Alegria Service Manual 7 2011-11

Alegria Analyser
Service Manual
Legal & warranty..............................................................................4
Safety Information...........................................................................5
References to other documentation ....................................................................................... 6
Intended Use..........................................................................................................................7
References to other documents ............................................................................................. 8
Tools required ........................................................................................................................ 9
General description ........................................................................10
Block Diagrams (overview) ............................................................11
General Theory of operation...........................................................12
ID Module ............................................................................................................................12
Dispensing Module...............................................................................................................12
Wash and Soak Module ....................................................................................................... 13
Analyse module ................................................................................................................... 14
Turning plate module ........................................................................................................... 14
Climate module .................................................................................................................... 14
User interface module ..........................................................................................................15
Printer module...................................................................................................................... 16
Mechanics............................................................................................................................ 16
Teleca Instrument Platform ..................................................................................................17
Hardware .............................................................................................................................18
Service Software on PC .......................................................................................................18
Maintenance...................................................................................19
Preventive Maintenance....................................................................................................... 19
Basic Function test instruction and record............................................................................ 20
Annual preventive maintenance instruction and record ........................................................21
Service, Trouble shooting...............................................................22
Initial information:................................................................................................................. 22
Symptoms ......................................................................................23
Service & Adjustment/replacement procedures.................................................................... 25
Error codes and actions ....................................................................................................... 26
Service centers...............................................................................37
Instruction: how to remove the front air filter ...............................38
Instruction: how to exchange dispense needles............................. 46
Instruction: how to exchange wash needles ..................................50
Instruction: how to exchange filter in bottles ................................54
Instruction: how to replace rear ventilation filter .......................... 57
Instruction: how to replace the fuses.............................................60
Instruction: how to adjust the tension of the dispense unit belt .... 63
Instruction: how to adjust the tension of the turning table belt.....66
Instruction: how to replace the printer .......................................... 69
Instruction: how to cut and assemble fluid lines and assemble couplings
.......................................................................................................72
2(101)
Instruction: how to remove the covers ..........................................76
Instruction: how to replace the OD module.................................... 91
3(101)
LEGAL & WARRANTY
The content of this manual are the property of ORGENTEC Diagnostika GmbH. Any
reproduction in whole or in part is strictly prohibited.
At the time of printing, this manual correctly described the device and its functions.
However, as modifications may have been carried out since the production of this
manual, the system package contains this manual and a service manual and may
contain one or more amendments to the manuals. This manual including the service
manual and any amendments must be thoroughly read, before using the device.
ORGENTEC Diagnostika GmbH is only responsible for the reliability and performance of
the device if the following are strictly observed:
Authorized personnel (see back of manual for authorized service centres) carry out all
service, repairs and modifications.
The device must be used in accordance with the intended use and the instructions put
forth in the Safety Information section (instruction for use and this manual).
ORGENTEC Diagnostika GmbH offers one-year warranty, from the day of purchase, on
defective material and assembly.
The warranty does not cover damage resulting from incorrect use or user
maintenance or from authorized software modification.
ORGENTEC Diagnostika GmbH is only responsible for replacement of defective parts,
not wear of parts.
ORGENTEC Diagnostika GmbH is not responsible for any personal injury or any
damage resulting from incorrect use or incorrect performed service of the analyser.
If the above points are not strictly observed, the warranty will be considered invalid.
4(101)
SAFETY INFORMATION
This product is CE marked in conformity with the requirements of the IVD Directive
98/79/EC. Adhere to the following recommendations for safe and proper operation of the
device:
Follow the packaging/ un-packaging procedure to avoid personal injuries, equipment

damage or property damage.
Never use the device near mobile telephones, CB radios or other forms of radio
communication, and/or electromagnetic fields. These may affect the performance of
the device. The analyser conforms to IEC/EN 61326 and shall not be exposed to
higher levels of disturbance.
Do not attempt to open the device or any cover unless it is described within this
manual.
The device has connections to mains supply e.g. 110-240V~ and special caution shall
be taken when working with the instrument (lethal current is possible from most
electronics).
Do not attempt to open the device or any cover unless it is described within this
manual.
Do not refill the fluid container(s) while the container(s) are in the device or when in
use.
Do not run the device without having the fluid bottles connected (waste, distilled
water, wash buffers 1 and 2).
Do not immerse the device in water or any other liquid (See the
Maintenance/Cleaning section for specific details).
Unplug the power connector from its power source before cleaning or servicing.
Failure to do so could result in equipment damage or personal injury.
Ensure that the power cord does not become pinched between mechanisms during
normal operation. Failure to do so can result in equipment damage.
Do not connect the power connector or any anything other than the appropriate input
on the device.
The analyser shall not be exposed to direct sunlight nor be placed in a draught
environment.
If the analyser shall be transported and the transport conditions is to be less than 0
degrees Celsius (32 Degree Fahrenheit) Then the analysers liquid system must be
emptied to avoid equipment damage.
Use only ORGENTEC Diagnostika GmbH spare parts, accessories and consumables.
All service shall be performed by ORGENTEC Diagnostika authorized personnel.
All service shall be performed by in an ESD safe environment (minimum requirement
is to use wrist strap and ESD conductive surface where the instrument is handled).
Handling of samples shall follow laboratory infection risk procedures.
Handling of device parts that has the possible risk of sample contamination shall
Always be performed with protective gloves.
5(101)
References to other documentation
The below topics are described in Instructions for use (Use the Instructions for use
together with this service manual).
Basic Information
Packaging/un-packaging Procedure
Packaging, Consumables and spare part list
Symbols
Installation
Power on/off procedure
General operation
Overview descriptions
Setup diagram
Software description
Shutdown
Replacement procedures
How to load and exchange sample plates/ samples
How to empty waste fluid and load buffers
How to load printer paper
How to remove Transport locking
Calibration
Software upgrade
Maintenance
Cleaning
Waste disposal
Technical specifications
Measures and weights
Classification
Operation conditions
Storage and transport conditions
6(101)
Intended Use
The Alegria analyser is intended for use by trained personnel to process and read IVD
test strips supplied by the ORGENTEC. The results obtained shall be used only in
conjunction with other medical evidence to diagnose conditions of the human body. The
Alegria analyser by it-self is not diagnostic. The instrument is to be used in medical
laboratories.
All service of the Alegria analyser is to be carried out by authorized service personnel.
This manual and the other manuals such as Intended Use shall be consulted for an
overview.
The intention of this service manual is to give an overview of the main parts and
systems in the instrument. References to other locations, such as manuals drawings or
part lists are to follow, if the referred document is not amended to the manual you may
need to contact you representative.
The manual will describe certain or common parts or procedures of interest and not all
details, i.e. the most common foreseeable issues that can be of interest.
7(101)
References to other documents
The below documents are of engineering type and require specific knowledge to
comprehend, if there are questions do not hesitate to contact your representative for
assistance.
Title Content
Instructions for Use Description of normal operation and technical data
Quick Guide A quick reference on how to get started using the
instrument
Service software manual Description of Service software
8(101)
Tools required
The table below gives an indication on the required tools for servicing the instrument.
# Type Size /type Qty

1 Allen key(s) 2-8 1 set
2 Screwdriver PH2 2
3 Screwdriver POZ 2
4 Screwdriver STD 1
5 Spanner 6-16 + 5,5 mm + 7 mm 1 set
6 Torque wrench (adjustable torque) X-XX 1
7 USB memory stick USB 1.1 compliant 1
8 Service Software
9 Service PC Laptop/notebook, 12-15” TFT 1
P4, 800Mhz, 256 Mb Ram
CD, USB 1.1/2.0 compliant
Serial port, Modem, LAN
Win 2000 / XP Pro.
Mouse/pointing device
10 Service PC cable Null modem cable 1

11 USB – Serial Adapter 1
11 Tension meter ContiTech VSM-1 1
12 Tube cutter 1
13 USB Keyboard 1
14 USB Hub 1
9(101)
GENERAL DESCRIPTION
The Alegria analyser is built up by a large number of different modules. Most of the
modules
contains hardware, software and mechanics.
The general functionality of the instrument is best described as an instrument that can
be loaded with test strips containing different fluids that the instrument will:
Collect, Mix and Analyse according to a test protocol (the user defines the protocol). The
results are presented on display and printed. To accomplish these things there are a
need for different modules (see general description). These modules are interconnected
and controlled by the instruments software.
The Instrument is divided into different modules such as:
ID module
Dispensing module
Wash and soak module
Analysis module
Turning plate module
Climate control module
User Interface module
Printer module
Teleca Instrument Platform
Service PC module
Motorized Sample bay
These modules are supported or contains the following:
Mechanics: custom made details (machined parts, fasteners, structural components)

Electronics: Printed Circuit Boards, discreet and active components, Display,
connectors etc.
Optics: LED’s, optical receivers, electronics
Climate system: fans, regulation electronics
Fluid system: pumps, tubing solenoids, valves, connections, and fluid containers.
Wiring: Connections and wiring harness
Enclosures: Plastic covers, sheet metal structure and chassis
OEM components: Power supply, TFT-display, Printer
Software: Operating system and application, embedded software.
10(101)
BLOCK DIAGRAMS (OVERVIEW)
All block diagrams are electronically appended:
Electronic connections diagram

Connection diagram for IO Board
Connection diagram for Motherboard
Fluid system diagram

Fluid system overview diagram
Wiring diagram
Internal cables diagram
Note:
Click the link and the document will be shown.
11(101)
GENERAL THEORY OF OPERATION
The Alegria analyser different modules are described in the following sections (list of
modules).
ID Module
The ID module consists of two barcode readers, one internal and one external. The
external is optional for the end user to use.
The module is responsible for linking patient data with a sample strip by reading the bar
code attached on the strip (CODE 128) with an external bar code reader. The module
also handles the identification and positioning of the test strips in the instrument with an
internal bar code reader (fixed).
The internal barcode reader is mounted to the chassis in a fixed position. The external
barcode reader is mounted to a holder on the right side of the instrument. It is
connected to a COM port on the back of the instrument and can be removed for
customers that do not wish to use it.
Dispensing Module
The Dispensing module should dispense sample and the liquids that are already pre-
filled in the strip (conjugate, substrate, cut-off, sample buffer) into other wells in the
strip. It moves in radial direction compared to the turning plate and in vertical direction.
The Dispensing module consists of a precision pump and two separate needles, one for
use of dispensing conjugate and one for use of dispensing the other liquids
(programmed by process developer with the Alegria Developer SW).
The separate needle for conjugate is to ensure that there is no risk for cross
contamination of conjugate with the other liquids.
The precision pump is set to dispense volumes in a range of 10-200 µl and smallest step
is 1µl, (The volumes to dispense are programmed by process developer with the Alegria
Developer SW).
Each needle can move independently of the other down into a well and up above the
strip so the carriage can reposition itself over the next well. Radially the distance
between the two needles is fixed so when one needle has to be moved in this direction
the other one will follow.
The whole needle feed tubing is filled with hydraulic fluid (distilled water) to achieve as
high accuracy as possible. All tubing’s and needles for the dispense system can be
washed with either distilled water or wash buffer.
12(101)
Wash and Soak Module
This Wash and Soak module actually consists of three separate stations, two identical
“wash & soak” stations and one dry suction station.
The “wash & soak” stations main task is to put wash buffer solution inside the two
reaction wells on the strips. The stations do not perform the actual cleaning of the wells.
This is done chemically by the wash buffer solution.
The station only removes whatever liquid present in the wells and thereafter fills it with
wash buffer. The reason that there are two identical stations is that the cleaning
procedure should be performed twice. The turning plate positions a strip under the first
station that sucks the reaction wells dry and fills them with wash buffer.
Then the turning plate moves on until the strip ends up underneath the other station.
The wells are sucked dry and filled once more.
The “drier” station main task is to remove wash buffer solution inside the two reaction
wells on the strips. The turning plate positions a strip under the station that sucks the
reaction wells dry.
All tubing’s and needles for the wash and soak system can be washed with either
distilled water or wash buffer.
Wash and Soak station

The wash and soak stations consists of two pair of needles, one pair for each reaction
well in the test strip. A pair of needles consists of one aspiration needle and one
dispense needle. The functionality of the wash and soak stations is that first it shall
aspirate the contents of the reaction well and then dispense wash buffer into the
reaction wells.
In order to ensure a complete aspiration of the liquids in the wells the aspiration needle
is longer than the dispensing needle and is also damped by a spring. This solution
facilitates the aspiration needles to always ensure contact with the bottom of the strip to
achieve the best performance when aspirating.
Dry suction station

The dry suction station consists of two aspiration needles, one for each reaction well.
The dry suction stations purpose is the aspirate the reaction wells completely dry before
the next liquid is dispensed into the reaction well.
These aspiration needles are damped with a spring to always ensure contact with the
bottom of the strip to achieve the best performance when aspirating.
Placement of stations
The three stations are placed inside the instrument so that there are two “empty”
rotation steps between each station, this means that if each step takes 30 seconds it will
take a strip 1 minute to pass from the “end” of one station to the “start” of the next
station.
This is since when the strip is filled with wash buffer it shall react for at least 30 seconds
in the well.
13(101)
Analyse module
This Analyse module measures the optical density of the test samples. It has two
channels, positioned over two adjacent wells. The measurements are made at 650 nm
and the range is 0 to 2,0 OD (Optical Density). LED´s are used as light source and
before each measurement a reference voltage is measured and the same voltage is then
used when measuring. This leads to a very accurate and self-calibrating system.
Turning plate module

This Turning plate module shall position each sample strip to its right position between
the different stations. A stepper motor drives the turning plate. A sensor records where
the home position is for the turning plate.
The turning plate is a rotating table inside the climate module, on the turning plate three
individual sample plates can be loaded. Each sample plate can hold up to 10 test strips.
The three sample plates are individually keyed to the turning plate so the user cannot
put them in the wrong position.
Climate module
The functionality of the Climate module is to keep a steady and controlled environment
around the test strips heating or cooling dependent on what’s needed. It is designed as
a closed compartment with the inner volume as small as possible to facilitate an efficient
temperature control. The compartment is designed as round “thick” plate with enhanced
insulation on all sides. In the middle of the “roof” of the climate chamber a peltier
element with a heat sink and a small fan is placed to evenly spread the heat/cooling in
the climate chamber.
Below the heat sink there is a “collector” in case there will be humidity drops, this will
then be collected an lead out through a hole in the engine shaft of the turning plate
module.
The temperature in the controlled environment around the test strips shall be 26 2 °C
during the analysis run. The ambient conditions are specified to a temperature of 20-
32°C and a relative humidity of 25 – 75% this in combination that the dew point shall
not exceed 23°C.
14(101)
User interface module
The user interfaces are defined to parts that the user can interact with, such as:
Touch screen
A 10-inch colour touch screen is used for the instrument.
Lid for printer paper

The printer is located below the touch screen but inside the lid for the fluid bottles, the
lid for paper is mounted on the internal printer. Therefore the lid for the fluid bottles
must be opened in order to open the printer lid to change printer paper. The lid for
paper is mounted on the internal printer
Lid for fluid bottles

In the front of the instrument the lid for the fluid bottled are located. When opening the
lid the bottles are located inside the lid but separate from the rest of the instrument, i.e.
any spillage of fluids when handling the bottles will not reach into the rest of the
instrument.
Door for loading sample plates

The door for loading sample plates is opened and closed mechanically by a DC motor.
The opening and closing is done by pushing a “Open” or “Close” button on the touch
screen. The lid is of the same material as the rest of the climate chamber. The motor is
current controlled so in case that something gets stuck in the opening when
opening/closing the lid the motor will stop to avoid damage on person or material.
Level sensors
The fluid bottles used in the instrument are:
Two 1L bottles for wash buffer.
One 2,5 L bottle for distilled water.
One 5 L bottles for waste.
The wash buffer and distilled water bottles are each equipped with a level sensors that
will warn if there is not enough liquid in the bottle to perform a analyse with 30 test
strips. If these sensors are disconnected from the instrument the instrument will warn
for low level in the bottles.
The waste bottle is equipped with a level sensor that will warn if there is not enough
space in the bottle to perform a analyse with 30 test strips. If this sensor is disconnected
from the instrument the instrument will warn for high level in the bottle.
External connections
Connections for modem, service PC, external USB printer and external barcode reader
are located at the back of the instrument.
ON/OFF switch
The mains power ON/OFF switch is located at the back of the instrument in the lower
right corner when standing in front of the instrument.
15(101)
Printer module
The instrument is equipped with an internal thermo-printer with a paper width off 112
mm. After the analyse sequence is finished the results are automatically printed
The printer is placed in the right front corner of the instrument. To replace the printer
paper, open the lid and the printer compartment door. The printer paper is fed out
through the printer compartment door and the fluid bottle lid/door.
An external printer can be connected to the USB port of the instrument and the result
will then be printed on this.
Mechanics
The mechanics has been divided into two categories, external and internal:
External Mechanics
The covers consists of four items made from PU, integral skin foam, front lid, top
cover and two identical side covers
The front lid is mounted to a sheet metal structure, fastened to the bottom plate by
hinge bolts and held closed by a magnetic lock.
The side covers are mounted to a sheet metal structure, which is fastened to the
bottom plate.
The top cover is mounted to a sheet metal plate fastened to the bottom of the base
plate, the back plate and indexed to the side covers.
The robot is adjusted relative to the top cover to reduce the tolerance chain.
The display is screwed up against the top cover, lifting it free from the underlying
structure. The screws are covered by screw caps.
Internal Mechanics
Waste pump:
This pump disposes of unwanted fluids. The pump can be used simultaneously by
several components and hence runs until the last component turns it off.
Robot structure:
The main inner mechanics part is the robot structure where most off the modules are
built up. ID-Module (Internal Identification), Dispensing module, Wash and Soak
module, Analysis Module (Light source and Analysis), Turning Plate Module, Climate
Module. When built up the modules can be test run on the robot level before the robot
is actually built into the instrument. This is to facilitate easy mounting and module
verification.
Cabling and cable clips:
Routing of cables and tubes for the purpose to make sure that the cabling does not
disturb any of the movements.
Mounting mechanics for PCBs:
The PCB´s are mounted on sheet metal parts that also act as parts of the supporting
structure. The touch display is mounted on a “tower” that connects with the back
panel and stabilizes it.
16(101)
Teleca Instrument Platform
Teleca Instrument Platform (TIP) is designed to be a flexible foundation for a wide range
of products. The TIP is based on distributed processing, with a main processor
communicating with slave processors via a serial link, “Local Bus”. The Alegria version of
TIP consists of three different parts:
The motherboard
The I/O-board
The analysis board
The motherboard is equipped with:

A 200-pin connector for fitting a Teleca CPU module, with a S3C2410X processor, RAM
and FLASH memory.
Three serial ports, built-in to the processor.
A four channel UART for serial communication.
An Ethernet controller.
Two USB ports, host and device.
One SD-card memory socket.
A socket for a SOCKET-MODEM, analogue, ISDN or GSM/GPRS.
An audio amplifier, for driving a loudspeaker.
Low-level stereo sound input and output.
Two LocalBus master connectors.
Backup battery for the real time clock.
A connector for a JTAG emulator.
The I/O-board is equipped with:

A LocalBus slave connector.
Five TMS320 signal processors, with support hardware.
Five connectors for JTAG emulators, one for each processor.
Each TMS320 processor controls:

Two 2-phase or 3-phase stepper motors.
Four PWM low side driver outputs.
One ON/OFF low side driver.
Four position sensors, optical or mechanical.
One quadrature sensor.
The analysis board is equipped with:

A LocalBus slave connector.
An MSP430 mixed mode processor.
A connector for a JTAG emulator.
A thermometer.
Supporting hardware for measuring optical density.
17(101)
Hardware
The hardware architecture spans over the modules and each electronics board handles
functionality for several modules.
High power drivers for motors, pumps and valves are located on the stepper board
together with corresponding sensor inputs for home sensors, quadrature encoders etc.
The main board handles communication, display interface and high-level logic.
The analysis module has its own hardware that also measures the chamber temperature
for the climate module.
Service Software on PC
From an external PC the user can connect to the instrument to download and test run
the different modules on the instrument. There are three different types of PC SW for
three different users.
End user
The end user can download a copy of the patient archive
Service technician
Same as end user and test run the different modules
Process developer
Same as service technician and create and download new analyse files to the
instrument.
18(101)
MAINTENANCE
On a weekly basis, test the device for proper function (basic function test) and inspect
cables for cuts and other damage. If in doubt, replace the relevant parts. Additional
Preventive maintenance is required according to the Service manual (see preventive
maintenance).
See Basic Function test instruction and record
Preventive Maintenance
The ORGENTEC Diagnostika instrument needs to be maintained properly. Preventive
maintenance and testing needs to be performed annually to ensure proper function of
the instrument and to ensure a long operational life.
Follow the annual preventive maintenance instruction and document the maintenance in
the record field. Check each item according to the instruction and make necessary
adjustments. If in doubt replace the relevant parts.
Also check to see that none of the instrument components have been removed or
modified. If so replace with original parts.
See Annual preventive maintenance test instruction and record
19(101)
Basic Function test instruction and record
Model: Serial number:

Date:
Function Procedure Result

General Clean the instrument if needed (use a damp cloth with
mild soap detergent). Wipe the instrument dry with a
dry cloth.
Controls Check touch screen.
TFT Display Check for visual abnormalities.
Fluid system Check for leakage.
Check bottom of device for fluid, if found verify from
where and if there is a leaks
Check fluid containers: levels and if the bottles are
clean, if not clean (empty and dismantle and clean
and refill)
Accessories Check all accessories for proper fit and function.
Monthly Perform the monthly cleaning of all instrument tubing
cleaning with the Alegria flush routine solution. (Monthly
Mandatory)
Performance Perform a run with Positive Control (ORG 310) and
test / QC test Negative Control (ORG 311) test devices.
Date:
Maintenance performed by:
OK Inspected/checked/tested ok RA Repaired
NOK Inspected/checked/tested Not ok RL Replaced
C Cleaned NA Not applicable
A Adjusted
20(101)
Institution: Date:
Model: Serial number:
Annual preventive maintenance instruction and

record
Function Procedure Result
Cables Inspect the power cable and the other cables (cord and plug) for cuts,
wear or breaks and replace if needed.
Date and time Check for date and time.
Change the battery on the mother board every 3 years.
TFT display Check touch screen and calibrate if needed. Check for visual
abnormalities. If damages larger than 1 x 1 cm, please replace.
Fluid system Check tubing and connections for leakage, obstruction and cracks, if
leakage or cracks then replace. Check bottom of device for fluid, if
found verify from where and if there is a leak.
Check all tubes and valves for contamination. Clean and wash.
Replace both pump heads of waste pump once a year.
Bottom filter Check the filter in the fluid containers, if found saturated replace
(minimum once a year).
Waste tube Replace the whole waste tube. Beginning from the pump head to the
waste container. But keep the Y-connection.
Air filters Clean instrument with vacuum cleaner for dust. Check the rear
ventilation filter for dust and obstruction. Replace the filter once a
year.
Accessories Check all accessories for proper fit and function.
Barcode scanner Clean barcode scanner and window.
Motors Check motor mounting screws for tightness, oil spindles.
Check dispense and Check drive belts for correct tension and wear. If signs of
turning plate drive deformation/wear then replace.
belt Frequency dispense belt 50 – 80 Hz (Target 65 Hz)
Frequency motor belt 138 – 179 Hz (Target 158.5 Hz)
Rotation plate Calibrate the rotation plate of the Alegria.
Analyse module and Check for contamination, clean, and check OD with ORG 3OD.
climate chamber Results: Strip 1 Strip 2 Strip 3 Strip 4
Check washing Verify that washing of reaction wells and washing of needles
function function properly. Also check dispensing and suction motors,
dispensing and turning plate motor. Check the liquid level in cavities
after washing. Inspect the needles for wear, if broken or has low
performance then replace.
Replace dispense Check the dispensing (volume 100 µl) of both dispensing needles.
needle Inspect for wear, if broken or has low performance then replace
(standard needle once a year; conjugate needle every 3 years).
Temperature Double check the internal temperature inside the climate chamber
against a calibrated external thermometer.
Performance test / Perform a run with Positive Control (ORG 310) and optional
QC test Negative Control (ORG 311) test devices.
Date:
Maintenance performed by:
OK Inspected/checked/tested ok RA Repaired
NOK Inspected/checked/tested Not ok RL Replaced
C Cleaned NA Not applicable
A Adjusted
ORGENTEC Diagnostika GmbH Postfach 100352 D-55134 Mainz / Germany
FD4.25F Maintenance Checklist; Version 3 valid from 2012-01-02
Page 1/1
SERVICE, TROUBLE SHOOTING
Initial information:
Begin gathering information about the problem. Start by asking the operator about
the issue to make it easier to find the problem, and to verify the problem.
Note: After any corrective action the preventive maintenance instruction should be
performed.
WARNING
Only facility-authorized personnel should trouble shoot the ORGENTEC Diagnostika
Alegria Analyser. Troubleshooting by unauthorized personnel could result in personal
injury, equipment damage or property damage.
WARNING
Follow the removal procedure if replacing any part, otherwise serious injury, equipment
damage or property damage could occur.
Start by checking the obvious things first:

Is the mains cable connected in both ends (wall outlet-Analyser) is the mains power
on?
Are the connections set as describes in the setup?
Is there any physical damage to cables?
Are there any parts obstructing the movement of the carousel?
Are there any physical damage to mechanical parts?
Is there fluid in the required containers
Is there any error messages on the display
Is there any user related problem
Is there any Error code reported, if so look up the error code and appropriate
measure
Check the error log for possible information about the problem
If you have a Instrument or spare part you can interchange a part to verify the problem.
If the problem persists then see the symptom section and its corrective actions.
22(101)
SYMPTOMS
Below is a list of fault symptoms, find the one(s) that is most similar to the problem
experienced with the instrument and follow the instruction(s).
Note these symptoms are the most anticipated.
Symptom Instruction
Printer quality is degraded or printout How to replace the printer
fails
Fluid line leaks How to cut and assemble fluid lines
Fluid is not distributed. Check the fluid bottle filters and if saturated
–Replace, See How to replace fluid bottle(s)
filters
Air bubbles in system. Ensure that fluid bottle filters are in the right
position in bottles (close to bottom of bottle
and not on surface of fluid).
Check for air leakage. How to cut and
assemble fluid lines
The dispense unit will not move: Check that the transport locking is removed,
see instructions for use
Dispense needles are not moving Check that the needle can move freely as
descried in How to change dispense needles,
if the spring is worn out replace the needle
and spring
Dispense needles are jammed If or for some reason the needle has been
bent, remove it and replace, see How to
change dispense needles
Wash(and soak) needles are jammed If or for some reason the needle has been
bent, remove it and replace, see How to
change wash needles
The dispense unit will not move:
Correctly How to adjust the tension of dispense unit
belt
Check that home sensor works properly, in z
direction for needles and in x-direction for
carriage.
Not at all How to adjust the tension of dispense unit
belt
If belt drive is broken –replace and follow the
how to adjust the tension instruction
Check in error log if encoder works properly.
The turning table will not rotate:
Correctly How to adjust the tension of turning table belt
Check that home sensor works properly.
Not at all How to adjust the tension of turning table belt
If belt drive is broken –replace and follow the
how to adjust the tension instruction
Check in error log if encoder works properly.
Incorrect volumes when dispensing. Check that the needle can move freely in z-
direction as descried in How to change
dispense needles.
23(101)
Symptom Instruction
(continue) Incorrect volumes when Check if there are air bubbles in hoses or in
dispensing. precision pump.
Ensure that connections are correctly
tightened to prevent air leakage See,
How to cut and assemble fluid lines
Flush system to remove bubbles, use an
alcohol dilution if air bubbles in precision
pump remains.
Check if needles are clogged.
Flooding inside climate chamber. Check waste pump functionality, motor
functional, clogging in hoses.
Check wash and soak stations aspiration
needles that they aspirate in correct speed.
Check wash and soak stations feed needles
that position the yet inside the reaction strips.
If not check needles are bent? Check
calibration of carousel.
Could it be condense water from heat sink?
Check that drainage from heat sink is not
clogged. Also check that heat sink collector is
not bent or damaged.
Internal barcode reader fails to read Check that the sample barcode is of type
barcodes. CODE 128.
Check that barcode is not damaged or
destroyed.
Check if it’s possible to read the specified
barcode in another position in instrument.
Yes: Is the sample holder within correct
tolerances.
No: Barcode reader not assembled in correct
position.
External barcode reader fails to read Check what standards the barcode reader are
barcodes. programmed to read.
Unstable yet on wash and soak Check for air leakage. How to cut and
stations when feeding fluid into assemble fluid lines
reaction wells or wash cups.
Droplets on needles. Check for air leakage. How to cut and
Check that back valves are working correctly
After any repair work on the Instrument the “Preventive maintenance instruction” must
be completed this to ensure the safe operation of the instrument.
If none of the fault symptoms corresponds to the problem experienced with the
Instrument then perform the “Preventive maintenance instruction” to locate the fault. If
problem still persists please contact your local ORGENTEC Diagnostika representative.
24(101)
Service & Adjustment/replacement procedures
The table below describes the adjustment and replacement procedures that may be
required.
Procedure
How to remove instrument covers
How to cut and assemble fluid lines
How to replace the printer
How to change the fuse
How to replace fluid bottle(s) filters
How to replace rear air filter
How to replace front Air filter
How to change dispense needles
How to replace wash needles
How to adjust the tension of dispense unit belt
How to adjust the tension of turning table belt
How to replace the Optical Density module
25(101)
Error codes and actions
The table below describes the error codes that the instrument can generate and
appropriate measures.
Error Explanation: Description / Solution:

Code:
0 General errors Not available
1 General errors Not available
2000 File access errors Not available
2001 File: Read error File is empty so no bytes can be
checked.
2002 File: Write error Files will be written in the cleanup
system, the archive and every file
manipulation procedure.
Failed to write Procfile in
procfilePath.
Failed open new procfile for writing.
Failed to write file
2003 File: Set file pointer error Not available
2004 File: End of file encountered Not available
2005 File: Open error Files will be opened in the calibrate
system procedure.
Falied to open file
2006 File: Close error Not available
2007 File: Remove error Not available
2008 File: Is full Not available
2009 File: Get size error Not available
2010 File: Set comm port mask error Not available
2011 File: Line read error Not available
2012 File: Failed to delete file The procedure is not able to delete a
file.
Failed to delete file. It may be in use.
3000 General exception errors Not available
3001 Assertion failed Not available
3002 Check expression failed Not available
3003 Index out of bounds Wrong position setting where the strip
is located. The first strip position has
to be in the range from 1 till 30. The
first strip position holds the first
position where a scanned strip is
placed.
4000 Stepper motor errors The system failed to calibrate the
stepper motors.
5000 Dispense initerror The system failed during the dispense
initialization. Following parameters are
involved:
Compensation table
CommonNeedleFlushTime
ConjugateNeedleFlushTime
pumpOffset
flushVolume
needleWashtime
26(101)
xSpeed
xRamp
zFastSpeed
zSlowSpeed
zFastRamp
zSlowRamp
pumpSpeed
pumpRamp
stationPosition
ConOffset
zWashNeddlePos
wellZpos
Failed to read Shake from
performance description.ini file
Failed to read Timeslot from
performance description.ini file
5001 The Dispense process description has ERROR: To or from well >8 or <1 &&
wrong values or format != 9
5002 DispCRVAPIError The system cleaning procedure has
failed to:
get Digitalotput
set Digitalotput
get Digitalinput
getActive
The system dispense procedure has
failed to:
pumping with DC motor
get Disp_pip_choice Digitalotput
set Disp_pip_choice Digitalotput to
active.
dispense Wash Needle Radial-
>moveAbs
dispense Wash Needle, Zmotor-
>moveAbs(%d)
dispense Wash Needle,Pump-
>moveAbs(%d)
get Digitalotput (dispWaterFeed)
set DODispWaterFeed Digitaloutput
Dispensing Failed CRVAPI Error
The lid movement procedure has
failed to:
Radial to the door open position
The performance test and start test
run failed:
Make sure washing the needles with
distilled water Failed to get
Digitalotput
6000 TimeSlotError / AnalyteError One step has taken to long time.
7000 Wash1CRVAPIError The setting of the valves in position
wash failed to get an Digitalotput
7001 Wash1InitError Not available
8000 Wash2CRVAPIError The drier process is involed.
Drier station failed pumping with D
Failed going down with the drier z-
27(101)
motor
8001 Wash2InitError The drier process was failed to
initialize.
Failed Drier Init
The wash process was failed to
initialize.
Failed During Wash2 Init
9000 Wash2InitError The close valve “InDry” process was
failed.
Failed to get Digitalotput
The drier station process was failed.
Failed to open valve
The open, close, cleaning and drieing
process was failed.
The dry station process was failed.
Failed to set valve
The open valve “InDry” process was
failed.
The going down to rinse position
process including the going down with
drier Z motor failed.
The going up with the needle process
including the going up with the drier Z
motor to home position failed.
9001 DrierInitError Not available
10000 OpticalCRVAPIError These errors describe the full range of
the optical measurement procedure:
ActivateODError
Error setting
DO_OD_MEASURE_REF active
ODMeasError
Error CRV_TIME_OUT waiting on
DO_OD_MEASURE_REF
Error %d waiting on
DO_OD_MEASURE_REF
ReadLedAndRefValues
// Read reference measurements
from OD module
Error reading AI_OD_LED1 value
Error reading AI_OD_LED2 value
Error reading AI_OD_REF1 value
Error reading AI_OD_STD_REF1
value
value
value
ReadSensorValues
// Read Sensor measurements from
OD module
Error reading AI_OD_SENSOR1
value
28(101)
Error reading AI_OD_SENSOR2
value
Analyse2Completed
// Reading result from OD module
Error reading AI_OD_RESULT1
value
Error reading AI_OD_RESULT2
value
DoODMeasurement
Error setting
Starting OD Measurement (ref)
DoRefMeasurement
Starting OD Ref Measurement
Error setting
10001 OpticalInitError The optical initialization failed.
Could not find value in section %S in
file '%S'",
m_stationPosition
m_delayODMeasStart
m_timeoutRefMeasurement
m_timeoutODMeasurement
m_minLEDValue
m_maxLEDValue
m_minRefValue
m_maxRefValue
Failed during Optical Analyte Init
10002 OpticalQCFileError Failed during reading QC ini file
10003 OpticalLEDValueError Not available
10004 OpticalRefValueError Not available
11000 RotateCRVAPIError These errors describe the full range of
the motion procedure with including
motor movement:
StartFlushWash
Failed When rotating to the flush
position
StartWashWash1
Failed when rotating to the flush
position
StartCleanWash2
Failed when rotating to the flush 2
position
StartRinseWash1Drier
Failed When rotating to the flush
position
trStartRinseWash2
position
WashOfWash2Needles
position
inLifeTimeOpen
Failed Rotate plate sm-motor moveabs
29(101)
CRVApiError=%d
trCloseLid
Failed Sync rotate position
trOpenLid
Failed Rotate plate sm-motor moveabs
CRVApiError=%d
inLidRotate() {
// Move the rotating plate one strip
step
RotateOne Cake itsRotatorMotor-
>move(%d)
Error=%d",m_stepsBetweenStrips,
retval);
inMoveMicroSteps
step
>move(%d)
Error=%d",offset,retval);
inMoveNofStripSteps
"MoveOneStripStep
itsRotatorMotor->moveRel(%d)
retval);
inServiceReadBarcode
// Start Barcode reader
" ReadBarcode itsRotatorMotor-
>move(%d) Error=%d",2 *
step.Reduce the step between the
strips with amount that are moved
with bar code scanner active
ReadBarcode itsRotatorMotor-
>move(%d) Error=%d"
inSyncPosition
Failed to sync encoder and Position
counter on the rotate motor");
inlLifeTimeMove
MoveOneStripStep itsRotatorMotor-
>moveRel(%d)
trMoveOneStripStep
MoveOneStripStep itsRotatorMotor-
>move(%d) Error=%d
trRotateOneCake
Failed to sync encoder and Position
counter on the rotate motor");
step
>move(%d)
retval);
trShake
Shake itsRotatorMotor->move(%d)
30(101)
Error=%d",m_shakeSteps,retval);
Shake itsRotatorMotor->STOP(%d)
Error=%d",m_stepsBetweenStrips,ret
val
Shake itsRotatorMotor->moveAbs()
Error=%d",retval);
ShakeAndMoveOneStripStep
Shake itsRotatorMotor->move(%d)
Error=%d",m_shakeSteps,retval);
Shake itsRotatorMotor->STOP(%d)
Error=%d",m_stepsBetweenStrips,ret
val);
MoveAbs itsRotatorMotor->moveAbs()
Error=%d"
11001 RotateInitError The movement initialisation failed:
m_flushStationPos
m_stripOnePos
m_stepsBetweenStrips
m_uniqueBarcode
m_servicePath
m_barcodeOffset
m_barcodeHalfAngle
m_shakeSteps
m_shakeSpeed
m_shakeRamp
Failed During Rotating Init
11002 RotateBarcodeWarning (internal This should happen if one or many
barcode reader) strips has an expired date
11003 Incompatible Performance numbers Failed to open or find " + barcode-
>inGetTestDefinition()+".ini" ;
11004 The Performance Description has inLifeTimeTestInit
wrong format Failed initialise procesdescription class
// m_firstStripPos is calculated in
prCalculateNoSteps()
11005 RotateBarcodeError trScanStrips
Barcode Error
11006 A strip has changed place between The strip has changed place according
different scans to first scan
11007 No strips found when scaning GotoPosition
Rotation plate: Failed to go
positio=%d
The else case is taken care of inside
prSetAnalyseProcessAttr method
No Strips found");
11008 RotatePerfFileError Failed reading test definition
calcMethod=%d",calcMethod);
"borderlineMin=%d",borderlineMin)
;
unitStr=%S",unitStr);
calibratorD=%d",calibratorD);
calibratorD=%d",calibratorA);
calibratorD=%d",calibratorB);
calibratorD=%d",calibratorC);
calibratorD=%d",calibratorD);
31(101)
12000 Log Not available
12001 Log: Corrupt or does not exist Not available
12002 Log: Write failed Not available
12003 Log: Bad file descriptor Not available
12004 Log: End of log entries Not available
12005 Log: Length error Not available
13000 Self monitoring errors Not available
13001 Sem: Intialisation error SemInitError
Failed during Temperature
Monitoring Init
Illegal value for cfg parameter
'ADCScaleP' in ini-file
'ADCScaleI' in ini-file
'RegulatorPeriod' in ini-file
'TemperatureTolerance' in ini-file
'TargetTemperature' in ini-file
'LogInterval' in ini-file
'TempArrayLength' in ini-file
13002 Sem Crv API Error SemCrvApiError
Error reading
AI_SENSOR_CLIMA_TEMP_LEVEL
Error writing
AO_PELTIER_CLIMA_TEMP_CONTR
OL
14000 Bar Code Reader: Initialization Error The internal and external
Could not find value in section %S
in file %S",
Illegal beeper intensity for the bar
code reader
Illegal start marker for the bar code
reader
Illegal stop marker for the bar code
reader
Illegal code marker for the bar code
reader
14001 Bar Code Reader: COM Port Error "Could not initialize COM port");
14002 Strip expired (external barcode Check strip ID first, since it has the
reader) hardest requirements on syntax.
Check if strip is valid and can be
used
// Legal strip ID
15000 Printer: Initialization Error Could not find value in section %S
in file %S",
Illegal character spacing for the
printer");
Illegal font size for the printer");
Illegal line spacing for the printer");
Illegal print density for the
32(101)
printer");
The format for the first line will be
long for the printer");
The format for the second line will
be long for the printer");
Could not initialize printer");
15001 Printer: COM Port Error Could not initialize external printer
port");
Could not initialize external printer
port");
port");
15002 Printer: Printing Error Failed to write to COM port");
Failed to write all data to COM
port");
Failed to open LPT1: with error
%d", err);
Failed to write ESC E to COM port");
port");
Failed to write to COM port");
port");
Failed to write to COM port,
errorcode: %d", err);
Failed to write all data to COM port,
wrote %d of %d",
Failed to write all data to COM port,
wrote %d of %d",
port");
Failed to write to COM port");
port");
15003 Printer: Out of Paper Error INTERNAL ONLY Printer out of paper
15004 Printer: Door open Error INTERNAL ONLY Printer door is open
16000 Start up, self test and monitoring Not available
16001 Startup: Error during application start Not available
up
17000 Lid sensor driver trCloseLid
trOpenLid
Faild open lid sm-motor moveabs
CRVApiError=%d",retval
LID: Failed reading
DI_SENSOR_DOOR_OPEN
LID: Failed turn climate fan on
LID: Failed turn climate fan off
Faild open lid sm-motor moveabs
CRVApiError=%d"
LID: Failed reading
DI_SENSOR_DOOR_OPEN
17001 Failed close or open the climate door Not available
17002 LidInitError Failed Lid Init
17003 LidOpenError Failed to open lid. The
33(101)
DI_SENSOR_DOOR_OPEN is not
Active
LID: Failed to open lid. The
DI_SENSOR_DOOR_OPEN is not
Active
17004 LidCloseError Failed close lid sm-motor moveabs
CRVApiError=%d
17005 Read from SSW Falied to read DigitalInput
(DI_SENSOR_DOOR_CLOSED) on
request from service PC
18000 Liquid levels To low level in WashBuffer 1 bottle
To little WashBuffer 1");
18001 WashBuf2LevelError To low level in WashBuffer 2 bottle

To little WashBuffer 2");
18002 DestWaterLevelError "To low level in destilled water
bottle");
To little DestWater
18003 WasteContainerLevelError To high level in waste bottle");
To much liquid in the waste");
19000 Self test:@Success Not available
19001 Self test:@General failure Not available
20000 Calibrate errors Failed During Calibration Init
20001 CalNoValuesAboveThreshold Calibrate: The values under the
threashold value are less then number
of points for accept (pointsForAccept
Calibrate: No values threshold. No
new homeposition
20002 Reference measurement failed during Calibrate: OD reference measurement

plate calibration
21000 TempOutOfRange Temperature out of range. Analyse
has been aborted
21001 Temperature Calibration error Not available
22000 AnalyseInitError Failed init Analyse class
(m_maxTempWait
23000 SSW specific Falied to read AnalogInput
Falied to set Analog Output
Falied to set Teperature Permanent
23001 SSWDigitalInputError Falied to read DigitalInput
24000 FAN errors Failed reading ini file Failed Fan Init
parameters
25000 OD Calibration error Failed During ODCalibration Init
25001 ODCalibCRVAPIError Error reading

AI_OD_VALUEODCAL1 value
Error reading
AI_OD_VALUEODCAL2 value
Error setting AO_OD_CALIBOD1TMP
value
Error setting AO_OD_CALIBOD2TMP
value
34(101)
25002 Failed to write permanent to flash Error setting AO_OD_CALIB_PRM
memory value
25003 Failed to calibrate Failed to calibrate OD module
30000 Not available

30001 Config Handling:@EEPROM Read/Write Not available
error
40000 ServUnknownCmd Unknown Service Command\n
50000 ComBegin Not available

50001 ComSocketConnectErr ComSocket: Could not read port
number
50002 ComSerialPortOpenErr Not available
50003 ComSocketDisconnectErr Not available
60000 SocketBegin Not available
60001 SocketReceiveError Not available
70000 LisBegin Not available
70001 Already connected Not available
70002 Time out error when waiting for ACK Not available
70003 Time out error when waiting for frame Not available
ACK
70004 NAK received when waiting for ACK Not available
when sending
70005 Time out error when sending, waiting Not available
for ack to send next line
70006 Time out error when receiving test Not available
orders
70007 Received unexpected EOT Not available

70008 Received unexpected ENQ Not available
70009 Connection lost error Not available
35(101)
Notes:
36(101)
SERVICE CENTERS
Germany
ORGENTEC Diagnostika GmbH
Carl-Zeiss-Straße 49
D-55129 Mainz
Germany
Tel. +49 - (0)6131 / 92 58 - 0

Fax +49 - (0)6131 / 92 58 58
http://www.orgentec.com
Authorized Service representative:
Manufactured by:
Orgentec Diagnostica GmbH, Carl-Zeiss-Straße 49, D-55129 Mainz , Germany
Tel. +49 - (0)6131 / 92 58 - 0 Fax +49 - (0)6131 / 92 58 58
http://www.orgentec.com/
Printed in Germany, November 2011
37(101)
INSTRUCTION: HOW TO REMOVE THE
FRONT AIR FILTER
What to do
This instruction is made up of four parts:
Information (safety, references and comments)

Things to be done in advance (pre-requisite).
Step by step procedure
Drawings
Start by reading the information section and if not performed, perform the pre requisite
instructions and then start the step-by-step procedure, use the drawings as a guide. At
last re-verse the procedure and test the instrument (according to the “Preventive
maintenance instruction”, It must be completed; this is to ensure the safe and proper
operation).
Note:
If none of the replace/ removal procedures solves the problem. Please contact your local
ORGENTEC Diagnostika representative.
Information
Safety precautions:
electronics).
always be performed with protective gloves.
References:
Comments:
38(101)
Pre-requisites
Removal/replacement procedures (required to be done prior to this specific procedure)
listed in order:
# Instruction/manoeuvre
1 If possible shut down the instrument, see instructions for use.
2 Remove the power cord.
3 Disconnect the fluid containers (cables and tubing) and remove the containers from
the device.
39(101)
Overview drawing (1)
The drawing below shows the general components of the external casing.
The following pages describe the parts that are to be removed or replaced.
# Part description
1 Top Cover
2 Rear panel (stainless steel)
3 Left side cover
4 Door Cover
5 Right side cover
40(101)
Removal sequence
The covers and parts shall be removed in the following order (re-assembled in the
reverse order).
Door cover
Inner dividing wall
Air filter
The following pages shows how to remove the air filter.
Caution:
When starting to remove covers locate a free surface to place the covers without
damaging them, preferably a desk with some protective cloth.
Remove Door cover

The table below describes how to remove and replace the part. See also the views on
the following pages for reference and identification.
# To do, remove: Required/tools/etc.

1 If not done shut down the instrument and remove the
power cord.
2 Open the door and disconnect the fluid lines and level
sensors then remove the fluid containers.
3 Place a cloth on the table under where the door opens See drawing 1, # 1
Remove the doorstop wire (left side); fold the door onto the
cloth.
4 Remove the Allen screws located at the pivot points of the
door (one on each side), collect the bushings.
5 If the door cover itself needs to be removed from the metal See drawing 1, # 2
structure then remove the four screws that attach the door
to the structure.
Note:
Reverse the order to assemble.
41(101)
Drawing (1)
The Pictures below describe the parts that are to be removed or replaced.
42(101)
Remove dividing wall/ cover

1 Remove the fluid compartment dividing cover, See drawing 2, # 1 and # 2
remove the 13 screws as shown and remove the
dividing cover.
2 Remove the air filter as shown (attached with See drawing 3
adhesive) remove any residues of the adhesive.
(Replace with a new air filter).
Note:
43(101)
Drawing (2)
44(101)
Drawing (3)
45(101)
INSTRUCTION: HOW TO EXCHANGE
DISPENSE NEEDLES
What to do

Drawings
instructions and then start the step by step procedure, use the drawings as a guide. At
operation).
Note:
Information
Safety precautions:
electronics).
References:
Comments:
Not holding the parts correctly may result in bending, kinking of the fluid lines/ tubes
and as a consequence leakage can be the result.
46(101)
Pre-requisites
listed in order
1 Shut down the instrument, see instructions for use
2 Remove the instrument top cover, see How to remove covers
Remove/Replace
The table below describes how to remove and replace the part. See also the View’s on
Ref To do, remove: Required/tools/etc.

1. Disconnect the needles from the hoses by loosing the See drawing 1 step 1
coupling (hold where indicated and loosen the coupling).
4. Inspect the tube /fluid line to see is there are any damage See drawing 1 step 4
or if the tune fluid line is not flush with the surface if the
ferrule
5. Un-screw the two screws on the front of the needle block. See drawing 2, step 1-
Remove the “holder plate”. 4
6. Gently remove the needle and the spring by pressing the See drawing 2, step 5 -
spring slightly down as at the same time removing the 6
needle in the arrow direction (out from the needle block).
7. Replace with a new needle and a new spring.
8. When inserting the needle ensure that the needle and
spring are in its correct position, and that the needle is
position in the needle guide.
9. Re-attach the “holder plate” with its two screws.
10. Ensure that the needle can move within the “holder plate”,
i.e. that the screws are not too tight.
11. Check the coupling /fluid line and if correct assemble See How to Cut and
instruction
12. Test run the new needles with SSW and ensure that there See Service software
is no air in the system and that the dispensing is working instructions
correctly (dispense the right amount).
47(101)
Drawing (1)
48(101)
Drawing (2)
49(101)
INSTRUCTION: HOW TO EXCHANGE WASH
NEEDLES
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
is to use wrist strap and ESD conductive surface where the instrument is
handled).
References:
Comments:
50(101)
Pre-requisites
listed in order
Remove the instrument top cover See, How to remove covers
Remove/Replace

1. Disconnect the needles from the hoses by loosing the See drawing 1 step 1 & 2
2. Un-screw the two screws on the front of the needle block. See drawing 1, step 3 -
Remove the “holder plate”. 6
3. Gently remove the needle and the spring by pressing the See drawing 1, step 7 -
spring slightly down as at the same time removing the 8
needle in the arrow direction (out from the needle block).
4. On the backside of the station a metal fork holds the fixed See drawing 2, step 9 –
needles, locate the two screw and unscrew them 10
5. Hold the metal fork and the needles and gently pull up to See drawing 2, step 11
remove the needles
6. Remove the needle from the metal fork by sliding it out
through the fork hole.
7. Replace the needles and reverse order to assemble
8. Tests run the new needles with the service software and See Service software
ensure that there is no air in the dispensing system and instruction
that the dispensing and aspirating are working correctly.
51(101)
Drawing (1)
52(101)
Drawing (2)
53(101)
INSTRUCTION: HOW TO EXCHANGE FILTER
IN BOTTLES
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
54(101)
Pre-requisites
listed in order
2 Open the front cover and disconnect the appropriate bottle to replace the filter in,
see instruction for use (how to disconnect the bottle(s)).
Remove/Replace

1. Unscrew the screw (securing the filter holder)
2. Remove the screw
3. Hold the plastic hose and the top part (where the arrows
indicate) and gently pull the filter out (replace the filter).
4. Reverse the order to assemble
55(101)
Drawing (1)
56(101)
INSTRUCTION: HOW TO REPLACE REAR
VENTILATION FILTER
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
57(101)
Pre-requisites
listed in order
Remove/Replace

1. Locate the filter cover and the nuts holding the cover, Appropriate spanner
unscrew the nuts
2. Remove the cover
3. Remove the filter
4. Replace the filter
5. Reverse order to assemble
58(101)
Drawing (1)
59(101)
INSTRUCTION: HOW TO REPLACE THE
FUSES
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
60(101)
Pre-requisites
listed in order
1 If possible shut down the instrument, see instructions for use
Remove/Replace

1. Remove the power cord (at the rear of the instrument)
2. Use a thin tip screwdriver and gently twist the fuse holder Thin tip screwdriver
out
3. Pull out the fuse holder; replace the fuses (fuses according
to technical specification, see instructions for use.
61(101)
Drawing (1)
62(101)
INSTRUCTION: HOW TO ADJUST THE
TENSION OF THE DISPENSE UNIT BELT
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
63(101)
Pre-requisites
listed in order
2 Remove the power cord
3 Remove the covers, according to How to remove the covers
Remove/Replace

1. Slightly loosen the motor bolts (bolts placed at number 4 & Spanner, See drawing
5).
2. Loosen the (adjustment) tension bolt and nut (number 2 & Allen key and spanner
3).
3. Adjust the tension with the bolt (number 3).
4. Use a tension meter (1) to set the tension to (65 +/- 15 Tension meter (1)
Hz).
5. When the tension is correct lock the adjustment bolt with Allen key and spanner
the nut (2)
6. Tighten the motor bolts (4 & 5) Spanner
7. Check the tension a final time, if the tension is correct then Tension meter (1)
the adjustment is concluded, if not re adjust until correct.
8. When correct re assemble the instrument
64(101)
Drawing (1)
65(101)
INSTRUCTION: HOW TO ADJUST THE
TENSION OF THE TURNING TABLE BELT
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
66(101)
Pre-requisites
listed in order
2 Remove the power cord
3 Remove the covers, according to How to remove the covers
Remove/Replace

1. Slightly loosen the motor bracket bolts Allen key, See drawing
(4 bolts placed at number 1).
2. Adjust the tension by moving the motor bracket Allen key
3. Secure the motor bracket bolts Allen key
4. Use a tension meter (1) to set the tension to (158,5 +/- Tension meter (2)
20,5 Hz).
5. When the tension is correct tighten the motor bracket bolts Allen key
6. Check the tension a final time, if the tension is correct then Tension meter (2)
the adjustment is concluded, if not re adjust until correct.
7. When correct reassemble the instrument
67(101)
Drawing (1)
68(101)
INSTRUCTION: HOW TO REPLACE THE
PRINTER
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
69(101)
Pre-requisites
listed in order
2 Remove instrument covers (top cover)
Remove/Replace
The table below describes how to remove and replace the part. See also the view’s on

1. Open the printer door, by pressing the lever down
2. Locate the 4 screws at the front of the printer (and the Allen key and
nuts on the inside of the chassis) unscrew the screws and appropriate spanner
remove the printer
3. Follow the cable and disconnect the printer cable
4. To assemble reverse the order
70(101)
Drawing (1)
71(101)
INSTRUCTION: HOW TO CUT AND
ASSEMBLE FLUID LINES AND ASSEMBLE
COUPLINGS
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
handled).
References:
Comments:
Never bend, kink or twist fluid lines, always ensure 90 degree cuts and ensure coupling
surface is flush with ferrule and fluid line
72(101)
Pre-requisites
listed in order
2 Remove the covers, see How to remove covers
Remove/Replace

1. Open the tube/fluid line cutter and check that the knife Tube cutter
edge is sharp
2. Load the fluid line into the tube (cutters appropriate hole See Drawing
fitting the diameter of the tube)
3. Fold the tube cutter knife down (cutting the fluid line See Drawing
/tube)
4. Pull out the tube /fluid line and Inspect the cross section See Drawing
cut, the cut shall be nice even and in 90 degree in both
horizontal and vertical plane (if not re cut)
5. Insert the tube/ fluid line into the coupling See Drawing
6. Place the ferrule onto the tube fluid line See Drawing
7. Gently pull/push the fluid line and ferrule back into the See Drawing
coupling
8. Pull push the ferrule and fluid line into the coupling See Drawing
9. Check that the fluid line/tube is aligned correctly (MUST BE See Drawing
PLAIN!) If not leakage will occur! And can cause other
problems.
73(101)
Drawing (1)
74(101)
Drawing (2)
75(101)
INSTRUCTION: HOW TO REMOVE THE
COVERS
What to do

Drawings
operation).
Note:
Information
Safety precautions:
electronics).
All service shall be performed in an ESD safe environment (minimum requirement is
to use wrist strap and ESD conductive surface where the instrument is handled).
always be performed with protective gloves.
References:
Comments:
76(101)
Pre-requisites
listed in order:
1 If possible shut down the instrument, see instructions for use.
2 Remove the power cord.
3 Disconnect the fluid containers (cables and tubing) and remove the containers from
the device.
77(101)
Overview drawing (1)
The drawing below shows the general components of the external casing.
The following pages describe the parts that are to be removed or replaced.
# Part description
1 Top Cover
2 Rear panel (stainless steel)
3 Left side cover
4 Door cover
5 Right side cover
78(101)
Removal sequence
The covers shall be removed in the following order (re-assembled in the reverse order).
Door cover
Inner dividing cover
Top cover
Left side cover
Right side cover
The following pages show how to remove the covers.
Caution!
When starting to remove covers locate a free surface to place the covers without
damaging them, preferably a desk with some protective cloth.
Remove Door cover


1 If not done shut down the instrument and remove the
power cord.
2 Open the door and disconnect the fluid lines, level sensors
and remove the fluid containers.
3 Place a cloth on the table under where the door opens See drawing 1, # 1
Remove the doorstop wire (left side); fold the door onto the
cloth.
4 Remove the Allen screws located at the pivot points of the
door (one on each side), collect the bushings.
5 If the door cover itself needs to be removed from the metal See drawing 1, # 2
structure then remove the four screws that attach the door
to the structure.
Note:
79(101)
Drawing (1)
80(101)
Remove top cover (and inner dividing cover)

1 Remove the 13 screws as shown and remove the See drawing 2, # 1 and # 2
fluid compartment dividing cover.
2 Remove the inspection panel at the rear panel. See drawing 3
3 Locate the three screws, easiest access way shown. See drawing 4
The two lower hand screws (at the bottom of the

display) are accessed from the front of the
instrument and the top screw is accessed from the
rear through the inspection cover entrance.
Hold the display frame and remove the hand

screws and gently lower the display and the frame
into a resting position inside the instrument.
4 Remove the 4 rear screws of the top cover as See drawing 5
shown.
5 Remove the two screws located in the fluid See drawing 6
compartment ceiling and the 2 screws located in
each of the side covers.
6 Have two persons gently lift off the top cover. See drawing 7
Note:
There are to guiding pins at the front of the case.
Note:
81(101)
Drawing (2)
82(101)
Drawing (3)
83(101)
Drawing (4)
84(101)
Drawing (5)
85(101)
Drawing (6)
86(101)
Drawing (7)
87(101)
Remove side covers (left and right, right side shown)

1 Loosen the 3 screws from the inside of the instrument. See drawing 8
2 Lift the side cover “up and out” (the cover is latched by 3 See drawing 9 and
key hole slots). focus shown.
Note:
The same procedure is used for the left side cover.
88(101)
Drawing (8)
89(101)
Drawing (9)
90(101)
INSTRUCTION: HOW TO REPLACE THE OD
MODULE
What to do

Drawings
maintenance instruction”. It must be completed; this is to ensure the safe and proper
operation). Please also have a look into the technical bulletin TB 0907 – How to
exchange the Transmitterboard and check its functionality.
Note:
Information
Safety precautions:
electronics).
Comments:
Never bend, kink or twist fluid lines.
91(101)
Pre-requisites
listed in order
2 Remove the covers, see How to remove covers
Remove/Replace

1. When all covers are removed (see instruction to do so), the -
door cover and the dividing wall must be removed.
2. Place a cloth on the table under where the door opens See drawing 1
remove the doorstop wire (left side); fold the door onto the
cloth.
3. Remove the Allen screw located at the pivot points of the See drawing 1
door (one of each side), collect the bushings.
4. Remove the dividing (remove the 13 screws as shown and See drawing 2
remove the dividing wall/cover).
5. Remove the Climate hose (from climate unit to rear filter) See drawing 3
6. Remove plane (Locate the three screws, remove them and, See drawing 4
disconnect any cabling/couplings to be able to lift of the
plane with the dispense/wash/soak stations)
Caution Note!
When lifting the plane, ensure to lift it straight up to avoid
needles bending.
7. Remove the trim by removing the screws around its See drawing 5
perimeter (8 screws).
8. Remove the rotating door / lid (lift it straight up). See drawing 6
9. Remove screws around the perimeter of the climate See drawing 7
module
(8 screws), Remove the climate module (straight up).
10. Remove the turning plate by removing the screws around See drawing 8
the center and the center of the turning plate.
11. Locate the OD module from beneath. Remove the 4 screws See drawing 9
(corners) to loosen the lid of the OD module.
12. Remove the 2 screws holding the OD module to the plane See drawing 9
(opposite diagonal position).
13. Remove the flat ribbon connector cable from the circuit -
board.
Note:
92(101)
Drawing (1)
93(101)
Drawing (2)
94(101)
Drawing (3)
95(101)
Drawing (4)
96(101)
Drawing (5)
97(101)
Drawing (6)
98(101)
Drawing (7)
99(101)
Drawing (8)
100(101)
Drawing (9)
101(101)
DI_SENSOR_DOOR_OPEN
SM_MOTOR_DISP_Z_MOVE QE_SENSOR_DISP_RAD_MOVE_POS
SM_MOTOR_DISP_CON_Z_MOVE DI_SENSOR_DISP_RAD_MOVE_HOME
AO_FAN_CABINET
DI_SENSOR_WB_WB2
DC_PELTIER_FAN
DI_SENSOR_DOOR_CLOSED
DO_VALVE_WB_MEDIA_SELECTION_1 SM_PUMP_DISP_LARGE_DISP
DO_VALVE_WB_MEDIA_SELECTION_2
DO_VALVE_WB_MEDIA_SELECTION_3
DC_PUMP_WASTE
DI_SENSOR_DRAIN_WATER_LEVEL
DI_SENSOR_DISP_CON_Z_MOVE_HOME
DI_SENSOR_WB_WB1
DO_VALVE_WB_MEDIA_SELECTION_4 DI_SENSOR_HATCH_OPEN
DI_SENSOR_DISP_Z_MOVE_HOME DI_SENSOR_ROT_MOVE_HOME
DI_SENSOR_DRIER_Z_MOVE_HOME
DI_SENSOR_WS2_Z_MOVE_HOME
QE_ENCODER_ROT_MOVE_POS
DI_SENSOR_WB_DEST_WATER
DI_SENSOR_WS1_Z_MOVE_HOME
VALV_CLEAN_DRY_SUCTION_NEEDLE
DC_PUMP_WS2_WASH_BUFFER_FEED
VALVE_DRIER_SUCTION
DC_PUMP_DRIER_SUCTION VALVE_WS1_WASH
VALVE_WS2_WASH
SM_MOTOR_WS1_Z_MOVE SM_MOTOR_DISP_RAD_MOVE SM_MOTOR_ROT_MOVE
SM_MOTOR_WS2_Z_MOVE SM_MOTOR_DOOR_MOVE SM_MOTOR_DRIER_Z_MOVE
DC_PUMP_DISP_PIP_WASH_FEED VALVE_DISP_PIP_WATER_FEED DC_PUMP_WS2_SUCTION
DC_PUMP_WS1_WASH_BUFFER_FEED VALVE_DISP_PIP_CHOICE DC_PUMP_WS1_SUCTION
Author: MS1
Date: 12.09.2011
Filename: 20100-3ME003-02 Connections.doc
OBS! Separate GND for 12V and 24V To Internal Printer To IO Board To Analysis Module
POWER TO IO BOARD
24V,12V,5V
To Bar Code To L CD
Mains in
Battery
AC/DC
24V
To
TouchScreen
AC/DC CPU Module
12V,5V,-12V SD Card To I2C
Thermometer
Modem
To Loudspeaker
220V Power to external

Bar Code Reader
Customer: Document:
Confidential DP1 Connections
Project: Doc. no. Date: Page:
20100 Carnival Confidential 2006-11-07 2(3)
Fluid handling
Dry Suction
2
Valve_Drier_Suction
3 1
Pump_Drier_Suction
Needle Wash Cup
Dispensing
Wash and Soak 2

Pump_Disp_Large_Disp
Wash and Soak 1

3
2
Valve_Disp_Pip_Choice
Valve_Disp_Pip_Wash_Feed 3 Valve_WS2_Wash
2 1
3 1
1
Valve_WB_Media_Selection _4
Valve_WS1_Wash Pump_WS2_Wash_Buffer _Feed
3
Pump_Disp_Pip_Wash_Feed
1 2
2
1
2
3
3
1
2
Pump_WS1_Wash_Buffer _Feed
Valve_Clean_Dry_Suction_Needle
Pump_WS1_Suction Pump_WS2_Suction
3
Pipette Wash Cup
Valve_WB_Media_Selection _2
Needle Wash Cup
2 1
Needle Wash Cup
3 3
Valve_WB_Media_Selection _3 Valve_WB_Media_Selection _1
2 1 2 1
Pump_Waste
Wash Waste
Wash
Distilled Buffer
Buffer
Solution 2
Water Solution 1
20100-1SA002-07 Product outline.pdf

2009-09-08
Empty
Refill
Refill
Refill
5 4 3 2 1
D D
Revision history:
Rev 01: 2004-08-26 BPn First Release - Cable lengths are approximate.
Rev 02: 2004-11-30 BPn Error fixes - Cable lengths are still approximate.
Added fixes for FLEX-card.
C C
B B
A A
Title
Top
Size Document Number Rev

A3 20100-3SC009-02-Internal cables 02
Date: Tuesday, November 30, 2004 Sheet 1 of 17

5 4 3 2 1
5 4 3 2 1
D D
To J3 on
Motherboard
J1 J2
1
3
2
4
Flat Cable 1
3
2
4
5 6 5 6
7
9
8
10
L = 1000 mm 7
9
8
10
11 12 11 12
13 14 13 14
C Mico MaTch 14 pole male CONN RCPT 7x2 C
To J2 on
Analysis
Processor
board
To J1 on
Analysis
Receiver
board
B J3 J4 B
1
3
2
4
Flat Cable 1
3
2
4
5 6 5 6
L = 120 mm
Mico MaTch 6 pole male Mico MaTch 6 pole male
To J2 on
Analysis
Processor
board
A A
Title
Analysis

Date: Thursday, September 09, 2004 Sheet 2 of 17

5 4 3 2 1
5 4 3 2 1
D D
L = 100 mm
J5
Red 1 To J9 on Motherboard
C C
J6
2
2
To external scanner 1 Black

DC-plug 2.1 mm
DC-plug 2.1 mm
Area = 0.22 mm2
Twisted cable
B B
A A
Title
External scanner power


5 4 3 2 1
5 4 3 2 1
D D
J7
L = 600 mm
1
1 Push-On 2.8 mm
J8
+ MG1
Blue 1
DC_PUMP_WS1_SUCTION DC-MOTOR White 2 J27 on IO-board
A 3
-
Area = 0.22 mm2
J9 Molex KK 3 pole
2
Push-On 2.8 mm
C J10 C
L = 600 mm
1
Push-On 2.8 mm
1
J11
+
MG2 Blue 1
DC_PUMP_WS2_SUCTION White 2 J28 on IO-board
A DC-MOTOR 3
-
Area = 0.22 mm2
J12 Molex KK 3 pole
2
Push-On 2.8 mm
J13
L = 1200 mm
1
Push-On 2.8 mm
1
J14
+
DC_PUMP_WASTE MG3 Blue 1
White 2 J32 on IO-board
B A DC-MOTOR 3
B
-
Area = 0.22 mm2
J15 Molex KK 3 pole
2
Push-On 2.8 mm
A A
Title
DC-motors 1


5 4 3 2 1
5 4 3 2 1
D D
J16
L = 850 mm
1
Push-On 2.8 mm
1
J17
+
MG4 Blue 1
DC_PUMP_DISP_PIP_WASH_FEED White 2 J33 on IO-board
A 3
DC-MOTOR
-
Area = 0.22 mm2
J18 Molex KK 3 pole
2
1
Push-On 2.8 mm
J19
L = 600 mm
1
Push-On 2.8 mm
1
J20
+
MG5 Blue 1
C DC_PUMP_WS1_WASH_BUFFER_FEED White 2 J34 on IO-board C
A 3
DC-MOTOR
-
Area = 0.22 mm2
J21 Molex KK 3 pole
2
Push-On 2.8 mm
J22
L = 600 mm
1
Push-On 2.8 mm
1
J23
+
MG6 Blue 1
DC_PUMP_WS2_WASH_BUFFER_FEED White 2 J35 on IO-board
A 3
DC-MOTOR
-
Area = 0.22 mm2
J24 Molex KK 3 pole
2
Push-On 2.8 mm
B B
J25
L = 600 mm
1
Push-On 2.8 mm
1
J26
+
MG7 Blue 1
DC_PUMP_DRIER_SUCTION White 2 J36 on IO-board
A DC-MOTOR 3
-
Area = 0.22 mm2
J27 Molex KK 3 pole
2
Push-On 2.8 mm
A A
Title
DC-motors 2


5 4 3 2 1
5 4 3 2 1
L = 300 mm
J28 CON1
D D
1 R_7 1
2 VCC1 R_6 2
3 VCC2 R_5 3
4 R_4 4
5 PIXCLK R_3 5
6 DISPEN R_2 6
7 VSYNC GND1 7
8 HSYNC 8
9 GND1 G_7 9
10 R_2 G_6 10
11 R_3 G_5 11
12 R_4 G_4 12
13 R_5 G_3 13
R_6 G_2
To LCD 14
15 R_7 GND2
14
15
To CON8 on
16 GND2 16 Motherboard
17 G_2 B_7 17
18 G_3 B_6 18
19 G_4 B_5 19
20 G_5 B_4 20
21 G_6 B_3 21
22 G_7 B_2 22
23 GND3 GND3 23
24 B_2 24
25 B_3 VSYNC 25
26 B_4 HSYNC 26
27 B_5 PIXCLK 27
28 B_6 28
C 29 B_7 DISPEN 29 C
30 30
VCC1 31
VCC2 32
JAE-FI-X30M
CON REC 2x16 2.00 mm
L = 300 mm
CON2 CON3
Area = 0.14 mm2
1 1
2 2
3 3
To CN1 on 4
5
4
5
To CON9 on
Backlight 6 6 Motherboard
7 7
Power Supply 8 8
9 9
B B
10 10
MOL51021-1000, 10P MOL51021-1000, 10P
L = 330 mm
J29 J30
Flat cable
1 1
To Touch Screen 2
3
2
3
To CON7 on
4 4 Motherboard
CON4 Male REC4 Female
A A
Title
Display


5 4 3 2 1
5 4 3 2 1
D D
L = 330 mm
C J31 J32 C
1
Area = 0.14 mm2 White 1
2 2
To CN6 3
4
3
4
To J7 on
on Printer 5 5 Motherboard
6 6
GND Black
AMP Quick 6 pole Molex KK 6 pole
L = 480 mm
B B
J33
To Power 4 +5V Red
terminal
1
2
To J8 on
on Printer 3 0V Black Motherboard
Molex KK 2 pole
Area = 0.22 mm2
A A
Title
Internal_printer


5 4 3 2 1
5 4 3 2 1
D D
C C
J34 J35
1 6 1 6
2
3
7
8
Flat Cable 2
3
7
8
4 9 4 9
5 10 L = 480 mm 5 10
CONN REC 5x2-R CONN REC 5x2-R
B To J2 on To J5 on B
I/O-board Motherboard
A A
Title
Local Bus


5 4 3 2 1
5 4 3 2 1
D D
C
L = 200 mm C
J36 J37
White
1 1 To CON13 on
LS1 + 2
Motherboard
Push-On 4.8 mm
Black
Molex KK 2 pole
J38
SPEAKER 1
Area = 0.22 mm2
Push-On 2.8 mm
B B
A A
Title
Loudspeaker


5 4 3 2 1
5 4 3 2 1
D
L = 1600 mm D
J39
Red 1
2 J64 on IO-board
AO_PELTIER_CLIMA_TEMP_CONTROL Black 3
Molex KK 3 pole
Area = 0.75 mm2
L = 1600 mm
J40
Red 1
2
DC_PELTIER_FAN Black J3 on IO-board
C C
Molex KK 2 pole
Area = 0.22 mm2
L = 1600 mm
J41 J42
1 Red 1
2 2
AO_FAN_CLIMA_COOLING Black 3 J21 on IO-board
Terminal block
Molex KK 3 pole
Area = 0.22 mm2
B B
L = 600 mm
J43 J44
1 Red 1
AO_FAN_CABINET 2 2 J22 on IO-board
Black 3
Terminal block
Molex KK 3 pole
Area = 0.22 mm2
A A
Title
Peltier element and fans


5 4 3 2 1
5 4 3 2 1
L = 440 mm
CON4
Area = 0.75 mm2
CON5
D D
1
2 -12V 1
3 +5V 2
4 +5V 3
5 +5V 4
To CON1 on 6
GND
5
PSU1
7
8 GND
6
7
To CON2 on
9 GND
+12V
8 Motherboard
10 9
11 GND 10
12 GND
13
AMP_MTA156_3.96, 10P
GND = Black AMP_MTA156_3.96, 13P
+5V = Red
+12V = White L = 300 mm
-12V = Blue J45
Area = 0.75 mm2
+24V = Green
1 1
L = 350 mm Area = 0.75 mm2 J47
Fork 3.2 mm
J46 +24V 1
C +24V 2 C
GND
2 1
GND
3
4
To J1 on
To TB2 on +12V
GND
5 I/O-board
Fork 3.2 mm 6
PSU2 +5V
GND
7
J48 8
4 1
Molex KK 3.96 8 pole

Fork 3.2 mm
J49
5 1
Fork 3.2 mm
L = 130 mm
Area = 0.75 mm2
J51
J50
To L on 1
Blue 1
To L1 on
B B
PSU2 mains conn
Fork 3.2 mm Push-On 6.3 mm
J53
J52
Brown To L2 on
To N on 1 1
mains conn
PSU2
J55
J54
To E on 1
Green/Yellow 1
To PG on
PSU2 mains conn
L = 130 mm
J56
5
Blue
To P1 on 4
3
Brown
A PSU1 2 Green/Yellow A
1
Molex KK 3.96 mm
J57
Title
Green/Yellow Power
To chassis 1
EYELET 4,2 MM HOLE A3 20100-3SC009-02-Internal cables 02

5 4 3 2 1
5 4 3 2 1
L = 600 mm
J59
J58
1
1 White 2
DI_SENSOR_WB_WB1 Blue 3 J46 on IO-board
4
2
BNC
D Area = 0.22 mm2 Molex KK 4 pole
D
L = 1200 mm
J60
U1
1 3 Red 1
White 2
DI_SENSOR_HATCH_OPEN Black 3 J47 on IO-board
2 4 Green 4
OPTO-FORK
Area = 0.14 mm2 Molex KK 4 pole
L = 1200 mm
J61
U2
1 3 Red 1
White 2
DI_SENSOR_DRIER_Z_MOVE_HOME Black 3 J41 on IO-board
2 4 Green 4
OPTO-FORK
C C
L = 600 mm
J62
U3
1 3 Red 1
White 2
DI_SENSOR_ROT_MOVE_HOME Black 3 J43 on IO-board
2 4 Green 4
OPTO-FORK
L = 1200 mm
J63
U4
1 3 Red 1
White 2
DI_SENSOR_WS1_Z_MOVE_HOME Black 3 J61 on IO-board
2 4 Green 4
OPTO-FORK
L = 1200 mm
B B
J64
U5
1 3 Red 1
White 2
DI_SENSOR_WS2_Z_MOVE_HOME Black 3 J63 on IO-board
2 4 Green 4
OPTO-FORK
L = 150 mm L = 850 mm
J65 J66 J67
U6
1 3 Red 4 4 Red 1
White 3 3 White 2
DI_SENSOR_DISP_Z_MOVE_HOME Black 2 2 Black 3 J56 on IO-board
2 4 Green 1 1 Green 4
OPTO-FORK
Molex KK 4 pole Molex KK 4 pole
J3 on FLEX-board
A A
Title
Sensors 1


5 4 3 2 1
5 4 3 2 1
L = 1000 mm
J69
J68
1
DI_SENSOR_WB_DEST_WATER 1 White 2 J57 on IO-board
D Blue 3 D
4
2
BNC
L = 1000 mm J71
J70
1
1 White 2
Blue 3
DI_SENSOR_DRAIN_WATER_LEVEL 4 J54 on IO-board
2
BNC
L = 1200 mm
J72
U7
1 3 Red 1
DI_SENSOR_DOOR_OPEN White 2
Black 3 J49 on IO-board
2 4 Green 4
C OPTO-FORK C
L = 1200 mm
J73
U8
1 3 Red 1
White 2
DI_SENSOR_DOOR_CLOSED Black 3 J53 on IO-board
2 4 Green 4
OPTO-FORK
L = 1200 mm
J75
J74
1
1 White 2
Blue 3
DI_SENSOR_WB_WB2 4 J52 on IO-board
2
BNC
B B
L = 600 mm
J76
U9
1 3 Red 1
White 2
DI_SENSOR_DISP_RAD_MOVE_HOME Black 3 J51 on IO-board
2 4 Green 4
OPTO-FORK
L = 150 mm L = 850 mm
J77 J78 J79
U10
1 3 Red 4 4 Red 1
White 3 3 White 2
DI_SENSOR_DISP_CON_Z_MOVE_HOME Black 2 2 Black 3 J58 on IO-board
2 4 Green 1 1 Green 4
OPTO-FORK
Molex KK 4 pole Molex KK 4 pole
A J4 on FLEX-board A
Title
Sensors 2


5 4 3 2 1
5 4 3 2 1
L = 1400 mm
MG8 J80
1 Red 4
SM_MOTOR_DRIER_Z_MOVE 2 Green 3
3 White 2 J10 on IO-board
4 Yellow 1
D MOTOR STEPPER 2-PHASE

Area = 0.14 mm2 Molex KK 4 pole D
L = 600 mm
MG9 J81
1 Red 4
SM_MOTOR_DOOR_MOVE 2 Green 3 J12 on IO-board
3 White 2
4 Yellow 1
MOTOR STEPPER 2-PHASE

L = 1400 mm
MG10 J82
1 Red 4
SM_MOTOR_WS1_Z_MOVE 2 Green 3
3 White 2 J15 on IO-board
4 Yellow 1
C C
L = 1400 mm
MG11 J83
1 Red 4
SM_MOTOR_WS2_Z_MOVE 2 Green 3 J16 on IO-board
3 White 2
4 Yellow 1

L = 150 mm L = 850 mm
MG12 J84 J85 J86
1 Red 4 4 Red 4
SM_MOTOR_DISP_Z_MOVE 2 Green 3 3 Green 3
3 White 2 2 White 2 J13 on IO-board
4 Yellow 1 1 Yellow 1
B B
MOTOR STEPPER 2-PHASE Molex KK 4 pole Molex KK 4 pole

J1 on FLEX-board
L = 150 mm L = 850 mm
MG13 J87 J88 J89
1 Red 4 4 Red 4
SM_MOTOR_DISP_CON_Z_MOVE 2 Green 3 3 Green 3
3 White 2 2 White 2 J14 on IO-board
4 Yellow 1 1 Yellow 1
MOTOR STEPPER 2-PHASE Molex KK 4 pole Molex KK 4 pole

J2 on FLEX-board
L = 1000 mm
MG14 J90
1 Black 4
SM_MOTOR_DISP_LARGE_DISP 2 Red 3
3 Green 2 J11 on IO-board
A 4 Blue 1 A

Title
2 phase stepper motors


5 4 3 2 1
5 4 3 2 1
L = 600 mm
D D
MG15 J91
1 Yellow 1
2 Blue 2 J37 on IO-board
3 Red 3

Area = 0.22 mm2 Molex KK 3.96
SM_MOTOR_ROT_MOVE
QE_ENCODER_ROT_MOVE_POS
J92 J93
5 Red 1
4 White 2
2 Black 4
1
AMP 103686-4/640442-5
C C
MG16 J94
R1 1R/5W R2 1R/5W
1 Yellow 1
2 Blue 2 J38 on IO-board
3 Red 3
R3 1R/5W
SM_MOTOR_DISP_RAD_MOVE
QE_ENCODER_DISP_RAD_MOVE_POS
J95 J96
5 Red 1
B B
4 White 2
2 Black 4
1
AMP 103686-4/640442-5
A A
Title
3 phase stepper motors


5 4 3 2 1
5 4 3 2 1
J97
L = 1200 mm
1
Push-On 2.8 mm
1
J98
+
MG17 Blue 1
VALVE_DRIER_SUCTION White 2 J19 on IO-board
A 3
DC-VALVE
D
-
Area = 0.22 mm2 D
J99 Molex KK 2.54
2
1
Push-On 2.8 mm
J100
L = 1200 mm
1
Push-On 2.8 mm
1
J101
+
MG18 Blue 1
VALVE_CLEAN_DRY_SUCTION_NEEDLE White 2 J20 on IO-board
A 3
DC-VALVE
-
Area = 0.22 mm2
J102 Molex KK 2.54
2
Push-On 2.8 mm
J103
C
L = 1200 mm C
1
Push-On 2.8 mm
1
J104
+
MG19 Blue 1
VALVE_WS1_WASH White 2 J17 on IO-board
A 3
DC-VALVE
-
Area = 0.22 mm2
J105 Molex KK 2.54
2
Push-On 2.8 mm
J106
L = 1200 mm
1
Push-On 2.8 mm
1
J107
+
MG20 Blue 1
VALVE_WS2_WASH White 2 J18 on IO-board
A 3
DC-VALVE
B
-
Area = 0.22 mm2 B
J108 Molex KK 2.54
2
Push-On 2.8 mm
J109
L = 600 mm
1
Push-On 2.8 mm
1
J110
+
MG21 Blue 1
VALVE_DISP_PIP_WATER_FEED White 2 J25 on IO-board
A 3
DC-VALVE
-
Area = 0.22 mm2
J111 Molex KK 2.54
2
Push-On 2.8 mm
A A
Title
Valves 1


5 4 3 2 1
5 4 3 2 1
J112
L = 500 mm
D 1 D
Push-On 2.8 mm
1
J113
+
MG22 Blue 1
VALVE_DISP_PIP_CHOICE White 2 J26 on IO-board
A 3
DC-VALVE
-
Area = 0.22 mm2
J114 Molex KK 2.54
2
1
Push-On 2.8 mm
J115
L = 600 mm
1
Push-On 2.8 mm
1
J116
+
MG23 Blue 1
VALVE_WB_MEDIA_SELECTION_1 White 2 J29 on IO-board
A 3
DC-VALVE
-
Area = 0.22 mm2
C J117 Molex KK 2.54 C
2
Push-On 2.8 mm
J118
L = 600 mm
1
Push-On 2.8 mm
1
J119
+
MG24 Blue 1
A 3
DC-VALVE
-
Area = 0.22 mm2
J120 Molex KK 2.54
2
Push-On 2.8 mm
J121
L = 300 mm
1
B B
Push-On 2.8 mm
1
J122
+
MG25 Blue 1
A 3
DC-VALVE
-
Area = 0.22 mm2
J123 Molex KK 2.54
2
Push-On 2.8 mm
J124
L = 600 mm
1
Push-On 2.8 mm
1
J125
+
MG26 Blue 1
A 3
DC-VALVE
-
Area = 0.22 mm2
A J126 Molex KK 2.54 A
2
Push-On 2.8 mm
Title
Valves 2


5 4 3 2 1

Alegria Service Manual 7 2011-11

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Alegria Analyser

Follow the packaging/ un-packaging procedure to avoid personal injuries, equipment

Power on/off procedure

# Type Size /type Qty

10 Service PC cable Null modem cable 1

The Instrument is divided into different modules such as:

These modules are supported or contains the following:

Mechanics: custom made details (machined parts, fasteners, structural components)

Electronic connections diagram

Fluid system diagram

Wash and Soak station

Dry suction station

Turning plate module

Lid for printer paper

Lid for fluid bottles

Door for loading sample plates

The motherboard is equipped with:

The I/O-board is equipped with:

Each TMS320 processor controls:

The analysis board is equipped with:

See Basic Function test instruction and record

See Annual preventive maintenance test instruction and record

Model: Serial number:

Function Procedure Result

Maintenance performed by:

Annual preventive maintenance instruction and

Maintenance performed by:

Start by checking the obvious things first:

Error Explanation: Description / Solution:

18001 WashBuf2LevelError To low level in WashBuffer 2 bottle

20002 Reference measurement failed during Calibrate: OD reference measurement

25000 OD Calibration error Failed During ODCalibration Init

25001 ODCalibCRVAPIError Error reading

25003 Failed to calibrate Failed to calibrate OD module

30000 Not available

50000 ComBegin Not available

70007 Received unexpected EOT Not available

70009 Connection lost error Not available

Tel. +49 - (0)6131 / 92 58 - 0

Authorized Service representative:

Information (safety, references and comments)

The following pages shows how to remove the air filter.

Remove Door cover

# To do, remove: Required/tools/etc.

# To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)

Ref To do, remove: Required/tools/etc.

Information (safety, references and comments)