TG - 950/950AT Theory Guide

Transcription

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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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
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67
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71
72
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73
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74
75
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80
80
81
82
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88
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89
90
90
90
91
92
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92
92
92
92
92
93
93
96
97
98
15JAN98 – TG3360-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POTENTIOMETRIC INCUBATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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110
111
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wash Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wash Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Algorithm Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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
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
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
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
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
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
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
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
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
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.
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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.
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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
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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.
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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.
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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.
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THEORY GUIDE
Detach 21
INPUT BLADE
ASSEMBLY
A44B2
INPUT BLADE
MOTOR
ELEVATOR
HOUSING
A44U2
INPUT BLADE
SENSOR
94
E015_6600ECB
E015_6600EA
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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
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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
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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,
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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.
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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
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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.
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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.
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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
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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.
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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..
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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
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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
• 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
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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.
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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
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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
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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
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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.
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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.
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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
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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.
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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.
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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
• 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 (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
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
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.
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
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.
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.
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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.
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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.
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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.
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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.
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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.
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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
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.
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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
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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
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;
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.
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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
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
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
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.
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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.
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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..
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
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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
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
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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
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
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
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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
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.
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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.
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
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
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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.
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
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.
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THEORY GUIDE
Diagnostics
of the board.
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.
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
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
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
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
of the BOARD.
A diagnostic CONNECTOR for test signals to be measured using the REFLECTOMETER DIAGNOSTIC TOOL
TL-4602 is provided.
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;
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.
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
of the BOARDS.
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
of the BOARDS.
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
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
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
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
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
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
256 Kb device at U66
JDEC pinout devices at U56 and U68
EIAJ pinout devices at U56 and U68
15JAN98 – TG3360-1
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
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
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.
Tg336001.fm+
Printed In USA
Ortho-Clinical Diagnostics, Inc.
■
100 Indigo Creek Drive
■
Rochester, N.Y. 14626

TG - 950/950AT Theory Guide

Transcription

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