on the RTI PCB assembly is positioned between the Sample and Reagent
flags so the sensor is not damaged when removing the bar code reader assembly. Ensure the
bar code reader is aligned as shown in Figure 11-35 "Bar Code Reader Home Position".
3. Move the bar code reader to its home position (left edge of the bar code reader aligned with the left edge
of the reagent module) as shown in Figure 11-35 "Bar Code Reader Home Position".

Figure 11-35 Bar Code Reader Home Position
Reagent
Module Left
Edge
Bar Code
Bar Code
Reader
Reader
Left Edge
4. Using an Allen wrench, remove the nine cap head screws securing the bar code reader assembly as
shown on Figure 11-36 "BCR Mounting Screws Location". Note that the screws are in three groups
of three. Each group of three forms a triangle as shown in Figure 11-37 "Mounting Screws". (The fig-
ure shows the screws at the left end of the bar code reader.)
Figure 11-36 BCR Mounting Screws Location
Bar Code Reader

Mounting Screw Locations

Figure 11-37 Mounting Screws
Mounting
Screws
5. Pull the bar code reader assembly forward to release it from the alignment pins on which it rests.
6. Remove one ribbon cable and one power cable attached to the bar code reader assembly from the
backplane board.
7. Remove the bar code reader assembly from the instrument.
Bar Code Reader Assembly Installation
To replace the bar code reader assembly, perform the preceding removal instructions then install the
assembly by performing the removal in reverse order.
NOTE: Position the RTI PCB sensor in the proper location before re-assembling the bar code
reader assembly on the instrument. Failure to do this damages the RTI sensor.
Bar Code Reader Removal/Replacement

The new Microscan Reader units have a beam angle that is oriented 5 further downward to allow the unit
to read a wider range of label placements. The new covers have a wider opening and are designed to cor-
rect "Ghosting" errors. A Ghosting error is caused by a reflection from the cover interfering with the trans-
mission of information to the reader
Bar Code Reader Removal
1. Remove two screws on the right and one screw on the left of the bar code reader cover.
2. Disconnect the cable from the red LED in the bar code reader cover and remove the cover.

3. Unplug the Barcode Scanner Interface Board from the Microscan unit as shown in Figure 11-38 "Bar-
code Scanner Interface Board".
Figure 11-38 Barcode Scanner Interface Board
Barcode Scanner Interface Board
4. Remove the two screws from the Barcode Reader Mounting Plate as shown in Figure 11-39 "Plate
Mounting Screws".
Figure 11-39 Plate Mounting Screws
Plate Mounting
Screws

5. Tilt the unit forward to expose the cable clamp on the rear of the plate and free the cable from the
assembly as shown in Figure 11-40 "Cable Clamp".
Figure 11-40 Cable Clamp
Cable Clamp
6. Remove the two screws holding the bar code reader bracket to the bar code reader as shown on Figure
11-41 "Bar Code Reader Mounting Screws".
Figure 11-41 Bar Code Reader Mounting Screws
Mounting
Screws
Bar Code Reader Installation
1. Align the Microscan unit to the plate and reinstall its mounting screws (see Figure 11-41 "Bar Code
Reader Mounting Screws").
2. Align the plate to its pins on the instrument and place the cable into the clamp on the back of the plate
(see Figure 11-40 "Cable Clamp").
3. Reinstall the two screws to mount the plate to the instrument (see Figure 11-39 "Plate Mounting
Screws").
4. Attach the Barcode Scanner Interface Board to the Microscan unit (see Figure 11-38 "Barcode Scan-
ner Interface Board").

5. Connect the indicator LED cable.

6. Place the cover and replace the three cover mounting screws.
RTI PCB Removal/Replacement
RTI PCB Removal
Perform the following steps to remove the RTI PCB. (Reference Figure 11-42 "RTI PCB" when performing
this procedure.)
1. Remove the Bar Code Reader Assembly from the instrument as described in "Bar Code Reader
Assembly Removal/Replacement".
1. Remove the ribbon cable on J1 connecting the RTI PCB to the X Axis PCB.
2. Remove the cable on J2 that connects the RTI PCB to the Bar Code Reader.
3. Remove the four screws holding the RTI PCB to the bar code reader bracket as shown on Figure 11-42
"RTI PCB". (Note the orientation of the RTI PCB and the order of the hardware being removed.)
Figure 11-42 RTI PCB
J2
J1
RTI PCB
X Axis PCB Mounting Screws
RTI PCB Installation
To replace the RTI PCB, perform the preceding removal instructions then install the assembly by performing

X Axis PCB Removal/Replacement
X Axis PCB Removal
NOTE:Units with SN 04050149 and below had an earlier version X Axis

PCB.
Perform the following steps to remove the X Axis PCB.
1. Remove the Bar Code Reader Assembly as previously described in this chapter.
2. Remove the following cables attached to the X Axis PCB as shown on Figure 11-43 "X Axis PCB".
J1 (Signal I/O) cable to Backplane PCB
J2 (Power) cable to power Backplane PCB
J3 (Encoder) cable to encoder
J4 (Left Limit) cable to bar code reader left limit sensor
J5 (Right Limit) cable to bar code reader right limit sensor
J6 Unused
J7 - cable to RTI PCB.
J8 cable to bar code reader drive motor
J9 Unused

Figure 11-43 X Axis PCB

J1 J2 J4 J8
J6
J7
J9 J3 J5
3. Remove the four screws holding the X Axis PCB to the X Axis mounting baracket.
4. Remove the X Axis PCB.
X Axis PCB Installation
To replace the X Axis PCB, perform the preceding removal instructions then install the assembly by per-
forming the removal in reverse order.
Earlier version X Axis PCB Replacement
For replacement, please order IL part number 00027613010, which includes an X Axis PCB without DIP
switch, jumper cable and instructions. This board requires jumper installation detailed below.
1. Remove Molex connector of barcode motor assy. from barcode X Axis PCB.
2. Insert and lock one jumper into positions p8-1 and p8-3 and the other jumper into positions p8-6 and p8-
8 as shown in Figure 11-44 "Jumper Placement".
Note: be sure to maintain the proper orientation of the pin to the connector housing to insure pins lock
securely.
3. Check electrical continuity between pins p8-1 and p8-3, p8-6 and p8-8.

Figure 11-44 Jumper Placement

P8-1/P8-3
Note
Orientation
P8-6/P8-8
Encoder Removal/Replacement
Encoder Removal
Perform the following steps to remove the Encoder

1. Remove the top cover and front panel as described in Top Skin Removal/Replacement in Chapter
4 and Front Panel Assembly Removal/Replacement in Chapter 4.
2. As shown on Figure 11-45 "Encoder Assembly Location", the encoder has a positioning screw for
locking and unlocking the encoder and a setscrew to tighten it on the shaft.
Figure 11-45 Encoder Assembly Location
Positioning Screw
Setscrew
3. The positioning screw is in the locked position as shown on Figure 11-46 "Encoder" with the slot in the
positioning screw aligned with the single dot on the cover. To remove the encoder, using a flat blade
screwdriver, turn the positioning screw to the unlocked position as shown in the figure. The slot in the
positioning screw should be aligned with the single dot on the cover.)

Figure 11-46 Encoder
Positioning screw in
Positioning screw in
locked position
unlocked position
(Uninstalled) (Installed)
4. Use an Allen Wrench to loosen the set screw accessible through the opening in the upper right rear of
the encoder as shown in Figure 11-46 "Encoder".
NOTE: The Encoder pulley must be rotated to locate the setscrew.
5. Pull the encoder, which snaps and unsnaps, to remove it from the shaft.
Encoder Installation
To replace the encoder, perform the preceding removal instructions then install the assembly by performing
the removal in reverse order. Note that the set screw must be tightened with the encoder positioning switch
in the unlocked position.
Curtain Removal/Replacement
The following procedures apply to both the left and right curtains. Where there is a difference in the proce-
dure for the right and left curtain, it is clearly defined.
Curtain Removal
Perform the following steps to remove the Curtain.

1. Remove the Bar Code Reader Assembly as previously described. (See "Bar Code Reader Assembly
Removal/Replacement").
2. Move the bar code reader next to the spool for the side of the curtain to be removed.
3. While holding the curtain material, remove the screws going through the curtain material and the mount-
ing bracket securing the curtain to the Bar Code Reader as shown on Figure 11-47 "BCR Curtain
Attachment".

Figure 11-47 BCR Curtain Attachment
Right
Curtain
Right Side Left Side
Mounting Mounting Screws
Screws
Left Curtain
4. Release the tension in the curtain by slowly turning the spool until it stops on its own (9 turns).
5. Unwrap the curtain material from the spool until the mounting bracket is exposed as shown on Figure
11-48 "Curtain Spool Attachment".
Figure 11-48 Curtain Spool Attachment
Curtain/Spool
Attachment
Screws
6. Remove the three Phillips head screws that attach the mounting bracket and curtain to the spool and
remove the mounting bracket and curtain from the spool.
Curtain Installation
To replace the curtain, perform the following steps to insert a new curtain.
1. Align the applicable curtain material (right or left) to the spool assembly (left or right) while noting the ori-
entation of the curtain material.
2. Attach the curtain to the travelling Bar Code Reader using the mounting bracket and three screws that
were removed. (Note: Do not tighten the screws at this time.)
3. Move the Bar Code Reader to the farthest position from the spool being replaced.
4. For the right curtain (as viewed from the front of the instrument), align the end of the curtain material to
the spool in a manner that the material coming off the spool comes off the front of the spool as shown on

Figure 11-49 "Right Curtain Spool Attachment". Turn the spool clockwise (CW) nine turns (to pro-
vide proper tension on the curtain material) and, while keeping tension on the spool, place the end of
the curtain material under the mounting bracket and tighten the three screws that attach the mounting
bracket and curtain to the spool.
Figure 11-49 Right Curtain Spool Attachment
Mounting
Screws
Mounting Right
Bracket Curtain
Right Spool Assembly
5. For the left curtain, align the end of the curtain material to the spool in a manner that the material coming
off the spool comes off the front of the spool as shown on Figure 11-50 "Left Curtain Spool Attach-
ment". Turn the spool counter-clockwise (CCW) nine turns (to provide proper tension on the curtain
material) and, while keeping tension on the spool, place the end of the curtain material in front of the
spool and under the mounting bracket and tighten the three screws that attach the mounting bracket
and curtain to the spool.
Figure 11-50 Left Curtain Spool Attachment
6. Slowly relieve the tension on the spool to allow it to turn and wind the curtain material on the spool.
7. Manually move the bar code reader from one end of its travel to the other (to properly align the material
under the mounting bracket holding it to the bar code reader).
8. Tighten the screws attaching the curtain to the travelling bar code reader assembly.

Bar Code Reader Drive Belt Removal/Replacement
Bar Code Reader Drive Belt Removal
Perform the following steps to remove the Bar Code Reader Drive Belt.
1. Remove the bar code reader assembly from the instrument as previous described. (See "Bar Code
Reader Assembly Removal/Replacement").
2. Using an Allen wrench, loosen the two screws that tension the drive belt as shown in Figure 11-51 "Bar
Code Reader Drive Belt Tension Adjustment". This releases the drive belt tension.
Figure 11-51 Bar Code Reader Drive Belt Tension Adjustment
Tension Adjustment
Screws
3. Using an Allen wrench, remove the two screws attaching the RTI PCB bracket to the bar code reader as
shown on Figure 11-52 "Bar Code Reader Drive Belt Fastening" and remove the RTI PCB and
bracket. (This must be removed to supply access to the belt clamps.)
NOTE: Removing the curtain material provides better access but is not required.

Figure 11-52 Bar Code Reader Drive Belt Fastening
RTI
Bracket
Screws
Drive Belt Clamp

Screws
4. Using an Allen wrench, remove the four screws on the drive belt clamp on one side of the RTI PCB
mounting bracket.
5. Using an Allen wrench, remove the four screws on the drive belt clamp on the other side of the RTI PCB
mounting bracket.
6. Remove the belt.
Bar Code Reader Drive Belt Installation
To replace the Bar Code Drive Belt, install the assembly by performing the following steps.
1. Place one end of the belt in one of the drive belt clamps as shown in Figure 11-53 "Bar Code Reader
Drive Belt Attachment".
Figure 11-53 Bar Code Reader Drive Belt Attachment
Belt Bracket Screws
Drive Belt Clamps Ensure cogs in belt

and clamp align.

2. While holding the clamp together over the belt, ensuring the last cog on the belt fits within the indenta-
tion at the bottom part of the clamp as shown on the figure, and the belt is between the four screw holes,
insert and tighten the four screws in the belt clamp using an Allen wrench.
3. Wrap the belt around the encoder and pulley at the ends of the bar code reader assembly and ensure
the belt is straight across the front of the bar code assembly as shown in as shown in Figure 11-54 "Bar
Code Reader Drive Belt Tension".
Figure 11-54 Bar Code Reader Drive Belt Tension
Ensure Straight Across
4. Bring the end of the belt to the other side of the travelling bar code reader assembly and place the end
of the belt in the drive belt clamp.
5. While holding the clamp together over the belt, ensuring the last cog on the belt fits within the indenta-
tion at the bottom part of the clamp and the belt is between the four screw holes, insert and tighten the
four screws in the belt clamp using an Allen wrench.
6. Verify the bar code reader assembly moves freely and the belt tracks properly over the pulleys.
NOTE: The belt is provided at the proper length and should require minor tension adjustment.
7. Adjust the belt tension so the belt is straight with no sag across the entire front of the bar code reader
assembly and an 8 or 10ml vial adapter laid on the middle of the belt moves it 0.2 to 0.3cm. To adjust
the tension, move the pulley to the left or right to increase or decrease the belt tension and tighten the
screws when the tension is correct.
8. Reattach the two screws securing the RTI PCB bracket to the bar code reader as shown on Figure 11-
52 "Bar Code Reader Drive Belt Fastening".
9. Reinstall the bar code reader assembly as described in "Bar Code Reader Assembly Removal/
Replacement".
Bar Code Reader Drive Motor Removal/Replacement
Bar Code Reader Drive Motor Removal
Perform the following steps to remove the Bar Code Reader Drive Motor.
1. Remove the bar code reader assembly as previous described. (See "Bar Code Reader Assembly
Removal/Replacement").
2. Using an Allen wrench, loosen the two screws that tension the drive belt and secure the drive belt motor
bracket as shown in Figure 11-55 "Bar Code Reader Drive Motor". This releases the drive belt ten-
sion.
3. Using an Allen wrench, remove the two screws and remove the motor bracket and motor from the bar
code reader assembly.

4. Remove the four TORX screws securing the bar code reader drive motor as shown on Figure 11-55
"Bar Code Reader Drive Motor".
Figure 11-55 Bar Code Reader Drive Motor
Torx Screws
Securing
Motor
Drive Belt tension Adjustment

5. Remove the bar code reader drive motor.
Bar Code Reader Drive Motor Installation
To replace the bar code reader drive motor, install the assembly by performing the removal in reverse order.
After reinstalling the motor bracket and motor, perform the following steps to verify the drive belt tracking
and tension.
1. Verify the bar code reader assembly moves freely and the belt tracks properly over the pulleys.
NOTE: The belt is provided at the proper length and should require minor tension adjustment.
2. Adjust the belt tension so the belt is straight with no sag across the entire front of the bar code reader
assembly and an 8 or 10 ml vial adapter laid on the middle of the belt moves it 0.2 to 0.3cm. To adjust
the tension, move the pulley to the left or right to increase or decrease the belt tension and tighten the
screws when the tension is correct.


Chapter 12 Thermal Control 12 - 1
Chapter 12
Thermal Control
12-1 Overview
Temperature Control
Certain modules in the ACL-TOP instrument are thermally regulated to maintain specified temperatures.
The following are the thermally controlled modules in the ACL-TOP instrument and the temperatures to
which they are kept.
Cuvette shuttle - 37 Centigrade
Incubator #1 - 37 Centigrade
Incubator #2 - 37 Centigrade
ORU Cradle - 37 Centigrade
Reagent Module - 15 Centigrade
Reagent Probes for Cavro - 37 Centigrade
Reagent Probes for Universal Arms - 37 Centigrade
Sample probe - for Base Top - Cavro - 37 Centigrade (CTS Sample arm is not heated).
Note that the temperature display is provided on the ACL-TOP system display by clicking on System ->
Instrument Status as shown on Figure 12-1 "System Temperature Display Selection".
Figure 12-1 System Temperature Display Selection
Clicking on the Temperatures tab in the resulting screen display shows the temperature of all thermal con-
trolled elements as shown in Figure 12-2 "Temperature Tab of Instrument Status Display".

12 - 2 Chapter 12 Thermal Control
Figure 12-2 Temperature Tab of Instrument Status Display
Physical layout for the thermal elements is included in the description of the module in which the element is
contained.
Interconnect diagrams for the thermal elements are included in the description of the module in which the
element is contained.

Thermal Sensing
Each thermal sensing circuit consists of a Thermistor, a conditioning circuit, may include a filter, and an ana-
log to digital converter as shown on Figure 12-3 "Thermal Sensing Block Diagram". A thermistor is a tem-
perature-sensitive resistor that changes its resistance dependent on the temperature. The thermistor
resistance is sensed by the conditioning circuit that converts the thermistor resistance to a proportional ana-
log voltage. Dependent on the individual circuit, the sensing circuit may provide filtering of the conditioning
circuit analog output. The analog output of the conditioning circuit/filter is input to an analog to digital con-
verter and produces a digital output proportional to the analog output of the conditioning circuit (and there-
fore the resistance of the Thermistor). The output of the analog to digital converter is input to the controller
of the thermal element and used to determine if the element requires power to heat or cool the element.
Figure 12-3 Thermal Sensing Block Diagram
Analog to
Conditioning Filter Digital
Thermistor Circuit (Optional) Converter
To Thermal
Control Circuit
Thermal Control
Each thermal control circuit consists of a Thermal Control Circuit, a Power Switch, may include coils and
capacitors, and a thermal element as shown on Figure 12-4 "Thermal Control Block Diagram". The
Probe Integrated Controller is the controller for probe thermal regulation. All other thermal controllers are the
corresponding controller boards. The controller does the recognition of the heating or cooling and turns on
the power switch to effect the change. The coils and capacitors (specific to the Reagent Plate and the
Probes) are used to eliminate spurious electrical signals into other areas of the instrument. The thermal ele-
ment actually performs the heating or cooling of the area.
Figure 12-4 Thermal Control Block Diagram
Thermal Power Coils and Thermal

Control Switch Capacitors for Element
Circuit
Fluctuations
(Optional)

Cuvette Shuttle Thermal Regulation

The Cuvette Shuttle is kept at 37 Centigrade. The heater is a heating pad and is located as shown on Fig-
ure 12-5 "Cuvette Shuttle Heater". The thermistor for the cuvette shuttle is on the other side of the assem-
bly from the heater as shown on Figure 12-6 "Cuvette Shuttle Thermistor" (the white wires go to the
thermistor). The overload protection is a thermal switch that disables current flow to the heating element
when the temperature reaches the cut-off point of the circuit. The thermal switch is in series with the heating
element. Normal function is restored only when the temperature goes below a 2nd thermal point of the cir-
cuit, that is lower than the cut-off temperature. The cuvette thermal control is provided by the Cuvette Con-
troller PCB using a Proportional Integral Derivative loop for control and a Field Effect Transistor as a power
switch.
Figure 12-5 Cuvette Shuttle Heater
Overload
Protection
Heater
Element

Figure 12-6 Cuvette Shuttle Thermistor
Cuvette
Shuttle
Thermistor
Incubator #1 Thermal Regulation

NOTE: The hardware drawings, PNs, etc. and this document refer to Incubator #1 being on
the Sample side of the instrument. The ACL-TOP software refers to Incubator #1 being on the
Reagent side of the instrument (not the ThermalCal software). Bear this in mind when trou-
bleshooting, etc. the instrument.
Incubator #1 is kept at 37 Centigrade. The heater is a heating pad and is located as shown on Figure 12-
7 "Incubator 1". The thermal control for Incubator #1 is provided by the ORU Controller PCB using a Pro-
portional Integral Derivative loop for control and a Field Effect Transistor as a power switch. The overload
protection is a thermal switch that disables current flow to the heating element when the temperature
reaches the cut-off point of the circuit. The thermal switch is in series with the heating element. Normal func-
tion is restored only when the temperature goes below the 2nd thermal point, which is lower than the cut-off
temperature.

Figure 12-7 Incubator 1
Thermistor
Overload
Protection
Heater
Element
Incubator #2 Thermal Regulation

NOTE: The hardware drawings, PNs, etc. and this document refer to Incubator #2 being on
the Reagent side of the instrument. The ThermalCal software refers to Incubator #2 being on
the Sample side of the instrument. Be aware of this when troubleshooting, etc. the instrument.
Incubator #2 is kept at 37 Centigrade. The heater is a heating pad and is located as shown on Figure 12-
8 "Incubator 2 Thermal Regulation". The thermal control for Incubator #2 is provided by the
ORU Controller PCB using a Proportional Integral Derivative loop for control and a Field Effect
Transistor as a power switch. The overload protection is a thermal switch that disables current
flow to the heating element when the temperature reaches the cut-off point of the circuit. The
thermal switch is in series with the heating element. Normal function is restored only when the
temperature goes below the 2nd thermal point, which is lower than the cut-off temperature.
Figure 12-8 Incubator 2 Thermal Regulation
Heater Element
Overload
Thermistor
Protection

Optical Reading Unit (ORU) Cradle Thermal Regulation

The ORU Cradle is kept at 37 Centigrade. Heating is performed by a heating pad and temperature control
is performed by a thermistor. There is one heating pad and thermistor mounted on each of the four ORU sta-
tions as shown on Figure 12-9 "Optical Reading Unit Thermal Regulation". The thermal control for the
ORU Cradle is provided by the ORU Controller PCB using a Proportional Integral Derivative loop for control
and a Field Effect Transistor as a power switch. The overload protection is a thermal switch that disables
current flow to the heating element when the temperature reaches the cut-off point of the circuit. The thermal
switch is in series with the heating element. Normal function is restored only when the temperature goes
below the 2nd thermal point, which is lower than the cut-off temperature.
Figure 12-9 Optical Reading Unit Thermal Regulation
Thermistors
Overload Protection
Heater Element
Reagent Module Thermal Regulation

The cooling of the reagent mounting plate is performed by three Thermal Electric Coolers mounted on the
mounting plate below a large heat sink as shown in Figure 11-9. The heat sink dissipates the heat generated
by the coolers and in turn is cooled by air flow from an inlet duct from on the middle lower edge of the front
panel assembly. This duct is the fresh air inlet to the reagent module and allows cool air to be blown across
the heat sink of the Reagent module. The air is exhausted out the rear of the instrument, using the integrated
channels in the base skin as duct work, as shown on Figure 12-10 "Cooling Fan Ductwork".

Figure 12-10 Cooling Fan Ductwork
Air Filter
Exhaust Duct Intake Duct

Exhaust
Duct
Mounted to the chassis base, between the reagent module and the base skin is a fan assembly, as shown
on Figure 12-11 "Fan Assembly", comprised of five fans mounted side-by-side in a single row. The middle
three fans provide inlet air to the Reagent module. These three fans are positioned below the center of the
heat sink to allow air to be blown directly at the heat sink (air is directed at the heat sink fins as opposed to
across the fins). The two outside fans of the fan assembly act as exhaust fans and exhaust air beneath the
base skin of the instrument. They create air flow away from the Reagent module as shown on Figure 12-11
"Fan Assembly".
Figure 12-11 Fan Assembly
Inlet Fans
Exhaust Fans
Air Inlet Vent
If the air inlet vent located on the middle lower edge of the front panel assembly is blocked or the air flow
impeded (i.e. lab papers sitting on countertop, etc.) system temperature out-of-range warnings and errors
can occur.

Reagent Cooling with Fan Speed Controller PCB.
Control of the Thermal Electric Coolers is performed by the Reagent Cooling with Fan Speed Controller
PCB mounted on the right side of the reagent module as shown in Figure 12-12 "Reagent Cooling with
Fan Speed Controller PCB". This PCB provides power to the Coolers when cooling is required as indi-
cated by a thermal sensor located on the mounting plate. The Reagent Cooling with Fan Speed Controller
PCB controls the speed of the three reagent cooling fans based on the heat sink temperature as indicated
by the sensor. The Reagent Rack Presence PCB also monitors the temperature of the mounting plate and
generates a signal causing a System temperature out-of-range indication if the temperature goes outside
its range of 15 Centigrade plus or minus 3 Centigrade.
Units below serial number 05070377 do not have the fan control PCB but can be upgraded using IL part
number 00029411300.
Reagent Rack Presence

PCB
Reagent Probes for Cavro Thermal Regulation

The reagent probes for Cavro units are kept at 37 Centigrade. There are two heaters and thermistors
mounted within the probe as shown on Figure 12-13 "Cavro Reagent Probe". The thermal control for the
Reagent Probe is provided by the Probe Integrated Controller PCB using a Proportional Integral Derivative
loop for control and a Field Effect Transistor as a power switch. Over load protection for the probe is pro-
vided by a fuse in the Probe Integrated Controller PCB.

Figure 12-13 Cavro Reagent Probe
Probe Integrated
Controller
PCB
Probe Heaters and

Thermistors
(within probe)
Reagent Probes for Universal Arms Thermal Regulation

The reagent probes for Universal Arms are kept at 37 Centigrade. There are two heaters and two ther-
mistors mounted within the probe as shown on Figure 12-14 "Universal Arms Reagent Probe". The
Reagent Probe thermal control is provided by the Probe Integrated Controller PCB using a Proportional Inte-
gral Derivative loop for control and a Field Effect Transistor as a power switch. Over load protection for the
probe is provided by a fuse in the Probe Integrated Controller PCB.
Figure 12-14 Universal Arms Reagent Probe
Probe Integrated
Controller PCB
Probe Heaters and
Thermistors
(within probe)

Cavro Sample Probe Thermal Regulation

The sample probes for Cavro units are kept at 37 Centigrade. There are two heaters and two thermistors
mounted within the probe as shown on Figure 12-15 "Cavro Sample Probe". The Sample Probe thermal
control is provided by the Probe Integrated Controller PCB using a Proportional Integral Derivative loop for
control and a Field Effect Transistor as a power switch. Over load protection for the probe is provided by a
fuse in the Probe Integrated Controller PCB.
Figure 12-15 Cavro Sample Probe
Probe Integrated
Controller
PCB
Probe Heaters and

Thermistors
(within probe)
CTS Sample Probe Thermal Regulation

The CTS Sample probe is not thermally controlled.
Adjustments
Mechanical adjustments and verification for the thermally controlled modules are covered in the Rack Han-
dling, Cuvette Handling and Robotics XYZ chapters of this manual.

ThermalCal Description
The following describes the requirements, use, and user interface of the Thermal Calibration Software (also
known as ThermalCal). The Thermal Calibration software enables the calibration of several thermally con-
trolled modules within the instrument. ThermalCal use is intended for Instrumentation Laboratory personnel
and authorized Service Personnel trained to support the ACL TOP.
NOTE: ThermalCal does NOT address the thermal calibration of the probes within the instru-
ment which are required to be calibrated by the manufacturer. Nor does it cover the calibra-
tion of the cuvette shuttle, which does not need calibration.
The software is a Windows 2000 application and is distributed with a required DLL called the Console DLL.
This DLL is required to support the communication with the TOP AM.
References
The following equipment is required to perform the calibration of the TOP AM:
Rack Thermistor Mount, IL Part Number 285211-00
Thermistor Probe Assembly, IL Part number 189960-00
Futura Thermal Test Fixture, IL Part number 189937-00
NOTE: Automatic mode is not intended for field use and is not included in the following
description and procedures.
User Interface
The Users Interface is a single dialog box as shown in Figure 12-16 "ThermalCal Dialog Initial State".
During operation, message boxes are used for additional interaction such as warnings and confirmations.
As shown in the figure, ThermalCal is initiated in automatic mode and, for field use, must be placed in man-
ual mode by clicking on the Go To Manual Mode button at the top left of the window.

Figure 12-16 ThermalCal Dialog Initial State
Once entering Manual Mode, the main dialog box is divided into several sections as shown in Figure 12-17
"Thermal Dialog after Changing to Manual Mode".
The User Interface screen is divided into four sections as follow:
The Mode Selection and Current Mode is indicated at the top.
Meter Connection and Status section (automatic mode) or the Temperature Entry section (manual
mode) is in the upper section
TOP AM Connection and Status section is in the middle
Calibration Status and Control section is at the bottom
The various buttons and controls have tool tips to simplify their use. Tool tips pop up whenever the mouse
is left over a control for more than a few seconds. The mouse needs to be an arrow cursor for the tool tip to
pop up. The following paragraphs describe each of these sections and provide information on their usage
during the calibration process.

Figure 12-17 Thermal Dialog after Changing to Manual Mode
Mode selection
and display
Temperature
Entry
ACL-Top Analytical
Module Connect-
ion and Status
Calibration
Status and
Control
Mode Selection and Display
At the top of the dialog box is a mode selection button and a message indicating the current mode.
NOTE: Automatic mode is not intended for field use and is not included in the following
descriptions and procedures.
Temperature Entry
The temperature data entry section is used to enter the temperature as measured by the probe and the
Futura tester. Clicking the Submit temperature button causes the system to record the temperature, display
the Entered Temperature, the Target temperature, and the Temperature difference in the lower part of the
screen. The software also submits the temperature to the system so it can calculate offsets/coefficients to
compensate for any differences between the measured temperature and the system controlled temperature.
ACL-TOP Connection and Status
The connection to the Analytical Module is performed through this portion of the ThermalCal screen. The
proper sequence for connecting to the AM is to have the CM Computer and the touch screen monitor ON,
the CM Software NOT running and the Analytical Module OFF. The CM is connected (normally) to the Ana-
lytical Module and is running the ThermalCal application. Once this is in place:

The Analytical Module must be turned on.

Wait 2 minutes for the TOP Analytical Module to start. Since the CM is not running, there is no
visual indication that the Analytical Module is operational.
Click the Connect to TOP button of the ThermalCal application.
The application connects automatically and updates the TOP Status to AM Connected as shown on Fig-
ure 12-18 "Screen after connecting to the TOP AM. (Manual Mode)".
The Display Coefficients button is used to display the coefficients presently stored in the TOP AM. An exam-
ple of the resulting display is shown in Figure 12-24 "Display Coefficient Settings".
Figure 12-18 Screen after connecting to the TOP AM. (Manual Mode)
Calibration Status and Control
The Calibration Status and Control portion of the ThermalCal screen is used to control the actual calibration
process. The process of calibrating each module is the same. This process is depicted in the flow chart in
Figure 12-19 "Calibration Process for a Single Module". This process is repeated for each module that
needs to be calibrated.

Figure 12-19 Calibration Process for a Single Module
The first step of calibrating any module is to select the module to be calibrated. The module is selected by
clicking on the module selection button with the name of the module on it. After the module is selected (or
before), the Thermistor Probe Assembly must be placed in the correct location for that module. The list
below gives the location of the thermistor when the module is being calibrated. When the module is
selected, a message box pops up reminding the user to check that the Thermistor Probe Assembly is in the
correct location.
RACK Reagent Rack Position 2 (from the rear of the instrument) of a Reagent Rack in location
R3.
ICU 1 Incubator 1 The fourth slot (from the left) of the incubator on the sample side of the TOP
AM.
ICU 2 Incubator 2 The fourth slot (from the left) of the incubator on the reagent side of TOP AM.
ORU 1 Optical Reading Unit 1 The slot of the leftmost Optical Reading Unit.
ORU 2 Optical Reading Unit 2 The slot of the Optical Reading Unit second from the left.
ORU 3 Optical Reading Unit 3 The slot of the Optical Reading Unit third from the left.
ORU 4 Optical Reading Unit 4 The slot of the rightmost Optical Reading Unit.

After the module is selected, a soaking period is started to ensure that the temperature of the TOP AM and
the thermistor have reached their true steady state values. During this period, the remaining soaking time is
displayed on the applications main screen. (See Figure 12-20 "Display of the Soaking Time Remain-
ing".)
Figure 12-20 Display of the Soaking Time Remaining
Soak Time Remaining
N
NOTE:When the first module is selected, if the TOP AM was not turned
off prior to connecting with ThermalCal, the message shown in Figure
12-21 "Time-out Message" is displayed. When this occurs, the TOP AM
must be shutdown, ThermalCal must be exited, and the process
restarted.
Figure 12-21 Time-out Message

When the temperature reading is stable, the wording Temp Stable is displayed as shown on Figure 12-22
"Temperature Stable Display". The screen then returns to the idle state waiting for another module to be
selected.
Figure 12-22 Temperature Stable Display
Temp Stable
Indication
Once the temperature is stable, the temperature reading from the Futura Thermal Test Fixture is entered in
the Enter Temperature Here box and the Submit Temp button is clicked. The ThermalCal software cal-
culate the temperature error from the target temperature versus the entered temperature. The entered tem-
perature, target temperature, and the temperature difference are displayed in the lower left part of the
ThermalCal dialog box.
If the Temp Difference is NOT within +/- 0.2 degrees, the Update Coefficients button is clicked for the
system to recalculate and store new coefficients. In this case, the software calculates new coefficients and
they are sent to the TOP AM. A new waiting period is then initiated and the check is repeated to validate the
calibration with the new coefficients.
If the Temp Difference is within 0.2 degrees of the target temperature, the Done button is clicked to end
the calibration of that module. When the temperature reading is stable and the Done button is clicked, a
message box is displayed for the user to confirm his choice. After clicking OK, a second message box is dis-
played showing the calibration offset that is saved in the TOP AM as shown in Figure 12-23 "Screen show-
ing Offset (Coefficient)". This value should be recorded as a record of the calibration. The screen then
returns to the idle state waiting for a new site to be selected. Note that after a site is calibrated and saved,
the button associated with that site displays Done.

Figure 12-23 Screen showing Offset (Coefficient)
The preceding process is be repeated for each module that requires calibration. When all modules are com-
pleted, the EXIT button in the upper right corner of the window is clicked. This displays a confirmation dia-
log box. Selecting OK in this dialog box exits the ThermalCal software.
Display Coefficients Screen
After ThermalCal is connected to an ACL-TOP and if a calibration is not being performed, a Display Coeffi-
cients dialog box is available. This dialog is displayed when the Display Coefficients button is clicked on.
The dialog lists the Offset coefficient for each module that can be calibrated. This allows for single screen
review of the calibration parameters of the ACL-TOP. The screen is shown in Figure 12-24 "Display Coef-
ficient Settings".
Figure 12-24 Display Coefficient Settings
The Calibration Settings window also provides for the entry of coefficients. Coefficients need to be entered
into the system whenever a thermal module or a controller card is replaced (the controller cards are used to
store the coefficients). In the case of the controller card, the coefficients are displayed before replacing the
card and are re-entered after the new card is inserted. For the thermal modules, the coefficients (as docu-
mented on the thermal module) are entered into the system when replacing the unit. It is recommended that
the calibration of each thermal module be performed after their replacement.
NOTE: To prevent faulty entries, the software only allows the offset to be adjusted by 200 at a time.

Other Handled Events
There are several other events that are handled by the software.
1. If the user selected the wrong module or needs to abort the current calibration for some reason, the
user can click the Stop button. This will display the confirmation message box shown in Figure 12-
25 "Message Box Confirming a Stop Calibration Request". If Yes is selected, the calibration will
be aborted and the previously saved calibration will be restored to the TOP AM.
Figure 12-25 Message Box Confirming a Stop Calibration Request
2. If a additional module is selected while a module is being calibrated, a warning is displayed as shown
in Figure 12-26 "Message Warning that a Second Module cannot be Selected " and the request is
ignored.
Figure 12-26 Message Warning that a Second Module cannot be Selected
3. If the EXIT button that exits the software is selected during a calibration, the following message is
displayed (see Figure 12-27 "Complete Calibration before Exiting message") and the request is
ignored.
Figure 12-27 Complete Calibration before Exiting message

ThermalCal Instructions for Adjusting Coefficients/Offsets
Load the ThermalCal Program
NOTE: ThermalCal must be performed with all ACL-TOP covers closed.
1. If the ThermalCal software is installed on the CM computer, double click on the ThermalCal icon on
the desktop, as shown on Figure 12-28 "ThermalCal Icon", to open the program.
Figure 12-28 ThermalCal Icon
N
NOTE:The most recent versions of ACL-TOP have the ThermalCal
software pre-installed on the CM. Verify it is not installed by clicking on
Start > Programs to display the list of installed programs and use the
installed version if available.
2. If the ThermalCal software is not loaded on the CM computer, load the software by performing the
following steps.
STEP 1: Insert the distribution CD-ROM into the computer.
STEP 2: Double click the My Computer icon on the desktop.
STEP 3: Double click the icon of the CD-ROM drive to open it.
STEP 4: Drag the ThermalCal folder onto the computer desktop.
STEP 5: Double click on the ThermalCal folder.
STEP 6: Double click on the ThermalCal icon.
3. Click on the Go To Manual Mode button as shown on Figure 12-29 "ThermalCal Screen" to
place the software in manual mode.

Figure 12-29 ThermalCal Screen
4. Verify the following:

The CM Computer and the touch screen monitor are ON.
The CM Software is NOT running.
The Analytical Module is OFF (power is off to the instrument).
The CM is connected (normally) to the Analytical Module and running ThermalCal.
5. Turn on the Analytical Module. (Power up the instrument.).
NOTE: Do not remove any of the instrument covers. ThermalCal; should be run with all cov-
ers in place.
6. Wait 2 minutes for the Analytical Module to start. (Because the CM software is not running, there is
no visual indication that the Analytical Module is operational.)
7. Click the Connect to TOP AM button of the ThermalCal application as shown on Figure 12-30
"Connecting ThermalCal Application to the AM".

Figure 12-30 Connecting ThermalCal Application to the AM
Connection Button
Test the Thermal Modules
8. Once the TOP AM Status: displays Connected, as shown in Figure 12-32 "AM Connected",
select the module to be tested by clicking on the module selection button with the name of the mod-
ule on it.
N
NOTE:When the first module is selected, if the TOP AM was not turned
off prior to connecting with ThermalCal, the message shown in Figure
12-31 "Time-out Message" is displayed. If this occurs, the TOP AM
must be powered down, ThermalCal must be exited, and the procedure
restarted.
Figure 12-31 Time-out Message

Figure 12-32 AM Connected
Connected Status
Selection of
Module To Be
Tested
9. Place the thermistor depending on the module to be calibrated. Ensure the thermistor is laying flat
and is all the way to the front of the slot. The locations are:
RACK Reagent Rack Position 2 (from the rear of the instrument) in location R3 of the
Reagent Rack.
ICU 1 Incubator 1 The fourth slot (from the left) of the incubator on the sample side of the
TOP AM as shown on Figure 12-33 "ICU1 Thermistor Placement".
Figure 12-33 ICU1 Thermistor Placement
ICU1 Thermistor
Placement
ICU 2 Incubator 2 The fourth slot (from the left) of the incubator on the reagent side of TOP
AM as shown on Figure 12-34 "ICU2 Thermistor Placement".

Figure 12-34 ICU2 Thermistor Placement
ICU2 Thermistor
Placement
See Figure 12-35 "ORU Thermistor Placement" for thermistor placement for the ORU heads.
ORU 1 Optical Reading Unit 1 The slot of the left most Optical Reading Unit.
ORU 2 Optical Reading Unit 2 The slot of the Optical Reading Unit second from the left.
ORU 3 Optical Reading Unit 3 The slot of the Optical Reading Unit third from the left.
ORU 4 Optical Reading Unit 4 The slot of the right most Optical Reading Unit.
Figure 12-35 ORU Thermistor Placement
ORU 4
ORU 1 ORU 2 ORU 3

10. Use the Thermistor Probe Assembly, IL PN 189960-00 as shown in Figure 12-36 "Thermistors
and Futura Test Fixture" for measuring the temperature in all but the Reagent Module. (The
probe is inserted in the back of the thermal module and slid to the front in the same manner a
cuvette is loaded.) Use the Rack Thermistor Mount, IL PN 285211-00, for the Reagent Rack by
placing the Probe Assembly into the mount, locking it into position and placing it in Position 2, loca-
tion R3, of the reagent rack.
11. Connect the other end of the thermal test probe into the Futura Thermal Test Fixture as shown in
Figure 12-36 "Thermistors and Futura Test Fixture".
Figure 12-36 Thermistors and Futura Test Fixture
Rack Thermistor Mount

(IL PN 285211-00) Thermistor Probe Assembly
(IL PN 189960-00)
Futura Connection
Futura Test Fixture

(IL PN 189937-00)
12. When the pop-up screen is displayed asking to verify the placement of the thermistor, verify the
thermistor placement and click the OK button to initiate the calibration. The instrument enters a
soaking period to ensure the temperature and thermistor have reached steady state values and
displays the soaking time remaining as shown on Figure 12-37 "Soak Time Remaining".

Figure 12-37 Soak Time Remaining
Soak Time
Remaining
13. After the soaking period ends and Temp Stable is displayed as shown on Figure 12-38 "Tem-
perature Input", enter the temperature displayed on the Futura Thermal Test Fixture into the
Enter Temperature Here box on the ThermalCal screen and click on the Submit Temperature
button.
Figure 12-38 Temperature Input
Temperature
Submission
Temperature
Stable
Indication

14. If the Temperature Difference (Deg C):, as shown in Figure 12-39 "Temperature Difference",
is more than 0.2 degrees, click the Update Coefficients button to store the coefficients gener-
ated as part of the ThermalCal procedure, initiate a new soaking period, and initiate a new calibra-
tion check using the new coefficients.
Figure 12-39 Temperature Difference
Temperature Difference
15. If the Temperature Difference (Deg C), as shown in Figure 12-39 "Temperature Difference",
is less than 0.2 degrees, click on the Done button. The system displays a message box on which
the Yes button should be clicked, as shown on Figure 12-40 "Save Calibration", to confirm the
calibration of the module is complete.
Figure 12-40 Save Calibration
16. A second message box is displayed showing the final calibrated offset that is saved in the TOP AM
as shown on Figure 12-41 "Calibration Offset".
Figure 12-41 Calibration Offset

17. Verify that the button for the module tested states Done as shown in Figure 12-42 "Done Indi-
cation". If so, select the next module by returning to "Test the Thermal Modules".
Figure 12-42 Done Indication
Done Indication
Save the Coefficients
18. If all modules to be calibrated are complete, click the Display Coefficients button in the Ther-
malCal window as shown on Figure 12-43 "Display Coefficients".

Figure 12-43 Display Coefficients
Display Coefficients Button
19. With the coefficients being displayed as shown on Figure 12-44 "Calibration Settings", click on
ALT + Print Screen to capture the screen content.
Figure 12-44 Calibration Settings
20. Click on the OK button in the Calibration Settings window to store the new coefficients and close
the window.
21. If the WordPad icon is not on the desktop, generate a shortcut to WordPad for storing of the
Screen content:
Double click on My Computer.
Select C: > Document and Settings > Administrator > Start Menu > Program >
Accessories.

Right click on the WordPad icon and select Create Shortcut.

Click on the WordPad icon and drag it to the desktop.
22. Close the Accessories window and return to the desktop.
23. Click on the WordPad icon to open the application.
24. Click on Edit > Paste to paste the screen capture into the file.
25. Click on File > Save As and save the file as C:\Thermal Coefficients. (If the file already
exists, replace it.)
26. Exit the WordPad application by clicking on File >Exit.
27. Exit the ThermalCal application by clicking on the Exit button in the upper right corner of the
screen.
Inputting Thermal Coefficients using ThermalCal

This procedure is used whenever one of the thermally controlled modules or a controller board is replaced.
When a thermal module is replaced, the coefficients, as written on the module, must be entered into the sys-
tem to ensure the proper temperature is maintained in the new module. When a controller board is replaced,
the coefficients that were stored in the previous controller board must be entered into the new controller
board.
NOTE: ThermalCal must be performed with all ACL-TOP covers closed.
the desktop, as shown on Figure 12-28 "ThermalCal Icon", to open the program.
N
NOTE:The most recent versions of ACL-TOP have the ThermalCal
software pre-installed on the CM. Verify it is not installed by clicking on
Start > Programs to display the list of installed programs and use the
installed version if available.
following steps.
Insert the distribution CD-ROM into the computer.
Double click the My Computer icon on the desktop.
Double click the icon of the CD-ROM drive to open it.
Drag the ThermalCal folder onto the computer desktop.
Open the ThermalCal application by double clicking on the ThermalCal icon.

3. Click on the Go To Manual Mode button as shown on Figure 12-46 "ThermalCal Screen" to
place the software in manual mode.
Mode Button

The CM is connected (normally) to the Analytical Module and running the thermal application.
5. Turn on the Analytical Module. (Power up the instrument.).
6. Wait 2 minutes for the TOP Analytical Module to start. (Since the CM software is not running, there
is no visual indication that the Analytical Module is operational.)

"Connecting ThermalCal to the AM".
Figure 12-47 Connecting ThermalCal to the AM
Connection
Button
Connection Status
8. Once the TOP AM Status displays Connected, as shown in Figure 12-48 "Connection Status",
click on the Display Coefficients button to display the stored coefficients of the system.

Figure 12-48 Connection Status
Connection
Status
Display Coefficients Button
9. Highlight the correct entry and enter the coefficient(s) for the new unit(s), as written from the calibra-
tion tag during the installation steps, into the box as shown in Figure 12-49 "Thermal Coefficient
Display".
Figure 12-49 Thermal Coefficient Display
10. Click on the OK button to store the new coefficients.

11. With the coefficients being displayed, click on ALT + Print Screen to capture the screen content.
12. Click on the OK button in the Calibration Settings window to store the new coefficients and close
the window.
13. Minimize the ThermalCal application.
14. If the WordPad icon is not on the desktop, generate a shortcut to WordPad for storing of the
Screen content:
Click on My Computer.
Select C:> Document and Settings > Administrator > Start Menu > Program >
Accessories.
Click on WordPad.
Right click and select Create Shortcut.
Click on the WordPad (2) icon and drag it to the desktop.
15. Close all Windows and return to the desktop.
17. Click on Edit > Paste to paste the screen capture into the application.
18. Click on File > Save As and save the file as C:\Thermal Coefficients. (If the file already exists,
replace it.)
19. Exit the WordPad application by clicking on File >Exit.
20. Maximize and then exit the ThermalCal application by clicking on the Exit button in the upper
right corner of the screen.
12-6 Diagnostics
The reagent block actual temperature, reagent block lower limit, and reagent block upper limit are displayed
on the Controllers, Covers, and Racks Diagnostic Screen as shown in Figure 12-50 "Controllers, Covers
and Racks Diagnostic Screen".

Figure 12-50 Controllers, Covers and Racks Diagnostic Screen
Reagent Temperature Area

As shown on Figure 12-51 "Reagent Temperature Area of Diagnostic Screen", the screen displays the
current, lower limit and upper limit temperatures.
Figure 12-51 Reagent Temperature Area of Diagnostic Screen
Temperature Troubleshooting
1. Open the ORU tab in the diagnostics window as shown in Figure 12-52 "ORU Tab of Diagnostic
Screen".

Figure 12-52 ORU Tab of Diagnostic Screen
Temperature Area

2. Check that the temperature readings for all four ORUs and the two incubators are within the upper
and lower limits as specified in the temperature portion of the screen as shown on Figure 12-53
"Temperature Portion of ORU Diagnostic Screen"
Figure 12-53 Temperature Portion of ORU Diagnostic Screen
3. Click on the Controllers, Covers and Racks tab of the Diagnostic screen. Check that the temperature
readings for the Reagent Block are within the upper and lower limits as specified in the temperature
portion of the diagnostic screen as shown on Figure 12-54 "Software, Covers and Racks Diagnos-
tic Screen".

Figure 12-54 Software, Covers and Racks Diagnostic Screen
Rea
4. Figure 12-55 "Reagent Block Temperature" provides a better depiction of the Block Temperature
area of the screen.
Figure 12-55 Reagent Block Temperature

5. At this time, temperature controls are not replaceable items. Therefore, if the readings are not within
specifications, replace the failing unit as described in the procedure identified in the following table.
Table 12-1 Procedures for Replacing Thermal Elements
Unit with Temperature Procedure

outside range
Incubator # 1 Incubator #1 Removal/Replacement in Chapter 9
Incubator # 2 CTS Hold/Incubator #2 Removal/Replacement in

Chapter 9
ORU # 1 through # 4 Removing/Replacing the ORU Assembly in

Chapter 10
None of the heaters or thermistors in the ACL-TOP instrument are replaceable at this time. Refer to Rack
Handling, Cuvette Handling and Robotics XYZ for removal/replacement procedures. Table 12-2 "Thermal
Control Module/Assembly, Driver, Controller" lists the thermal elements, the PCBs containing the driv-
ers for the thermal elements and the controller for the thermal elements.
Table 12-2 Thermal Control Module/Assembly, Driver, Controller
Module Module/ Module/ Driver for Controller for

Assembly Assembly thermal thermal element
containing Removal/ element
thermal element Replacement
Procedure
Cuvette shuttle Cuvette Shuttle Cuvette Shuttle Cuvette Shut- Cuvette CPU
Assembly Assembly tle Y-Axis
Removal/ Board
Replacement in
Chapter 9
Incubators Cuvette Handling CTS Hold/Incu- Incubator ORU CPU

Assembly bator #2 Heater Board
Removal/
Replacement in
Chapter 9
Incubator #1
Removal/
Replacement in
Chapter 9

ORU heads Optical Reading Removing/ ORU Interface ORU CPU

Unit Replacing the Board
ORU Assembly
in Chapter 10
Reagent plate Reagent Assem- Reagent Mod- Reagent Cool- Rack CPU
bly ule Removal/ ing PCB
Replacement in
Chapter 11
Probes FET/Coil/Cap Probe Trouble- Probe Inte- Probe Integrated

shooting in grated Control- Controller PCB
Chapter 8 ler PCB

Chapter 13 Waste Management System 13 - 1
Chapter 13
13-1 Overview
The Waste Management System consists of the Bulk Fluid Waste Management Subsystem and the
Cuvette Waste Management Subsystem. The Bulk Fluid Waste Subsystem includes those components
that are involved in disposing of the HemosIL Rinse Fluid Waste, and the Clean A Fluid Waste, that are by-
products of rinse and clean operations. The Cuvette Waste Subsystem includes those components that are
involved in disposing of cuvette waste.
The Bulk Fluid Waste Management consists of the Sample Accumulator, Reagent Accumulator, Waste
Fluid Presence Sensor, Peristaltic Waste Pump and Waste Bottle.

Figure 13-1 "Layout of the Waste Management System" shows the physical layout of the Waste Management System. The Sample Accumulator is shown in red,
the Reagent Accumulator is shown in green, the Cuvette Waste Shelf is shown in cyan, the Cuvette Waste Drawer is shown in magenta and the Waste Bottle is
shown in yellow. The location of the Waste Pump is indicated in blue.
Figure 13-1 Layout of the Waste Management System
Cuvette Waste Shelf
Waste Bottle
Sample Accumulator Reagent Accumulator
Peristaltic Waste Pump Cuvette Waste Drawer

The Interconnect Diagram for the Bulk Fluid Waste Management System is included in the Interconnect Dia-
gram for the Fluid Handling System (see Interconnect Diagrams in Chapter 7).
The Interconnect Diagram for the Cuvette Waste Management System is included in the Interconnect Dia-
gram for the Cuvette Handling System (see Interconnect Diagrams in Chapter 9).
Bulk Fluid Waste Management Subsystem

The Bulk Fluid Waste Management consists of the following components:
Sample Accumulator
Reagent Accumulator
Waste Fluid Presence Sensor
Peristaltic Waste Pump
Waste Bottle
Sample and Reagent Accumulators
Each ACL TOP Instrument is equipped with two Fluid Accumulators that contain both a Waste Fluid Collec-
tion Tank and a Rinse/clean Station to support each probe. All ACL TOP Instruments utilize the same
Reagent Side Accumulator. Instruments equipped with Cavro arms have a different Sample Side Accumu-
lator than instruments equipped with IL arms and CTS.

13 - 4 Chapter 13 Waste Management System
Figure 13-2 The Sample and Reagent Accumulators
Sample Accumulator Reagent Accumulator
CTS Accumulator
Reagent Side Accumulator
The Reagent Side Accumulator is identical on all ACL TOP instrument configurations. The Reagent Side
Accumulator contains two Rinse/clean stations, a Clean Pump, two Clean Valves, a Fluid Level Sensor, and
a reservoir to hold excess rinse and other waste fluids. The Waste Fluid Reservoir is a solvent-bonded
assembly made of PVC. The front of the reservoir is clear to allow operators to observe the fluid level during
Diagnostics. The two center stacks in the Accumulator are vent tubes to equalize the pressure within the
Waste Reservoir. Fluid is removed by the Waste Pump via the 1/8-27 NPT barb fitting at the bottom of the
reservoir.
Figure 13-3 The Reagent Side Accumulator
Reagent Accumulator

The Reagent Side Accumulator has a Rinse cup and a Clean cup for each Reagent Arm. The Clean Cups
are filled by the Clean Pump. Each Clean Cup has a 24V DC solenoid valve which energizes when Clean
A Fluid is required. The valves are normally closed (N/C), but they are opened to allow Clean A Fluid to
pass when requested by the ACL TOP software. Clean A Fluid is moved by the Clean Pump as described
in Chapter 7 Fluid Movement.
The metal bracket on the Accumulator is made of a chemically resistant material to protect the finish from
the Hydrochloric Acid in the Clean A Fluid. The metal surface around the Rinse/clean Stations should be
wiped clean on a regular basis with an isopropyl alcohol pad.
Sample Side Accumulator
ACL TOP Instruments with Cavro Arms use the Sample Side Accumulator shown in Figure 13-2 "The Sam-
ple and Reagent Accumulators". Instruments with the CTS Sample Arm use the Sample Side Accumula-
tor shown in Figure 13-4 "The Sample Side Accumulator (CTS)".
Sample Side Accumulators for ACL TOP Instruments with Cavro Arms
The Sample Side Accumulator on an ACL TOP with Cavro Arms contains two Rinse/clean Stations, a Clean
Pump, two Clean Valves, a Fluid Level Sensor, and a reservoir to hold excess rinse and other waste fluids.
The Waste Fluid Reservoir is a solvent-bonded assembly made of PVC. The front of the reservoir is clear
to allow operators to observe the fluid level during Diagnostics. The two center stacks in the Accumulator
are vent tubes to equalize the pressure within the Waste Reservoir. Fluid is removed by the Waste Pump
via the 1/8-27 NPT barb fitting at the bottom of the reservoir.
Sample Side Accumulators for ACL TOP Instruments with CTS Sample Arms
The Sample Side Accumulator on an ACL TOP with CTS Sample Arms contains one Rinse/clean Stations,
a Clean Pump, two Clean Valves, a Fluid Level Sensor, and a reservoir to hold excess rinse and other waste
fluids (see Figure 13-4 "The Sample Side Accumulator (CTS)"). The Waste Fluid Reservoir is a solvent-
bonded assembly made of PVC. The front of the reservoir is clear to allow operators to observe the fluid
level during Diagnostics. There are two vent ports on the top of the reservoir to equalize the pressure within
the Waste Reservoir. The Waste Reservoir has a larger capacity to hold the additional Rinse fluid generated
by the CTS external wash function. Fluid is removed by the Waste Pump via the 1/8-27 NPT barb fitting at
the bottom of the reservoir.
Figure 13-4 The Sample Side Accumulator (CTS)

This accumulator has one clean/rinse station on the right side of the assembly. The clean/rinse station is
unique to this accumulator. In addition to the clean cup and a standard rinse location, this clean/rinse station
also holds an external wash station with filter for use in CTS equipped instruments. When equipped with
CTS, rinse fluid is supplied to the external rinse location by a dedicated diaphragm pump located in the CTS
Bulk fluidics module. The clean cup can hold the same volume as the base top accumulator (250uL) and is
filled by the clean pump. The clean pump is a 24V DC solenoid driven with a 2 Hz pulse. No solenoid valves
are used on this accumulator assembly because the clean pump is self-checking. Clean fluid is moved by
the clean pump as described in Chapter 7 Fluid Movement.
The metal bracket on the Accumulator is made of a chemically resistant material to protect the finish from
the Hydrochloric Acid in the Clean A Fluid. The metal surface around the Rinse/clean Stations should be
wiped clean on a regular basis with an isopropyl alcohol pad. Holder for filter changer is located on CTS
accumulator.
Waste Fluid Removal in the Accumulator
Fluid level in all accumulators is monitored by a capacitance sensor mounted on the back side of the accu-
mulator. The sensor sees through the plastic wall of the accumulator and detects waste fluid when it
reaches the height of the sensor. The sensor has an amber LED which illuminates when the sensor is trig-
gered. The sensitivity of the sensor is fixed an cannot be adjusted by the operator or by service personnel.
The sensor is positioned to trigger when fluid in the accumulator reaches approximately 80% of the total
capacity. When the sensor triggers, the ACL TOP system turns on the Waste Pump. The Waste Pump is left
running for a length of time that is sufficient to drain most of the fluid in the accumulator. After the Waste
Pump turns off, a small volume of fluid is left in the accumulator to increase the efficiency of the Waste Pump
the next time it is used.
The Waste Pump
The Waste Pump is located above the Rinse Pump Box and to the right of the Reagent Module. The Waste
Pump has a peristaltic design and it consists of a pump head with four rollers and three waste tubes. The
back tube is connected to the Sample Side Accumulator, the center tube to the Reagent Side Accumulator,
and the front tube to the Reagent Area Cold Plate (refer to Figure 13-5 "The Parts of the Waste Pump").
The pump head is turned by a 24V DC motor. The motor terminates at a bulkhead-mounted connector on
the Waste Pump assembly. An interconnect cable ties the Waste Pump motor to the fluidic connector PCB
located in the lower center of the ACL TOP.
Figure 13-5 The Parts of the Waste Pump
Tube to Reagent Accumulator
Tube to Sample Accumulator
Debubbler

The Waste Pump tubes are molded to a specific length from a rubber formulation developed by Instrumen-
tation Laboratory. The end of each tube has a molded hub reinforced by an aluminum ring. (The aluminum
ring acts as a bearing surface when it is installed.) Proper tension of the Waste Pump tubes is critical to effi-
cient operation of the pump.
When the Waste Pump head turns, the rollers spin with the head. The movement of the rollers along the
waste tubing creates a peristaltic action very similar to the act of swallowing food. This operation draws fluid
out of the accumulators and reagent area and into the waste bottle, or floor drain, located below the ACL
TOP. The rollers are independent of each other; to decrease friction and wear, the rollers spin freely when
they are drawn across the waste tubing.
The Waste Pump is controlled by the ACL TOP system software. It can also be controlled within the Fluidic
Diagnostics Menu. The pump is operated each time one of the two accumulator fluid height sensors is trig-
gered and every 20 minutes to drain condensation from the reagent area cold plate. The duration of oper-
ation is controlled by software timing. Operation is timed to leave a small volume of fluid in the accumulator.
The waste pump is capable of dry priming the waste lines, but functions most efficiently when primed by a
head volume. If full drainage of both accumulators is desired for service, the pump can be operated from
the Fluidic Diagnostics Menu. Prior to shipment of the instrument, the shipping preparation routine should
be run to fully purge the accumulators of waste fluid.
Waste pump tubes should be replaced by service personnel on a scheduled basis. Prior to replacement of
the tubes, the Waste Accumulators and lines should be fully drained by running the Waste Pump from the
Fluidic Diagnostics Menu.
If the ACL TOP has not been used for several weeks, it is possible for the tubes to take a set. If this hap-
pens, unhook the tubes from the bracket and roll them between two fingers to reestablish the tube cross
section.
Cuvette Waste Management Subsystem

The Cuvette Waste Shelf Assembly collects the cuvette waste for the Instrument. After a cuvette has been
used for analysis, the Cuvette Shuttle leaves the cuvette on the Waste Shelf. Figure 13-6 "The Waste Shelf
Assembly" shows the Waste Shelf Assembly and the Waste Container.
Figure 13-6 The Waste Shelf Assembly
Sonic Sensor
Waste Shelf
Waste
Container

The Waste Shelf accommodates up to six cuvettes before dumping them into the Waste Container. The
Waste Shelf continues to dump cuvettes into the Waste Container until a sonic sensor senses that the pile
of waste cuvettes has reached a maximum height. The maximum height is usually reached when there are
about 200 cuvettes in the Waste Container. Figure 13-6 "The Waste Shelf Assembly" shows the location
of the sonic sensor on the Waste Shelf.
Note: The sonic sensor height is not adjustable. It is a fixed height built into the Waste Shelf Assembly.
When the pile of waste cuvettes has reached the maximum height, the user is notified via an onboard LED
panel and by a message to the computer screen.
The horizontal tilt of the Waste Shelf can be changed with the horizontal tilt adjustment (m3 cap screw)
shown in Figure 13-7 "Tilt Adjustment and Positional Sensor". The horizontal tilt of the Waste Shelf is
set at the time when the Instrument is assembled. However, the horizontal tilt adjustment can be used to
make a field adjustment of the horizontal tilt of the Waste Shelf. If it is necessary to make a field adjustment,
the Waste Shelf should be adjusted so that it becomes horizontal to the table surface. Verification that the
Waste Shelf is horizontal is done by performing a series of successful Cuvette Shuttle drop-offs. (Verify the
drop-offs of the cuvettes with the Cuvette Shuttle under the Diagnostics screen.)
The Waste Shelf Platform also uses a slotted sensor to sense the up and down positions of the shelf (shown
in Figure 13-7 "Tilt Adjustment and Positional Sensor"). A linear plunge solenoid is the mechanism that
creates the rotation of the Waste Shelf itself (i.e., the solenoid tilts the Waste Shelf to the dump position).
An extension spring is used as the return mechanism (i.e., returns the shelf back to the horizontal position).
Figure 13-7 Tilt Adjustment and Positional Sensor
Sensor Adjustment
Screw
Tilt Adjustment Screw

and Sensor Location

Board Descriptions
This section provides high-level descriptions of the PCBs in the Waste Management System.
Fluidics Connector/Controller Board
Located between the Sample side and Reagent side incubators below the metal cover.
Interfaces to the Fluidic controller board to provide control of all fluidic pumps and solenoid valves.
Provides sensor inputs for Liquid sensors, Rinse, Clean, and liquid waste in the internal accumu-
lators and external liquid waste bottle.
Provides solenoid power to cover interlocks, Sample and Reagent front cover sensors, and emer-
gency stop button.
Fluidic LED Board
Located on the front of the instrument on the right hand side.

Provides a visual indication of the liquid level status of Clean, Rinse and liquid waste.
Provides Visual indication of waste cuvette height.
Cuvette Waste Interface Board
Located on the cuvette waste shelf.

Provides the electrical interface to the mechanical waste shelf in order to perform the function of
dumping cuvettes into a waste container.
Features a buffered feed through connection that supports a distance ranging module to gauge the
cuvette waste height.
Interfaces the controller signals to fire a solenoid, and to communicate with the ranging module.
Provides return sensor signals to the controller from the optical door open/close sensor and
mechanical drawer presence sensor.

This section contains verification procedures for the Bulk Fluid Waste Management Subsystem and the
Cuvette Waste Management Subsystem.
Verification of the Bulk Fluid Waste Management Subsystem

Verification of the operation of the Bulk Fluid Waste Management Subsystem is done by filling the Sample
(or Reagent) Accumulator and then pumping the Accumulator contents into the Bulk Fluid Waste Container.
To do this, use the following steps:
1. Go the Fluids tab in Diagnostics and slowly fill the Sample Accumulator until the virtual LED for the Sam-
ple Accumulator turns green. At the same time, visually inspect for leaks around the Sample Accumula-
tor.
2. From the Fluids tab, run the Waste Pump for 90 seconds or until the virtual LED for the Sample Accumu-
lator turns off.
3. Repeat for Reagent Accumulator.
Verification of the Cuvette Waste Management Subsystem

Verification of the operation of the Cuvette Waste Management Subsystem is done by successfully moving
cuvettes from the Cuvette Loader to the Cuvette Waste Container. To do this, use the following steps:
1. Ensure that there are at least two cuvette strips in the Transport Deck.
2. Click on the Cuvettes tab in Diagnostics.
3. Use the "Move Cuvettes" function to move 11 cuvettes from the Cuvette Loader to the Cuvette Waste
Container. (Note: Enter 11 in the Number of cuvettes field.)

13-6 Diagnostics
This section describes the Diagnostics for the Waste Management Subsystem. The following section
describes the Diagnostics for the Bulk Fluid Waste Management Subsystem. Refer to "Diagnostics for the
Cuvette Waste Management Subsystem" for information on Diagnostics for the Cuvette Waste Manage-
ment Subsystem.
Bulk Fluid Waste Management Subsystem

The diagnostics for the Bulk Fluid Waste Management Subsystem are in the Waste sensors area and the
Waste pump Area of the Fluids tab. Figure 13-8 "The Fluids Tab" shows the Fluids tab.

Figure 13-8 The Fluids Tab

Waste Sensors Area

The Waste Sensors Area contains virtual LEDs that indicate the status of the Sample Accumulator, the
Reagent Accumulator, and the Bulk Waste Fluid Container. Figure 13-9 "The Waste Sensors Area"
shows the Waste area.
Figure 13-9 The Waste Sensors Area
The virtual LED Sample waste fluid full turns red when the Sample Accumulator is full.
The virtual LED Reagent waste fluid full turns red when the Reagent Accumulator is full.
The virtual LED Waste container turns red when the Bulk Waste Fluid Container is full.
Waste Pump Area

The Waste Pump Area contains the Waste pump on virtual LED, which turns green when the Waste pump
is running. The Waste Pump Area also contains a utility for running the Waste pump. Figure 13-10 "The
Waste Pump Area" shows the Waste area.
Figure 13-10 The Waste Pump Area
Enter in the Duration box the length of time (in seconds) to run the Waste pump.
Click the Start button to run the Waste pump. If the Stop button is not clicked before the end of the specified
duration, the Waste pump runs for the selected duration. If the Stop button is clicked before the end of the
specified duration, the Waste pump stops immediately.

Diagnostics for the Cuvette Waste Management Subsystem

The diagnostics for the Cuvette Waste Management Subsystem are in the Move cuvette(s) area and the Waste Area of the Cuvettes tab. Figure 13-11 "The
Cuvettes Tab" shows the Cuvettes tab.
Figure 13-11 The Cuvettes Tab

Move Cuvette(s) Area

Figure 13-12 "The Move Cuvette(s) Area" shows the Move Cuvette(s) area. The Move Cuvette(s) area
may be used to move cuvettes to the Waste Container and thereby test the functioning of the Cuvette Waste
Management Subsystem. The Start button initiates the Move cuvette(s) function.
Figure 13-12 The Move Cuvette(s) Area
Move
The user can move cuvettes through the slots on the instrument. Both the direction and reuse of the same
cuvette are options.
The requested operation is not executed if the Shuttle is not initialized, the Gripper is extended, or the num-
ber of cuvettes to be moved is not greater than zero or there is a cuvette in the shuttle.
The module(s), and position in the modules, to which the cuvette is be moved can be selected. Multiple posi-
tions, or all positions, in each module may be selected.
The selectable modules and positions are as follows:
Table 13-1 Selectable Modules and Positions
Module Position
Loader Not Applicable
Hold Area Positions 1-14
ORU Positions 1-4
Waste Not Applicable

If the Cuvette Waste module is not selected, the cuvette moves through each selected position and stop at
the last selected module and position, and the number of cuvettes can be set to any value from 1 through 99.
If the Cuvette Loader module is not selected, the number of cuvettes field can be set to any value from 1
through 99.
Note: Shuttle motors can not be disabled when a move is in progress.
Clear All Cuvettes
Selecting the "Clear all Cuvettes" button transfers all cuvettes in CTS Hold/Incubator #2, all cuvettes in Incu-
bator #1, and all cuvettes in the ORU to the Cuvette Waste Assembly.
Waste Area
The Waste Area contains buttons that control the operation of the Waste Shelf (Accumulator), virtual LEDs
that indicate the status of the Waste Assembly, and Sensors for the Waste Assembly. Figure 13-13 "The
Waste Area" shows the Waste area.
Figure 13-13 The Waste Area
Start, Stop, and Clear Accumulator Buttons
Select the Stop button to turn off the Ultrasonic sensor for the Waste Shelf. The Ultrasonic sensor is turned
off to make adjustments or to pull out the Waste Drawer, etc.
Select the Start button to turn on the Ultrasonic sensor for the Waste Shelf. This is done when it is desired
to have the Waste Shelf resume its normal operation (i.e., during dumping waste cuvettes into the Waste
Drawer).
Select the Clear Accumulator button to rotate the Waste Shelf to the "down" position. When the Waste Shelf
is in the "down" position, the shelf is tilted to allow any cuvettes on the shelf to drop into the Waste Con-
tainer.

Virtual LEDs
The upper-left portion of the Waste Area contains virtual LEDs for all of the sensors in the Waste Assembly.
When the sensor is enabled, the virtual LED turns green.
The state of each of the following sensors is shown in the Waste Area of the Cuvettes tab:
Cuvette waste inserted This sensor indicates whether the Waste Container is inserted or
removed. The virtual LED for this sensor turns green when the Waste Container is inserted and red
when the Waste Container is removed.
Cuvette waste door This sensor indicates whether the Waste Door is open or closed. The virtual
LED for this sensor turns green when the Waste Door is opened.
Accumulator up This sensor indicates when the Accumulator is in the "up" position. (When the
Accumulator is in the "up" position, the shelf is horizontal and can hold cuvettes. When the Accu-
mulator is in the "down" position, the shelf is tilted down and any cuvettes on the shelf are dumped
into the Waste Container.)
Other Sensors in the Waste Area
The Cuvette waste level field indicates the height of the waste cuvettes in the Waste Container. The
Waste full limit field indicates the maximum allowable height of waste cuvettes in the Waste Container.
When the waste cuvettes reach the height specified in the Waste warning limit field, a user warning is sent
to the computer screen. When the waste cuvettes reach the height specified in the Waste full limit field,
the Instrument goes into a controlled stop (standby mode). Refer to the Operators Manual for more infor-
mation on controlled stops.
Waste Shelf Assembly Removal/Replacement
Waste Shelf Assembly Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Waste Shelf Assem-
bly, the following covers must be removed: Reagent Syringe Cover, Reagent Accumulator/Wash Rinse
Cover, Reagent Module Cover, Top Skin, Front Panel, Peristaltic Pump Cover, Upper Skin (Reagent Side),
and Right Inner Skin.
After the covers have been removed, do the following to remove the Waste Shelf Assembly:
1. Remove cables P1, P2, and P6 from connectors J1, J2, and J6 from the Cuvette Waste PCB (see Fig-
ure 13-14 "Connectors on the Cuvette Waste PCB").
2. Remove cables from connectors J1, J2, J3, J4, and J5 on Front Panel Disconnect PCB Assembly (see
Figure 13-15 "Three Captive Screws").
Note: Connectors J3, J4, and J5 are on the front of Front Panel Disconnect PCB; connectors J1 and
J2 are on the rear of Front Panel Disconnect PCB.

3. Loosen the three captive screws shown in Figure 13-15 "Three Captive Screws" and remove the
Waste Shelf Assembly.
Figure 13-14 Connectors on the Cuvette Waste PCB
J6 Connector
J2 Connector
J1 Connector
Figure 13-15 Three Captive Screws
PCB Assembly Door Switch Cuvette Waste Captive Screw

Waste Shelf Assembly Installation

1. Position the module for correct location and tighten the three captive screws.
2. Connect cables P1, P2, and P6 to connectors J1, J2, and J6 on the Cuvette Waste PCB.
3. Connect cables to connectors J1, J2, J3, J4, and J5 on PCB Assembly 275030-00 (see Figure 13-15
"Three Captive Screws").
Note: Connectors J3, J4, and J5 are on the front of PCB Assembly 275030-00; connectors J1 and J2
are on the rear of PCB Assembly 275030-00.
4. Verify the operation of the Waste Assembly by moving 11 cuvettes from the Cuvette Loader to every
position in the system (i.e., CTS Hold Incubator #2, Incubator #1, ORU, and Cuvette Waste Container).
Refer to "Verification of the Cuvette Waste Management Subsystem" for information on how to do
this.

Sample Accumulator Removal/Replacement

Sample Accumulator Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Sample Accumula-
tor, all of the inside covers on the sample and on the reagent side must be removed.
After the covers have been removed, do the following to remove the Sample Accumulator:
1. Go the Fluids tab in Diagnostics and run the Waste Pump for 90 seconds with three repetitions. This
ensures that the Accumulator is empty.
CAUTION: Ensure that the Instrument is powered OFF before the

following steps are performed.
2. Remove the cover over the Fluidic Connector/Controller PCB by loosening the two captive screws (see
Figure 13-16 "The Fluidic Connector/Controller PCB"). (Note: The captive screws fasten into Incu-
bator #1 and Incubator #2.)
3. Remove Connector J2 from the Fluidic Connector/Controller PCB (see Figure 13-16 "The Fluidic Con-
nector/Controller PCB").
Figure 13-16 The Fluidic Connector/Controller PCB
Connector J2
Connector J9
Captive Screws for

the Fluidic Connector/
Controller PCB Cover
4. Loosen the two captive screws on either end of the Sample Accumulator (see Figure 13-17 "The Sam-
ple Accumulator (with the Sample Module Removed)").
5. Lift the Accumulator up and remove the Clean Line from the Clean Pump and the Waste tubing from the
bottom of the Accumulator (see Figure 13-17 "The Sample Accumulator (with the Sample Module
Removed)"). As the Accumulator is lifted, guide the attached cable away from the Instrument.

Figure 13-17 The Sample Accumulator (with the Sample Module Removed)
Captive Screws
Waste Tubing
Sample Accumulator Installation
1. Connect the Waste tubing to the bottom of the Accumulator.

2. Connect Clean Line to the Clean Pump.
3. Carefully guide the Accumulator into the Instrument. Ensure that the captive hardware is aligned.
4. Attach Connector J2 to the Fluidic Connector/Controller PCB.
5. Tighten the two captive hardware screws on the Accumulator.
6. Go the Fluids tab in Diagnostics and slowly fill the Sample Accumulator until the virtual LED for the Sam-
ple Accumulator turns green. At the same time, visually inspect for leaks around the Sample Accumula-
tor.
lator turns off.
8. Repeat steps 6 and 7.

CTS Accumulator Removal/Replacement

CTS Accumulator Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the CTS Accumulator,
all of the inside covers on the sample and on the reagent side must be removed.
Note: The CTS Accumulator is mounted to the instrument in the same way as the Sample Accumulator.
After the covers have been removed, do the following to remove the CTS Accumulator:

Connector J2
Connector J9
Captive Screws for

4. Loosen the two captive screws on either end of the CTS Accumulator (see Figure 13-19 "CTS Accu-
mulator").
bottom of the Accumulator. As the Accumulator is lifted, guide the attached cable away from the Instru-
ment.

Figure 13-19 CTS Accumulator

Captive Screws
CTS Accumulator Installation

6. Go the Fluids tab in Diagnostics and slowly fill the CTS Accumulator until the virtual LED for the Sample
Accumulator turns green. At the same time, visually inspect for leaks around the Sample Accumulator.
lator turns off.
Reagent Accumulator Removal/Replacement

Reagent Accumulator Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Reagent Accumula-
tor, all of the inside covers on the sample side and on the reagent side must be removed.
After the covers have been removed, do the following to remove the Reagent Accumulator:


Connector J2
Connector J9
Captive Screws for

4. Loosen the two captive screws on either end of the Reagent Accumulator (see Figure 13-21 "The
Reagent Accumulator (with the Reagent Module Removed)").
bottom of the Accumulator (see Figure 13-21 "The Reagent Accumulator (with the Reagent Module
Removed)"). As the Accumulator is lifted, guide the attached cable away from the Instrument.
Figure 13-21 The Reagent Accumulator (with the Reagent Module Removed)
Captive Screws
Note: The Waste Tubing for the Reagent Accumulator is beneath the module and is not shown in Figure
13-21 "The Reagent Accumulator (with the Reagent Module Removed)".

Reagent Accumulator Installation

6. Go the Fluids tab in Diagnostics and slowly fill the Reagent Accumulator until the virtual LED for the
Reagent Accumulator turns green. At the same time, visually inspect for leaks around the Reagent
Accumulator.
7. From the Fluids tab, run the Waste Pump for 90 seconds or until the virtual LED for the Reagent Accu-
mulator turns off.
Waste Pump Removal/Replacement
Waste Pump Removal
Refer to Chapter 4 Enclosure/Chassis for details on cover removal. To remove the Waste Pump, all of
the inside covers on the sample side and on the reagent side must be removed.
After the covers have been removed, do the following to remove the Waste Pump:
9. Remove the four screws on top of the Waste Pump cover, as shown onFigure 13-22 "Waste Pump
Cover Screws". Lift and remove the cover.
Figure 13-22 Waste Pump Cover Screws
Cover
Screws Screws
10. Disconnect the Waste Pump motor cable.

11. Loosen the Waste Output Tube bracket as shown on Figure 13-23 "Waste Pump Removal"

Figure 13-23 Waste Pump Removal
Cap Head
Screws
Waste Output
Tube Bracket
Output Tubes from

EP20 Waste Tubing
12. Disconnect the Waste Output tube from the bottom of the debubbler.
13. Disconnect the output tubes from the EP20 Waste Tubing to the debubbler as shown on Figure 13-23
"Waste Pump Removal".
14. Disconnect the input tubes to the EP20 Waste Tubing.
15. Remove the four cap head screws securing the Waste Pump as indicated on Figure 13-23 "Waste
Pump Removal".
16. Lift and remove the Waste Pump from the instrument.
Waste Pump Installation
1. Place the Waste Pump on top of the Waste Pump Bracket and attach it to the bracket using the four
socket head cap screws as shown on Figure 13-24 "Waste Pump Mounting".

Figure 13-24 Waste Pump Mounting
Mounting Waste Tube

Screws Clamp
Tubes from
Debubbler
2. Connect the three tubes from the top of the debubbler to the ends of the EP-20 waste pump tubing as
shown on Figure 13-24 "Waste Pump Mounting".
3. Connect the Waste Pump motor cable.
4. Place the Waste Tube in the Waste Tube Clamp (as shown on Figure 13-24 "Waste Pump Mounting")
and connect the waste tube to the bottom of the debubbler.
NOTE: Ensure there are no kinks in the tubing.
5. Install the new Waste Pump cover using the four captive screws as shown in Figure 13-25 "Assembly
with Waste Pump Cover".
Figure 13-25 Assembly with Waste Pump Cover
Cover
Screws


Chapter 14 Preventive Maintenance 14 - 1
Chapter 14
The recommended preventive maintenance procedures contained within are based on the unit processing
500 tests per day and having those tests spread evenly throughout the day. These recommended sched-
ules should be adapted for those units processing different volumes.
There are two ACL-TOP maintenance procedures, a primary procedure, and a secondary procedure. The
primary procedure is performed on an annual basis (with the first occurance taking place one year after the
installation). The secondary procedure is not as comprehensive as the primary and is also performed on an
annual basis, six months after the primary procedure (with the first occurance taking place six months after
the installation). In this manner, the ACL-TOP receives either a primary or secondary maintenance every
six months. The steps required in each procedure are identified in the checklist on the following page. The
succeeding pages contain the detailed steps required for both the primary and secondary procedures and
clearly identify what step is associated with each procedure.
Parts Required
For the primary PM, the ACL-TOP Primary PM Kit, P/N 00029412000, is required. This kit contains all parts
that are required during the maintenance activity.
For the secondary PM, new syringes/tips are required that must be obtained prior to the maintenance activ-
ity. Prior to performing the PM, the FSE performing the PM should verify the syringe pumps installed in the
instrument (there are currently Hamilton and Cavro/Tecan syringe pumps in the ACL-TOP) and ensure
they have the correct syringes for the installed pumps.
14-1 Base TOP Preventive Maintenance
The following pages provide a printable checklist that should be completed and signed for each Preventive
Maintenance activity as well as instructions for each ot the actions to be performed. Note that the following
is for the Base TOP system and is to be done in conjunction with the maintenance for the CTS portion of the
system as described in if the system being PMd is CTS.

14 - 2 Chapter 14 Preventive Maintenance
ACL TOP Preventive Maintenance Checklist

ACCOUNT: _____________________ DATE: _______________
Address: ______________________________
______________________________
Model: ____________________Serial No.: ___________
Service Manual Refer- Com

PM Activities Primary Secondary
ences plete
1. Rinse Waste Accumulators with
X Ch. 7 Fluid Movement
DH2O
2. Inspect Fluidic System for Leakage
X X Ch. 7 Fluid Movement
and Damage
3. Replace All Syringes/Tips X X Ch. 7 Fluid Movement
4. Perform Disk Defragmenter X X Ch. 2 - Installation
5. Replace Air Filters X X Ch. 12 - Thermal Control
6. Replace Bulkhead Connectors X Ch. 7 Fluid Movement
7. Replace Pump to Probe Tubing on All
X Ch. 7 Fluid Movement
Arms
8. Replace Waste Tubing on Peristaltic
X Ch. 13 Waste Management
Pump
9. Clean Cavro/Tecan Arms X X Ch. 8 Robotic XYZ Arms
10. Clean ORU X X Ch. 10 Reaction Detection
11. Perform Air and Factor Diluent
X X Ch. 10 Reaction Detection
Blanking
12. Verify Cuvette Shuttle Alignment
X X Ch. 9 Cuvette Handling
and All Indexers
13. Perform Coordinate Adjustment X Ch. 8 Robotic XYZ Arms
14. Perform Flow Rate Test for all Arms X X Ch. 8 Robotic XYZ Arms
Ch. 10 Reaction Detection
15. Check Stirrer Bar Rotation X
Ch. 7 Fluid Movement
16. Check Instrument Software
X X Ch. 2 - Installation
Versions
17. Verify Touch Screen Calibration X Ch. 2 - Installation
18. Check Instrument Temperatures X Ch. 12 - Thermal Control
19. Perform Wipe down and Cleaning X X Ch. 2 - Installation
20. Verify a Ghost Image of the hard
X X` Ch. 2 - Installation
drive exists
Customer Name: __________________Service Engineer Name: __________________
Signature: _______________________Signature: _______________________

ACL-TOP Maintenance
1. Rinse Waste Accumulators with DH2O.

(Primary PM Only)
1. Open the Fluids tab in the Diagnostics screen.
2. Remove the Sample and Reagent area interior covers of the instrument as described in Chapter 4
of the ACL-TOP Service Manual.
3. Using a syringe with tubing attached, carefully add distilled water to fill each accumulator until the
appropriate virtual LED on the Fluids tab indicates the accumulator is full.
4. Run the waste pump until the accumulators are empty; visually verify that the accumulator is empty
and the LEDs on the Fluids tab are off.
5. Repeat steps c and d two more times.
2. Inspect the Fluidic System for Leakage and/or Damage
(Primary and Secondary PM)
1. Ensure the ACL-TOP instrument is in the Ready state.
2. Power down the instrument using the Power On/Off switch on the right rear of the instrument.
3. Inspect all components of the fluidic system, especially the components not normally replaced, such
as pumps and valves.
4. If the Rinse tubing is found to be in need of replacement, perform the following steps to replace it.
a. Remove the Rinse Tubing that attaches to the Sample Syringe Pump.
NOTE: Do not unscrew the barbed fitting on the Rinse tubing line of the Syringe
Pump Valve. The barbed fitting is torqued to a precise specification. If the torque
is changed, it could cause imprecision.
If this is a Primary PM:

1. Remove the precision tubing to one of the arms as stated in PM Activity 7 to use in this
procedure.
15. Cut off the fittings on the ends of the precision tubing.
16. Insert one end of the precision tubing into the end of the New Rinse tubing removed from
the Syringe Pump, as shown on Figure 14-1 "Use of Precision Tubing as Threader for
Rinse Tubing". (Ensure it is inserted far enough into the Rinse tubing to provide a tight fit.)
Figure 14-1 Use of Precision Tubing as Threader for Rinse Tubing
Precision Tubing Rinse Tubing

17. Using the precision tubing as a threader, feed, and pull the new Rinse tubing through the
tubing guide and use it to pull the tubing through to the rinse box and remove the threader.
NOTE: Feed the new Rinse tubing along the same path to the Rinse Box as the
old tubing.
If this is a secondary PM, tape the new tubing to the end of the old tubing and carefully feed and pull
the new tubing through the guide tube to the Rinse Pump.
b. Mark the tubing in indelible ink or with a stick-on tag to identify it and connect it to the Rinse
Pump.
c. Cut and connect the other end of the rinse tubing to the Syringe pump.
d. Repeat the above steps for the rinse tubing on the other syringe pumps.
5. If the Waste Outlet or Rinse Input tubing is found to be in need of replacement, perform the follow-
ing steps to replace it.
1. Remove sample module, reagent module, ORU cradle, and the Right Skin of the
instrument (along with the prerequisite top skin, front panel assembly, and inner right skin)
as described in Chapter 4 of the ACL-TOP Service Manual.
18. Remove the four (4) screws attaching the I/O Fluidics Panel to the unit. Then remove the
center screw above the "Clean" coupling that attaches the panel to the back fluidics cover.
(See Figure 14-2 "I/O Fluidics Panel Screws".)
Figure 14-2 I/O Fluidics Panel Screws
Center Screw
Corner Screws
Corner Screws
19. See Figure 14-3 "I/O Fluidic Panel Removal". To replace the Rinse Input Tubing,
carefully pull the panel forward. Detach the Tygon Tubing from the back of the Rinse
coupling, run the new Tygon tubing to the Rinse Pump box area and cut the tubing
ensuring there will be enough tubing to connect to the Rinse Input connection on the Rinse
Box.

Figure 14-3 I/O Fluidic Panel Removal
Clean Line
Rinse Input Line
Waste Outlet Line
20. See Figure 14-3 "I/O Fluidic Panel Removal". To replace the Waste Outlet Tubing,
carefully pull the panel forward. Detach the Tygon Tubing from the back of the Waste
coupling, run the new Tygon tubing to the Waste Pump box area and cut the tubing
ensuring there will be enough tubing to connect to the bottom of the debubbler next to the
Waste Pump.
NOTE: Ensure the Tygon tubes are connected to the correct couplings.
21. Connect the tubing to the Rinse Pump connector or to the debubbler.
22. If this is a minor PM, re-assemble the bulkhead portion of the instrument . If it is a major
PM, do not re-assemble the bulkhead as it is removed to replace the bulkhead connectors
in step 6 of the major PM.
6. If the CTS, Sample, or Reagent Accumulator tubing is found to be in need of replacement, perform
the following steps to replace it.
1. Remove the Sample or Reagent Accumulator as described inRemoval/Replacement in
Chapter 13.
23. Replace the tubing with the harness (tubing with tees and connectors) as supplied in the
PM kit and described in the ACL-TOP Service Manual.
3. Replace all Syringes/Tips (IL PN 00287839801).
1. Refer to the Online Help for Syringe Replacement.
2. Enter Maintenance Mode and select the appropriate syringe.
3. Follow the on screen prompts to replace the syringe (including the syringe tip).
4. Perform the Disk Defragmenter on the C Drive
1. Exit the ACL-TOP Application.
2. Power down the Analytical Module by turning off the AC Main switch on the right, rear side of the
instrument.
3. Click on Start --> Programs --> Accessories --> System Tools --> Disk Defragmenter.
4. Select Actions and then Defragment. The defragmenter may take a half hour or more to run.
5. While the defragmenter program is running, perform the following PM activities with the power to the
Analytical Module OFF.
5. Replace the Main Air Filter (IL PN 0028617300) and Power Supply Air Filter (IL PN
0028454300)

1. The main air filter is located under the front of the instrument, directly beneath the reagent module.
To remove the filter, slide the filter toward the front of the unit.
2. The 24-volt power supply has a filter that is located under the left rear of the unit. To remove the fil-
ter, slide it to the left.
6. Replace the Bulk Head Connectors
(Primary PM Only)
1. Ensure power has been turned OFF to the instrument.
2. Remove the Right Skin of the instrument (along with the prerequisite top skin, front panel assembly,
and inner right skin) as described in the ACL-TOP Service Manual.
3. Remove the four (4) screws attaching the I/O Fluidics Panel to the unit. Then remove the center
screw above the Clean coupling that attaches the panel to the back fluidics cover. (See Figure
14-4 "Fluidics Panel Screws".
Figure 14-4 Fluidics Panel Screws
Center Screw Four Corner Screws
4. Pull the panel forward. Tag the Tygon Tubing Lines as Clean, Rinse, and Waste as shown on
Figure 14-5 "I/O Fluidics Panel Removal". Detach the Tygon Tubing from the back of the fluidic
couplings and discard the fluidic panel. Attach Tygon Tubing lines to the new Fluidics Panel
Assembly - P/N 286069-01.
NOTE: Ensure the Tygon tubes are connected to the correct couplingsI

Figure 14-5 I/O Fluidics Panel Removal
CLEAN Line
Rinse Line
Waste Line
5) Re-assemble the bulkhead portion of the instrument in reverse order.

7. Replace Pump to Probe Precision Tubing on all Arms (IL PN 0028741600).
(Primary PM Only)
1. Remove the tubing clamp from the top of the arm.
2. Slide the probe cover off the probe.
3. Loosen the two setscrews that hold the probe on the z shaft.
4. Unscrew the minstack fitting.
5. Unscrew the right hand fitting on the syringe pump and pull the tubing from the tubing guide.
6. Save the used tubing for use as a threader if replacing the Rinse Tubing.
7. Replace the tubing, retighten the screws, and re-install the tubing clamp.
8. Replace Three Waste Pump Winding Tubing on Peristaltic Pump (IL PN 0028760501).
1. Remove one of the Waste Pump Winding tubes (see Figure 14-6 "Waste Pump Windings") by
sliding the end to the side to disengage it from the pump housing.

Figure 14-6 Waste Pump Windings
Waste Pump
Winding Tubes
2. Disconnect the waste tubing from the end of the tube, connect it to the new tube, and engage the lip
of the new tube under the indentation in the pump housing.
3. Repeat steps 1 and 2 for the other end of the tube.
4. Repeat the above steps for the other Waste Pump Windings.
9. Clean the ORU Cradle.
1. Using clean, dry cotton applicators, carefully wipe an ORU cuvette slot from the front to the rear,
inspect the applicator for dirt or foreign substances, and repeat until the applicator is clean.
2. Repeat for each ORU.
10. Cavro/Tecan Arms Cleaning
Z-Rack Assembly
NOTE: Do not use alcohol or solvents when cleaning the Z-rack.
1. Ensure power to the instrument has been turned OFF.

2. With a lint-free cloth, wipe the Z-rack thoroughly. If necessary, use a toothbrush to remove dust or
dirt from the Z-rack teeth.
Cleaning X-frame, flex-cable channel, square shaft pinion, arms

The Cavro/Tecan arms must be cleaned every six months. However, if the instrument is operated in a
dusty or humid environment, it must be cleaned more often. Follow the instructions below to prevent
damage to the instrument.
2. Remove the arm end caps and covers.
3. Wipe the arm(s) using a lint-free cloth dampened with isopropyl alcohol to remove any residual dust.

NOTE: Use only isopropyl alcohol and a lint-free cloth to clean the Cavro/Tecan
arms. Other cleaning agents may affect the performance of the instrument.
4. Wipe the inside of the flex cable channel (see Figure 14-7 "Flex Cable Channel") using a lint-free
cloth dampened with isopropyl alcohol.
Figure 14-7 Flex Cable Channel
Flex Cable Channel

5. Wipe the inside of the X-frame with a lint-free cloth dampened with isopropyl alcohol, ensuring that
the lubricant on the X-axis guide rails is not removed. See Figure 14-8 "X Frame and Rails".
Figure 14-8 X Frame and Rails
X-Axis Guide Rails

X Frame
6. Wipe the square shaft pinion located underneath the arm(s) (see Figure 14-9 "Y Frame and
Rails") using a lint-free cloth dampened with isopropyl alcohol.
NOTE: When cleaning the square shaft pinion, ensure alcohol does not enter the
Z-bearing or wiped on the Y-axis guide rails.
Figure 14-9 Y Frame and Rails
Z Bearing Square Shaft Pinion
Y-Axis Guide Rails
X or Y-axis Guide Rails Lubrication (ONLY as necessary)

Do not wipe the X or Y-axis guide rails. The guide rails are lubricated with grease that does not require
removal unless they are "extremely" dirty. If extremely dirty or if the factory applied lubricant is wiped
away, they should be cleaned ONLY using the following procedure.
NOTE: Never clean the X or Y-axis guide rails with alcohol or solvents. Serious
damage to the instrument may occur.



2. Move the arm(s) to the far right side of the X-frame.
3. Apply a thin film of Food Grade Lubricant to the rails.
Lubricant should not be visible or collect during operation.
If lubricant is visible or collects when the element is moved, wipe the lubricated area with a dry
lint-free cloth to remove the excess lubricant.
11. Perform Air and Factor Diluent Blankings
1. Apply power to the instrument by pressing the power switch on the right rear of the instrument.
2. Access the Diagnostic screen.
3. Select the ORU tab on the Diagnostics screen.
4. Verify that ORUs 1-4 are enabled (Green LED) as indicated on Figure 14-10 ".ORUs Enabled"
Figure 14-10 .ORUs Enabled
5. If all four ORU Enabled LEDs are not lit, click on any box without a check mark as shown in Figure
14-11 "ORU Enabling Portion of Diagnostic Screen" and click on the Save button. Verify that
the green LED light, indicating the ORU is enabled, is lit.
Figure 14-11 ORU Enabling Portion of Diagnostic Screen

6. Click on the Start Air Blanking for all ORUs button, in the Optical Blankings portion of the diag-
nostic screen as shown in Figure 14-12 "Air Blanking of All ORUs"
Figure 14-12 Air Blanking of All ORUs
Start Air Blanking

for All ORUs Button
7. Upon completion of the Air Blanking (approximately 5 minutes), a message box is displayed show-
ing the readings for each channel as shown on Figure 14-13 "Air Blanking Value Reading" Ver-
ify all readings are between 500000 and 1200000 and the drift is less than 6% (< 6.0). If all
readings are within specifications, select the radio button marked Overwrite for the instrument to
use the new readings. If all readings are not within specification, troubleshoot the problem.
Figure 14-13 Air Blanking Value Reading

8. Click on the Start Factor Diluent Blanking for all ORUs button, in the Optical Blankings portion
of the diagnostic screen as shown in Figure 14-14 "Factor Diluent Blanking for all ORUs".
Figure 14-14 Factor Diluent Blanking for all ORUs
Factor Diluent Blanking

for All ORUs Button
9. Ensure Factor Diluent is available in the instrument as requested by the message box.
NOTE: All mechanical assemblies (Arms, Loader, Shuttle, and Bar Code Reader)
must be initialized (using the radio buttons in diagnostics) or the blanking will
immediately fail. In addition, Cuvettes, Rinse, and Clean A must be available in
the instrument.
10. Upon completion of the Factor Diluent Blanking (approximately 30 minutes), a message box is dis-
played showing the readings for each channel as shown on Figure 14-15 "Factor Diluent Blank-
ing Readings". Factor Diluent Blanking Readings. Verify all readings are between 500000 and
1200000 and the drift is less than 6% (< 6.0). If all readings are within specifications, select the
radio button marked Overwrite. If all readings are not within specification, select the radio button
marked Cancel and troubleshoot the problem.
Figure 14-15 Factor Diluent Blanking Readings

12. Verify Cuvette Shuttle Alignment

End of Limit Sensor Check
1. If not already done, remove the Sample and Reagent Area Interior Covers.
2. With the instrument powered on, select the Cuvettes tab on the Diagnostics screen.
3. Click on the Disable Shuttle Motors button.
4. Perform the following steps to check the Left Limit Sensor of the Cuvette Shuttle Assembly as
shown on Figure 14-16 "Left and Right End-of-Limit Sensors".
Figure 14-16 Left and Right End-of-Limit Sensors
a. Manually move the Cuvette Shuttle Assembly all the way to the left most end of the Shuttle Travel.
(When the Cuvette Shuttle reaches the lifetimes end of the Shuttle Travel, the virtual LED for
Shuttle Left Limit should turn green.)
b. If the virtual LED for Shuttle Left Limit does not turn green, adjust the sensor bracket up or down.
c. Repeat steps a and b (above) until you can make the virtual LED for Shuttle Left Limit turn green.
d. Repeat steps a through c (above) for the Right Limit Sensor of the Cuvette Shuttle Assembly.
Cuvette Shuttle Verification/Alignment

Verifying and aligning the Cuvette Shuttle consists of three discrete tasks:
Z Height and Tilt Check and Adjustment
Y Check and Adjustment
X Check and Adjustment
These tasks are described in the following paragraphs.
Z Height and Tilt Check and Adjustment
1. Disable the Cuvette Shuttle by clicking the Disable Shuttle Motors button in the Shuttle area of
the Cuvettes Diagnostics Tab.
2. Orient the Cuvette Shuttle Assembly so the front face of the Shuttle is directly in front of the Align-
ment Tool, as shown in Figure 14-17 "Shuttle Alignment Tool".

Figure 14-17 Shuttle Alignment Tool
3. Loosen the orange thumbscrews on the Alignment Tool and attempt to insert the dowel pin (located
in the center of the Alignment Tool) into the front face of the Shuttle Assembly.
4. If the dowel pin fits smoothly, the shuttle height and tilt is correct and proceed to the Y Check and
Adjustment below. If the dowel pin does not fit smoothly into the front face of the Shuttle Assembly,
perform the following steps:
a. Using a 2.5mm Allen wrench, loosen the Z Height and Tilt Locking Screws (see Figure 14-17
"Shuttle Alignment Tool"
b. Using a 1.5mm Allen wrench, adjust the Z height and tilt by turning the Z Height and Tilt Adjust-
ment Screws (see Figure 14-18 "Z Height and Tilt Adjustments"). (Note: Turning the screws
clockwise lowers the shuttle; turning the screws counterclockwise raises the shuttle.) The align-
ment is correct when 1) the dowel fits smoothly into the front face of the Shuttle Assembly and 2)
the front face of the Alignment Tool is completely flush (perpendicular) with the mating face on the
front of the Cuvette Shuttle Assembly.
Figure 14-18 Z Height and Tilt Adjustments

c. Tighten the Z Height and Tilt Locking Screws to secure the adjustment.
5. With the Z Height and Tilt Locking Screws tightened, re-check the adjustment as follows:
The dowel should fit smoothly into the front face of the Shuttle Assembly.
The front face of the Alignment Tool should be completely flush (perpendicular) with the mating
face on the front of the Cuvette Shuttle Assembly. (The Alignment Tool surface should not be
tilted against the front surface of the Cuvette Shuttle.)
6. If the adjustment is not correct, repeat step 4 above.
Y Check and Adjustment
1. Orient the Cuvette Shuttle Assembly so the front face of the Shuttle is directly in front of the cuvette
pick-up position on the Loader.
2. To check the Y adjustment, slowly turn the Turning Wheel to move the gripper assembly toward the
cuvette until the Y-axis LED comes on. (The Turning Wheel and Y-axis LED are shown in Figure
14-19 "Y Axis LED and Turning Wheel".) Check that the front face of the Gripper is flush with the
front face of the cuvette. If it is flush, the adjustment is correct. Proceed to the "X Check and Adjust-
ment". If the Gripper is not flush, proceed with step 3.
Figure 14-19 Y Axis LED and Turning Wheel
3. Using a 2.5mm Allen wrench, loosen the Y-Axis Sensor lock down screw (see Figure 14-20 "Y-
Axis Adjustment and Locking Screws").
Figure 14-20 Y-Axis Adjustment and Locking Screws

4. Turn the Turning Wheel until the front face of the Gripper Assembly is flush with the front face of a
cuvette located at the Cuvette Pick-up position on the Loader Assembly. (The Turning Wheel is
shown in Figure 14-19 "Y Axis LED and Turning Wheel".)
5. Using a 2.5mm Allen wrench, turn the Y-Axis Sensor Adjustment screw until the Y-Axis LED comes
on with the Gripper Assembly just touching the front face of the Cuvette at the Cuvette Pick-up
position. (The Y-Axis Sensor Adjustment screw is shown in Figure 14-20 "Y-Axis Adjustment
and Locking Screws". The Y-Axis LED is shown in Figure 14-19 "Y Axis LED and Turning
Wheel".)
NOTE: Turning the Y-Axis Sensor Adjustment screw in a counterclockwise direc-

tion will move the Y-Axis (and Gripper) Sensor towards the front of the Instrument.
6. After the alignment of the Y-Axis Sensor has been set, tighten the Y-Axis Adjustment Locking screw
to secure the adjustment. (The Y-Axis Adjustment Locking screw is shown in Figure 14-20 "Y-Axis
Adjustment and Locking Screws".)
7. When the Y-Axis Sensor is properly adjusted, slight turns of the Y-Axis Sensor Adjustment screw
make the LED go on and off. If the adjustment is not correct, repeat steps 5 and 6.
X Check and Adjustment
NOTE: Ensure the Instrument is powered ON. Before starting this adjustment,
clean the Shuttle alignment rails on the back of each assembly, using a paper
towel, and clean the X-Axis sensor using a dry cotton swab.
1. Initialize the Cuvette Shuttle by clicking the Initialize Shuttle button in the Shuttle area of the
Cuvettes Diagnostics Tab.
2. In the Move Cuvette section, move one cuvette into the first Hold Area position by performing the
following steps.
a. Click on the Loader box.
b. Click on the Hold Area radio button and click on the first box in the Hold area.
c. In Number of Cuvettes, enter 1.
d. Click on the Move radio button and click on the Start button.
3. Perform the following steps to move one cuvette into the first Hold area position:
Click on the Extend radio button and click on the Start button.
Click on the Grab radio button and click on the Start button.
4. As the Gripper grabs the cuvette, visually check whether the gripper is centered inside the cuvette.
If it is centered, the X-Axis alignment is correct. If it is not centered, proceed with the next step to
perform the X adjustment.
5. Click on the Disable Shuttle button.
6. Using a 2.5mm Allen wrench, loosen the X-Axis lock down screw. (See Figure 14-21 "X-Axis
Adjustment and Locking Screws"). Turn the X-Axis adjustment screw clockwise to move the
Gripper to the left, or counterclockwise to move it to the right. Tighten down the locking screw.

Figure 14-21 X-Axis Adjustment and Locking Screws
7. Click on the Initialize Shuttle button and repeat steps 2 and 3 to check for proper centering of the
Gripper inside the cuvette. Repeat steps 2 through 6 until proper alignment is achieved.
8. Using steps 2 and 3 above, check the alignment in other areas by selecting that position in the
Move Cuvette section.
9. The shuttle alignment is complete.
13. Coordinate Adjustment
(Primary PM Only)
1. Before the Coordinate Adjustment is performed, verify that ALL interior instrument covers are
removed.
2. Clean all probe tips and probe alignment positions, including the Rinse cup, using an alcohol prep
pad.
3. Open the Probes tab in the Diagnostic screen.
4. Disable all Arms.
5. Open the Controllers, Covers, Racks tab in the Diagnostic screen.
6. Click on the Initialize the Bar Code Reader Motor button.
7. Open the Probes tab in the Diagnostic screen.
"Arm Selection".

Arm Selection Coordinate Adjust
9. Click on the Coordinate Adjust button on the Probes tab as shown on the figure.
10. After the arms coordinate adjustment is complete, repeat steps 8 and 9 for each arm.
14. Perform Flow Rate Test for All Arms
The Flow Rate Test is used to determine if the rinse fluidics are functioning properly.
1. Open the Probes tab of the Diagnostic screen.
"Arm Selection".
Arm Selection
3. Click on the Flow Rate Test button in the Rinse portion of the screen (lower left) as shown in Fig-
ure 14-24 "Flow Rate Test Buttons".
Figure 14-24 Flow Rate Test Buttons

4. Based on the arm selected, the system displays a message stating where to place a graduated con-
tainer. The locations are:
Sample Arm: Sample Track 6, Position 5

5. Place the graduated container in the indicated position.
6. Select the number of seconds for the pump to run (5 seconds) in the Duration: box in the Rinse
portion of the screen as shown on Figure 14-24 "Flow Rate Test Buttons".
7. NOTE: If necessary, the Stop button can be clicked on to discontinue the test.
8. Click the Start button Rinse area of the screen.
9. After the probe has dispensed Rinse solution into the graduated container for the set length of time,
measure the volume of solution in the graduated beaker. The flow rate must be as shown in Table
14-1. Rate Flow Measurements.
Table 14-1 Rate Flow Measurements
Base Top CTS
Volume After 5 Seconds Flow Rate Volume After 5 Seconds Flow Rate
5.150.5ml (4.65 to 5.65ml) 1.03ml/sec 5.581.04ml (4.54 to 6.61ml) 1.12 ml/sec
(0.10ml) (0.20ml)
10. If the flow rate is too low, i.e., not enough Rinse is deposited in the beaker; check the fluidic rinse
tubes for any restrictions and the rinse pump for proper operation. If the flow rate is too high, check
the rinse pump and check valves.
15. Check Stirrer Bar Rotation.
(Secondary PM Only)
1. Insert a stirrer bar into two reagent vials and insert the vials into the first (rearmost) two positions in
a reagent rack.
2. Verify the bars spin when the rack is inserted in each reagent slot.
16. Check Instrument Software Version.
1. Click on System --> Instrument Status as shown on Figure 14-25 "System Software Versions-
Display Selection".
Figure 14-25 System Software VersionsDisplay Selection
2. Click on the SW-Version tab tab in the resulting screen to display the software revisions and verify
the software is at the latest revision, as shown in Figure 14-26 "Software Revisions Display" .

(Refer to the ACL-TOP Information Notifications for the current mandatory and recommended soft-
ware revisions.)
Figure 14-26 Software Revisions Display
17. Check the Touch Screen Calibration.

(Secondary PM Only)
The first method is to click on the Elo shortcut on the Windows desktop, select "Align, and fol-
low the prompts.
The second method, if the short cut is missing, is Start -->Settings -->Control Panel -->Select
Elo, click on Align, and follow the prompts.
18. Check Instrument Temperatures.
(Secondary PM Only)
1. Click on System --> Instrument Status as shown on Figure 14-27 "System Temperature Dis-
play Selection".
Figure 14-27 System Temperature Display Selection
2. Click on the Temperatures tab in the resulting screen to display the temperature of all thermal con-
trolled elements as shown in Figure 14-28 "Temperature Tab of Instrument Status Display".

Figure 14-28 Temperature Tab of Instrument Status Display
3. Record the coefficients as stored in the instrument using the ThermalCal program as described
below.
NOTE: ThermalCal must be run with all covers closed.
ThermalCal Operating Procedure for Storing Coefficients
Inputting Thermal Coefficients using ThermalCal

1. If any CM software is running, close the applications.
the desktop, as shown on Figure 14-29 "ThermalCal Icon" to open the program.
NOTE: The most recent versions of ACL-TOP have the ThermalCal software pre-
loaded on the CM. Verify it is not loading by clicking on Start > Programs to dis-
play the list of installed programs.
following steps.
a. Insert the distribution CD-ROM into the computer.

b. Double click the My Computer icon on the desktop.

c. Double click the icon of the CD-ROM drive to open it.
d. Drag the ThermalCal folder onto the computer desktop.
e. Open the ThermalCal application by double clicking on the ThermalCal icon.
4. ThermalCal boots into the Automatic mode. Click on the Go to Manual Mode button as shown
on Figure 14-30 "ThermalCal Screen".

6. Turn on the Analytical Module. (Power up the instrument.)
7. Wait 4 minutes for the TOP Analytical Module to start. (Since the CM software is not running, there
is no visual indication that the Analytical Module is operational.)

"Connecting ThermalCal to the AM".
Figure 14-31 Connecting ThermalCal to the AM
Connection Button
Connection Status
9. Wait until the TOP AM Status displays Connected, as shown in Figure 14-32 "Connection Sta-
tus - Connected".
Figure 14-32 Connection Status - Connected

10. Once the TOP AM Status: displays Connected, click on the Display Coefficients button to
display the stored coefficients of the system as shown in Figure 14-33 "Thermal Coefficient Dis-
play".
Figure 14-33 Thermal Coefficient Display
11. With the coefficients being displayed, click on ALT + Print Screen to capture the screen content.
12. Minimize the ThermalCal application.
13. If there is not a WordPad icon on the desktop, generate a shortcut to WordPad for storing of the
Screen content:
Click on "My Computer".
Select C:/ --> Document and Settings --> Administrator --> Start Menu --> Program -->
Accessories.
Click on WordPad.
Right click and select Create Shortcut.
Click on the WordPad icon and drag it to the desktop.
Close all Windows and return to the desktop.
15. Click on Edit --> Paste to paste the screen capture into the application.
16. Click on File --> Save As and save the file as C:\Thermal Coefficients.
17. Exit the WordPad application by clicking on File --> Exit.
18. Maximize and then exit the ThermalCal application by clicking on the Exit button in the upper
right corner of the screen.
19. Perform a General Wipe Down of the Instrument

Perform a wipe down of the exterior and interior of the instrument using a moistened lint free
cloth.
20. Verify there is a Ghost Image of the CM Hard Drive
The Ghost Image procedure creates an image of the entire Control Module hard drive content includ-
ing Windows 2000 and all ACL-Top application software. This image must be created any time there is
a major system upgrade or during PM and can be used to restore the CM computer to its condition at
the time of the ghost Image generation.
To determine if a ghost image needs to be created, check with the Lab Supervisor.
NOTE: It is highly recommended that Medical Grade Media be used to store the
image created by this procedure. Always store the media according to manufac-
tures specifications.
Per the Symantec Ghost license agreement, this tool may only be used on ONE CM PC for each CM
Recovery Kit obtained from IL.
NOTE: Read through this entire process before beginning. Be sure to read each
step fully before executing.
1. Click on Start -> Shutdown ->Shutdown -> OK to power off the computer (if it is not already shut-
down).
2. Turn on the CM computer and immediately insert the Symantec Ghost Boot CD into the CD/DVD
Drive.
3. Select OK in the Ghost message box.
4. In the Ghost application, select Local Partition To Image
5. When the Select local source drive by clicking on the drive number window is displayed,
select the correct drive (only one should be available), and select OK.
6. When the Select source partition(s) from Basic drive: 1 window is displayed, select the correct
partition (only one should be available), and select OK.
7. The File name to copy image to window is displayed.
8. Insert a blank CD-R into the CD Drive.
NOTE: If the CM has a DVD R/RW Drive, the door of the drive will have DVD R/
RW label, then a DVD-R may be used to create the image.
9. Select the CD/DVD Drive (@CD-R1. DVD Drive) from the Look in: dropdown list, and then
select Save
10. A message box is displayed asking to compress the image. Select High.
11. A message box is displayed asking to copy a bootable floppy to the CD/DVD disc. Select NO.
12. A message box is displayed asking to proceed. It also provides an estimate of the number of CDs
or DVDs that are needed to store the image, although the estimate is usually very high. Select
Yes.
13. A warning message about spanned NTFS images is displayed. Select Yes.
14. The image starts to be created, and a progress bar is displayed indicating how long it will take the
image to be created.

15. If more than one CD/DVD is necessary to save the image file, a prompt is displayed requiring
another blank CD/DVD to be inserted.
16. Label each CD/DVD with the name of the CM computer, the number of the CD/DVD used, and the
date.
17. After completion of the Ghost image, it must be verified for correct content. In the Ghost applica-
tion, select Local Check Image File.
18. Insert the Ghost image CD/DVD (Disk 1 if there are multiple discs) into the CD/DVD Drive.
19. Select the CD/DVD Drive (@CD-R1) from the Look In dropdown menu, and click on Open.
20. A message box is displayed asking to proceed with the image file integrity check. Select Yes and
the verification process begins. A progress indicator is displayed showing what percentage of the
validation has been completed.
NOTE: If more than one CD/DVD is required to store the image file, a prompt is
displayed to insert the next CD/DVD at the appropriate time.
21. When the validation has completed successfully, a message box is displayed, Image file passed
integrity check. Click on Continue.
22. If the integrity check fails, the Ghost Image procedure must be re initiated using high-quality
media. If it fails again, contact technical support.
23. Exit Ghost by selecting Quit from the menu, remove the CD/DVD, and restart the computer.
24. Provide the CD/DVD(s), labeled as stated in step 16, to the Lab Supervisor for proper storage.
14-1 CTS PreventiveMaintenance
For CTS, the following checklist is to be completed in addition to the Base TOP Preventive Maintenance.
Each of these ites are specific to the CTS portion/aspect of the system.

ACL TOP CTS Preventive Maintenance Checklist

ACCOUNT: _____________________ DATE: _______________
Address: ______________________________
______________________________
Model: ____________________Serial No.: ___________
Service Manual Refer- Com
PM Activities Primary Secondary
ences plete
1. Replace Piercer Tip X Ch. 15 CTS Piercer
2. Replace the Probe and Seal
X X Ch. 15 CTS Piercer
Assembly.
3. Replace the piercer probe. X X Ch. 15 CTS Piercer
4. Replace all pneumatic Tygon tubings X Ch. 7 - Fluid Movement
5. Clean the belt residue inside the
frame near the belt tensioning X Ch. 8 Robotic XYZ Arms
assembly for the X axis for all arms.
6. Clean belt residue on cable tray ( X
X Ch. 8 Robotic XYZ Arms
axis) for all arms.
7. Wipe down the X axes on top of the
bearing rails on each arm.
8. Verify the belt tension and adjustment
for the X axis of each arm.
9. Remove the covers and clean the Y
axis of each arm.
10. Clean the cable residue and dust on
contact surface of cable guides of X Ch. 8 Robotic XYZ Arms
the Y axe on each arm.
11. Wipe down the bearing rails on the
Y axes for each arm.
12. Wipe down the rack shafts for the Z
axis on each arm.
13. Check for backlash, looseness, etc.
for all parts on the Z axis of each X Ch. 8 Robotic XYZ Arms
arm.
Customer Name: _____________________Service Engineer Name: _____________________
Signature: __________________________Signature: __________________________

Chapter 15 CTS Piercer 15 - 1
Chapter 15
CTS Piercer
WARNING: Piercing Hazard. Do not put hand inside Instrument while it is
in motion.
BIOHAZARD: The Sample probe and Piercer probe should be treated as a

biohazard item and laboratory precautions for biohazard material should
be taken in its handling and disposal.
15-1 Overview
The Closed Tube Sample (CTS) Piercer provides piercing and sampling of capped/uncapped Sample
Tubes for the ACL-TOP instrument. The piercer is a part of the Sample Robotic Arm and is a separate arm
assembly from non-CTS instruments. As shown in Figure 15-1 "CTS Piercer Components", the CTS
Piercer is comprised of 3 components:
Telescoping CTS Assembly
Sample Probe-n-Seal Assembly
CTS Piercer Probe
The Telescoping CTS Assembly and its components are not customer replacable parts while the Probe-n-
Seal Assembly and CTS Piercer Probe are both replacable on an as needed basis by customers and/or dur-
ing scheduled service by service personnel.

15 - 2 Chapter 15 CTS Piercer
Figure 15-1 CTS Piercer Components

Sample
Piercer Probe-n-Seal
Probe Assembly
Telescoping
CTS
Assembly
The piercer probe consists of the probe that pierces the cap of a sample tube, as well as a sample probe
(located in the center of the piercer probe) that aspirates or dispenses a sample. The sample probe is inside
the Piercer Probe that protects the sample probe during piercing. The Sample Probe-n-Seal Assembly, in
turn, is mounted within the Telescoping CTS Assembly.
The ACL-TOP instrument uses HemosIL Rinse solution for cleaning the sample tube and as a working fluid.
As a working fluid, the solution is used to ensure displacements created in the Syringe Pump are precisely
replicated at the probe tip when samples are aspirated or dispensed. The HemosIL Rinse solution accom-
plishes this by limiting the compressibility of the system. Refer to Chapter 7 Fluid Movement for detailed
information on how the instrument uses the HemosIL Rinse solution and conducts fluid movement.
Figure 15-2 "CTS Piercer Location" shows the physical location of the CTS Piercer. As shown, the CTS
Piercer is located within the Sample Arm.

Figure 15-2 CTS Piercer Location
CTS Piercer Probe
Sample Arm

Figure 15-3 "CTS Piercer Interconnect Diagram" contains the Interconnect Diagram for the CTS Sample
Arm.
Figure 15-3 CTS Piercer Interconnect Diagram
J J J
J
J1 3 5 6
9
1 J
4
J13
J1 J1
0
J1 4
2 J
7
J15
J J J
J16 8
2 1
J
3
J
J
4
3 J
1
J
1
J
J J
2
5 5
J J J
6 6 4
J J J
7 2 8
CTS Piercer
J J
J 8 2 J
1
J 5
J J
7 J J 3 1 J
3 2 4
J J
9 6
J
J 5
4
J COAXIAL PIERCER
6 28654100 LLD

The following paragraphs list the functions of the PCBs and their functions relative to the Sample Arm
Assembly with the CTS Piercer.
Board Descriptions
CTS X Axis Board
Provides the electrical interface to the mechanical arm assembly.

Drives the stepper motor that moves the arm in the X direction to coordinate positions.
Power distribution point to/from the fuse PCB and the controllers through ribbon cables.
Provides the drive circuitry for the X-Axis Motor.
Drives the interface circuitry for the X-Axis encoder.
Provides the drive circuitry for the Air Pump, Fluid Pump, and the Air Pressure Sensor input inter-
face.
Provides pass through connections for RS-232 signals to the syringe pumps and the FET switch
controlling power to the syringe pump.
Provides a CAN bus feed through to the controller for the master computer communications.
CTS Controller Interface Board
Subsystem controller that controls XYZ Motion.

Provides communications with master controller through the CAN Bus.
Interfaces with Controller Interface to decode data and an address for Digital I/O.
Provides an Analog to Digital Converter for Power Supply Voltage Monitoring.
Includes encoder counters for the X, Y, and Z motors.
Dip Switch selectable for SMP, IRP,. and STP, configurations.
Communications to Probe heater board PIC, through SPI communications.
CTS Y Driver Board

Drives the stepper motor, which moves the arm in the Y direction to coordinate positions.
Provides drive circuitry for the Y-Axis Motor.
Provides interface circuitry for the Y-Axis encoder.
Supports three probes, with two heating elements per probe.
Converts PWM to a variable DC Voltage for the two probe heaters.
Converts a 30kHz PWM signal from the probe microcontroller and converts it to a DC voltage. (The
DC voltage minimizes the switching surges on the power supply, and the noise impact on the instru-
ment. It also reduces interference with the LLD circuitry.)

Provides two optical slot sensor interfaces that provide limit sensing for X-Axis travel.
Provides two optical slot sensor interfaces that provide limit sensing for Y-Axis travel.
CTS Z Driver Board

Drives the stepper motor, which moves the probe to coordinate positions in the Z direction.
Contains an integrated controller/driver IC that drives the motor in full, half, quarter, and eighth step
movements.
Provides interface circuitry for the Z-Drive motor encoder in the Universal Arm.
Provides the interfaces drive circuitry for the piercer lock solenoid and the rack lock solenoid.
Includes an optical switch interface for travel limit measurements.
Includes pass through connections for the Heated Probe and CTS probe PCBs.
CTS Travelling Signal Interconnect)
The Travelling Signal Interconnect PCB is specific to the CTS version of the ACL-TOP instrument. As such,
it contains all circuitry that controls the piercer aspect of the probe. This includes:
The interface circuitry for the CTS mechanism.
A solenoid driver for the Lock Solenoid that switches the probe between Piercer and Sample mode.
Provides optical slot sensor interfaces that provide limit sensing for
cap sensing,
piercer lock sensing, and
piercer position sensing.
a Liquid Level Detection (LLD) circuit to control the sample probe LLD.
15-4 CTS Piercer Theory of Operation
Piercer and Sample Mode

The CTS Piercer has two operating modes, Sample and Piercer. When the piercer probe is in the down
position to pierce the cap of a sample tube, it is in piercer mode. When the sample probe is extended and
ready to aspirate or dispense a sample, it is in sample mode.

Figure 15-4 "Piercer Probe in Piercer and Sample Mode" shows the CTS Piercer Probe in piercer and
sample mode. As depicted on the left side of the figure, when in piercer mode, the Piercer Probe is locked
in the down position, entirely covers the sample probe, and is able to pierce the cap of a sample tube. As
depicted on the right side of the figure, when the CTS Piercer is in sample mode, the CTS Piercer Probe is
locked in the up position, the sample probe is exposed and ready to aspirate or dispense a sample. Note
that the foot is shown covering the probe. The foot moves up and down with the Piercer Probe until the foot
encounters the cap of a closed top sample.
Figure 15-4 Piercer Probe in Piercer and Sample Mode
Piercer Mode Sample Mode
Foot Foot
Pierce
Probe Sample Probe
Extended
Probe Status LEDs

The CTS Piercer Probe has one red and one green status LED, located on the Telescoping CTS Assembly
(as shown on Figure 15-5 "Status LEDs"). When the Probe is in piercer mode, both status LEDs (green
and red) are off. When the Probe is in sample mode, the green status LED is on and the red status LED is
off. As shown in the table,
the red LED is only on when the probe is changing modes
the green LED is on in Sample mode and off in Piercer mode.
Table 15-1 "Status LEDs" shows the on/off state of the LEDs in each of the three operating modes of the
CTS Piercer Probe
NOTE: The green status LED indicates the position of the CTS Piercer Probe when the Tele-
scoping CTS Assembly is home in the Z-axis. (Home is considered to be when it is traveling
between the tube, bottle, incubator, or wash/clean positions.) When sampling or dispensing,
the software does not assess the state of the piercer probe.
Table 15-1 Status LEDs
Operating Mode Green LED Red LED
Piercer Mode OFF OFF
Sample Mode ON OFF
Changing Mode ON/OFF ON

Figure 15-5 Status LEDs
Green Status LED
Red Status LED
Sample and Piercer LLD

The Sample and Piercer Liquid Level Detection (LLD) sensing is driven by a capacitance differential circuit.
The sensor output uses a coaxial cable that connects the probes to the electronics to enable Liquid Level
Detection (LLD) in tubes, bottles, or the cuvette. The sample LLD senses the liquid while the piercer LLD
prevents intermittent LLD signals from affecting the detection. During the LLD operation, the brake rack is
locked and the electrical connection between the brake rack and retraction shaft is broken, thereby breaking
the ground path for the Piercer LLD circuit. By using the Piercer as part of the circuit, false indications are
eliminated when the pressures exerted by cap piercing causes the sample and piercer probe to touch. The
Sample and Piercer LLD cable are connected as shown in Figure 15-6 "LLD Cables".
Note: LLD is also used to perform the coordinate adjustment for the CTS Piercer Probe. This is accom-
plished by having the probe contact the edges of specified locations within the sample rack and using
the capacitance differential circuit to sense that contact.
Figure 15-6 LLD Cables
Sample LLD
Piercer LLD Cable
Cable
Probe Foot
Except when in a tube, the foot moves with the CTS Piercer Probe. The foot protects the probe from dam-
age, the user from potential injury, and has an attached air line used to remove any droplets left on the
piercer probe after a Deep Wash. Refer to Chapter 7 (Fluid Movement) for more information about Deep
Washing.

Piercer Lock/Lock Solenoid/Sensor

Figure 15-7 "Piercer Lock Components" shows the components of the Piercer Lock Assembly, the
piercer probe, and the piercer lock with the elongated hole and the hole through which the lock optical sen-
sor determines the position of the lock. The Piercer Lock consists of a plate with an elongated hole through
which the piercer probe extends that is used to lock hold the probe in position. Note that the Piercer Lock
Solenoid is a bit of a misnomer because when energized, it unlocks the probe. When the Piercer Lock Sole-
noid is not engaged, i.e., the probe is locked in position, the narrow part of the elongated hole fits into the
indentations in the probe and locks it in place (either for Sample or Piercer mode). When the Piercer Lock
Solenoid is energized, it retracts the CTS Piercer Lock and the large part of the elongated hole allows the
piercer probe to move. The solenoid is only energized long enough for the probe to move out of the locked
position, thereby changing modes. Power being applied to the Piercer Lock Solenoid is indicated by the red
status LED (indicating a mode change). When the CTS Lock is disengaged, the CTS Piercer Probe moves
along with the sample probe.
The Piercer Lock Sensor, shown in dotted lines on the figure, consists of an optical sensor that sees light
through a hole in the lock as long as the solenoid is not energized (and the probe is locked). When the
Piercer Lock Solenoid is supplied power, it retracts the Piercer Lock and the hole is moved, blocking the light
path of the sensor. This change in the sensor output is used to indicate to the instrument that the lock is
being released and the probe is changing modes.
Figure 15-7 Piercer Lock Components
Pierce Mode Piercer Lock Sensor

Lock Position
Probe Indentations Piercer Lock
Sample Mode
Lock Position
Elongated hole
in Piercer Lock Piercer
Lock
Piercer Piercer Lock
Probe Solenoid
Sensor
Hole
Solenoid Shaft

Cap Detect Sensor

As shown on Figure 15-8 "Cap Detect Sensor", the Cap Detect Sensor is an optical sensor. It detects the
CTS Piercer encountering a sample tube cap by the hold down flag, which is attached to the Brake Rack,
breaking its beam. When a cap is encountered by the foot, which is attached to the Brake Rack, the foot
stops its travel while the CTS Piercer Assembly continues its travel. This action drives the hold down flag up
until the Cap Detect optical sensor is no longer blocked indicating to the system the cap has been detected.
The changing of the Cap Detect Sensor output causes the system to lock the foot (also known as the CTS
Hold-Down) on the CTS Piercer via a brake in the Universal Arm. The locking of the foot enables the system
to hold the sample tube in place during piercing and aspiration.
Figure 15-8 Cap Detect Sensor
Hold Down Flag

Brake Rack
Cap Detect Sensor
Piercer Position Sensor

The Piercer Position Sensor is an optical sensor used to determine whether the CTS Piercer is in sample
mode or piercer mode. It does this by detecting the position of the hold down flag attached to the Brake
Rack. Figure 15-9 "Piercer Position Sensor" shows the Piercer Position Sensor and the hold down flag.
When in Sample mode (and in home position on the Z-axis, which is when the software checks it), the flag
blocks the Piercer Position optical sensor and indicates to the system the probe is in Sample mode.
The Retraction Shaft and Retraction Shaft Contact are used to change from Piercer to Sample mode as
described in "Operation of the CTS Piercer Probe".
Figure 15-9 Piercer Position Sensor
Retraction Shaft Hold Down Flag
Contact
Brake Rack
Piercer Position
Sensor
Retraction Shaft

Operation of the CTS Piercer Probe

As shown in Figure 15-10 "Z-Drive Rack and Brake Rack", the Telescoping CTS Assembly is attached to
the Z-Drive Rack used to provide vertical (Z-Axis) movement to the assembly in the same manner it supplies
vertical movement to a non-CTS probe assembly. In contrast, the Brake Rack is part of the CTS Piercer
Probe and is used to provide the vertical (Z-Axis) movement to the CTS Piercer Probe.
Figure 15-10 Z-Drive Rack and Brake Rack
Z-drive
Rack
Brake Rack
The Telescoping CTS Assembly is attached to the Z-Drive Rack that provides vertical (Z-Axis) movement to
the entire Telescoping CTS Assembly. Internal to the Telescoping CTS Assembly, the Brake Rack is used
to provide the vertical (Z-Axis) movement to the Piercer Probe. To go to Piercer Mode, the software locks
the Brake Rack in position, energizes the Piercer Lock Solenoid (unlocking the piercer probe), and drives
the Z-Drive Rack up. The Piercer Lock Solenoid is only energized long enough for the Brake rack to move
enough that the lock no longer enters the detent on the brake rack. With the Telescoping CTS Assembly
being driven up via the Z-Axis motor in the Arm, and the brake rack locked, the Retraction Shaft Contact
pushes down the Piercer Retraction Shaft (and the Piercer Support Bracket attached to its bottom) as
shown on Figure 15-9 "Piercer Position Sensor". With the Piercer Lock Solenoid no longer energized, the
lock (which is spring loaded) latches into the upper detent of the piercer probe, locking the probe in the
piercer position. If either the lock fails to pull back, or fails to latch into the detent, the lock sensor is used to
sense the failure and an error condition is indicated and an Emergency Stop is initiated.
Note that the Retraction shaft has a spring on it that is used to raise the Brake Rack (and the piercer probe)
when the Piercer Lock Solenoid is energized allowing the CTS Piercer to change from Piercer to Sample
mode.

Figure 15-11 Retraction Shaft and Contact
Retraction Shaft Contact
Retraction Shaft
Piercer Support
Bracket
The following provides a step-by-step sequence of the CTS assembly from being in pierce mode, piercing
the cap of the sample tube and aspirating of the sample, dispensing of the sample, washing of the probes,
and back to the pierce mode.
1. The CTS Telescoping Assembly is in Pierce Mode with the Pierce Probe locked in the down position
ready to pierce.
2. The sample arm is moved to a position above a test tube by moving in both X (left to right) & Y axes
(front to back).
3. The CTS Telescoping Assembly is driven down (Z-axis) via the Z-axis stepper motor and the Z-Drive
Rack until the Cap Detect Sensor is triggered by the Hold-Down Flag attached to the Brake Rack.
4. When the Cap Detect Sensor is triggered, the Brake is energized, locking the Brake Rack in place.
The Foot (also known as the CTS Hold-Down) that is attached to the bottom of the Brake Rack, keeps
the test tube in-place during piercing and aspiration. The location of the encoder (attached to back of
Z-axis stepper motor) is stored to allow the CTS Telescoping Assembly to return to the same position
after aspirating a sample from the test tube.
5. The CTS Telescoping Assembly is driven down (Z-axis - via the Z-axis stepper motor and the Z-Drive
Rack) piercing the cap and then retracted slightly to relieve the CTS Lock from any external forces
created from the cap piercing.
6. The Travelling Signal Interconnect Board applies power to the Piercer Lock Solenoid unlocking the
CTS Piercer Lock and the CTS Telescoping Assembly is driven down to allow the piercer to be locked
in Sample Mode (up position) once the Piercer Lock Solenoid has power removed.
7. The CTS Telescoping Assembly is driven up to ensure the Sample Probe is not in sample and an LLD
baseline is taken. The LLD baseline value allows the CTS Telescoping Assembly to sense a change
in capacitance when fluid is contacted by the Sample Probe.
8. The CTS Telescoping Assembly is moved down until sample is contacted (as determined by the LLD)
and submerged in the sample.

9. The sample is aspirated from the test tube, the CTS Telescoping Assembly is moved up slightly and
air is aspirated and an air gap created to ensure the volume of sample is protected inside the sample
probe.
10. The CTS Telescoping Assembly is driven out of the cap back to the original location where the Foot
was locked on top of the cap.
11. The CTS Telescoping Assembly is left in Sample Mode and dispenses in the Incubator area and then
continues to the Wash Cup.
12. After the Sample Probe and Piercer are washed, the Brake Rack is locked in place and the CTS
Piercer is driven up, forcing the Retraction Shaft Contact to push the Piercer Retraction Shaft Down
and forcing the CTS Pierce probe down into Pierce Mode.
13. With the Piercer Lock Solenoid no longer energized, the lock (which is spring loaded) latches into the
detent in the brake shaft locking the probe in the piercer position.
14. The Piercer Lock Sensor senses the Piercer Lock motion and ensures the Piercer Lock is fully
engaged on the Piercer shaft.
15. The CTS Telescoping Assembly is in Pierce Mode and is ready to pierce the next capped test tube.
Adjustments and verifications for the CTS Piercer consist of Initializing the Arms and Adjusting the Coordi-
nates. Initializing Arms and Adjusting Coordinates are both performed from the Probes tab of the ACL-TOP
Diagnostic screen as shown on Figure 15-12 "Probes Tab of Diagnostic Screen".

Figure 15-12 Probes Tab of Diagnostic Screen
Disable Sample
Initialize All Arms Button Arm Button
Probes Tab
Probe Pull
Down List
Coordinate Adjust Button

Initialize Arms
Perform the following steps to initialize the Robotic Arms:
1. Click the Initialize All Arms button on the Probes Diagnostics Screen. This starts the Arms Initial-
ization process. (This process can take 4 - 5 minutes.)
2. After the Arms Initialization process has completed, click on the CTS tab to display the CTS Diagnos-
tics Screen (see Figure 15-13 "CTS Tab of Diagnostic Screen").
3. At the CTS Diagnostics Screen,
In the Piercer Loop Test portion of the screen enter 50 in Loop Count
CAUTION: Running the Loop Count beyond 50 cycles may cause the
solenoid to overheat and result in injury or equipment damage.
Click on the Start button
Verify that the Status changes to Pass
4. When the system passes the Piercer Loop Test, the Arms are re-initialized and the instrument is ready
for use.
Adjust Coordinates
To adjust the Robotic Arm Coordinates, perform the following steps (see Figure Figure 15-12 "Probes Tab
of Diagnostic Screen":
1. Open the Diagnostics window by clicking on System --> Diagnostics.
2. Click on the Probes tab in the diagnostics window.
3. Click on the Disable Sample Arm button.
4. Select Sample Arm from the Probe pull-down list.
5. Click the Coordinates Adjust button. This starts the Coordinates Adjustment process.
The Coordinates Adjust process takes 20 - 30 minutes during which time the Sample probe will touch vari-
ous portions of the Sample module, take coordinate readings and calculate the proper coordinates for future
probe movements.
15-6 Diagnostics
CTS Piercer diagnostics are on the CTS tab. The CTS tab contains five areas: the Piercer loop test area,
the Fluid test area, the Foot test area, the Sensors area, the Air pressure valve area, and the Air accu-
mulator valve area. Figure 15-13 "CTS Tab of Diagnostic Screen" shows the CTS tab.

Figure 15-13 CTS Tab of Diagnostic Screen

Disable CTS Operation

This button disables the CTS operation (in the Diagnostic Mode). Upon exiting Diagnostics and re-initializing
the ACL-TOP, the system reverts to CTS operation. While CTS operation is disabled the system does not
pierce caps and runs in non-pierce mode. This mode will provide higher throughput if the samples do not
have caps.
Piercer Loop Test Area

Figure 15-14 "Piercer Loop Test Area" shows the Piercer Loop Test Area.
Figure 15-14 Piercer Loop Test Area
This test causes the piercer to switch from piercer mode to sample mode and back to piercer mode. The
number of repetitions can be selected in the Loop Count field. Click the Start button to start the Piercer
Loop Test. Click the Stop button to stop a Piercer Loop Test in progress. At the end of the test the Sta-
tus: display shows the result.
CAUTION: Running the Loop Count beyond 50 cycles may cause the
solenoid to overheat and result in injury or equipment damage.
Foot Test Area

This test checks for slippage of the foot when the brake in the arm is engaged. The status of pass or fail is
displayed at the end of the test. Click the Start button to start the Foot Test and the Stop button to stop
a Foot Test in progress. Basically, in this test the foot brake is locked and the Z-drive rack is moved against
the brake. The foot should not move up (since it is locked) and Z-slippage values are checked to verify they
are within the anticipated move distance (with some tolerance). This ensure the brake doesn't slip, i.e., the
foot should stay at the same height on the Z-drive racks move up.
Sensors Area
Figure 15-15 "Sensors Area" shows the Sensors Area. Each of the LEDs in the Sensor area can display
red or green to indicate the condition of the item. Following the figure is the list of sensors with an explana-
tion of what their indications mean.

Figure 15-15 Sensors Area
Virtual LEDs are supplied for the following sensors:

Air Pressure - The LED is green when the air pressure is above 26psi (where it should be) and red
when the pressure is below 26psi.
Piercer Lock Solenoid - The LED is green when the Piercer Lock Solenoid is not engaged (the
piercer probe is locked) and red when the Piercer Lock Solenoid is not engaged (the piercer probe
is unlocked).
Piercer Position - The LED is green when the probe is in Pierce Mode and red when it is in Sample
Mode.
Tube Cap - The LED is green when the Tube Cap Sensor is not blocked by the flag and red when
it is blocked by the flag.
Fluid Pump - The LED is green when the pump is off and red when the pump is on.
Air Controls
Air Pressure Valve
This Air Pressure Valve buttons, as shown on Figure 15-16 "Air Valve, Pressure Release Buttons" allows
the user to open and close the air pressure valve. The LED being green indicates the valve is open and red
indicates it is closed. If working properly, the valve should be able to be heard as air is released and the air
pump turns on.

Figure 15-16 Air Valve, Pressure Release Buttons
Air Accumulator Valve

This Air Accumulator buttons, as shown on Figure 15-16 "Air Valve, Pressure Release Buttons" allow the
user to open and close the air accumulator valve. The LED being green indicates the valve is open and red
indicates it is closed. If working properly, the valve should be able to be heard as air is released and the air
valve turns is activated.
Air Pressure
This Air Pressure buttons, as shown on Figure 15-16 "Air Valve, Pressure Release Buttons" allow the air
pressure to be released from, or restored to, the CTS Piercer. If working properly, the valve should be able
to be heard as air is released and the air pressure LED should light after the pressure is restored using the
Restore button.
Probe-n-Seal Assembly Removal/Installation

NOTE: It is not necessary to remove any of the instrument covers to perform this procedure.
Probe-n-Seal Assembly Removal
1. Click on System -->Diagnostics then select the Controllers, Covers and Racks tab from the Diag-
nostics Screen.
2. Click the Unlock Sample Cover button on the Controllers, Covers and Racks tab.
3. Open the Sample Cover on the instrument.
4. Power off the instrument by turning off the main power switch.
5. Manually move the CTS Piercer Arm into the sample area. Ensure that the piercer probe, and the
sample probe, stay above the skins as the arm is moved.
6. Using Figure 15-17 "Probe-n-Seal Assembly Connections." as a reference,

Disconnect the 1/4 air line from the front of the Probe-n-Seal Assembly
Loosen the Tube Support Bracket screw by turning it counter-clockwise until the bracket can be
removed.
Remove the fluid line from the top of the Probe-n-Seal Assembly by sliding the sleeve back over the
tubing, then removing the tubing.
Figure 15-17 Probe-n-Seal Assembly Connections.
Fluid Line
New Figure
1/4 Air Line

Tube Support
Bracket Screw
7. Remove, by gently pulling on the connector, the Sampling Probe LLD cable from the front of the CTS
Telescoping Assembly (see Figure 15-18 "Sampling Probe LLD Cable").
Figure 15-18 Sampling Probe LLD Cable
Sample Probe
LLD Cable
8. Push the Z-drive rack down so that it is just above the Sample Plate. (This is done by pushing down
on the top of the Z-drive rack.)
9. Loosen the thumbscrew on the side of the Telescoping CTS Assembly (see Figure 15-19 "CTS
Assembly Thumbscrew") by turning it counter-clockwise. The thumbscrew is spring loaded and will
pop outward when loosened it all the way. The Piercer Probe Hold Down Bracket that is attached to
the thumbscrew should also pop outward enabling the removal of the Probe-n-Seal assembly.

Figure 15-19 CTS Assembly Thumbscrew
Thumbscrew
10. Carefully pull the Probe-n-Seal assembly, as shown on Figure 15-20 "Probe-n-Seal Assembly" up
and out of its mounting. Do not bend the sample probe as the probe is pulled out of its mounting. (The
Probe-n-Seal Assembly can be loosened by gently rocking it.)
N
NOTE:To remove the sample probe without bending it, the Z-drive must
first be pushed down as far as possible. With the Z-drive in this position,
the Robotic Arm is cleared when pulling the sample probe out of its
mounting.
Figure 15-20 Probe-n-Seal Assembly
Probe-n-Seal Assembly Installation
1. Ensure that the main power switch for the instrument is turned off.

2. Push the Z-drive rack down so that it is just above the Sample Plate. (This is done by pushing down
on the top of the Z-drive rack.)
N
NOTE:The Z-drive Rack must be down to insert the Probe-n-Seal
Assembly without bending it.
3. Ensure the Probe-n-Seal Hold Down Bracket is not blocking the hole as shown on Figure 15-21
"Probe-n-Seal Hold Down Bracket".
Figure 15-21 Probe-n-Seal Hold Down Bracket
Probe-n-Seal Hold
Down Bracket
4. Insert the Probe-n-Seal Assembly in its mounting, as shown on Figure 15-22 "Inserting the Probe-n-
Seal Assembly", and gently push down on the Assembly until its seats and the Probe-n-Seal Hold
Down Bracket can be slid over its lip.
N
NOTE:Make sure the Telescoping CTS Assembly is held to prevent
motion of the Assembly as the Probe-n-Seal Assembly is seated.
Otherwise, damage the CTS Piercer Probe may occur.

Figure 15-22 Inserting the Probe-n-Seal Assembly
5. Push the Piercer Probe Hold Down Bracket over the top lip of the Probe-n-Seal Assembly.
6. Tighten the thumbscrew as shown on Figure 15-23 "CTS Thumbscrew" on the side of the Telescop-
ing CTS Assembly by turning it clockwise. (Make the thumbscrew finger-tight.)
Figure 15-23 CTS Thumbscrew
Thumbscrew
7. Connect the Sampling Probe LLD cable to the front of the Telescoping CTS Assembly as shown on
Figure 15-24 "Sampling Probe LLD Cable".

Figure 15-24 Sampling Probe LLD Cable
Sample Probe
LLD Cable
8. Using Figure 15-25 "Probe-n-Seal Assembly Connections." as a reference,

Install the fluid line to the top of the Probe-n-Seal Assembly by sliding the fluid line over the steel
tube and sliding the sleeve over the end of the tubing.
Reinstall the Tube Support Bracket and tighten the screw by turning it clockwise until the bracket is
tight.
Connect the 1/4 air line to the front of the Probe-n-Seal Assembly.
Figure 15-25 Probe-n-Seal Assembly Connections.
Fluid Line
New Figure
1/4 Air Line

Tube Support
Bracket Screw
9. It is recommended the system be powered up and the Piercer loop test be executed with a count of 50
as described in "Piercer Loop Test Area".
10. Initialize the arms, remove the sample area interior skins as described in "Sample Area Interior
Skins Removal".
11. Adjust the coordinates as described in Coordinate Adjust in Chapter 8 and reinstall the sample
area interior skins.
Piercer Probe Removal/Installation

NOTE: It is not necessary to remove any of the instrument covers to perform this procedure.

Piercer Probe Removal
nostics Screen.
2. Click the Unlock Sample Cover button on the Controllers, Covers and Racks tab.
5. Remove the Probe-n-Seal Assembly as described in "Probe-n-Seal Assembly Removal".
6. Raise the Telescoping CTS Assembly as high as necessary to access the knurled nut on the bottom
of the Piercer (see Figure 15-26 "Piercer Probe Knurled Nut").
Figure 15-26 Piercer Probe Knurled Nut
CTS Piercer Lock
Knurled Nut
7. Loosen the knurled nut by turning it counter-clockwise. (Pliers may be needed to do this.) Loosen the
nut until it falls into the foot.
8. Push the Z-drive rack down until the Foot is just above the Sample Plate. (This is done by pushing
down on the top of the Z-drive rack.)
9. Push, and hold in, the CTS Piercer Lock on the right-hand side of the Telescoping CTS Assembly as
shown on Figure 15-26 "Piercer Probe Knurled Nut" to release pressure on the piercer probe.
10. While holding the CTS Piercer Lock in, remove the piercer probe by pulling up on the probe top. Do
not use tools to pull out the piercer probe. It may be necessary to twist and move the probe back and
forth to remove it.
WARNING: Piercing Hazard. Do not put hand inside Instrument while it is

in motion.

Figure 15-27 CTS Piercer Probe Removal/Insertion
CTS Piercer Probe
CTS Piercer Lock
Piercer Probe Installation
1. Ensure the main power switch for the instrument is turned off.
2. Push in the CTS Piercer Lock on the side of the Telescoping CTS Assembly, and hold it all the way in
(see Figure 15-27 "CTS Piercer Probe Removal/Insertion").
3. While holding in the CTS Piercer Lock, guide the piercer probe into its mounting.
N
NOTE:As the piercer probe is inserted into its mounting, the flat side of
the piercer probe threads must face the front of the instrument. This is
required for proper seating of the probe.
4. Push down on the piercer probe until it locks into the down position.
5. Apply a drop of Loctite #222 (Low Strength) to the thread on the top of the piercer probe.
6. Re-fasten the piercer probe knurled nut (see Figure 15-26 "Piercer Probe Knurled Nut") ensuring
the nut is tight.
7. Install the Probe-n-Seal Assembly as described in "Probe-n-Seal Assembly Installation".
8. Power up the system and execute the Piercer loop test with a count of 50 as described in "Piercer
Loop Test Area".
Skins Removal".

Telescoping CTS Assembly Removal/Installation

NOTE: it is not necessary to remove any instrument covers to perform this procedure.
CAUTION: Do not remove the Telescoping CTS Assembly without first

removing the sample probe (see "Probe-n-Seal Assembly Removal") and
the piercer probe (see "Piercer Probe Removal"). Serious injury and
equipment damage can result from removing these items in any sequence
other than described in the following procedure.
Telescoping CTS Assembly Removal
nostics Screen.
2. Click the Unlock Sample Cover button on the Controller, Covers and Racks tab.
5. Remove the sample probe as described in "Probe-n-Seal Assembly Removal".
6. Remove the piercer probe as described in "Piercer Probe Removal".
7. Referencing Figure 15-28 "Removal of Telescoping CTS Assembly", perform the following steps:
Disconnect the air line from the Foot.
Remove, and discard, the tie wrap from the air line.
Loosen, but do not remove, the hose clamp screw
Slide the ribbon cable to the left to remove it from the flange to which the hose clamp is mounted.
Remove the piercer probe LLD cable.
Using an Allen wrench, remove the Telescoping CTS Assemblys four cover screws.
Lift the Telescoping CTS Assemblys cover off.
NOTE: Save the screws and hardware removed from the top of the Telescoping CTS Assem-
bly. They are required to re-assemble the Telescoping CTS Assembly.

Figure 15-28 Removal of Telescoping CTS Assembly
Cover Screws
Cover Hose Clamp

Screw
Ribbon Piercer Probe LLD

Cable Cable
Air Line
Tie Wrap
8. Pull up on the front of the ribbon cable connector to remove the flexible cable from the PCB (see Fig-
ure 15-29 "CTS Piercer Board").
N
NOTE:To open the Ribbon Cable Connector, pull up the front of the
Connector Tab. Push the front of the two-piece connector down to secure
the ribbon cable connection.
Figure 15-29 CTS Piercer Board
Ribbon Cable
Connector
9. Raise the Telescoping CTS Assembly all the way.

10. Using a 2.5mm Allen wrench, remove the screw and hardware from the top of the Brake Rack (see
Figure 15-30 "Brake Rack Screw"). (Note: Save the screw and hardware; they are required to reas-
semble the Telescoping CTS assembly.)
Figure 15-30 Brake Rack Screw
Brake Rack Screw
11. Insert a 1.5mm Allen wrench through the set screw access hole as shown on Figure 15-31 "Tele-
scoping CTS Assembly Set Screw", and loosen, but do not remove, the set screw securing the
Telescoping CTS Assembly to the Z-drive rack). (Note: Loosen the set screw only to the extent that
the head of the screw can be seen when looking from the top of the assembly.)
Figure 15-31 Telescoping CTS Assembly Set Screw
Set
Screw
Location
Set
Screw
Access
12. While holding the Telescoping CTS Assembly to keep it from falling, use a 2.5mm Allen wrench to
remove the screw at the bottom of the Z-drive rack (see Figure 15-31 "Telescoping CTS Assembly
Set Screw"). (Note: The Telescoping CTS Assembly becomes free when the screw is removed. Do
not allow the assembly to drop.)

Figure 15-32 Z-Drive Rack Screw

Brake Rack
Z-drive
Rack Screw
13. Slide the Telescoping CTS Assembly off the arm and remove it from the instrument.
14. Save the screw removed in step 12, along with the lock washer and star washer. They are used when
installing the Telescoping CTS Assembly.
Telescoping CTS Assembly Installation
2. Using a 2.5mm Allen wrench to hold the Z-drive rack screw in place in the bottom of the Telescoping
CTS Assembly (along with the lock washer and star washer) as shown on Figure 15-33 "Z-Drive
Rack Screw (Bottom View of Assembly)", slide the Brake Rack up through the Spline Bearing in
the arm.
Figure 15-33 Z-Drive Rack Screw (Bottom View of Assembly)
Brake Rack
Z-drive
Rack Screw

N
NOTE:Steps 3 through 7 must be performed in the sequence stated to
ensure proper alignment of the Brake Shaft and the Z-drive shaft. If the
Brake Shaft and the Z-drive Shaft are not properly aligned, the two shafts
may bind, resulting in improper operation of the CTS Piercer Assembly.
3. Tighten the Z-drive Rack screw as shown in Figure 15-33 "Z-Drive Rack Screw (Bottom View of
Assembly)" until it is finger tight, then loosen (turn the screw counter clockwise) 1/2 to one full turn.
Ensure the star washer is on the bottom and the lock washer is between the star washer and the
screw head.
4. Use a 2.5mm Allen wrench to fasten the Brake Rack screw as shown in Figure 15-34 "Brake Rack
Screw" to the top of the Brake Rack.
Figure 15-34 Brake Rack Screw
Brake Rack Screw
5. Push the Telescoping CTS Assembly all the way up.

6. Insert a 1.5mm Allen wrench through the set screw access hole as shown on Figure 15-31 "Tele-
scoping CTS Assembly Set Screw", and tighten the set screw that secures the Telescoping CTS
Assembly to the Z-drive rack.

Figure 15-35 Telescoping CTS Assembly Set Screw
Set
Screw
Location
Set
Screw
Access
7. Using a 2.5mm Allen wrench, tighten the Z-drive Rack screw that was finger tightened in step 3.
8. Re-connect the ribbon cable as shown in Figure 15-29 "CTS Piercer Board". The black side of the
cable-end must face the front of the instrument as shown in Figure 15-29 "CTS Piercer Board".
N
NOTE:To open the Ribbon Cable Connector, pull up the front of the
Connector Tab. Push the front of the two-piece connector down to secure
the ribbon cable connection.
Figure 15-36 CTS Piercer Board
Ribbon Cable
Connector

9. In addition, the cable-end must be fully seated and level in the connector and the cable routed as
shown on the right side of Figure 15-37 "Ribbon Cable Routing/Connection". Ensure the cable is
folded with a clearly defined right turn leading to the PCB and under the mounting bracket.
Figure 15-37 Ribbon Cable Routing/Connection
Incorrect Cable Correct Cable

Routing/Connection Routing/Connection
10. Fasten the cover screws, lock washers, and flat washers to the cover of the of the Telescoping CTS
Assembly. Ensure that the front/right screw location has the screw, lock washer, and star washer (in
that order) fastened through the cover.
11. Using Figure 15-38 "Connection of Telescoping CTS Assembly" as a reference:
Connect the LLD Cable for the piercer probe.
Place the Ribbon Cable between the Flange and the Telescoping CTS Assembly.
Feed the smaller of the two air tubes (1/16 Tygon tube) through the hose clamp in the direction
shown in the figure. Leave a service loop in the tube as shown in Figure 15-39 "Connecting Air
Tube to the Foot".
Verify:
the hose clamp is in a straight, vertical position
the ribbon cable hangs down straight from the Ribbon Cable Connector
the horizontal portion of the ribbon cable is even and level
the ribbon cable rises up straight behind the flange secured by the hose clamp
there is an adequate service loop in the portion of the ribbon cable above the flange
Note: Ensure the service loop is long enough that the Ribbon Cable does not impede the Z-axis movement
of the Telescoping CTS Assembly.
Secure the ribbon cable between the Flange and the Telescoping CTS Assembly by tightening the
hose clamp screw.

Figure 15-38 Connection of Telescoping CTS Assembly
Cover Screws
Cover Hose Clamp

Screw
Ribbon Piercer Probe LLD

Cable Cable
Air Line
12. Connect the air line from the Telescoping CTS Assembly to the Foot as shown in Figure 15-39 "Con-
necting Air Tube to the Foot". Note that this figure clearly displays the service loop in the air tube as
mentioned in the previous step.
13. Secure the air tube to the steel tube on the Foot with a tie wrap ensuring the head of the tie wrap faces
the front of the instrument, as shown in the figure. This prevents the head of the tie wrap from hitting
the back wall of the Sample Module.
Figure 15-39 Connecting Air Tube to the Foot
Service Loop
Small Air Tube
Tie Wrap
14. Cut any excess length from the end of the tie wrap.

15. Replace the piercer probe as described in "Piercer Probe Installation".

16. Replace the Probe-n-Seal Assembly as described in "Probe-n-Seal Assembly Installation".
17. Power up the instrument.
Skins Removal".


Chapter 16 Schematics 16 - 1
Chapter 16
Schematics
16-1 Overview:
This section contains the schematics for the TOP Instrument.
16-2 Schematics
The schematics in this chapter are listed in ascending order by drawing number.
The following schematics are applicable to the Base TOP:
27501100 Figure 16-1 "Power Interconnect Fuse PCB (Drawing # 27501100)"
27502100 Figure 16-2 "Back Plane PCB (Drawing # 27502100, Sheet 1 of 6)"
27503100 Figure 16-8 "Front Panel Disconnect PCB (Drawing # 27503100)"
27504100 Figure 16-9 "PC104 Can Bus PCB (Drawing # 27504100, Sheet 1 of 4)"
27505100 Figure 16-13 "Fluidics Controller PCB (Drawing # 27505100, Sheet 1 of 5)"
27506100 Figure 16-18 "Fluidics Connector PCB (Drawing # 27506100, Sheet 1 of 4)"
27507100 Figure 16-22 "Fluidics LED PCB (Drawing # 27507100)"
27552100 Figure 16-23 "ORU Detector PCB (Drawing # 27552100, Sheet 1 of 3)"
27554100 Figure 16-26 "ORU Interface PCB (Drawing # 27554100, Sheet 1 of 3)"
27555100 Figure 16-29 "Incubator Heater PCB (Drawing # 27555100)"
27556100 Figure 16-30 "Emitter PCB (Drawing # 27556100)"
27600100 Figure 16-31 "Y-Axis PCB (Drawing # 27600100, Sheet 1 of 2)"
27601100 Figure 16-33 "Shuttle/Barcode X-Axis PCB (Drawing # 27601100)"
27602100 Figure 16-34 "Cuvette Loader Interface PCB (Drawing # 27602100)"
27604100 Figure 16-35 "Cuvette Sensor PCB (Drawing # 27604100)"
27605100 Figure 16-36 "Cuvette Waste Interface PCB (Drawing # 27605100)"
27607100 Figure 16-37 "Heated Probe PCB (Drawing # 27607100)"
27608100 Figure 16-38 "Probe DC Driver PCB (Drawing # 27608100, Sheet 1 of 2)"
27609100 Figure 16-40 "Probe Interconnect PCB (Drawing # 27609100)"
27611100 Figure 16-41 "Cuvette Loader Flex Cable PCB (Drawing # 27611100)"

16 - 2 Chapter 16 Schematics
27700100 Figure 16-42 "Sample Rack Presence PCB (Drawing # 27700100)"

27701100 Figure 16-43 "Reagent Rack Presence PCB (Drawing # 27701100, Sheet 1 of 2)"
27702100 Figure 16-45 "Reagent KeyBoard PCB (Drawing # 27702100)"
27703100 Figure 16-46 "Reagent Cooling PCB (Drawing # 27703100)"
27704100 Figure 16-47 "Magnetic Stirring PCB (Drawing # 27704100, Sheet 1 of 2)"
27705100 Figure 16-49 "Sample Key Board PCB (Drawing # 27705100, Sheet 1 of 2)"
27710100 Figure 16-51 "Remote Travel Interface PCB (Drawing # 27710100)"
27800100 Figure 16-52 "Rack Controller CPU PCB (Drawing # 27800100, Sheet 1 of 3)"
27810100 Figure 16-55 "Rack Controller Interface PCB (Drawing # 27810100, Sheet 1 of 7)"
The following schematics are applicable to the CTS TOP:
27605100 Figure 16-62 "Cuvette Waste Interface PCB (Drawing # 27605100)"
27613100 Figure 16-63 "X Motion Control PCB W/ out Dip (Drawing # 27613100)"
28630100 Figure 16-64 "CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 of 9)"
28631100 Figure 16-73 "Y Axis U Arm PCB (Drawing # 28631100, 1 of 2)"
28633100 Figure 16-75 "Z Driver PCB (Drawing # 28633100, Sheet 1 of 3)"
28634100 Figure 16-78 "CTS Traveling Interconnect PCB (Drawing # 28634100)"
28641100 Figure 16-79 "U Arm Fuse Board PCB (Drawing # 28641100)"

Figure 16-1 Power Interconnect Fuse PCB (Drawing # 27501100)

Figure 16-2 Back Plane PCB (Drawing # 27502100, Sheet 1 of 6)






Figure 16-8 Front Panel Disconnect PCB (Drawing # 27503100)

Figure 16-9 PC104 Can Bus PCB (Drawing # 27504100, Sheet 1 of 4)




Figure 16-13 Fluidics Controller PCB (Drawing # 27505100, Sheet 1 of 5)





Figure 16-18 Fluidics Connector PCB (Drawing # 27506100, Sheet 1 of 4)




Figure 16-22 Fluidics LED PCB (Drawing # 27507100)

Figure 16-23 ORU Detector PCB (Drawing # 27552100, Sheet 1 of 3)



Figure 16-26 ORU Interface PCB (Drawing # 27554100, Sheet 1 of 3)



Figure 16-29 Incubator Heater PCB (Drawing # 27555100)

Figure 16-30 Emitter PCB (Drawing # 27556100)

Figure 16-31 Y-Axis PCB (Drawing # 27600100, Sheet 1 of 2)

Figure 16-32 Y-Axis PCB (Drawing # 27600100, Sheet 2 of 2)

Figure 16-33 Shuttle/Barcode X-Axis PCB (Drawing # 27601100)

Figure 16-34 Cuvette Loader Interface PCB (Drawing # 27602100)

Figure 16-35 Cuvette Sensor PCB (Drawing # 27604100)

Figure 16-36 Cuvette Waste Interface PCB (Drawing # 27605100)

Figure 16-37 Heated Probe PCB (Drawing # 27607100)

Figure 16-38 Probe DC Driver PCB (Drawing # 27608100, Sheet 1 of 2)

1 2 3 4 5 6 7 8
REVISIONS
+24V +5V
+5V +24V TP1 TP2 TP4 TP3 REV DESCRIPTION BY CHECKED APPROVED DATE
1
A TO BACKPLANE
+5V 0 ORIGINATED PER ECO# 15203 S.RATTA D.VO G.JAMIOL 4/17/02 A
1 CONNECTORS CHANGES PER CO L16763 D.COX D.VO C.BERGERON 23SEP03
P 2 RESTORE ORIG CONNECTORS PER CO L17655 D.COX 28SEP04
J2 R3 R4
3.32K 22.1K
1
2 B_S_SMPLE_PROBE_PIC_RESET
2
3 2
4 B_S_RGT1_PROBE_PIC_RESET
5
LED2
6 B_S_RGT2_PROBE_PIC_RESET LED1
1 +24V
7 1 +24V
Current Limit Resistor +24V
8 SMPLE_PROBE_CS Current Limit Resistor Current Limit Resistor
for Probe protection
B 9
10 RGT1_PROBE_CS
P
for Probe protection for Probe protection
B
11 10_WATT_WIRE_WOUND 10_WATT_WIRE_WOUND
10_WATT_WIRE_WOUND
12 RGT2_PROBE_CS
R6 SAMPLE PROBE R2
13 R1 REAGENT 2 PROBE
4 REAGENT 1 PROBE 4
14 SPI_CLK 4
15 INTERCONNECT INTERCONNECT INTERCONNECT
16 B_SPI_DATA_OUT
J3 J5
17 1 J4 1
+24V 1
18 SPI_DATA_IN SMPLE_DC_HEAT1 2 RGT2_DC_HEAT1 2
RGT1_DC_HEAT1 2
19 3 3
SOLID STATE RELAY 3
20 SMPLE_PROBE_IRQ SMPLE_DC_HEAT1 4 RGT2_DC_HEAT1 4
RGT1_DC_HEAT1 4
21 5 5
PWR_IN 1 +DC_LOAD 5
C 22
23
24
RGT1_PROBE_IRQ
RGT2_PROBE_IRQ
+5V
2 -DC_LOAD
SMPLE_DC_HEAT1
SMPLE_DC_HEAT2
6
8
RGT1_DC_HEAT1 6
7
RGT2_DC_HEAT1
RGT2_DC_HEAT2
6
8
C
RGT1_DC_HEAT2 8
25 9 9
3 +_CONTROL 9
26 SMPLE_PROBE_PIC_RESET SMPLE_DC_HEAT2 10 RGT2_DC_HEAT2 10
RGT1_DC_HEAT2 10
27 11 11
4 -_CONTROL 11
28 RGT1_PROBE_PIC_RESET SMPLE_DC_HEAT2 12 RGT2_DC_HEAT2 12
RGT1_DC_HEAT2 12
29 B_PROBE_RESET_IRQ 13 13
13
30 RGT2_PROBE_PIC_RESET RELAY1 SMPLE_PWM_HEAT_1 14 RGT2_PWM_HEAT_1 14
RGT1_PWM_HEAT_1 14
15 15
15
SMPLE_PWM_HEAT_2 16 RGT2_PWM_HEAT_2 16
RGT1_PWM_HEAT_2 16
17 17
17
B_SMPLE_SPI_DATA_IN 18 B_RGT2_SPI_DATA_IN 18
B_RGT1_SPI_DATA_IN 18
19 19
19
D +24V
+5V S_SMPLE_PROBE_PIC_RESET
B_SMPLE_PROBE_PIC_RESET
20
21
22
+5V S_RGT1_PROBE_PIC_RESET 20
21
+5V S_RGT2_PROBE_PIC_RESET
B_RGT2_PROBE_PIC_RESET
20
21
22
D
B_RGT1_PROBE_PIC_RESET 22
23 23
23
SPI_DATA_OUT 24 SPI_DATA_OUT 24
P SPI_DATA_OUT 24 P
25 P 25
25
SMPLE_PROBE_IRQ 26 RGT2_PROBE_IRQ 26
RGT1_PROBE_IRQ 26
PWR_IN 27 27
27
B_SMPLE_PROBE_CS 28 B_RGT2_PROBE_CS 28
B_RGT1_PROBE_CS 28
J1 29 29
29
1 B_SMPLE_SPI_CLK 30 B_RGT2_SPI_CLK 30
B_RGT1_SPI_CLK 30
2
C13 C14 C15 D7
R20
0
R22
0
R21
0
3
FR301
4 1000UF 1000UF 1000UF
E E
P
U6 TP17 U4
1
SMPLE_PROBE_PIC_RESET 11 A1 Y1 9 B_SMPLE_PROBE_PIC_RESET RGT1_PROBE_PIC_RESET 11 A1 Y1 9 B_RGT1_PROBE_PIC_RESET
TP18
1
U1 SMPLE_PROBE_CS 13 A2 Y2 7 B_SMPLE_PROBE_CS RGT1_PROBE_CS 13 A2 Y2 7 B_RGT1_PROBE_CS

SMPLE_PROBE_PIC_RESET 1
3 SPI_DATA_IN 15 A3 Y3 5 B_SMPLE_SPI_DATA_IN SPI_DATA_IN 15 A3 Y3 5 B_RGT1_SPI_DATA_IN U5
S_RGT1_PROBE_PIC_RESET 2 RGT2_PROBE_PIC_RESET 2 A1 Y1 18 B_RGT2_PROBE_PIC_RESET
SPI_CLK 17 A4 Y4 3 B_SMPLE_SPI_CLK SPI_CLK 17 A4 Y4 3 B_RGT1_SPI_CLK
SN74ACT00A RGT2_PROBE_CS 4 A2 Y2 16 B_RGT2_PROBE_CS
G G
SN74ACT244A SN74ACT244A SPI_DATA_IN 6 A3 Y3 14 B_RGT2_SPI_DATA_IN
U3 19 19
1 SPI_CLK 8 A4 Y4 12 B_RGT2_SPI_CLK
3 PROBE_RESET_IRQ
G
4.75K
+5V 2
F SN74ACT244A
R5
U1
SN74ACT32
TP16
F
1
4
6
S_RGT2_PROBE_PIC_RESET 5 U6 U4
2 A1 Y1 18 S_RGT1_PROBE_PIC_RESET 2 A1 Y1 18 B_S_RGT1_PROBE_PIC_RESET
SN74ACT00A
SPI_DATA_OUT 4 A2 Y2 16 B_SPI_DATA_OUT S_SMPLE_PROBE_PIC_RESET 4 A2 Y2 16 B_S_SMPLE_PROBE_PIC_RESET
U5
6 A3 Y3 14 6 A3 Y3 14 S_RGT2_PROBE_PIC_RESET 11 A1 Y1 9 B_S_RGT2_PROBE_PIC_RESET
8 A4 Y4 12 8 A4 Y4 12 13 A2 Y2 7
G G
15 A3 Y3 5
SN74ACT244A SN74ACT244A
1 1 17 3
A4 Y4
U3
G
4
6 +5V SN74ACT244A
5 19
SN74ACT32
TP15
1
G 9
10
U3
8
+5V +5V +5V
ALL_PROBE_CS
G
SN74ACT32
R7
+5V +5V +5V +5V +5V
U3 4.75K
12
11
13
U7 Instrumentation Laboratory
4
SN74ACT32 C1 C2 C3 6
B_SMPLE_PROBE_CS 5 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
0.1UF 0.1UF 0.1UF
SN74ACT08
U1 U1 Title
12 9 C4 C5 C6 C7 C8
11 8 APPROVALS DATE
13 10 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF
U7 DRAWN
B_RGT1_PROBE_CS 1 SN74ACT00A SN74ACT00A
3 Saverio Ratta 04/17/02 Probe DC Driver Board
B_RGT2_PROBE_CS 2 CHECKED
D.VO 04/17/02
SN74ACT08
H
APPROVED
G.JAMIOL 04/17/02
SIZE DWG. NO. REV. SHEET

H
D 276081_00 2
1 of 2
SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-39 Probe DC Driver PCB (Drawing # 27608100, Sheet 2 of 2)

1 2 3 4 5 6 7 8
REVISIONS
+5V
REV DESCRIPTION BY CHECKED APPROVED DATE
A SEE SHEET 1 A
R23 R24 R25 R26
1K 1K 1K 1K
U2 +24V
SAMPLE PROBE +24V
SMPLE_PWM_HEAT_1 2 A1 Y1 18 B_SMPLE_PWM_HEAT_1
SMPLE_PWM_HEAT_2 4 A2 Y2 16 B_SMPLE_PWM_HEAT_2
RGT1_PWM_HEAT_1 6 A3 Y3 14 B_RGT1_PWM_HEAT_1
RGT1_PWM_HEAT_2 8 A4 Y4 12 B_RGT1_PWM_HEAT_2
G
SN74ACT240
1
R8
B +5V
22.1K R9
22.1K
B
2
D5 C16 C17 2 D6 C12 C18
TP5
1
LED3 100U 100U TP8
1
L5 100U 100U
1 LED4 L6
SMPLE_DC_HEAT1
1 SMPLE_DC_HEAT2
R28 R27 550UH
550UH
1K 1K
2
TP6 TP7 2
1
U2 D
U8 D
RGT2_PWM_HEAT_1 11 A1 Y1 9 B_RGT2_PWM_HEAT_1 B_SMPLE_PWM_HEAT_1 9 U8
8 G B_SMPLE_PWM_HEAT_2 12
RGT2_PWM_HEAT_2 13 A2 Y2 7 B_RGT2_PWM_HEAT_2 B_SMPLE_PROBE_PIC_RESET 10 1 11 G
C PROBE_RESET_IRQ 15
17
A3
A4
G
Y3
Y4
5
3
B_PROBE_RESET_IRQ SN74ACT08
IRLR024N
S
3
B_SMPLE_PROBE_PIC_RESET 13
SN74ACT08
1
IRLR024N
S
C
FET6 3
SN74ACT240 FET5
19
R15
R19
10.0K
10.0K
P
P
+24V
REAGENT PROBE 1
D +24V
D
R10
22.1K
2
R11 D4 TP12
C11 C20
1
22.1K
D3 LED5 100U 100U

2 C10 C19 TP10 L3
1
1
RGT1_DC_HEAT2
100UF 100UF 550UH
L2
LED6
RGT1_DC_HEAT1 TP11 2
1
1
550UH
E TP9
2
B_RGT1_PWM_HEAT_2
B_RGT1_PROBE_PIC_RESET
4
5
U8
6
1
G
D
E
1
D
U8 SN74ACT08 S
B_RGT1_PWM_HEAT_1 1
3 G IRLR024N
B_RGT1_PROBE_PIC_RESET 2 1 3
FET4
SN74ACT08 S
IRLR024N R18
3
FET3 10.0K
P
R14
10.0K
P
REAGENT PROBE 2
+24V
F +24V
F
R12 R13
22.1K 22.1K
2 D1 C23 C21 2 D2 C9 C22

100UF 100UF TP20
1
100UF 100UF TP19
1
LED7 L4 LED8 L1
1 RGT2_DC_HEAT1 1 RGT2_DC_HEAT2
550UH 550UH
TP14
1
TP13 2
1
G B_RGT2_PWM_HEAT_1 9
U7
8 G
D
B_RGT2_PWM_HEAT_2 12
U7
D
2
G
B_RGT2_PROBE_PIC_RESET 10 1 11 G
B_RGT2_PROBE_PIC_RESET 13 1
SN74ACT08 S
SN74ACT08 S
IRLR024N
3 IRLR024N
FET1 3 Instrumentation Laboratory
FET2
R16 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
R17
10.0K
10.0K Title
P
P APPROVALS DATE
DRAWN
Saverio Ratta 04/17/02 Probe DC Driver Board

CHECKED
D.VO 04/17/02
H
APPROVED
G.JAMIOL 04/17/02

H
D 276081_00 2
2 of 2
SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-40 Probe Interconnect PCB (Drawing # 27609100)

Figure 16-41 Cuvette Loader Flex Cable PCB (Drawing # 27611100)

Figure 16-42 Sample Rack Presence PCB (Drawing # 27700100)

Figure 16-43 Reagent Rack Presence PCB (Drawing # 27701100, Sheet 1 of 2)

Figure 16-44 Reagent Rack Presence PCB (Drawing # 27701100, Sheet 2 of 2)

Figure 16-45 Reagent KeyBoard PCB (Drawing # 27702100)

Figure 16-46 Reagent Cooling PCB (Drawing # 27703100)

Figure 16-47 Magnetic Stirring PCB (Drawing # 27704100, Sheet 1 of 2)

Figure 16-48 Magnetic Stirring PCB (Drawing # 27704100, Sheet 2 of 2)

Figure 16-49 Sample Key Board PCB (Drawing # 27705100, Sheet 1 of 2)

Figure 16-50 Sample Key Board PCB (Drawing # 27705100, Sheet 2 of 2)

Figure 16-51 Remote Travel Interface PCB (Drawing # 27710100)

Figure 16-52 Rack Controller CPU PCB (Drawing # 27800100, Sheet 1 of 3)



Figure 16-55 Rack Controller Interface PCB (Drawing # 27810100, Sheet 1 of 7)







Figure 16-62 Cuvette Waste Interface PCB (Drawing # 27605100)

1 2 3 4 5 6 7 8
REVISIONS
A 0 ORIGINATED PER ECO # 15079 S.RATTA A
+24V
R10 R11 R12 R13

4.7K 4.7K 4.7K 4.7K
1
B 3
4 P B
5 U1
2 A1 Y1 18
6
4 A2 Y2 16
7 B_CH_WASTE_DOOR_OPEN_CLOSE
6 A3 Y3 14 B_CH_ACCUM_SOL_ENABLE
8
8 A4 Y4 12 B_CH_LED_CONTROL
9
G
WHITE
10 MC74ACT244
1 +24V J6 TP10
11 CH_ACCUM_SOL_ENABLE COMMON 1 1
12 CH_LED_CONTROL NORNALLY OPEN 2

U4
13 N/C 3 2 1 IN1 OUT1 6 DRAWER_OPEN
14 CH_ULTRASONIC_INIT
TO MICROSWITCH +5V
15 CUV_WASTE_ULTRASONIC_BINH 2 GND VCC 5
Hardware Debaounce Implementation
C 16
17
18
CH_CUV_WASTE_ACC_SOL_FLAG
CH_DRAWER_OPEN
R6
4.7K
R3
4.7K
R5
22.0K 3 IN2
MAX6817
OUT2 4 Drawer Removal Switch
C
19
Accumulator Dump
20 CH_ULTRASONIC_ECHO_INIT LED4 J3 TO ACCUM DUMP SOLENOID
21 1 1 RED
GREEN LED
MBRS340T3
22 2 2 N/C
SOLENOID ACTIVE D5
23 3 3 BLK
24 U1
11 A1 Y1 9 B_CH_ULTRASONIC_INIT
25
13 A2 Y2 7 B_CH_ULTRASONIC_BINH
26
DRAWER_OPEN 15 A3 Y3 5
J1 CUV_WASTE_ACC_SOL_FLAG 17 A4 Y4 3
+5V
2
G
D
MC74ACT244
19
D 1
G
D
S
3
IRL510
Q2
P
U2
18 2 B_ULTRASONIC_ECHO_INIT
B_CH_WASTE_DOOR_OPEN_CLOSE 16
Y1
Y2
A1
A2 4 CH_WASTE_DOOR_OPEN_CLOSE Spares Gates

14 Y3 A3 6 +5V
U3
12 Y4 A4 8 4
6
G
5
MC74ACT244
1
MC74ACT86
E +5V
R9
4.7K
C8
470UF
TO ULTRASONIC WASTE
9
10
U3
8 E
R4 WHITE MC74ACT86
SENSOR
TP7 J5 U3
+5V 3.0K WHITE 12
9 +5V 11
TP6 9 13
B_CH_ULTRASONIC_BINH 8 BINH
8
MC74ACT86
U3 ULTRASONIC_ECHO 7 ECHO
1 7
3 WHITE 6 N/C
2 6
To Waste Door R14 R15 Green LED3 TP8

5
5 N/C
MC74ACT86
SONSORS ON B_CH_ULTRASONIC_INIT 4 INIT
180 4.7K 4
Sensor 3 N/C
WHITE 3
WHITE 2 N/C
J2 2
ANODE 1 1 TP11 TP5 1 GND
1
F +5V 2
OUTPUT 3
2
3 CH_WASTE_DOOR_OPEN_CLOSE SWITCH_CONTROL
+5V
11
13
A1
A2
U2
Y1
Y2
9
7
F
CATHODE 4 4 SWITCH_CONTROL
15 A3 Y3 5
DET.GND 5 5
17 A4 Y4 3
G
R7 R8
MC74ACT244
2 19
4.7K 180 TO CUV_WASTE_ACC_
D
SOL_FLAG SENSOR
J4
B_CH_LED_CONTROL G TP9
1 1 1 ANODE
S 2 2 +5V
IRLR024N CUV_WASTE_ACC_SOL_FLAG 3 3 OUTPUT

3
Q1 SWITCH_CONTROL 4 4 CATHODE
5 5 N/C
G RED
6 6 DET.GND
G
RED +24V
+5V TP4
TP3 +24V
+5V
R1 R2 Instrumentation Laboratory
3.0K 22.0K 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
LED1 LED2
C1 C2 C3 C4 C5 C6 C7 BLACK BLACK
Green 10UF 0.1UF 0.1UF 0.1UF 0.1UF
Green 10UF 0.1UF
Title
+5V +24V TP1 TP2 APPROVALS DATE

FOR U1 FOR U2 FOR U3 FOR U4 U4
D_GND P_GND DRAWN
Saverio Ratta 02/28/01

CHECKED Cuvette Waste Interface Board
P
H P DIGITAL GROUND POWER GROUND

APPROVED

H
1 of 1
D 276051-00 0 SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-63 X Motion Control PCB W/ out Dip (Drawing # 27613100)

1 2 3 4 5 6 7 8
ALL 33UF capacitors are 35V Aluminum E ALL 0.1UF and 0.01UF capacitors are 50V Ceramic 0805 REVISIONS
+15V +5V
POWER +5V TP1 TP11 +24V +15V
INPUT SIGNAL +24V TP4 TP13 +24V REV DESCRIPTION BY CHECKED APPROVED DATE
1
A CON6L TP3 TP12
0 ORIGINATED PER ECO # L17382 A
1
S.RATTA 12may04
1
C2
2 Tantalum Cap size A 35V
1 0.1UF
+24V
3 U2
2 C11
C20
C25 C32 C31 C30 C29 C26 C21 C27 0.22UF
4
3 10UF C19 33UF 33UF 33UF 33UF 33UF 0.1UF 10UF 0.1UF +5V P TP14
5 0.1UF
4 10NF
U2
1
6
5 15 C24
VS_1 VREF
7
6 +5V A 8 7
IN1 BOOT1
8 CH_X_MOT_ENABLE P
C1 13 6
A IN2 OUT1
9 BCX_R_LIMIT J2 0.1UF
P U1 17 4
ENABLE OUT2
10 BCX_L_LIMIT U10
B_/CLOCK 2 GND1
To Back Cover Fan
11 1
10NF
TP15
R22 Stepper Motor
1
3 14 +24V
GND2 BOOT2 C12
12X_MOT_HOLD_CURRENT TP10 TP8 TP7 TP2
Connector
1
10 5 16 1.8
SN74ACT02 GND3 SENSE
13 CH_X_MOT_CW/CCW U4
B 14
15 SM3_ENC_A 4.7K
CH_X_MOT_ENABLE
SM1/SM3_CLK
CH_X_MOT_HALF/FULL
2
6
A1
A2
A3
Y1
Y2
Y3
18
16
14
B_HALF/FULL
B_ENABLE
18 P18
19 P19
10 P10
L297
INH1
A
B
4
5
GND4
L6201P_A C13
10NF
VREF_L297 1
2
J8
2
B
16 P VREF_L297_R 3
1 2 3 4 6 7 8 9 CH_X_MOT_RESET 8 12 /B_RESET 20 P20 SEN1 14 SENS_1 SENS_1
A4 Y4
17 SM3_ENC_B 4
G
R26 B_CW/CCW 17 P17 C 7 J9
18 SN74ACT244 5
1 CONTROL 11 P11 D 9 P
R21
19 SM1/SM3_CLK HOLD_CURRENT 6
INH2 8 1W_R_SENSE1
20 7
OSC_L297 16 OSC 0.22
SEN2 13 SENS_2
CH_X_MOT_CW/CCW
21 TRANS_SMPL_B HOLD_CURRENT_R 8
VREF_L297 15 VREF SYNC 1
CH_Y_MOT_CW/CCW
22 TRANS_RGT_B
HOME 3 P Dual Row SW_LED_CON
Y_MOT_HOLD_CURRENT
23 Tantalum Cap size A 35V
X_MOT_HOLD_CURRENT R23
24 TX0 U1
+5V C15
25
+5V 0.01UF +24V
C17
1.8
LR024N
2
26 RX0 0.22UF D
U10 U10
10NF
C 27
28 CTS0
+24V
R16
10K
P
+5V
U3
VS_1 VREF
15
0.01UF
TP16
C14
B_BAR_SEN_LED_CTRL
B_CH_LED_CONTROL
8
9
10
11
12
13
1 G
S C
3
1
29 U10 C16
R19 SN74ACT02 SN74ACT02 FET1
5 8 7
IN1 BOOT1
30 RTS0 4
10K 6 13
IN2 OUT1
6 FET1 17A Logic D-Pack
31 1 N/C N/C 8
C10
21khz
SN74ACT02 17 4 Plated Mounting Holes
0.1UF ENABLE OUT2
32 SPI_CLK C8 2 VIN N/C 7
U10 GND1 TP17
33 0.1UF 3 TEMP VOUT 6
0.01UF
14
C23 GND2 BOOT2
1
34 B_SPI_DATA_OUT 4 GND TRIM 5
6.8NF 16 C18 TH1
GND3 SENSE
35 C28
U8 GND4 +24V
36 SHUTTLE_ADC_CS 0.1UF
Sub System SW1 SW2 SW3 SW4
R18
37
P L6201P_A G1
38 B_CH_CUV_IN_MOD P 100K TP9
OFF OFF OFF X To Y-Axis Board
Cuvette Hand P
39 B_CHY_GRIPPER_FOW SENS_2
OFF ON ON X +24V J6
1
40 B_CHY_GRIPPER_REV Rack Hand

+5V +24V 40
R20
D 41
42 B_CHY_CUV_IN_GRIP
43CH_GRIP_SOL_ENABLE
VREF_L297
VREF_L297_R
+5V
C3
0.1UF
1W_R_SENSE2
0.22
39
38
D
U3 37
44 B_CH_MOD_POS HOLD_CURRENT_R P
36
45 R7 P
R9 35
C9 C22
R8
46 0.1UF 0.1UF 5.11K Ground Guard
13.3K
13.3K
VREF and Hold 34
47 CH_Y_MOT_ENABLE Current Signals Buffering for Signals to the Y-Axis Board
To connector J8 10 5 33
48 CH_Y_MOT_RESET P
P 32
49 CH_LED_CONTROL P U7
4
B_CH_Y_MOT_RESET 31
V+ 2 A1 Y1 18
5 8 HEAT_CON_SH B_HEAT_CON_SH
50 VL D 4.7K
B_CH_Y_MOT_HALF/FULL 30
4 A2 Y2 16
51CH_Y_MOT_HALF/FULL B_X_MOT_HOLD_CURRENT 6 1 HOLD_CURRENT CH_GRIP_SOL_ENABLE B_CH_GRIP_SOL_ENABLE
IN S 1 2 3 4 6 7 8 9 B_CH_LED_CONTROL 29
6 A3 Y3 14
3 SHUTTLE_ADC_CS B_SHUTTLE_ADC_CS
52 CH_Y_MOT_CW/CCW GND N/C 2 +5V B_CH_Y_MOT_ENABLE
R25 8 12 28
CH_MOD_POS A4 Y4 B_CH_MOD_POS
53 HEAT_CON_SH 7 V- +5V
G 27
R17 0
54 SN74ACT244 R27
1 B_SPI_CLK 26
E 55
56
SM2_CLK
U9
DG417
5.11K
10 5 C7
0.1UF
+5V
SPI_DATA_OUT
25
24
E
57 Y_MOT_HOLD_CURRENT +5V P U7 P
P 23
58 BAR_SEN_LED_CTRL
B_SM2_CLK 22
4.7K
59 CH_X_MOT_RESET
U7 21
60 CH_X_MOT_HALF/FULL 1 2 3 4 6 7 8 9 11 9
CH_CUV_IN_MOD A1 Y1 B_CH_CUV_IN_MOD B_CH_Y_MOT_CW/CCW 20
R24 13 A2 Y2 7
CHY_GRIPPER_FOW B_CHY_GRIPPER_FOW B_CH_GRIP_SOL_ENABLE 19
J1
15 A3 Y3 5
R1 CHY_GRIPPER_REV B_CHY_GRIPPER_REV B_SHUTTLE_ADC_CS 18
J3 4.75K R2
CHY_CUV_IN_GRIP 17 A4 Y4 3 B_CHY_CUV_IN_GRIP
4.75K B_Y_MOT_HOLD_CURRENT 17
G
+5V 5
U5 U6 16
SN74ACT244
4 2 18 SM3_ENC_B 2 18 19
A1 Y1 SPI_CLK A1 Y1 B_SPI_CLK B_HEAT_CON_SH 15
3 4 A2 Y2 16 SM3_ENC_A CH_Y_MOT_ENABLE 4 A2 Y2 16 B_CH_Y_MOT_ENABLE
ENCODER 14
2 TRANS_SMPL 6 A3 Y3 14 TRANS_SMPL_B 6 A3 Y3 14
Left Limit Sensor CH_Y_MOT_HALF/FULL B_CH_Y_MOT_HALF/FULL CH_CUV_IN_MOD 13
+5V
F R4
121
R3
2.7K
Single Row 1 TRANS_RGT 8 A4
G
1
Y4 12
SN74ACT244
TRANS_RGT_B 8 A4
G
1
Y4 12
SN74ACT244
CHY_GRIPPER_FOW
CHY_GRIPPER_REV
CHY_CUV_IN_GRIP
12
11 F
10
1
1 +5V Bar Code Reader Interface CH_MOD_POS 9

Dual Row 2 TP5
8
3 L_LIMIT +15V
U6 7
R14 R15
4 SW_LED_CON 11 A1 Y1 9 +5V
SM2_CLK B_SM2_CLK 4.75K 4.75K 6
C5
5 +5V 13 A2 Y2 7
0.1UF X_MOT_HOLD_CURRENT B_X_MOT_HOLD_CURRENT 5
6 U5 15 A3 Y3 5 B_CH_Y_MOT_RESET
CH_Y_MOT_RESET 4
TRANS_SMPL 1
C6
17 A4 Y4 3
P 0.1UF 2 3
G
J4 U6
U5 TRANS_RGT 3 2
SN74ACT244
11 9 BCX_L_LIMIT 19
A1 Y1 10 5 1
4
13 A2 Y2 7 BCX_R_LIMIT
+5V 5
CH_LED_CONTROL 15 A3 Y3 5 B_CH_LED_CONTROL
6
G Right Limit Sensor

BAR_SEN_LED_CTRL 17 A4
G
19
Y4 3
SN74ACT244
B_BAR_SEN_LED_CTRL 4.7K
1 2 3 4 6 7 8 9 CH_X_MOT_CW/CCW
CH_Y_MOT_CW/CCW
11
13
A1
A2
Y1
Y2
U4
9
7
B_CW/CCW
B_CH_Y_MOT_CW/CCW
TX0
7
8
G2
A G
R28 9
15 A3 Y3 5
Y_MOT_HOLD_CURRENT B_Y_MOT_HOLD_CURRENT
RX0 10
17 A4 Y4 3
X_MOT_HOLD_CURRENT
2.7K 11
R5 G
TP6 +15V +24V +5V
121 R6
SN74ACT244 +5V CTS0 12 Instrumentation Laboratory
19
LED1
1
13
1 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
RTS0 14
2
C4
G3 15 Title
0.1UF
3 R_LIMIT R13 R12 R11 U11 U11
11 A1 Y1 9 2 A1 Y1 18 R10 U4 16 APPROVALS DATE
4 SW_LED_CON 13.3K 21.5K 3.0K
Single Row 13 A2 Y2 7 4 A2 Y2 16 2.87K 17 DRAWN Schematic,
5
15 5 6 14 18 Saverio Ratta 05/12/04
6
A3 Y3 A3 Y3
+24V CHECKED X Motion Control bd.
17 A4 Y4 3 8 A4 Y4 12 19
SPI_DATA_OUT B_SPI_DATA_OUT
G G without DIP
H J5
LED4 LED3 LED2
19
SN74ACT244
B_SHUTTLE_ADC_CS
1
SN74ACT244
20
J7
APPROVED

H
1 of 1
A P P D 276131-00 1 SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-64 CTS Controller Interface PCB (Drawing # 28630100, Sheet 1 of 9)

1 2 3 4 5 6 7 8
REVISIONS
A VDD +15V +24V 0 Released per co L18255 DRC S.RATTA G.DAVID 26MAY05 A
0C CHANGED C99, +24V,PGND PLANE PER CO L18579 DRC 1SEP05
VDD TP1 TP2 +15V TP3 TP4 +24V TP5 TP6
VDD +15V +24V
1 CHANGED MOTOR/ENCODER RESET WIRING BJW
RED BLACK RED BLACK RED BLACK
R6 R7 R8
3.01K 12.1K 20.0K
R2 R3 R4
3.01K 13.3K 22.1K +5V_MON +15V_MON +24V_MON
C1 C2 C3 C4 C5 C6 C7 C8 2.00V 3.48V 4.02V
47UF 47UF 47UF 0.1UF 22UF 0.1UF 10UF 0.1UF
LED1 LED2 LED3 R9 R10 R11 R68

VDD +15V +24V 2.00K 3.65K 4.02K 4.02K
GREEN GREEN GREEN DO NOT POPULATE
B GND
GND
A P
GND
B
A P
GND
A P
VDD VDD
C 10K RP1 C
16
C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23
0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF
U1 U1 U1 U1 U1 U1 U1 U1 U1 U1 U1 U1 U1 U2 U3
10
11
12
13
14
15
GND
SPARE5
VDD SPARE4
U4
1
D C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 C36 C37 C38
2
SN74LS09
3
D
0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF
U4 U5 U6 U6 U7 U7 U9 U11 U12 U13 U14 U15 U16 U17 U18 U4
9
8
10
GND
SN74LS09
U4
12
11
13
VDD
SN74LS09
U2
13 12
E C39 C40 C41 C42 C43 C44 C45 C46 C47 C48 C49 C50 C51 C52 C53
MC74ACT04
E
0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF U53
11 A1 Y1 9
U19 U20 U21 U22 U23 U24 U25 OSC1 U26 U26 U26 U26 U26 U26 U26
13 A2 Y2 7
15 A3 Y3 5
GND
17 A4 Y4 3
G
MC74ACT244
19
VDD
GND
F C54
0.1UF
C55
0.1UF
C56
0.1UF
C57
0.1UF
C58
0.1UF
C59
0.1UF
C60
0.1UF
C61
0.1UF
C62
0.1UF
C63
0.1UF
C64
0.1UF
C65
0.1UF
C66
0.1UF
C67
0.1UF
C68
0.1UF
F
GND
VDD
Note:
Mounting holes for the
board are to be plated and
G C69
0.1UF
C70
0.1UF
C71
0.1UF
C72
0.1UF
C73
0.1UF
C74
0.1UF
C75
0.1UF
C76
0.1UF
C77
0.1UF
C78
0.1UF
C79
0.1UF
C95
0.1UF
C96
0.1UF
C97
0.1UF
C98
0.1UF attached to the CGND net
G
on the board.
GND
Instrumentation Laboratory
113 HARTWELL AVENUE, LEXINGTON MASS. 02421
Title
APPROVALS DATE
DRAWN
Brian Walker 7/06/04 UNIVERSAL ARM
CHECKED
S.RATTA 5/27/05 CONTROLLER BOARD
H
APPROVED
G.DAVID 5/27/05

1 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
VDD REVISIONS
VDD
A REFER TO PAGE 1 A
C80 C81 C82
0.01UF 0.1UF 0.1UF
107
116
126
18
28
39
50
65
84
96
7
VDDE1
VDDE2
VDDE3
VDDE4
VDDE5
VDDE6
VDDE7
VDDE8
VDDE9
VDDE10
VDDE11
R12 C83 1
17.8K 0.01UF VDDI1
63 2
VDDI2 VSSI1
GND
61 34
VDDSYN VSSI2
64 59
XFC VSSI3
19 101
VSTBY VSSI4
DATA[00:15] ADDR[00:18]
GND
A1 A1
B VDD VDD
IN
A2
A3
0
1
111
110
D0
D1
MC68332
132 PQFP
A0
A1
90
20
0
1
A2
A3
IN
B
A4 2 109 21 2 A4
D2 U1 A2
VDD
A5 3 108 22 3 A5
D3 A3
A6 4 105 23 4 A6
D4 A4
10K RP2 DNP RP3
16
16
A7 5 104 24 5 A7
D5 A5
A8 6 103 25 6 A8
D6 A6
10K RP4
16
A9 7 102 26 7 A9
D7 A7
A10 8 100 27 8 A10
D8 A8
1
10
11
12
13
14
15
10
11
12
13
14
15
A11 9 99 30 9 A11
D9 A9
A12 10 98 31 10 A12
D10 A10
10
11
12
13
14
15
PCS00 A13 11 97 32 11 A13
D11 A11
PCS01 A14 12 94 33 12 A14
D12 A12
C PCS02
PCS03
A15
A16
13
14
93
92
D13
D14
A13
A14
35
36
13
14
A15
A16
EEPROM_PUP
C
PQS1/MOSI A17 15 91 37 15 A17 RESET_PUP
D15 A15
PQS2/SCK 38 16 A18 RESET_IN
A16
41 17 A19
A17
MODCLK/PF0 78 42 18 A20
MODCLK/PF0 A18
IRQ1*/PF1 77
IRQ1*/PF1
IRQ2*/PF2 76
IRQ2*/PF2
R54
IRQ3*/PF3 75 113 CS0_RAMH
IRQ3*/PF3 BR*/CS0*
IRQ4*/PF4 74
IRQ4*/PF4 BG*/CS1*
114 0 CS1_CAN
CAN_IRQ 73 115 CS2_UART1

IRQ5*/PF5 BGACK*/CS2*
R55
IRQ6*/PF6 72 118 CS3_RAML
IRQ6*/PF6 PC0/FC0/CS3*
IRQ7*/PF7 71
IRQ7*/PF7 PC1/FC1/CS4*
119 0 CS4_IO_8BIT
120 CS5_UART2
PC2/FC2/CS5*
D DSACK0*/PE0
DSACK1*/PE1
89
88
DSACK0*/PE0
DSACK1*/PE1
PC3/A19/CS6*
PC4/A20/CS7*
121
122
CS6_EXT/A19
CS7_EXT/A20
D
87 123 CS8_IO_16BIT/A21
AVEC*/PE2 PC5/A21/CS8*
RMC*/PE3 86 124 CS9_EXT/A22
RMC*/PE3 PC6/A22/CS9*
R34
DS*/PE4 85 125 CS10_EXT/A23
DS*/PE4 A23/CS10*
R35
AS*/PE5 0 82
AS*/PE5
R52
SIZ0/PE6 0 81
SIZ0/PE6 CSBOOT*
112 CSBT_FLASH
SIZ1/PE7 80
SIZ1/PE7
0
TPUCH[00:15]
A1 56 DSCLK/BKPT
DSCLK/BKPT
IN
58 FREEZE
FREEZE
A2 0 16
TPUCH0
55 IFETCH*/DSI
IFETCH*/DSI
A3 1 15
TPUCH1
54 IPIPE*/DSO
IPIPE*/DSO
A4 2 14
TPUCH2
57
TSC
E A5
A6
A7
3
5
13
12
11
TPUCH3
TPUCH4
TPUCH5
PQS1/MOSI
R36
R37
CPU_MISO
CPU_MOSI
E
PQS0/MISO
43 PQS2/SCK 0 CPU_SCK
A8 6 10
TPUCH6 0
44 PCS[00:03]
PQS1/MOSI
A9 7 9 A1
TPUCH7
45
PQS2/SCK IN
A10 8 6
TPUCH8
46 0 A2
PQS3/PCSO*/SS*
A11 9 5
TPUCH9
47 1 A3
PQS4/PCS1*
A12 10 4
TPUCH10
48 2 A4
PQS5/PCS2*
A13 11 3
TPUCH11
49 3 A5
PQS6/PCS3*
A14 12 132
TPUCH12
A15 13 131
TPUCH13
52
PQS7/TXD
A16 14 130
TPUCH14
53
RXD
A17 15 129
TPUCH15
128
T2CLK
F R13
GND
60
XTAL
RESET*
HALT*
BERR*
68
69
70
RESET
HALT
BERR
F
R38
1 332K 62
EXTAL CLKOUT
66 SYSCLK
40.000KHZ
R39
X1
R/W*
79 33 RD/WR*
X1 R14
SHLDPAD
33
VSSE10
VSSE11
10M
VSSE1
VSSE2
VSSE3
VSSE4
VSSE5
VSSE6
VSSE7
VSSE8
VSSE9
X2
4
133
8
17
29
40
51
67
83
95
106
117
127
VDD 40.0 KHZ Crystal

C84 C85 Fsys = 40kHz (4*(Y+1)*2^((2*W) + X)) GND
10PF 10PF
Fsys = 16Mhz, Y = 49, W = 1, X = 0
GND
G 1
2
DS*/PE4
BERR
VDD
G
3
4 DSCLK/BKPT
U2
5 R40
RD/WR*_INV 1 2 RD
6 FREEZE Instrumentation Laboratory
33
7 RESET MC74ACT04
R15
8 IFETCH*/DSI U2
825
9 SER_IRQ 3 4 IRQ4*/PF4 Title
10 IPIPE*/DSO APPROVALS DATE

MC74ACT04
U2 DRAWN
J1 Brian Walker 7/06/04 UNIVERSAL ARM
SW1 5 6 RESET
GND CHECKED
ADM705
CONTROLLER BOARD
1 3 U4 MC74ACT04
H 68K BDM Connector GND

2 4 RESET_IN
GND
1
6
MR
PFI
WDI
RESET
PFO
WDO
7
8
RESET_PUP
4
SN74LS09
6 RESET
APPROVED

2 of 9
H
U3 D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
A REFER TO PAGE 1 A
ADDR[00:18]
DATA[00:15]
PROGRAM FLASH DEBUG SRAM SYSTEM SRAM

A1
IN
128K x 16 Flash A1 256K x 16 SRAM A1 256K x 16 SRAM
A1 IN IN
A2 0 29F200A IN K6X4016C3F A1 K6X4016C3F A1
A2 0 IN A2 0 IN
A3 1 25 A0 DQ0
29 0 A2 TSOP TSOP
A3 1 5 A0 I/O1
7 0 A2 A3 1 5 A0 I/O1
7 0 A2
A4 2 24 A1 DQ1
31 1 A3
A4 2 4 A1 I/O2
8 1 A3 A4 2 4 A1 I/O2
8 1 A3
A5 3 23 A2 DQ2
33 2 A4
B A6
A7
4
5
22 A3
21 A4
DQ3
DQ4
35
38
3
4
A5
A6
A5
A6
A7
3
5
3
1
A2
A3
A4
I/O3
I/O4
I/O5
9
10
13
2
4
A4
A5
A6
A5
A6
A7
3
5
3
1
A2
A3
A4
I/O3
I/O4
I/O5
10
13
9 2
4
A4
A5
A6
B
A8 6 20 A5 DQ5
40 5 A7
A8 6 44 A5 I/O6
14 5 A7 A8 6 44 A5 I/O6
14 5 A7
A9 7 19 A6 DQ6
42 6 A8
A9 7 43 A6 I/O7
15 6 A8 A9 7 43 A6 I/O7
15 6 A8
A10 8 18 A7 DQ7
44 7 A9
A10 8 42 A7 I/O8
16 7 A9 A10 8 42 A7 I/O8
16 7 A9
A11 9 8 A8 DQ8
30 8 A10
A11 9 27 A8 I/O9
29 8 A10 A11 9 27 A8 I/O9
29 8 A10
A12 10 7 A9 DQ9
32 9 A11
A12 10 26 A9 I/O10
30 9 A11 A12 10 26 A9 I/O10
30 9 A11
A13 11 6 A10 DQ10
34 10 A12
A13 11 25 A10 I/O11
31 10 A12 A13 11 25 A10 I/O11
31 10 A12
A14 12 5 A11 DQ11
36 11 A13
A14 12 24 A11 I/O12
32 11 A13 A14 12 24 A11 I/O12
32 11 A13
A15 13 4 A12 DQ12
39 12 A14
A15 13 23 A12 I/O13
35 12 A14 A15 13 23 A12 I/O13
35 12 A14
A16 14 3 A13 DQ13
41 13 A15
A16 14 22 A13 I/O14
36 13 A15 A16 14 22 A13 I/O14
36 13 A15
A17 15 2 A14 DQ14
43 14 A16
Connected for A17 15 21 A14 I/O15
37 14 A16 A17 15 21 A14 I/O15
37 14 A16
A18 16 1 A15 DQ15/A-1
45 15 A17
VDD 512K x 16 flash A18 16 20 A15 I/O16
38 15 A17 A18 16 20 A15 I/O16
38 15 A17
C CS6_EXT/A19
A19
A20
17
18
48 A16
17 N/C
16 N/C RY/BY* 15
A19
A20
17
18
19
18
A16
A17
A19
A20
17
18
19
18
A16
A17 C
CSBT_FLASH 6 CS
RAM_CS 6 CS
R64 RD/WR*_FLASH 11 WE
RD/WR*_FLASH 17 WE
RD/WR*_SRAM 17 WE
10K CSBT_FLASH 26 CE
RD_FLASH 41 OE
RD_SRAM 41 OE
RD_FLASH 28 OE
40 UB
CS0_RAMH 40 UB
FLASH_PUP 47 BYTE
39 LB CS3_RAML 39 LB
B_RESET 12 RESET
R53
GND U6 U7
0
U5
GND
For use with debugger only.
D Remove U4 when U6 is installed R41
33
RD/WR*_INV
D
and vice versa. U52 R42
RD/WR* 2 A1 Y1 18 RD/WR*_FLASH
4 A2 Y2 16 33
6 A3 Y3 14
R43
8 A4 Y4 12 RD/WR*_SRAM
G 33
MC74ACT244
1 R44
RD/WR*_245
33
GND
R45
RD/WR*_CAN
33
E 11
13
A1
A2
U52
Y1
Y2
9
7
R46
33
RD/WR*_PLD
E
RD 15 A3 Y3 5
R47
VDD VDD VDD VDD VDD VDD VDD VDD 17 A4 Y4 3 RD_FLASH
G 33
MC74ACT244
19 R48
RD_SRAM
D1 thru D17 are all MBR0520LT1
33
GND
D1 D2 D3 D4 D5 D6 D7 D8
VDD
U8
+5V_MON 1 20
CH0 VCC
F +15V_MON
PRESSURE_VACUMM_PUMP_SENSE
2
4
CH1
CH2
CH3
V- 11
C86 C87 CPU_MOSI 5

SI
U9
SO
2 CPU_MISO
F
0.1UF 47UF
EXT2_MON 5 CPU_SCK 6
CH4 SCK
+24V_MON 6 10 EEPROM_CS 1
CH5 DGND CS
EXT4_MON 7 12 EEPROM_PUP 3
CH6 AGND WP
EXT5_MON 8 9 7
CH7 COM HOLD
0
D17
CPU_MOSI 15 AT25040
DIN
D9 D10 D11 D12 D13 D14 D15 D16 R1
+ CPU_SCK 18 19 GND
R59
CLK SSO
0
C99 CPU_ADC_CS 17 16
4.7UF CS DOUT 512 x 8 EEPROM
A
16V
GND GND GND GND GND GND GND GND GND GND 14
REF+
13
REF-
G LTC1296
CPU_MISO
G
+15V
U10
2 VIN VOUT 6 Instrumentation Laboratory
3 TEMP TRIM 5
C88 4 GND
0.1UF REF02 Title
APPROVALS DATE
DRAWN
CHECKED
CONTROLLER BOARD
H
A APPROVED

3 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
A REFER TO PAGE 1
A
U11
2 A1 Y1 18
4 A2 Y2 16
6 A3 Y3 14
8 A4 Y4 12
G
MC74ACT244
1
DATA[00:15] B_DATA[00:15] DATA[00:15] BDIR_DATA[00:15]
A1 A1 A1 A1
B IN
A2
A3
0
1 11 A1
U11
Y1 9
0
1
A2
A3
IN IN
A2
A3
0
1
18
17
B1
B2
U13
A1
A2
2
3
0
1
A2
A3
IN
B
A4 2 13 A2 Y2 7 2 A4 A4 2 16 B3 A3 4 2 A4
A5 3 15 A3 Y3 5 3 A5 A5 3 15 B4 A4 5 3 A5
A6 4 17 A4 Y4 3 4 A6 A6 4 14 B5 A5 6 4 A6
G
A7 5 5 A7 A7 5 13 B6 A6 7 5 A7
MC74ACT244
A8 6 19 6 A8 A8 6 12 8 6 A8
B7 A7
A9 7 7 A9 A9 7 11 B8 A8 9 7 A9
A10 8 8 A10 A10 8 DIR G 8 A10

MC74ACT245
A11 9 U12 9 A11 A11 9 1 19 9 A11
2 A1 Y1 18
A12 10 10 A12 A12 10 10 A12
4 A2 Y2 16
A13 11 11 A13 A13 11 11 A13
6 A3 Y3 14
A14 12 12 A14 A14 12 12 A14
C A15
A16
13
14
8 A4
G
1
Y4 12
MC74ACT244
13
14
A15
A16
A15
A16
13
14 18 B1
U14
A1 2
13
14
A15
A16 C
A17 15 15 A17 A17 15 17 B2 A2 3 15 A17
16 B3 A3 4
15 B4 A4 5
VDD
U12 14 B5 A5 6
11 A1 Y1 9
13 B6 A6 7
13 A2 Y2 7
12 B7 A7 8
15 A3 Y3 5
R16 11 B8 A8 9
17 A4 Y4 3
4.99K DIR G
G
MC74ACT245
1 19
MC74ACT244
19
RD/WR*_245
INTF_DATA_ENA
D GND D
VDD
U17
2 A1 Y1 18
4 A2 Y2 16
6 A3 Y3 14
8 A4 Y4 12
G
MC74ACT244
1
ADDR[00:18] B_ADDR[00:11]
A1 A1
R65 R66 R67 R63 IN IN
10K 10K 10K 10K A2 0 0 A2
UNIVERSAL ARM TPU CONFIGURATION U17
A3 1 11 A1 Y1 9 1 A3
E TPUCH00 11 A1
U15
Y1 9 X_MOT_CLK
A4
A5
2
3
13
15
A2
A3
Y2
Y3
7
5
2
3
A4
A5
E
A6 4 17 A4 Y4 3 4 A6
X_MOT_CLK 13 A2 Y2 7 TPUCH01 X_MOT_IRQ_TPU_01
G
A7 5 5 A7
TPUCH02 15 A3 Y3 5 Y_MOT_CLK MC74ACT244
A8 6 19 6 A8
Y_MOT_CLK 17 A4 Y4 3 TPUCH03 Y_MOT_IRQ_TPU_03
A9 7 7 A9
G
MC74ACT244 A10 8 8 A10
19
A11 9 U18 9 A11
2 A1 Y1 18
A12 10 10 A12
4 A2 Y2 16
A13 11 11 A13
U15 6 A3 Y3 14
TPUCH04 2 A1 Y1 18 Z_MOT_CLK
8 A4 Y4 12
Z_MOT_CLK 4 A2 Y2 16 TPUCH05
G
Z_MOT_IRQ_TPU_05
B_TPU_IN6 6 A3 Y3 14 TPUCH06 MC74ACT244
1
F From PLD
X-LIMITS_COLLISION_AVOID 8 A4
G
1
Y4 12
MC74ACT244
TPUCH07
F
U18
U16 RESET 11 A1 Y1 9 B_RESET
AIR_BUBBLE_DETECT 11 A1 Y1 9 TPUCH08
RESET 13 A2 Y2 7 B_RESET
Y_EOT_LIMITS 13 A2 Y2 7 TPUCH09
OR'ED INPUT
SPARE4 15 A3 Y3 5
CAP_SENSE_TUBE_RELEASE 15 A3 Y3 5 TPUCH10
OR'ED INPUT
SPARE5 17 A4 Y4 3
TPUCH11 17 A4 Y4 3
G
G
MC74ACT244
19
MC74ACT244
19
G Z_MOT_HOME_SENSE
LLD_IRQ
2
4
A1
A2
U16
Y1
Y2
18
16
TPUCH12
TPUCH13
GND
G
GEN_CONT_STOP_IRQ 6 A3 Y3 14 TPUCH14
Z_MOTOR_STEP_SIZE_SYNC 8 A4 Y4 12 TPUCH15
G
1
MC74ACT244 Instrumentation Laboratory
Title
GND APPROVALS DATE
DRAWN
CHECKED
CONTROLLER BOARD
H
APPROVED

4 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
VDD VDD REV DESCRIPTION BY CHECKED APPROVED DATE
A REFER TO PAGE 1 A
ADDR[00:07]
A1
IN
A2 7
10K RP6
16
A3 6
A4 5
A5 4
A6 3
10
11
12
13
14
15
A7 2
VDD VDD
A8 1
A9 0
Mode3, non Intel, non mux'ed
B R17
3.01K LTC485
PROBE_LLD_FREQ_DIF_B
B
8
VCC
UART_IOR
2 RE
44
43
42
41
40
39
38
37
36
35
34
UART_IOW R
LED5 LLD_FREQUENCY_IN 1 RO B 7
RD*/E
ALE/AS
AD0
AD1
AD2
VCC
MODE0
AD3
AD4/MOSI
AD5
AD6/SCK
SER_CS
CAN 3 DE R20
D
GREEN 4 DI A 6 121
A1
1 RD/WR* AD7 33 IN GND
5
CS1_CAN 2 32 8 A2
REFDES=U21
CS P1.0/AD8
PROBE_LLD_FREQ_DIF_A
3 DSACK0 P1.1/AD9 31 9 A3
4 P2.7/WRH* P1.2/AD10 30 10 A4
5 P2.6/INT* P1.3/AD11 29 11 A5 GND
6 28 12 A6
P2.5 AS82527 P1.4/AD12
7 P2.4 P1.5/AD13 27 13 A7
REFDES=U19
C 10
8
9
P2.3
P2.2
P2.1
P1.6/AD14
P1.7/AD15
MODE1
26
25
24
14
15
A8
A9
VDD C
11 P2.0 RESET 23 B_RESET
INT*/VCC/2
CLOCKOUT
RDY/MISO
XTAL1
XTAL2
AGND
DNGD
RX1
RX0
TX1
TX0
LTC485
SPI_CLK_DIF_B
8
12
13
14
15
16
17
18
19
20
21
22
VCC
8 or 16 MHZ Crystal 2 RE
R
1 RO B 7
X2 CAN_IRQ 3 DE R21
D
B_SPI_CLK 4 DI A 6 121
GND GND
GND
5
16MHZ TP7 TP8 REFDES=U22
1
WHITE WHITE SPI_CLK_DIF_A
D 22PF
C89
22PF
C90
PCA82C250 GND
D
1 TXD CANH 7
4 RXD CANL 6
GND
R18
8 RS VREF 5
VDD
2.74K
U20
R19
1.82K LTC485
SPI_DATA_OUT_DIF_B
8
VCC
2 RE
R
E GND
MISO 1
4
RO
DE
DI
D
B 7
A 6
R22
121
E
GND
5
VDD
REFDES=U23
SPI_DATA_OUT_DIF_A
BDIR_DATA[00:15]
A1
IN
GND
A2 8
A3 9
A4 10
VDD
A5 11
A6 12
A7 13
F A8
A9
14
15 CTS LTC485
SPI_DATA_IN_DIF_B F
8
VCC
2 RE
U25
48
D4 47
D3 46
D2 45
D1 44
D0 43
42
41
40
39
38
37
R
1 RO B 7
1NC1 NC3 36
NC6
VCC
DCD
DSR
CTS
NC4
RI
3 DE R23
2D5 MR 35 B_RESET D
MOSI 4 DI A 6 121
3D6 OUT1 34
VDD GND
5
4D7 DTR 33
REFDES=U24
5RCLK RTS 32 RTS SPI_DATA_IN_DIF_A
16C550PQFP
6NC5 OUT2 31
SIN 7SIN INTRPT 30 SER_IRQ

GND
SOUT 8SOUT RXRDY 29
9CS0 A0 28 B_ADDR00
C91 C92 MAX232A C93 C94
0.1UF 0.1UF 0.1UF 0.1UF
10CS1 A1 27 B_ADDR01 1 16
C1+ VCC
G
TXRDY
SER_CS 11CS2 A2 26 B_ADDR02 3

C1- GND
15
G
XOUT
WR1
WR2
VSS
RD1
RD2
DDIS
NC2
XIN
NC0
ADS
12BAUDOUT NC 25
VDD 4 2
C2+ V+
GND
13
14
15
16
17
18
19
20
21
22
23
24
5 6
C2- V-
Serial Port 1 SOUT 11 T1IN T1OUT 14

T1
SIN 12 R1OUT R1IN 13
R24 R56 R1
0 4.99K 113 HARTWELL AVENUE, LEXINGTON MASS. 02421

GND GND
1.8432MHZ
RTS 10 T2IN T2
T2OUT 7 Title
1 ENA GND GND
VDD 4
CTS 9 R2OUT R2
R2IN 8 APPROVALS DATE
2 GND OUT 3 DRAWN

REFDES=U26 Brian Walker 7/06/04 UNIVERSAL ARM
OSC1 UART_IOW CHECKED
GND CONTROLLER BOARD
GND
H
UART_IOR APPROVED

5 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
A
GENERAL_CONTROLLED_STOP_IRQ2
GENERAL_CONTROLLED_STOP_IRQ1
TUBE_RELEASE_SENSE
B_8B_REG7_IN7
B_8B_REG7_IN6
B_8B_REG6_IN1
Y_EOT_LIMITS
LLD_CNTR_CLR
CPU_ADC_CS
Y END OF TRAVEL LIMITS
REFER TO PAGE 1 A
B_8B_REG6_IN0 EEPROM_CS
TUBE_CAP_SENSE
X_LEFT_LIMIT B_8B_REG5_IN5 SPI_ENA
X_RIGHT_LIMIT B_8B_REG5_IN4 Z_DAC_CS
Y_REV_LIMIT B_8B_REG5_IN3 Z_ADC_CS
B_8B_REG5_IN2 SPI_CS6
Y_FOW_LIMIT
SPI_CS7
B_ADDR[00:11]
A1
IN
A2 0
A3 1 U27
A4 2
IO7687
IO7586
IO7485
IO7383
IO7282
IO7181
IO7080
IO6979
IO6878
IO6777
IO6674
IO6573
IO6472
IO6371
IO6270
IO6169
IO6067
IO5966
IO5865
B A5
A6
A7
3
5
4
3
IO1
IO2 B
2 IO3 LAB H LAB G
A8 6 IO57 63 PROBE_TYPE_SPI_CS
1 IO4
A9 7 IO56 62 PROBE_CS
100 IO5
A10 8 IO55 60 X_MOT_ENC_CS VDD
99 IO6 LAB A
A11 9 IO54 59 Y_MOT_ENC_CS
98 IO7
A12 10 IO53 58 Z_MOT_ENC_CS
96 IO8 LAB F
A13 11 IO52 57 INTF_DATA_ENA
95 IO9
IO51 56 8B_REG1_CS
94 IO10
55
EPM7128SQC100-15 IO50
SYSCLK 89 INPUT/GCLK1 IO49 54
B_RESET 91 INPUT/GCLRN
VCCIO;5,20,36,53,68,84
90 INPUT/OE1 R25 R26
C TDI 6
92 INPUT/OE2/GCLK2
TDI GNDIO;13,28,45,61,76,97
VCCINT;41,93
IO48
IO47
52
51
8B_REG2_CS
8B_REG3_CS
1.00K 1.00K
C
TMS 17 TMS GNDINT;40,88 1 TCK
IO46 50 LLD_IRQ
TCK 64 TCK 2
IO45 49 GEN_CONT_STOP_IRQ
TDO 75 TDO 3 TDO
IO44 48 8B_REG4_CS
4
BIT_ADDR_BIT8 16 IO11 LAB E IO43 47 8B_REG5_CS
5 TMS
BIT_ADDR_BIT7 15 IO12 IO42 46 8B_REG6_CS
6
BIT_ADDR_BIT6 14 IO13 IO41 44 8B_REG7_CS
7
BIT_ADDR_BIT5 12 IO14 LAB B IO40 43 8B_REG8_CS
8
BIT_ADDR_BIT4 11 IO15 IO39 42 LLD_LATCH
9 TDI
BIT_ADDR_BIT3 10 IO16
10
LAB C LAB D
J2 R27
1.00K
D BIT_ADDR_BIT0 7 IO19
D
IO20
IO21
IO22
IO23
IO24
IO25
IO26
IO27
IO28
IO29
IO30
IO31
IO32
IO33
IO34
IO35
IO36
IO37
IO38
R28
27
26
25
24
23
22
21
19
18
39
38
37
35
34
33
32
31
30
29
GND GND
O
GND
R5
33
PLD ISP connector

SYSCLK_DIV2 CS2_UART1
PCS[00:03] AS*/PE5
A1
IN B_DATA08
A2 0 CS4_IO_8BIT
A3 1 CS8_IO_16BIT/A21
A4 2 SER_CS
E BIT_ADDR_REG_CS
A5 3 LLD_LOW_BYTE
LLD_HIGH_BYTE
E
BIT_ADDR_BIT10 UART_IOR
BIT_ADDR_BIT9 UART_IOW
R49
SYSCLK_DIV2_X
U30 U53 33
Z_DAC_CS 2 A1 Y1 18 B_Z_DAC_CS SYSCLK_DIV2 2 A1 Y1 18
R51
Z_ADC_CS 4 A2 Y2 16 B_Z_ADC_CS 4 A2 Y2 16 SYSCLK_DIV2_Z
U28 SPI_CS6 6 A3 Y3 14 B_SPI_CS6 6 A3 Y3 14 33

2 A1 Y1 18
SPI_CS7 8 A4 Y4 12 B_SPI_CS7 8 A4 Y4 12 R50
BIT_ADDR_BIT0 4 A2 Y2 16 B_RACK_LOCK_BRAKE_CONTROL SYSCLK_DIV2_Y
G G
33
F BIT_ADDR_BIT1
BIT_ADDR_BIT2
6
8
A3
A4
G
Y3
Y4
14
12
B_PIERCER_LOCK_SOLENOID_CONTROL
B_VENT_SOLENOID_CONTROL 1
MC74ACT244
1
MC74ACT244
F
MC74ACT244
U30 GND
1 PROBE_TYPE_SPI_CS 11 9 B_PROBE_TYPE_SPI_CS
A1 Y1
PROBE_CS 13 A2 Y2 7 B_PROBE_CS
U28 15 A3 Y3 5 MOSI
BIT_ADDR_BIT3 11 A1 Y1 9 B_CTS_PRESSURE_PUMP_CONTROL
17 A4 Y4 3 B_SPI_CLK
BIT_ADDR_BIT4 13 A2 Y2 7 B_CTS_FLUID_PUMP_CONTROL
G
BIT_ADDR_BIT5 15 A3 Y3 5 B_CTS_VACUUM_PUMP_CONTROL MC74ACT244
19
BIT_ADDR_BIT6 17 A4 Y4 3 B_PRESSURE_VAC_SOL_CONTROL
G
MC74ACT244
19
GND
U29
G BIT_ADDR_BIT7
BIT_ADDR_BIT8
BIT_ADDR_BIT9
2
6
A1
A2
A3
Y1
Y2
Y3
18
16
14
B_SPARE_VALVE_CONTROL
B_SYRINGE_PUMP_POWER_ENABLE
G
U29
BIT_ADDR_BIT10 8 A4 Y4 12 B_LLD_ON_OFF MISO 11 A1 Y1 9
G
13 A2 Y2 7
MC74ACT244
15 5
1 A3 Y3 Instrumentation Laboratory
17 A4 Y4 3
G 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
MC74ACT244
19 Title
GND SPI_ENA APPROVALS DATE
DRAWN
GND CHECKED
CONTROLLER BOARD
H
APPROVED

6 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
A
VDD VDD VDD
REFER TO PAGE 1 A
10K RP7 10K RP8 10K RP9
16
16
16
VDD
BDIR_DATA[00:15]
1
10
11
12
13
14
15
10
11
12
13
14
15
10
11
12
13
14
15
A1
IN
A2 8 1D0 VDD 20
SP_BUF1
A3 9 19D1
SP_BUF2
A4 10 18D2
8B_REG5_CS
A5 11 17D3 VSS 10
8B_REG6_CS
B 8B_REG7_CS
8B_REG8_CS
X-Motor Encoder Counter
A6
A7
A8
12
13
14
14D4
13D5
12D6
GND
B
HCTL2016
A9 15 11D7
PLCC-20
U31 U32 SYSCLK_DIV2_X 2CLK
Z_MOT_HOME_SENSE 2 A1 Y1 18
8B_REG5_CS 1 OC BDIR_DATA[00:15] B_X_MOT_ENC_A 9CHA
4 A2 Y2 16 A1
11 G IN B_X_MOT_ENC_B 8CHB
Y_FWD_LIMIT_SENSE 6 A3 Y3 14 Interface Address
B_8B_REG5_IN0 3 1D 1Q 2 8 A2 8B_REG1_OUT4 7RST
Y_REV_LIMIT_SENSE 8 A4 Y4 12 Low Byte 41 High Byte 42
B_8B_REG5_IN1 4 2D 2Q 5 9 A3 B_ADDR00 3SEL
G
MC74ACT244 B_8B_REG5_IN2 7 3D 3Q 6 10 A4 X_MOT_ENC_CS 4OE
1
B_8B_REG5_IN3 8 4D 4Q 9 11 A5
B_8B_REG5_IN4 13 5D 5Q 12 12 A6 U33
B_8B_REG5_IN5 14 6D 6Q 15 13 A7
VDD
U31 B_8B_REG5_IN6 17 7D 7Q 16 14 A8 BDIR_DATA[00:15]
C X_RIGHT_LIMIT_SENSE
X_LEFT_LIMIT_SENSE
11
13
15
A1
A2
A3
Y1
Y2
Y3
9
5
B_8B_REG5_IN7 18 8D
MC74ACT373
8Q 19 15 A9
A1
IN
A2 8 1D0 VDD 20 C
A3 9 19D1
17 A4 Y4 3
A4 10 18D2
G
MC74ACT244 A5 11 17D3 VSS 10
19
A6 12 14D4 GND
A7 13 13D5
Y-Motor Encoder Counter A8 14 12D6
HCTL2016
A9 15 11D7
U34 U35 PLCC-20
TUBE_CAP_SENSE 11 A1 Y1 9 SYSCLK_DIV2_Y 2CLK
8B_REG6_CS 1 OC
TUBE_RELEASE_SENSE 13 A2 Y2 7 A1 B_Y_MOT_ENC_A 9CHA
11 G IN
RACK_LOCK_SOLENOID_SENSE 15 A3 Y3 5 B_Y_MOT_ENC_B 8CHB
B_8B_REG6_IN0 3 1D 1Q 2 8 A2
PIERCE_SOL_LOCK_SENSE 17 A4 Y4 3 Interface Address 8B_REG2_OUT4 7RST
B_8B_REG6_IN1 4 2D 2Q 5 9 A3
G
Low Byte 47 High Byte 48 B_ADDR00 3SEL
D 19
MC74ACT244 B_8B_REG6_IN2
B_8B_REG6_IN3
B_8B_REG6_IN4
7
13
3D
4D
5D
3Q
4Q
5Q
6
12
10
11
12
A4
A5
A6
Y_MOT_ENC_CS 4OE
D
U36
B_8B_REG6_IN5 14 6D 6Q 15 13 A7
B_8B_REG6_IN6 17 7D 7Q 16 14 A8
U34
PROBE_PIC_RESET 2 A1 Y1 18 B_8B_REG6_IN7 18 8D 8Q 19 15 A9 VDD
BDIR_DATA[00:15]
AIR_BUBBLE_DETECT 4 A2 Y2 16 MC74ACT373 A1
IN
6 A3 Y3 14
A2 8 1D0 VDD 20
8 A4 Y4 12
A3 9 19D1
G
MC74ACT244 A4 10 18D2
1
A5 11 17D3 VSS 10
A6 12 14D4 GND
A7 13 13D5
E VENT_SOLENOID_SENSE 2
4
A1
A2
U37
Y1
Y2
18
16 8B_REG7_CS 1 OC
U38
Z-Motor Encoder Counter
A8
A9
SYSCLK_DIV2_Z
14
15
12D6
11D7
2CLK
HCTL2016
PLCC-20
E
A1
FLUID_PUMP_SENSE 6 A3 Y3 14 11 G IN B_Z_MOT_ENC_A 9CHA
8 A4 Y4 12 B_8B_REG7_IN0 3 1D 1Q 2 8 A2 Interface Address B_Z_MOT_ENC_B 8CHB

G
B_8B_REG7_IN1 4 2D 2Q 5 9 A3 Low Byte 4D High Byte 4E 8B_REG3_OUT4 7RST
MC74ACT244
1 B_8B_REG7_IN2 7 6 10 A4 B_ADDR00 3SEL
3D 3Q
B_8B_REG7_IN3 8 4D 4Q 9 11 A5 Z_MOT_ENC_CS 4OE
B_8B_REG7_IN4 13 5D 5Q 12 12 A6
B_8B_REG7_IN5 14 6D 6Q 15 13 A7 U39
U37 B_8B_REG7_IN6 17 7D 7Q 16 14 A8
11 A1 Y1 9
B_8B_REG7_IN7 18 8D 8Q 19 15 A9
13 A2 Y2 7
MC74ACT373
GENERAL_CONTROLLED_STOP_IRQ1 15 A3 Y3 5 U41
2 A1 Y1 18 B_X_MOT_ENC_A
F GENERAL_CONTROLLED_STOP_IRQ2 17 A4
G
19
Y4 3
MC74ACT244 Y_MOT_ENC_A
4
6
A2
A3
Y2
Y3
16
14
B_X_MOT_ENC_B
B_Y_MOT_ENC_A F
Y_MOT_ENC_B 8 A4 Y4 12 B_Y_MOT_ENC_B
G
WHITE TEST POINTS MC74ACT244
1
TP9 TP10 TP11 TP12

U40
GND U41
8B_REG8_CS 1 OC Z_MOT_ENC_A 11 A1 Y1 9 B_Z_MOT_ENC_A
A1
11 G IN Z_MOT_ENC_B 13 A2 Y2 7 B_Z_MOT_ENC_B
3 1D 1Q 2 8 A2 SP_BUF1 15 A3 Y3 5
4 2D 2Q 5 9 A3 SP_BUF2 17 A4 Y4 3
G
7 3D 3Q 6 10 A4
MC74ACT244
8 9 11 A5 19
4D 4Q
13 5D 5Q 12 12 A6
G 14
17
18
6D
7D
8D
6Q
7Q
8Q
15
16
19
13
14
15
A7
A8
A9
GND
G
MC74ACT373
4
REFDES=SW2 Instrumentation Laboratory

D
Title
APPROVALS DATE
5
DRAWN
CHECKED
CONTROLLER BOARD
GND
H
APPROVED

7 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
Inverter on motor enable signal REV DESCRIPTION BY CHECKED APPROVED DATE

U2
A 9 8
allows for active low enable
signal on the driver board. REFER TO PAGE 1 A
MC74ACT04
U43
B_DATA[00:15] 8B_REG1_OUT[0:7] 2 A1 Y1 18
A1 A1 A1
IN
U42 IN IN 4 A2 Y2 16
A2 8 3 1D 1Q 2 0 A2 A2 0 6 A3 Y3 14
A3 9 4 2D 2Q 5 1 A3 A3 1 8 A4 Y4 12 X_MOT_ENABLE
G
A4 10 7 3D 3Q 6 2 A4 A4 2 X_MOT_HALF/FULL
MC74ACT244
A5 11 8 9 3 A5 A5 3 1 X_MOT_CW/CCW
4D 4Q
A6 12 13 5D 5Q 12 4 A6 A6 4 8B_REG1_OUT4 X_MOT_RESET L297 & ON BOARD ENCODER 1 /RESET
A7 13 14 6D 6Q 15 5 A7 A7 5 X_MOT_HOLD_CURRENT
U43
A8 14 17 7D 7Q 16 6 A8 A8 6 11 A1 Y1 9
A9 15 18 8D 8Q 19 7 A9 A9 7 13 A2 Y2 7
CLK
CLR 15 A3 Y3 5
B 8B_REG1_CS
11 1
MC74ACT273
B_RESET
17 A4
G
Y4 3
MC74ACT244
VDD
B
19
B_RESET U2
11 10
5 10
MC74ACT04
U45
8B_REG2_OUT[0:7] 2 A1 Y1 18
A1 A1 A1
IN
U44 IN IN 4 A2 Y2 16
A2 8 3 1D 1Q 2 0 A2 A2 0 6 A3 Y3 14
4.7K
A3 9 4 5 1 A3 A3 1 8 12 Y_MOT_ENABLE 9 8 7 6 4 3 2 1
2D 2Q A4 Y4
RP11
G
A4 10 7 3D 3Q 6 2 A4 A4 2 Y_MOT_HALF/FULL
MC74ACT244
A5 11 8 9 3 A5 A5 3 1 Y_MOT_CW/CCW
4D 4Q
A6 12 13 5D 5Q 12 4 A6 A6 4 8B_REG2_OUT4 Y_MOT_RESET L297 & ON BOARD ENCODER 2 /RESET
C A7
A8
A9
13
14
15
14
17
18
6D
7D
8D
6Q
7Q
8Q
15
16
19
5
7
A7
A8
A9
A7
A8
A9
5
7
11
13
A1
A2
U45
Y1
Y2
9
7
Y_MOT_HOLD_CURRENT
BDIR_DATA[00:15]
C
CLK A1
CLR 15 A3 Y3 5 U55 IN
MC74ACT273
11 1 17 3 LLD_FREQUENCY_IN 1 19 8 A2
A4 Y4 CLKA Y0
G
B_RESET 2 CLKB Y1 18 9 A3
8B_REG2_CS MC74ACT244
19 LLD_LOW_BYTE 3 17 10 A4
GAL Y2
LLD_HIGH_BYTE 4 GAU Y3 16 11 A5
5 GBL Y4 15 12 A6
6 GBU Y5 14 13 A7
U47
8B_REG3_OUT[0:7] 2 A1 Y1 18 LLD_LATCH 7 RCLK Y6 13 14 A8
A1 A1 A1
IN
U46 IN IN 4 A2 Y2 16 8 RCOA Y7 12 15 A9
A2 8 3 1D 1Q 2 0 A2 A2 0 6 A3 Y3 14 9 BEN CLR 11 LLD_CNTR_CLR
A3 9 4 2D 2Q 5 1 A3 A3 1 8 A4 Y4 12 Z_MOT_ENABLE
G 74LV8154
D A4
A5
A6
10
11
12
7
13
3D
4D
5D
3Q
4Q
5Q
6
12
2
4
A4
A5
A6
A4
A5
A6
2
4 8B_REG3_OUT4
1
MC74ACT244
Z_MOT_SLEEP
Z_MOT_CW/CCW
Z_MOT_RESET
ON BOARD ENCODER 3 /RESET
D
A7 13 14 6D 6Q 15 5 A7 A7 5
U47
A8 14 17 7D 7Q 16 6 A8 A8 6 11 A1 Y1 9 Z_MICRO_CONT_1
A9 15 18 8D 8Q 19 7 A9 A9 7 13 A2 Y2 7 Z_MICRO_CONT_2
CLK
CLR 15 A3 Y3 5 VDD
MC74ACT273
11 1 17 3
A4 Y4
G
B_RESET
8B_REG3_CS MC74ACT244
19
R57
4.99K
U54
U49
8B_REG4_OUT[0:7] 11 A1 Y1 9
E A1
IN
A2 8 3 1D
U48
1Q 2 0 A2
A1
IN
A1
IN
A2 0
13
15
A2
A3
Y2
Y3
7
5
LED_DISPLAY_A
LED_DISPLAY_B
7
1
A
B
AA 13
AB 12
E
A3 9 4 2D 2Q 5 1 A3 A3 1 17 A4 Y4 3 LED_DISPLAY_C 2 C AC 11
G
A4 10 7 3D 3Q 6 2 A4 A4 2 LED_DISPLAY_D 6 D AD 10
MC74ACT244
A5 11 8 9 3 A5 A5 3 19 B_RESET 3 9
4D 4Q LT AE
A6 12 13 5D 5Q 12 4 A6 A6 4 4 BI AF 15
A7 13 14 6D 6Q 15 5 A7 A7 5 5 LE AG 14 VDD
U49
A8 14 17 7D 7Q 16 6 A8 A8 6 2 A1 Y1 18 PROBE_PIC_RESET_CONTROL
CD4511BNSR
A9 15 18 8D 8Q 19 7 A9 A9 7 4 A2 Y2 16
CLK
CLR 6 A3 Y3 14 GND
14 13 12 11 10 9 8
MC74ACT273 RP10
11 1 8 12
A4 Y4
470 R58
G
8B_REG4_CS
MC74ACT244 475
1
F VDD
1 2 3 4 5 6 7
3
8
10
GND
AA
AD
AE
AF
AG
AB
AC
R29 R30 R31 R32 ADP 7
3.01K 3.01K 3.01K 3.01K CDP 6 HEARTBEAT_LED
CC
LED4
9
LED6 LED7 LED8 LED9
GREEN RED GREEN GREEN
GND
HEARTBEAT ERROR TEST1 TEST2
U50
G A1
IN
A2 8 13 D
Q0
Q1
4
5
LED_DISPLAY_A
LED_DISPLAY_B G
BIT_ADDR_REG_CS 14 G Q2 6 LED_DISPLAY_C
Q3 7 LED_DISPLAY_D
B_ADDR00 1 S0 Q4 9 HEARTBEAT_LED
B_ADDR01 2 S1 Q5 10 ERROR_LED Instrumentation Laboratory

B_ADDR02 3 S2 Q6 11 TESTPOINT1
Q7 12 TESTPOINT2
CLR
Title
MC74ACT259
15 APPROVALS DATE
DRAWN
CHECKED
CONTROLLER BOARD
H
APPROVED

8 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
A Debug CAN
REFER TO PAGE 1 A
To Y Motor Driver Board
CAN_H
+24V
1 R33
2 DNP
3
4 CAN_L 1
To Z Motor Driver Board
2 B_PROBE_PWM_HEAT_2
J3 VDD +24V
GND 3
4 B_PROBE_PWM_HEAT_1
B 5
7 X_LEFT_LIMIT_SENSE
B
1
8
2
9 X_RIGHT_LIMIT_SENSE
3 Z_MOT_SLEEP
10
4
11 B_PROBE_PIC_RESET
5 Z_MOT_RESET
12 PROBE_DC_HEATER_2
To X Motor Driver Board 6 B_PROBE_TYPE_SPI_CS
7 Z_MOT_ENABLE
+24V 14 PROBE_DC_HEATER_2
8
+15V 15 PROBE_DC_HEATER_2
9 TUBE_CAP_SENSE
VDD 16
10
17
11 Z_MOT_CW/CCW
C 1 B_CTS_FLUID_PUMP_CONTROL
19
20
PROBE_DC_HEATER_1
PROBE_DC_HEATER_1
12
13
14
PIERCE_SOL_LOCK_SENSE
C
2 CAN_L 21 PROBE_DC_HEATER_1
15 Z_MOT_CLK
3 22
16
4 CAN_H 23
17
5 B_HEARTBEAT_LED 24
18 B_PROBE_CS
6 25
19 Z_MICRO_CONT_1
7 26
20
8 RS232_RX 27
21 Z_MICRO_CONT_2
9 X_MOT_RESET 28
22 PROBE_PIC_RESET_CONTROL
10 RS232_TX
23
11 J5
24 B_Z_ADC_CS
12
1
25 B_SPARE_VALVE_CONTROL
13 GENERAL_CONTROLLED_STOP_IRQ2 P CGND
D 14
15
26
27
28
B_VENT_SOLENOID_CONTROL
PROBE_LLD_FREQ_DIF_A
D
16 GENERAL_CONTROLLED_STOP_IRQ1
29 RACK_LOCK_SOLENOID_SENSE
17 B_CTS_VACUUM_PUMP_CONTROL
30 PROBE_LLD_FREQ_DIF_B
18
To Y Motor Driver Board 31 TUBE_RELEASE_SENSE
19
32
20 B_CTS_PRESSURE_PUMP_CONTROL
VDD 33 B_Z_DAC_CS
21 B_PRESSURE_VAC_SOL_CONTROL
34 SPI_DATA_IN_DIF_A
22
35
23
36 SPI_DATA_IN_DIF_B
24 FLUID_PUMP_SENSE
37 Z_MOT_HOME_SENSE
25 J6
38
26 Y_INDEX
20 39
E 27
28
29
19
18
Y_FWD_LIMIT_SENSE
Y_REV_LIMIT_SENSE
40
41
SPI_CLK_DIF_A
Z_MOTOR_STEP_SIZE_SYNC
E
17 42 SPI_CLK_DIF_B
30
16 43
31 Y_MOT_HOLD_CURRENT
15 44
32 Y_MOT_RESET
14 45 Z_MOT_ENC_A
33
13 46 SPI_DATA_OUT_DIF_A
34 X_MOT_HOLD_CURRENT Y_MOT_HALF/FULL
12 47 Z_MOT_ENC_B
35
11 48 SPI_DATA_OUT_DIF_B
36 Y_MOT_ENABLE
10 49
37 X_MOT_ENC_B
9 50 B_PIERCER_LOCK_SOLENOID_CONTROL
38 B_ERROR_LED Y_MOT_CLK
8 51 PROBE_PWM_HEAT_1
39
7 52 B_RACK_LOCK_BRAKE_CONTROL
40 Y_MOT_ENC_B
6
F 41
42
X_MOT_ENC_A
X_MOT_CLK
5
4
Y_MOT_ENC_A
53
54
55
PROBE_DC_HEATER_1
PROBE_PWM_HEAT_2
F
43 PRESSURE_VACUMM_PUMP_SENSE
3 56 PROBE_DC_HEATER_1
44
2 57
45 B_SYRINGE_PUMP_POWER_ENABLE Y_MOT_CW/CCW
1 58 PROBE_DC_HEATER_2
46 X_MOT_ENABLE
VDD 59
47
48
49 X_MOT_CW/CCW J7
50 X_MOT_HALF/FULL R60
10K GND
J4
1
GND U51 P CGND
PROBE_PWM_HEAT_1 2 A1 Y1 18 B_PROBE_PWM_HEAT_1
SPARE1 4 16
A2 Y2
G A
VDD
PROBE_PWM_HEAT_2
PROBE_PIC_RESET
6
8
A3
A4
G
Y3
Y4
14
12
B_PROBE_PWM_HEAT_2
B_PROBE_PIC_RESET G
P
1
MC74ACT244
1
CGND
GND
R62 R61 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
10K 10K
U51 Title
SPARE2 11 A1 Y1 9
APPROVALS DATE
SPARE3 13 A2 Y2 7
DRAWN
HEARTBEAT_LED 15 A3 Y3 5 B_HEARTBEAT_LED Brian Walker 7/06/04 UNIVERSAL ARM
ERROR_LED 17 3 B_ERROR_LED CHECKED
A4
G
Y4 CONTROLLER BOARD
H
19
GND
MC74ACT244 APPROVED

9 of 9
H
D 286301-00 1 SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-73 Y Axis U Arm PCB (Drawing # 28631100, 1 of 2)

1 2 3 4 5 6 7 8
REVISIONS
A 0 RELEASED PER CO L18074 D.COX 15MAR05 A

+5V
To Interface Connector Board
J6
Y_MOT_CW/CCW
20
19
PRESSURE_PUMP_SENSE
18
17
B_Y_ENC_A
16
B 15
14
B_Y_ENC_B
Y_MOT_CLK
+5V
B
13 +5V +24V
12
Y_MOT_ENABLE
11 C23
0.1UF
10 C6
Y_MOT_HALF/FULL 0.1UF
9
8 10 5 Tantalum Cap size A 35V

Y_MOT_RESET
7
C26
Y_MOT_HOLD_CURRENT U5 +24V P
6 Y_MOT_HALF/FULL 2 18 B_HALF/FULL 0.22UF
A1 Y1
4.7K +5V
5 Y_MOT_HOLD_CURRENT 4 16 B_Y_MOT_HOLD_CURRENT
A2 Y2 10NF
B_Y_HOME_REV_LIMIT U2
4 1 2 3 4 6 7 8 9 INDEX 6 14 B_INDEX 5
A3 Y3 C13
B_Y_FOW_END_TRAVEL 15
3 VS_1 VREF
R20 PROBE_PIC_RESET 8 A4 Y4 12 B_PROBE_PIC_RESET P
8 7
2 G IN1 BOOT1
C 1
B_INDEX
1
SN74ACT244
C19
0.1UF
13
17
1
IN2
ENABLE
OUT1
OUT2
6
4
R4
C
GND1
10
10NF 1.8
14
GND2 BOOT2 C15 To Y Axis Motor
11
+5V 16
GND3 SENSE
20 CON8L
10NF
B_Y_MOT_CLK 18 P18 A 4 GND4
U5 19 P19 L297 B 6 C11
Y_MOT_RESET 11 A1 Y1 9 B_Y_MOT_RESET
B_Y_MOT_ENABLE 10 P10 INH1 5 L6201P_A 1
R11
Y_MOT_CW/CCW 13 A2 Y2 7 B_Y_MOT_CW/CCW
B_Y_MOT_RESET 20 P20 SEN1 14 SENS_1 SENS_1 2
Y_ENC_A 15 A3 Y3 5 B_Y_ENC_A 10K
B_Y_MOT_CW/CCW 17 P17 C 7 3
Y_ENC_B 17 A4 Y4 3 B_Y_ENC_B
CONTROL 11 P11 D 9 4
G R9
INH2 8 Panasonic Type PRX2W2.22CT 5
SN74ACT244
19
+5V OSC_L297 16 OSC SEN2 13 SENS_2 0.22 +24V 6
VREF_L297 15 VREF SYNC 1 SYNC 7
D To ARM Controller Interface Board

R10
HOME
U4
3
C21
0.1UF
Tantalum Cap size A 35V
R3
8
J2
D
C18 P
1.8
+24V 10K 0.01UF C27
+24V 0.22UF
10NF
1 P
U3
0.01UF C12
21khz
2 5
15
VS_1 VREF C14
3 P
8 7 P
IN1 BOOT1
4
C8 13 6
6.8NF IN2 OUT1
5
17 4
ENABLE OUT2
6 1
GND1
7 10
0.01UF
14
GND2 BOOT2
8 11
16 C9
GND3 SENSE
9 PROBE_HEATER_1 20
1
E 10
11
TH1 TH2
GND4
L6201P_A
E
12
13 Test Equipment Connector Header SENS_2

P
14 PROBE_HEATER_2
R5
15 VREF_L297 1
Panasonic Type PRX2W2.22CT
16 VREF 2
1
0.22
17 3
+24V
18 PROBE_PIC_RESET SYNC 4
19 5 P
20 B_X_RIGHT_LIMIT
+5V TP7 TP1
21 1
1
N/C N/C 8
22 B_X_LEFT_LIMIT 2 P J7
C20 VIN N/C 7
F 23
24
25 PROBE_PWM_HEAT_1
0.1UF
3
4
TEMP
GND
VOUT
TRIM
6
5
VREF
VDD
F
C5
C39 C38 C37 C28
26 U6
47UF 47UF 47UF 10UF C10
0.1UF
27 PROBE_PWM_HEAT_2 0.1UF
R8
28
P 100K
P TP3
J5
1
+24V
Running Power ~ 1.73A

P VREF_L297 Vref L297 ~ 0..381V
Holding Power ~ 0.517A

Vref L297 ~ 0.114V
+24V
C16
R7
0.1UF
8.25K TP5 TP6
1
G P
G
4
V+ P
5 8 C36 C33 C32 C31 C30 C29 C34 C35 C17
VL D 100UF 100UF 100UF 100UF 68UF 68UF 100UF 100UF 0.1UF
B_Y_MOT_HOLD_CURRENT 6 1
IN S
3
GND N/C 2 Instrumentation Laboratory
7 V-
R6
3.24K P Title
DG417
U7 APPROVALS DATE
DRAWN SCHEMATIC,
P
P Saverio Ratta 01/10/05
CHECKED Y DRIVER BD,
UNIVERSAL ARM
H
APPROVED

1 of 2
H
D 286311-00 0 SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-74 Y Axis U Arm PCB (Drawing # 28631100, 2of 2)

1 2 3 4 5 6 7 8
REVISIONS
A TO PRESSURE PUMP SENSOR

+5V
SEE SHEET 1 A
LEFT_LIMIT_OPTICAL SENSOR RIGHT_LIMIT_OPTICAL SENSOR
J3
1 PS_OFFSET_ADJ
VDD VDD
2
3 PRESSURE_PUMP_SENSE
R12 R14
121 121
B OPT1
VREF
3
VCC
OPT2
VREF
3
VCC B
Y Foward End of Travel Connector 1 A 1 A
VOUT 4 X_LEFT_LIMIT VOUT 4 X_RIGHT_LIMIT

+5V
+24V
2 K GND 5 2 K GND 5
R18
GND GND GND GND
120
1
3 Y_FOW_END_TRAVEL R2
4
R25 22.1K
C 5
2.2K
2 D2 C4 C2 C
+5V 1/2 Watt
J4 100UF 100UF
L1
1
+5V LED2 TP4
P 1 PROBE_HEATER_1
560UH
10 5 2
C24
D
0.1UF U8
B_PWM_HEAT_1 4
To Y- Reverse HOME Limit Sensor 4.7K 6 G
B_PROBE_PIC_RESET 5 1
VDD 1 2 3 4 6 7 8 9 S
SN74ACT08
R21 IRLR024N
3
D 2
4
A1
A2
U1
Y1
Y2
18
16
FET2
D
CON6L PROBE_PWM_HEAT_1 6 A3 Y3 14 B_PWM_HEAT_1
R22
P
120 PROBE_PWM_HEAT_2 8 12 B_PWM_HEAT_2
A4 Y4
+5V
G
1
SN74ACT240
1
2
Y_HOME_REV_LIMIT
3 +24V
4
C7
5 0.1UF
+5V
6
GND
U1
J8 Y_MOT_CLK 11 9 B_Y_MOT_CLK
A1 Y1 R19
E Y_MOT_ENABLE 13
15
A2
A3
Y2
Y3
7
5
B_Y_MOT_ENABLE 2.87K R26
2.2K
R1
22.1K
E
Y_MOT_HOLD_CURRENT 17 A4 Y4 3 2 D1
G
1/2 Watt 2 C3 C1
SN74ACT240 Full Power
19
To Y Motor Encoder
LED5
/Hold Power LED 100UF 100UF
1
TP2
+5V +5V 1 P LED1 L2

1 PROBE_HEATER_2
560UH
CON6L
2
D
U8
1 10 5 B_PWM_HEAT_2 1
Y_ENC_A 3 G
2 B_PROBE_PIC_RESET 2 1
Y_ENC_B
3
F 4
5
4.7K
1 2 3 4 6 7 8 9
SN74ACT08
IRLR024N
S
3
FET1
F
INDEX
6 R23
U9
X_RIGHT_LIMIT 2 A1 Y1 18 B_X_RIGHT_LIMIT
J1 X_LEFT_LIMIT 4 16 B_X_LEFT_LIMIT P
A2 Y2
6 A3 Y3 14 +5V
8 A4 Y4 12
G
+5V SN74ACT244
1
C25
+5V +24V
0.1UF
+5V
G R24
10 5
C22
Y_FOW_END_TRAVEL 11 A1
U9
Y1 9 B_Y_FOW_END_TRAVEL
2.87K
R16
22.1K
R17
G
4.7K 0.1UF Y_HOME_REV_LIMIT 13 7
A2 Y2 B_Y_HOME_REV_LIMIT 2 2
15 A3 Y3 5
1 2 3 4 6 7 8 9
17 3
A4
G
Y4
LED3 LED4
U8 SN74ACT244
9 19 1 1 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
8
10
Title
SN74ACT08
P APPROVALS DATE
U8 DRAWN SCHEMATIC,
12
11 Saverio Ratta 12/10/04
13 CHECKED Y DRIVER BD,
SN74ACT08
UNIVERSAL ARM
H
APPROVED

2 of 2
H
D 286311-00 0 SCALE
N/A
1 2 3 4 5 6 7 8

Figure 16-75 Z Driver PCB (Drawing # 28633100, Sheet 1 of 3)

1 2 3 4 5 6 7 8
REVISIONS
+5V
A To CTS Controller Interface Board

Z_HOME_SENSOR
+5V
0 RELEASED PER CO L18255 D.COX 26MAY05 A
0A ADDED VREF TO ADC CIRCUITRY (PROTOTYPE)
+5V +24V
10 5
4.7K
RP5
1 2 3 4 6 7 8 9
1
R28
2
120 PROBE_PWM_HEAT_1 To Heated Probe Board
3
PROBE_PWM_HEAT_2
4 Z_MOT_SLEEP
5 PROBE_TYPE_SPI_CS
Z_ADC_CS
6 Z_MOT_RESET 1
B 7
8 Z_MOT_ENABLE
2
3 Z_MOT_HOME_SENSE
TUBE_CAP_SENSE
Z_DAC_CS PRB+24V
TP5
+24V
1
PIERCE_SOL_LOCK_SENSE
9 4
PIERCER_POSITION_SENSE
10 TUBE_CAP_SENSE 5
1
11 PIERCE_SOL_LOCK_SENSE
J4 2
12 Z_MOT_CW/CCW
3
13 To CTS Probe / Sensor Board
4
14
+24V +5V 5
15
+5V 6
16 Z_MOT_CLK
PROBE_DC_HEATER_1 7
17 PROBE_CS F1
MOTOR ENCODER PROBE_DC_HEATER_1 8
18
+5V PROBE_DC_HEATER_1 9
19 J3
3.0A 1 PROBE_DC_HEATER_1 10
C 20
21
22
Z_MICRO_CONT_1
PROBE_PIC_RESET
Z_MICRO_CONT_2
2
3
11
12 C
1 4 PROBE_PWM_HEAT_1 13
23 Z_ADC_CS
2 5 14
24
3 Z_MOT_ENC_A 6 15
25 TP6
4 Z_MOT_ENC_B 7 B_SPI_DATA_IN 16
1
26 SPARE_VALVE_CONTROL
5 8 17
27 PROBE_LLD_FREQ_DIF_A
6 PIERCER_LOCK_SOLENOID_CONT 9 18
28 VENT_SOLENOID_CONTROL
J5 10 B_SPI_DATA_OUT 19
29 PROBE_LLD_FREQ_DIF_B
B_SPI_DATA_OUT 11 20
30 PIERCER_POSITION_SENSE +24V PRB+24V
12 21
31
B_SPI_DATA_IN 13 PROBE_PIC_RESET 22
32 B_TUBE_RELEASE_SENSE
14 PROBE_LLD_FREQ 23
33 SPI_DATA_IN_DIF_A
B_SPI_CLK 15 24
D 34
35
36
Z_DAC_CS
SPI_DATA_IN_DIF_B
TUBE_CAP_SENSE
16
17 Not used Probe reset

25
26
D
PIERCER_POSITION_SENSE 18 27
37
R7 R8 R9 R10 PIERCE_SOL_LOCK_SENSE 19 B_PROBE_CS 28
38 B_Z_MOT_HOME_SENSE
8.2 8.2 8.2 8.2 20 29
39 SPI_CLK_DIF_A
1 Watt 1 Watt 1 Watt 1 Watt B_PROBE_TYPE_SPI_CS 21 30
40
22 B_SPI_CLK 31
41 SPI_CLK_DIF_B
PROBE_LLD_FREQ 23 32
42 B_STEP_SIZE_CHANGE_SYNC
24 33
43
PROBE_PWM_HEAT_2 34
44
R11 R12 R13 R14 35
45 SPI_DATA_OUT_DIF_A
1
8.2 8.2 8.2 8.2 36
46 B_Z_MOT_ENC_A CGND P
1 Watt 1 Watt 1 Watt 1 Watt PROBE_DC_HEATER_2 37
47 SPI_DATA_OUT_DIF_B
E 48
49
B_Z_MOT_ENC_B
PIERCER_LOCK_SOLENOID_CONT
+5V VDD
+5V
PROBE_DC_HEATER_2
PROBE_DC_HEATER_2
PROBE_DC_HEATER_2
38
39
40
E
50
P J1
51 RACK_LOCK_BRAKE_CONT TP3
1
52 PROBE_PWM_HEAT_1 TP1
1
54
R18
55 PROBE_DC_HEATER_1 Rack Lock Brake Connector
3.01K
56 PROBE_PWM_HEAT_2 +24V
58
C1 C12 C16 C17 C22 C25 C26 C27 C28 C29 C30 2
59 PROBE_DC_HEATER_2 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF
33UF
60
U7 U12 U4 U2 U8 U9 U3 U11 U10 U1 LED2
F J2
1 RACK_LOCK_BRAKE_PWR
1
2 F
1
P CGND J8
Note: +24V
+24V
Vent Solenoid Connector
+24V
TP4 TP2
Mounting holes for the
1
board are to be plated 1
VENT_SOLENOID_PWR
and attached to the R19 2
22.1K 3
G CGND net on the board.

C20 C21 C2 C3 C4 C5 C6 C19 C23 C31
SPARE_SOLENOID_PWR
4
J9
G
2
47UF 47UF 33UF 33UF 33UF 33UF 0.1UF 0.1UF 0.1UF 0.1UF
U7 U7 U7 U7 U5 U13 LED3
1
Title
P APPROVALS DATE
P DRAWN
CTS / Universal Arm
Brian Walker 02/23/05
CHECKED
Z Driver Board
H
APPROVED

1 of 3
H
D 286331-00 0A SCALE
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
+5V
A SEE SHEET 1 A
10 5
4.7K
RP1 1 2 3 4 6 7 8 9
U2
Z_MOT_CLK 2 A1 Y1 18 B_Z_MOT_CLK
U12
Z_MOT_CW/CCW 4 A2 Y2 16 B_Z_MOT_CW/CCW SPI_CLK 2 A1 Y1 18 B_SPI_CLK
Z_MICRO_CONT_1 6 A3 Y3 14 B_Z_MICRO_CONT_1 SPI_DATA_IN 4 A2 Y2 16 B_SPI_DATA_IN
B Z_MICRO_CONT_2 8 A4
G
1
Y4 12
SN74ACT244
B_Z_MICRO_CONT_2 Z_ADC_CS
Z_DAC_CS
6
8
A3
A4
G
Y3
Y4
14
12
B_Z_ADC_CS
B_Z_DAC_CS
B
SN74ACT244
1
U2
STEP_SIZE_CHANGE_SYNC 11 A1 Y1 9 B_STEP_SIZE_CHANGE_SYNC
U12
Z_MOT_ENABLE 13 A2 Y2 7 B_Z_MOT_ENABLE SPI_DATA_OUT 11 A1 Y1 9 B_SPI_DATA_OUT
Z_MOT_RESET 15 A3 Y3 5 B_Z_MOT_RESET 13 A2 Y2 7
Z_MOT_SLEEP 17 A4 Y4 3 B_Z_MOT_SLEEP 15 A3 Y3 5
G
17 A4 Y4 3
SN74ACT244 G
19
SN74ACT244
19
C C
Z_ADC_CS
+24V
+5V +24V
C13
0.22UF Optional Diodes
D 1 1 1 1
Assist in decreasing
Dissipation of Driver Device D

P
D7 D6 D5 D4
20
10
28
15
U7
VREG
LOGIC_SUPPLY
LOAD_SUPPLY1
LOAD_SUPPLY2
B_Z_MOT_CLK 19 STEP 2 2 2 2
B_Z_MOT_CW/CCW 3 DIR
HOME 2 STEP_SIZE_CHANGE_SYNC J6
Blanking Time set to 1
1.4 Microseconds B_Z_MOT_SLEEP 27 SLEEP 2
OUT1A 4 Z-MOT_A
6 RC1 3
OUT1B 25 Z_MOT_/A
9 RC2 4
5 PFD 5
OUT2A 11 Z-MOT_B
6
18 Z_MOT_/B
B_Z_MOT_ENABLE 26 A3977TSSOP OUT2B
7
R29 C9 ENABLE
E 30.1K 0.001UF
30.1K
R30 C10
0.001UF
R31
0
B_Z_MOT_RESET
B_Z_MICRO_CONT_1
B_Z_MICRO_CONT_2
17
13
12
RESET
MS1
SENSE1 1
1 1 1 1
8
To Z Motor
E
MS2 D8 D3 D2 D1
8 REF SENSE_2 14 8 Pin Dual Row
16 2 2 2 2
SR
+5V
R1 R2
AGND
PGND
VCP
CP1
CP2
C14
R3 R4 0.39 0.39
7
21
22
23
24
C15 0.22UF
+24V 1 Watt 5% 1 Watt 5%
P 0.39 0.39
0.22UF
1 Watt 5% 1 Watt 5%
R6 P
4.75K C11
C7 0.22UF
F P
0.22UF P
F
TP7
Populate to activate
Synchronous Rectification
(No Diodes Installed)
P Current setting 1.85A per Phase Note:
R5 When Vref = 3.478V
1
0 If disabled insure extenal Motor driver design allows for 2.5A

Diodes are used with motor
worth of power inorder to facilitate
the peircing of a cap in microstep mode.
If motor driver is allowed to run full
+5V power in full step mode, the attached
+5V_REF
+24V motor will over-heat, ruining the motor.
This is not a design issue but rather a
G B_SPI_CLK
B_SPI_DATA_IN
1
2
U4
CLK
DIN
VDD
VOUT
8
7
R20 1
2
U6
VREF
IN+
VDD
CLK
8
7 B_SPI_CLK
+5V_REF warning to the potential in case it was G
B_Z_DAC_CS 3 CS REF 6 3 IN- DOUT 6 SPI_DATA_OUT 1 N/C N/C 8 to happen.
4.75K
4 DOUT GND 5 4 VSS CS 5 B_Z_ADC_CS 2 VIN N/C 7
LTC1451 MCP3201 3 TEMP VOUT 6

C18 Instrumentation Laboratory
4 GND TRIM 5 0.1UF
U13 U6
Title
APPROVALS DATE
DRAWN
CTS / Universal Arm
CHECKED
Z Driver Board
H
APPROVED

2 of 3
H
D 286331-00 0A SCALE
1 2 3 4 5 6 7 8


1 2 3 4 5 6 7 8
REVISIONS
+5V
+5V REV DESCRIPTION BY CHECKED APPROVED DATE
A SEE SHEET 1 A
10 5
10 5
4.7K
4.7K
RP3
RP2 1 2 3 4 6 7 8 9
1 2 3 4 6 7 8 9
5
RS485_PUP1 6 D2
RS485_PUP2
U3 RS485_PUP3 G
PROBE_TYPE_SPI_CS 2 A1 Y1 18 B_PROBE_TYPE_SPI_CS B_FET_CONTROL 4
RS485_PUP4 S
PROBE_CS 4 A2 Y2 16 B_PROBE_CS
3
B 6
8
A3
A4
G
Y3
Y4
14
12 +5V
B_SPARE_VALVE_CONTROL
B_FET_CONTROL
IRF7103
Q2 B
SN74ACT244 B_RACK_LOCK_BRAKE_CONT
1 P
+24V
+5V
U3 R17
Z_MOT_ENC_A 11 A1 Y1 9 B_Z_MOT_ENC_A
4.75K 1
Z_MOT_ENC_B 13 A2 Y2 7 B_Z_MOT_ENC_B
Z_MOT_HOME_SENSE 15 A3 Y3 5 B_Z_MOT_HOME_SENSE
TUBE_RELEASE_SENSE 17 3 B_TUBE_RELEASE_SENSE
D12
A4 Y4 LTC485
SPI_DATA_OUT_DIF_B
8
G
VCC
2
SN74ACT244
19
C RS485_PUP3
RS485_PUP3
2
3
RE
RO
DE
R
B 7
R22
SPARE_SOLENOID_PWR
C
D
+5V B_SPI_DATA_OUT 4 DI A 6 121
D
7
GND 8 D2
5
U8
SPI_DATA_OUT_DIF_A
G
B_SPARE_VALVE_CONTROL 2
S
1
10 5
IRF7103
Q2
4.7K
P
RP4
1 2 3 4 6 7 8 9
+24V
D U1
+5V
D
2 A1 Y1 18
1
4 A2 Y2 16
6 A3 Y3 14 LTC485
SPI_DATA_IN_DIF_B D11
8
8 A4 Y4 12 B_FET_CONTROL VCC
G
2 RE
2
SN74ACT240 R
1 SPI_DATA_IN 1 RO B 7
3 DE R21 VENT_SOLENOID_PWR
D
RS485_PUP1 4 DI A 6 121
GND
5
D
7
U9
U1 8 D2
SPI_DATA_IN_DIF_A
SPARE_VALVE_CONTROL 11 A1 Y1 9 B_SPARE_VALVE_CONTROL
E VENT_SOLENOID_CONTROL
RACK_LOCK_BRAKE_CONT
13
15
17
A2
A3
A4
Y2
Y3
Y4
7
3
B_RACK_LOCK_BRAKE_CONT
B_VENT_SOLENOID_CONTROL 2
G
1
S E
G
IRF7103
SN74ACT240 Q1
19
+5V
+24V
LTC485
SPI_CLK_DIF_B
8
VCC
1
2 RE
R
D10
F SPI_CLK
RS485_PUP2
1
4
RO
DE
DI
D
B 7
A 6
R26
121 2 F
GND
5
U10 RACK_LOCK_BRAKE_PWR
SPI_CLK_DIF_A
5
6 D2
G
B_RACK_LOCK_BRAKE_CONT 4
S
3
IRF7103
Q1
+5V
G P
G
LTC485
PROBE_LLD_FREQ_DIF_B
8
VCC
RS485_PUP4 2 RE Instrumentation Laboratory

R
1 RO B 7
RS485_PUP4 3 DE R25
D
PROBE_LLD_FREQ 4 DI A 6 121 Title
GND APPROVALS DATE

5
U11
DRAWN
PROBE_LLD_FREQ_DIF_A CTS / Universal Arm
CHECKED
Z Driver Board
H
APPROVED

3 of 3
H
D 286331-00 0A SCALE
1 2 3 4 5 6 7 8

Figure 16-78 CTS Traveling Interconnect PCB (Drawing # 28634100)

1 2 3 4 5 6 7 8
REVISIONS
+5V REV DESCRIPTION BY CHECKED APPROVED DATE
A
In From Z-Axis Board
FFC Type Connecetor
0 RELEASED PER CO L D.COX 14APR05 A
+5V +24V
10 5
J2
1
4.7K
2 B_PROBE_LLD_FREQ
3 1 2 3 4 6 7 8 9
RP1
4 PROBE_TYPE_SPI_CS SPARE2 +5V
5 SPARE1
6 B_PIERCE_SOL_LOCK_SENSE PIERCER_LOCK_SOL_CONT
7 B_PIERCER_POSITION_SENSE SPARE3
8 B_TUBE_CAP_SENSE WP
B 10
9
SPI_CLK
U1
HOLD
AT25040AN-10SI-2_7
U1
B
11 SPI_DATA_IN 2 18 5 2 11 9 B_SPI_DATA_OUT
A1 Y1 SI SO A1 Y1
12 SPI_DATA_IN SPI_CLK 4 A2 Y2 16 6
SCK SPARE1 13 A2 Y2 7 R8 R9
280 280
13 PROBE_TYPE_SPI_CS 6 14 B_PROBE_TYPE_SPI_CS 1 SPARE1 15 5
A3 Y3 CS A3 Y3
14 B_SPI_DATA_OUT 8 12 WP 3 SPARE2 17 3
A4 Y4 WP A4 Y4
G 7 G
15 HOLD HOLD
SN74ACT244 SN74ACT244
16 PIERCER_LOCK_SOL_CONT 1 19
U4
17 2 4
B_PROBE_TYPE_SPI_CS
18
LED2
19
20 RED GRN
21
1 3
C 22
23
24
C
U2 U2
PIERCE_SOL_LOCK_SENSE 2 A1 Y1 18 B_PIERCE_SOL_LOCK_SENSE 11 A1 Y1 9
TUBE_CAP_SENSE 4 16 B_TUBE_CAP_SENSE SPARE3 13 7 +5V

1
A2 Y2 A2 Y2
P CGND PIERCER_POSITION_SENSE 6 A3 Y3 14 B_PIERCER_POSITION_SENSE 15 A3 Y3 5
PROBE_LLD_FREQ 8 A4 Y4 12 B_PROBE_LLD_FREQ PIERCER_LOCK_SOL_CONT 17 A4 Y4 3 B_PIERCER_LOCK_SOL_CONT

G G
Note: 1
SN74ACT244
19
SN74ACT244
Mounting Holes for the board R12

3.01K
are to be plated and attached
to the CGND net on the board.
D +24V
D
Piercer Lock and Tube Cap Sensors
+5V LED4 1
+24V
+5V D2
2
1
1 N/C N/C 8 TP6 U7
5
CON10L 2 VIN 7 B_PIERCER_LOCK_SOL_CONT 2 4 1
R1 R3 N/C
6 PIERCER_LOCK_SOL_PWR
R2 R4
3
J3
E 1
120 120
4.75K 4.75K C8
3
4
TEMP
GND
VOUT
TRIM
6
5
VREF_LLD
TC4S584
DRV101
4
E
3
0.1UF U6
2 U5
3 U5
C3
4
PIERCE_SOL_LOCK_SENSE 0.1UF 100ms Delay 50% Duty Cycle
5
TUBE_CAP_SENSE
6 U3
7 C10
R13
8 0.1UF
28.7K
9
10
R5
1
C2
33.2K TP3
CTS_PROBE_LLD
F U3
F
5
0.1UF 2 4 PROBE_LLD_FREQ P
Piercer Position Sensor
3
TC4S584
+5V
Piercer Lock Solenoid

D1 +24V
BZV55C10V
+5V +24V CON2L
1
TP1 TP4
R6 R7
1
120 4.75K PIERCER_LOCK_SOL_PWR
2
J4
1
J1
G 2
4
PIERCER_POSITION_SENSE
+5V VDD +24V

R10
3.01K
R11
22.1K
G
5
C1 C7 Title
LLD Detection LLD Detection C4 C5 C6 C11 C9
10UF 33UF APPROVALS DATE
1 CTS_PROBE_LLD 1 CTS_PROBE_LLD 0.1UF 0.1UF 0.1UF 0.1UF 0.1UF
DRAWN
LED1 LED3 CTS Traveling Signal
1
1
2 2 Brian Walker 02/28/05
U1 U2 U4 U6 U7
3 3 TP2 TP5 CHECKED Interconnect Board
4 4
COAX CONN COAX CONN
H J5
5
J6
5
P
APPROVED

H
1 of 1
P D 286340-00 0 SCALE
1 2 3 4 5 6 7 8

Figure 16-79 U Arm Fuse Board PCB (Drawing # 28641100)

1 2 3 4 5 6 7 8
REVISIONS
#20 GUAGE WIRE REV DESCRIPTION BY CHECKED APPROVED DATE
A Barrier Terminal Black

FROM POWER SUPPLIES
F19
Universal Arm Set 1
F23 F21
+24V_SYSTEM_F_UA1 1
2
J11
A
+24V_SYSTEM +24V_SYSTEM_F_UA1 +5V_POWER +5V_POWER_F_UA1 +15V_POWER +15V_POWER_F_UA1
3
USING #10 GUAGE WIRE 8A 4A 2A
+15V_POWER_F_UA1 4
Green Green Green +5V_POWER_F_UA1 5
1 +24V_SYSTEM Diffused Diffused Diffused 6
2 +24V_SYSTEM_GND 7
3 +28V_COOLING LED11 LED15 LED13 8 TO SIDE PANEL CAN BUS

4 +28V_COOLING_GND 9 TO BACKPLANE USING
R2 R12 R9 CAN_BUS_FUSE
1
5 +5V_GND 1 Watt 5% 10
1.8K 240 1.1K DUAL ROW #16 GUAGE WIRE
6 +5V_POWER 11 2 J9
7 +15V_GND 12
+5V_BACKPLANE 1
8 +15V_POWER 13
MECCA MECCA MECCA J2 2
B 9
10
-15V_GND
-15V_POWER
MECCA
14 MECCA
TO CAVRO ARMS
+5V_BP_CONTROLLERS 3
4 B
J1 SAMPLE_CAVRO_PWR +15V_BACKPLANE 5
-15V_BACKPLANE 7
MECCA
8
D1 J5
1 +5V_BACKPLANE 9
Universal Arm Set 2 #20 GUAGE WIRE FR301
2 10
J10
+24V_SYSTEM_F_UA2 1 3 +5V_BP_CONTROLLERS 11
F20 F24 F22
F25 +24V_SYSTEM +24V_SYSTEM_F_UA2 +5V_POWER +5V_POWER_F_UA2 +15V_POWER +15V_POWER_F_UA2
2 4 12
+24V_SYSTEM CAN_BUS_FUSE
3 REAGENT_CAVRO_PWR 5 +15V_BACKPLANE 13
8A 4A 2A
2A +15V_POWER_F_UA2 4 6 14
Green Green Green
Green +5V_POWER_F_UA2 5 7 -15V_BACKPLANE 15
Diffused Diffused Diffused
C LED17
Diffused
LED12 LED16 LED14

6
8
MECCA
FR301
D2
8
+5V_BACKPLANE
16
17
18
C
9 +5V_BP_CONTROLLERS 19
R14
R3 R13 R11 JP2
1 Watt 5% 1.8K 240 1.1K 10 20
1 Watt 5% 1.8K 1 2
11 +15V_BACKPLANE 21
12 22
JP1
MECCA MECCA MECCA 13 CAVRO_RESET_1 23
MECCA MECCA 1 2
14 CAVRO_RESET_2 24
MECCA
1
MECCA
G2 G1
TO BACKPLANE
USING #16 GUAGE WIRE
D BACKPLANE SYSTEM
FUSE +5V
Level II CPU
Board +5V
BACKPLANE SYSTEM
FUSE +15V
BACKPLANE SYSTEM
FUSE +24V
Level III CPU
BOARDS +5V
CAVRO ARM POWER CONTROL RELAYS +24V_BACKPLANE 1
J4 D
+5V_POWER
+5V_POWER +5V_POWER +15V_POWER +24V_SYSTEM 2
SOLID STATE RELAY +28V_COOLING_BD 3
4
4A 8A F3 +24V_CAVRO 1 +DC_LOAD +24V_BACKPLANE 5
F4
F5
F17
FUSE SIZE 4A FUSE SIZE 4A F8 FUSE SIZE 4A

FUSE SIZE 8.0A
6
TIME DELAY 4A SAMPLE_CAVRO_PWR 2 -DC_LOAD +28V_COOLING_BD 7

TIME DELAY 4A TIME DELAY 4A TIME DELAY
8
SAMPLE SIDE CAVRO_RESET_1 3 +_CONTROL +24V_BACKPLANE 9

+24V_BACKPLANE +5V_BP_CONTROLLERS
+5V_BACKPLANE +5V_LEVEL_II_CPU +15V_BACKPLANE 10
4 -_CONTROL +28V_COOLING_BD 11
12
E Green
Diffused
Green
Diffused
Green
Diffused
Green
Diffused MECCA
RELAY1
CON12
E
MECCA
R15
R17 TO DC DRIVER BOARD
LED4
LED6 LED3
R16 LED7 LED9 SOLID STATE RELAY
0.5 WATT
40.2 40.2 +24V_CAVRO 1 +DC_LOAD +24V_DC_DRIVER 1
40.2 R5
D3 R6 D5 2
3.0V Zener D4 1 Watt 5% 1.8K 3.0V Zener
1N5225 240 1N5225 REAGENT_CAVRO_PWR 2 -DC_LOAD 3
Diode 13.0V Zener Diode
1N5243 4
0.5 WATT Diode 0.5 WATT
REAGENT SIDE CAVRO_RESET_2 3 +_CONTROL
0.5 WATT J3
MECCA
MECCA MECCA MECCA 4 -_CONTROL MECCA
MECCA
F BACKPLANE SYSTEM RELAY2

SPARE FUSES F
DC Driver REAGENT COOLING BACK PANEL CAVRO ARM UNITS
FUSE -15V MECCA 4A 8A
Board +24V Board +28V FANS +24V
-15V_POWER
+24V_SYSTEM +28V_COOLING +24V_SYSTEM

+24V_SYSTEM F9 F12
4A 8A
F18
F7 F6 FUSE SIZE 2A
2A F10 F14
F2 F1 FUSE SIZE 8.0A TIME DELAY TO LEVEL II CPU BOARD TO BACK PANEL FAN1
8A 4A 2A
FUSE SIZE 8.0A 8A FUSE SIZE 12.5A FUSE SIZE 2A 2A TIME DELAY
12.5A
TIME DELAY SLOW BLOW TIME DELAY 1 BP_FANS_FUSE
1
-15V_BACKPLANE +5V_LEVEL_II_CPU 2
F13 F15
+24V_CAVRO 2
+24V_DC_DRIVER 3 2A 12.5A
G +28V_COOLING_BD BP_FANS_FUSE
Green
LED10
4
5
MECCA
J6
F11 F16 G
6
Green Diffused
Green Green Green Diffused
Diffused Diffused Diffused
C1 MECCA J8 Instrumentation Laboratory
LED8 1000U
LED1 113 HARTWELL AVENUE, LEXINGTON MASS. 02421
LED5 LED2 35V
R10 TO BACK PANEL FAN2 Title
R7
1 Watt 5% R8 0.5 WATT 1.1K APPROVALS DATE
1 Watt 5% R4 1 Watt 5% R1 1.8K
1.8K DRAWN Universal Arm
2.2K 1.8K 1 Watt 5% BP_FANS_FUSE
1 Saverio Ratta 08/18/04 Power Interconnect
CHECKED
2 FUSE BOARD
H MECCA
MECCA MECCA
MECCA
MECCA
MECCA
J7
APPROVED

H
D 286411-00 D
1 of 1
SCALE
N/A
1 2 3 4 5 6 7 8

16 - 82 Chapter 16 Schematics

Chapter 17 Assembly Drawings/Part Numbers 17 - 1
Chapter 17
Assembly Drawings/Part
Numbers
17-1 Saleable Parts List
The following lists the parts that are saleable by Instrumentation Laboratory.
Table 17-1 Saleable Parts/ Modules
9746606 MAGNETIC, STIR BARS, ACL 6/PK
18794301 SYRINGE INSTALL TOOL
27501001 FUSE BOARD
27503001 PCB FRONT PANEL
27540400 ASSY WASTE BOTTLE FAKEOUT PLUG CIRC LOCK
27554001 ORU INTERFACE
27555001 ASSY INCUBATOR HEATING
27555001 ASSY INCUBATOR HEATING
27602001 PCB LOADER
27604001 PCB CUVETTE SENSOR
27605001 PCB CUVETTE WASTE
27610001 ASSY POLAROID RANGING BD TESTED
27612001 S/S BCR SCANNER INT LED ASSY
27613010 PCB ASSY X-MOT CONT BD W/OUT DIP REPLAC
27700001 PCB SAMPLE PRESENCE
27701001 PCB RACK PRESENCE
27703001 PCB REAGENT COOLING
27704001 PCB STIRRER
27707001 PCB ASSY SAMPLE KEYPAD TESTED
27707101 PCB ASSY REAGENT KEYPAD TESTED
27707201 FLUIDICS LED PANEL
27710001 PCB REMOTE TRAVEL INTERFACE BD
27711001 PCB ASSY, REAGENT COOLING BD W/FAN SPEED
27753801 S/S HEATER STRIP W/PROTECTION
27753901 S/S INCUBATOR 1 & 2 THERMISTOR
27754501 S/S LOADER PIVOT TABLE SENSORS
27755711 FAN DUCT ASSY W/9" CABLE
27755901 MODIF. THERMISTOR BLOC REACTIFS ACL TOP
27757012 FAN CHASSIS ASSY W/12" CABLE
27757013 FAN CHASSIS ASSY W/42" CABLE
27760001 S/S EMERGENCY STOP SWITCH
27765500 REPLACEMENT KIT SAMPLE DOOR OPTL SENSOR

17 - 2 Chapter 17 Assembly Drawings/Part Numbers

27765601 SOLENOID ASSY SAMPLE SHIELD LOCK KIT
27994801 FUSE, 2A 63V REMOVABLE QTY 10
27999000 FLOPPY DRIVE MODEL FD-235 HF
28110001 S/S ASSY CUVETTE WASTE SHELF
28116301 WASTE DRAWER
28116401 WASTE DOOR
28137101 PULLEY BELT DRIVE
28141701 S/S, CUVETTE LOADER ASSY
28161601 S/S SHUTTLE X MOTOR ASSY
28162101 S/S SHUTTLE BCR LINEAR BEARING
28162701 S/S SHUTTLE X IDLER PULLEY ASSY
28165001 S/S ASSY SHUTTLE ASSY
28166900 MANUAL SERVICE ACL TOP CD VERSION
28182801 SHUTTLE SENSOR ASSY
28183101 MOUNT, ADJ 'X' AXIS SENSOR
28185001 SHUTTLE SOLENOID
28185601 S/S APERTURE, CUVETTE PRESENCE SENSOR
28201501 S/S BCR X MOTOR ASSY
28204801 BAR, ALIGNMENT SAMPLE
28204901 S/S REAGENT GUIDE
28205201 S/S SAMPLE HEEL ASSY
28205801 S/S REAGENT HEEL ASSY
28208601 SUPPORT, DILUENT
28209001 ASSY, MONITOR/KEYBOARD SUPPORT
28210500 KIT, 2D BARCODE UPGRADE
28211101 BARCODE SCANNER LINEAR
28211301 KIT BCR COVER UPGRADE ASSY
28211401 BCR, LINEAR, 6 DEGREE TILT, SALEABLE
28254900 CURTAIN, RIGHT
28255300 CURTAIN, LEFT
28300301 CAVRO, 2 ARM
28300501 CAVRO, 1 ARM
28300601 S/S CAVRO, Z RACK
28302001 LLD SENSOR, ACL TOP SALEABLE
28302701 CAVRO CCU 9000 PCB
28302801 S/S FLAG, CAVRO
28302901 S/S PCB,TECAN SYSTEMS ARM BD W/O ALIDUM
28304601 S/S FUSE KIT, (1.6A, 2.0A, 3.15A)
28304701 S/S CABLE, FLEXIBLE ARM COMMON
28304801 S/S BRACKET, Y-IDLER PULLEY
28304901 S/S SINGLE ARM X BELT
28305001 S/S LEFT DUAL ARM BELT
28305101 S/S RIGHT DUAL ARM BELT
28305201 S/S Y TRAVEL BELT
28305301 S/S Z DRIVE BELT
28305401 S/S GREASE
28305501 S/S Y-ARM ASSY L340 IL TOP
28305601 S/S Y-ARM ASSY R340 IL TOP


28305701 S/S ASSY, Y-IDLER PULLEY
28307901 S/S SENSOR, OPTICAL, RSP9000
28320901 ASSY, ARM SINGLE, CTS
28321001 ASSY, ARM DOUBLE
28356801 S/S DIDVIDER WALL RIGHT
28386300 ASSY, FILTER CHANGER, CTS
28401101 KIT CABLE ASSY RESTRAINT
28420001 S/S BCR OPTICAL ENCODER
28444701 PLUNGER, LATCH, SOLENOID, SAMPLE S/S
28445001 S/S SAMPLE DOOR ASSY
28445900 WINDOW, REAGENT DOOR
28446001 ASSY REAGENT DOOR
28447501 S/S POWER ENTRY MODULE
28448301 S/S DOOR STUD
28448401 S/S DOOR STUD
28451901 S/S SENSOR ULTRASONIC
28453102 S/S BATTERY 3.6 LITHIUM W/CABLE
28453701 POWER SUPPLY 24V
28454001 POWER SUPPLY 5/15V
28454301 FILTER POWER SUPPLY
28470201 SENSOR FLAG S/S
28512501 S/S ASSY REAGENT RACK ASSY
28519301 S/S REAGENT MODULE FLAG
28519701 DUCT ASSY
28521100 ASSY, RACK RACK MOUNT THERMISTOR
28578601 S/S ASSY SAMPLE RACK ASSY
28579301 S/S SAMPLE HOUSING SENSOR FLAG
28608101 BACKPLANE ASSY
28608201 COMPUTER HOUSING
28608301 DC DRIVER ASSY
28612701 SNAP DETENT
28613501 SOLENOID SHIELD LOCK
28614101 DOOR LOCK ASSY
28617301 FILTER REAGENT COOLING
28621201 PCB CUVETTE CONTROLLER
28621301 PCB RACK CONTROLLER
28621401 PCB ORU CONTROLLER ACL TOP
28622801 COMPUTER MONITOR 17" TOUCH SCREEN ACLTOP
28622911 ASSY ACL TOP CM PC
28623500 KIT START-UP,ACL TOP
28640001 PC/104 CAN BUS PCB
28702301 CONN / CONT FLUIDS PCB ASSY
28712401 RINSE TUBING, ACL TOP
28712501 WASTE TUBING, ACL TOP
28713200 ASSY, CLEAN ASPIRATOR, ACL TOP
28713400 ASSY, 4L RINSE, ASPIRATOR, ACL TOP
28713600 VALVE, CHECK, 1/8 BARB, 5 PSI
28735500 PUMP XP 3.000


28739801 SYRINGE
28740300 FITTING, 1/4-28 THD TO 1/16 BARB
28741600 ASSY, PUMP/PROBE TUBE
28745501 S/S PUMP,PRECISION,PSD4-IL W/SYRINGE/VAL
28749801 ASSY,SYRINGE,250 UL FOR PSD4 PUMP W/INST
28749901 S/S ASSY, VALVE HV3-2-Y, PSD4-IL
28750001 S/S SEAL (TIP) 250UL SYRINGE, HAMILTON
28758701 S/S CLEAN / RINCE CUP ASSY
28759501 S/S SAMPLE ACCUMULATOR ASSY
28759601 S/S REAGENT ACCUMULATOR ASSY
28760501 PUMP TUBING, ACL TOP
28761601 ASSY, WASTE PUMP, SALEABLE
28771801 ASSY WASTE BOTTLE PRESENCE SENSOR
28775901 ASSY ACL TOP PROBE HOUSING
28816801 S/S ASSY, INCUBATOR #1
28817201 S/S ASSY, INCUBATOR #2
28819201 TOOL, CUVETTE ALIGNMENT
28820401 BRACKET, INDEXER ASSY MTG
28825001 S/S ASSY ORU CRADLE ASSY
28829501 CLIP, ORU CUVETTE SPRING
28911601 SYRINGE TIP, 250uL 6/PK ACL TOP
28912801 O-RING PIVOT TABLE
28913601 BELT 6MM WIDE
28916401 S/S SHUTTLE TIMING BELT
28919201 S/S LOADER CUVETTE PUSHER MOTOR BELT
28919401 S/S LOADER X PORT MOTOR BELT
28940600 COUPLING, INSERT, 1/8 FLOW
28940700 COUPLING, PANEL, 1/8 FLOW, HC-V
28940800 COUPLING, INSERT, 1/4 FLOW, HC-V
28940900 COUPLING, PANEL, 1/4 FLOW, HC-V
29225301 CD-R, BLANK
29225401 DVD-R, BLANK
29226604 CD ON-LINE HELP V2.2 ACL TOP
29228402 CD,ACL TOP THERMAL CAL SW V1.5
29401100 CUVETTE WASTE LINER 10 PK, ACL TOP
29404000 HARD DRIVE, BLANK
Table 17-2 Saleable Kits

27754001 KIT LEVEL 2 CPU POWER CABLE UPGRADE ASSY
28321100 ASSY, PNEU UPGRADE, CTS
28321800 KIT, CTS LAUNCH CONFIG. UPGRADE
28321900 KIT, ARM UPGRADE, CTS
28533201 KIT REAGENT DRAIN TUBE UPGRADE ASSY
28850001 KIT EMITTER ASSEMBLY
29227403 KIT,ACL TOP AM SW UPD RACK V2.09
29236905 KIT,ACL TOP TEST DEF LIB P4.8 (NON-BCI)
29236906 KIT TEST DEF LIBRARY P5.0 ACL TOP

Table 17-2 Saleable Kits

29239801 KIT,ACL TOP V2.1/P4.8 SW UPGRADE (BCI)
29239901 KIT,ACL TOP V2.1/P4.8 SW UPGDE(NON-BCI)
29240923 KIT, MAIN SYS SW INSTALL ACL TOP V2.7.7
29241602 KIT,ACL TOP P4.8 TEST DEF LIBRARY (BCI)
29242300 KIT, ACL TOP LANGUAGE TRASLATION
29404900 KIT,WASTE SHELF INTERLOCK SWITCH UPGD
29405200 KIT, BUNDLED UPGRADE, A
29405300 KIT, BUNDLED UPGRADE, B
29405800 KIT, TOP CM PC RECOVERY
29410000 KIT, FLOOR DRAIN, ACL TOP
29411000 KIT UPGRADE LIQUID WASTE FULL/PRESENCE
29411300 UPGRADE KIT, FAN NOISE ACL TOP
29411500 KIT ORU CABLES
29411600 KIT OPTICS ADJUSTMENT ORU
Table 17-3 Saleable Cables

27750001 S/S CB POWER SWITCH TO 5/15 PWR SUPPLY
27750401 S/S CB FLUIDCS CTRL P13 TO VALVES/SENSOR
27750501 CABLE ASSY BARCODE X-AXIS TO L LIMIT
27750601 CABLE ASSY BARCODE X-AXIS TO R LIMIT
27750703 S/S CB BACK PIN P30 TO BCR X-AXIS BD P2
27750704 S/S CB BACK PIN P29 TO SHTL X-AXIS BD P2
27750801 S/S CB BACK PIN P38 TO BCR X-AXIS BD P1
27751101 S/S CB BACK PIN P34 TO CAVRO ARMS
27751201 S/S CB CUV WASTE INTF BD P3 TO ACCUM SOL
27751401 CUVETTE WASTE TO DOOR OPEN SENSOR
27751401 CUVETTE WASTE TO DOOR OPEN SENSOR
27751501 S/S CB BACK PIN P40 TO CUV LOADER BD P1
27751601 S/S CB BACK PIN P20 TO EMITTER BD P1
27751701 CUV WASTE TO DRAWER OPEN SWITCH
27751801 S/S FLUIDICS LED
27751901 S/S CB BACK PIN P32 TO FLUIDCS CTLR P1
27753601 S/S CB BACK PIN P36 TO FLUIDCS CTLR P7
27753703 S/S CB INCB HTG BD 2 P1 TO BACK PIN P12
27753704 S/S CB INCB HTG BD 1 P1 TO BACK PIN P3
27754601 S/S CB EMITTER BD P1 TO BACK PIN P17
27754701 S/S CB BACK PIN P26 TO ORU INTFC BD P15
27754803 S/S CB ORU INTFC BD P2 TO BACK PIN P16
27754804 S/S CB ORU INTFC BD P1 TO BACK PIN P15
27755101 S/S CB CANBUS P3 TO BACK PIN P25
27755201 S/S CB CANBUS P4 TO FLUIDCS CTLR P1
27755301 S/S CB PROBE DC BD P2 TO BACK PIN P2
27755401 S/S CB FUSE BD P3 TO PROBE DC DRVR BD P1
27755501 S/S CB BACK PIN P28 TO RGT COOLNG BD P3
27755601 S/S CB BACK PIN P18 TO RGT COOLING BD P1
27756001 S/S CB CAVRO RGT SYRG PMP TO CCU P1
27756201 S/S CB RGT RACK BD P2 TO RGT STRRG BD P1

Table 17-3 Saleable Cables

27756301 S/S CB BACK PIN P13 TO RGT RACK P1
27756501 S/S CB CAVRO SMPL SYRG PMP TO CCU P1
27756701 S/S CB SMPL RACK BD P1 TO BACK PIN P1
27756901 S/S CB BACK PIN P23 TO SHTL X-AXIS BD P1
27757004 S/S CB FUSE BD P9 W/ FAN
27757101 S/S CB SHTL X-AXIS BD J4 W/LFTLMT SNSR
27757201 S/S CB SHTL X-AXIS BD P5 W/RTTLM SNSR
27757301 S/S CB SHTL X-AXIS BD P8 W/SHTL MTR
27758201 S/S CB FS BD P8.CPU P3 TO FLOPPY DR
27758901 S/S CB BCR X-AXIS BD P7 TO RMT TRVL P1
27759101 FLEX CABLES, PROBE DC DRIVER
27759501 FLEX CABLE
27759601 S/S CB SHTL X-AXIS BD P6 TO Y-AXIS BD P1
27759801 S/S CB FLUIDCS CTRL P3 TO DR SENSORS
27760101 S/S CB FRONT PNL BD P5 TO RGT KYPD BD P1
27760301 S/S REAGENT ACCUM FLUIDIC HARNESS
27760401 S/S CB FLUIDICS CTLR P2 TO SMPL PUMP/VAL
27760601 S/S CB FLUIDCS CTRL P6 WASTE SNSR BD P3
27760701 S/S CB FLUIDS CTLR P6 TO RINSE PUMP P1
27761101 S/S CB INCUBATOR TO GROUND
27761301 S/S CB FUSE BD P4 TO BACK PIN P27
27761401 S/S CB 5V PWR SPPLY TO FUSE BD P1
27761501 S/S CB 24V PWR SPPLY TO FUSE BD P1
27761601 S/S CB FUSE BD J9 TO BACK PIN BD J21
27761701 S/S CB 277606 CB P1/J1 TO RNS CLN WASTE
27761801 S/S CB +15V PWR SPPLY TO FUSE BD P1
27761901 S/S CB -15V PWR SPPLY TO FUSE BD P1
27762101 S/S CB FLUIDCS CTRL P8 TO FRONT BD P1
27762201 S/S CB BACK PIN P22 TO FRONT PANL BD P2
27762301 S/S CB FRONT PNL BD P4 TO SMP KYPD BD P1
27762501 S/S CB CPU BD P2 W/SPEAKER
27762601 S/S CB BACK PIN P14 TO SIDE PANEL P1
27762801 S/S CB PROBE DC DRVR BD P12 TO SIDE PANL
27763001 S/S CB X-AXIS MTR TO GRND
27763205 S/S CB REAGENT GROUND STRAP CB 550
27764601 S/S CB RMT TRVL BD P2 TO BCR SCNNR P3
27764701 S/S CB CUV LOADR BD P6 TO SENSORS
27764800 CABLE ASSY, REAGENT COOLING TO THERMIST
27769001 S/S CB SAMPLE GRND TO REAGENT GRND
28651401 S/S CB U-ARM X-AXIS BD P13 TO BLK FLD P1
28652101 S/S CB U-ARM X-AXIS BD P2 TO BLK FLD P2
28652501 S/S CB R1 SYRNG PUMP TO CCU P5
28652601 S/S CB SMPL SYRNG PUMP TO CCU P7
28653501 S/S CB FLUIDCS CONN P2 TO VALVES/SENSOR
28653701 S/S CB R2 SYRNG PUMP TO CCU P7
28654201 S/S CB BACK PIN P31 TO SYRNG PUMP P2

Table 17-4 Saleable Adapters

28520500 ADAPTER FOR 4 ML VIAL ACL TOP
28520900 ADAPTER 10 ML VIAL, ACL TOP
28525300 ADAPTER, ALIQUOT TUBES, 5 PCS
28525400 ADAPTER, PEDIATRIC TUBES, 5 PCS
28526001 ADAPTER, DILUENT, 4ML, ACL-TOP, 2PCS
28529300 ADAPTER SET MICRO TUBE
Table 17-5 Saleable Rack Sets

28780001 TRAY 12 SAMPLE RACKS ACL TOP 1 PCS
28780201 TRAY 6 SAMPLE RACKS ACL TOP 1 PCS
29400501 SAMPLE RACK SET 01-12, ACL TOP
29400601 RACK SET REAGENT, RA-RF ACL TOP
29400602 RACK SET REAGENT, RG-RM ACL TOP
29400711 ACL TOP DILUENT RACK SET DA-DC
29400712 RACK SET, DILUENT DD-DF, ACL TOP

17-2 Assembly Drawings
The following pages include the Assembly Drawings for ACL-TOP along with the Bill of Material that applies
to the drawing.
Part No. Description
28111001 Figure 17-1 "2811001, ASSY, WASTE SHELF"

28116301 Figure 17-2 "28116301 ASSY, WASTE DRAWER"
28116401 Figure 17-3 "28116401 ASSY, WASTE DOOR"
28141701 Figure 17-4 "28141701 ASSY, LOADER"
28161601 Figure 17-5 "28161601 X-MOTOR ASSEMBLY"
28165001 Figure 17-6 "28165001 ASSY CUVETTE SHUTTLE"
28200001 Figure 17-7 "28200001 ASSY, BARCODE MODULE"
28201501 Figure 17-8 "28201501 MOTOR ASSY"
28209001 Figure 17-9 "28209001 ASSY, MONITOR/KEYBOARD SUPPORT"
28200300 Figure 17-10 "28200300 ASSY, 2-ARM RIGHT CAVRO"
28300500 Figure 17-11 "28300500 ASSY, 1-ARM, LEFT CAVRO"
28321001 Figure 17-12 "28321001 ASSEMBLY, ARM, DOUBLE"
28366901 Figure 17-54 "28366901 CTS Accumulator"
28320901 Figure 17-13 "28320901 ASSEMBLY, ARM, CTS"
28383001 Figure 17-55 "28383001 Assy CTS Bulk Fluidics"
28395001 Figure 17-14 "28395001 PROBE, HEATED, ACL-TOP"
28445001 Figure 17-15 "28445001 ASSY SAMPLE DOOR"
28446001 Figure 17-16 "28446001 ASSY REAGENT DOOR"
28512501 Figure 17-17 "28512501 ASSY, REAGENT TOP"
28519700 Figure 17-18 "28519700 DUCT ASSY, REAGENT COOLING"
28578601 Figure 17-19 "28578601 ASSY, SAMPLE HOUSING"
28578621 Figure 17-20 "28578621 ASSY, CTS SAMPLE HOUSING"
28602701 Figure 17-21 "28602701 ASSY, COMPUTER"
28608000 Figure 17-22 "28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY)"
Figure 17-23 "28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY)"

28608101 Figure 17-24 "28608101 ASSY, BACKPLANE"
28608201 Figure 17-25 "28608201 ASSY, COMPUTER HOUSING"

28608301 Figure 17-26 "28608301 DC DRIVER ASSY"

28612000 Figure 17-27 "28612000 ASSY, FRONT, TOP SKIN"
28612700 Figure 17-28 "28612701 SNAP DETENT"
28621201 Figure 17-29 "28621201 PCB, CUVETTE ASSY."
28621301 Figure 17-30 "28621301 PCB, RACK ASSY."
28621401 Figure 17-31 "28621401 PCB, ORU ASSY."
28660002 Figure 17-32 "28660002 ASSY, TELESCOPE CTS"
29403701 Figure 17-33 "29403701 CRU, SAMPLE PROBE N SEAL"
29403601 Figure 17-34 "29403601 PIERCER PROBE, CTS"
28712020 Figure 17-35 "28715801 ASSY, RINSE PUMP, BASE TOP"
28715821 Figure 17-36 "28715821 ASSY, RINSE PUMP, CTS"
28735500 Figure 17-37 "28735500 ASSY, PUMP SINGLE XP3000"
28759500 Figure 17-38 "28759501 ASSY, CWR STATION, SAMPLE"
28759601 Figure 17-39 "28759601 ASSY, CWR STATION, REAGENT"
28761600 Figure 17-40 "28774601 ASSY, WASTE PUMP"
28775900 Figure 17-41 "28775900 ASSY, ACL TOP PROBE HOUSING"
28816801 Figure 17-42 "28816801 ASSY, INCUBATOR #1 (REAGENT SIDE)"
28817201 Figure 17-43 "28817201 ASSY, INCUBATOR #2 (SAMPLE SIDE)"
28820501 Figure 17-44 "28820501 8 POS INC INDEXER ASSY"
28821501 Figure 17-45 "28821501 7 POS INC INDEXER ASSY"
28825000 Figure 17-46 "28825000 ASSY, ORU CRADLE"
PCB Assemblies
27501001 Figure 17-47 "27501001 ASSY, FUSE BOARD"

27503001 Figure 17-48 "27503001 PCB ASSY FRONT PANEL DISCONNECT"
27605001 Figure 17-49 "27605001 PCB CUVETTE WASTE INTERFACE"
27613010 Figure 17-50 "27613010 PCB ASSY X-MOTION CONTROL BD W/OUT DIP"
27700001 Figure 17-51 "27700001 PCB SAMPLE RACK PRESENCE"
27707001 Figure 17-52 "27707001 SAMPLE KEYPAD ASSEMBLY"
27707101 Figure 17-53 "27707101 REAGENT KEYPAD ASSEMBLY"
28641001 Figure 17-56 "28641001 CTS Sample & IL Double Arm Fuse Board"

Figure 17-1 2811001, ASSY, WASTE SHELF
00027610001
ASSY POLAROID RANGING BOARD
00027605001
PCB CUVETTE WASTE
00025703001
PCB FRONT PANEL

Figure 17-2 28116301 ASSY, WASTE DRAWER

Figure 17-3 28116401 ASSY, WASTE DOOR

Figure 17-4 28141701 ASSY, LOADER
00027602001
PCB LOADER
0002919201
CUVETTE PUSHER
BELT
00027604001
PCB ASSY CUVETTE
SENSOR BOARD
00028137101
PULLEY, BELT DRIVE
00028912801
O-RING, PIVOT TABLE
00028913601
BELT 6mm WIDE

Figure 17-5 28161601 X-MOTOR ASSEMBLY

Figure 17-6 28165001 ASSY CUVETTE SHUTTLE
00027604001
PCB CUVETTE SENSOR
0002818500
SHUTTLE SOLENOID
00028185601
APERATURE CUVETTE
PRESENCE SENSOR
00028182801
SHUTTLE SENSOR ASSY

Figure 17-7 28200001 ASSY, BARCODE MODULE
00028205201
SAMPLE HEEL
00028255300 00028204801
CURTAIN, LEFT BAR, ALIGNMENT SAMPLE
(8x)
00028162101
BCR LINEAR BEARING
00028208601
BAR, ALIGNMENT DILUENT
(3x)
00027710001 00028204901
PCB REMOTE TRAVEL BAR, ALIGNMENT REAGENT
INTERFACE (13x)
00028205801
REAGENT HEEL
00028254900
CURTAIN, RIGHT
00027613010
PCB X MOTION CONTROL

Figure 17-8 28201501 MOTOR ASSY

Figure 17-9 28209001 ASSY, MONITOR/KEYBOARD SUPPORT

Figure 17-10 28200300 ASSY, 2-ARM RIGHT CAVRO

Figure 17-11 28300500 ASSY, 1-ARM, LEFT CAVRO

Figure 17-12 28321001 ASSEMBLY, ARM, DOUBLE

Figure 17-13 28320901 ASSEMBLY, ARM, CTS

Figure 17-14 28395001 PROBE, HEATED, ACL-TOP

Figure 17-15 28445001 ASSY SAMPLE DOOR

Figure 17-16 28446001 ASSY REAGENT DOOR

Figure 17-17 28512501 ASSY, REAGENT TOP
00028519301
REAGENT MODULE FLAG
00027704001
PCB STIRRER
00027711001
PCB ASSY REAGENT COOLING
BOARD W/ FAN SPEED
00027701001
PCB RACK PRESENCE

Figure 17-18 28519700 DUCT ASSY, REAGENT COOLING
00027755711
FAN W/9 CABLE
00027755713
FAN W/18 CABLE
00027755712
FAN W/15 CABLE
00027762901
DOUBLE FAN

Figure 17-19 28578601 ASSY, SAMPLE HOUSING
00027700001
PCB SAMPLE PRESENCE
00028579301
SAMPLE HOUSING SENSOR FLAG

Figure 17-20 28578621 ASSY, CTS SAMPLE HOUSING
00027700001
PCB SAMPLE PRESENCE
00028579301
SAMPLE HOUSING SENSOR FLAG

Figure 17-21 28602701 ASSY, COMPUTER
00028640001
PCB PC-104
00027999000
FLOPPY DRIVE
MODEL FD-235 HF

Figure 17-22 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY)

Figure 17-23 28608000 ASSY, CHASSIS FOUNDATION (REFERENCE ONLY)

Figure 17-24 28608101 ASSY, BACKPLANE

Figure 17-25 28608201 ASSY, COMPUTER HOUSING
00028602701
ASSY, COMPUTOR
00028456102
BATTERY, 3.6 LITHIUM W/CABLE

Figure 17-26 28608301 DC DRIVER ASSY

Figure 17-27 28612000 ASSY, FRONT, TOP SKIN

0002844601
REAGENT DOOR
0002844501
SAMPLE DOOR
0002848401
DOOR STUD
00028448301
DOOR STUD
00028444701
PLUNGER LATCH
SOLENOID
00027760001
EMERGENCY STOP SWITCH
00027707001 00028445900
SAMPLE KEYPAD WINDOW, REAGENT DOOR
00027707101
REAGENT KEYPAD

Figure 17-28 28612701 SNAP DETENT
NOTE: FOR USE WITH 00028618700

BACK WALL ASSY (LEFT) AND
00028618800 BACK WALL ASSY (RIGHT)

Figure 17-29 28621201 PCB, CUVETTE ASSY.

Figure 17-30 28621301 PCB, RACK ASSY.

Figure 17-31 28621401 PCB, ORU ASSY.

Figure 17-32 28660002 ASSY, TELESCOPE CTS

Figure 17-33 29403701 CRU, SAMPLE PROBE N SEAL

Figure 17-34 29403601 PIERCER PROBE, CTS

Figure 17-35 28715801 ASSY, RINSE PUMP, BASE TOP

Figure 17-36 28715821 ASSY, RINSE PUMP, CTS

Figure 17-37 28735500 ASSY, PUMP SINGLE XP3000
00028739801
SYRINGE

Figure 17-38 28759501 ASSY, CWR STATION, SAMPLE
00028758701
CLEAN RINSE CUP
00027760401
FLUIDIC HARNESS

Figure 17-39 28759601 ASSY, CWR STATION, REAGENT
00028758701
WASH RINSE CUP
00027760301
S/S REAGENT ACCUM FLUIDIC HARNESS

Figure 17-40 28774601 ASSY, WASTE PUMP
00028760501
PUMP TUBING, ACL TOP

Figure 17-41 28775900 ASSY, ACL TOP PROBE HOUSING
00027994801
FUSE 2A 6.3V REMOVABLE

Figure 17-42 28816801 ASSY, INCUBATOR #1 (REAGENT SIDE)
00027753901
INCUBATOR 1 & 2 THERMISTER
00027753801
S/S HEATER STRIP W/ PROTECTION
00027755001
ASSY INCUBATOR HEATING

Figure 17-43 28817201 ASSY, INCUBATOR #2 (SAMPLE SIDE)
00027753901
INCUBATOR 1 & 2 THERMISTER
0002755501
ASSY INCUBATOR HEATING
00027753801
HEATER STRIP W/ PROTECTION
00028819201
TOOL, CUVETTE ALIGNMENT

Figure 17-44 28820501 8 POS INC INDEXER ASSY

Figure 17-45 28821501 7 POS INC INDEXER ASSY

Figure 17-46 28825000 ASSY, ORU CRADLE
0002885001
EMITTER ASSY
00027554001
PCB ORU INTERFACE

Figure 17-47 27501001 ASSY, FUSE BOARD

Figure 17-48 27503001 PCB ASSY FRONT PANEL DISCONNECT

Figure 17-49 27605001 PCB CUVETTE WASTE INTERFACE

Figure 17-50 27613010 PCB ASSY X-MOTION CONTROL BD W/OUT DIP

Figure 17-51 27700001 PCB SAMPLE RACK PRESENCE

Figure 17-52 27707001 SAMPLE KEYPAD ASSEMBLY

Figure 17-53 27707101 REAGENT KEYPAD ASSEMBLY

Figure 17-54 28366901 CTS Accumulator

Figure 17-55 28383001 Assy CTS Bulk Fluidics

Figure 17-56 28641001 CTS Sample & IL Double Arm Fuse Board


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ACL-TOP

October, 2006 PN 28166900 Rev 03

ACL-TOP Service Manual 1

Ghost Image Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14

2 ACL-TOP Service Manual

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

ACL-TOP Service Manual 3

4 ACL-TOP Service Manual

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

ACL-TOP Service Manual 5

Rinse Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 80

6 ACL-TOP Service Manual

Adjustments and Verifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 47

ACL-TOP Service Manual 7

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

8 ACL-TOP Service Manual

Cuvette Handling/Rack Handling X-Axis PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 16

ACL-TOP Service Manual 9

10 ACL-TOP Service Manual

ACL-TOP Service Manual 11

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

12 ACL-TOP Service Manual

ACL-TOP Service Manual 13

14 ACL-TOP Service Manual

ACL-TOP Service Manual 1

2 ACL-TOP Service Manual

ACL-TOP Service Manual 3

4 ACL-TOP Service Manual

ACL-TOP Service Manual 5

6 ACL-TOP Service Manual

ACL-TOP Service Manual 7

8 ACL-TOP Service Manual

ACL-TOP Service Manual 9

10 ACL-TOP Service Manual

ACL-TOP Service Manual 11

12 ACL-TOP Service Manual

ACL-TOP Service Manual 13

14 ACL-TOP Service Manual

ACL-TOP Service Manual 15

16 ACL-TOP Service Manual

Safety and Compliance

ACL-TOP Service Manual

Height: 44.4 cm 17.5 inches

The maximum external dimensions for the monitor are:

Height 43.1 cm 17 inches

ACL-TOP Service Manual

Disclaimer Regarding User-Defined Tests

WARNING Warning statements provide information about

CAUTION Caution statements provide information about per-

ACL-TOP Service Manual

NOTE Note statements contain important user information.

BIOHAZARD Biohazard statements alert you to potentially

WARNING Use extreme caution. (CTS Probe is moving)

Attention: See Instructions for Use

ACL-TOP Service Manual

Caution: Risk of Electric Shock

Note: Important User Information

Attention: Consult Documents

In Vitro Diagnostic Device

Contents sufficient for <n> tests

Protective Conductor Terminal - Earth

ACL-TOP Service Manual

Bar Code Reader Hazard