TG - 950/950AT Theory Guide
Transcription
TG - 950/950AT Theory Guide
Publication No. TG3360-1 15JAN98 Supersedes Pub. Nos. TG3360-02 to TG3360-15, TG3360-17 and TG3363-01 01JUN95 and 27JUN95 THEORY GUIDE for the Vitros 950 Chemistry System Vitros 950AT Chemistry System E015_0900HA E015_0932HA © Ortho-Clinical Diagnostics, Inc. PLEASE NOTE The information contained herein is based on the experience and knowledge relating to the subject matter gained by Ortho-Clinical Diagnostics, Inc. (OCD) prior to publication. No patent license is granted by this information. OCD reserves the right to change this information without notice, and makes no warranty, express or implied, with respect to this information. OCD shall not be liable for any loss or damage, including consequential or special damages, resulting from any use of this information, even if loss or damage is caused by the negligence or other fault of OCD. This equipment includes parts and assemblies sensitive to damage from electrostatic discharge. Use caution to prevent damage during all service procedures. Table of Contents Description Page Power Control and Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65x0 POWER CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL UNIT and MASTER COMPUTER ASSEMBLY. . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Major Assemblies of the CONTROL UNIT/MASTER COMPUTER . . . . . . . SLIDE SUPPLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BARCODE READER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARTRIDGE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slide Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INNER PLUNGER ASSEMBLY, OUTER PLUNGER ASSEMBLY, SLIDE COUNT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPENSER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Control of SLIDE SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . DISTRIBUTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISTRIBUTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDE BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEPPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Initialization Routine of the SLIDE ROTOR . . . . . . . . . . . . . . . . . . . SAMPLE SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ac MOTOR, SAMPLE TRAY CARRIER, CLAMP, GEAR AND SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOME SENSOR, ENCODER DISK, TRAY POSITION SENSOR . . . . . . . . SHUTTLE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive Sample Identification (PSID). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular CONNECTOR PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED and Audible Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 9 11 13 13 13 16 16 17 17 18 19 21 22 27 27 27 29 30 31 31 31 32 32 33 33 34 35 35 37 37 37 37 37 37 37 37 15JAN98 – TG3360-1 RS-232 Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Communication Port Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pitch, Skew, and Tilt Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER SUPPLY PORT CONNECTOR PIN Assignments . . . . . . . . . . . . . . COMMUNICATIONS PORT CONNECTOR PIN Assignments . . . . . . . . . . . INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE METERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation of the Sample Metering System Overview . . . . . . . . . . . . . Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reaspiration Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROBOSCIS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIVOT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRUCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP DISPOSAL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDE PRESENT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drop Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WETNESS DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUP AND GUARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85x0 PYLON INTERCONNECT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25x0 TRUCK INTERCONNECT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82x0 A/D CONVERTER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63x0 WETNESS DETECTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WETNESS DETECTOR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33x0 SAMPLE and REFERENCE METERING DRIVER BOARD . . . . . . . . REFERENCE FLUID METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Theory - See the SAMPLE METERING Theory of Operation . . . . . . . . . . . . . . . . . . . . . REFERENCE FLUID METERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTATING CONE and CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFERENCE ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESERVOIR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HARNESSES, SENSORS, and SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . 84x0 REFERENCE METERING BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33x0 SAMPLE and REFERENCE METERING DRIVER BOARD . . . . . . . . RATE/COLORIMETRIC INCUBATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15JAN98 – TG3360-1 38 38 38 39 39 40 40 40 40 40 41 41 41 41 41 46 46 46 47 47 48 50 50 50 51 51 51 51 52 53 53 53 53 54 54 54 54 54 54 54 55 55 55 55 55 56 56 56 56 57 57 57 58 58 58 59 59 3 THEORY GUIDE PRECONDITION STATION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . INCUBATOR DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFERENCE SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . READ SYNC SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-ELEMENT ARRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEPPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RATE/COLORIMETRIC PICKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RATE/COLORIMETRIC REFLECTOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . READ SYNC SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFERENCE SLIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHUTTER and VARIABLE IRIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COLORIMETRIC INCUBATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECONDITION STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCUBATOR DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEPPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTOR AND GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENCODER DISK, 7-ELEMENT ARRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . COLORIMETRIC REFLECTOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COLORIMETRIC PICKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCARD DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEATER HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER WHEEL ASSEMBLY, STEPPER MOTOR . . . . . . . . . . . . . . . . . . . . PHOTODETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFLECTOMETER LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFLECTOMETER Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIC ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIC COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIDDLE COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMMUNO-RATE/COLORIMETRIC KNOB ASSEMBLY . . . . . . . . . . . . . . . POTENTIOMETRIC KNOB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . POTENTIOMETRIC COVER HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation of the COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT AND TURN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation of the LIFT AND TURN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . PIVOT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LATCH PAWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESET LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESET SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT POST LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INPUT STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 60 61 62 62 63 63 64 65 67 67 69 70 71 72 72 73 73 73 74 75 77 77 78 79 79 80 80 81 82 83 83 83 84 86 86 86 87 87 88 88 89 89 90 90 90 91 92 92 92 92 92 92 92 93 93 96 97 98 15JAN98 – TG3360-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POTENTIOMETRIC INCUBATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEATER PLATE ASSEMBLY Thermal Components . . . . . . . . . . . . . . . . . . . THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISK POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE MOTOR AND GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . CAP LIFT CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDE REGISTRATION CAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISK STABILIZER SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCARD TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SLIDE STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCUBATOR DISK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAPORATION CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING RETAINER (CAP SPRING ASSEMBLY) . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR/CM INCUBATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEATER PLATE ASSEMBLY Thermal Components . . . . . . . . . . . . . . . . . . . THERMISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISK DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . READ SYNC SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SENSOR CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM DISCARD CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEAR PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEALED BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANTI-ROTATION CLIP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCUBATOR DISK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENCODER DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENCODER CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHITE REFERENCE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRESSURE PAD SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE LOAD SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR/CM PICKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCARD CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RACK GUIDE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PICKER RACK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLAG ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PICKER FINGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR/CM PICKER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15JAN98 – TG3360-1 98 99 99 100 100 101 101 101 101 101 101 101 101 102 102 103 103 103 103 103 104 105 105 106 106 107 107 107 107 107 107 108 108 108 109 109 109 109 109 109 109 109 110 111 111 113 113 114 114 114 114 115 115 115 115 115 115 115 115 5 THEORY GUIDE Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR SLIDE TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PICKER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PICKER POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSERT BLADE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PICKER PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RACK and ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSERT BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATEN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE LOAD SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP LOCATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMMUNO-WASH FLUID METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immuno-Rate Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Possible Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMMUNO-WASH FLUID (IWF) METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incubation and Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple Point Immuno-Rate Calibration Model Description . . . . . . . . . . . . . . . . . . Calibration Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concentration Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Point Immuno-Rate Calibration Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concentration Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wash Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wash Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Algorithm Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concentration Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example Calibration Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example Sample Options - Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . IR/CM REFLECTOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functions of the REFLECTOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAMPHOUSE (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIRROR MOUNT CASTING (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFLECTOMETER HOUSING (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHUTTER ASSEMBLY (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIELD STOP ASSEMBLY (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EYEPIECE LENS (G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slide Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COLLIMATOR LENS (H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 116 117 117 118 118 118 118 119 119 120 121 121 122 122 122 122 125 125 125 126 126 127 127 128 129 129 129 130 130 130 130 131 131 131 131 132 132 132 132 132 133 133 133 133 134 135 135 135 135 136 137 137 137 137 137 138 138 138 15JAN98 – TG3360-1 FILTER WHEEL (J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 RELAY LENS (K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 PHOTODETECTOR (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Mechanical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 LAMPHOUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 SHROUD and SHROUD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Optics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 SIDE COVER AND SHUTTER MECHANISM . . . . . . . . . . . . . . . . . . . . . . . 142 IRIS DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 IRIS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 EYEPIECE LENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 LENS RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 FILTER WHEEL, POSITION SENSOR, FILTER WHEEL MOTOR, ELASTOMERIC DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 RELAY LENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 PHOTODETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 1350 COLORIMETRIC REFLECTOMETER BOARD . . . . . . . . . . . . . . . . . . 147 1700 STEPPER MOTOR DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . 147 1820 STEPPER MOTOR DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . 148 2570 TRUCK INTERCONNECT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 2900 DIAGNOSTIC DISPLAY BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 3050 TOUCH MATRIX INTERFACE BOARD . . . . . . . . . . . . . . . . . . . . . . . 149 3100 VIDEO DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 3200 DIAGNOSTIC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 3380 SAMPLE AND REFERENCE METERING DRIVER BOARD . . . . . . . 150 4200 COLORIMETRIC PHOTODETECTOR BOARD . . . . . . . . . . . . . . . . . . 151 4450 TRANSDUCER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 4700 ELECTROMETER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 5000 REFLECTOMETER/ELECTROMETER CONTROLLER (REC) BOARD 152 5100 ELECTROMETER ADAPTER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . 153 550x SLIDE SUPPLY BARCODE BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . 153 6060 DISTRIBUTION BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 6201 SERIAL COMMUNICATION (AT-4) BOARD . . . . . . . . . . . . . . . . . . . 154 6300 WETNESS DETECTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 6500 POWER CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 6600 UTILITY BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 7060 MOTHERBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 7170 INTERRUPT CONTROLLER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . 156 7290 MECHANISM COMPUTER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 7750 SERIAL ISOLATOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 7680 INTELLIGENT SERIAL I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 8050 RATE REFLECTOMETER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 810x PHOTODETECTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 8260 DROP DETECTION BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 8470 REFERENCE METERING BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 8570 PYLON INTERCONNECT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 8800 REFLECTOMETER DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . 161 8900 REFLECTOMETER MiC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 9000 MASTER COMPUTER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 910x DIGITAL I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 92xx MODULE CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 9350 ANALOG I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 9400 HUMIDITY AND VOLTAGE INPUT BOARD . . . . . . . . . . . . . . . . . . . 164 9510 THERMISTOR AMPLIFIER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . 164 960x AC MOTOR DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 9760 THERMAL DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 15JAN98 – TG3360-1 7 THEORY GUIDE FORMS PRINTER Series 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function of the CONTROL PANEL Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVER BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOGIC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOGIC BOARD JUMPER Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER SUPPLY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRINTHEAD Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRACTOR MECHANISM/ROLLER DRIVE Subsystem . . . . . . . . . . . . . . . . CARRIAGE DRIVE and Z-AXIS DRIVE Subsystem . . . . . . . . . . . . . . . . . . . RIBBON DRIVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 166 166 167 167 168 169 170 171 172 173 174 176 15JAN98 – TG3360-1 Power Control and Distribution Section 1: Power Control and Distribution Overview The System is configurable to operate on several voltage ranges from 190 to 240 V DC ±10% and at an AC line frequency of 50 or 60 Hz. Different configurations of POWER CORDS are available to allow connection to a variety of WALL RECEPTACLES found throughout the world. AC power enters the System through a standard IEC CONNECTOR on the front of the System. AC power passes through a LINE FILTER and the MAIN POWER SWITCH/CIRCUIT BREAKER to a large TRANSFORMER for isolation and voltage step-down. The TRANSFORMER has multiple input voltage TAPS that are configured at installation. The output of the TRANSFORMER provides 115 V AC through the CIRCUIT BREAKER PANEL to the MONITOR, AC DRIVER BOARDS, and POWER SUPPLIES of the System. Note One side of the secondary outputs of the TRANSFORMER is referenced to ground. The primary is not ground referenced. Detach 1 IEC CONNECTOR LINE FILTER LINE CORD MONITOR MAIN POWER SWITCH TRANSFORMER CIRCUIT BREAKER PANEL POWER PANEL POWER SUPPLIES E015_9001BC Line voltage and other critical conditions are monitored by the 65x0 POWER CONTROL BOARD located in the CIRCUIT BREAKER PANEL. If the input voltage or the temperature of the CARD RACK are out of specification or other critical conditions exist, a TRIP COIL in the MAIN POWER SWITCH is energized by the 65x0 BOARD to shut down the System. 15JAN98 – TG3360-1 9 THEORY GUIDE SOLID STATE RELAY (3) When the System is energized, power is applied to standby circuits, specifically: MONITOR, computers, RATE/COLORIMETRIC and IR/CM REFLECTOMETER LAMPS, FANS, and environmental circuitry. During the transition to ON mode, SOLID STATE RELAYS in the CIRCUIT BREAKER PANEL are energized to apply power to the operate circuits, specifically: COLORIMETRIC REFLECTOMETER LAMP, MOTOR DRIVER BOARDS and ISOLATION BOARD external serial PORTS. E015_0906ACA E015_0906AA CIRCUIT BREAKER PANEL Most of the POWER SUPPLY outputs can be measured at TEST POINTS located on the CIRCUIT BREAKER PANEL. This eliminates the need to remove PANELS to access individual POWER SUPPLIES. Another method of monitoring the POWER SUPPLIES is to touch the “ENVIRONMENTAL MONITORING” target. This screen displays the current output values and will alert the operator when any POWER SUPPLY is out of specification. Touching “START” updates the displayed values every 10 seconds. TEST POINTS E015_0911GCB E015_0911GC 10 15JAN98 – TG3360-1 Power Control and Distribution 65x0 POWER CONTROL BOARD The 65x0 BOARD, located behind the CIRCUIT BREAKER PANEL, is the POWER CONTROL BOARD in the System and has a computer which communicates with the 90x0 MASTER COMPUTER BOARD. The 65x0 BOARD checks the System for conditions that require either an immediate power shutdown or a sequence power shutdown. Immediate Power Shutdown The conditions for an immediate power shutdown are: • the INTERLOCK SWITCH for the CARD RACK is open • the temperature in the CARD RACK exceeds the limit Sequence Power Shutdown The conditions for a sequence power shutdown are: • a command from the MASTER COMPUTER • AC input voltage is high or low • the +5 V DC is low • No flow of air (Blower Malfunction) Detach 2 65x0 BOARD 15JAN98 – TG3360-1 CIRCUIT BREAKER PANEL E015_0908HCA E015_0908HA 11 THEORY GUIDE DISABLE/ENABLE SWITCH “EN S1” Caution NEVER leave the DISABLE/ENABLE SWITCH “EN S1” disabled for extended durations. The DISABLE/ ENABLE SWITCH does not prevent all shutdowns. A fire hazard exists if the SWITCH is left in the disable position. During the diagnostic procedures you will be instructed to use the DISABLE/ENABLE SWITCH “EN S1”. The SWITCH, located on the 65x0 BOARD, is used to disable the 65x0 BOARD to diagnose a malfunction causing a power shutdown. R1 T1 C4 C2 C7 231 C5 R6 CR1 RV1 C3 U4 C18 C25 C21 R5 U14 C26 R11 C38 U10 C30 C31 P1 C27 C28 C29 R12 C33 R15 C34 R14 R13 39 U15 40 R20 S2 D S 3 4 5 6 7 1 2 8 9 1 1 1 0 1 2 D S 16 TP7 EN S1 P4 DDDDD SSSSS TP5 TP4 TP3 TP2 R19 DDDDD SSSSS TP6 C27 R16 R17 D D S S 2 1 CR3 U21 + C36 TP1 U18 U17 R18 C35 U20 UPC U15 Y1 U16 SS 6500 U9 U8 R10 Q2 C32 2 1 U13 C22 ORDER + + R6 R7 R8 R9 + C40 C20 U12 C24 CR2 C39 C19 U7 U6 C23 + 19 20 U5 C17 1 U3 C13 C11 C18 P3 U11 U1 U2 VR2 RV2 PRI VR1 C15 C12 + R4 C10 C8 C9 R3 T2 6 132 2 +1 C14 Q1 P2 + C6 TP8 C1 PRI 1 3 1 4 DISABLE / ENABLE SWITCH "EN S1" E002_1068DCA E002_1068DA The 65x0 BOARD has LEDs to indicate the cause of some TRIP COIL shutdown conditions. See the Diagnostics section of the Service Manual. 12 15JAN98 – TG3360-1 CONTROL UNIT and MASTER COMPUTER ASSEMBLY Section 2: CONTROL UNIT and MASTER COMPUTER ASSEMBLY Overview As a system, the CONTROL UNIT/MASTER COMPUTER provides an interface for the operator to command operations of the System and to receive information from the System. The MASTER COMPUTER system provides high level - non-real time processing for the System. Major Assemblies of the CONTROL UNIT/MASTER COMPUTER • The CONTROL UNIT consists of the components associated with the operator interface: – VIDEO MONITOR – TOUCH FRAME – KEYBOARD – CONTROL UNIT PLATFORM – MONITOR ROCKER – CONTROL UNIT ARM – CABLES Detach 3 CONTROL UNIT PLATFORM E015_1904AA 15JAN98 – TG3360-1 13 THEORY GUIDE The MASTER COMPUTER ASSEMBLY is a chassis that houses and provides EMI shielding for: – 9000 MASTER COMPUTER BOARD (a personal computer motherboard) – 3100 VIDEO DRIVER BOARD – 3050 TOUCH MATRIX INTERFACE BOARD – FIXED DISK DRIVE – 6201 AT-4 SERIAL COMMUNICATION BOARD – 3200 DIAGNOSTIC BOARD – FAN – BATTERY – CABLES Detach 4 BATTERY MASTER COMPUTER BOARD CIRCUIT BOARDS FAN E015_1917GCB E015_1917GA • The FLOPPY DIAGNOSTIC ASSEMBLY is a chassis that houses and provides EMI shielding for: – FLOPPY DISK DRIVE – 2900 DIAGNOSTIC DISPLAY BOARD – SPEAKER – ACTUATION COUNTER 14 15JAN98 – TG3360-1 CONTROL UNIT and MASTER COMPUTER ASSEMBLY Detach 5 SPEAKER ACTUATION COUNTER FLOPPY DISK DRIVE 2900 DIAGNOSTIC BOARD E015_1914DCC E015_1914DA For more information on the circuit boards in the CONTROL UNIT/MASTER COMPUTER ASSEMBLY, see the CIRCUIT BOARDS section in the Theory Guide. For additional information, see the Diagnostics section of the Service Manual. 15JAN98 – TG3360-1 15 THEORY GUIDE Section 3: SLIDE SUPPLIES Overview The System contains 2 SLIDE SUPPLIES that are environmentally controlled slide storage and dispensing mechanisms. Slides are manually placed in the SLIDE SUPPLY by the operator through the CARTRIDGE LOAD DOOR into concentric RINGS. The top cartridge bar code label is read by the BARCODE READER BOARD to identify the type of chemistry, generation number and lot number of the slide cartridge in that NEST. The slides are stored in the SLIDE SUPPLY until a request from the 90x0 MASTER COMPUTER BOARD to dispense a slide is received by the 92x2 SLIDE SUPPLY 1 MCB or 92x3 SLIDE SUPPLY 2 MCB. The CARTRIDGE ROTOR moves the requested cartridge by rotating to the Dispense position. The PLUNGER moves the slide cartridge up into the Dispense station in the PLATEN BODY ASSEMBLY. The DISPENSER BLADE pushes the slide out of the cartridge and into the SLIDE BLOCK which moves the slide to the SAMPLE METERING ASSEMBLY for spotting. Detach 6 BAR-CODE READER BOARD PLATEN BODY ASSEMBLY CARTRIDGE ROTOR MOTOR DISPENSER ASSEMBLY CARTRIDGE LOAD DOOR E002_2040BCA E002_2040BA SLIDE SUPPLY 1 contains a total of 45 NESTS organized in 2 concentric RINGS. The OUTER RING contains 27 NESTS and the INNER RING contains 18 NESTS. SLIDE SUPPLY 2 contains a total of 30 NESTS organized in 2 concentric RINGS. The OUTER RING contains 18 NESTS and the INNER RING contains 12 NESTS. The ROTOR moves the cartridge NESTS to the Load position where cartridges can be loaded or removed, and to the Dispense position where a slide is dispensed. The ROTOR is driven bidirectionally by a STEPPER MOTOR. Each SLIDE SUPPLY contains a BARCODE READER BOARD; 55x1 for SLIDE SUPPLY 1 and 55x2 for SLIDE SUPPLY 2. At the completion of the “Cartridge Loading” operation, the ROTOR revolves so the bar code label on each cartridge can be read by the BARCODE READER BOARD. The bar code label contains information regarding test identification, slide generation number and lot number. 16 15JAN98 – TG3360-1 SLIDE SUPPLIES The DOOR SWITCH indicates to the 72x0 MECHANISM COMPUTER BOARD that the CARTRIDGE LOAD DOOR is closed and that the slide cartridges are to be scanned to determine the validity of the slide cartridges in the SLIDE SUPPLY. The DOOR SWITCH is a magnetic REED SWITCH that is actuated by a magnet in the DOOR. DOOR SWITCH E002_2007ACA E002_2007AA BARCODE READER BOARD Each BARCODE READER BOARD has 4 SENSORS - 2 SENSORS for the INNER RING and 2 SENSORS for the OUTER RING. The BARCODE READER BOARD allows the System to identify the Generation No., SO No. (test identification), and Lot No. of each cartridge. The purpose of the BARCODE READER BOARD is to read the 2 bar codes on the top cartridge label as the slide cartridges are rotated in the CARTRIDGE ROTOR. The signal from the BARCODE READER is sent to the 92x8 SLIDE SUPPLY BARCODE BOARD which analyzes the scanned digital data; determines the chemistry type, generation number, and lot number; and sends the outputs to the 72x0 MECHANISM COMPUTER BOARD. CARTRIDGE ROTOR ENCODER DISK 7-ELEMENT ARRAY A bidirectional STEPPER MOTOR drives the CARTRIDGE ROTOR clockwise or counterclockwise to move a specified NEST to either the Load position or the Dispense position. A 7-ELEMENT ARRAY and an ENCODER DISK provide the binary number of the NEST at the Dispense position to the 72x0 MECHANISM COMPUTER BOARD. NEST E002_2009ACC E002_2009AC 15JAN98 – TG3360-1 17 THEORY GUIDE The HOME SENSOR controls the stopping and precise positioning of the CARTRIDGE ROTOR. The 2 SLOTS in the ENCODER DISK for the STEPPER MOTOR indicate to the 92x2 SLIDE SUPPLY 1 MCB and to the 92x3 SLIDE SUPPLY 2 MCB that the nest position indicated by the 7-ELEMENT ARRAY is in the exact position for slide dispensing or cartridge loading. HOME SENSOR E002_2005ACD E002_2005AC Slide Dispensing After tests are programmed, the CARTRIDGE ROTOR moves the correct CARTRIDGE to the Dispense position. If more than one cartridge for the same test is in the SLIDE SUPPLY, the NEST is selected based on the order in which the cartridges were loaded. The cartridge loaded first will always be emptied before a subsequently loaded cartridge. DISPENSER BLADE, not visible E002_2040ACE E002_2040AA 18 15JAN98 – TG3360-1 SLIDE SUPPLIES At the Dispense position, a PLUNGER is activated which rises to press on the ANTI-BACKUP PLATEN inside the cartridge. The pressure exerted by the PLUNGER presses the stack of slides to the top of the cartridge and the cartridge to the top of the Dispense position. The SLIDE COUNT SENSOR on the PLUNGER ASSEMBLY measures the approximate number of slides in the cartridge. PLUNGER ASSEMBLY E002_2033ACJ E002_2033AA With the PLUNGER in the Dispense Position, the DISPENSER BLADE moves from the center of the SLIDE SUPPLY through the top of the cartridge to push a slide from the cartridge through the SLIDE TUNNEL in the PLATEN BODY and into the awaiting SLIDE BLOCK. When the dispense action is completed, the DISPENSER BLADE moves back to the home•position in the center of the SLIDE SUPPLY, and the PLUNGER is retracted to the home• position, to allow free movement of the CARTRIDGE ROTOR. INNER PLUNGER ASSEMBLY, OUTER PLUNGER ASSEMBLY, SLIDE COUNT SENSOR The 72x0 MECHANISM COMPUTER BOARD sends a signal to energize the PLUNGER MOTOR. The ac MOTOR activates the PLUNGER to rotate, then the ELEVATOR SPRING provides the force to raise the PLUNGER into a slide cartridge which raises the entire slide cartridge to the correct position for dispensing a slide. The slide cartridge raises all the slides so that the top slide is in the Dispense position. After the slide is dispensed, the ac MOTOR is energized and lowers the PLUNGER. The drive for the MOTOR is stopped after a FLAG enters the HOME SENSOR. PLUNGER MOTOR E002_2033ACK E002_2033AA 15JAN98 – TG3360-1 19 THEORY GUIDE ELEVATOR SPRING MOTOR HOME FLAG A 7-ELEMENT ARRAY (SLIDE COUNT SENSOR) is located at both the INNER PLUNGER and OUTER PLUNGER ASSEMBLIES. During the slide dispense cycle, the PLUNGER raises into the cartridge and a notched FLAG enters the SLIDE COUNT SENSOR. The SENSOR reads the position of the FLAG and determines how many slides remain in the slide cartridge. The accuracy of the slide count varies depending on the number of slides in the cartridge. SLIDE COUNT SENSOR SLIDE COUNT FLAG E002_2043ACE E002_2043AC The slide counting system uses a 7-ELEMENT ARRAY to determine the number of slides in a cartridge. The 7ELEMENT ARRAY monitors the position of an ENCODER DISK mounted on the PLUNGER ASSEMBLIES in each SLIDE SUPPLY. Cartridge slide counts occur during 2 different System operations - “Cartridge Loading” and “Sample Processing”. The slide counting process is slightly different during these 2 operations. “Cartridge Loading” The System obtains initial slide count information during “Cartridge Loading”. The same information is obtained when you do the “Recover Contents” procedure. When a cartridge is loaded, the SLIDE SUPPLY moves the cartridge to the BARCODE READER BOARD where the bar code on top of the cartridge is read. The cartridge is then moved over the PLUNGER ASSEMBLY. The PLUNGER lifts the cartridge to the height necessary to dispense a slide into a SLIDE BLOCK. As the PLUNGER moves, the attached ENCODER DISK blocks or unblocks elements of the 7-ELEMENT ARRAY. The pattern of blocked or unblocked elements determines the “Plunge Value” for each cartridge. Each “Plunge Value” represents a slide count range as indicated in the table. Plunge Value 0 1 2 3 4 5 6 7 Slide Count Range 0 1-5 6 - 10 11 - 15 16 - 20 21 - 30 31 - 40 41 - 60 Mid-Range Value 0 3 8 13 18 25 35 60* * When a “Plunge Value” of 7 is obtained, the slide count will be 60, not mid-range as would occur with “Plunge Values” 1 - 6. A slide count of 60 will be displayed for both 50- and 60-slide cartridges. During the “Cartridge Loading” or “Recover Contents” operation, the mid value in each range is assigned to the cartridge unless a slide count of 0 or 41 - 60 is detected. In those instances, a slide count of either 0 or 60 will be assigned respectively. “Sample Processing” During normal System operation, the software counts down the number of slides in each cartridge as slides are dispensed. When the next element of the 7-ELEMENT ARRAY is unblocked, the highest value for the 20 15JAN98 – TG3360-1 SLIDE SUPPLIES corresponding slide count range is assigned. As slides continue to be dispensed, the software continues counting down the slides in the cartridge. When 6 slides are left an Attention Code is posted on the ERROR LOG, alerting the operator to load another cartridge. Example: If a cartridge containing 22 slides is loaded into the System, the PLUNGER ASSEMBLY determines a “Plunge Value” of 5. The mid-range slide count is 25. As slides are dispensed during “Sample Processing”, the next element of the 7-ELEMENT ARRAY is unblocked. The slide count displayed becomes 20 because this is the highest value in the next slide count range. If a slide cartridge containing one slide is loaded into the System, a slide count of 3, mid-range for a “Plunge Value” of 1, is displayed in inventory. When the last slide is dispensed the “Plunge Value” determined is 0 and the DISPENSER BLADE MOTOR will not actuate. This prevents the DISPENSER BLADE from stalling against the slide cartridge causing Condition Codes AC3 for SLIDE SUPPLY 1 or BC3 for SLIDE SUPPLY 2. If these codes occur, adjustment of the PLUNGER might be necessary. Cartridge Inventory Retention The Cartridge Inventory Retention feature stores slide supply inventory information on the FIXED DISK. This feature allows storage of slide supply inventory while the System is deenergized. The Cartridge Inventory Retention database is updated each time “Cartridge Loading” is exited and each time an orderly shutdown is done. The Cartridge Retention database stores cartridge location, slide type, generation number, lot number, and slide count. If an orderly shutdown does not occur, for example, a power failure or deenergizing before the prompt, the slide count remains at the last updated value in the database. The slide count data is not updated in the Cartridge Inventory database each time a slide is used. DISPENSER ASSEMBLY STEPPER MOTOR DISPENSER BLADE DRIVE GEAR DISPENSER BLADE RACK BACK-UP ROLLER E002_2014BCB E002_2014BC The STEPPER MOTOR drives the DISPENSER ASSEMBLY that causes the DISPENSER BLADE to enter a slot at the top of the slide cartridge at the Dispense position. The DISPENSER BLADE pushes the top slide from the slide cartridge into the SLIDE BLOCK at the Dispense position. The STEPPER MOTOR is then reversed to return the DISPENSER BLADE to the home•position. When the DISPENSER BLADE enters the HOME SENSOR, the STEPPER MOTOR stops. The success of the dispensing operation is determined by counting the number of steps taken for the STEPPER MOTOR to return the DISPENSER BLADE to the HOME SENSOR which must equal the number of steps taken to dispense the slide. An incorrect count means the DISPENSER BLADE did not travel the full length to the SLIDE BLOCK ASSEMBLY. The BACK-UP ROLLER keeps the DISPENSER BLADE RACK engaged with the DRIVE GEAR. Note Condition codes AC3 and BC3 (slide jams) can be caused by a bent DISPENSER BLADE. You might want to attempt to straighten the DISPENSER BLADE if required. The OUTER RING may be more prone to jams due to the fact that the PLATEN must be lifted. Thus, this assembly is more susceptible to tolerance buildups. If you are addressing this concern pay close attention to the adjustments in this area. 15JAN98 – TG3360-1 21 THEORY GUIDE Environmental Control of SLIDE SUPPLIES HEAT PUMP ASSEMBLY The purpose of the environmental monitoring in the SLIDE SUPPLIES is to maintain the temperature at less than 24°C which helps to protect the slides in the slide cartridges. An additional purpose of the environmental monitoring is to monitor the relative humidity (RH) to prevent slide readings that are not correct. The RH specification for SLIDE SUPPLY 1 is 25 - 45%, and the RH specification for SLIDE SUPPLY 2 is 0 - 20%. The environmental monitoring for each of the SLIDE SUPPLIES has the following assemblies: • HEAT PUMP ASSEMBLY • INSTRUMENTATION THERMISTOR • CONTROL THERMISTOR • SALT PADS, DESICCANT PACKS • HUMIDITY SENSORS The SLIDE SUPPLY is cooled by the HEAT PUMP ASSEMBLY to maintain the temperature at less than 24×C. The HEAT PUMP ASSEMBLY has 3 THERMOELECTRIC UNITS installed between the COLD PLATE and the HEAT SINK. The COLD PLATE touches the bottom of the LOWER HOUSING ASSEMBLY. An AIR DUCT ASSEMBLY directs room-temperature air from the BLOWER ASSEMBLY to the HEAT PUMP ASSEMBLY. HEAT PUMP ASSEMBLY The THERMOELECTRIC UNIT cools the SLIDE SUPPLY by removing heat from the COLD PLATE and transferring it to the HEAT SINK. The COLD PLATE is thermally coupled to the SLIDE SUPPLY LOWER CASTING. If one of the THERMOELECTRIC UNITS fails, marginal cooling performance might be experienced. E002_2033ACL E002_2033AA THERMOELECTRIC UNIT COLD PLATE HEAT SINK HEAT PUMP 22 The HEAT PUMP ASSEMBLY is fastened to an aluminum CASTING surrounded by a plastic, insulated COVER. The aluminum walls and center post are designed as a low resistance path to conduct heat that has entered the SLIDE SUPPLY to the HEAT PUMP. Because of the size of SLIDE SUPPLY 1 and the larger surface area for heat to penetrate, the HEAT PUMP is designed to be more efficient. The HEAT PUMP for SLIDE SUPPLY 1 incorporates a corrugated sheet metal HEAT SINK that decreases the resistance of heat to move from the thermal electrics to the air flow path. E002_2020ACB E002_2020AC 15JAN98 – TG3360-1 SLIDE SUPPLIES Detach 7 THERMISTOR E002_2008DCE E002_2008DC The temperature of the SLIDE SUPPLY is checked by the INSTRUMENTATION THERMISTOR and the CONTROL THERMISTOR. The INSTRUMENTATION THERMISTOR sends the analog voltage to the 95x0 THERMISTOR AMPLIFIER BOARD, the 93x0 ANALOG I/O BOARD, and the 72x0 MECHANISM COMPUTER BOARD where the voltage is converted to a temperature value. Also, the CONTROL THERMISTOR sends an analog voltage to the 95x0 BOARD, the 93x0 BOARD, and the 72x0 BOARD where the voltage is compared to a reference voltage. The MECHANISM COMPUTER then sends a signal which energizes or deenergizes the HEAT PUMP ASSEMBLY. 15JAN98 – TG3360-1 23 THEORY GUIDE SLIDE SUPPLY 2 SLIDE SUPPLY 2 DESICCANT PACK (10) DESICCANT PACK (10) TRAY ACCESS DOOR E002_2026ACB E002_2026AA TRAY ACCESS DOOR E002_2026ACB E002_2026AA The RH of the SLIDE SUPPLIES is maintained by the use of SALT PADS for SLIDE SUPPLY 1 and DESICCANT PACKS for SLIDE SUPPLY 2. The SLIDE SUPPLY must be sealed to prolong the life of the SALT PADS and DESICCANT PACKS, which are also affected by the ambient relative humidity. Air infiltration occurs during “Cartridge Loading” and during dispensing of the slides. A good seal around wires and GASKETS is important for maximum SALT PAD and DESICCANT PACK life. Analog Control HEAT PUMP The THERMISTOR for the SLIDE SUPPLY provides an analog voltage to indicate the temperature through the 95x0 THERMISTOR AMPLIFIER BOARD to the 93x0 ANALOG I/O BOARD. The 93x0 BOARD sends a signal to energize and deenergize the HEATER to control the temperature. HEAT PUMP ASSEMBLY The 93x0 BOARD sends a “Heater Control” signal to the COMPARATOR and the OPERATIONAL AMPLIFIER on the 97x1 THERMAL DRIVER BOARD which controls a POWER TRANSISTOR. The POWER TRANSISTOR controls the amount of current to the THERMOELECTRIC HEAT PUMP. An LED on the 97x1 BOARD operates to indicate when the HEAT PUMP is energized. E002_2033ACL E002_2033AA 24 15JAN98 – TG3360-1 SLIDE SUPPLIES THERMOELECTRIC HEAT PUMPS ELECTRONICS CARD RACK POWER PANEL SLIDE SUPPLY 93x0 BOARD 97xx BOARD THERMOELECTRIC HEAT PUMP 95x0 BOARD CARD RACK THERMISTOR E015_9000BC The THERMISTOR monitors the temperature which provides an analog voltage through the 95x0 THERMISTOR AMPLIFIER BOARD to the 93x0 ANALOG I/O BOARD for conversion to temperature readings. The 93x0 BOARD sends an “Analog Control” signal to the COMPARATOR and the OPERATIONAL AMPLIFIER on the 97x2 THERMAL DRIVER BOARD which controls a POWER TRANSISTOR. The POWER TRANSISTOR controls the amount of current to the HEAT PUMP. An LED indicates that the HEAT PUMP is cooling. 15JAN98 – TG3360-1 25 THEORY GUIDE HUMIDITY SENSORS HUMIDITY SENSOR E002_2008DCD E002_2008DC The 2 HUMIDITY SENSORS in SLIDE SUPPLY 1 monitor the high humidity limit and the low humidity limit. The single HUMIDITY SENSOR in SLIDE SUPPLY 2 monitors the high humidity limit. The HUMIDITY SENSORS provide a voltage to the 94x0 HUMIDITY AND VOLTAGE BOARD, the 93x0 ANALOG I/O BOARD, and the 72x0 MECHANISM COMPUTER BOARD which determines if the relative humidity is within the specification. The SALT PADS and the DESICCANT PADS control the humidity by absorbing or releasing moisture inside the SLIDE SUPPLY. 26 15JAN98 – TG3360-1 DISTRIBUTOR Section 4: DISTRIBUTOR DISTRIBUTOR ASSEMBLY Overview The DISTRIBUTOR has 2 main functions: 1. To deliver the slides from the SLIDE SUPPLY to the Metering Position for spotting and then to the appropriate INCUBATOR for processing; 2. To hold patient samples and sample TIPS for delivery to the Metering Position where the samples are spotted onto the slides. Each patient sample is applied with a new TIP. SAMPLE SUPPLY CARRIER RATE/COLORIMETRIC SHUTTLE COLORIMETRIC SHUTTLE SLIDE BLOCK (6) SLIDE ROTOR E015_2603DCA E015_2603DA To accomplish these tasks, the DISTRIBUTOR is made up of a number of assemblies that include: • SLIDE ROTOR • 6 SLIDE BLOCKS • ROTOR STOP SENSOR • SAMPLE SUPPLY • RATE/COLORIMETRIC SHUTTLE • COLORIMETRIC SHUTTLE 15JAN98 – TG3360-1 27 THEORY GUIDE Slide Path A slide is inserted into the SLIDE BLOCK at the Dispensing Position of one of the SLIDE SUPPLIES. The SLIDE ROTOR rotates in a clockwise direction to move the SLIDE BLOCK from the Dispensing Position, past a REGISTRATION ROLLER, to the Metering Position. The REGISTRATION ROLLER pushes the slide into the SLIDE BLOCK so that the slide is in the correct position for spotting. After the slide is spotted, it is transported to one of the INCUBATORS for processing. At the RATE/ COLORIMETRIC INCUBATOR and COLORIMETRIC INCUBATOR, a SHUTTLE moves the slide out of the SLIDE BLOCK and into the PRECONDITION STATION of the assigned INCUBATOR. The next action by the SHUTTLE moves the slide into the INCUBATOR. At the PIC ASSEMBLY, the INPUT STATION ELEVATOR transfers the slide. The INPUT BLADE moves the slide out of the SLIDE BLOCK, onto the ELEVATOR, and then into one of the 2 INCUBATORS in the PIC ASSEMBLY. Detach 8 INPUT STATION R O IC T P BA U C IN IR/ CM PM PIC ASSEMBLY E015_7210DCB E015_7210DA The empty SLIDE BLOCKS return to the Dispensing Positions of the SLIDE SUPPLIES to complete the rotation of the SLIDE ROTOR. If a test is cancelled by the 72x0 MECHANISM COMPUTER BOARD after dispensing a slide, the unused slide is not shuttled out of the SLIDE BLOCK. The subsequent loading of a new slide into the SLIDE BLOCK pushes the unused slide out of the SLIDE BLOCK and into the SLIDE DISPOSAL PAN. 28 15JAN98 – TG3360-1 DISTRIBUTOR SLIDE ROTOR ROTOR ARM levered FLAG ROTOR STOP SENSOR The DISTRIBUTOR ROTOR is a STEPPER MOTORdriven device with 6 equally spaced ARMS relating to its 6 discrete stopping positions. The end of each ARM holds a SLIDE BLOCK. At the end of each DISTRIBUTOR movement, the 6 SLIDE BLOCKS align with SLIDE SUPPLY 1, SLIDE SUPPLY 2, the Metering Position, RATE/COLORIMETRIC INCUBATOR, COLORIMETRIC INCUBATOR, and PIC INPUT STATION ELEVATOR. The ROTOR STOP SENSOR, a single HORSESHOE SENSOR, detects that the ROTOR has correctly reached a stopping position. One of the 6 ARMS actuates a levered FLAG so that the SENSOR is interrupted at each stopping position. E002_1664ACB Detach 9 REGISTRATION ROLLER levered FLAG ROTOR STOP SENSOR 15JAN98 – TG3360-1 E002_1674DCI 29 THEORY GUIDE SLIDE BLOCKS large ROLLER SPRING, not visible small ROLLER (2) SPRING (2), not visible LOCATING PIN, not shown LOCATING PIN, not shown E002_1605DCC E002_1605DC The SLIDE BLOCK transports a slide from position to position and places the slide at the correct INCUBATOR. One type of SLIDE BLOCK is used in all 6 positions. The DISPENSE BLADE of the SLIDE SUPPLY inserts the slide partially into the SLIDE BLOCK at the Dispense Position of the SLIDE SUPPLY. The SLIDE ROTOR moves the SLIDE BLOCK past the REGISTRATION ROLLER which follows the outer edge of the SLIDE BLOCK to push the slide into the correct horizontal position. A set of ROLLERS and SPRING ASSEMBLIES, within the SLIDE BLOCK, align the slide vertically. The vertical and horizontal positioning of the slide is critical for the drop of fluid to be properly placed on the slide when it is at the Metering Position. To provide vertical alignment of the SLIDE BLOCK to the Dispense Position, Metering Position, PRECONDITION STATIONS, and PIC INPUT STATION, a portion of the SLIDE BLOCK has some vertical movement. The SLIDE BLOCK consists of 2 parts linked by a flexible plastic strip and 4 LOCATING PINS. The linkage allows the portion of the SLIDE BLOCK carrying the slide to ride on the RAMPS of the various stations independently of the portion of the SLIDE BLOCK secured to the ROTOR ARM. 30 15JAN98 – TG3360-1 DISTRIBUTOR Mechanical Drive GEAR AND PULLEY ASSEMBLY BELT PLATE AND POST ASSEMBLY A12B3 SLIDE ROTOR MOTOR E002_1674DCJ The A12B3 SLIDE ROTOR MOTOR drives the SLIDE ROTOR through an interface of a COGGED TIMING BELT, PULLEYS, and GEARS which are mounted on a PLATE ASSEMBLY. This DRIVER ASSEMBLY provides drive to a pressure CLUTCH GEAR at the base of the SLIDE ROTOR. The CLUTCH provides operator safety by limiting the torque of the drive of the SLIDE ROTOR. Electrical Circuits The A12B3 MOTOR that drives the SLIDE ROTOR is a dc STEPPER MOTOR that rotates in response to dc pulses from the 17x1 STEPPER MOTOR DRIVER BOARD in the Power Panel. The 92x0 DISTRIBUTOR/INPUT STATION MCB in SLOT 9 drives the number of pulses that the 17x1 BOARD sends to the MOTOR. The 92x0 MCB also monitors the A12U4 SLIDE ROTOR SENSOR to track the position of the SLIDE ROTOR. The 92x0 MCB communicates with the 72x0 MECHANISM COMPUTER BOARD which controls and tracks the status of the SLIDE ROTOR. This computer control allows for programmed speed, acceleration and deceleration of the SLIDE ROTOR. STEPPER MOTOR The SLIDE ROTOR moves from one position to the next position in 4 seconds. The 72x0 MECHANISM COMPUTER BOARD issues a command to the STEPPER MOTOR to accelerate to 2400 half steps per second. This takes approximately 0.15 seconds. The MOTOR moves 400 half steps per revolution and one SLIDE BLOCK 15JAN98 – TG3360-1 31 THEORY GUIDE advance requires 6 MOTOR revolutions, or 2400 half steps. The velocity is maintained for approximately 1 second, then the STEPPER MOTOR is commanded to decelerate another 0.15 seconds. The STEPPER MOTOR drives the ROTOR into the SLIDE ROTOR SENSOR through 1 more step, and the SENSOR signals the software that the ROTOR is in position. The acceleration/deceleration is rapid, yet gradual enough to prevent “slosh”, or spillage of sample fluid from the drop-hole onto other parts of the slide. This is the normal ramp speed of the SLIDE ROTOR STEPPER MOTOR. Initialization The initialization and homing of the DISTRIBUTOR is linked with the initialization of the other assemblies of the System. The SHUTTLES for the RATE/COLORIMETRIC INCUBATOR and the COLORIMETRIC INCUBATOR must be at their home positions before any DISTRIBUTOR ROTOR motion. The 72x0 MECHANISM COMPUTER BOARD determines that the SHUTTLES are in the home positions before commanding the DISTRIBUTOR to home. The INPUT BLADE and the INPUT STATION ELEVATOR must be moved to retracted/safe positions before initialization of the DISTRIBUTOR ROTOR. ROTOR STOP SENSOR Initialization of the DISTRIBUTOR causes the SLIDE ROTOR to move in the following manner. The first ROTOR movement is slow speed until actuation of the ROTOR STOP SENSOR because the STEPPER MOTOR slow steps until the SENSOR is actuated. After the position of the ROTOR is known, the next ROTOR movement is normal ramp speed to the actuation of the STOP SENSOR again. The purpose of the second move is to assure a clear ROTOR path. Even if the ROTOR is already in a valid ROTOR position, it will be moved to the next position. E002_1664ACC The SLIDE ROTOR initialization routine does not end at this point if the entire System has been initialized. In a complete initialization, the SLIDE ROTOR will perform additional steps after the other assemblies complete initialization. The SLIDE ROTOR will step each ARM to the PIC PM INCUBATOR. At the PIC INPUT STATION, the INPUT BLADE will perform the cycle of loading slides into the PM INCUBATOR for each ROTOR ARM. This routine clears the SLIDE BLOCKS of any possible slides. Software Initialization Routine of the SLIDE ROTOR At the end of initialization of the SLIDE ROTOR, the 72x0 MECHANISM COMPUTER BOARD will assign the SLIDE BLOCK and ROTOR ARM at the Metering Position as a PM type. The next ARM counterclockwise will be assigned to CM and so forth. This sequence, counterclockwise, from the start would be as follows: PM, CM, RATE/ CM, PM, CM, RATE/CM. At the end of initialization, the ARM at the RATE/CM INCUBATOR is identified as RATE/CM. The ARM at the CM INCUBATOR is identified as a CM. The ARM at the PIC INCUBATOR is identified as PM. The ARM at SLIDE SUPPLY 1 is assigned as RATE/CM and the ARM at SLIDE SUPPLY 2 is CM. This assignment occurs any time the SLIDE ROTOR is initialized. Whichever SLIDE BLOCK and ARM is at the Metering Position is assigned as a PM SLIDE BLOCK and ARM. There is no hardware difference between the SLIDE BLOCKS or ROTOR ARMS. This assignment is only a software function in the MECHANISM COMPUTER and is necessary for timing of machine events. 32 15JAN98 – TG3360-1 DISTRIBUTOR SAMPLE SUPPLY SAMPLE SUPPLY SAMPLE TRAY CARRIER The SAMPLE SUPPLY is a component of the DISTRIBUTOR and supports the SAMPLE TRAY CARRIER, an assembly that has been nicknamed the “flower pot”. The design allows the use of Primary Container Sampling (sampling directly from a TUBE) and from CUPS with the use of the proper ADAPTERS. The SAMPLE SUPPLY can hold a maximum of 40 sample containers and TIPS. The SAMPLE SUPPLY usually advances in a clockwise direction to bring up a specific sample. For a STAT sample, the SAMPLE SUPPLY moves in either direction to obtain the shortest path to the Metering Position. E002_1638ACF A 7-ELEMENT ARRAY identifies the position of the CUP at the Metering Position by interpreting an ENCODER DISK on the SAMPLE SUPPLY GEAR AND SHAFT ASSEMBLY. The ENCODER DISK and 7-ELEMENT ARRAY are checked 2 times to make sure the SAMPLE SUPPLY is in the correct position; once before the SAMPLE SUPPLY moves and again after it stops. This routine helps eliminate the possibility of the SAMPLE SUPPLY stopping in the wrong position and sampling from the wrong sample container. The design of the SAMPLE TRAY allows for direct aspiration from the original collection container. The TRAY holds 16 x 100 mm TUBES directly while additional tube sizes, micro-collection containers, and CUPS are accommodated through the use of color-coded ADAPTERS. A TAB on the ADAPTER identifies the type of container to the System, which uses this information to control the limit of travel and rate of descent of the PROBOSCIS during aspiration. Therefore, different sample container sizes can be processed at the same time. With Positive Sample Identification (PSID), a sample identification number, assigned by the laboratory is stored, along with the sample program, in the Laboratory Information System, LIS, or entered at the KEYBOARD. A BAR CODE LABEL containing this number is affixed to the sample container. In the PSID mode, the TRAY moves in a clockwise direction. When “START SAMPLING” is touched, the System moves the sample past the BARCODE SCANNER and the coded ID is matched with the specific test programming for that sample. If the SCANNER does not find a sample within 20 positions, sampling will stop. 15JAN98 – TG3360-1 33 THEORY GUIDE ac MOTOR, SAMPLE TRAY CARRIER, CLAMP, GEAR AND SHAFT ASSEMBLY CLAMP A bidirectional ac MOTOR, A12B4, drives the parts which move a specific SAMPLE TRAY and sample container to the Metering Position. The 4 SAMPLE TRAYS are installed on the SAMPLE TRAY CARRIER. The CLAMP, which is part of the SAMPLE TRAY CARRIER, provides correct alignment of the SAMPLE TRAY and sample container with the PROBOSCIS ASSEMBLY at the Metering Position. E002_1638ACG The GEAR AND SHAFT ASSEMBLY is driven, through the WORM DRIVE CLUTCH ASSEMBLY and the CAM AND SHAFT ASSEMBLY, by the A12B4 SAMPLE TRAY ac MOTOR. The 72x0 MECHANISM COMPUTER BOARD controls the ac MOTOR through the 91x4 DIGITAL I/O BOARD and the 96x1 ac MOTOR DRIVER BOARD. Detach 10 GEAR AND SHAFT ASSEMBLY CAM AND SHAFT ASSEMBLY WORM DRIVE CLUTCH ASSEMBLY A12B4 SAMPLE TRAY MOTOR 34 E002_1609DCD E002_1609DC 15JAN98 – TG3360-1 DISTRIBUTOR HOME SENSOR, ENCODER DISK, TRAY POSITION SENSOR ENCODER DISK A12U1 7-ELEMENT ARRAY A12U5 SAMPLE SUPPLY HOME SENSOR E002_1611DCC E002_1611DC The position of the SAMPLE TRAY and the sample container is identified by the ENCODER DISK and the A12U1 TRAY POSITION SENSOR which is a 7-ELEMENT ARRAY. The 72x0 MECHANISM COMPUTER BOARD determines the position of the next sample for the Metering Position, calculates the number of positions to move, and selects clockwise or counterclockwise movement of the SAMPLE TRAY MOTOR. The MECHANISM COMPUTER reads the position of the SAMPLE TRAY CARRIER each time a FLAG enters the A12U5 HOME SENSOR. This SENSOR is located in the SAMPLE DRIVE ASSEMBLY and monitors the ac MOTOR revolutions. When the A12U1 TRAY POSITION SENSOR detects the requested position, the MECHANISM COMPUTER commands the ac MOTOR to stop. The MECHANISM COMPUTER monitors the A12U1 TRAY POSITION SENSOR and the A12U5 SAMPLE SUPPLY HOME SENSOR through the 91x4 DIGITAL I/O BOARD. SHUTTLE ASSEMBLIES The DISTRIBUTOR contains 2 SHUTTLE ASSEMBLIES: • RATE/COLORIMETRIC SHUTTLE • COLORIMETRIC SHUTTLE The SHUTTLE moves a slide from the SLIDE BLOCK to the PRECONDITION STATION and then moves the slide from the PRECONDITION STATION into the INCUBATOR. An ac MOTOR moves the SHUTTLE in a rectangular path of travel. First it moves upward, then forward, then downward and back. The 72x0 MECHANISM COMPUTER BOARD checks the status of the SHUTTLE HOME SENSOR. If all is correct, the MECHANISM COMPUTER sends a signal to energize the ac DRIVE MOTOR through the 96x0 ac MOTOR DRIVER BOARD. The MECHANISM COMPUTER then determines if the SHUTTLE left home and waits for the HOME SENSOR to activate again so it can deactivate the DRIVE MOTOR. Certain conditions must be met before the DRIVE MOTOR is energized. The MECHANISM COMPUTER checks that the SHUTTLE ASSEMBLY, the SLIDE ROTOR, and the INCUBATOR DISK are in the correct position before sending a signal to the MOTOR. The 2 SHUTTLE ASSEMBLIES are electrically similar and operate in the same manner. 15JAN98 – TG3360-1 35 THEORY GUIDE The MECHANISM COMPUTER controls the A12B5 RATE SHUTTLE MOTOR through the 92x5 RATE INCUBATOR MCB and the 96x1 ac MOTOR DRIVER BOARD. It monitors the A12U7 RATE SHUTTLE HOME SENSOR through the 92x5 MCB. The A12B1 COLORIMETRIC SHUTTLE MOTOR is controlled by the MECHANISM COMPUTER through the 92x6 COLORIMETRIC SYSTEM MCB and 96x1 ac MOTOR DRIVER BOARD. The A12U2 CM SHUTTLE HOME SENSOR is monitored through the 92x6 MCB. 36 15JAN98 – TG3360-1 Positive Sample Identification (PSID) Section 5: Positive Sample Identification (PSID) Overview The PSID consists of a CCD SCANNER that interfaces with the 72x0 MECHANISM COMPUTER BOARD through the 77x0 SERIAL ISOLATOR BOARD and 76x0 SERIAL I/O BOARD. The SCANNER decodes the sample ID bar code and on request from the 72x0 BOARD, transmits the ID to the 72x0 BOARD through an asynchronous serial link to the 77x0 BOARD. The 72x0 BOARD then matches the sample ID with its program and processes the appropriate tests. The SCANNER is self-contained and requires one CONNECTOR for power and for the serial communications link. Hardware Introduction The major components of the PSID are the CCD SCANNER and the host instrument or equipment. Electrical power is generally supplied to the SCANNER by the host system. Modular CONNECTOR PORTS The RS-232 Communications Port is an 8-PIN SOCKET modular CONNECTOR PORT and is the PORT for connecting the ASYNCHRONOUS SERIAL COMMUNICATIONS INTERFACE CABLE. This PORT allows triggering capability at PIN 2 for an external triggering device, such as an object SENSOR or a SWITCH. Power and ground connections are also on this PORT. The POWER SUPPLY PORT is a 6-PIN SOCKET modular CONNECTOR PORT and can be used as an alternative power connection to the SCANNER. PIN 3 offers Code 39 Wand Emulation output or second SCANNER digital input (black high) and bar image out. This PORT is not used on the 950 System. LED and Audible Indicator The yellow LED on the back PANEL is a visual indicator. Normally defaulted to “OFF”, the yellow LED may be enabled to blink on either a “Good Read” (decoded) scan or a “No Read” scan. A “No Read” scan means that a scan timeout has expired without a valid read. The reason for this may be one or more of the following: 1. no label present 2. wrong type label 3. no valid check digit 4. insufficient votes 5. unreadable label The BEEPER is linked to the yellow LED. The blink/beep can be disabled by using a configuration command. The BEEPER also sounds on power up or reconfiguration as an audible self-check of software configuration. Operating Theory Normal Operation The CCD SCANNER looks for data input from the scanning circuitry, which includes the LED bar that illuminates the barcode target, the CCD SENSOR which focuses the scattered optical energy from the barcode symbol, and the peak detectors and comparator which generates a digital representation of the barcode symbol to send to the microprocessor. When the SCANNER sees a trigger, a read cycle is started. The read cycle is completed when a barcode is read or the read timeout expires. 15JAN98 – TG3360-1 37 THEORY GUIDE Detach 11 LED Pulse Generator LED Bar CCD Sensor Peak Detectors and Comparators Auxiliary Trigger (Optional) Second Scanner Digital Input (Optional) Decode RS - 232 Communications E015_9012BC A trigger can be a hardware trigger, such as an object SENSOR, or a software command, such as a serial trigger command or continuous read trigger mode command, from the host. During a read cycle, the SCANNER evaluates scanner data for a valid barcode symbol. If a valid barcode symbol is seen, data is placed into the output queue where it may be transmitted to the host through the RS-232 communications port. An option is available to configure the SCANNER to send a “No Read” message when the read cycle times out. RS-232 Communications Port Caution Do not use a host communications CABLE with more wires connected than are required for the application. Damage to equipment within the system may result if the communications connection is improperly wired. The RS-232 communications port CONNECTOR at the SCANNER is an 8-PIN modular SOCKET for interfacing to the host system or other communications device. All communications between the host system and the SCANNER occur using an Asynchronous ASCII protocol. Miscellaneous Communication Port Pinouts The following signals not related to communications are also available at this port. Below is a brief description of some of the RS-232 Communications Port pinouts, indicating whether they are an input or output line. PIN 2 Is a Trigger/Enable (input) PIN 6 +5 V DC Power PIN 1 Shield PIN 3 Ground Auxiliary Trigger The scanned data input can be controlled by an external triggering device connected to the Trigger/Enable line (PIN 2 of the Communications Port). The actual trigger can be as simple as a foot actuated RELAY SWITCH and as sophisticated as an optical SENSOR. The Trigger/Enable line action depends on output mode, as follows: • Bar/Space Output Mode - continuous scan while active • ASCII Output Mode - read while active - transmit on timeout 38 15JAN98 – TG3360-1 Positive Sample Identification (PSID) Power Requirements Power is supplied to the SCANNER from the 77x0 SERIAL ISOLATOR BOARD. DC operating voltage is +5 volts. The power source is connected to the I/O Port through PINS 1, 3, and 6 of the CONNECTOR. Pitch, Skew, and Tilt Tolerance Y PITCH OR ROLL R o Rotation about the Y-axis + _7 X Z Bar Code Label Y SKEW OR YAW o Rotation about the X-axis +25 /-40 o (0 to +15 specular reflection interference) o R X Z Bar Code Label Y TILT Rotation about the Z-axis controlled by bar code length and height X R Z Bar Code Label Back View R = Rotation E015_9011DC 15JAN98 – TG3360-1 39 THEORY GUIDE Electrical Specifications Operating Currents Operating Voltage: Operating Current: +5 V ± 5% 150 mA POWER SUPPLY PORT CONNECTOR PIN Assignments Not used on the 950 System. PIN 1 2 3 4 5 6 6-PIN Modular CONNECTOR Signal Function +5 V DC 5 volt Power Connection Reserved Do not connect Optional configurations Auxiliary Input/Output available Default Reset Reset to factory default configuration Ground System Ground Shield Cord Shield COMMUNICATIONS PORT CONNECTOR PIN Assignments PIN 1 2 3 4 5 6 7 8 8-PIN Modular CONNECTOR Signal Function Shield Cord Shield Trigger/Enable Trigger Signal to Decoder Scanner Enable (Input) Ground System Ground RX Data Recieve Data (Input) TX Data Transmit Data (Output) VCC +5 V DC Power (Input) RTS Ready to Send (Output) CTS Clear to Send (Input) INDICATORS Yellow LED - Good Read or No Read LED When illuminated, this LED indicates a good (valid) read or no (failed) read, corresponding to the BEEPER/LED configuration command setting. BEEPER The BEEPER is connected in parallel with the good read/no read INDICATOR LED to give audible indication of valid or failed reads. The good read/no read INDICATOR is configurable and can be disabled. 40 15JAN98 – TG3360-1 SAMPLE METERING Section 6: SAMPLE METERING Metering Theory Introduction Metering is the delivery system that ensures that the proper amount of fluid is deposited onto the slide. The function of the METERING ASSEMBLY is to deliver 10 µL or 11 µL of the proper fluid (patient sample or reference fluid) to the slide in the precise area it is needed. To do this basic function, metering must accomplish numerous subfunctions which include: • Picking up a SAMPLE TIP • Aspirating reference fluid • Aspirating patient fluid • Precisely positioning the TIP for both CM and PM slides • Accurate and precise dispensing of the patient sample • Accurate and precise dispensing of the reference fluid • Maintaining pressure in the SAMPLE TIP between drops • Removing the used SAMPLE TIP Operational Overview All of the analog to digital conversion of PRESSURE TRANSDUCER signals from both PUMPS and wetness detection is done on the 8260 A/D CONVERTER BOARD and is controlled by the 92x9 REFERENCE METERING AND TRANSDUCERS MCB. The need to share the pressure and wetness information between the 92x4 SAMPLE METERING MCB and the 92x9 MCB makes the 2 systems heavily interrelated at the software level. This presents unique challenges in timing of the movements. The reference drop is always 10 µL. The sample drop may be 10 or 11 µL depending on the the chemistry being processed. Accuracy of all drops must be within ±0.5 µL. Precision must be 0.2 µL SD or less. The sample and reference drops must match within 0.5 µL. The volume aspirated for REFERENCE METERING is always 6 drops plus a volume for waste and pressure control. The volume aspirated for SAMPLE METERING depends on the number of tests programmed and the type of tests requested. The fluid volume is adjusted so that less waste is used for smaller TIP fills. The waste volume ensures that dispensing is done from the cylindrical portion of the TIP, not when the fluid level is in the tapered portion. This provides greater pressure uniformity. A portion of the aspirated volume is dispensed back into the fluid to help equalize pressure and ensure that fluid is at the end of the TIP. This is called priming. Pressure is constantly monitored on SAMPLE METERING and PUMP steps are taken to keep the pressure constant. This is called servoing. There are 3 servo levels set based on the volume in the TIP. REFERENCE METERING does not servo. Control of the devices is through the SENSORS and step counting. For instance, the position of the PUMPS is absolutely known only at one point - when the FLAG is in the SENSOR. After that the software keeps track of the steps taken in the aspirate (away from the SENSOR) and dispense (toward the SENSOR) directions to know where the PUMP PISTON is. Other devices, like the TRUCK have more than one SENSOR, but still move into and out of other positions based on steps counts; for example, TRUCK at Tip Position. Normal Operation The assemblies must be initialized. Initialization moves all of the mechanisms on SAMPLE and REFERENCE METERING to validate their ability to function. The single exception is the REFERENCE METERING PUMP. This device will move in the dispense direction if it is out of the SENSOR. If it is in the SENSOR, it will not move. The reason for this exception has to do with the commands available to the 72x0 MECHANISM COMPUTER BOARD to control the assemblies. On the first reset at STANDBY to ON transition, the REFERENCE PUMP will move out of and back into the SENSOR to initially locate itself. 15JAN98 – TG3360-1 41 THEORY GUIDE The following sequence occurs when metering is operating correctly: Fluids Prepared and Chemistry System Programmed The operator does the following: • prepares the sample fluid and places it on the SAMPLE SUPPLY • installs a disposable RESERVOIR and puts a TIP onto the REFERENCE TIP RETAINER • programs the number and type of tests desired SAMPLE METERING TIP is Put on the PROBOSCIS When metering is turned on, SAMPLE METERING moves the TRUCK forward to the Tip Position over the SAMPLE SUPPLY. If the PUMP is not reset, i.e., FLAG in the SENSOR, the PUMP is also moved to try and reset it. The PROBOSCIS is brought down onto the TIP and the TIP is seated onto the PROBOSCIS. Just as the PROBOSCIS begins to seat, the movement is slowed for more torque to better seat the TIP. The PROBOSCIS moves to the Lift Position and the TRUCK moves back to the sample container, above the sample fluid. The REFERENCE METERING TIP has already been installed. Fluid is Aspirated The 72x0 MECHANISM COMPUTER BOARD sends a command to meter that includes the total amount to be aspirated. The 92x4 SAMPLE METERING MCB then adjusts the aspirated volume based on the total volume. Based on this, the maximum “sniff” depth and the total depth for aspiration are found. A request is sent to the 92x9 MCB to read the PRESSURE TRANSDUCER. This atmospheric reading is used in error reporting. Information from the second PCS SENSOR, which is wired into the 92x9 MCB, is returned to SAMPLE METERING. At this time, REFERENCE METERING may or may not be preparing to aspirate depending on the order and type of test requested. If a REFERENCE FLUID aspiration is about to occur, REFERENCE METERING will also take an atmospheric reading. At this point, SAMPLE METERING moves the PROBOSCIS quickly down toward the sample container to the highest point above which fluid can be found. A request is sent to the 92x9 MCB to monitor the sample pressure to detect fluid. The PROBOSCIS starts down slowly in a single step fashion. The PUMP takes 3 steps mixed in between 5 steps of the PROBOSCIS, that is, 3 5 3 5 3 5. This is the “sniff” for fluid. When the pressure being monitored drops below the atmospheric by 200 mV for 2 consecutive reads, the 92x9 MCB signals the 92x4 MCB that fluid is found. See Figures 1 and 2 at the point labelled [1] . 42 15JAN98 – TG3360-1 SAMPLE METERING Figure 1. Overview 3 1 2 4 E015_0003HC The top trace is from the SAMPLE PRESSURE TRANSDUCER The bottom trace is from the REFERENCE PRESSURE TRANSDUCER One complete PM cycle is shown Each horizontal grid is 5 ms Each vertical grid is about 300 mV 15JAN98 – TG3360-1 43 THEORY GUIDE Figure 2. Overview 1 2 3 4 E015_0004HC The top trace is from the SAMPLE PRESSURE TRANSDUCER The bottom trace is from the WETNESS DETECTOR circuitry on the 82x0 BOARD One complete CM cycle is shown Each horizontal grid is 500 ms Each vertical grid is about 300 mV on the Sample Pressure Each vertical grid is about 5 V on the WETNESS DETECTOR The PROBOSCIS withdraws by 18 half steps to prevent being buried too deeply in the fluid and calculates the speed at which the PROBOSCIS must move down (based on which container is present from the state of the 2 PCS SENSORS located on the CUP AND RETAINER ASSEMBLY) in order to aspirate the fluid and keep the TIP below the fluid meniscus for the type of container present. The 92x9 REFERENCE METERING MCB continues to monitor the sample pressure for another 200 ms to ensure that the fluid found was not on the CAP. If the pressure rises back toward atmospheric by 150 mV, a “spike” is declared and aspiration is stopped. If not, the PROBOSCIS moves down while the PUMP aspirates until the TIP has the correct volume of fluid. If a reference aspiration is to occur, it begins to aspirate fluid as soon as the spike detection is complete. This allows the 92x9 MCB to do only one thing at a time. It does not drive the REFERENCE PUMP MOTOR at the same time it is monitoring the sample aspiration, except during reaspiration. Prime Occurs After successful aspirations, both SAMPLE and REFERENCE METERING wait for a period of time called the dwell. The dwell time for SAMPLE METERING is approximately 8 ms and for REFERENCE METERING approximately 6 ms. See Figure 1. On SAMPLE METERING, this is to allow possible viscous patient fluids such as serum from multiple myeloma patients to finish flowing into the TIP and come to rest. This is not necessary for REFERENCE FLUID, but the dwell allows for the prime to occur at a time offset from the SAMPLE METERING prime. 44 15JAN98 – TG3360-1 SAMPLE METERING When SAMPLE METERING primes, approximately 8 µL of the fluid is dispensed back. This ensures that the fluid meniscus forms at the end of the TIP and may possibly eject any particulate matter picked up. Pressure is checked to see if the TIP is plugged. A second prime occurs when the TIP is in position for a drop. REFERENCE METERING primes back a full 10 µL. See Figure 1 at the point labelled [2] . The TIPS are Positioned for the Drop If it is a PM slide, REFERENCE METERING drives the PUMP CARRIAGE ASSEMBLY through the gearing on the Z-TRACK against the STOP TAB. This causes the REFERENCE ARM to lift out of the disposable RESERVOIR. Once the REFERENCE ARM is clear of the UP/DOWN SENSOR, the MOTOR drives in the reverse direction until it again hits the STOP TAB at the Metering Position which causes the REFERENCE ARM to move into the SLIDE BLOCK. The PROBOSCIS slowly withdraws from the fluid to a level slightly above the fluid. At this point, if it is a small TIP fill, less than 6 drops, another 2 µL of fluid is primed. This step prevents very thin fluids from expanding the meniscus. The PROBOSCIS now moves completely out of the container. The chemistry type is evaluated. If it is not a PM chemistry, the PIVOT starts to move out to reach the Pivot Position. The TRUCK moves back to the SLIDE BLOCK or home position. The PROBOSCIS starts down. Servo is started to maintain pressure in the TIP. The fluid is pulled back to keep it from coming out of the TIP as the PROBOSCIS starts down. The TIP settles into the SLIDE BLOCK. See Figure 1 at the point labelled [3] and Figure 2 at the point labelled [2] . WETNESS DETECTOR reads begin. Fluid is Dispensed The 92x4 MCB checks the SLIDE PRESENT SENSOR to be sure a slide is in place. Final calculations for dispense steps are made for the first drop, TIP fill, and chemistry type. The 92x9 MCB is sent a message to start the drop detection routine. Servo brings the pressure back up to the baseline pressure. The PUMP is started and run for the number of steps necessary for the calculated dispense volume. The ACTUATION COUNTER is incremented. The TIP dwells at the slide for about 250 ms and then begins to pull away. See Figure 2 at the point labelled [3] . The Drop is Evaluated The drops are evaluated on the 92x9 MCB for bubbles, plugs, and wetness errors if it is a CM type slide. The arrays created as the drop is metered are used to find these error conditions. If problems are found, the information is reported to the 72x0 MECHANISM COMPUTER BOARD. Pressure is Maintained in the SAMPLE TIP Servo operates while the PROBOSCIS is at the Pause Position to maintain the pressure in the TIP. Depending on the fluid volume in the TIP, 3 servo ranges are specified. When the fluid volume is greater, a greater negative pressure is needed in the PUMP to hold the fluid in the TIP. This changes at approximately 8 and 2 drops. See Figure 2 at the point labelled [4] . More Fluid is Aspirated if Required If the total number of samples to be tested is greater than can be done in one aspiration, a “double dip” occurs. The PROBOSCIS goes to the Lift Position, the TRUCK moves to the sample container, and the PROBOSCIS aspirates more fluid. The cycle of positioning for the drops and dispensing is repeated. If more than 6 PM tests are programmed, the 72x0 BOARD will reset the REFERENCE PUMP and aspirate 6 more drops at the correct time. It will repeat this reaspiration as needed. The SAMPLE TIP is Ejected When the final drop has been metered, the PROBOSCIS raises out of the SLIDE BLOCK and the TRUCK moves toward the back. The PIVOT, if it is in the RATE/CM position, moves in. The EJECT BRACKET on SAMPLE METERING engages the PROBOSCIS and the TIP is dropped into the TIP DISPOSAL BOX. The TRUCK starts forward to the home position while the PUMP resets. The assembly is now ready for the next sample. 15JAN98 – TG3360-1 45 THEORY GUIDE The REFERENCE PUMP is Reset At the last PM drop, the REFERENCE PUMP is reset. This may occur before SAMPLE METERING completes resetting. SAMPLE METERING ASSEMBLY Overview The purpose of the SAMPLE METERING ASSEMBLY is to dispense a drop of patient sample onto each slide for the colorimetric and potentiometric tests. The Sample Metering system has the following assemblies: • PROBOSCIS ASSEMBLY • PROBOSCIS PIVOT MOTOR (ACTUATOR AND EXTENSION ASSEMBLY) • TRUCK ASSEMBLY • PUMP ASSEMBLY • TIP DISPOSAL BOX PROBOSCIS PIVOT MOTOR TRUCK ASSEMBLY PROBOSCIS ASSEMBLY TIP DISPOSAL BOX PUMP ASSEMBLY E015_3605ACA E015_3605AC E015_3603ACE E015_3603AC Normal Operation of the Sample Metering System Overview To diagnose and repair the SAMPLE METERING ASSEMBLY, it is necessary to check for normal operation. Initialization The software checks that the TIP DISPOSAL BOX is in the correct position. The PROBOSCIS ASSEMBLY moves to the Lift Position. The TRUCK ASSEMBLY moves to the Eject Position and then to the home position. The PROBOSCIS ASSEMBLY moves to the home position. SAMPLE TIP The TRUCK ASSEMBLY moves to the Tip Position. The PROBOSCIS ASSEMBLY moves to the Tip Position, then moves to the Lift Position. The TRUCK ASSEMBLY moves to the sample container position. Sample Container The PROBOSCIS ASSEMBLY moves to the sample container position. Fluid is aspirated from the sample container. 46 15JAN98 – TG3360-1 SAMPLE METERING Slide The PROBOSCIS ASSEMBLY moves to the Lift Position. The TRUCK ASSEMBLY moves to the home position. The PROBOSCIS ASSEMBLY pivots to the colorimetric position, then moves to the Metering Position. The SLIDE PRESENT SENSOR operates. The WETNESS DETECTOR operates. Dispense and Eject The fluid is dispensed onto the slide. The DROP DETECTOR operates. The PROBOSCIS moves to the Pause Position and pivots to the potentiometric position. The PROBOSCIS ASSEMBLY moves to the Lift Position. The TRUCK ASSEMBLY moves to the Eject Position and to the home position. The PROBOSCIS ASSEMBLY moves to the home position. Sequence of Operation The order of events in the sample metering sequence is: 1. Move the TRUCK to the Tip Position, reset the METERING PUMP. 2. Lower the PROBOSCIS to the Tip Position to pick up the TIP. 3. Raise the PROBOSCIS to the Lift Position. 4. Move the TRUCK to the sample container position. 5. Lower the PROBOSCIS to the fluid level and begin level sensing. 6. Actuate the PUMP to aspirate the programmed volume of sample fluid from the sample container into the SAMPLE TIP. The TIP follows the fluid level as it decreases. 7. Meter 10 µL of fluid back into the sample container. 8. Raise the PROBOSCIS to the Lift Position. 9. Move the TRUCK to the home position. 10. Pivot the PROBOSCIS to the colorimetric Metering Position. 11. Lower the PROBOSCIS to the Metering Position. 12. Actuate the PUMP to dispense 11 µL of fluid (multiple-point rate and immuno-rate tests) or 10 µL (all other tests) on the slide. 13. Raise the PROBOSCIS to the Pause Position. 14. Pivot the PROBOSCIS to the potentiometric position if a potentiometric slide is in the Metering Position. 15. Repeat steps 10 through 14 for the programmed number of slides for the current sample container. 16. Move the PROBOSCIS to the home position. 17. Move the TRUCK to the Eject Position; eject the used TIP and return to the home position. Return to step 1 for the next sample container. Reaspiration Capability The Sample Metering System includes the capability to aspirate twice from a sample so that a maximum of 40 slides can be spotted from 1 sample container. Whenever more than 20 slides are programmed for a single sample container, the test list is divided into 2 parts. Sufficient fluid is aspirated to spot the slides in the first list. Instead of ejecting the TIP from the PROBOSCIS, the Sample Metering System aspirates fluid again from the same sample container; then the slides on the second list are spotted before the TIP is ejected. 15JAN98 – TG3360-1 47 THEORY GUIDE PROBOSCIS ASSEMBLY PROBOSCIS ASSEMBLY The purpose of the PROBOSCIS ASSEMBLY is to hold the SAMPLE TIP which contains the volume of patient sample. The volume for the drop size is 10 µL for colorimetric and potentiometric tests, and 11 µL for rate tests. The STEPPER MOTOR rotates the PINION GEAR to move the PROBOSCIS in a vertical direction. If a colorimetric slide is at the Metering Position, the PROBOSCIS PIVOT MOTOR (ACTUATOR AND EXTENSION ASSEMBLY) pivots the PROBOSCIS from the potentiometric to the colorimetric position. There are 6 vertical positions for the PROBOSCIS: • Lift Position • Home Position • Cup Position • Tip Position E015_3603ACD E015_3603AC • Pause Position • Metering Position The PAUSE SENSOR and the HOME SENSOR check the position of the PROBOSCIS ASSEMBLY. HOME SENSOR PAUSE SENSOR E002_3707DCB E002_3707DC The PROBOSCIS ASSEMBLY is attached to the TRUCK CARRIER and is part of the RACK AND HOUSING ASSEMBLY. The PROBOSCIS is a conical shaped part which provides the seat for the TIP. It has a channel to 48 15JAN98 – TG3360-1 SAMPLE METERING allow air flow through the PROBOSCIS and an attachment for the PUMP TUBING. The PROBOSCIS is attached to a RACK GEAR through a PLUNGER and SPRING. This allows for compression of the PROBOSCIS into the SLIDE BLOCK while also allowing for compliance of the TIP to the BLOCK. The 8 in. long RACK is driven by the PROBOSCIS DRIVE MOTOR through a SPRING AND PINION ASSEMBLY and is supported by a series of BEARINGS. A FLAG is attached to the RACK to activate the POSITION SENSORS. The FLAG has a cutout to allow sensing of a no TIP condition and a window to allow precise sensing. The SPRING AND PINION ASSEMBLY allows the force of the TIP seating onto the PROBOSCIS to be controlled so that full sealing of the TIP onto the PROBOSCIS is accomplished but seal integrity and ease of removal is maintained. A SPRING in the PINION ASSEMBLY is prewound to set the force of the PROBOSCIS during TIP pick-up. 25xO BOARD RACK AND HOUSING ASSEMBLY The 25x0 TRUCK INTERCONNECT BOARD is attached to the RACK ASSEMBLY. This is the INTERCONNECT BOARD that sends SENSOR signals to the control electronics through the FLEX RIBBON CABLE and power from the driver circuits to the STEPPER MOTORS for the PROBOSCIS and PIVOT. All of the parts are attached to the front of the TRUCK CARRIER by a SHAFT and BEARING arrangement. This allows the entire assembly to move left to right like a door where the SHAFT and BEARINGS are like the hinge. E015_3603ACC E015_3603AC The 72x0 MECHANISM COMPUTER BOARD sends signals to the 92x4 SAMPLE METERING MCB to energize the STEPPER MOTOR. The energized STEPPER MOTOR moves the PROBOSCIS to one of the 6 vertical positions. If the slide at the Metering Position is not a potentiometric slide, the 92x4 MCB sends signals through the 85x0 PYLON INTERCONNECT BOARD and the 25x0 TRUCK INTERCONNECT BOARD to energize the PROBOSCIS PIVOT MOTOR. The result of this action pivots the PROBOSCIS from the potentiometric position to the colorimetric position. 15JAN98 – TG3360-1 49 THEORY GUIDE PIVOT ASSEMBLY The PIVOT ASSEMBLY provides the power to move the RACK AND HOUSING in the way previously mentioned. It consists of the linear ACTUATOR and the EXTENSION LINKAGE. PIVOT MOTOR The linear ACTUATOR is a STEPPER MOTOR that moves a SHAFT in and out of the MOTOR BODY. The SHAFT is connected to the LINKAGE which is, in turn, attached to the RACK AND HOUSING through BEARINGS. The PIVOT ASSEMBLY is attached to a feature on the TRUCK CARRIER. Power is sent to the MOTOR through the 25x0 BOARD and the pivot motion is detected by a SENSOR that also feeds back through the 25x0 BOARD. The FLAG that activates the SENSOR is attached to the TRUCK CARRIER. E015_3606ACA E015_3606AC When the linear ACTUATOR SHAFT is stepped out of the MOTOR, the entire RACK AND HOUSING ASSEMBLY pivots and moves in an arc to the left. It is returned to the right when the MOTOR is stepped back. TRUCK ASSEMBLY The purpose of the TRUCK ASSEMBLY is to move the PROBOSCIS ASSEMBLY in a horizontal direction. The STEPPER MOTOR for the TRUCK ASSEMBLY drives the COG BELT and the WORM GEAR, which moves the TRUCK and the PROBOSCIS to the correct position. There are 4 horizontal positions for the TRUCK ASSEMBLY: TRUCK ASSEMBLY • Home Position • Cup Position • Tip Position • Eject Position E015_3603ACB E015_3603AC The HOME SENSOR sends a signal to the 92x4 MCB when the FLAG is in the HOME SENSOR. The EJECT SENSOR sends a signal to the 92x4 BOARD when the FLAG is in the EJECT SENSOR. The result of these actions checks the position of the TRUCK ASSEMBLY. TIP DISPOSAL BOX When the TRUCK ASSEMBLY moves to the EJECT SENSOR, the PROBOSCIS ASSEMBLY is rotated by the EJECT LEVER causing a downward motion which removes the TIP from the PROBOSCIS. The TIP falls into the TIP DISPOSAL BOX. The S5 SWITCH detects that the TIP DISPOSAL BOX is in the correct position. 50 15JAN98 – TG3360-1 SAMPLE METERING PUMP ASSEMBLY The PUMP is a PISTON air displacement device driven by a 3.6° STEPPER MOTOR through a LEAD SCREW system. Two different anti-backlash systems are used to eliminate hysteresis. The body of the PUMP includes MOUNTINGS for the PRESSURE TRANSDUCER. PRESSURE TRANSDUCER PUMP EMPTY SENSOR TUBING When the PISTON in the PUMP ASSEMBLY is at the zero-volume position or full dispense position, a FLAG enters the PUMP EMPTY SENSOR which shuts off the MOTOR. TUBING for the SAMPLE METERING ASSEMBLY PUMP E015_3610ACB E015_3610AC The flexible plastic TUBING is used to transfer vacuum and/or pressure from the PUMP ASSEMBLY to the PROBOSCIS. The vacuum and/or pressure is transferred to both the PROBOSCIS and to the PRESSURE TRANSDUCER. SLIDE PRESENT SENSOR The SLIDE PRESENT SENSOR is a reflective-type, infrared SENSOR. The SLIDE PRESENT SENSOR checks that a slide is in the SLIDE BLOCK before fluid is dispensed from the TIP. The beam from the SENSOR reflects off the corner of the slide in the SLIDE BLOCK. The output from the SENSOR is checked by the 92x4 MCB at the beginning of the dispense cycle and stops the cycle if a slide is not available. Drop Detection System A drop detection sysem consisting of a PRESSURE TRANSDUCER and WETNESS DETECTOR monitors the metering operation. The PRESSURE TRANSDUCER detects changes in pressure in the Sample Metering System as fluid is aspirated from a sample container and deposited onto a slide. The following conditions can be detected by the PRESSURE TRANSDUCER: • Plugged SAMPLE TIP • No sample fluid • Bubble in the TIP WETNESS DETECTOR The purpose of the WETNESS DETECTOR is to check that a drop of fluid is dispensed from the TIP onto a colorimetric, a two-point rate, or a multiple-point rate slide. The WETNESS DETECTOR is located on the 63x0 WETNESS DETECTOR BOARD. A filtered light from a small LAMP is reflected off the bottom of the slide and is detected by a LEAD SULFIDE CELL. Before a drop of fluid is dispensed, the LEAD SULFIDE CELL sends a voltage signal to the 82x0 A/D CONVERTER BOARD. After a drop of fluid is dispensed onto a slide, a second voltage signal is sent to the 82x0 BOARD. The second voltage signal is less than the first voltage signal because a color change has occurred on the slide which indicates that a drop of fluid has been dispensed. 15JAN98 – TG3360-1 51 THEORY GUIDE Detach 12 SLIDE PRESENT SENSOR 63xO BOARD LAMP LEAD SULFIDE CELL E002_3716DCC E002_3716DC CUP AND GUARD ASSEMBLY The CUP AND GUARD ASSEMBLY features a SPRING system that loads the CUP RETAINER down at all times. It does not interact with the COVER mechanism in any way. To remove the TRAY on the SAMPLE SUPPLY, the operator rotates an ACCESS LEVER upward which pivots the CUP RETAINER out of the way. CUP AND GUARD ASSEMBLY E015_3603ACA E015_3603AC 52 15JAN98 – TG3360-1 SAMPLE METERING Electrical HARNESSES The MAIN HARNESS was reworked to allow the electrical changes made. A new HARNESS was created to interface with the new 85x0 PYLON INTERCONNECT BOARD. No changes were made to the following CABLES. They are the same as the 700C Chemistry System. • the FLEX CABLE that connects the 25x0 TRUCK INTERCONNECT BOARD to the 85x0 BOARD • the short RIBBON CABLE that connects the 82x0 A/D CONVERTER BOARD to the 92x4 SAMPLE METERING MCB • the SHIELDED CABLE that connects the 82x0 BOARD to the 63x0 WETNESS DETECTOR BOARD The 2 CABLES that connect the SAMPLE and REFERENCE TRANSDUCERS to the 82x0 BOARD were reworked to allow use of the PUMP TRANSDUCER from the 250 Chemistry System. See the Interconnect Diagrams for more detailed information on the harnessing. SWITCHES The SAMPLE METERING ASSEMBLY has 2 SWITCHES. 1. The TIP DISPOSAL BOX PRESENT SWITCH is used to detect the presence of a TIP DISPOSAL BOX before allowing metering to keep TIPS from being discarded into the mechanisms of the System. 2. The SERVICE INTERLOCK SWITCH is provided to allow adjustments to be made. It is wired normally closed. To remove power from the STEPPER MOTORS, depress the SWITCH momentarily to break the circuit or pull out on the KNOB to remove the power. SENSORS The SAMPLE METERING ASSEMBLY has 8 interrupted HORSESHOE SENSORS. • TRUCK EJECT - located above the TRUCK GUIDE PLATE and mounted on the UPPER PYLON toward the back of the assembly. When the FLAG mounted on the TRUCK CARRIER is in this SENSOR, the TRUCK is at the Eject Position. • TRUCK HOME - located above the TRUCK GUIDE PLATE and mounted on the UPPER PYLON near the center of the assembly. When the FLAG mounted on the TRUCK CARRIER is in this SENSOR, the TRUCK is at the home position above the SLIDE BLOCK. • PROBOSCIS HOME - the top SENSOR on the RACK AND HOUSING ASSEMBLY. When the FLAG on the RACK SHAFT is in this SENSOR, the PROBOSCIS is in the up or home position, ready to move. • PROBOSCIS PAUSE - the lower SENSOR on the RACK AND HOUSING ASSEMBLY. When the FLAG on the RACK SHAFT is in this SENSOR, the PROBOSCIS is in the Pause Position. It is above the SLIDE BLOCK allowing the DISTRIBUTOR ROTOR to turn, but not fully back to the level of the SAMPLE SUPPLY. • PIVOT HOME - when this SENSOR is blocked the PIVOT is at the PM Position. This is with the linear ACTUATOR in the MOTOR. The pivoting mechanism is against the TRUCK CARRIER. • PCS TOP - located on the CUP AND GUARD ASSEMBLY. This SENSOR is blocked when one of the TUBE ADAPTERS actuates a SPRING. This indicates, along with the PCS BOTTOM SENSOR what type of sample container is being sampled. • PCS BOTTOM - located on the CUP AND GUARD ASSEMBLY. This SENSOR is blocked when one of the TUBE ADAPTERS actuates a SPRING. This indicates, along with the PCS TOP SENSOR, what type of sample container is being sampled. • PUMP EMPTY - when actuated by the PISTON FLAG, this SENSOR indicates the PISTON is fully into the bore of the PUMP, i.e., the PUMP is empty. In addition to the interrupted SENSORS, one reflective ARROWHEAD SENSOR is in the SAMPLE METERING ASSEMBLY. This SLIDE PRESENT SENSOR is mounted in the METERING RAMP ASSEMBLY. When a slide is present in the SLIDE BLOCK, the light from the LED side of the SENSOR is reflected back to the detector side 15JAN98 – TG3360-1 53 THEORY GUIDE and the signal goes low. Because this SENSOR is not apertured like the interrupted SENSORS, it is much more sensitive to any ambient light. 85x0 PYLON INTERCONNECT BOARD This BOARD is an interconnect and isolation board. It passes the STEPPER MOTOR signals from the driver section to the 25x0 TRUCK INTERCONNECT BOARD and ultimately to the MOTORS. In addition, it takes the SENSOR signals and feeds them through an optical isolator to the 92x4 MCB controller. All 7 of the POSITION SENSORS and the reflective SLIDE PRESENT SENSOR go through the 85x0 BOARD. The power section uses a “switching” regulator that steps down the existing 15 V DC input to 5 V for use in the SENSOR operation without extensive heat generation. The placement of components and connectors was done with assembly and service ease in mind. 25x0 TRUCK INTERCONNECT BOARD This is a very simple INTERCONNECT BOARD that has locking connectors for the PROBOSCIS and PIVOT SENSORS. The PIVOT MOTORS and PROBOSCIS MOTORS also connect into the BOARD. The FLEX RIBBON CABLE connects and carries all signals to the 85x0 BOARD. 82x0 A/D CONVERTER BOARD The 82x0 BOARD is the link between the analog SENSORS and the digital computer. It takes the analog signals from the WETNESS DETECTOR system and from the PRESSURE TRANSDUCERS on both SAMPLE and REFERENCE METERING and converts the voltage to a digital value. In addition, it furnishes the power to drive the WETNESS DETECTOR LAMP and the 63x0 WETNESS DETECTOR BOARD, as well as the TRANSDUCERS. On command from the 92x9 REFERENCE METERING MCB, the desired signal is multiplexed into the A/D section and the data made available on the data lines. TRANSDUCER The TRANSDUCER is mounted on the PUMP. This device is a strain gauge type of TRANSDUCER. The signal is amplified by the circuitry attached to the TRANSDUCER and fed back to the 82x0 BOARD. 63x0 WETNESS DETECTOR BOARD This BOARD has one operational amplifier that conditions the signal from the LEAD SULFIDE CELL. The 2.5 V DC for the WETNESS DETECTOR LAMP passes through this BOARD. WETNESS DETECTOR System The WETNESS DETECTOR System consists of the 63x0 BOARD, the LEAD SULFIDE CELL, and a 2.5 V LAMP. The 82x0 BOARD provides power to the LAMP. The light from the LAMP is reflected off the slide and the CELL picks up the light which is filtered to 1945 nm. The 63x0 BOARD amplifies the signal and sends it to the 82x0 BOARD. Software monitors the voltage to determine when fluid has touched the slide. 33x0 SAMPLE and REFERENCE METERING DRIVER BOARD This BOARD is located in the DRIVER BOARDS area. There are 5 STEPPER MOTOR drives available; 3 of these are L/R type drives but have been implemented for the 950 Chemistry System using FET technology. This increases power efficiency and increases the torque available. These drives power the PIVOT, PROBOSCIS, and TRUCK mechanisms. The other 2 drives are chopper type and power the SAMPLE and REFERENCE METERING PUMPS. Circuitry is available on the 33x0 BOARD to drive the ACTUATION COUNTER. 54 15JAN98 – TG3360-1 REFERENCE FLUID METERING Section 7: REFERENCE FLUID METERING Metering Theory - See the SAMPLE METERING Theory of Operation REFERENCE FLUID METERING ASSEMBLY Introduction The function of the REFERENCE FLUID METERING ASSEMBLY is to deliver 10 mL of reference fluid to the potentiometric slide at the Metering Position. To do this basic function, it must accomplish numerous subfunctions which include: • Aspirating reference fluid • Precisely positioning the REFERENCE TIP in the SLIDE BLOCK in preparation for dispensing a drop • Accurate and precise dispensing of the reference fluid Overview ROTATING CONE REFERENCE ARM ASSEMBLY TRANSDUCER not visible TIP SLEEVE PUMP ASSEMBLY 84x0 REFERENCE METERING BOARD CAM BASE PLATE E015_4002DCB E015_4002DA The REFERENCE FLUID METERING contains the following assemblies: • BASE PLATE • ROTATING CONE 15JAN98 – TG3360-1 55 THEORY GUIDE • CAM ASSEMBLY • REFERENCE ARM ASSEMBLY • RESERVOIR ASSEMBLY • PUMP ASSEMBLY The BASE SUPPORT locates the REFERENCE METERING ASSEMBLY in the correct plane. It has bosses to mount the CIRCUIT BOARD electronics. There is a slot and an access cutout to mount the PUMP ASSEMBLY. BASE PLATE The BASE PLATE provides the mounting feature for the ROTATING CONE and the disposable RESERVOIR. A SHAFT through the center of the PLATE accepts the ROTATING CONE and CAM mechanisms. Slots are in the PLATE to mount the DRIVE MOTOR and the SENSOR. The motion of the assembly in the circular direction is limited by 2 STOP TABS. The PLATE is fastened to the SUPPORT by 3 SCREWS. The holes for the SCREWS are slotted to allow adjustment of the BASE PLATE to the correct position for the TIP to interface with the SLIDE BLOCK. ROTATING CONE and CAM The ROTATING CONE holds the REFERENCE ARM at the needed 18× angle to interface with the SLIDE BLOCK. The CAM allows motion up and down. It is a CAM profile that the ROTATING CONE rides over supported by a BEARING. The bottom of the CAM has a GEAR that engages the DRIVE MOTOR and provides a circular motion. A slot cut in the bottom is sensed by the HOME/OUT SENSOR. The ROTATING CONE ASSEMBLY is held to the SHAFT on the BASE PLATE by a SCREW and TENSION SPRING. REFERENCE ARM ASSEMBLY The REFERENCE ARM ASSEMBLY snaps onto the ROTATING CONE and has the TIP RETAINER molded into it. The REFERENCE ARM has a channel cut through it to provide air flow and to allow aspirating and dispensing of fluid. The TIP attaches to the end of the REFERENCE ARM. There are SEALS at the TIP interface and a TUBING FITTING at the end of the channel. A vent helps to equalize pressures. The TIP SLEEVE fits onto the REFERENCE ARM ASSEMBLY. The TUBING is routed through the REFERENCE ARM to the PUMP. The REFERENCE ARM has a STOP to prevent tipping the assembly too far back when changing TIPS and allowing fluid to run into the TIP RETAINER. PUMP ASSEMBLY The PUMP is a PISTON air displacement device driven by a STEPPER MOTOR through a LEAD SCREW system. Two different anti-backlash systems are used to eliminate hysteresis. The body of the PUMP includes MOUNTINGS for the TRANSDUCER ASSEMBLY. One SENSOR monitors the movement of the PISTON by a FLAG mounted on the PISTON DRIVE SHAFT. 56 15JAN98 – TG3360-1 REFERENCE FLUID METERING RESERVOIR ASSEMBLY SPRING PIN COVER SEAL RESERVOIR NEST E015_4001DCB E015_4001DA The RESERVOIR ASSEMBLY is composed of a NEST which is a plastic part mounted by 2 SCREWS to the BASE PLATE ASSEMBLY, a disposable RESERVOIR, a COVER HOLDER and COVER, a PIN and a SPRING which helps to seal the COVER over the RESERVOIR. Slots in the NEST mount allow adjustment of the COVER and RESERVOIR HOUSING to the TIP. Electrical HARNESSES, SENSORS, and SWITCHES The REFERENCE METERING ASSEMBLY has 3 WIRING HARNESSES: 1. The MAIN HARNESS brings power to the 84x0 REFERENCE METERING BOARD. It also brings the PUMP drive signals from the 33x0 SAMPLE AND REFERENCE METERING DRIVER BOARD. 2. The SENSOR HARNESS brings the signals from the 2 interrupted SENSORS to the 84x0 BOARD. 3. The MOTOR ADAPTER brings the drive signals for the ROTATIONAL MOTOR from the 84x0 BOARD to the MOTOR. 15JAN98 – TG3360-1 57 THEORY GUIDE The REFERENCE METERING ASSEMBLY has 2 SENSORS. One detects when the REFERENCE ARM has cleared the SLIDE BLOCK or RESERVOIR and is called UP/DOWN METERING POSITION SENSOR. The other is the HOME/OUT RESERVOIR POSITION SENSOR that detects the position of the REFERENCE ARM at the RESERVOIR or the SLIDE BLOCK. This assembly has no INTERLOCK SWITCHES. 84x0 REFERENCE METERING BOARD The 84x0 BOARD mounts to the side of the REFERENCE METERING ASSEMBLY. It accepts SENSOR inputs from the PUMP and the POSITION SENSORS and reports to the 92x9 REFERENCE METERING AND TRANSDUCERS MCB. It accepts drive position signals from the 92x9 MCB and drives the REFERENCE ARM ASSEMBLY to the correct position for metering. It does not drive or control the PUMP. Its only interaction with the PUMP is passing the PUMP EMPTY SENSOR signal to the 92x9 MCB. The 84x0 BOARD has a 6811 microcontroller and the necessary RAM and ROM memories. The microcontroller monitors the following 3 command signals from the 92x9 MCB that controls the Reference Metering function: 1. Initialize - restart the REFERENCE METERING ASSEMBLY 2. TIP change - lift the REFERENCE ARM out of the RESERVOIR to change the TIP 3. Normal move - commands movement either to the RESERVOIR or to the slide Based on the logic state of the commands and the current position of the REFERENCE ARM ASSEMBLY indicated by the POSITION SENSORS, the 84x0 BOARD moves the mechanism to the correct place. The position is reported to the 92x9 MCB as either RESERVOIR or slide. TRANSDUCER The TRANSDUCER is mounted on the PUMP. This device is a strain gauge type of TRANSDUCER. The pressure signal is amplified by the circuitry attached to the TRANSDUCER and fed back to the 82x0 A/D CONVERTER BOARD on the SAMPLE METERING ASSEMBLY. 33x0 SAMPLE and REFERENCE METERING DRIVER BOARD This BOARD is located in the DRIVER BOARDS area. There are 5 STEPPER MOTOR drives available; 3 of these are L/R type drives that power the PIVOT, PROBOSCIS, and TRUCK mechanisms. The other 2 drives are chopper type and power the SAMPLE and REFERENCE METERING PUMPS. Circuitry is available on the 33x0 BOARD to drive the ACTUATION COUNTER. 58 15JAN98 – TG3360-1 RATE/COLORIMETRIC INCUBATOR Section 8: RATE/COLORIMETRIC INCUBATOR Overview The RATE/COLORIMETRIC INCUBATOR is an environmentally controlled system which maintains the temperature at 37°C to allow proper incubation of colorimetric and multiple-point rate slides. The slides are read by the RATE/COLORIMETRIC REFLECTOMETER to determine the concentration of analytes. Slides are moved from the SLIDE BLOCK to the PRECONDITION STATION by the RATE SHUTTLE. The PRECONDITION STATION warms the slides to 37°C to prevent cold slides from being placed into the thermally controlled RATE/COLORIMETRIC INCUBATOR. After a preheat period, the SHUTTLE moves the slide into 1 of 24 positions in the INCUBATOR DISK. The 3 remaining positions are used by the REFERENCE SLIDES. The slides remain in the INCUBATOR for approximately 5 minutes as they are incubated and read by the RATE/ COLORIMETRIC REFLECTOMETER. The INCUBATOR DISK cycles continuously except when a slide is either moved into or removed from the INCUBATOR. Detach 13 PRECONDITION STATION Read Station position E015_5006BCA E015_5006BA The slides pass over the Read Station position in the INCUBATOR and are read “on the fly” multiple times during the incubation process. A READ SYNC SENSOR is used to synchronize the position of the slide with the position of the REFLECTOMETER so that the center of the slide is read by the REFLECTOMETER. When the slide reading is completed, the slide is removed from the INCUBATOR by the RATE/COLORIMETRIC PICKER and moved to the DISCARD CHUTE. 15JAN98 – TG3360-1 59 THEORY GUIDE PRECONDITION STATION ASSEMBLY The purpose of the PRECONDITION STATION is to raise the temperature of the slide to approximately 37°C before the slide is inserted into the INCUBATOR DISK. The RATE SHUTTLE moves a slide onto the top surface of the PRECONDITION STATION BLOCK. The slide is held in position against the bottom of the BLOCK by the TUNNEL COVER SPRING. A TUNNEL COVER PAD, which functions as an anti-evaporation cover to assist the performance of the chemistry on some colorimetric tests, is over the PRECONDITION STATION. TUNNEL COVER SPRING TUNNEL COVER PAD PRECONDITION STATION BLOCK E010_0049ACB E010_0049AC The PRECONDITION STATION BLOCK is heated to 37.7 to 38.7°C by a RESISTANCE HEATER driven by the 97x1 THERMAL DRIVER BOARD. A THERMISTOR for the PRECONDITION STATION provides an analog voltage used by the 95x0 THERMISTOR AMPLIFIER BOARD, 93x0 ANALOG I/O BOARD, 72x0 MECHANISM COMPUTER BOARD, and the 97x1 THERMAL DRIVER BOARD to monitor and control the temperature of the PRECONDITION STATION. The slide remains on the PRECONDITION STATION BLOCK for 12 seconds and then is moved by the RATE SHUTTLE into an open position in the INCUBATOR DISK. THERMISTOR, not visible E002_4608ACB E002_4608AC 60 15JAN98 – TG3360-1 RATE/COLORIMETRIC INCUBATOR INCUBATOR DISK The INCUBATOR DISK holds the slide for the remainder of the incubation period. The slides are read in the INCUBATOR at the Read Station. During the time the slide is in the INCUBATOR, 54 readings for rate and 5 readings for colorimetric and 2-point rate slides are taken as the slide passes over the Read Station. INCUBATOR DISK PRESSURE PAD The INCUBATOR contains 27 positions - 3 positions that hold REFERENCE SLIDES and the remaining 24 positions for the rate or colorimetric slides. Each individual position in the INCUBATOR has a PRESSURE PAD, SLIDE SPRING, and SLIDE SPRING GUARD to help prevent evaporation and hold the slide in place. SLIDE SPRING SLIDE SPRING GUARD E010_0053ACK E010_0053AC The PRESSURE PAD is made of white plastic, and each is assayed for uniform reflectance. To ensure uniform reflection, they are packaged in a set of 24, and they are to be replaced all at once as a complete set of 24. Diagnostic software has a uniformity test to evaluate the uniformity of the reflectance to determine the need for replacement. All PRESSURE PADS must be within a tolerance for correct chemistry precision on certain colorimetric tests. During each 12 second cycle, the INCUBATOR DISK revolves for approximately 4.5 seconds and is stopped for approximately 7.5 seconds to allow slides to enter and exit the INCUBATOR. During the 4.5 seconds the INCUBATOR DISK is moving, it makes 2 complete revolutions plus 1 additional position. It is at that last position the slide is picked and the next slide from the PRECONDITION STATION is inserted. As the PICKER is removing the slide from the INCUBATOR, the DISCARD DOOR is raised and the slide is discarded into the SLIDE DISPOSAL BOX. 15JAN98 – TG3360-1 61 THEORY GUIDE REFERENCE SLIDES REFERENCE SLIDE N0. 3 POSITION 19 REFERENCE SLIDE No. 1 POSITION 1 REFERENCE SLIDE No. 2 POSITION 10 E002_2725HCE E002_2725HA The INCUBATOR DISK contains 3 identical REFERENCE SLIDES located in positions 1, 10 and 19. The REFERENCE SLIDE readings are used to calculate the actual reflected density of chemistry slides. The REFERENCE SLIDES are also read periodically to determine the health of the rate/colorimetric system. If the readings from the REFERENCE SLIDES are low a condition code, usually HE2, is posted. READ SYNC SENSOR ENCODER DISK READ SYNC SENSOR E015_5004BCB E015_5004BC In conjunction with the ENCODER DISK, the READ SYNC SENSOR in the INCUBATOR monitors the position of the INCUBATOR DISK. When the SENSOR indicates that the INCUBATOR DISK is in position, a reading is taken for the slide at the Read Station. It is typically around 200 A/D Counts, however the specification calls for the reading to be as low as possible. A very high read sync reading can cause chemistry performance issues to arise. 62 15JAN98 – TG3360-1 RATE/COLORIMETRIC INCUBATOR The adjustment of the READ SYNC SENSOR ensures that chemistry slide readings are taken from the center of the slide. The adjustment is made using the RATE ALIGNMENT SLIDE TL-3425, which has a small black square in the center. When doing the adjustment, the specification is for the reading to be as low as possible. This ensures that the REFLECTOMETER readings are based on the optimum density position of the slide. The adjustment value is in A/D Counts and is a function of the test tool reflectance and the light output of the REFLECTOMETER in addition to the centering of the test tool slide. 7-ELEMENT ARRAY 7-ELEMENT ARRAY E015_5004BCC E015_5004BC After entering the INCUBATOR the slides must be tracked by the 72x0 MECHANISM COMPUTER BOARD. The 7-ELEMENT ARRAY reads the ENCODER DISK to determine the position of a slide in the INCUBATOR DISK. The 7-ELEMENT ARRAY then transmits binary information to the 92x5 RATE REFLECTOMETER MCB. This SENSOR is also used for stopping the INCUBATOR DISK. It is very important to make sure the DISK stops in the correct place so the slides can enter and exit without any jamming problems. Thermal Control THERMISTORS are used to monitor the temperature of the INCUBATOR. An error is reported on the STATUS CONSOLE if the temperature is outside operating specifications. Results for slides in the INCUBATOR are reported with a flag to indicate an abnormal incubation temperature. If the rate/colorimetric system is enabled in subsystem control, sample metering cannot be initiated or resumed until the INCUBATOR has reached operating temperature. INSTRUMENTATION AND CONTROL SENSOR, not visible HEATER,not visible The LOWER HEATER AND CONNECTOR ASSEMBLY is installed below and in direct contact with the LOWER INCUBATOR HOUSING. The LOWER INCUBATOR HOUSING includes a LOWER MAIN HEATER and a LOWER AUXILIARY HEATER. The LOWER MAIN HEATER allows variable heat output to maintain 37°C, after the temperature has stabilized. The LOWER AUXILIARY HEATER is energized during the warm up and is deenergized when the temperature reaches the stabilized range. The analog outputs of the CONTROL and INSTRUMENTATION THERMISTORS are averaged and used to monitor and control the temperature of the INCUBATOR. LOWER INCUBATOR E002_4608ACC HOUSING E002_4608AC 15JAN98 – TG3360-1 63 THEORY GUIDE The thermal monitor and control system consists of the 95x0 THERMISTOR AMPLIFIER BOARD, 93x0 ANALOG I/O BOARD, 97x0 THERMAL DRIVER BOARD, 72x0 MECHANISM COMPUTER BOARD, and 90x0 MASTER COMPUTER BOARD and the controlling software. To check that the CONTROL and INSTRUMENTATION THERMISTORS and associated analog circuitry are operating correctly, the software compares the values from each of the THERMISTORS and reports an error if the values exceed a limit. A 55°C AUTOMATIC RESET THERMOSTAT and a 73°C MANUAL RESET THERMOSTAT, wired in series, protect the system from exceeding unsafe temperatures by disconnecting power to the MAIN HEATERS. Detach 14 AUTOMATIC RESET THERMOSTAT MANUAL RESET THERMOSTAT E015_5004BCD E015_5004BC STEPPER MOTOR A STEPPER MOTOR rotates the INCUBATOR DISK in a clockwise direction only. The INCUBATOR DISK is a floating disk, and is not tightly retained in the vertical direction to the HOUSING of the INCUBATOR. As a result, the DRIVE GEAR must be set with a minimum of backlash to prevent the DISK from drifting upward. INCUBATOR DRIVE MOTOR E002_4610ACC E002_4610AC 64 15JAN98 – TG3360-1 RATE/COLORIMETRIC INCUBATOR DRIVE GEAR INCUBATOR DISK RING GEAR The DRIVE GEAR is attached to the SHAFT of the STEPPER MOTOR and drives the RING GEAR which is part of the INCUBATOR DISK. E002_4616ACA E002_4616AA RATE/COLORIMETRIC PICKER The purpose of the PICKER is to move a slide from the INCUBATOR DISK to the DISCARD CHUTE. The PICKER is aligned with the INCUBATOR so that the PICKER FINGERS enter the INCUBATOR DISK without touching the PRESSURE PAD or SLIDE SPRING. DISCARD DOOR PICKER FINGERS E010_0053ACL E010_0053AC The HOME SENSOR and the PICKER CLEAR SENSOR identify the position of the PICKER for the 92x5 RATE REFLECTOMETER MCB. The 72x0 MECHANISM COMPUTER BOARD sends a signal, through the 91x1 DIGITAL I/O BOARD, to the 92x5 BOARD which controls the sequence of the PICKER. When the FLAG is in the PICKER CLEAR SENSOR, a signal is sent to the 92x5 BOARD to indicate that the PICKER has cleared the INCUBATOR. The ac MOTOR then actuates for the RATE SHUTTLE. This sequence is completed in less than 2.0 seconds. 15JAN98 – TG3360-1 65 THEORY GUIDE Detach 15 SPRING CAM FLAG SENSOR E002_4606BCB E002_4606BC The ac MOTOR operates the RATE PICKER and the CAM MECHANISM which operates the DISCARD DOOR. When the RATE PICKER moves from the INCUBATOR, the DISCARD DOOR opens and the slide from the INCUBATOR falls into the DISCARD CHUTE. The force of the SPRING returns the PICKER FINGERS to the home position. 66 15JAN98 – TG3360-1 RATE/COLORIMETRIC REFLECTOMETER Section 9: RATE/COLORIMETRIC REFLECTOMETER Overview The RATE/COLORIMETRIC REFLECTOMETER is a high precision instrument designed to read reflection densities with very high resolution. During the incubation of rate and colorimetric slides, readings are taken as the slide moves over the Read Station in the RATE/COLORIMETRIC INCUBATOR while the INCUBATOR DISK rotates. Read Station E015_5006ACI E015_5006AA A synchronization signal from the READ SYNC SENSOR activates the A/D CONVERTER on the 80x0 RATE REFLECTOMETER BOARD to record the voltage from the 81x1 RATE PHOTODETECTOR BOARD. The A/D CONVERTER converts the analog signal to a digital signal and transmits it to the 59x0 MASTER COMPUTER BOARD for processing. READ SYNC SENSOR E015_5002ACB E015_5002AC 15JAN98 – TG3360-1 67 THEORY GUIDE Detach 16 VARIABLE IRIS SHUTTER COLLIMATOR LENS EYEPIECE LENS LAMP FILTER WHEEL RELAY LENS OBJECTIVE LENS E015_5407DCB E015_5407DA During the read of the slide, a 5 mm spot of light from the REFLECTOMETER LAMP is projected onto the bottom of the slide using LENSES and MIRRORS. The reflected light from the slide is proportional to the development of dye in the slide at that point of incubation. The reflected light from the slide passes through a LENS and one of the FILTERS on the FILTER WHEEL to the PHOTODETECTOR of the 81x1 BOARD. The PHOTODETECTOR converts light energy to voltage. The intensity of light projected onto the slide is controlled by a VARIABLE IRIS. The amount of light projected onto the slide must be within operating limits for proper operation of the REFLECTOMETER. Light for the RATE/COLORIMETRIC REFLECTOMETER is generated by a tungsten-halogen LAMP. The light is projected and conditioned by a series of LENSES, MIRRORS and FILTERS and is directed at a 45° angle to the slide when it is in position at the Read Station in the RATE/COLORIMETRIC INCUBATOR. The clear Estar surface of the slide reflects the majority of incident light, however, some light passes through the chemical reagents that react with the sample fluids to form colors which absorb certain wavelengths of light. The chemical reagents are covered by a reflective white spreading layer and the INCUBATOR PAD which diffusely reflects the penetrating light. The diffusely reflected light is reflected back through the COLLIMATOR LENS through a narrow bandpass FILTER of the FILTER WHEEL focused by the RELAY LENS and projected to the PHOTODETECTOR on the 81x1 RATE PHOTODETECTOR BOARD. The signal from the 81x1 BOARD is amplified and is sent to the 80x0 RATE 68 15JAN98 – TG3360-1 RATE/COLORIMETRIC REFLECTOMETER REFLECTOMETER BOARD to be measured. The FILTER WHEEL contains the following narrow bandwidth FILTERS: 340 nm 400 nm 460 nm 540 nm 600 nm 630 nm 670 nm 680 nm Some chemistries, such as SSCR, TBIL, and some other colorimetric chemistries are sensitive to light. To prevent color development from excessive exposure to light, a SHUTTER ASSEMBLY is provided. A MOTOR opens the SHUTTER only when a slide reading occurs. The 80x0 BOARD is responsible for the control of the RATE/COLORIMETRIC REFLECTOMETER with its associated mechanisms, specifically, the FILTER WHEEL and the conversion of the readings from the PHOTODETECTOR into useful information for the System. FILTER WHEEL The FILTER WHEEL uses an ENCODER DISK and an optical SENSOR to determine the position of the FILTER. The ENCODER DISK indicates the position the FILTER is in, or if the FILTER is not in a correct position. During initialization, the FILTER WHEEL is moved to a start position and then advances to each different position for each FILTER, in consecutive order. Upon completion of initialization, the computer stores the correct position of each FILTER in memory. The FILTER WHEEL, like the DISTRIBUTOR, must use the initialization process to reset. To reset, the computer determines where the FILTER WHEEL is, records its current location, and moves the FILTER in the FILTER WHEEL to the correct position as needed. FILTER WHEEL The 80x0 RATE REFLECTOMETER BOARD and the 18x2 STEPPER MOTOR DRIVER BOARD provide control and drive for the FILTER WHEEL MOTOR. The FILTER WHEEL ASSEMBLY can be driven in either direction to quickly move the correct FILTER for the slide at the Read Station. SENSOR ENCODER DISK E015_5406GCA E015_5406GA 15JAN98 – TG3360-1 69 THEORY GUIDE READ SYNC SENSOR The READ SYNC SENSOR that is part of the RATE/ COLORIMETRIC INCUBATOR, is the key to taking the reading from the slide at the proper time. The reason that timing is so important is because the readings are taken as the slide rotates in the INCUBATOR DISK. The INCUBATOR does not stop so the reading can be taken. ENCODER DISK The READ SYNC BIT on the ENCODER DISK in the INCUBATOR is read by the READ SYNC SENSOR which sends a signal to the 80x0 RATE REFLECTOMETER BOARD when a slide is above the Read Station. READ SYNC SENSOR E015_5002ACC E015_5002AC RATE/COLORIMETRIC REFLECTOMETER Readings Rate Chemistries The data from the RATE/COLORIMETRIC REFLECTOMETER is used to measure the rate of color change of rate slides. During the 5-minute incubation cycle, the RATE/COLORIMETRIC REFLECTOMETER takes 54 readings to determine the enzyme level for a specific test. Each time a slide is read, the PHOTODETECTOR sends a signal to the 80x0 BOARD. The A/D CONVERTER on the 80x0 BOARD changes the signal to a digital value which is sent to the 59x0 MASTER COMPUTER BOARD. The 59x0 BOARD stores each of the digital values into memory. After the 5-minute incubation cycle is completed, the MASTER COMPUTER uses all of the digital values stored in memory to calculate the enzyme level. Colorimetric and Two-Point Rate Chemistries The measurement process for two-point rate and colorimetric chemistries is: 1. Five measurements are taken. 2. The highest and lowest measurements are discarded. 3. The System determines a line by using a linear regression technique derived from the 3 remaining measurements. 4. The value derived from the linear regression process is equivalent to the read and incubation time of the RATE/ COLORIMETRIC INCUBATOR subsystem. 5. For two-point rate tests, steps 1 - 4 are done once more at the next appropriate incubation time. The method of using 5 measurements enables the detection of variations during the measurement process. 70 15JAN98 – TG3360-1 RATE/COLORIMETRIC REFLECTOMETER REFERENCE SLIDES REFERENCE SLIDE N0. 3 POSITION 19 REFERENCE SLIDE No. 1 POSITION 1 REFERENCE SLIDE No. 2 POSITION 10 E002_2725HCE E002_2725HA The 3 identical REFERENCE SLIDES in the INCUBATOR DISK are used by the 80x0 BOARD to calibrate the REFLECTOMETER. The REFERENCE SLIDES are used by the REFLECTOMETER to calculate the reflectance of test slides used in the calculation of reflectance of slides read in the INCUBATOR. Different REFERENCE SLIDES are used for different FILTER wavelength REFLECTOMETER readings. 600 4 630 5 670 3 7 680 BOSS 540 Diameter 2.9 inches 6 Filter Wavelength 340 400 460 540 600 630 670 680 2 460 1 0 400 340 Color* Opaque Purple Blue Green Orange Red Deep Red Deep Red Reference Slide ** 1 2 2 2 3 3 3 1 Incubator Position 1 10 10 10 19 19 19 1 * Look through the FILTER from the side shown in the graphic to define the color. E015_5404AC 15JAN98 – TG3360-1 ** All 3 REFERENCE SLIDES are the same; however, the software for the rate/colorimetric system is from the 700 System, therefore different wavelength FILTERS are read using different REFERENCE SLIDE positions. 71 THEORY GUIDE SHUTTER and VARIABLE IRIS SHUTTER The SHUTTER is moved in and out of the light path of the REFLECTOMETER by a STEPPER MOTOR. A FLAG and 2 optical SENSORS are used to determine the position of the SHUTTER. The 80x0 BOARD provides control and drive for the SHUTTER. Detach 17 VARIABLE IRIS SHUTTER SENSOR STEPPER MOTOR THUMBSCREW E015_5407DCA E015_5407DA VARIABLE IRIS The IRIS is located in the optical path of the REFLECTOMETER. A THUMBSCREW located on the REFLECTOMETER actuates a linkage to adjust the aperture of the IRIS. LAMP The LAMP must emit consistent light energy over a wide spectrum of light wavelengths for the REFLECTOMETER system to operate properly. Due to the stringent demand for consistent light, a LAMP will be unusable by the REFLECTOMETER before the FILAMENT actually burns out. 72 15JAN98 – TG3360-1 COLORIMETRIC INCUBATOR Section 10: COLORIMETRIC INCUBATOR Overview PRECONDITION STATION Slides are moved from the SLIDE BLOCK to the COLORIMETRIC PRECONDITION STATION by the COLORIMETRIC SHUTTLE. After a preheat period, the SHUTTLE moves the slide into 1 of 27 positions in the INCUBATOR DISK. SLIDE RETAINER PICKER position The COLORIMETRIC INCUBATOR is an environmentally controlled system that is used to allow proper incubation of colorimetric and 2-point rate slides. INCUBATOR DISK The INCUBATOR DISK rotates to allow insertion of subsequent slides and the removal of slides at the COLORIMETRIC PICKER position after the incubation period of 5 minutes is completed. The slide is moved by the PICKER into the Read Station position in the REFLECTOMETER for reading measurements. E015_4600ACB E015_4600AC PRECONDITION STATION HEATER PRECONDITION STATION BLOCK FOAM SLIDE RETAINER PRECONDITION STATION HOUSING THERMISTOR, not visible E002_2307BCD E002_2307BC The purpose of the PRECONDITION STATION ASSEMBLY is to raise the temperature of the slide before the slide is inserted into the INCUBATOR DISK. The COLORIMETRIC SHUTTLE moves the slide from the SLIDE BLOCK to the COLORIMETRIC PRECONDITION STATION where a SLIDE RETAINER holds the slide securely in position. The slide remains in the PRECONDITION STATION for one 12-second instrument cycle. The PRECONDITION STATION elevates the temperature of the slide from instrument ambient temperature to near 37°C, the temperature of the INCUBATOR. The RETAINER TUNNEL COVER PAD prevents evaporation during this period. The next movement of the SHUTTLE moves the slide from the PRECONDITION STATION into the INCUBATOR. The PRECONDITION STATION BLOCK is heated to 37.3 - 38.7°C by a 5-watt resistance HEATER driven by the 97x1 THERMAL DRIVER BOARD. A THERMISTOR for the PRECONDITION STATION provides an analog voltage that is used by the 95x0 THERMISTOR AMPLIFIER BOARD, 93x0 ANALOG I/O BOARD, 72x0 MECHANISM COMPUTER BOARD, and 97x1 THERMAL DRIVER BOARD to monitor and control the temperature of the PRECONDITION STATION. The PRECONDITION STATION HOUSING engages the SLIDE RETAINER and holds the FOAM and the PRECONDITION STATION ASSEMBLY against the bottom of the 15JAN98 – TG3360-1 73 THEORY GUIDE PRECONDITION STATION BLOCK. This functions as an insulator to prevent the heat from transferring between the BLOCK and the LOWER INCUBATOR HOUSING. INCUBATOR DISK DRIVE GEAR INCUBATOR DISK RING GEAR The INCUBATOR DISK contains 27 individual positions that hold the slides for the remainder of the required incubation time which was initiated in the PRECONDITION STATION. Each position is covered by a PRESSURE PAD which reduces evaporation from the slide and traps any gases necessary to the reaction taking place in the slide. The SLIDE SPRINGS hold the slide in the correct position. The INCUBATOR DISK moves 1 position at a time in a counterclockwise direction and advances once every 3 seconds. This equalizes the temperature within the COLORIMETRIC INCUBATOR. E002_2304ACA E002_2304AC The temperature of the INCUBATOR is maintained at 36.6 - 37.4°C by 2 resistance HEATERS, located above and below the INCUBATOR DISK. Slides are inserted into the INCUBATOR at every 4th position and may remain in the INCUBATOR for up to 4 complete rotations of the DISK, therefore, each slide can be presented at the PICKER position 4 times. Depending upon the test methodology, the System will remove a slide from the INCUBATOR, read it, and then either discard it or reinsert it into the same position in the INCUBATOR DISK in order to take another reading on a subsequent revolution. The maximum incubation time, at the end of the 4th revolution, is approximately 5 minutes, including the time spent in the PRECONDITION STATION. A 7-ELEMENT ARRAY monitors the position of the INCUBATOR DISK. Signals from this SENSOR indicate which position is at the PRECONDITION STATION for slide loading, and also which position is at the PICKER position for slide unloading. Results will not be reported for slides which received other-than-normal incubation caused by any delay in the incubation cycle. 74 15JAN98 – TG3360-1 COLORIMETRIC INCUBATOR Thermal Control UPPER HEATER AND CONNECTOR ASSEMBLY UPPER INCUBATOR HOUSING E002_2306DCC E002_2306DC THERMISTORS are used to monitor the temperature of the INCUBATOR. An error is reported on the STATUS CONSOLE if the temperature is outside operating specifications. Results for slides in the INCUBATOR are reported with a flag to indicate an abnormal incubation temperature. If the colorimetric system is enabled in subsystem control, sample metering cannot be initiated or resumed until the INCUBATOR has reached operating temperature. The UPPER HEATER AND CONNECTOR ASSEMBLY is installed above and in direct contact with the UPPER INCUBATOR HOUSING. The UPPER INCUBATOR HOUSING includes an UPPER MAIN HEATER and an UPPER AUXILIARY HEATER. The UPPER MAIN HEATER allows variable heat output to maintain 37°C, after the temperature has stabilized. The UPPER AUXILIARY HEATER is energized during the warm up and is deenergized when the temperature reaches the stabilized range. 15JAN98 – TG3360-1 75 THEORY GUIDE Detach 18 LOWER HEATER AND CONNECTOR ASSEMBLY LOWER INCUBATOR HOUSING INSTRUMENTATION THERMISTOR CONTROL THERMISTOR E002_2308DCB E002_2308DC The LOWER HEATER AND CONNECTOR ASSEMBLY is installed below and in direct contact with the LOWER INCUBATOR HOUSING. The LOWER INCUBATOR HOUSING includes a LOWER MAIN HEATER and a LOWER AUXILIARY HEATER. Both HEATERS function in the same manner as the upper HEATERS. The analog outputs of the CONTROL and INSTRUMENTATION THERMISTORS are averaged and used to monitor and control the temperature of the INCUBATOR. The thermal monitor and control system consists of the 95x0 BOARD, 93x0 BOARD, 97x0 BOARD, 72x0 MECHANISM COMPUTER BOARD, and 90x0 MASTER COMPUTER BOARD and the controlling software. To check that the CONTROL and INSTRUMENTATION THERMISTORS and associated analog circuitry are operating correctly, the software compares the values from each of the THERMISTORS and reports an error if the values exceed a limit. A 55°C AUTOMATIC RESET THERMOSTAT and a 73°C MANUAL RESET THERMOSTAT wired in series protect the system from exceeding unsafe temperatures by disconnecting power to the MAIN HEATERS. AUTOMATIC RESET THERMOSTAT MANUAL RESET THERMOSTAT 76 E015_4602ACB E015_4602AC 15JAN98 – TG3360-1 COLORIMETRIC INCUBATOR STEPPER MOTOR INCUBATOR COVER A unidirectional STEPPER MOTOR rotates the INCUBATOR DISK. The 92x6 COLORIMETRIC SUBSYSTEM MCB and the 18xx STEPPER MOTOR DRIVER BOARD provide control and drive for the MOTOR. A15J3 FASTENER (3) A15P1 A15P2 E002_2300ACA E002_2300AC MOTOR AND GEAR ASSEMBLY DRIVE GEAR INCUBATOR DISK 15JAN98 – TG3360-1 RING GEAR The MOTOR AND GEAR ASSEMBLY allows the INCUBATOR DISK to be rotated by the STEPPER MOTOR. The DRIVE GEAR engages with and drives the RING GEAR which is a part of the INCUBATOR DISK. E002_2304ACA E002_2304AC 77 THEORY GUIDE ENCODER DISK, 7-ELEMENT ARRAY 7-ELEMENT ARRAY ENCODER DISK 78 The ENCODER DISK and the 7-ELEMENT ARRAY send binary codes to the 92x6 BOARD to identify the position of the INCUBATOR DISK. E015_4602ACC E015_4602AC 15JAN98 – TG3360-1 COLORIMETRIC REFLECTOMETER Section 11: COLORIMETRIC REFLECTOMETER Overview The COLORIMETRIC REFLECTOMETER measures the color density of colorimetric and two-point rate chemistry slides to determine the concentration of an analyte in a sample. Incubated slides are transported from the COLORIMETRIC INCUBATOR to the Read Station through the use of the COLORIMETRIC PICKER mechanism. At the Read Station, the HEATER HOUSING ASSEMBLY warms the slides to prevent condensation on the slides and the color density of the slide is read. PICKER FINGERS SLOT SPRING RETAINER E002_3330ACA E002_3330AC Light from the COLORIMETRIC LAMP is projected onto the bottom surface of the slide through the use of FILTERS, LENSES, and a MIRROR. Light reflected from the slide is detected and converted to an electrical signal by the PHOTODETECTOR. The signal from the PHOTODETECTOR, which is proportional to the analyte concentration on the slide, is amplified by the 42x0 COLORIMETRIC PHOTODETECTOR BOARD and converted to a digital value by the 13x0 COLORIMETRIC REFLECTOMETER BOARD. The digital value is communicated to the 59x0 MASTER COMPUTER BOARD for processing. Detach 19 WHITE REFERENCE AREA SLIDE IN READ STATION APERTURE FILTER LENS LAMP HOUSING LAMP LENS APERTURE INFRARED FILTER MIRROR PHOTODETECTOR FILTER WHEEL E002_3338BCA E002_3338BA After the slide reading, the PICKER moves the slide out of the Read Station. If the slide is to be discarded, the DISCARD DOOR is raised to expose the DISCARD CHUTE. The PICKER moves the slide to the DISCARD CHUTE where the slide falls into the COLORIMETRIC SLIDE DISPOSAL BOX. The DISCARD DOOR is not opened if the methodology of the slide requires an additional incubation and reflection density reading. In this case, the PICKER moves the slide over the top of the closed DISCARD DOOR and returns the slide to the INCUBATOR. 15JAN98 – TG3360-1 79 THEORY GUIDE COLORIMETRIC PICKER COLORIMETRIC REFLECTOMETER COLORIMETRIC REFLECTOMETER CONNECTOR A18P1 CONNECTOR A18P1 E002_3308ACA E002_3308AC E002_3308ACA E002_3308AC The PICKER mechanism is actuated by a bidirectional STEPPER MOTOR that is driven by the 18x2 STEPPER MOTOR DRIVER BOARD. Two SENSORS provide positional feedback to the 92x6 COLORIMETRIC SUBSYSTEM MCB which controls the movement of the PICKER. When the PICKER is in the home position, the PICKER FINGERS are elevated above the INCUBATOR DISK by contacting an adjustable SETSCREW in the DISCARD DOOR COVER. As the PICKER FINGERS move to the Read Station, the PICKER FINGERS descend and “hook” a slide in the INCUBATOR SLOT below. The PICKER FINGERS then pull the slide into the Read Station where it is read. DISCARD DOOR DISCARD DOOR SENSOR The DISCARD DOOR is actuated by a the 18x2 DRIVER BOARD. A POSITION SENSOR provides feedback to the 92x6 COLORIMETRIC SUBSYSTEM MCB which controls the operation of the SOLENOID. When the SOLENOID is energized, a LINKAGE opens the DISCARD DOOR allow slides to be discarded by the PICKER. FLAG E002_3335ACA E002_3335AC 80 15JAN98 – TG3360-1 COLORIMETRIC REFLECTOMETER HEATER HOUSING ASSEMBLY HEATER HOUSING ASSEMBLY PRESSURE PAD,not visible E002_3323ACA E002_3323AC 15JAN98 – TG3360-1 A resistive HEATER and THERMISTOR in the HEATER HOUSING ASSEMBLY heat the WHITE REFERENCE to 42 - 50°C to prevent condensation on the surface of the slide. The HEATER HOUSING in conjunction with the PRESSURE PAD and SPRING hold the slide down over the aperture for proper density readings. WHITE REFERENCE The purpose of the WHITE REFERENCE is to provide a reference reading used to validate the correct operation of the REFLECTOMETER. The readings of the WHITE REFERENCE by the PHOTODETECTOR are made by the beam of light reflected from the bottom surface of the WHITE REFERENCE before a slide is moved into the Read Station. 81 THEORY GUIDE FILTER WHEEL ASSEMBLY, STEPPER MOTOR The FILTER WHEEL, which lies in the path of the incident light, has 7 narrowband FILTERS. Each FILTER is separated by a dark surface which is used when dark readings are required. The FILTERS are located on the radii of the FILTER WHEEL as follows: FILTER WHEEL E002_3344ACB E002_3344AC FILTER Number 0 1 2 3 4 5 6 7 Wavelength (nm) 680 670 630 600 540 (not used) 460 400 The FILTER WHEEL is driven bidirectionally by a STEPPER MOTOR to bring the appropriate FILTER into the light path. SENSOR Each type of test requires a designated FILTER for the slide reading. The FILTER WHEEL ASSEMBLY has 7 FILTERS. The FILTER WHEEL has a hole pattern representing the binary value for the number of the FILTER in the light path. A SENSOR reads the binary code and sends a signal to indicate the position of the FILTER WHEEL to the 13x0 COLORIMETRIC REFLECTOMETER BOARD. E002_3345ACB E002_3345AC The 13x0 BOARD, which is controlled by the 72x0 MECHANISM COMPUTER BOARD, operates and controls the speed of the bidirectional STEPPER MOTOR that drives the FILTER WHEEL ASSEMBLY. A decal and a pointer visually indicate the number of the FILTER in the light path. During the operation of the REFLECTOMETER, the system checks for light leaks. To do this, the FILTER WHEEL is moved to a position halfway between 2 FILTERS so that the light path from the LAMP to the Read Station is blocked. LAMP COVER ASSEMBLY 82 E002_3306ACA E002_3306AC 15JAN98 – TG3360-1 COLORIMETRIC REFLECTOMETER PHOTODETECTOR voltage signal to 13x0 BOARD PHOTODETECTOR The PHOTODETECTOR is connected to the 42x0 COLORIMETRIC PHOTODETECTOR BOARD. The amount of light reflected onto the PHOTODETECTOR is determined by the color density of the slide. A preamplifier on the 42x0 BOARD amplifies the voltage of the PHOTODETECTOR to be within a range of 0 -10 V dc required for the A/D CONVERTER on the 13x0 BOARD. The A/D CONVERTER changes the PHOTODETECTOR voltage to a digital number from 0 to 65,535. E002_3314ACC E002_3314AC Optical System WHITE REFERENCE AREA SLIDE IN READ STATION APERTURE FILTER LENS LAMP HOUSING LAMP LENS APERTURE INFRARED FILTER MIRROR PHOTODETECTOR FILTER WHEEL E002_3338BCA E002_3338BA The optical system consists of an illuminator that projects a 3 mm spot of light on the center of the slide at a 45° angle. The 2-lens optical component gathers light from the LAMP and collimates it before projecting it onto the slide. The PHOTODETECTOR receives the reflected, diffuse light from the slide. The tungsten-halogen LAMP is located in a ventilated HOUSING designed to minimize the aging effects of lampheat buildup. The LAMP is powered by a highly regulated direct-current POWER SUPPLY. The PHOTODETECTOR is located at a point directly beneath the Read Station. The PHOTODETECTOR converts the reflected light into a voltage measurement which is then amplified and converted to digital form for use in computing the test result. The dynamic range of the REFLECTOMETER is optimized by automatically adjusting the voltage gain and null counts separately for each FILTER. REFLECTOMETER LAMP The REFLECTOMETER LAMP is the light source that is projected onto the bottom of the slide for reading by the PHOTODETECTOR. A constant voltage for the LAMP is required for correct slide reading. 15JAN98 – TG3360-1 83 THEORY GUIDE The INFRARED FILTER is a heat-absorbing FILTER to remove heat from the light beam to prevent damage to the 7 FILTERS. The FILTERS, in the FILTER WHEEL ASSEMBLY, block all but the light of the desired wavelength. The APERTURE forms the light into a 3 mm beam. A MIRROR reflects the light beam up to the center of the slide. The BAFFLE ASSEMBLY allows only light reflected down from the slide to strike the PHOTODETECTOR. REFLECTOMETER Reading When the ANALYZER is initialized, the REFLECTOMETER takes a dark reading and a WHITE REFERENCE reading for each FILTER. The data is stored in the 59x0 MASTER COMPUTER BOARD and compared with the dark reading and the WHITE REFERENCE reading taken before each slide reading. During normal operation of the REFLECTOMETER, the 59x0 BOARD compares the initialization values to each slide reading. Any values that are not within specification result in a condition code. The data from the REFLECTOMETER are used to calculate the analyte concentration in a slide. The REFLECTOMETER uses 3 reads to calculate a density of reflection DR. Reading 1 - Dark Reading The FILTER WHEEL is moved to a position between 2 FILTERS so that the light to the Read Station is blocked. This reading produces a low reference value for the 59x0 MASTER COMPUTER BOARD. Reading 2 - WHITE REFERENCE Reading The FILTER that is used to read the slide for reading 3 moves into the light path and the filtered light reflects off the WHITE REFERENCE to produce a high reference value for the 59x0 BOARD. Reading 3 - Slide Reading The PICKER moves the slide from the INCUBATOR to the Read Station. The filtered light, from the same FILTER used in reading 2, makes a slide reading. This reading must be between the low and high reference values. When Mechanism Exercise Diagnostics is used, the “NULL” and “GAIN” numbers displayed on the screen are used with the “REF”, “DARK” and “SLIDE” numbers to diagnose a malfunction in the REFLECTOMETER. A computer on the 13x0 COLORIMETRIC REFLECTOMETER BOARD controls the A/D CONVERTER. The signal from the 42x0 COLORIMETRIC PHOTODETECTOR BOARD is amplified by 2 OP AMPS on the 13x0 BOARD. The first OP AMP is a unity gain inverting amplifier. The second OP AMP is a programmable gain amplifier. Circuits on the 13x0 BOARD adjust the A/D CONVERTER to allow for any light leakage in the REFLECTOMETER and noise in the circuitry. The ZERO-CROSSING SIGNAL from the 65x0 POWER CONTROL BOARD is used by the A/D CONVERTER on the 13x0 BOARD at the point when the ac line voltage changes from positive to negative, or from negative to positive. The computer on the 13x0 BOARD uses the data from the dark readings and reference readings to determine the adjustments for correct operation of the OP AMPS. These adjustments for correct operation are made by the A/D CONVERTER and are the “NULL” and “GAIN” signals displayed on the screen. Data from the 13x0 BOARD is used by the 72x0 MECHANISM COMPUTER BOARD to calculate the colorimetric test results. When “CYCLE REFL PICKER” is touched in MEDs, the dark and reference readings are determined, the “>GAIN” and “NULL” signals are sent to the computer by the A/D CONVERTER, and then the slide moves to the correct position and a reading is determined. The results of the dark, reference, and slide readings are displayed on the screen. 84 15JAN98 – TG3360-1 COLORIMETRIC REFLECTOMETER The following values are examples of typical gains which can be measured in MEDs. FILTER No. 0 1 2 3 4 5 6 7 15JAN98 – TG3360-1 Wavelength 680 670 630 600 540 Blank 460 400 Gain 8.0 8.0 12.0 16.0 24.0 -48.0 192.0 85 THEORY GUIDE Section 12: PIC ASSEMBLY PIC COVERS Overview POTENTIOMETRIC COVER HINGE (2) IR/CM KNOB ASSEMBLY POTENTIOMETRIC COVER ASSEMBLY IC T P BA U C IN O R IR/ CM PM PM KNOB ASSEMBLY WIRE COVER MIDDLE COVER ASSEMBLY IR/CM COVER ASSEMBLY E015_7210DCA E015_7210DA The PIC COVERS are thermally insulating COVERS that help maintain the temperature of the PIC INCUBATORS at 36.9 - 37.1°C (98.5 - 98.7°F). They also provide access to the POTENTIOMETRIC and IMMUNO-RATE/ COLORIMETRIC INCUBATORS to clear a jam, clean EVAPORATION CAPS, and do maintenance or service procedures. The IR/CM and POTENTIOMETRIC COVER ASSEMBLIES are injection molded shells with insulating FOAM inside. The IR/CM COVER also provides insulation between the IR/CM HOT PLATE and the PIC SUPPORT. The PIC COVERS contain: IMMUNO-RATE/COLORIMETRIC COVER ASSEMBLY MIDDLE COVER ASSEMBLY POTENTIOMETRIC COVER ASSEMBLY WIRE COVER 86 IMMUNO-RATE/COLORIMETRIC KNOB ASSEMBLY POTENTIOMETRIC KNOB ASSEMBLY POTENTIOMETRIC COVER HINGE 15JAN98 – TG3360-1 PIC ASSEMBLY MIDDLE COVER ASSEMBLY HINGE INSERT (4) RELEASE PLATE PM HOT PLATE SCREWS OUTER PLATE MIDDLE PLATE OUTER PLATE 1/4-TURN RECEPTACLE WIRE COVER INSERT MIDDLE COVER E015_7213GCA E015_7213GA E015_7212GCA E015_7212GA The MIDDLE COVER ASSEMBLY consists of an injection molded plastic COVER and several other components. Threaded INSERTS are molded into the COVER, a RECEPTACLE for the 1/4-turn FASTENER is ultrasonically inserted into the COVER, and 4 PLATES are heat staked onto the COVER. The MIDDLE COVER is fastened to the POTENTIOMETRIC HOT PLATE with 5 SCREWS to help increase the strength of the COVER and to help keep it flat around the outer edge to aid in sealing the INCUBATORS. The 1/4-turn FASTENER is used in conjunction with the POTENTIOMETRIC KNOB ASSEMBLY and holds the POTENTIOMETRIC COVER to the MIDDLE COVER. The PLATES on the bottom of the COVER act as RETAINING PLATES for the LIFT AND TURN ASSEMBLY. The RELEASE PLATE actuates the RESET LEVER on the LIFT AND TURN ASSEMBLY when the COVER UNIT is closed. WIRE COVER The WIRE COVER pivots open on a SHAFT to allow removal of the wires for the POTENTIOMETRIC INCUBATOR and ELECTROMETER from the MIDDLE COVER. The WIRE COVER also acts as a STRAIN RELIEF for the wires when the COVER UNIT is being lifted and rotated to obtain access to the IR/CM INCUBATOR. A SCREW fastens the WIRE COVER to the MIDDLE COVER and keeps it closed. 15JAN98 – TG3360-1 87 THEORY GUIDE IMMUNO-RATE/COLORIMETRIC KNOB ASSEMBLY IR/CM KNOB ASSEMBLY SPRING RETAINING COLLAR COMPRESSION SPRING TOWER TOWER SHAFT E015_7206DCB E015_7206DA The IR/CM KNOB ASSEMBLY consists of several components. The TOWER is screwed to the center of the POTENTIOMETRIC HOT PLATE. When the PIC COVERS are closed, the TOWER SHAFT engages the IR/CM HOT PLATE and connects the SHAFT and KNOB to ground. The stepped diameter in the TOWER SHAFT contacts the PIVOT PLATE and connects it to ground, thereby grounding the LIFT SPRING for the LIFT AND TURN ASSEMBLY. The COMPRESSION SPRING applies a downward load to help hold the PM INCUBATOR against the IR/CM INCUBATOR. Loctite is used to fasten the TOWER SHAFT to the KNOB making an assembly that cannot be separated. POTENTIOMETRIC KNOB ASSEMBLY The POTENTIOMETRIC KNOB ASSEMBLY is a smaller version of the IR/CM KNOB with a special long 1/4turn FASTENER SHAFT. It has an EJECTOR SPRING to provide a lifting action as the 1/4-turn FASTENER is rotated. 88 15JAN98 – TG3360-1 PIC ASSEMBLY POTENTIOMETRIC COVER HINGE The HINGE is an adjustable friction HINGE attached to the POTENTIOMETRIC COVER and the MIDDLE COVER. It provides a pivoting point for the POTENTIOMETRIC COVER and holds the COVER open in any position between horizontal and vertical without closing. Operation of the COVERS Obtaining Access to the POTENTIOMETRIC INCUBATOR Rotate the POTENTIOMETRIC KNOB 1/4 turn and open the POTENTIOMETRIC COVER. Friction in the HINGES keeps the COVER open in any position. To close the COVER, manually lower it and rotate the POTENTIOMETRIC KNOB 1/4 turn to lock the COVER. Obtaining Access to the IR/CM INCUBATOR and/or Associated Components [1] Check that the POTENTIOMETRIC COVER is closed and locked. [2] Rotate the IR/CM KNOB to disengage it from the IR/CM INCUBATOR. [3] Using the 2 LIFT TABS on the POTENTIOMETRIC COVER, lift the POTENTIOMETRIC COVER and the MIDDLE COVER as one unit approximately 51 mm (2 in.). An UPPER STOP on the LIFT POST limits the upward travel. [4] Rotate the COVER UNIT counterclockwise approximately 40° until the MIDDLE COVER hits the STOP on the PIVOT PLATE. Do steps 1 - 4 in the reverse order to close the COVERS. 15JAN98 – TG3360-1 89 THEORY GUIDE LIFT AND TURN ASSEMBLY Overview SCREW (4) The LIFT AND TURN ASSEMBLY is a mechanism that, used in conjunction with the MIDDLE COVER, provides access to the IMMUNO-RATE/ COLORIMETRIC INCUBATOR. The POTENTIOMETRIC INCUBATOR, between the POTENTIOMETRIC COVER and the MIDDLE COVER, lifts off the IR/CM INCUBATOR approximately 51 mm (2 in.), then rotates approximately 40° to expose the IR/CM INCUBATOR. PIVOT PLATE The LIFT AND TURN ASSEMBLY contains: • PIVOT PLATE • LIFT POST RESET SPRING • LATCH PAWL • RESET LEVER • RESET SPRING • DRUM ASSEMBLY RESET LEVER • LIFT POST LOCATOR • 4 SCREWS LIFT POST LOCATOR DRUM ASSEMBLY LATCH PAWL (2) E015_7207CCA E015_7207CA Operation of the LIFT AND TURN ASSEMBLY The lifting action is done by a COMPRESSION SPRING. One end of the SPRING is located in the PIC SUPPORT and the other end is halfway up inside the LIFT POST. The SPRING provides approximately 44.48 N (10 lbs) of upward force when it is in the lowered position. This is approximately equal to the combined weight of the POTENTIOMETRIC COVER, MIDDLE COVER, ELECTROMETER, POTENTIOMETRIC INCUBATOR, and LIFT AND TURN ASSEMBLY. When the SPRING is in the raised position, it provides approximately 28.69 N (6 lbs) of upward force. A maximum of 17.79 N (4 lbs) of lifting force should be applied when the COVERS are lifted to obtain access to the IR/CM components. The LIFT POST is guided by a LIFT BEARING. A BEARING RETAINER holds the LIFT BEARING in the IR/ CM HOT PLATE. The other end of the LIFT BEARING is located in the PIC SUPPORT. A cross-hole near one end of the LIFT BEARING is engaged by the BEARING RETAINER to hold the LIFT BEARING to the HOT 90 15JAN98 – TG3360-1 PIC ASSEMBLY PLATE. The BEARING RETAINER contacts the bottom of a SLOT in the LIFT POST to limit the lifting action to 51 mm (2 in.). RESET LEVER/ RELEASE PLATE interface When the COVERS are rotated around the PIVOT PLATE, the RESET LEVER disengages the RELEASE PLATE on the bottom of the MIDDLE COVER at about 1 - 2° of rotation. The mechanism in the LIFT POST goes from the closed position to the open position through the transfer of motion from the RESET LEVER to the LATCH PAWLS through the DRUM ASSEMBLY. The LATCH PAWLS in the open position extend approximately 2.54 mm (0.100 in.) beyond the end of the LIFT POST in the open position. The extended PAWLS rest on top of the BEARING POST to provide a stop in the downward direction. Closing the COVER UNIT retracts the PAWLS allowing the LIFT POST and COVER UNIT to be lowered. PIVOT POINT E015_7214GCA E015_7214GA Detach 20 CLOSED POSITION OPEN POSITION E015_7215BA PIVOT PLATE The PIVOT PLATE is a steel plate the MIDDLE COVER moves on as it is rotated to obtain access to the IR/CM components. The PIVOT PLATE has an offset bend that allows it to clear the IR/CM INCUBATOR DISK and ENCODER GUARD on the bottom and to clear the ELECTROMETER on the top. 15JAN98 – TG3360-1 91 THEORY GUIDE LIFT POST The LIFT POST is the main component of the LIFT AND TURN ASSEMBLY. Square SLOTS on the sides guide the LATCH PAWLS. The bottom of the vertical SLOT acts as a STOP when the LIFT AND TURN ASSEMBLY is raised. The top of the LIFT POST has guides for the RESET LEVER and a FIXED STOP for the RESET SPRING. A hole for the DRUM ASSEMBLY is located in the top of the LIFT POST and the bottom has a hole for the LIFT SPRING. LATCH PAWL The LATCH PAWLS rest on the end of the BEARING when the LIFT POST is raised and keep the COVER UNIT from falling while it is rotated for access to the IR/CM components. The SLOTS in the PAWLS engage DOWEL PINS in the DRUM ASSEMBLY. RESET LEVER The RESET LEVER is a metal plate that turns the DRUM ASSEMBLY to actuate the LATCH PAWLS. The RESET LEVER contacts the RELEASE PLATE on the MIDDLE COVER as the COVER UNIT is rotated closed. The LEVER is between the LIFT POST and PIVOT PLATE, but has clearance to move freely. RESET SPRING The RESET SPRING is a COMPRESSION SPRING that pushes on the RESET LEVER to extend the LATCH PAWLS when the COVER UNIT is rotated to obtain access to the IR/CM components. DRUM ASSEMBLY The DRUM ASSEMBLY transfers the motion of the RESET LEVER to extend and retract the LATCH PAWLS. The bottom of the DRUM ASSEMBLY has 2 DOWEL PINS that engage the LATCH PAWLS and the top has one DOWEL PIN that engages the RESET LEVER. LIFT POST LOCATOR The LIFT POST LOCATOR is a long PIN that minimizes rotation of the PIVOT PLATE around the LIFT POST. The LOCATOR moves up and down in a SLOT in the IR/CM HOT PLATE. SCREWS The flat head SCREWS hold the LIFT POST and LIFT POST LOCATOR to the PIVOT PLATE. The SCREWS must be below the top surface of the PIVOT PLATE so they do not rub on the MIDDLE COVER. 92 15JAN98 – TG3360-1 PIC ASSEMBLY INPUT STATION Overview A44B1 ELEVATOR MOTOR A44U3 ELEVATOR HOME POSITION SENSOR ( top SENSOR, A44P/J5) A44U1 ELEVATOR CLEAR POSITION SENSOR (bottom SENSOR, A44P/J6) PIC SUPPORT E015_6602DCB E015_6602DA The INPUT STATION provides the means of moving slides from the DISTRIBUTOR SLIDE BLOCKS into either the upper PM INCUBATOR or the lower IR/CM INCUBATOR. The DISTRIBUTOR has no SHUTTLE to insert slides into the PIC INCUBATORS. The INPUT STATION has 2 MOTORS and 3 SENSORS. One MOTOR drives the ELEVATOR to the correct position with the help of 2 SENSORS. The other MOTOR and SENSOR control the INPUT BLADE ASSEMBLY which moves the slides out of the SLIDE BLOCK onto the ELEVATOR and into the INCUBATORS. The assembly consists of the ELEVATOR HOUSING and the INPUT BLADE ASSEMBLY located at the back of the PIC ASSEMBLY. The PIC ASSEMBLY provides the supporting interface that the ELEVATOR travels on. The parts necessary for vertical movement of the ELEVATOR are mounted on either the PIC SUPPORT or on the HEATER PLATE of the IR/CM INCUBATOR. The A44B1 ELEVATOR MOTOR, A44U1 ELEVATOR CLEAR SENSOR, and A44U3 ELEVATOR HOME POSITION SENSOR are mounted to the PIC SUPPORT. 15JAN98 – TG3360-1 93 THEORY GUIDE Detach 21 INPUT BLADE ASSEMBLY A44B2 INPUT BLADE MOTOR ELEVATOR HOUSING A44U2 INPUT BLADE SENSOR 94 E015_6600ECB E015_6600EA 15JAN98 – TG3360-1 PIC ASSEMBLY The BEARING GUIDES and BEARING LEAF SPRINGS are mounted to the IR/CM INCUBATOR PLATE. The GUIDES and SPRINGS are part of the features that maintain the correct interface between the ELEVATOR and PIC ASSEMBLY. SPRING B See the procedure in the Service Manual for the correct installation of the BEARING GUIDES and LEAF SPRINGS. A correct installation LEAF SPRING The MOTOR and SENSORS provide vertical movement and control. A B BEARING GUIDE E015_7229GCA E015_7229GA COVER The ELEVATOR HOUSING is a one-piece molded part that supports the INPUT BLADE ASSEMBLY, the A44B2 INPUT BLADE MOTOR, and the A44U2 INPUT BLADE SENSOR. A COVER fits into the ELEVATOR HOUSING cavity to provide operator access and vertical constraint of slides. The HOUSING has 2 FLAGS that help provide control over vertical movement of the ELEVATOR. Several other molded features provide for the correct operation of the ELEVATOR and the INPUT BLADE ASSEMBLY. CLEAR FLAG E015_6604GCB E015_6604GA HOME FLAG 15JAN98 – TG3360-1 95 THEORY GUIDE The INPUT BLADE ASSEMBLY consists of the following 3 parts: • BLADE • COMPLIANT SPRING • RACK The RACK is a molded part with features for controlled movement and support of the BLADE and the SPRING. The RACK has TEETH and FLAGS for horizontal movement on the ELEVATOR HOUSING. FLAG wide SLOT E015_6607ACA E015_6607AA narrow SLOT TEETH SPRING INPUT BLADE TAB on SPRING The purpose of the SPRING is to allow the slide to fully seat in the INCUBATOR NEST without binding or jamming. The correct assembly of these 3 parts requires that the TABS on the SPRING are under the INPUT BLADE. When assembled correctly, the SPRING will not sit too high in the assembly and slip over the BACK STOP for the BLADE preventing correct operation of the SPRING. RACK E015_6606ACA E015_6606AA Normal Operation The DISTRIBUTOR ROTOR ARM places the SLIDE BLOCK over the INPUT STATION ELEVATOR. The ELEVATOR moves up from home position to the PM Position slightly moving the SLIDE BLOCK upward. The INPUT BLADE moves from the Retracted Position to push the slide out of the SLIDE BLOCK and onto the ELEVATOR slide path and into one of the INCUBATORS. The correct cycle of moves depends on the type of slide delivered into the ELEVATOR. If a potentiometric slide is delivered, the INPUT BLADE moves the slide out of the ELEVATOR and directly into the PM INCUBATOR NEST. The slide is moved slightly too far into the NEST and is corrected later by the REGISTRATION CAM. The ELEVATOR will not move vertically until the INPUT BLADE is in the Clear Position, then the ELEVATOR moves down to the home position. This allows the SLIDE ROTOR ARM to rotate without hitting the INPUT STATION ELEVATOR. The INPUT BLADE moves to the Retracted Position after the ELEVATOR is at the home position. If any other type slide is delivered, the following actions occur. The INPUT BLADE pushes the slide out of the SLIDE BLOCK onto the ELEVATOR slide path and moves the slide into the ELEVATOR Holding Area. The ELEVATOR moves down to the IR/CM INCUBATOR. The INPUT BLADE moves the slide out of the ELEVATOR Holding Area into the IR/CM INCUBATOR NEST. The INPUT BLADE STEPPER MOTOR attempts to move the INPUT BLADE slightly too far into the INCUBATOR NEST. The SPRING on the INPUT BLADE ASSEMBLY compresses to allow this movement without damage. The slide is fully seated against the back 96 15JAN98 – TG3360-1 PIC ASSEMBLY wall of the INCUBATOR NEST. The INPUT BLADE moves to the Clear Position to allow the ELEVATOR to move. The ELEVATOR moves to the home position to wait for the next cycle. The INPUT BLADE moves to the Retracted Position. Electrical CLEAR POSITION FLAG limit of travel HOME POSITION FLAG offset downward Bottom edge clear of DISTRIBUTOR interfering with DISTRIBUTOR Middle position Top edge offset upward E015_6605GC The power and control wires for the INPUT STATION are bundled with the PIC ASSEMBLY HARNESS. The 3 SENSORS are monitored by the 92x0 DISTRIBUTOR MCB in SLOT 9. The INPUT STATION, which is physically part of the PIC ASSEMBLY, is controlled by the 92x0 MCB and not the 92x7 PIC INCUBATOR MCB in SLOT 3. The power for the MOTORS is provided by the 17x2 STEPPER MOTOR DRIVER BOARD in the POWER PANEL. The A44B1 ELEVATOR MOTOR provides the drive to move the ELEVATOR between its 3 operating positions - Home, PM Level, and IR/CM Level. The A44U3 ELEVATOR HOME SENSOR and the A44U1 ELEVATOR CLEAR SENSOR provide the control. The HOME SENSOR is the top SENSOR and the CLEAR SENSOR is the bottom SENSOR. The 2 SENSORS monitor the FLAGS on the ELEVATOR HOUSING and communicate the position of the ELEVATOR to the 92x0 MCB. The 92x0 MCB looks at the outputs of both SENSORS to determine if the ELEVATOR is at the top or bottom position of its travel. The primary purpose of the CLEAR SENSOR is to determine when the ELEVATOR is below and clear of the path of the SLIDE ROTOR ARMS. Note The SENSORS are offset by 12.7 mm (0.5 in.). The graphic represents the logical combinations of the SENSOR values as seen by the microprocessor. direction of insertion into INCUBATOR DISK HORSESHOE SENSOR WIDE SLOT DISK Depth DISK Depth adjusted E015_8004BCA E015_8004BC In ELEVATOR Clear to move NARROW SLOT Retract INSERT BLADE SENSOR slot configuration The A44B2 INPUT BLADE MOTOR drives the INPUT BLADE ASSEMBLY through its 4 positions with the A44U2 INPUT BLADE HOME SENSOR. The 4 positions of the INPUT BLADE are Retracted, Clear, Elevator, 15JAN98 – TG3360-1 97 THEORY GUIDE and Disk Depth. The SENSOR detects the notches or SLOTS cut into the FLAG that is part of the RACK HOUSING. The positions are determined by timing the notches and the edges of the FLAG. Software Logic Once initialized, the INPUT BLADE is in the Retracted Position. This is also the final position the INPUT BLADE will be in on completion of its moves. For slides intended for the IR/CM INCUBATOR, the INPUT BLADE makes the following moves: Move from Retracted to Elevator Position Move from Elevator to Rotor Depth Position Move from Rotor Depth to Clear Position Move from Clear to Retracted Position For slides intended for the PM INCUBATOR, the INPUT BLADE makes the following moves: Move from Retracted to Rotor Depth Position Move from Rotor Depth to Clear Position Move from Clear to Retracted Position Once initialized, the ELEVATOR is in the Home Position. This is also the Clear Position for the SLIDE ROTOR ARM path. The Home Position is the final position the ELEVATOR will be in on completion of its moves. For slides intended for the PM INCUBATOR, the ELEVATOR makes the following moves: Move from Home to PM Level Position Move from PM Level to Home Position For slides intended for the IR/CM INCUBATOR, the ELEVATOR makes the following moves: Move from Home to PM Level Position Move from PM Level to IR/CM Level Position Move from IR/CM Level to Home Position Adjustments The adjustments for the INPUT STATION are software controlled through the “ADJUSTMENTS” screen in “DIAGNOSTICS”. No mechanical adjustments are required. The INPUT BLADE has only the adjustment for the DISK Depth Position. This adjustments sets the distance that the INPUT BLADE will move past the edge of the FLAG and place the slide in the INCUBATOR NEST. The distance is the same for both the PM and IR/CM INCUBATORS. In the IR/CM INCUBATOR, the slide will be seated against the back wall of the NEST. In the PM INCUBATOR, the slide will be moved slightly too far into the NEST. The REGISTRATION CAM in the PM INCUBATOR will place the slide in the correct position. The ELEVATOR has only 2 adjustable positions - the PM Level and IR/CM Level positions. The purpose of these adjustments is to set the ELEVATOR slide path at the same vertical height as the slide paths of the INCUBATORS. 98 15JAN98 – TG3360-1 PIC ASSEMBLY POTENTIOMETRIC INCUBATOR Overview A46S2 AUTOMATIC RESET THERMOSTAT DISCARD TRACK DISK STABILIZER SPRING A46S1 MANUAL RESET THERMOSTAT CAP LIFT CAM THERMISTOR ASSEMBLY SLIDE STOP SLIDE REGISTRATION CAM A46B1 PM DISK DRIVE MOTOR A46U1 POSITION SENSOR A46A1 HEATER ROPE E015_6800ECB E015_6800EA The POTENTIOMETRIC INCUBATOR has 2 functions: 1. to incubate the potentiometric slides before placing them in position for reading by the ELECTROMETER 2. to receive slides for discard during initialization of the DISTRIBUTOR 15JAN98 – TG3360-1 99 THEORY GUIDE The POTENTIOMETRIC INCUBATOR is the upper incubator of the 2-tiered PIC INCUBATOR System. The major components of this INCUBATOR are a HEATER PLATE ASSEMBLY and a rotating DISK ASSEMBLY. The HEATER PLATE ASSEMBLY provides the mass necessary to keep the temperature stable and is the support structure for the other components in the module. The DISK ASSEMBLY constrains and transports the slides while they are in the INCUBATOR. The remaining POTENTIOMETRIC INCUBATOR components provide the control, power and monitoring functions. The electrical devices consist of: • A46B1 PM DISK DRIVE MOTOR • A46U1 PM POSITION SENSOR • A46A1 PM HEATER ROPE • A46S1 and A46S2 THERMOSTATS • A46R1 and A46R2 THERMISTORS The mechanical components consist of: • SPRING RETAINER (CAP SPRING ASSEMBLY) • EVAPORATION CAPS • DISCARD TRACK • SLIDE REGISTRATION CAM • DISK STABILIZER SPRING • BEARINGS • CAP LIFT CAM • SLIDE STOP The PM INCUBATOR processes the PM slides in a manner similar to the 250 System. The INCUBATOR temperature is set at 37 (± 0.4)°C (98.6°F) and the incubation time is approximately 2 minutes (~132 sec). Normal Operation The INPUT STATION ELEVATOR delivers the slide to the PM INCUBATOR. The ELEVATOR INPUT BLADE inserts the slide into the NEST of the DISK. The EVAPORATION CAP that is in this location is always in the up position and allows slide insertion without slide to CAP contact. The CAP in this position is lifted by a passive CAM mounted in the HEATER PLATE underneath the DISK. The INCUBATOR DISK rotates or indexes 1 nest position counterclockwise every 12 seconds. Initially, when the slide was inserted by the INPUT STATION BLADE, the slide was pushed slightly too far into the SLOT. During indexing the slide is repositioned correctly by the SLIDE REGISTRATION CAM located towards the center of the DISK and just before the ELECTROMETER Read Position. After the 11th index, or in the 12th position, the ELECTROMETER reads the slide. The ELECTROMETER reading of the slide takes place on the DISK. The slide then travels on the DISK until pushed out into the DISCARD TRACK. In the PM INCUBATOR there is no ejection mechanism to remove slides. Slides are ejected by the insertion of a new slide into an occupied SLOT. The ejected slide is pushed into the DISCARD TRACK and remains there until another ejected slide pushes it into the DISCARD CHUTE. HEATER PLATE ASSEMBLY Thermal Components The PM HEATER PLATE ASSEMBLY thermal control consists of a HEATER PLATE, HEATER ROPE, HEATER ROPE COVER and 2 THERMISTORS. The THERMISTORS and HEATER ROPE provide thermal control to maintain a temperature of 37°C (98.6°F) on the INCUBATOR DISK. The 2 THERMISTORS face the inner edge of the INCUBATOR DISK and monitor the temperature of the DISK to keep the DISK and the slides on it at the specified temperature. The ROPE is fit into a channel cut in the HEATER PLATE for maximum heat transfer between the ROPE and PLATE. The COVER keeps the ROPE in position in the HEATER PLATE. 100 15JAN98 – TG3360-1 PIC ASSEMBLY THERMOSTATS The 2 THERMOSTATS, wired in series with the HEATER ROPE, will interrupt HEATER ROPE power if the HEATER PLATE temperature exceeds safety limits. The AUTOMATIC RESET THERMOSTAT will trip at 55°C (131°F) and the MANUAL RESET THERMOSTAT will trip at 73°C (163.4°F). DISK POSITION SENSOR The DISK POSITION SENSOR detects the notches in the INCUBATOR DISK to provide control of the DISK and to stop it in the correct position. The SENSOR is mounted from beneath the HEATER PLATE in a cutout. The EMITTER and DETECTOR of the SENSOR extend above the top of the HEATER PLATE, and the DISK edge with the notches travels between the EMITTER and DETECTOR. The side of the SENSOR must be mounted flush against the wall of the HEATER cutout with the notched ends. This establishes a common reference for adjustment of the DISK Stopping Position in all Systems. DRIVE MOTOR AND GEAR ASSEMBLY The DRIVE MOTOR AND GEAR ASSEMBLY provides drive to the INCUBATOR DISK. The assembly is mounted to the HEATER PLATE with 3 SCREWS. The normal duty cycle of the MOTOR is one position index once every 12 seconds. The index move itself takes approximately 0.5 seconds. CAP LIFT CAM To prevent contamination from unabsorbed fluid drops, the CAP LIFT CAM lifts the EVAPORATION CAPS to provide clearance between the drops on the slides and the CAPS. The CAM is located on the HEATER PLATE at the ELEVATOR position underneath the DISK. It is here that new slides are inserted into the POTENTIOMETRIC INCUBATOR. The CAM has 3 RAMPS, one for each of the 3 EVAPORATION CAP LEGS. The RAMPS are positioned to lift the 3 LEGS simultaneously so that the CAP moves in a vertical direction. SLIDE REGISTRATION CAM The SLIDE REGISTRATION CAM is used to provide the final fine position of the slide just before it is read by the ELECTROMETER. The slides are initially inserted beyond their final desired location. This CAM then adjusts the position of every slide accurately and precisely. DISK STABILIZER SPRING This SPRING presses a small plastic PAD down onto the INCUBATOR DISK and keeps the DISK on its BEARINGS. The SPRING acts to keep the INCUBATOR DISK in balance and compensates for the effects of the ELECTROMETER reading and CAP lifting forces. Both the size and the location of the STABILIZER SPRING force are important for proper operation. The head of the SCREW that fastens the SPRING also acts to establish a bending line and thus controls the SPRING tension. It is important to use only the specified SCREW here. In addition, the SPRING should be fastened in the position where it is almost touching the DISCARD TRACK. An easy servicing method to keep this distance is to use the DISTRIBUTOR ALIGNMENT TOOL TL-4309 as a SHIM between the SPRING and DISCARD TRACK when fastening the SPRING. DISCARD TRACK The DISCARD TRACK guides used PM slides into the DISCARD CHUTE after which the slide drops into the SLIDE DISPOSAL BOX. One of its key features is a FLEXURE that holds a slide in the TRACK until a subsequent slide takes its place by pushing the first slide down the DISCARD CHUTE. A single used slide will be found in the TRACK since there is no BLADE to eject slides. Slides can only be ejected when they are displaced by subsequent slides or if they are manually removed. SLIDE STOP To prevent slides from falling out during the lift and rotate access to the IR/CM INCUBATOR, a passive SLIDE STOP guards the NEST at the ELEVATOR entrance to the PM INCUBATOR. 15JAN98 – TG3360-1 101 THEORY GUIDE BEARINGS The BEARINGS serve both to center the rotation of the DISK and to provide the vertical support for the DISK. The material used in the BEARINGS is conductive and prevents build up of static on the DISK. The BEARINGS are not fastened to the HEATER PLATE because the DISK STABILIZER SPRING maintains a downward force on the DISK. INCUBATOR DISK ASSEMBLY The INCUBATOR DISK has 15 positioning notches machined in the outer rim. Except for home position, all of these notches are equal in size. The notch for home position, also known as position No. 1, is longer. The leading edges of all the notches are equally spaced around the DISK. However, the trailing edge of the home position notch occurs later than the trailing edge of the other notches. This difference enables the software to track the position of the DISK. The INCUBATOR DISK carries a maximum of 15 slides in the NESTS formed by 15 plastic GUIDES and 15 CAPS. 12 of the GUIDES are mounted with SCREWS and 3 are mounted with STUDS which also fasten the SPRING RETAINER to the DISK. EVAPORATION CAP SPRING RETAINER GUIDE LEG notch INCUBATOR NEST 102 E015_6802DCB E015_6802DA 15JAN98 – TG3360-1 PIC ASSEMBLY GUIDES The GUIDES serve to constrain slides on the INCUBATOR DISK and to provide a bearing surface for the EVAPORATION CAP LEGS. The notch and fence features of the GUIDE prevent the ELECTROMETER from dropping to take slide readings when the DISK is not in a Read Position and the DISK cannot rotate if the ELECTROMETER is down in a Read Position. EVAPORATION CAPS The EVAPORATION CAPS cover the drop wells of the potentiometric slides in the INCUBATOR DISK. They have 3 LEGS that extend through the INCUBATOR DISK to interface with a passive CAP LIFTING CAM. The CAPS are lifted as they approach the ELEVATOR position and are lowered as they move away. With the CAP lifted, the drops of fluid on the slide will not contaminate the CAP. A drop well in the CAP provides clearance for the drops of fluid that have not yet been absorbed by the slide after the CAP comes back down. The material used in the manufacture of the CAPS is static dissipative plastic and prevents the build up of static on the CAPS which could influence slide fluids. SPRING RETAINER (CAP SPRING ASSEMBLY) All of the EVAPORATION CAPS are retained by one assembly. The SPRING RETAINER applies spring pressure on all of the CAPS. This helps the CAPS to form a seal against the potentiometric slides, preventing the evaporation of both the patient and reference fluids. A slight depression and slight rotation of this assembly allows removal and replacement without tools. This permits the removal of the CAPS for cleaning and provides access to the NESTS. Electrical The DISK POSITION SENSOR is monitored by the 92x7 PIC INCUBATORS MCB in SLOT 3. The MCB looks for the leading and trailing edges of the notches that pass the SENSOR. The timing of these edges by the MCB is used to track the home position notch, the position of the DISK, the speed of the DISK rotation, DISK stopping position, and error detection. The DISK DRIVE MOTOR is driven by the 17x2 STEPPER MOTOR DRIVER BOARD. The 17x2 BOARD sends a series of pulses to the MOTOR. The number of pulses determines the distance the MOTOR will move. Each pulse steps the MOTOR 0.0305 cm (0.012 in.). The number of pulses sent by the DRIVER BOARD is controlled by the 92x7 MCB. The MCB, in turn, is controlled by the 72x0 MECHANISM COMPUTER BOARD. The temperature of the POTENTIOMETRIC INCUBATOR is maintained by a HEATER ROPE, THERMISTORS, and CIRCUIT BOARDS. The 97x2 THERMAL DRIVER BOARD provides the power to the HEATER ROPE in the HEATER PLATE. The 2 THERMISTORS monitor the temperature of the INCUBATOR DISK and provide voltage readings to the 95x0 THERMISTOR AMPLIFIER BOARD in SLOT 12. The 95x0 BOARD amplifies and sends the voltages to the 93x0 ANALOG I/O BOARD in SLOT 14. The 93x0 BOARD converts these analog voltages to a digital value and stores them for access by the MECHANISM COMPUTER. The MECHANISM COMPUTER software compares the values from each of the THERMISTORS and reports errors if these values exceed limits. These values also determine the digital signal returned to the 93x0 BOARD where the digital signal is converted into a voltage. The 93x0 BOARD then sends the voltages to the 97x2 THERMAL DRIVER BOARD. Software Logic INCUBATOR DISK Initialization The assumption is made that the position of the DISK is unknown when initialization of the DISK is requested. The DISK will slow step to the next leading edge of a notch to establish a consistent starting point. The DISK then moves 16 positions. This ensures that all 15 notches pass completely through the SENSOR at the same speed. All of the notches are the same size except for home position which is larger. The notches are timed to determine which is home position and thus DISK position is now known. The DISK is then moved to the home position to complete the initialization. 15JAN98 – TG3360-1 103 THEORY GUIDE Adjustments There is only one mechanical adjustment in the POTENTIOMETRIC INCUBATOR. This is the mesh of the DRIVE MOTOR GEAR to the GEAR TEETH on the inner diameter of the DISK. Correct adjustment of the GEAR mesh prevents binding or backlash during DISK rotation. Incorrect GEAR mesh will affect the accuracy and consistency of the DISK Stopping Position. The adjustment of the GEAR mesh will not be correct if the PM INCUBATOR is not at 37°C (98.6°F) during the adjustment procedure. The expansion and contraction of the INCUBATOR components vary sufficiently with temperature to affect adjustment of the GEAR mesh. The other adjustment, which is for DISK Stopping, is a software adjustment. The DISK Stopping adjustment affects the position of the INCUBATOR NEST at the INPUT STATION ELEVATOR and at the ELECTROMETER. Before doing the software adjustment, check that the DISK POSITION SENSOR is mounted correctly.. 104 15JAN98 – TG3360-1 PIC ASSEMBLY IR/CM INCUBATOR Overview A45S1 AUTOMATIC RESET THERMOSTAT HEATER PLATE A45S2 MANUAL THERMOSTAT RESET 2 THERMISTORS, not visible HEATER ROPE A45B1 DISK DRIVE MOTOR HEATER ROPE COVER E015_7200ECB E015_7200EA 15JAN98 – TG3360-1 105 THEORY GUIDE The IR/CM INCUBATOR has 2 functions: 1. to incubate the IR, CM, and Rate slides for the appropriate times 2. to move the slides to their destinations for processing. These destinations are the IR SLIDE TRANSPORT, IR/CM PICKER, and the Read Station in the IR/CM HEATER PLATE for the IR/CM REFLECTOMETER to read the slides. The IR/CM INCUBATOR is the lower incubator of the 2 level PIC INCUBATOR System. The major components of this INCUBATOR are: • HEATER PLATE ASSEMBLY • rotating DISK ASSEMBLY • IR/CM PICKER ASSEMBLY The HEATER PLATE ASSEMBLY provides the mass to keep the temperature stable and supports the other components in the PIC ASSEMBLY. Also, the HEATER PLATE ASSEMBLY has the mechanical features to retain the BEARINGS for the INPUT STATION ELEVTOR. The DISK ASSEMBLY constrains and transports the slides while they are in the INCUBATOR. The IR/CM PICKER ASSEMBLY mounts to the IR/CM HEATER PLATE and removes the slides no longer necessary. The IR/CM REFLECTOMETER mounts to the IR/CM HEATER PLATE from below. The HEATER PLATE contains the Read Station through which the REFLECTOMETER sees the slides passing in the DISK above. The Read Station is located between DISK positions 15 and 16 counting clockwise from the ELEVATOR position. The remaining IR/CM INCUBATOR components provide the control, power, and monitoring functions. The electrical devices consist of: • A45B1 IR/CM DISK DRIVE MOTOR • A45A1 IR/CM HEATER ROPE • A45U1 IR/CM READ SYNC SENSOR • A45S1 and 145S2 THERMOSTATS • A45R1 and A45R2 THERMISTORS The mechanical components consist of: • PM DISCARD CHUTE • SENSOR CLAMP • SEALED BEARING • ANTI-ROTATION CLIP and TAPE • WEAR PADS • ENCODER DISK • ENCODER CLAMP • PRESSURE PADS (CAPS) • SPRING GUARD • PRESSURE PAD SPRING • SIDE LOAD SPRING Normal Operation The IR/CM INCUBATOR accepts IR, CM, and Rate slides from the INPUT STATION ELEVATOR and transports them, after proper incubation, to be read by the REFLECTOMETER. The IR slides go through additional processing steps in the IR SLIDE TRANSPORT. The IR/CM REFLECTOMETER reads the slides as they pass over the Read Station position. After the slides are read, they are moved to the IR/CM PICKER to be discarded. HEATER PLATE ASSEMBLY Thermal Components The IR/CM HEATER PLATE ASSEMBLY thermal control consists of a HEATER PLATE, HEATER ROPE, and 2 THERMISTORS (A45R1 and A45R2). The THERMISTORS and HEATER ROPE proide thermal control to 106 15JAN98 – TG3360-1 PIC ASSEMBLY maintain the INCUBATOR DISK at a temperature of 37°C (98.6°F). The 2 THERMISTORS are in an assembly that is mounted in the HEATER PLATE beneath the INCUBATOR DISK. They monitor the rotating DISK above to keep the DISK and slides at the correct temperature. The HEATER ROPE fits into a channel and is held in place with a COVER to maximize heat transfer to the heater plate. The software uses the output of the THERMISTORS to control the HEATER ROPE power to maintain the correct INCUBATOR DISK temperature. THERMISTORS The 2 THERMISTORS, set in epoxy side by side in an assembly that is mounted to the IR/CM HEATER PLATE, are used to provide monitoring for possible SENSOR drift or malfunction. It must be noted that the IR/CM THERMISTOR ASSEMBLY should have long leads as should the RATE/CM THERMISTOR ASSEMBLY. The excess wire must be coiled inside the cavity on the COVER and the COVER PLUG installed. This is to prevent lower THERMISTOR readings caused by heat loss through the wires. The INCUBATOR will heat to a higher temperature than 37°C when operating at a low ambient room temperature. An environment of 60°F druves a shift of 0.2 to 0.3°C in the INCUBATOR temperature when there is not enough coiled wire. THERMOSTATS The 2 THERMOSTATS, A45S1 and A45S2, are wired in series with the HEATER ROPE to provide protection against unsafe HEATER PLATE temperatures. The AUTOMATIC RESET THERMOSTAT will trip at 55°C (131°F) and the MANUAL RESET THERMOSTAT will trip at 73°C (163.4°F). The AUTOMATIC THERMOSTAT is required by UL specifications and the MANUAL THERMOSTAT is required by Japanese specifications. These are the same THERMOSTATS that are used on the 250 System. DISK DRIVE MOTOR The A45B1 DRIVE MOTOR ASSEMBLY consists of a STEPPER MOTOR and a GEAR modled onto the SHAFT. The MOTOR ASSEMBLY is mounted to the IR/CM HEATER PLATE with a STANDOFF and 3 SCREWS. Access to one of the SCREWS requires rotating the DISK and positioning the hole in the DISK over that SCREW. One additional SCREW mounts the STANDOFF and the GROUND WIRE to the MOTOR, but is not necessary for mounting the MOTOR. To position the INCUBATOR NESTS accurately depends upon the MOTOR step resolution of 0.1 mm (0.004 in.). This eliminates the need to mechanically adjust the SENSOR. Adjustments to the stopping position of the DISK are done by changing the softwere step counts on the screen. READ SYNC SENSOR The READ SYNC SENSOR, A45U1, has 2 functions. The Read Sync signal is routed to the 5000 REC BOARD and split into 2 signals. One of the signals is used to provide the Read Sync control for the IR/CM REFLECTOMETER. The other signal is routed to the 92x7 MCB for IR/CM DISK stopping control. SENSOR CLAMP The SENSOR CLAMP is designed to seat the READ SYNC SENSOR to the same position even after removing the SENSOR. In practical terms, however, the interference between the SENSOR HARNESS and the SENSOR INSULATION PLUG will have some adverse effect on the SENSOR position. The HARNESS should be tempararily removed during the fastening of the CLAMP to prevent this interference. PM DISCARD CHUTE The PM DISCARD CHUTE sits, unfastened, within a square hole in the IR/CM INCUBATOR. The CHUTE passes slides from the PM INCUBATOR through the IR/CM INCUBATOR into the PICK SLIDE DISPOSAL BOX. External design features prevent the DISCARD CHUTE from dropping through the hole. Internally, RIBS prevent slides from attaching to the walls of the CHUTE and creating jams. 15JAN98 – TG3360-1 107 THEORY GUIDE WEAR PADS The WEAR PADS provide the vertical support (Z axis) for the DISK ASSEMBLY. The 3 PADS help maintain consistent INCUBATOR NEST heights at the slide transfer points for the INPUT STATION, IR SLIDE TRANSPORT, and IR/CM PICKER. DISCARD CHUTE READ SYNC SENSOR SENSOR CLAMP THERMISTOR (2) WEAR PAD E015_7205DCB E015_7205DA SEALED BEARING The BEARING provides horizontal support for the DISK ASSEMBLY (X and Y axis). The use of s SEALED BEARING will prevent grease migration to other parts of the INCUBATOR which is a problem that occurs with unsealed BEARINGS. ANTI-ROTATION CLIP ASSEMBLY The ANTI-ROTATION CLIP mounts to the inner race of the DISK BEARING with double-sided tape. The CLIP fits into a CUTOUT in the HEATER PLATE ASSEMBLY to prevent the inner race of the BEARING from rotating and wearing away the HEATER PLATE ASSEMBLY. Wear of the HEATER PLATE will cause excessive 108 15JAN98 – TG3360-1 PIC ASSEMBLY movement of the DISK ASSEMBLY resulting in various problems, for example, slide jams, erroneous REFLECTOMETER readings, etc. INCUBATOR DISK ASSEMBLY The IR/CM INCUBATOR is an aluminum DISK with 27 NESTS cut into it. Slides are transported in 26 of the NESTS while 1 NEST holds the WHITE REFERENCE SLIDE; a Spectralon block.. The block is secured to the NEST to prevent accidental removal. The bottom of each NEST location has a 1.1 cm (0.441 in.) diameter hole. Alignment of each NEST hole and a hole in the HEATER PLATE ASSEMBLY allows the IR/CM REFLECTOMETER to read the contents of all of the NESTS on the DISK. Thus, the Spectralon block, PRESSURE PADS, and slides can be optically read without removing them from the DISK. ENCODER DISK The ENCODER DISK is a steel ring that has 27 SLOTS and mounts to the IR/CM DISK ASSEMBLY. One of the SLOTS is wider and is uded to determine the home position. The F SENSOR reads the SLOTS to control the speed of the DISK, to track slide position, and to actuate the REFLECTOMETER read circuit. The ring has specially placed holes that matc PINS in the DISK ASSEMBLY to assure that home position does not change with disassembly and assembly of the INCUBATOR. ENCODER CLAMP The ENCODER CLAMP is steel ring that, with 3 SCREWS, holds down the ENCODER DISK to the top of the DISK ASSEMBLY. The correct SCREWS must be used on the CLAMP because of the very tight clearance between the SCREW heads and the parts of the MID COVER and LIFT AND TURN ASSEMBLY. The use of incorrect SCREWS will cause errors in the operation of the DISK ASSEMBLY. The errors range from complete stall of the DISK to intermittent stalling and noises. WHITE REFERENCE BLOCK One NEST on the INCUBATOR DISK ASSEMBLY does not transport any slides at all. This NEST carries the WHITE REFERENCE BLOCK for the IR/CM REFLECTOMETER. The block of Spectralon is fastened in this position and cannot be removed by the IR/CM PICKER. This BLOCK provides the consistent reference values for performing IR/CM REFLECTOMETER readings. PRESSURE PADS The chemistry slides are held in place by 26 PRESSURE PADS which also reduce slide fluid evaporation. The variability of PAD to PAD reflectance is minimized by sorting the PADS on a certified test fixture. A sorted lot contains 26 PRESSURE PADS that are optically matched to be within a 0.03 reflectance range of each other. The PRESSURE PADS must be replaced as a set of 26. PRESSURE PAD SPRING The SPRING provides the pressure of the PAD against the slide. This keeps the slide firmly in position as the slide must be stable to obtain proper readings by the REFLECTOMETER. This pressure also seals the PAD against the slide to reduce evaporation. SPRING GUARD The SPRING GUARD protects the PRESSURE PAD SPRING. The GUARD prevents excessive flexing of the SPRING and the resulting damage. A damaged SPRING can cause slide jams, slide jitters, incorrect evaporation, etc. SIDE LOAD SPRING The SIDE LOAD SPRING applies pressure against the edge of a slide and seats the slide against the side wall of the NEST. This provides a constant reference edge for all slides for reliable REFLECTOMETER readings. The SIDE LOAD SPRINGS in the IR/CM INCUBATOR are not secured with SCREWS. They fit into a cavity that constrains them in their proper place and allows for the proper Spring tension on the slide. In other models, tightening the SIDE 15JAN98 – TG3360-1 109 THEORY GUIDE LOAD SPRING MOUNTING SCREWS can distort the SIDE LOAD SPRING and change the SPRING tension. There is no distortion of the SPRING when constrained in the cavity of the IR/CM INCUBATOR DISK. ENCODER DISK CLAMP ENCODER DISK INCUBATOR DISK ASSEMBLY SEALED BEARING ANTI-ROTATION CLIP, not visable SPRING GUARD SIDE LOAD SPRING WHITE REFERENCE BLOCK PRESSURE PAD SPRING PRESSURE PAD E015_7202ECB E015_7202EA Electrical The DISK POSITION SENSOR A45U1 is monitored by the 50x0 REC BOARD and the 92x7 MCB in SLOT 3. The output signal from the SENSOR is routed to the 5000 REC BOARD. Here the signal is divided to provide the Read Sync control for the IR/CM REFLECTOMETER and the DISK stopping control on the 92x7 MCB. The 110 15JAN98 – TG3360-1 PIC ASSEMBLY REFLECTOMETER reads are synchronized to the edge of the Read Sync pulse. The REFLECTOMETER read occurs 60 ms after the pulse edge. The MCB looks for the leading and trailing edges of the notches that pass the SENSOR. The timing of these edges by the MCB is used to track the home position notch, the position of the DISK, the speed of the DISK rotation, DISK stopping position,and for error detection. The DISK DRIVE MOTOR A45B1 is driven by the 17x2 STEPPER MOTOR DRIVER BOARD. The 17x2 BOARD sends a series of pulses to the MOTOR. The number of pulses determines the distance the MOTOR moves. Each pulse steps the MOTOR 0.01018 cm (0.004 in.). The number of pulses sent by the DRIVER BOARD is controlled by the 92x7 MCB. The MCB is controlled by the 72x0 MECHANISM COMPUTER BOARD. The temperature of the IR/CM INCUBATOR is maintained by a HEATER ROPE, THERMISTORS, and CIRCUIT BOARDS. The 97x2 THERMAL DRIVER BOARD provides the power to the HEATER ROPE. The 2 THERMISTORS monitor the temperature of the INCUBATOR DISK and provide voltage readings to the 95x0 THERMISTOR AMPLIFIER BOARD in SLOT 12. The 95x0 BOARD amplifies and sends the voltages to the 93x0 ANALOG I/O BOARD in SLOT 14. The 93x0 BOARD converts these analogvoltages to a digital value and stores them for access by the MECHANISM COMPUTER. The MECHANISM COMPUTER software compares the values from each of the THERMISTORS and reports errors if these values exceed limits. These values also determine the digital signal returned to the 93x0 BOARD where the digital signal is converted into a voltage. The 93x0 BOARD then sends these voltages to the 97x0 THERMAL DRIVER BOARD. Software Logic INCUBATOR DISK Initialization The assumption is made that the position of the DISK is unknown when initialization of the DISK is requested. The DISK will slow step to the next leading edge of a notch. This produces a consistent starting point tht prevents false measurements during the next portion of the procedure. The DISK then moves 28 positions. This ensures that all 27 notches pass completely through the SENSOR at the same speed. All of the notches are the same size except for home position which is larger. The widths of the notches are measured in units of time. From this list of notch times, the home position and the present position of the DISK can be determined. The DISK is moved to home position from this known position. DISK NEST Positions The physical locations of the READ SYNC SENSOR (also DISK POSITION SENSOR), and the NEST at the INPUT STATION ELEVATOR are 16 indexes apart when counting clockwise from the ELEVATOR. When the IR/CM INCUBATOR DISK is in home position, the home position notch is by the SENSOR. The Spectralon slide is in this position by the SENSOR. Therefore, the software considers the Spectralon slide to be in Nest position No. 16 on the DISK and the NEST in front of the ELEVATOR to be NEST position No. 1. Normal DISK Movements Each 12 second machine cycle during normal opertion, the INCUBATOR DISK will make alternating moves. The first move is 1 refolution plus 16 positions (1N+16) and the second move is 3 positions (+3). Different actions take place during these alternating movement cycles. During the 1N+16 cycle, a washed IR slide is inserted into the DISK and the IR/CM PICKER discards a slide. During the +3 cycle, the INPUT STATION ELEVATOR inserts a slide into the DISK and a slide is picked out of the DISK into the IR SLIDE TRANSPORT. DISK Idle State During the idle state of the IR/CM INCUBATOR, the DISK is advanced one NEST position every 30 seconds to help reduce cold spots. Adjustments The IR/CM INCUBATOR has only one mechanical adjustment. This is the mesh of the DRIVE MOTOR GEAR to the GEAR TEETH on the inner diameter of the DISK. Correct adjustment of the GEAR mesh prevents binding or backlash during DISK rotation. Incorrect GEAR mesh will affect the accuracy and consistency of the DISK stopping position and of the Read Sync with the IR/CM REFLECTOMETER. 15JAN98 – TG3360-1 111 THEORY GUIDE The adjustment of the GEAR mesh will not be correct if the INCUBATOR is not at 37°C (98.6°F) during the adjustment procedure. The expansion and contraction of the INCUBATOR components vary sufficiently with the temperature to affect the adjustment of the GEAR mesh. The other adjustments are made through software. These are the DISK Stopping Position and READ SYNC SENSOR and are independent of each other. The DISK Stopping Position affects the position of the NESTS at the INPUT STATION ELEVATOR, IR SLIDE TRANSPORT, and IR PICKER. The READ SYNC SENSOR adjustment affects the timing of the reading of the slides by the REFLECTOMETER. 112 15JAN98 – TG3360-1 PIC ASSEMBLY IR/CM PICKER Overview A43U1 POSITION SENSOR COVER PICKER RACK RACK GUIDE ASSEMBLY DISCARD CHUTE PICKER FINGERS INSULATORS not visable BASE PLATE ASSEMBLY A43B1 PICKER MOTOR E015_7203ECB E015_7203EA The IR/CM PICKER has the function of removing slides from the IR/CM INCUBATOR DISK. In normal operation, these slides have been processed and the REFLECTOMETER has performed the required reads. The IR/CM PICKER is a subassembly of the IR/CM INCUBATOR in the PIC System. The PICKER FINGERS of the IR/CM PICKER center on the 4th NEST position clockwise from the INPUT STATION ELEVATOR. The 15JAN98 – TG3360-1 113 THEORY GUIDE PICKER mounts to the IR/CM HEATER PLATE with 2 SCREWS. The BASE of the PICKER ASSEMBLY is secured by constraining features designed into the PIC SUPPORT FRAME. The PICKER removes the slides from the IR/CM INCUBATOR and into a CHUTE in the IR/CM PICKER BASE ASSEMBLY. The PICKER has 2 positions in its operational cycle. They are the Home Position and the Inserted Position. In the Home Position, the PICKER FINGERS are retracted outside the INCUBATOR and clear of the rotating DISK. The Inserted Position occurs between the movement cycles of the INCUBATOR. At this time, the PICKER FINGERS are fully inserted into the INCUBATOR and then retracted. During retraction a slide is pulled out for disposal. The IR/CM PICKER consists of the following components: • BASE PLATE ASSEMBLY • DISCARD CHUTE ASSEMBLY • PICKER COVER • RACK GUIDE ASSEMBLY • PICKER RACK ASSEMBLY • FLAG ASSEMBLY • PICKER FINGERS • PICKER MOTOR • POSITION SENSOR Normal Operation The Home Position for the PICKER is with the FINGERS fully retracted and out of the IR/CM INCUBATOR. This prevents the FINGERS from interfering with the rotation of the INCUBATOR DISK. When commanded to remove a slide, the PICKER MOTOR drives the RACK ASSEMBLY, on which the PICKER FINGERS are mounted, into the INCUBATOR. The PICKER FINGERS ride on the top of the slide and drop down behind the slide after they pass the slide edge. The POSITION SENSOR detects the edge of the FLAG (Inserted Position) and causes the MOTOR to reverse direction. The FINGERS pull the slide out of the NEST and out of the INCUBATOR. The slide drops into the DISCARD CHUTE in the PICKER BASE ASSEMBLY and is guided into the PIC SLIDE DISPOSAL BOX. The PICKER FINGERS are back at Home Position. The POSITION SENSOR detects the edge of the FLAG (Home Position) on the RACK ASSEMBLY and the MOTOR goes into Standby power status. The command to pick a slide will only occur during the 1N+16 cycle of the INCUBATOR DISK movement sequence. Actions that occur during the alternating movement cycles of the INCUBATOR are in the section for the IR/CM INCUBATOR. BASE PLATE ASSEMBLY The BASE PLATE ASSEMBLY is the support structure for all of the other parts in the IR/CM PICKER. The BASE PLATE ASSEMBLY mounts to the PIC System on the IR/CM HEATER PLATE. The lower part of the BASE is constrained by design features in the PIC SUPPORT to prevent the PICKER from flexing on the MOUNTING SCREWS. INSULATOR The 2 INSULATORS serve to reduce the heat loss from the INCUBATOR to the PICKER BASE. One side of the INSULATORS has an adhesive surface which is applied to the surface of the INCUBATOR. DISCARD CHUTE The DISCARD CHUTE fits into the BASE PLATE ASSEMBLY and is secured by the same 2 SCREWS that mount the BASE PLATE ASSEMBLY to the HEATER PLATE. The DISCARD CHUTE guides slides into the PIC SLIDE DISPOSAL BOX. 114 15JAN98 – TG3360-1 PIC ASSEMBLY RACK GUIDE ASSEMBLY The RACK GUIDE ASSEMBLY mounts to the BASE PLATE ASSEMBLY with 2 SCREWS. The position of the RACK GUDE is not adjustable because 2 molded PINS lock it to the BASE. The RACK GUIDE provides support, throughout the length of motion, to the RACK ASSEMBLY. The GUIDE also has a design feature to hold the SENSOR without a FASTENER or adjustment. PICKER RACK ASSEMBLY The PICKER RACK ASSEMBLY rides on the RACK GUIDE. The design of each assembly fits 3 surfaces together to provide the necessary constraints to travel and relatively large bearing surfaces. A metal PIN molded into the RACK provides support for the PICKER FINGERS. The PICKER FINGERS should pivot freely on the PIN. Heat staked onto the RACK is a metal form that acts as a FLAG and as a PRESSURE SPRING on the PICKER FINGERS. FLAG ASSEMBLY The FLAG ASSEMBLY is not an individual part for service. It is attached to the RACK during assembly. The FLAG provides the edges that the SENSOR sees as Home Position and Inserted Position when the RACK is moved. The FLAG ASSEMBLY has a portion formed to act as a SPRING on the PICKER FINGERS. This is to provide a slight downward force to ensure that the FINGERS capture the slide. This feature also acts as a stop to hold the PICKER FINGERS up at approximately 40°. The PICKER FINGERS can be raised temporarily to 90° without causing damage to the FLAG. PICKER FINGERS The PICKER FINGERS mount on the metal PIN molded into the PICKER RACK ASSEMBLY and an E-RING holds the FINGERS to the PIN. IR/CM PICKER MOTOR The PICKER MOTOR mounts to the BASE PLATE through 2 holes. The tolerance of these holes is the adjustment available for the mesh between the MOTOR GEAR and the TEETH of the PICKER RACK ASSEMBLY. POSITION SENSOR The POSITION SENSOR detects the edges of the FLAG ASSEMBLY and helps determine if the PICKER FINGERS are at the Home Position or the Inserted Position. The SENSOR fits into a cavity in the RACK GUIDE ASSEMBLY and is held in place with a low force SPRING. Electrical The IR/CM PICKER POSITION SENSOR (A43U1) is monitored by the 92x7 MCB in SLOT 3. The IR/CM PICKER MOTOR (A43B1) is driven by pulses sent by the 17x2 STEPPER MOTOR DRIVER BOARD. The 17x2 DRIVER BOARD is controlled by the 92x7 MCB. The MCB is controlled by the 72x0 MECHANISM COMPUTER BOARD. Software Logic Initialization When the PIC System energizes, the assumption is that all the devices are in an unknown position. As a result of this assumption, a specific sequence of movements take place to successfully initialize the PIC System. Some of these moves do not occur during normal operation. The PICKER can initialize with the SENSOR either blocked or unblocked. If the SENSOR is blocked, the FINGERS are somewhere inside the INCUBATOR. In this case, the MOTOR slow steps the FINGERS toward Home Position. When the SENSOR becomes unblocked, the FINGERS are in the Home Position and outside of the INCUBATOR. If the SENSOR is unblocked at initialization, the FINGERS can be at either the Home Position or the Inserted Position. The MOTOR will be commanded to move the FINGERS toward Home Position. The SENSOR will be monitored for a blocked condition by the FLAG. 15JAN98 – TG3360-1 115 THEORY GUIDE • If the change does not occur in a specified time, it is assumed that the FINGERS were at the Home Position. The MOTOR reverses and drives the FINGERS toward the Inserted Position until the SENSOR is blocked again. The MOTOR again reverses and drives the FINGERS toward the unblocked Home Position of the FLAG. • If the change to blocked does occur in the specified time, the FINGERS continue to move toward the unblocked state of the SENSOR at Home Position. In this case, it is assumed that the FINGERS were at the Inserted Position and must be moved out of the INCUBATOR and to the Home Position. Normal Operation During normal operation, the PICKER waits at the Home Position until called to move into the INCUBATOR and remove a slide. Upon command, the MOTOR drives the PICKER into the INCUBATOR. When the SENSOR detects the edge of the FLAG, the MOTOR reverses direction and drives the PICKER back to the Home Position. Adjustments The IR/CM PICKER ASSEMBLY has no adjustments. 116 15JAN98 – TG3360-1 PIC ASSEMBLY IR SLIDE TRANSPORT Overview SLIDE TRANSPORT HOUSING A42U2 BLADE POSITION SENSOR ROD RACK INSET BLADE MOTOR BRACKET A42U1 PICKER POSITION SENSOR GEAR SPRING HOUSING A42B2 INSERT BLADE MOTOR PICKER MOTOR BRACKET A42B1 PICKER MOTOR E015_8001ECB E015_8001EA The function of the IR SLIDE TRANSPORT is to remove a slide from the IR/CM INCUBATOR, place the IR slide in the correct position for the application of wash fluid, and insert the slide back into the IR/CM INCUBATOR. The IR SLIDE TRANSPORT is located on the left side of the PIC System in front of SLIDE SUPPLY 1. The SLIDE TRANSPORT fastens to the IR/CM INCUBATOR HEATER PLATE and to the PIC SUPPORT. The IR SLIDE 15JAN98 – TG3360-1 117 THEORY GUIDE TRANSPORT interfaces with the IR/CM INCUBATOR and the IMMUNO-WASH FLUID METERING ASSEMBLIES. The IR/CM INCUBATOR transports and incubates the slides. The IWF METERING ASSEMBLY stores and meters the Immuno-Wash Fluid. The major parts of the IR SLIDE TRANSPORT are: • SLIDE TRANSPORT HOUSING • INSERT BLADE MOTOR BRACKET • PICKER MOTOR BRACKET These 3 parts make up the support structure for the rest of the components in this assembly. The BRACKETS fasten to the HOUSING that is the unifying part for the assembly. The remaining parts provide the control, power, and monitoring functions of this assembly. The electrical components consist of: • A42B1 PICKER MOTOR • A42U1 PICKER POSITION SENSOR • A42B2 INSERT BLADE MOTOR • A42U2 BLADE POSITION SENSOR The mechanical components consist of: • PICKER PLATE ASSEMBLY • INSERT BLADE • RACK and ROD • PLATEN ASSEMBLY • TIP LOCATOR ASSEMBLY Normal Operation The DISTRIBUTOR delivers the spotted IR slide to the INPUT STATION ELEVATOR. The ELEVATOR moves down to the IR/CM INCUBATOR level and inserts the slide into a NEST during a +3 disk move cycle. The slide incubates for approximately 5 minutes at 37°C ± 0.1°C. The slide is pulled out of the DISK and into the IR SLIDE TRANSPORT during another +3 disk move cycle. The slide is placed 3.2 mm (0.126 in.) off center for application of wash fluid by the IWF METERING ASSEMBLY. After the slide is washed, it is inserted back into the IR/CM INCUBATOR DISK during a 1N+16 disk move cycle. The slide incubates for approximately 2.5 minutes and the IR/CM REFLECTOMETER takes readings. When the slide is no longer necessary, it is discarded by the IR/CM PICKER during a 1N+16 disk move cycle. PICKER MOTOR The A42B1 PICKER MOTOR drives the PICKER PLATE ASSEMBLY toward and away from the IR/CM INCUBATOR. PICKER POSITION SENSOR The A42U1 PICKER POSITION SENSOR monitors the FLAG of the PICKER PLATE ASSEMBLY to determine if the position of the PICKER PLATE ASSEMBLY is in or out of the INCUBATOR. INSERT BLADE MOTOR The A42B2 INSERT BLADE MOTOR drives the INSERT BLADE toward and away from the IR/CM INCUBATOR. The GEAR AND HOUSING ASSEMBLY on the MOTOR SHAFT are designed to provide compliance for the INSERT BLADE during slide detection and slide insertion into the DISK. During slide presence detection, this compliance allows the slide to push the INSERT BLADE back to detect a notch edge without binds. 118 15JAN98 – TG3360-1 PIC ASSEMBLY During the insertion of a slide into the INCUBATOR DISK, the INSERT BLADE MOTOR continues to turn for a short time to wind up the SPRING in the GEAR AND HOUSING ASSEMBLY. This SPRING windup during slide insertion performs 2 functions: 1. The slide is seated firmly against the back WALL of the DISK NEST. Therefore, the REFLECTOMETER will read the same spot. 2. The compliance of the GEAR AND HOUSING ASSEMBLY keeps the MOTOR from stalling and missing steps that would cause position errors on the next move. BLADE POSITION SENSOR The A42U2 BLADE POSITION SENSOR monitors the notches in the INSERT BLADE which allows the MCB to determing the position of the BLADE. PICKER PLATE ASSEMBLY The PICKER PLATE ASSEMBLY has several features built into it. A portion is bent at a right angle to become the FLAG for the PICKER POSITION SENSOR. The rest of the features provide support for the PICKER PIN, PICKER FINGERS, PICKER SPRING, PICKER PLATE GUIDE, BEARING, and RACK. The PICKER PIN mounts to the PICKER PLATE ASSEMBLY and provides pivoting support to the PICKER FINGERS. The BEARING is located between the PICKER PIN and the PICKER FINGERS. The formed hook of the BEARING fits around the bottom of the ACTUATOR ARM. The PICKER SPRING presses against the BEARING and provides the downward force on the PICKER FINGERS which ensures the picking of a slide. The EXTENSION SPRING assists the PICKER SPRING. The function of the BEARING is to reduce wear or gouging of the moving parts. The PICKER FINGERS place the slide on the PLATEN ASSEMBLY for wash metering by the IWF METERING ASSEMBLY. 15JAN98 – TG3360-1 119 THEORY GUIDE The PICKER PLATE GUIDE keeps the PICKER PIN, which is on the PICKER PLATE ASSEMBLY, parallel to the slide plane. PICKER PLATE GUIDE PICKER SPRING PICKER BEARING PICKER PLATE ASSEMBLY PICKER PIN PICKER FINGERS RACK ROD E015_8002ECB E015_8002EA RACK and ROD The RACK mounts to the PICKER PLATE ASSEMBLY and provides the transfer of drive from the PICKER MOTOR to the PICKER PLATE ASSEMBLY. An additional feature of the RACK is the hole bored through lengthwise. This is the supporting feature for the PICKER PLATE ASSEMBLY through its range of travel on the ROD. The ROD passes through the RACK and is supported on both ends by the HOUSING. 120 15JAN98 – TG3360-1 PIC ASSEMBLY INSERT BLADE The INSERT BLADE has several features and performs 2 functions. A lengthwise slot rides on a guide structure on the HOUSING to keep the BLADE straight. A RACK of TEETH on one edge provides the transfer of drive from the MOTOR to the BLADE. The BLADE has 4 notches that provide the edge transitions for monitoring by the POSITION SENSOR. The 2 functions of the BLADE are to move the slide back into the INCUBATOR and to provide slide presence detection. TIP LOCATOR ASSEMBLY SIDE LOAD SPRING INSERT BLADE SLIDE TRANSPORT HOUSING PLATEN ASSEMBLY PLATEN SPRING E015_8003DCB E015_8003DA PLATEN ASSEMBLY The PLATEN ASSEMBLY is a vertically flexible support plate. The PLATEN SPRING applies upward force on the PLATEN. This provides the proper clearance for different slide thicknesses and places the slide flush against the TIP LOCATOR. 15JAN98 – TG3360-1 121 THEORY GUIDE SIDE LOAD SPRING The SIDE LOAD SPRING fits into a cavity formed in the HOUSING. This is the same SIDE LOAD SPRING that is used in the IR/CM INCUBATOR NESTS. The SIDE LOAD SPRING positions the slide against the back edge of the TIP LOCATOR. TIP LOCATOR ASSEMBLY The TIP LOCATOR ASSEMBLY serves several functions. It has a CAM, or stopper, whose function is to raise the PICKER FINGERS when they are in the INCUBATOR. This is to provide clearance between the PICKER FINGERS and the SCREWS in the INCUBATOR NESTS. Another function is to position the slide the same every time for wash dispensing. This is performed by the lower back edge which provides a constant reference for one direction of slide positioning. Finally, one feature positions the TIP of the IWF METERING ASSEMBLY at the same location each time. This will dispense the wash fluid to the same spot on every slide. Electrical The System provides the dc voltages and the interface signals to operate the electrical components. The electrical components in this assembly are the 2 MOTORS and 2 SENSORS. The A42B1 PICKER MOTOR and the A42B2 INSERT BLADE MOTOR are driven by the 17x1 STEPPER MOTOR DRIVER BOARD. The 17x1 BOARD sends a series of pulses to the MOTORS upon command from the 92x1 MCB in SLOT 2. The 92x1 MCB also monitors the A42U1 PICKER POSITION SENSOR and the A42B2 INSERT BLADE POSITION SENSOR to control the movements of the MOTORS. Software Logic Initialization The IWF METERING ASSEMBLY initializes before the IR SLIDE TRANSPORT. This confirms that the TIP of the IWF METERING is at Home Position before the PICKER FINGERS are moved and prevents collision between the PICKER FINGERS and the IWF METERING ARM and TIP. The IR SLIDE TRANSPORT initializes by moving the INSERT BLADE and the PICKER FINGERS to Home Position. Normal Operation Each 12 second machine cycle during normal operation, the IR/CM INCUBATOR DISK makes alternating rotational moves. The first move is 1 revolution plus 16 positions (1N+16) and the next move is 3 positions (+3). Different IR SLIDE TRANSPORT actions take place during these alternating DISK cycles. During the 1N+16 cycle, a washed IR slide is inserted back into the INCUBATOR DISK. During the +3 cycle, a slide is picked out of the DISK and pulled into the IR SLIDE TRANSPORT. Slide Presence Detection No slide presence/detection SENSORS exist either at the IR SLIDE TRANSPORT Metering Position or in the IR/CM INCUBATOR NEST. These functions are performed by the MCB timing the notches in the INSERT BLADE. The Home Position of the PICKER FINGERS is inserted in the IR/CM INCUBATOR, and the Home Position of the INSERT BLADE is fully retracted. - for Wash Metering When the IR/CM Disk places an IR slide by the IR SLIDE TRANSPORT, the IR PICKER FINGERS are commanded to transport the slide out into the IR SLIDE TRANSPORT Wash Metering Position. At the same time, the IR INSERT BLADE advances to a position approximately 15.0 mm ( 0.6 in.) from Home Position. The INSERT 122 15JAN98 – TG3360-1 PIC ASSEMBLY BLADE SENSOR becomes unblocked by the notch located between edges 5 and 6. As a result, the INSERT BLADE MOTOR switches to low power. Conditions for slide detection for Wash Metering are set. 12 3 4 56 78 E015_2311BC 1 2 3 4, 5 6 7 8 No slide in INCUBATOR Slide in INCUBATOR BLADE clears INCUBATOR No function Slide detection Home No function As the PICKER FINGERS pull the slide into the Metering Position, the slide contacts the INSERT BLADE. The slide pushes the BLADE toward its Home Position. The INSERT BLADE notch edge 6 moves past the BLADE SENSOR and the SENSOR becomes blocked. The MCB recognizes that a slide is present and commands the INSERT BLADE MOTOR to move to Home Position. The BLADE is retracted at a faster rate than the PICKER FINGERS are pulling the slide into the Metering Position. This speed is necessary so that the INSERT BLADE will not affect the final positioning of the slide by the PICKER FINGERS. After positioning the slide, the PICKER FINGERS move back into the INCUBATOR to Home Position. If the INSERT BLADE notch edge 6 did not move past the INSERT BLADE SENSOR, an error would be posted. INSERT BLADE at Home Position SENSOR slide at Wash Position slide in Disk E015_2312BC 15JAN98 – TG3360-1 123 THEORY GUIDE - for DISK Insertion After completing the wash cycle of the slide, the INSERT BLADE pushes the slide into the INCUBATOR DISK. The BLADE SENSOR detects the passing of notch edge 2 and the SENSOR becomes unblocked. If a slide is present, the BLADE will stop with the notch, between edges 1 and 2, under the BLADE SENSOR. The MCB recognizes that a slide was inserted into the IR/CM DISK. The INSERT BLADE moves to Home Position. If the slide is not present, the BLADE continues to move into the INCUBATOR. Edge 1 of the notch is detected by the SENSOR. The MCB determines that the slide did not load into the INCUBATOR DISK. The INSERT BLADE is retracted to Home Position. The MCB sends the failure condition to the MECHANSIM COMPUTER and MASTER COMPUTER. An error code, 408-35, is posted and the PIC Systen cannot be operated. Adjustments The IR SLIDE TRANSPORT has 2 software adjustments that may need to be performed: 1. The Step Count selection of the PICKER FINGERS to position the slide for IWF Metering. 2. The Step Count necessary to correctly place the PICKER FINGERS in the Home Position. This Step Count affects the height of the FINGERS above the MOUNTING SCREWS on the INCUBATOR DISK. The only mechanical procedure that might be classified as an adjustment is the correct assembly of the GEAR AND HOUSING ASSEMBLY for the INSERT BLADE DRIVE MOTOR. Incorrect wind up of the SPRING will affect the compliance of the BLADE when seating the slide. This procedure is in the Service Manual. 124 15JAN98 – TG3360-1 IMMUNO-WASH FLUID METERING Section 13: IMMUNO-WASH FLUID METERING Immuno-Rate Slides Description Hospital laboratories and clinics use immuno-rate tests to monitor the levels of therapeutic drugs and other low concentration analytes in patients. Examples of immuno-rate chemistries and their clinical significance are: Abbreviation CRP Full Name Chemistry Type C-Reactive Protein End point colorimetric Clinical Significance The most sensitive of the acute-phase proteins which assesses the inflammatory status and early tissue damage of disease conditions. Increased levels of CRP might indicate: • myocardial infarction • stress • trauma • infection • inflammation • surgery • malignant diseases PHBR Phenobarbital Rate PHYT Phenytoin Rate • rheumatoid arthritis An anti-epileptic agent used to treat most forms of epilepsy, often used together with PHYT to treat grand mal seizures. An anti-epileptic agent used to treat: • grand mal seizures • focal seizures DGXN Digoxin Rate • arrhythmia A cardiac drug used in the treatment of: • Congestive heart failure • Atrial fibrillation Immuno-rate slides use a complex chemical reaction to identify and measure the concentration of an analyte in the sample fluid. Immuno-rate analytes are antigens, which are proteins or carbohydrates, such as toxins or enzymes, that stimulate the production of antibodies. Immuno-rate slides contain: • A label, which is a chemical substance, that binds to a molecule and distinguishes that molecule from neighboring molecules. In this case, the label is bound to an antigen (the analyte of interest). The labelled antigen competes with analytes in the sample fluid to bind with the antibody in the slide. During the wash cycle, any labels that are not bound are washed to the edges of the slide and do not contribute to the reflection density. • A given quantity of an antibody which is bound to polymer beads and immobilized throughout the slide. Antibodies are proteins that combine with and neutralize antigens. Both the analyte in the sample fluid and the labelled antigen can combine with the antibody in the slide. • A magenta dye that allows the REFLECTOMETER to check that the wash cycle executed correctly. • A chemical, lueco dye, that reacts with the wash fluid and changes to a blue color providing a reflection density. 15JAN98 – TG3360-1 125 THEORY GUIDE Sequence of Events • Fluid is metered onto the slide – special rate slide – routine metering cycle – 11 µL of sample fluid is metered onto the slide – label (horseradish peroxidase - HRP) on the spreading layer dissolves – label attaches to the antigen of interest • The slide is incubated – routine incubation cycle of approximately 5 minutes – initial reaction occurs – drug in patient sample and label compete for binding sites – equilibrium between the drug and the label is established • The slide is washed – slide is removed from INCUBATOR – IWF ARM moves from RESERVOIR – 12 µL of wash fluid (peroxide substrate solution) is dispensed onto the slide over 15.5 to 27.5 seconds – unbound label migrates to the edge of the read area • The slide is incubated – slide is returned to the INCUBATOR – shortened incubation cycle of approximately 21⁄2 minutes – the label catalyzes the oxidation of leuco dye resulting in the formation of a blue color in an inverse relationship to the amount of drug present in the patient sample for DGXN and PHYT; for CRP the relationship is direct – the rate of dye formation in the center of the slide is measured for DGXN and CRP – the intensity of the dye formation is measured for CRP Possible Error Conditions Rule 1: ANY SIZE SAMPLE DROP + ANY WASH = RESULT Rule 2: ANY SIZE SAMPLE DROP + NO WASH = NO RESULT Error Condition No sample drop + wash Small sample drop + wash Big sample drop + wash Good sample drop + small wash Good sample drop + big wash Good sample drop + no wash Concentration WETNESS DETECTOR error, Spline range error, outside System range error, or low outlier Low outlier Possible outlier Low outlier *Acceptable result (most likely) No result * Because the purpose of the wash is to move the unbound label from the read area, a larger than normal wash should not adversely affect the result. The result may be biased, but still acceptable. Precision may be impacted. 126 15JAN98 – TG3360-1 IMMUNO-WASH FLUID METERING IMMUNO-WASH FLUID (IWF) METERING Overview When immuno-rate chemistries are programmed, the slide is dispensed into the SLIDE BLOCK from SLIDE SUPPLY 1. At the Metering Position, 11 µL of sample fluid is metered onto the center of the slide. The slide is moved to the IR/CM INCUBATOR and incubated for 51⁄2 minutes. During the first reaction, the drug in the patient sample and the label dissolved from the spreading layer compete for binding sites. When the initial incubation cycle is completed, the SLIDE TRANSPORT PICKER moves the slide to the IWF METERING position. SLIDE SUPPLY 1 IR/CM INCUBATOR, not visible E015_0917GCB E015_0917GC 15JAN98 – TG3360-1 127 THEORY GUIDE Metering Cycle IWF PUMP MOTOR IWF ARM RESERVOIR E015_4301HCA E015_4301HA The IMMUNO-WASH FLUID METERING ASSEMBLY aspirates 13 µL of wash fluid to prime the TIP, then dispenses 1 µL of the prime back into the RESERVOIR. The IWF ARM rotates to the wash position. The wash fluid is a formation of buffer, surfactants, and peroxide. The peroxide reacts with horseradish peroxidase, HRP, resulting in the dye change to a blue color. Note The prime is the chemistry required wash volume established by the Calibration Disk and can vary by the type of chemistry being processed. A typical prime would be the chemistry required volume of 12 µL + 1 µL. The IWF PUMP MOTOR moves 1 step each 80 ms allowing the PUMP to dispense 12 µL of wash fluid across the slide during 15.4 seconds. The software monitors for only 2 drop detection conditions: 1. a flat line “No Fluid” condition 2. a plugged TIP condition 128 15JAN98 – TG3360-1 IMMUNO-WASH FLUID METERING Incubation and Reading Center Read After the wash cycle, the label catalyzes the oxidation of the leuco dye resulting in the formation of a blue color to provide a reflection density for readings. The rate of dye formation in the center of the slide is measured. Sample Fluid Y Wash Fluid X When the wash cycle is completed, the INSERT BLADE moves the slide to the IR/CM INCUBATOR for another 2 1/2 minutes. The System does not reserve an INCUBATOR position for the post-wash incubation. The 72x0 MECHANISM COMPUTER BOARD determines availability and delays both sample and immuno-wash metering as necessary until positions are available in the INCUBATOR DISK. E015_4306AC For competitive binding, or rate assays, (PHYT, DGXN, PHBR), the blue dye has a reverse relationship to the amount of drug present in the patient sample . A light color slide indicates that a high concentration of a drug is present. A dark color slide indicates a low concentration of a drug. View from bottom of Slide Rate chemistries are read a total of 23 times - 19 of the readings made at 670 nm provide the results; 2 readings at 540 nm and 2 additional readings at 670 nm check that the wash cycle was completed successfully. Low Concentration High Concentration E015_4305AC For non-competitive binding assays (CRP), the color concentration is in direct relation to the level of the drug in the sample. C-Reactive Protein (CRP) is read a total of 5 times - 1 reading at 670 nm provides the result; 2 readings at 540 nm and 2 additional readings at 670 nm check that the wash cycle was completed successfully. Competitive Binding Assay Operational Overview The IWF Metering System is driven by the 17x1 STEPPER MOTOR DRIVER BOARD. The 50x0 REFLECTOMETER/ELECTROMETER CONTROLLER (REC) BOARD and the 92X1 IMMUNO-RATE MCB provide SENSOR signals and communications processing. The assembly has 3 positions available: • RESERVOIR or Home • Maintenance • Metering The PUMP is also driven by the 17x1 BOARD and has a one drop capacity. Electronics The 50x0 BOARD processes the TRANSDUCER signal and the 92x1 BOARD processes the POSITION SENSOR signals and provides communications to the 17x1 BOARD. The 17x1 BOARD drives the PUMP and POSITION MOTORS. 15JAN98 – TG3360-1 129 THEORY GUIDE The 92x1 BOARD is located in the CARD RACK SLOT 2. The 50x0 BOARD is in the PIC ELECTRONICS ENCLOSURE. The 17x1 BOARD is located in the POWER PANEL area. PUMP The PUMP is an itegrated unit that contains the STEPPER MOTOR, PROBOSCIS, and TRANSDUCER. The PUMP is designed to meter one drop at a time with some volume remaining after dispense. The PUMP uses Vitros DT exclusively and is equipped with a TIP removal device. Diagnostics Software is provided for problem diagnosis and includes an automated Leak Test and MEDs functions. Multiple Point Immuno-Rate Calibration Model Description Calibration Model The System uses a multiple-point rate method to estimate the concentration of an analyte in samples analyzed with Vitros Chemistry Products Immuno-Rate Slides. The System measures the rate of change occurring in the reflection density of the slide during the incubation period after the application of a wash fluid, such as the signal generating reagent. Several measurements are taken over a 2 1/2 minute time interval at the appropriate wavelength of the analyte being measured. The reflection density of each reading is then computed from the measured reflectance. The reflection densities may be transformed before the rate calculation to linearize the kinetic curve. An algorithm is also applied to detect and eliminate anomalous measurements, such as noise spikes, that might distort the response curve. Density Immuno-Rate Response Curve An initial rate is calculated over an early time window. This initial rate is then compared to known low and high rates corresponding to the rates found for samples with concentrations at the ends of the dynamic range for the analyte. The time window for samples with low rates will be comprised of the early window combined with the window extension. The time window of samples with high rates will be equal to the early window. The time window for samples with rates falling in between the known low and high rates will consist of the early window along with a portion of the window extension. Window Extension Early Window Time Time Window E015_4304GC The final rate is calculated using the densities falling within the determined time window. The software has 2 rate determination techniques available. One technique applies a least squares regression to the densities and times to find the rate. The other technique finds the maximum rate occurring within the time window by fitting a linear combination of orthogonal polynomials to the densities and times and then differentiating the fitted curve to find the maximum rate. The rate calculation technique used can be analyte and slide generation specific. 130 15JAN98 – TG3360-1 IMMUNO-WASH FLUID METERING Equation 14 X = A0 + A1 * g1(rate) + A2 [g2 (Rate)]k where X = A0 A1 A2 g1, g2 k rate = = = = = = (a) concentration of the analyte in the sample (b) Log10 (concentration) of the analyte in the sample intercept slope parameter curvature adjustment parameter transform functions predetermined curvature coefficient final calculated rate Calibration During calibration, multiple reflectance readings are taken from the slides of 3 calibrators and converted to either reflection density or transformed reflection density. The time windows for each of the calibrators are determined and rates are computed. The rates are used to determine the 3 calibration parameters by solving Equation 14 for the unknown A0, A1, and A2. Concentration Determination The calibration parameters A0, A1, and A2, can be used in Equation 14 to convert the computed rate of the sample into an analyte concentration. Fixed Point Immuno-Rate Calibration Model Calibration Model The System uses a colorimetric fixed-point rate method to estimate the concentration of an analyte in samples analyzed with Vitros Chemistry Products Immuno-Rate CRP Slides. The System calculates the reflectance of the slide at a specific wavelength after a fixed interval of incubation after the application of a wash fluid as the signal generating reagent. Several measurements are taken over a 2 1/2 minute time interval at the appropriate wavelength of the analyte being measured. The reflection density of each reading is then computed from the measured reflectance. The final reflection density is calculated using a subset of the reflection density readings which were measured over a desired time interval during incubation. A least squares regression of the reflection densities and known read times is performed. A fixed time read time is predicted through the regression line to obtain the final reflection density. An algorithm is then applied to the subset of reflection densities to detect anomalous measurements, such as noise spikes, because any noise spike will distort the calculated final reflection density. Equation 15 X = A0 + A1 • g1(DR) + A2 • [g2 (DR]k where X = DR A0 A1 A2 g1, g2 k = = = = = = 15JAN98 – TG3360-1 (a) concentration of the analyte in the sample (b) Log10 (concentration) of the analyte in the sample reflection density intercept slope parameter curvature adjustment parameter transform functions predetermined curvature coefficient 131 THEORY GUIDE Calibration During calibration, multiple reflectance readings are taken from the slides of 3 calibrators and are converted to reflection densities. The reflection densities are determined for each of the calibrators. The assigned concentration of each calibrator, referred to as the supplementary assigned value, or SAV, and the reflection density of each calibrator are used to solve for the unknown A0, A1, and A2 in Equation 15. Concentration Determination The calibration parameters A0, A1, and A2, can be used in Equation 15 to convert the reflection density of the sample into an analyte concentration. Wash Detection Wash Detection Each immuno-rate assay includes a wash detection test to detect when an inadequate volume of wash fluid has been dispensed onto the slide. Inaccurate predictions may result when this condition is present. The 2 typical types of wash errors are: 1. Not enough wash fluid is metered onto the slide. 2. The proper amount of fluid is metered, but not enough wash fluid spreads over the area of the slide where the reflectance measurement is made. A wash error could also be caused by instrument component problems, inappropriate calibration information, or an interfering substance in the sample being processed. Algorithm Description A water washable dye, referred to as DYEs, is added to the dry chemistry slides during manufacturing. This dye produces reflection density at a secondary wavelength different from the primary wavelength at which reflection densities used in the prediction of analyte concentration are read. The change in density at the secondary wavelength is monitored to detect a proper wash. The spectrum of the dye formed by the reaction of the wash fluid with the bound label, referred to as DYEp, contributes color at the secondary wavelength as well as the primary wavelength. After the chemistry slide is washed, a blue dye forms reflection density at 670 nm. An inadequate wash is detected by monitoring the amount of reflection density contributed at the secondary wavelength by DYEs. The majority of the reflection density readings are taken at the primary wavelength during the incubation period following the application of the wash fluid, but a number of reflection density readings are also taken at the secondary wavelength. Define Equation 16. RATIO = Density at Secondary Wavelength Density at Primary Wavelength Equation 17. RATIOexpected = B0 + B1 • Conc + B2 • Conc2 where RATIOexpected Conc B0 B1 B2 = = = = = expected ratio for the given concentration predicted concentration for the sample wash detection intercept parameter wash detection slope parameter wash detection curvature parameter During the processing of a sample, the actual ratio from Equation 16 is calculated using the reflection density measurement taken by the System. Refer to this ratio as RATIOactual. If Equation 18. (RATIOactual - RATIOexpected) > Pre-Defined Tolerance. A wash failure error is returned. 132 15JAN98 – TG3360-1 IMMUNO-WASH FLUID METERING Calibration During calibration, multiple reflectance readings, at the primary and secondary wavelengths, are taken from the slides of 3 calibrators and are converted to reflection densities. Ratios are calculated for each calibrator as described in Equation 16. The assigned concentration of each calibrator, referred to as the supplementary assigned value or SAV, and the ratio of each calibrator are used to solve for the unknown B0, B1, and B2 in Equation 17. Concentration Determination The wash algorithm parameters B0, B1, and B2, are used in Equation 17 along with the predicted concentration of the sample to determine RATIOexpected. This expected ratio is then used in Equation 18 along with the actual ratio of the sample, RATIOactual, to determine if a wash error occurred. Notes: 1. Wash detection is not looked at during calibration 2. Primary = 670 nm 3. Secondary = 540 nm Examples Example Calibration Report CALIBRATION REPORT ANALYZER NAME: TEST: CRP FLUID: SERUM SITE TEMP: 23.4 C LOT/GENERATION 3742-7961 PARAMETERS INTERCEPT 1.92012 SLOPE 6.10536 E+01 CURVATURE 0.00000 SUB DEP: DENSITY 1.29261 E+01 WASH DET TO 1.00000 WASH INTER 1.01859 WASH SLOPE -3.87878 E-03 WASH CURVE 3.44353 E-05 15JAN98 – TG3360-1 LEVEL 1 2 3 LOT No. 0240118 0237219 0237320 BOTTLE 18 19 20 CAL DATE: mm/dd/yy CAL TIME:hh:mm SAV -mg/L 17. 28. 66. RESPONSE 9.95971 E-01 1.10686 1.27417 133 THEORY GUIDE Example Sample Options - Calibration Parameters CRP SERUM OPTION - Calibration Parameters Lot Number : 37427961 Intercept : 1.92012 Slope : 6.10536 E+01 Curvature or Slope 2 : 0.00000 Blank Correction Coef : 0.00000 User Modified Calibration : N Date of Last Calibration : mm/dd/yy Time of Last Calibration : hh/mm Site Temperature at Cal : 2.33799 E+01 IR Wash Tolerance : 1.00000 IR Wash Intercept : 1.02859 IR Wash Slope : -3.87878 E-03 IR Wash Curvature : 3.44353 E-05 134 15JAN98 – TG3360-1 IR/CM REFLECTOMETER Section 14: IR/CM REFLECTOMETER Overview The IR/CM REFLECTOMETER is a precision instrument that can resolve minute changes in reflection density. It is capable of selecting one of several discrete wavelengths, completing a reading, and transmitting the raw data to a computer in a fraction of a second. The REFLECTOMETER utilizes state-of-the-art microcontroller computers contained on the 89x0/5A5 REFLECTOMETER MiC BOARD. These computers, known as MiCs and mMiCs, are used to provide the control required to precisely move STEPPER MOTORS under the control of the 89x0/5A5 BOARD and the 88x0/5A2 REFLECTOMETER DRIVER BOARD. In addition, the microcontrollers monitor SENSOR inputs from position sensitive components. A microcontroller also processes the analog signal input from a light sensing element in conjunction with an A/D CONVERTER. The REFLECTOMETER MiCs receive operational instructions from on•board software contained in various memory devices. The software also includes error trapping and error notification to higher level computers. The mMiCs software is responsible for STEPPER MOTOR operation. The optical system is divided into 2 parts. One part generates light of a specific quality. Through selective wavelength conditioning and a series of LENSES, the resulting light is projected in a concentrated spot onto the subject to be read. The other part of the optical system collects the light reflected from the subject. Through discrete filtering, which allows only one wavelength to pass through the FILTER, the intensity of the chromatic reflection of light is measured by a PHOTODETECTOR element. Functions of the REFLECTOMETER The IR/CM REFLECTOMETER incorporates 3 main disciplines: optical, mechanical, and electrical. The optical module is a single subassembly integrating the light source, optical system, Vitros slide, narrow bandpass FILTERS, and collection optics. The mechanical module incorporates mounting features, SENSORS, STEPPER MOTORS to drive the FILTER WHEEL and SHUTTER, and an IRIS. The electrical module consists of the 89x0/5A5 REFLECTOMETER MiC BOARD, 88x0/5A2 REFLECTOMETER DRIVER BOARD, and the 50x0 REFLECTOMETER/ELECTROMETER CONTROL (REC) BOARD. These boards supply all the necessary electronics for the REFLECTOMETER. Optical Theory The IR/CM REFLECTOMETER optical system consists of: • a stable, well controlled light source • a set of light conditioning FILTERS • COLD MIRROR • LENSES • a set of highly selective discrete wavelength FILTERS • a PHOTODETECTOR The REFLECTOMETER is used to measure the diffuse reflected light from the base of a Vitros chemistry slide. The slide produces a dye in direct proportion to the amount of a particular analyte contained in a patient sample. The REFLECTOMETER measures the changes in the amount of dye, as the chemical reaction takes place throughout the incubation period for the slide. An analog signal is produced by the PHOTODETECTOR in response to the reflected light from the slide. The analog signal is converted to a digital signal that is used, in conjunction with a signal from a known standard, to determine the density of the dye. The density is used to output a result in the form of a chemical concentration. 15JAN98 – TG3360-1 135 THEORY GUIDE The following optical components make up the REFLECTOMETER. The characters in parenthesis, for example (B3), in the text indicate the components labeled in the following graphic. F3 F2 F1 H G J1 F C J K L E B D1 J2 D2 D3 A3 B1 A1 A2 A E015_7508DCA E015_7508DA LAMPHOUSE (A) The light source of the optical system is designed to produce a spot of light on the bottom of the slide. The light is concentrated into a small oval spot approximately 5 x 7 mm. The oval characteristic is produced because the slide is illuminated at a 45° angle. The light is generated using a 125 W incandescent tungsten halogen LAMP (A1) that is precisely selected to meet the specifications. The LAMP draws approximately 6 A from a regulated POWER SUPPLY producing 18 V DC. The LAMPHOUSE also contains a concave MIRROR (A2) located behind the LAMP FILAMENT. The center of the MIRROR’S curvature is placed so that it is on the same optical axis as the LAMP FILAMENT. In this position, the image of the LAMP FILAMENT is projected back onto the physical LAMP FILAMENT. The reflected energy from the concave MIRROR provides additional heating of the LAMP FILAMENT. The concave MIRROR adds 20% more energy to the total output of light energy from the LAMP as measured at the PHOTODETECTOR. It is very important that the FILAMENT of the LAMP remains in the center of the light path. The REFLECTOMETER requires the FILAMENT to be centered to achieve, and in most cases exceed, multiple reading 136 15JAN98 – TG3360-1 IR/CM REFLECTOMETER precision goals. The FIXED LAMP BASE was designed to accomplish this requirement. It also serves the purpose of properly heat sinking the LAMP BASE to increase the life of the LAMP. The FIXED LAMP BASE was designed with easy LAMP changes in mind. The OBJECTIVE LENS (A3) is located on the optical center and in front of the LAMP FILAMENT. This LENS directs the light from the LAMP FILAMENT to the next optical component in the REFLECTOMETER. MIRROR MOUNT CASTING (B) The light from the OBJECTIVE LENS is directed onto a special optical component known as a COLD MIRROR (B1). A COLD MIRROR is unique in that it can be manufactured to selectively transmit and reflect certain wavelengths of light. The COLD MIRROR in the REFLECTOMETER is designed to transmit almost all of the infrared energy. This reduces the potential for induced thermal effects on the chemistry slide. The COLD MIRROR is also designed to reflect specific amounts of the visible light, and virtually all of the ultraviolet light produced by the LAMP. The net effect of the COLD MIRROR is to provide a custom balance of the spectral energy from the LAMP. This is done by transmitting undesirable light wavelengths and surplus light energy through the MIRROR; and reflecting a “balanced” amount of each of the desired wavelengths. The orientation of the COLD MIRROR is critical to the operation of the REFLECTOMETER. The coatings that are applied to the glass substrate are directional. A small ARROW on the edge of the MIRROR indicates the correct orientation. The ARROW should point inward, toward the recess in the MIRROR MOUNT CASTING. If the MIRROR is reversed, the spectral balance of the COLD MIRROR will be affected. This affect may be seen in significant voltage changes at the PHOTODETECTOR. REFLECTOMETER HOUSING (C) The REFLECTOMETER HOUSING supports the balance of the optical components. The HOUSING provides location features for all the optical components. SHUTTER ASSEMBLY (D) The SHUTTER mechanism is located in the REFLECTOMETER HOUSING immediately following the COLD MIRROR. The SHUTTER ASSEMBLY consists of the SHUTTER STEPPER MOTOR (D1), the SHUTTER VANE (D2), and 2 POSITION SENSORS (D3). All of these components are mounted to the REFLECTOMETER HOUSING SIDE COVER. The SHUTTER VANE is used to block the light from the LAMPHOUSE for the following 3 reasons: 1. To block the light so that a Dark reading can be taken. Dark readings are taken once every revolution of the INCUBATOR DISK. 2. To block light when a chemistry slide passes over the REFLECTOMETER, and a reading is not required. This reduces the overall light energy that the chemistry slide “sees” over a 5 minute incubation cycle. Some chemistries are sensitive to an effect known as photolysis; exposure to light can cause a density change in the chemistry slide. The most photosensitive chemistry slide is SSCREA. 3. To reduce heating the slide from a source other than the INCUBATOR HEATER. Uncontrolled heating can induce error in the processing of a slide. BAFFLE (E) The BAFFLE is a small plastic part that is glued in place in the REFLECTOMETER HOUSING after the SHUTTER ASSEMBLY. It performs the simple task of blocking a small unwanted part of the light reflected by the COLD MIRROR. This unwanted light, if unblocked, could cause light other than that reflected from the chemistry slide to enter the collection optics. This stray light could cause the density of a slide to be incorrectly calculated. FIELD STOP ASSEMBLY (F) The FIELD STOP ASSEMBLY is mounted in the REFLECTOMETER HOUSING after the BAFFLE. It is mounted in molded grooves at the top and bottom of the HOUSING. The FIELD STOP ASSEMBLY consists of 3 parts: 15JAN98 – TG3360-1 137 THEORY GUIDE • IRIS (F1) • APERTURE STOP (F2) • TRIMMER FILTER (F3) IRIS (F1) The IRIS is a mechanical device that allows adjustment of the amount of light passing through an optical system. When the circular opening of the IRIS is adjusted, the light intensity is increased or decreased, whichever is required, thus adjusting the amount of light that illuminates the slide. The LAMPS are manufactured with a variability in the amount of light output they provide. The IRIS allows the user to properly adjust the intensity, still maintaining a correctly centered LAMP. The IRIS is adjustable by the customer and may allow LAMP changes to be made without requiring a recalibration. The IRIS in the IR/CM REFLECTOMETER is located just behind the TRIMMER FILTER as a part of the assembly known as the FIELD STOP. This location is where an internal image of the FILAMENT is formed by the set of LENSES known as the OBJECTIVE LENS ASSEMBLY. APERTURE STOP (F2) The APERTURE STOP is simply a square metal plate with a square hole in it which is used to decrease the amount of the light from the LAMP. The APERTURE STOP also desensitizes the effects of LAMP FILAMENT movement due to vibration. TRIMMER FILTER (F3) The TRIMMER FILTER is used to “fine tune” the light from the COLD MIRROR to produce the correct amounts of light energy at specific wavelengths. It also has an infrared coating that removes unwanted radiation above 700 nm. The TRIMMER FILTER is part of a matched set of optical components (COLD MIRROR, TRIMMER FILTER, and FILTER WHEEL are a set). EYEPIECE LENS (G) The EYEPIECE LENS is placed after the FIELD STOP ASSEMBLY. This LENS gathers the light received from the FIELD STOP ASSEMBLY and converges it into a small 5 mm spot. When viewed on the bottom of the slide, the spot appears oval in shape (approximately 5 x 7 mm) because the light is directed onto the slide at a 45° angle. The light that is directed onto the bottom of the is measured to determine the density of the dye produced by the chemistry slide. Slide Plane The location the slide base, or the read surface of the slide, relative to the bottom of the INCUBATOR DISK is known as the “Slide Plane”. An image of the FILAMENT at the slide plane would result in a nonuniform spot. COLLIMATOR LENS (H) The diffuse light reflected from the bottom of the slide, or more accurately from the dye produced in the reagent layer, is collected ty the COLLIMATOR LENS. This LENS is paced at a position directly beneath the slide to collect the light at a 90° angle to the bottom of the slide. The COLLIMATOR LENS collimates or reshapes the light to a different size. FILTER WHEEL (J) The FILTER WHEEL is placed so that the beam of light from the COLLIMATOR LENS is directed onto one FILTER at a time. Each FILTER is designed so that the peak of the light permitted to pas is at a predetermined wavelength. The FILTERS are generally referred to as narrow bandpass FILTERS. The dyes used in the chemistry slides require very careful control of the peak wavelength to produce acceptable chemistry precision. 138 15JAN98 – TG3360-1 IR/CM REFLECTOMETER The FILTERS used on the IR/CM FILTER WHEEL pass very narrow bands of light at 340, 400, 540, 630, and 670 nm. All of the light reflected from the slide that is not at the peak wavelength or does not fall within the bandwidth for a FILTER, is subtracted from the light by the FILTER as the light passes through. The FILTER WHEEL is driven by a STEPPER MOTOR (J2) at its center to bring each of the 5 FILTERS into place beneath the output of the COLLIMATOR LENS. A series of notches around the edge of the FILTER WHEEL allows the 89x0/5A5 REFLECTOMETER MiC BOARD to determine the position of the FILTER WHEEL through a SENSOR input. RELAY LENS (K) The RELAY LENS is in the center of the optical path beneath the FILTER WHEEL. It is aligned to collect all the light transmitted by a FILTER stack on the FILTER WHEEL. The RELAY LENS is factory set for the correct reduction of the light shaft for each REFLECTOMETER. Although the adjustment screw is accessible, it should never be adjusted in the field. This adjustment requires a complex optical fixture to properly set the reduction size. PHOTODETECTOR (L) The PHOTODETECTOR is precisely positioned on a mounting surface on the bottom of the RELAY LENS ASSEMBLY. The PHOTODETECTOR consists of a PHOTODIODE and a preamplifier as well as CABLE and CONNECTOR. The RELAY LENS collects all the light energy transmitted from the FILTER WHEEL and reduces the size of the light shaft so that it exactly matches the active area of the PHOTODETECTOR. The output of the PHOTODETECTOR is connected to the 89x0/5A5 BOARD. The light striking the active area of the PHOTODETECTOR is converted to a current which is converted to a digital voltage by an A/D CONVERTER. The digital output is sent by the 89x0/5A5 BOARD to the 90x0 MASTER COMPUTER BOARD to be used in the calculation of the concentration. Mechanical Overview The IR/CM REFLECTOMETER consists of 3 main mechanical assemblies. These include the LAMPHOUSE ASSEMBLY, MIRROR MOUNT CASTING ASSEMBLY, and the Optics Module. The LAMPHOUSE and the Optics Module are bolted to the MIRROR MOUNT CASTING. Precise positioning of the REFLECTOMETER is critical to the operation of the ANALYZER and its ability to predict accurate and precise results. Positioning accuracy is ensured through a Locating Hole on the top of the Optics Module and a mating PIN as part of the INCUBATOR. To ensure the proper distance from the Slide Plane and the COLLIMATOR LENS, the support SCREWS for the Optics Module must be fully installed. The POST must contact the bottom surface of the INCUBATOR to obtain the proper Z axis distance. A resistance measurement is used to determine the correct mounting of the REFLECTOMETER. LAMPHOUSE ASSEMBLY The LAMPHOUSE ASSEMBLY is comprised of a main CASTING with heat extraction “PIN FIN” features. Attached to the main CASTING are: • a THERMISTOR • 2 THERMOSTATS • OBJECTIVE LENS • SPHERICAL MIRROR • HEAT GUARD • FIXED LAMP BASE ASSEMBLY The LAMPHOUSE is cooled by forced air from an adjacent DUCT. The air supplied by the DUCT is directed onto the LAMPHOUSE and the heat is carried away from the metal of the LAMPHOUSE as well as from the PIN FINS. 15JAN98 – TG3360-1 139 THEORY GUIDE The THERMOSTATS mounted to the LAMPHOUSE provide a thermal safety system for the REFLECTOMETER. The 2 THERMOSTATS monitor the temperature of the LAMP CASTING. They are wired in series with the LAMP POWER SUPPLY. The THERMOSTATS are different in 2 ways: 1. One must be manually reset and the other resets automatically when the temperature falls below the trip point. 2. The MANUALLY RESETABLE THERMOSTAT trips at 110°C. The AUTOMATIC THERMOSTAT trips at 135°C. In the instance of cooling air failure, these THERMOSTATS will interrupt the power to the LAMP, eliminating the heat generated by the LAMP. Also located in the LAMPHOUSE is a THERMISTOR. This device is mounted inside the cavity near the LAMP. The THERMISTOR is used to monitor the LAMPHOUSE temperature and will shut down the REFLECTOMETER if the temperature is < 40°C or > 120°C. The FIXED LAMP BASE ASSEMBLY is attached to the LAMPHOUSE CASTING by SCREWS. The FIXED LAMP BASE provides stable and precise positioning for the LAMP. It also provides heat sink cooling for the LAMP by conducting the heat away from the ceramic base of the LAMP. This is accomplished by a series of 3 SPRINGLOADED LOCATORS. The LOCATORS provide a reference point so that the LAMP is in a fixed position and also provide force to hold the LAMP BASE against the reference surfaces. Because the reference surfaces are part of the metal base, the heat is conducted through the metal base to external PIN FINS. A LAMP EXTRACTION TOOL is provided to aid in removing the LAMP. It is important not to touch the LAMP during installation. Foreign material such a finger oil can degrade the performance of the LAMP. 140 15JAN98 – TG3360-1 IR/CM REFLECTOMETER Detach 22 COLD MIRROR MIRROR MOUNT CASTING AUTOMATIC THERMOSTAT PIN FINS MANUAL THERMOSTAT LAMP BASE LAMP OBJECTIVE LENS E015_7501ECB E015_7501EA 15JAN98 – TG3360-1 141 THEORY GUIDE SHROUD and SHROUD COVER SHROUD SHROUD COVER E015_7500DCA E015_7500DA The SHROUD and SHROUD COVER work together in performing the important function of thermal control for the LAMP HOUSING. The SHROUD interfaces to the cooling FAN DUCT located on the front of the ANALYZER. A FAN, located at the end of the DUCT and at the back of the ANALYZER, draws air across the LAMP HOUSING to remove heat. It is important to note that the air flow is front to back through the ANALYZER. The SHROUD and COVER ensure that the air is drawn through the opening in the SHROUD, across the HOUSING, down the DUCT and out the back of the ANALYZER. Without the SHROUD, the air flow is not sufficient to cool the HOUSING and the THERMOSTAT will trip or the LAMP will burn out. Therefore, the REFLECTOMETER should never be operated without the SHROUD and SHROUD COVER installed. Optics Module The Optics Module is comprised of a plastic HOUSING to which the remaining optical components are mounted. SIDE COVER AND SHUTTER MECHANISM The SHUTTER DRIVE MOTOR is a STEPPER MOTOR and is driven by the 8800/5A2 REFLECTOMETER DRIVER BOARD. The SHUTTER DRIVE MOTOR moves the SHUTTER VANE, attached to the MOTOR SHAFT, through approximately 90° of travel. The SHUTTER VANE has a SENSOR FLAG as part of its design. 142 15JAN98 – TG3360-1 IR/CM REFLECTOMETER The fully open and fully closed position of the SHUTTER VANE is determined by 2 SENSORS. The software also can detect the condition where neither or both SENSORS are blocked or unblocked at the same time. This occurrence generates an error condition. Detach 23 SHUTTER DRIVE MOTOR SLIDE COVER POSITION SENSOR SHUTTER VANE E002_2718DCC E002_2718DC IRIS DRIVE MECHANISM The REFLECTOMETER IRIS consists of 2 main components - the IRIS DRIVE MECHANISM and the IRIS ASSEMBLY. The IRIS DRIVE MECHANISM is a small subassembly mounted to the exterior of the Optics Module housing. It consists of a metal from to which a threaded SHAFT and a FOLLOWER BLOCK are attached. The IRIS DRIVE is positioned so that the FOLLOWER BLOCK mounted on the threaded SHAFT can engage the ADJUSTMENT LEVER of the IRIS. A PIN pressed into the IRIS ADJUSTING LEVER acts as a CLEVIS to allow the LEVER to maintain contact with the FOLLOWER BLOCK throughout its full travel. As the FOLLOWER BLOCK is moved, it moves the IRIS ADJUSTING LEVER. The Optics Module housing has a slot in the back wall so the ADJUSTING LEVER of the IRIS protrudes from the housing. IRIS ASSEMBLY The IRIS ASSEMBLY is a multi-leaved adjustable circular aperture. An ADJUSTMENT LEVER integral to the IRIS ASSEMBLY, mates with the FOLLOWER BLOCK in the DRIVE MECHANISM to adjust the aperture diameter. 15JAN98 – TG3360-1 143 THEORY GUIDE One SCREW attaches the IRIS ASSEMBLY to the APERTURE STOP on the side away from the light source. A PIN in the IRIS ASSEMBLY mates with the TRIMMER PLATE to correctly orient the LEVER with respect to the DRIVE MECHANISM. EYEPIECE LENS This LENS is responsible for collecting the light from the TRIMMER FILTER and converging it into a small spot on the bottom of the slide. LENS RETAINER The LENS RETAINER has 2 purposes: 1. to secure the COLLIMATOR LENS in place 2. to locate the REFLECTOMETER with respect to the INCUBATOR The LENS RETAINER has a hole precisely molded into it. When fitting the INCUBATOR to the REFLECTOMETER, a PIN that is part of the INCUBATOR is guided into the LENS RETAINER. This action locates the REFLECTOMETER collection optics with the INCUBATOR DISK. 144 15JAN98 – TG3360-1 IR/CM REFLECTOMETER Detach 24 ADJUSTMENT LEVER LENS RETAINER TRIMMER PLATE PIN IRIS COLLIMATOR LENS FILTER WHEEL SENSOR EYEPIECE LENS RELAY LENS FILTER WHEEL PHOTODETECTOR DRIVE MOTOR E015_7502ECB E015_7502EA 15JAN98 – TG3360-1 145 THEORY GUIDE FILTER WHEEL, POSITION SENSOR, FILTER WHEEL MOTOR, ELASTOMERIC DAMPER The FILTER WHEEL consists of a plastic disk with places for 8 FILTERS. Provisions on the FILTER WHEEL allow each FILTER to be centered and glued in place over a clear aperture hold. The FILTER WHEEL has precisely placed and accurately sized slots on its outer edge. There is one slot for each filter stack. An optical SENSOR mounted on the outside of the HOUSING detects the slots as the FILTER WHEEL rotates. The active elements of the SENSOR are passed through the Optics Module plastic housing so that they are aligned above and below the slots in the edge of the FILTER WHEEL. All but one of the slots are the same width, the wider slot indicates the home position of the FILTER WHEEL. The FILTER WHEEL is mounted on the FILTER WHEEL DRIVE MOTOR with a WASHER and a NUT through the center of the WHEEL. A V-shaped DETENT on the bottom of the FILTER WHEEL center engages a steel PIN pressed into the MOTOR SHAFT. The groove and PIN prevent the WHEEL from spinning on the SHAFT after the NUT is tightened. The FILTER WHEEL DRIVE MOTOR is mounted to the Optics Module housing with 4 SCREWS. The DAMPER is mounted to the lower SHAFT of the DRIVE MOTOR and cancels rotational vibration of the MOTOR SHAFT when the MOTOR is commanded to stop. RELAY LENS The RELAY LENS passes the light from the FILTER WHEEL to the PHOTODETECTOR and reduces the light shaft to accurately fit the active area of the PHOTODETECTOR. PHOTODETECTOR The RELAY LENS provides a locating feature to correctly align the PHOTODECTOR with the lenses in the RELAY LENS. The RETAINER secures the PHOTODETECTOR to prevent vibration. 146 15JAN98 – TG3360-1 CIRCUIT BOARDS Section 15: CIRCUIT BOARDS 1350 COLORIMETRIC REFLECTOMETER BOARD Location Mounted in a metal HOUSING that is attached to the front of the COLORIMETRIC REFLECTOMETER. Function Provides Analog-to-Digital (A/D) conversion of the COLORIMETRIC REFLECTOMETER 4200 PHOTODIODE BOARD. Processes outputs of the FILTER WHEEL POSITION SENSORS. Controls movement of the REFLECTOMETER FILTER based on ENCODER SENSOR signals and REFLECTOMETER Read functions. Drive for the MOTORS controlled by the 1350 BOARD is provided by the 1822 BOARD. Power 8 V dc is supplied to the 1350 BOARD. A Regulator mounted to the metal HOUSING for the BOARD generates 5 V dc from the supplied 8 V dc. The regulated 5 V dc supplies power to a 15 V dc DC-DC converter and to 5 V dc logic components of the BOARD. The 15 V dc is used for 4200 BOARD signal amplification and A/D conversion. Diagnostics Upon resetting or energizing the System, Computer System Checks verify the operation of the BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams.. A 4-DIGIT DIAGNOSTIC DISPLAY located on the BOARD provides board diagnostics used for factory service on the BOARD. 1700 STEPPER MOTOR DRIVER BOARD Location Two (2) 1700 BOARDS are located in the POWER PANEL Function The 1700 BOARD contains circuitry to drive 6 STEPPER MOTORS. There are 6 similar, separate driver circuits that are individually controlled by input signals. Each circuit has the same command bus structure consisting of 4 functional control lines and 2 current control lines. All driver circuits have the same electrical architecture but the drive capability (current supplying capacity) of each circuit is different. All circuits are bipolar chopper drives capable of full or half step modes. There are 3 current levels available from each drive circuit. These levels are set up in the DAC and Logic section of the BOARD and are used for: Standby current Run current Accelerate/Decelerate current The BOARD is able to accommodate INTERLOCK SWITCHES for each driver circuit if necessary. There are also FUSES on the power to the drive circuits. The 1700 BOARD was designed with the concept that 2 BOARDS would be necessary for each System. Because the BOARD is used 2 times, the design is generic enough to be interchangeable but specific enough to be able to drive various size MOTORS. This is achieved in part by the inclusion of DIGITAL-TO-ANALOG CONVERTERS (DACs). The DACs, in conjunction with a fixed sense RESISTOR, are used to set the referrence voltage/feedback voltage that sets the motor winding current level. 15JAN98 – TG3360-1 147 THEORY GUIDE The DAC values are loaded from the 9270 BOARD when the System is energized or reset. The DAC values are volatile, therefore are lost when power is removed from the BOARD. Power The INPUT POWER CONNECTOR P4 is a 10-position PIN CONNECTOR that contains PINS for the 26.5 V dc (used for MOTOR drive), the 9.5 V dc (used to create 5 V dc) and the returns for both of these supplies. The INTERLOCK CONNECTOR J5 is a 12-position CONNECTOR that provides the ability for 6 INTERLOCK SWITCHES to be incorporated, one for each drive circuit. This allows 26.5 V dc to be routed either to INTERLOCK SWITCHES in the System and back to the CONNECTOR or to JUMPER wiring in the CONNECTOR when no INTERLOCK SWITCH is required. The 9.5 V dc powers a switching regulator that creates 5 V dc. The 5 V dc (Vcc) is used for all logic power on the BOARD and is the voltage source for the 2.5 V dc reference voltage that is used for DAC reference voltages. The 9.5 V dc and the 5 V dc returns are common, but they are separate from the 26.5 V dc return. LEDs illuminate when the 9.5 V dc, the 5 V dc (Vcc), and the incoming 26.5 V dc are present. The incoming 26.5 V dc is split into 4 paths and routed through 4 FUSES before being sent out to the 6 INTERLOCK SWITCHES (or JUMPERS) through CONNECTOR J5. The 26.5 V dc for the first 3 drive circuits goes through individual 3.15 A FUSES while the last 3 circuits share a common 3.15 A FUSE. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 1820 STEPPER MOTOR DRIVER BOARD Location Two (2) 1820 BOARDS are located in the POWER PANEL of the 950 System. Function Each 1820 BOARD contains 6 STEPPER MOTOR DRIVERS and 2 SOLENOID DRIVERS. The BOARDS provide driver for MOTORS and SOLENOIDS of several System modules. Signals from the 92x0 BOARDS and the 13x0 BOARD control the drive circuitry inputs of the 1820 BOARDS. The inputs are optically isolated to protect the 92x0 and 13x0 BOARDS from transients and noise generated on the 1820 BOARDS. Field Effect Transistors (FET) are utilized to switch power to the outputs of the 1820 BOARDS. Power The BOARD is powered by 26.5 V dc and 9.5 V dc supplies. Onboard Regulators produce 5 V dc and 12 V dc for logic components on the BOARD. The 26.5 V dc is used to power the outputs of the MOTOR and SOLENOID drive circuitry. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 2570 TRUCK INTERCONNECT BOARD Location SAMPLE METERING TRUCK Function Provides an interface for connection of components located on the TRUCK to the SAMPLE METERING FLEX CABLE. 148 15JAN98 – TG3360-1 CIRCUIT BOARDS Power Not applicable. Diagnostics None. 2900 DIAGNOSTIC DISPLAY BOARD Location FLOPPY DIAGNOSTIC ASSEMBLY Function Permits remote viewing of the 2-digit diagnostic codes generated by the 3200 DIAGNOSTIC BOARD. Serves as an interconnect BOARD for the FLOPPY DIAGNOSTIC ASSEMBLY: • supplies power to the FLOPPY DRIVE from the 3200 BOARD • supplies drive signal to the ACTUATION METER from the 3200 BOARD • supplies drive for the SPEAKER from the 3200 BOARD Contains a SWITCH for PROGRAM LOAD/RESET purposes Contains LEDs for FIXED DISK DRIVE activity and watchdog activity (watchdog indicator not used on the 950 System) Power 12 and 5 V dc are provided to the 2900 BOARD from the 3200 BOARD Diagnostics See the Diagnostics section of the Service Manual: Bootup Process - MASTER COMPUTER 3050 TOUCH MATRIX INTERFACE BOARD Location MASTER COMPUTER ASSEMBLY Function Processes X - Y coordinate data from the TOUCH FRAME. The processed data is communicated to the MASTER COMPUTER BUS for processing. Power 5 V dc is supplied to the 3050 BOARD from the 90x0 MASTER COMPUTER BOARD. Diagnostics Upon resetting or energizing the System, MASTER COMPUTER onboard Health Checks and Computer System Checks verify the operation of the 3050 BOARD and the TOUCH FRAME. 3100 VIDEO DRIVER BOARD Location MASTER COMPUTER ASSEMBLY 15JAN98 – TG3360-1 149 THEORY GUIDE Function Generates video signals for the CONTROL UNIT MONITOR. Power 5 V dc is supplied from the 90x0 MASTER COMPUTER BOARD. Diagnostics Upon resetring or energizing the System, MASTER COMPUTER onboard Health Checks verify the operation of the 3100 BOARD. 3200 DIAGNOSTIC BOARD Location MASTER COMPUTER ASSEMBLY Function • Displays and performs MASTER COMPUTER Health Checks for the 90x0 MASTER COMPUTER BOARD and its associated BOARDS . • Contains circuitry for amplification and control of audio to the SPEAKER. • Provides drive for the ACTUATION METER. • Interfaces reset signals to and from the CARD RACK. • Interfaces power monitoring signals from the 90x0 MASTER COMPUTER BOARD to the CARD RACK. • Interfaces with the 29x0 DIAGNOSTIC DISPLAY BOARD for remote diagnostic display, FIXED DISK DRIVE activity, reset, power to the FLOPPY DRIVE, SPEAKER, and ACTUATION METER. • Programming for the BOARD is stored in FLASH memory and may be programmed by performing: Procedure DIAGNOSTIC BOARD FLASH Download Section CONTROL UNIT and MASTER COMPUTER ASSEMBLY Power 5 V dc and ±12V dc power is supplied to the 3200 BOARD from the 90x0 MASTER COMPUTER BOARD. Diagnostics TEST POINTS are provided for power. See the CIRCUIT BOARD diagrams. See the Diagnostics section of the Service Manual for additional information; Bootup Process - MASTER COMPUTER 3380 SAMPLE AND REFERENCE METERING DRIVER BOARD Location POWER PANEL Function Provides drive for the SAMPLE METERING TRUCK, PROBOSCIS, and PIVOT MOTORS and SAMPLE and REFERENCE METERING PUMPS. This BOARD contains a drive circuit for an ACTUATION COUNTER but it is not used on the 950 System. Signals from the 92x4 SAMPLE METERING MCB control the drive circuitry for the MOTORS and the 92x9 MCB control the drive circuitry for the PUMPS. 150 15JAN98 – TG3360-1 CIRCUIT BOARDS The inputs of the 3380 BOARD are optically isolated to protect the 92xx BOARDS from transients and electrical noise generated on the 3380 BOARD. Field Effect Transistors (FETs) and integrated drive circuits are used to switch power at the outputs of the BOARD. Power 26.5 and 9.5 V dc supply onboard regulators to produce 5 V dc and 12 V dc for logic components on the BOARD. The 26.5 V dc is used to power the outputs. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 4200 COLORIMETRIC PHOTODETECTOR BOARD Location Inside the COLORIMETRIC REFLECTOMETER Function Amplifies the CM REFLECTOMETER PHOTODIODE. The amplified PHOTODIODE signal is converted to a digital signal on the 13x0 COLORIMETRIC REFLECTOMETER BOARD for processing. Power The 4200 BOARD is powered by ±15 V dc supplied from the 13x0 BOARD. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 4450 TRANSDUCER BOARD Location The 4450 BOARD is an integral part of the SAMPLE and REFERENCE METERING PUMP ASSEMBLY. Function Amplifies and normalizes the transducer element in the PRESSURE TRANSDUCER ASSEMBLY. Signals from the BOARD are converted to digital signals on the 82x0 A/D CONVERTER BOARD. Power The 4450 BOARDS are powered by +12 V dc from the 82x0 BOARD. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 4700 ELECTROMETER BOARD Location In the ELECTROMETER Function The 4700 BOARD contains CONTACTS that provide electrical connection to potentiometric slides. The BOARD amplifies the slide voltage and converts the voltage to a digital value. The digital value is transmitted in a serial format to the 50x0 REC BOARD where it is processed. 15JAN98 – TG3360-1 151 THEORY GUIDE Power +5 and ±15 V dc are supplied to the 4700 BOARD from the 50x0 REC BOARD. The +5 V dc is used to power the digital circuitry of the BOARD. The ±15 V dc is converted to ±5 V dc for the analog circuits of the BOARD. Diagnostics No service usable TEST POINTS are provided on the 4700 BOARD, however, signals associated with the 4700 BOARD can be measured on the 5100 ELECTROMETER ADAPTER BOARD. See the CIRCUIT BOARD diagrams for TEST POINT information. Reference tests are performed during normal operation. If reference readings are not within expected limits, a condition code will be reported. See the ELECTROMETER section in the Theory of Operation for the PIC ASSEMBLY for additional information. No onboard Health Checks or Computer System Checks are performed on the this BOARD. 5000 REFLECTOMETER/ELECTROMETER CONTROLLER (REC) BOARD Location PIC ELECTRONICS ASSEMBLY Function The 5000 REC BOARD is an interface between the ELECTROMETER and IR/CM REFLECTOMETER subsystems and the 9102 DIGITAL I/O BOARD. The 8900/5A5 REFLECTOMETER MiC BOARD and 8800/5A2 REFLECTOMETER DRIVER BOARD accept commands from the 5000 REC BOARD and send them to the IR/ CM REFLECTOMETER. The REFLECTOMETER interface consists of: • +15 V dc • a 2-wire serial communications interface • 2 control lines • a 5 V dc monitor line The ELECTROMETER interface consists of: • ±15 V dc • 10 control lines • 2 drive signals for the ELECTROMETER CONTACTS MOTOR • a signal indicating ELECTROMETER CONTACTS up • a 5 V dc monitor line The interface to the 9102 DIGITAL I/O BOARD is through a Programmable Peripheral Interface (PPI). This interface transfers data from the REFLECTOMETER and ELECTROMETER through the DIGITAL I/O BOARD to the 7290 MECHANISM COMPUTER BOARD. The REC BOARD also contains the interface circuitry for the IMMUNO•RATE PRESSURE TRANSDUCER. The REC BOARD receives the output signal from the PRESSURE TRANSDUCER, scales and gains the signal, does an A/D conversion, and sends the digital pressure reading to the 9271 IMMUNO•RATE MODULE CONTROL BOARD. The central controller on the REC BOARD is a Motorola 68HC110E0 microprocessor. The 6811 microprocessor addresses a DUART (Dual Universal Asynchronous Receiver Transmitter), RAM, and FLASH memory. The FLASH memory contains application code and boot•up code. The RAM provides temporary data storage. The DUASRT provides 2 serial channels for communication - one is for REFLECTOMETER communications through the REFLECTOMETER MiC BOARD, the other is a spare communication channel. The DUART also provides additional input and output ports addressable from the 6811 microprocessor. A Programmable Logic Device (PLD) is also on the BOARD for decoding the address lines of the 6811 microprocessor in order to implement the desired memory map. 152 15JAN98 – TG3360-1 CIRCUIT BOARDS Another function of the REC BOARD is thermal monitoring of the RATE LAMP HOUSING. The THERMISTOR, mounted on the inside wall of the RATE LAMP HOUSING, is read by the REC BOARD and an error is reported to the MASTER COMPUTER if the temperature is too high or too low. The REC BOARD also contains circuitry that monitors whether the IR/CM INCUBATOR COVER is open. However the INTERLOCK SWITCH for the circuitry has been removed from the PIC System. Other functions performed by the REC BOARD include: • voltage monitoring on the +26.5 V dc, +15 V dc, and -15 V dc POWER SUPPLIES • monitoring the output from the READ SYNC SENSOR (which indicates slide position and synchronizes REFLECTOMETER reads) • monitoring the 50/60 Hz AC line frequency The REC BORD also is equipped with 2 spare serial communication test ports - one from the 6811 microprocessor and the other from the DUART. These ports could be used as debug ports or control ports where information from the REC BORD could be sent to a PC or the PC could write commands to the REC BOARD. Power The REC BOARD accepts power inputs of +26.5 V dc and +9.5 V dc from the MAIN POWER SUPPLY. The MAIN POWER SUPPLY tolerances are: POWER SUPPLY +26.5 V dc +9.5 V dc Minimum 25.0 V dc 9.0 V dc Maximum 30.0 V dc 11.3 V dc The REC BOARD converts the +26.5 V dc into ±15 V dc which powers the analog circuitry. The +26.5 V dc is also converted into +18 V dc for use as the supply voltage for the ELECTROMETER CONTACTS DC MOTOR. The +9.5 V dc is converted into +5 V dc which is used as the Vcc supply on the REC BOARD. Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the BOARD.. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 5100 ELECTROMETER ADAPTER BOARD Location Adjacent to the ELECTROMETER Function Interfaces the CABLES from the ELECTROMETER to the HARNESS of the PIC ASSEMBLY. Power No power is required for this BOARD. Diagnostics TEST POINTS for power, drive, and signals for the ELECTROMETER are located on this BOARD. See the CIRCUIT BOARD diagrmas for TEST POINT information. 550x SLIDE SUPPLY BARCODE BOARDS Location Mounted above the CARTRIDGE ROTOR in SLIDE SUPPLIES 1 and 2 15JAN98 – TG3360-1 153 THEORY GUIDE Function The 550x BOARD contains 4 reflective SENSORS that are directed toward, and focused on, the plane of the top of the slide cartridges in the SLIDE SUPPLIES. As the SLIDE ROTOR rotates, the bar•code labels on the top of the cartridge pass under the SENSORS. The output of the SENSORS varies according to the amount of light reflected from bar•codes forming a stream of analog signals. Circuitry on the 550x BOARD converts the analog output of the SENSORS to a stream of digital signals. These streams of digital signals are synchronized with the CARTRIDGE ROTOR POSITION SENSOR and decoded by the 92x8 MCB to determine generation number, SO number, and lot number represented by the bar•code on the cartridge. Power The 550x BOARDS are powered by +5 V dc supplied by the 92x8 MCB. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS are defined in the CIRCUIT BOARD diagrams. 6060 DISTRIBUTION BOARD Location Top of the CARD RACK Function Serves as an interconnect between the 7070 CARD RACK MOTHERBOARD and the System HARNESS. A THERMOSTAT located on the BOARD monitors overtemperature conditions in the CARD RACK. Power None. Diagnostics No onboard Health Checks are performed. Computer System Checks verify communications through the 6060 BOARD. Access to the CONNECTOR PINS that connect the 6060 BOARD to the 70x0 MOTHERBOARD is provided by an access cover on the top of the CARD RACK. Use the 60x0 CIRCUIT BOARD diagrams to determine the signals available on these PINS. 6201 SERIAL COMMUNICATION (AT-4) BOARD Location In the MASTER COMPUTER ASSEMBLY connected to the BUSS of the MASTER COMPUTER Function Provides a 4-channel RS232 interface between the 90x0 MASTER COMPUTER BOARD and the 77x0 SERIAL ISOLATION BOARD for communication to the printers, lab computer, and CARD RACK. Power The 6201 BOARD is powered by +5 V dc and ±12 V dc supplied from the 90x0 MASTER COMPUTER BOARD. 6300 WETNESS DETECTOR BOARD Location Mounted to the BRACKET for the SAMPLE METERING RAMP 154 15JAN98 – TG3360-1 CIRCUIT BOARDS Function The 6300 WETNESS DETECTOR BOARD amplifies the signal generated by the LEAD SULFITE CELL used to monitor fluid absorption in a slide. The 6300 BOARD also serves as an interconnect to pass power to the WETNESS DETECTOR LAMP. The 82x0 A/D CONVERTER BOARD converts the analog signal to digital for processing. See “WETNESS DETECTOR” in the SAMPLE METERING Theory of Operation for additional information. Power The 6300 BOARD is powered by ±15 V dc supplied from the 82x0 BOARD. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINT tables are provided in the CIRCUIT BOARD diagrams. 6500 POWER CONTROL BOARD Location Behind the CIRCUIT BREAKER PANEL Function The 6500 BOARD monitors and processes critical System conditions, such as ac Input Voltage, Overtemp Thermostat statuses, +5 V dc low, Card Rack Interlock Switch, low air flow, Mechanism Computer “Shutdown” request, and MCB “Go to Standby” request. The BOARD reacts to these conditions based on severity, causing immediate shutdown of the System for CARD RACK INTERLOCK SWITCH OPEN and CARD RACK temperature or sequential power shutdown for all other shutdown conditions. Outputs of the BOARD consist of status signals to the 91x4 BOARD, solid state relay control lines for operate mode power supplies, and Trip Coil Drive for energizing the TRIP COIL in the MAIN POWER SWITCH. The 6500 BOARD also contains circuitry that generates a logic level square wave signal based on Zero Crossing of the ac input power. This signal is used to synchronize Reflectometer Readings with the Zero Crossing of the ac input power to eliminate electrical noise when Reflectometer Readings are taken. Power The 6500 BOARD is powered by +9.5 V dc and +17 V dc. Onboard Regulators generate +12 V dc and +5 V dc and a DC to DC CONVERTER produces ±15 V dc from the +5 V dc. Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the BOARD. Diagnostic LED indicators, TEST POINTS, and a DISABLE SWITCH are provided. For additional information, see the following procedure in the Service Manual: Procedure Section MAIN POWER SWITCH - Diagnostics Automatic Shutdown (Trip Coil) See the CIRCUIT BOARD diagrams for more information: Diagram Section 6500 Power Control Board Power Control and Distribution 6500 Circuit Board Circuit Boards 15JAN98 – TG3360-1 155 THEORY GUIDE 6600 UTILITY BOARD Location CARD RACK, SLOT 1 Function The 6600 UTILITY BOARD serves several unrelated function: 1. Provides SLIDE SUPPLY LOAD DOOR SWITCH debounce and delay 2. Provides CM REFLECTOMETER start and reset buffering 3. Contains a momentary switch for convenient access to Program Load/Reset when working in the CARD RACK area 4. Contains circuitry for serial communication channel selection. MASTER to MECHANISM COMPUTER serial communications pass through this circuitry. 5. Provides 2 clock signals • a 43.478 KHz clock used on 700 and 500 series ELECTROMETERS • a 307.2 KHz clock used on 700 and 500 series Systems for 9201 Service MCB USART Timing Power The 6600 BOARD is powered by +5 V dc and ±12 V dc supplied by the 70x0 MOTHERBOARD Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 7060 MOTHERBOARD Location The back vertical surface of the CARD RACK Function Provides interconnection of all CIRCUIT BOARDS in the CARD RACK. Also distributes power from dc HARNESSES to CARD RACK CIRCUIT BOARDS and interfaces with analog signal HARNESSES. Power +5 V dc and ±12 V dc is supplied to the MOTHERBOARD from the System POWER SUPPLIES Diagnostics Upon resetting or energizing the System, Computer System Checks verifies the operation of many traces on the MOTHERBOARD. No onboard Health Checks are performed on this BOARD. 7170 INTERRUPT CONTROLLER BOARD Location CARD RACK, SLOT 13 Function Multiplexes several interrupt signals to a single interrupt line on the 72x0 MECHANISM COMPUTER BOARD. On the 950 System, the multiplexed interrupt signals are; 76x0 Serial I/O Board Interrupt, 93x0 Analog I/O Board Interrupt, and 80x7 Math Coprocessor Interrupt from the 72x0 BOARD. The 7170 BOARD also provides the clock for the multibus. 156 15JAN98 – TG3360-1 CIRCUIT BOARDS Power The 7170 BOARD is powered by +5 V dc supplied by the 70x0 MOTHERBOARD. Diagnostics Upon resetting or energizing the System, Computer System Checks verifies the operation of the BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 7290 MECHANISM COMPUTER BOARD Location CARD RACK, SLOT 20 Function The 7290 MECHANISM COMPUTER BOARD is the main computer for the CARD RACK. The key function of the MECHANISM COMPUTER is to process work provided to it by the 90x0 MASTER COMPUTER BOARD. This work is in the form of a Test List and involves: 1. Prioritizing and dividing the tests based on type and metering order. 2. Scheculing all the events required to process a specific test through the various mechanisms of the System. 3. Sending the commands which correspond to the seceduled events to the level 2 tasks at the appropriate time. 4. Level 2 tasks request the MCBs to process the commands at the time they are sent and verify that they have completed within some time tolerance. (A level 2 task is a MECHANISM COMPUTER software task which communicates with the MCB through hardware ports). Power The 72x0 BOARD operates on +5 V dc supplied from the 70x0 MOTHERBOARD. Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the BOARD. See the Diagnostics section of the Service Manual: MECHANISM COMPUTER Health Check LED Sequence 7750 SERIAL ISOLATOR BOARD Location Back of the System behind the CARD RACK Function The 7750 SERIAL ISOLATOR BOARD provides isolated RS-232 serial communication paths from the MASTER COMPUTER ASSEMBLY to ancillary equipment such as a primary and auxiliary printer as well as a lab computer. The 7750 BOARD also provides RS-232 serial communication paths from the CONTROL UNIT/MASTER COMPUTER ASSEMBLY to the 72x0 MECHANISM COMPUTER BOARD through the 76x0 SERIAL I/O BOARD and the 66x0 UTILITY BOARD. The 7750 BOARD is an 8-channel BOARD; 4 channels are optional and dependant upon either a 2nd 4-port serial I/ O BOARD or an 8-port serial I/O BOARD being added to the MASTER COMPUTER ASSEMBLY. Of the 4 standard channels, 3 provide an isolated RS-232 path from the MASTER COMPUTER ASSEMBLY to ancillary equipment: • Primary printer • Auxiliary printer • Lab computer 15JAN98 – TG3360-1 157 THEORY GUIDE An internal RS-232 path is also provided from the 76x0 SERIAL I/O BOARD in the CARD RACK to internal PSID hardware. All isolated channels are configured as Data Communication Equipment (DCE) with the exception of the lab computer channel which is configured as Data Terminal Equipment (DTE). The standard isolated channels allow a “Data Carrier Detect” (DCD) input from a remote device to be substituted for a “Data Set Ready” (DSR) input or a “Busy” output signal to the remote device to be substituted for a “Data Terminal Ready” (DTR) output by relocating plug-in JUMPERS. Power Offboard DC Supplies +5 V dc “A” available from the MASTER COMPUTER ASSEMBLY through the 62x1 SERIAL I/O BOARD ±12 V dc “A” available from the MASTER COMPUTER ASSEMBLY through the 62x1 SERIAL I/O BOARD +5 V dc “B” Standby voltage, PS9 ±12 V dc “B” Standby voltage, PS9 Diagnostics No onboard Health Checks are performed on this BOARD. Upon resetting or energizing the System, Computer System Checks verifies the operation of the BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 7680 INTELLIGENT SERIAL I/O BOARD Location CARD RACK Function The 7680 INTELLIGENT SERIAL I/O BOARD is a 7-channel serial communication BOARD that provides a serial communication interface for the 7290 MECHANISM COMPUTER BOARD. It functions similarily to the AT-4 BOARD. Due to parts obsolescence for the 7670 BOARD, the 7680 BOARD was designed to replace all earlier versions of the 76x0 BOARD. The 7680 BOARD uses an 80C186 CPU rather than the 8086 CPU that the 7670 BOARD used. The 80C186 is upward compatible with the software of the 8086, but offers some hardware and software enhancements. In the 500, 700C and 950 Systems, only 2 of the 7 serial channels are used due to the migration of the MASTER COMPUTER from the CARD RACK to the PC or ICU-based MASTER COMPUTER. The table below shows the utilization of serial channels for the PC (ICU)-based Systems versus CARD RACK-based MASTER COMPUTERS. CARD RACK MASTER COMPUTER Based 700 System 1. CRT and Keyboard 2. Touch Screen 3. Lab Computer 4. Printer A 5. Printer B 6. Modem 7. PSID 158 ICU-Based - 500, 700C, 950 Systems 1. Master Computer 2. Not used 3. Not used 4. Not used 5. Not used 6. Not used 7. PSID 15JAN98 – TG3360-1 CIRCUIT BOARDS The software that operates the 7680 BOARD and allows it to communicate with the devices is downloaded from the system FIXED DISK to the 7670 RAM. The downloaded software allows the 7680 BOARD to setup and configure the serial channels. The downloaded code sets up Inter-Processor Message (IPM) buffers that allow the 72x0 MECHANISM COMPUTER BOARD to communicate with the 7 devices and perform other 7680 BOARD communication management operations. The 7680 BOARD has a total of 16 Kb of PROM. The PROMs contain the program code that is executed at powerup to perform the Health Checks and also allow the proper program application code to be downloaded to RAM. Diagnostics LEDs An indicator LED is provided to allow visual verification of the “health” of the 7680 BOARD. After the download code is executed, the flashing LED serves as a watchdog timer. Action Reset of Power Up On•Board Health Checks Pass Application Code Downloaded and Processor Running Health Check LED Status OFF ON Flashing TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 2-DIGIT DISPLAY The 7680 BOARD has hardware to use Port 220H to drive a 2-digit, pseudo Hex display. This circuitry was used during the BOARD debug to provide information regarding the status of individual subsystem tests. After power•up, as the PROM code performs the onboard Health Check tests, the Hex display indicates the progress through the tests. If a test fails, the Hex code displayed remains, and the microprocessor halts. If all the Health Checks pass, “AA” is displayed. Health Check Software The onboard Health Check program for the 7680 BOARD has been enhanced. A small program was written to test for at least minimal functionality of the CPU. The PROMs are accessed as both a Byte and as a WORD for the checksum test. More complete tests of RAM were written to access data as both a Byte and a Word. The USART and interrupt tests reflect more closely how they are used in the Download code. They have also been enhanced to provide a better test of their functionality. Upon resetting or energizing the System, onboard Health Checks and Computer System Checks are performed. 8050 RATE REFLECTOMETER BOARD Location Left of the RATE/CM REFLECTOMETER, above the CARD RACK Function • Controls movement of the RATE/CM FILTER WHEEL based on SENSOR signals and commands from the MECHANISM COMPUTER. The FILTER WHEEL control signals feed the 18x2 STEPPER MOTOR DRIVER BOARD to drive the FILTER WHEEL MOTOR. • Provides control and drive for the SHUTTER based on SENSOR signals and commands from the MECHANISM COMPUTER. • Provides A/D conversion of the analog signal from the 81x0 PHOTODIODE BOARD in the REFLECTOMETER. Power The 8050 BOARD is powered with an input voltage of +9.5 V dc. A Regulator mounted to the HOUSING for the BOARD generates +5 V dc to power a +15 V dc DC/DC CONVERTER and logic components of the BOARD. The +15 V dc is used for 810x PHOTODETECTOR BOARD power and A/D conversion. 15JAN98 – TG3360-1 159 THEORY GUIDE Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the board. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 810x PHOTODETECTOR BOARD Location RATE/CM and IR/CM REFLECTOMETERS Function Contains the PHOTODETECTOR and applification for REFLECTOMETER measurements Power ±15 V dc Diagnostics None. 8260 DROP DETECTION BOARD Location Right side of the SAMPLE METERING PYLON Function • Provides A/D conversion of the 44xx SAMPLE and REFERENCE PRESSURE TRANSDUCER BOARDS. • Provides A/D conversion of the analog signal from the 63x0 WETNESS DETECTOR BOARD. • Provides regulated power to the WETNESS DETECTOR LAMP. • Controlled by the 92x9 MCB. Power The BOARD operates on a +26.5 V dc supply. +5 V dc and ±15 V dc are produced by onboard Regulators to power the circuitry on the BOARD. Diagnostics No onboard Health Checks or Computer System Checks are performed on this board. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 8470 REFERENCE METERING BOARD Location Attached to the REFERENCE METERING ASSEMBLY Function • Provides control and drive for the REFERENCE METERING mechanism based on POSITION SENSOR status and 92x9 MCB commands. • Buffers the PUMP POSITION SENSOR signal that is sent to the 92x9 MCB. See the REFERENCE FLUID METERING Theory of Operation for more information. 160 15JAN98 – TG3360-1 CIRCUIT BOARDS Power The 8470 BOARD is powered by +26.5 V dc for STEPPER MOTOR drive and +15 V dc that is converted to +5 V dc for logic power. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 8570 PYLON INTERCONNECT BOARD Location Left side of SAMPLE METERING PYLON Function • Provides an interface between MOTORS and SENSORS located on the SAMPLE METERING ASSEMBLY and the HARNESS of the System. • Provides power for the EMITTERS of SENSORS on the SAMPLE METERING ASSEMBLY. Power The BOARD is powered by +15 V dc. An onboard Regulator produces +5 V dc to power logic components on the BOARD and SENSORS connected to the BOARD. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINT and LED indicators are defined in the CIRCUIT BOARD diagrams. 8800 REFLECTOMETER DRIVER BOARD Location Inside the PIC ELECTRONICS ASSEMBLY Function The 8800 BOARD is identical to the REFLECTOMETER DRIVER BOARD used in the 250 System. The BOARD has 2 chopper drive circuits to drive the IR/CM REFLECTOMETER FILTER WHEEL and the SHUTTER MOTOR. The 8800 BOARD receives control signals from the 89x0 REFLECTOMETER MiC BOARD. The 8800 BOARD also contains circuitry to power an IRIS MOTOR, however a motorized IRIS is not used on the IR/CM REFLECTOMETER. Power The BOARD is powered by +5 V dc and +24 V dc. Logic components of the BOARD are powered by +5 V dc. The MOTOR drivers are powered by +24 V dc. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 8900 REFLECTOMETER MiC BOARD Location Inside the PIC ELECTRONICS ASSEMBLY 15JAN98 – TG3360-1 161 THEORY GUIDE Function The 8900 BOARD is identical to the REFLECTOMETER MiC BOARD used in the 250 System. The 8900 BOARD: • Provides control for the IR/CM REFLECTOMETER FILTER and SHUTTER MOTORS based on POSITION SENSOR status and commands from the 50x0 REC BOARD. • Provides A/D conversion of the analog signal from the 810x PHOTODETECTOR BOARD in the REFLECTOMETER. Power +5 and +15 V dc is supplied to the 8900 BOARD from the 50x0 BOARD. An onboard DC/DC CONVERTER converts the +5 V dc to ±15 V dc. +5 V dc is used to power logic components of the BOARD. ±15 V dc powers the A/D CONVERTER. +15 V dc supplied to the BOARD powers a gated Regulator. +12 V dc is used for programming the FLASH Memory. Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the BOARD. A diagnostic CONNECTOR for test signals to be measured using the REFLECTOMETER DIAGNOSTIC TOOL TL-4602 is provided. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 9000 MASTER COMPUTER BOARD Location Inside the MASTER COMPUTER ASSEMBLY Function The 9000 MASTER COMPUTER BOARD is a Personal Computer Motherboard with RMX III operating system. (RMX III is a real-time operating system.) The MASTER COMPUTER runs control software that is responsible for high level processing and control of the System. Several other BOARDS are installed on the 9000 MASTER COMPUTER BOARD; • 6201 AT-4 BOARD used for serial communication to the CARD RACK, printers and lab computer • 3050 TOUCH MATRIX INTERFACE BOARD used to decode touch coordinate information from the TOUCH FRAME mounted to the MONITOR • 3100 VIDEO DRIVER BOARD used to produce images on the MONITOR • 3200 DIAGNOSTIC BOARD used to test the operation of the MASTER COMPUTER BOARD Power A ±12 and +5 V dc POWER SUPPLY mounted within the MASTER COMPUTER ASSEMBLY supplies power to the BOARD. Diagnostics See the Diagnostics section of the Service Manual; Bootup Process - MASTER COMPUTER CONTROL UNIT / MASTER COMPUTER Diagnostics 162 15JAN98 – TG3360-1 CIRCUIT BOARDS 910x DIGITAL I/O BOARD Location CARD RACK, SLOTS 15 - 18 Function Provides a digital interface between the 72x0 MECHANISM COMPUTER BOARD and the 92xx MODULE CONTROL BOARD, 80x0 RATE REFLECTOMETER BOARD, 94x0 HUMIDITY AND VOLTAGE INPUT BOARD, 13x0 COLORIMETRIC REFLECTOMETER BOARD, and 65x0 POWER CONTROL BOARD. Power The 910x BOARD is powered by +5 V dc supplied from the 70x0 MOTHERBOARD. Diagnostics Upon resetting or energizing the System, Computer System Checks verifies the operation of the BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 92xx MODULE CONTROL BOARD Location CARD RACK, SLOTS 2 - 11 Function Provides digital control for System subsystem mechanisms based on SENSOR status and commands issued by the MECHANISM COMPUTER. The non-volatile code used by the MCBs is resident on socketed PROMs on the 925x series MCB and on EEPROMs (Electrically Eraseable) on the 927x series BOARDS. Changes to the non-volatile code on the 925x series BOARDS require a PROM replacement. The non-volatile code on the 927x BOARDS is updated when the System is booted. The volatile code on both the 925x and 927x MCBs is stored in RAM and is downloaded from the FIXED DISK by the MASTER COMPUTER each time the System is energized or reset. See the CIRCUIT BOARD diagrams for application specific information for each CARD RACK SLOT. Power The 92xx MCBs are powered by +5 V dc supplied from the 70x0 MOTHERBOARD. Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the BOARDS. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 9350 ANALOG I/O BOARD Location CARD RACK, SLOT 14 Function Provides analog control and monitoring of environmental systems of the System. The 9350 BOARD receives amplified THERMISTOR and HUMIDISTAT signals from the 94x0 HUMIDITY AND VOLTAGE INPUT BOARD and the 95x0 THERMISTOR AMPLIFIER BOARD. Digital outputs of the 9350 BOARD interface with thermal drive circuits on the 97xx THERMAL DRIVER BOARDS to power HEATERS and THERMOELETRICS. Commands from the MECHANISM COMPUTER control the 9350 BOARD and data from the 9350 BOARD is communicated to the MECHANISM COMPUTER. 15JAN98 – TG3360-1 163 THEORY GUIDE Power The 9350 BOARD is powered by +5 V dc. An onboard DC/DC CONVERTER generates ±15 V dc which is reduced to ±12 V dc by onboard Regulators. +5 V dc powers the logic components of the BOARD. ±15 V dc powers the D/A CONVERTER on the BOARD. ±12 V dc powers the A/D CONVERTER on the BOARD. Diagnostics Upon resetting or energizing the System, onboard Health Checks and Computer System Checks verify the operation of the BOARDS. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 9400 HUMIDITY AND VOLTAGE INPUT BOARD Location CARD RACK, SLOT 13 Function Contains the 3 circuits that apply an ac voltage through a SERIES RESISTOR, CAPACITOR, and HUMIDISTAT (located in the SLIDE SUPPLIES) to produce an ac voltage proportional to the Relative Humidity experienced by the HUMIDISTATS. The proportional ac voltage is amplified and converted to a dc signal by an RMS/DC CONVERTER and set to the 93x0 ANALOG I/O BOARD for A/D conversion and processing. Note It is necessary to apply an ac voltage to prevent migration of salts (plating) on the elements of the HUMIDISTATS. Accuracy of the HUMIDISTATS is compromised if dc voltage (for example, from a Continuity Test) is applied to the HUMIDISTAT. Contains 11 circuits to attenuate and buffer voltages from various power supplies in the System. The attenuated voltages are sent to the 93x0 BOARD for A/D conversion and processing. Power The 9400 BOARD is powered by +5 V dc supplied by the 70x0 MOTHERBOARD. An onboard DC/DC CONVERTER converts the +5 V dc to ±15 V dc. ±15 V dc is converted to +9 V ac. ±15 V dc powers the amplifiers and RMS/DC CONVERTERS on the BOARD. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 9510 THERMISTOR AMPLIFIER BOARD Location CARD RACK, SLOT 12 Function Amplifies and buffers THERMISTORS located throughout the System to voltages proportional to temperature. The outputs of the BOARD are sent to the 93x0 ANALOG I/O BOARD for A/D conversion and processing. Each channel of the 9510 BOARD has a switch that electrically substitutes a fixed precision RESISTOR for calibration purposes. 164 15JAN98 – TG3360-1 CIRCUIT BOARDS Power The 9510 BOARD is powered by +5 V dc supplied from the 70x0 MOTHERBOARD. Two (2) onboard Regulators produce ±10 V dc and ±15 V dc. The ±15 V dc powers the amplifiers on the BOARD. The +10 V dc is used to power the voltage devices at the input of the BOARD. Diagnostics TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 960x AC MOTOR DRIVER BOARD Location POWER PANEL Function The 960x BOARD provides drive for ac MOTORS throughout the System. Each BOARD contains 5 unidirectional drive circuits and 2 bidirectional drive circuits. The inputs of the BOARDS are controlled by signals from the MCBs. Power The 960x BOARDS are powered by +9.5 V dc and 115 V ac. An onboard Regulator produces +5 V dc to power the dc circuits on the BOARD. 115V ac powers the drive output circuitry of the BOARD. Diagnostics TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 9760 THERMAL DRIVER BOARD Location Two (2) 9760 BOARDS are located in the POWER PANEL Function The 9760 BOARD 1. Receives analog input commands The 9760 BOARDS receive analog control signals from the 9350 ANALOG I/O BOARD to drive either resistive heaters or thermoelectric heater/coolers. 2. Receives digital input commands The 9760 BOARDS receive digital control signals from the 9350 BOARD to switch thermoelectric heater/ coolers and operate the auxiliary heaters. 3. Supply thermal drive capabilities for INCUBATORS, SLIDE SUPPLIES, Read Stations, Wash Stations, and PRECONDITION STATIONS. Power The 9760 BOARD is powered by 17 V dc and 24 V dc. An onboard regulator converts 17 V dc to 5 V dc to power logic components of the BOARD. Drive components of the BOARD are powered by 24 and 17 V dc. Diagnostics No onboard Health Checks or Computer System Checks are performed on this BOARD. TEST POINTS and LED indicators are defined in the CIRCUIT BOARD diagrams. 15JAN98 – TG3360-1 165 THEORY GUIDE Section 16: FORMS PRINTER Series 5 Overview POWER SUPPLY ASSEMBLY LOGIC BOARD DRIVER BOARD E015_8233HCA E015_8233HA The FORMS PRINTER Series 5 contains: • CONTROL PANEL • DRIVER BOARD • LOGIC BOARD • POWER SUPPLY ASSEMBLY • PRINTHEAD • TRACTOR MECHANISM • CARRIAGE DRIVE MECHANISM • RIBBON DRIVE 166 15JAN98 – TG3360-1 FORMS PRINTER Series 5 CONTROL PANEL F1 Select Paper Path Form Select Pitch Quality Front Clear Error Form Align form Feed Setup/ Test F2 Config. Status On Line The CONTROL PANEL contains a KEYPAD with 15 pressure actuated keys and an LCD ASSEMBLY that has 2 lines of 16 characters each. A 28-pin flat CABLE connects the CONTROL PANEL to the DRIVER BOARD. The keys send signals through the DRIVER BOARD to the LOGIC BOARD. The LCD ASSEMBLY operates from +5 V dc and ground. The LOGIC BOARD provides 3 control signals and 8 address/data signals to the LCD ASSEMBLY for controlling the displayed characters. E015_8202GA Function of the CONTROL PANEL Keys When the PRINTER is energized, the regular configuration and operation menus and regular setup and testing menus are available. Pressing a key on the CONTROL PANEL provides access to the appropriate menu. Key F1 Select F2 Paper Path Pitch Setup/Test Form Select Quality Status Form Config Font Form Align On Line Clear Error Form Feed 15JAN98 – TG3360-1 Function Associated with messages and symbols shown at the left end of the display Selects items shown on the display Associated with messages and symbols shown at the right end of the display Allows selection of the primary paper path or an alternate path Allows selection of character spacing Provides access to adjustment menus, allows reports of current settings, testing basic functions, and changing features Allows selection of one of 10 preset formats Allows selection from 3 print quality choices Provides a brief summary of printer status and current settings on the display Allows changing format values Allows selection of a standard or optional font Provides access to the form alignment menu to move the paper up or down in the print station Selects on-line or off-line operation Clears error messages from the display Advances paper to the top of the next form 167 THEORY GUIDE At the Adjust, Setup, and Test screen, pressing “Clear Error”, “Status”, and “On Line” will transfer the default parameters from ROM into the non-volatile RAM on the LOGIC BOARD. All forms parameters in the non-volatile RAM will be set at the default condition. Any forms parameters set by the customer are returned to the default values. Another sequence, “Clear Error”, “Status”, and “Form Feed”, is available for access to the factory ADJUST menu. All of the form parameters in the non-volatile RAM will be set to the default condition. Any forms parameters set by the customer are returned to the default values. Pressing the “F1” or “F2” keys on the CONTROL PANEL repeatedly, moves you through the SELECT menus to view the selections available. With the ADJUST selection displayed, pressing the “Select” key accesses the ADJUST menu. Pressing the “F2” key repeatedly, moves you through the ADJUST menu to view the adjustments available. When the adjustment wanted is displayed, pressing the “Select” key accesses the software for that adjustment. DRIVER BOARD P2 J13 P8 P7 DRIVER BOARD E015_8213BCE E015_8213BA The DRIVER BOARD contains all of the MOTOR and PRINTHEAD drivers which receive input signals from the LOGIC BOARD through CONNECTOR P2. The logic drivers provide power to drive the various DRIVE MOTORS that operate the CARRIAGE, RIBBON, TRACTORS, PAPER FEED ROLLERS, Z-AXIS MOTOR, and the PRINTHEAD PINS. Reference voltages for the logic drivers are provided by the reference voltage generation circuit. CONNECTORS connect the CABLES for the DRIVE MOTORS, PRINTHEAD, CONTROL PANEL, FAN, and POWER SUPPLY to the DRIVER BOARD. The SERIAL INTERFACE CABLE is connected to CONNECTOR P8. The PARALLEL INTERFACE CABLE is connected to CONNECTOR P7. CONNECTOR J13 is the GROUND CONNECTOR for connecting the chassis ground and signal ground with a JUMPER. 168 15JAN98 – TG3360-1 FORMS PRINTER Series 5 LOGIC BOARD BATTERY LOGIC BOARD E015_8210BCB E015_8210BA J2 J1 The LOGIC BOARD contains the microprocessor, ROMs, RAMs, communication logic, PRINTHEAD logic, input/ output logic, and JUMPERS. The microprocessor controls the operation of the entire PRINTER. A lithium BATTERY keeps voltage applied to the non-volatile RAM which retains data when the external ac power is disconnected or the PRINTER is deenergized. The non-volatile RAM contains all the operating parameters of the PRINTER, such as the forms parameters, adjustment data parameters, communication parameters, and SENSOR data. The communications logic provides a serial and parallel interface between the microprocessor and a host computer through CONNECTOR J1. The MOTOR and SENSOR signals are interfaced to the microprocessor through CONNECTOR J2. The PRINTHEAD signals are formed in the PRINTHEAD logic and PRINTHEAD pulse width logic and sent to the DRIVER BOARD through CONNECTOR J2. 15JAN98 – TG3360-1 169 THEORY GUIDE LOGIC BOARD JUMPER Configurations JUMPER E1-E2 E3-E4 E5-E6 E6-E7 E5-E6 E6-E7 E8-E9 E9-E10 E8-E9 E9-E10 E11-E12 E12-E13 E11-E12 E12-E13 E14-E15 E15-E16 E14-E15 E15-E16 E17-E18 E18-E19 E20-E21 E21-E22 E20-E21 E21-E22 E23-E24 E24-E25 E23-E24 E24-E25 170 Connected Yes Yes Yes No No Yes Yes No No Yes Yes No No Yes Yes No No Yes No Yes Yes No No Yes Yes No No Yes Function Enables the 16 MHz crystal oscillator Normal operation JDEC pinout devices at U56 and U68 EIAJ pinout devices at U56 and U68 Demand/Strobe type parallel interface protocol (Printronix Special) Strobe/ACK/BUSY type parallel interface protocol (Centronics Standard) Demand/Strobe type parallel interface protocol (Printronix Special) Strobe/ACK/BUSY type parallel interface protocol (Centronics Standard) 256 Kb devices at U48 and U65 512 Kb devices at U48 and U65 256 Kb device at U66 256 Kb devices at U55 and U67 512 Kb devices at U55 and U67 JDEC pinout devices at U56 and U68 EIAJ pinout devices at U56 and U68 15JAN98 – TG3360-1 FORMS PRINTER Series 5 POWER SUPPLY ASSEMBLY POWER SUPPLY LOGIC BOARD POWER ENTRY ASSEMBLY LED TRANSFORMER AC POWER SWITCH VOLTAGE SELECTOR E015_8235HCA E015_8235HA 5A FUSE LINE FUSE AC POWER RECEPTACLE The POWER SUPPLY ASSEMBLY consists of the POWER ENTRY ASSEMBLY and the POWER SUPPLY BOARD. The POWER ENTRY ASSEMBLY contains the ac POWER RECEPTACLE, the input line FUSE, the VOLTAGE SELECTOR, and the ac POWER SWITCH. The POWER SUPPLY BOARD is a switching type power supply. It is divided into a high voltage section and a low voltage section. The high voltage section contains the EMI FILTER, the surge voltage protectors and THERMISTORS, RECTIFIERS, the switching circuit, and control logic. A TRANSFORMER couples the high voltage section to the low voltage section. The low voltage section contains control logic, the +5 V dc, +12 V dc, -12 V dc, and +40 V dc circuits. The 5 V dc circuit includes a 5 A FUSE and a green LED which indicates that all voltages are present. 15JAN98 – TG3360-1 171 THEORY GUIDE PRINTHEAD Subsystem PRINT HEAD CONNECTOR RETAINER MOUNTING SCREWS CONNECTOR (3) The PRINTHEAD subsystem consists of: • PRINTHEAD • PAPER SENSOR • RIBBON SHIELD • CARRIAGE ASSEMBLY The PRINTHEAD is fastened to the CARRIAGE ASSEMBLY by 2 LOCATOR PINS, the PRINTHEAD CONNECTOR RETAINER, and 2 SCREWS. One of the LOCATOR PINS fits tight to precisely locate the PRINTHEAD on the CARRIAGE ASSEMBLY. PRINT HEAD RIGHT LOCATOR PIN LEFT LOCATOR PIN The PRINTHEAD contains 18 needles driven by 18 SOLENOIDS located on the PRINTHEAD. The LOGIC BOARD provides the signals that drive the SOLENOIDS. The signals are the same timing signals that drive the CARRIAGE DRIVE MOTOR. The SOLENOID signals go from the LOGIC BOARD to the PRINTHEAD DRIVERS on the DRIVER BOARD. The outputs from the PRINTHEAD DRIVERS go through the TOP and BOTTOM PRINTHEAD CABLES and through the PRINTHEAD CONNECTORS to the SOLENOIDS. A thermal SENSOR located on the PRINTHEAD provides an output through the BOTTOM PRINTHEAD CABLE and through the DRIVER BOARD to the LOGIC BOARD. When the LOGIC BOARD senses that the PRINTHEAD is hot, approximately 100°C (212°F), the PRINTHEAD prints unidirectionally until it cools to approximately 80°C (176°F). When the PRINTHEAD has cooled, it resumes printing bidirectionally. E015_8217CCA E015_8217CA The PAPER SENSOR ASSEMBLY contains 2 SENSORS. One SENSOR looks for the left edge hole in the PLATEN. The other SENSOR looks for the edge of the paper. The SENSOR ASSEMBLY provides top of form, left edge, and left margin signals over the BOTTOM PRINTHEAD CABLE through the DRIVER BOARD to the LOGIC BOARD. Circuits on the LOGIC BOARD process the signals to determine the top of form, left edge, and left margin of the paper. The RIBBON SHIELD on the CARRIAGE ASSEMBLY is a shield between the ribbon and the paper. A small hole in the SHIELD exposes the ribbon to the paper under the PRINTHEAD NEEDLES. The RIBBON SHIELD helps prevent: • paper damage from the vertical and horizontal movements of the ribbon • paper jams between the ribbon and the PLATEN 172 15JAN98 – TG3360-1 FORMS PRINTER Series 5 TRACTOR MECHANISM/ROLLER DRIVE Subsystem ROLLER MOTOR TRACTOR MECHANISM E015_8236DCB E015_8236DA The same MOTOR drives both the TRACTOR MECHANISM and the ROLLERS. The LOGIC BOARD provides signals to the DRIVERS on the DRIVER BOARD to drive the MOTOR. 15JAN98 – TG3360-1 173 THEORY GUIDE CARRIAGE DRIVE and Z-AXIS DRIVE Subsystem The CARRIAGE DRIVE MECHANISM consists of: • CARRIAGE DRIVE MOTOR ASSEMBLY • CARRIAGE DRIVE BELT • CARRIAGE DRIVE BELT TENSION ASSEMBLY The CARRIAGE ASSEMBLY moves on the CARRIAGE SHAFT and CARRIAGE GUIDE SHAFT. CARRIAGE DRIVE MOTOR CARRIAGE DRIVE BELT SCREW (4) E015_8212CCA E015_8212CA 174 15JAN98 – TG3360-1 FORMS PRINTER Series 5 Detach 25 CARRIAGE SHAFT CARRIAGE GUIDE SHAFT BEARING WASHER Z-AXIS CAM ARM CARRIAGE ASSEMBLY E015_8211HCA E015_8211HA The CARRIAGE DRIVE BELT, driven by the CARRIAGE DRIVE MOTOR ASSEMBLY, pulls the CARRIAGE ASSEMBLY on the CARRIAGE SHAFT. The BELT TENSION ASSEMBLY can be adjusted to keep the DRIVE BELT at the correct tension. A SCREW on the CARRIAGE ASSEMBLY provides a connection point for the WIRE ROPE that drives the RIBBON ASSEMBLY. The Z-AXIS DRIVE MECHANISM consists of: • CARRIAGE SHAFT • CARRIAGE GUIDE ASSEMBLY • CAM ARM ASSEMBLIES • Z-AXIS DRIVE MOTOR ASSEMBLY The right and left CAM ARM ASSEMBLIES hold the CARRIAGE SHAFT and CARRIAGE GUIDE SHAFT together. An ECCENTRIC INDICATOR on each end of the CARRIAGE GUIDE SHAFT rotate within the BUSHINGS and CAM ARM ASSEMBLIES to move the CAM ARM ASSEMBLIES in a z-axis direction. Because the CARRIAGE SHAFT is attached to the CAM ARM ASSEMBLIES, the SHAFT and CARRIAGE ASSEMBLY move in a z-axis direction as the CARRIAGE GUIDE SHAFT is rotated. The z-axis movement moves the CARRIAGE ASSEMBLY toward or away from the PLATEN to compensate for various thicknesses of paper and multipart forms. 15JAN98 – TG3360-1 175 THEORY GUIDE RIBBON DRIVE MECHANISM RIBBON DRIVE MECHANISM RIBBON CARTRIDGE TRAY WIRE ROPE E015_8230ECB E015_8230EA The RIBBON DRIVE MECHANISM consists of a RIBBON CARTRIDGE TRAY that the ribbon cartridge is mounted in and driven from. The RIBBON CARTRIDGE TRAY contains a RIBBON DRIVER that is driven by a WIRE ROPE under the TRAY and attached to the CARRIAGE ASSEMBLY. When the CARRIAGE ASSEMBLY moves from right to left, the RIBBON DRIVER rotates and moves the ribbon in the ribbon cartridge from right to left. When the CARRIAGE ASSEMBLY moves in the right to left direction, the ribbon does not more. 176 15JAN98 – TG3360-1 Vitros is a trademark. 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