Automated SPE Cartridge Extractor Modules. Service Manual

Transcription

1 Automated SPE Cartridge Extractor Modules Service Manual

2 16 Northwestern Drive, Salem, NH Telephone: (603) Toll-Free: (800) USA Only Website: Copyright 2014 by Horizon Technology, Inc. All rights reserved. Horizon Technology, Inc. reserves the right to change the information in this document without notice. No part of this work may be processed, reproduced, or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system, except as may be expressly permitted in writing by Horizon Technology, Inc. SmartPrep and SPE-DEX are registered trademarks of Horizon Technology; Inc. Chemraz is a registered trademark of Greene-Tweed. Windows is a registered trademark of Microsoft Corporation. All other product names herein are used for identification purposes only and are recognized as properties (including trademarks, registered trademarks, and referenced copyrighted materials) of their respective holders. P/N: REV A (Dec 2014) 1

3 Table of Contents Preface... 3 Manual Audience and Intent... 3 Product Safety... 3 Electro-Static Discharge... 4 Personal Protective Equipment... 4 Technical Support... 4 Notes: Preventative Maintenance Cleaning Daily Weekly Monthly... 6 Supplies Required... 6 Lubrication of Rails and Lead Screw... 6 Lubrication of Cartridge Holders Preventative Maintenance Kits/Accessories Kit, 1, 3 & 6 ml Plunger Seal Procedure Kit, 12 Port Valve, Seal & Rotor or Seal alone Kit, Syringe Pump Procedure Waste block Seal Procedure Troubleshooting Service Kits and Replacement Procedures Service Parts List Smartprep Sample or Reagent Valve Complete Module Smartprep Plumbing Kit Procedure - Installation Procedure Driver Board Replacement Installation Smartprep XY Platform Module Sample or Reagent Valve Head (Plumbed) Installation Procedure Schematics Electrical Schematics Tubing Schematics

4 Preface Manual Audience and Intent This manual, which is intended for all service technicians with Horizon Technology product service training, provides the information needed to maintain, troubleshoot, & repair the SmartPrep. The information may contain typographical errors or technical inaccuracies and is subject to change without notice. Modifications or enhancements may also be made to the product at any time. For the most current information, consult the Horizon website at or contact Horizon Technical Support. Product Safety Eye protection in the form of safety glasses or goggles is highly recommended when operating the SmartPrep Module or any chemical processing. If reagents, liquids, or vapors come into contact with the eyes, follow the appropriate first aid procedures set forth in the laboratory s safety manual. Protection of the hands is essential when working with reagents or any hazardous material. Wear gloves selected on the basis of the hazard. If reagents or other chemicals come into contact with the skin, follow the appropriate first aid procedures set forth in the laboratory s safety manual. The SmartPrep Modules are designed for bench top or fume hood operation. If installed on a bench top, the reagent bottles should be placed under a vapor vent exhaust fan. The end of the exhaust hose should be ducted into a local exhaust device to avoid the discharge of potentially toxic vapors and fumes into the laboratory atmosphere. The equipment must be set up and operated in a wellventilated area. Care must be taken when the SmartPrep is in operation, to ensure that your hand is not near the SPE cartridge plunger, when the plunger is moving down into the SPE cartridge. The plunger motor has significant torque and could pinch your hand or finger. Do not work with volatile reagents without adequate ventilation from chemical fume hoods or other protective devices. Any suitable chemically compatible container can be used to contain the reagents. However, it is preferable to use a glass bottle, such that a small hole can be drilled through the cap, allowing the reagent sip line to be inserted through the hole. This will minimize the amount of reagent vapor that can escape in the atmosphere. Identify all reagents with suitable labels. The waste containers can be any suitable container and can be located on the bench beside each SmartPrep Module. During the reagent rinse sequence, reagents are sprayed from the tip of the reagent rinse nozzle. Be sure the reagent rinse cap assembly is securely fastened to the sample bottle to be rinsed before initiating this rinse sequence. 3

5 Electro-Static Discharge Disconnect the power cord FROM BACK OF UNIT before working on the module. Unplugging from a wall receptacle is not sufficient for ESD protection as the power supply in the cord holds a charge To reduce the risk of electrical shock, an Electro-Static discharge mat should be used when troubleshooting or repairing the SmartPrep. Personal Protective Equipment Due to the nature of use for the SmartPrep, it is recommended that proper Personal Protective Equipment (PPE) be used when servicing the SmartPrep. This is to include safety glasses and gloves, but may include additional PPE based on your safety requirements. Technical Support Visit the Horizon website for technical information in addition to that provided in this guide: If you have questions about the SmartPrep extraction system that are not fully addressed in this guide or our website, please contact the Horizon Technology Technical Customer Support Center: Phone: (603) Fax: (603) support-service@horizontechinc.com Customer Support Center hours are Monday through Friday, 8:00 a.m. to 5:00 p.m. EST. The Center provides expert technical support including troubleshooting, repair instructions, service and installation scheduling, and replacement part information. 4

6 Notes: 5

7 1. Preventative Maintenance 1.1. Cleaning Daily On a daily basis when the instrument is in routine operation: Clean up any spills immediately using a soft, dry cloth. Follow that by wiping the area with a cloth made damp with a mild nonabrasive general purpose laboratory cleaning solution. Do not spray a cleaning solution directly onto the instrument. Avoid contact with solvents and remove dirt buildup on the touch screen. To clean the touch screen, use a mild nonabrasive cleaning solution on a damp cloth. Do not spray cleaner directly onto the touch screen Weekly At the beginning of the week when the instrument is in routine operation: Check the gas supply and tubing to ensure that all of the fittings are properly seated and that the tube is not damaged in any way Monthly Routine inspection of the rails and lead screw will prevent erratic movement of the XY shuttle. A thin film of lubricant is needed on each rail and on the lead screw to assure smooth operation Maintaining a thin film of lubrication on each cartridge holder keeps them from sticking in the down position Supplies Required Teflon lubrication or equivalent. Swab or lint free cloth applicator. Clean, dry cloths. Lubrication of Rails and Lead Screw Turn off the power to the unit and unplug the AC power cord from the back. Follow standard ESD precautions Remove the drip tray Remove the side cover from the SmartPrep. Apply a small amount of lubricant on the applicator Coat the exposed sections of rail with a thin film of lubricant Gently slide XY platform by hand to other end of rail Apply lubricant to the now exposed rail 6

8 Apply lubricant to the lead screw on both sides of the mounting block. The screw action will distribute the lubricant along the screw Wipe up any excess or spilled fluid Lubrication of Cartridge Holders Manually push down on cartridge holder Apply small amount of lubricant to applicator Coat holder with thin film Release and press holder up and down should move freely 7

9 1.2. Preventative Maintenance Kits/Accessories This is a list of the standard preventative maintenance kits & accessories that can be purchased at Horizon Technology. Part # Description Kit, 1 ml Plunger Seal Kit, 3 ml Plunger Seal Kit, 6 ml Plunger Seal SEAL Kit, 12 Port Valve (Seal & Rotor) Kit, 12 Port Valve (Seal Only) Valve Seal Disk & Rotor Kit, Syringe Pump Waste block Seal Tool, Waste Block Seal 8

10 Preventative Maintenance Procedures: Kit, 1, 3 & 6 ml Plunger Seal Procedure PURPOSE: The purpose of this procedure is to provide instruction for the preventative maintenance/service of the Smart Prep Plunger using the 1mL,3mL,6mL Plunger Seal PM Service Kits (1mL), (3 ml), (6mL). TOOLS: inch Hex (Allen) Wrench for disassembly of the Plunger top clamp. - Paper Towel PARTS REQUIRED: - Plunger Seal PM Service Kit (1mL), (3 ml), (6mL). The Service Kit includes 2 Replacement Plunger Seals. Plunger Seal Plunger Seals PROCEDURE: 1. Remove the tubing from the top of the Plunger by gently pulling it off the stainless tube. A paper towel may be used to gain a better grip on the smooth tubing. 9

11 Tubing Plunger Arm Plunger Assembly Tubing attached to Plunger Installed Plunger Assembly 2. Loosen the Knurled Nut from the top of the Plunger and hold it on the plunger shaft. 3. Lift the Plunger up and out of the Plunger Arm and Stripper Block. 4. Keep the Knurled Nut with Plunger for reuse. 5. Using a Allen key, insert the end of the Allen wrench into the opening of the set screw located on the collar on top of the Plunger shaft and loosen the set screw. Collar Allen Key Knurled Nut Plunger and Allen Key 6. Carefully slide the collar up off the stainless tube. Place aside for later reinstallation. 7. Carefully slide the Plunger Tip and stainless tube assembly out the bottom of the Plunger Tube. 10

12 Collar Stainless tube Plunger Tip Disassembled Plunger Plunger Seal (O-ring) 8. Remove the old Seal by sliding it up off the Plunger Tip and over the stainless tube. Plunger Tip and O-ring O-ring slid up Plunger O-ring Removed 9. The Plunger may, if needed, be cleaned with Isopropyl Alcohol (IPA). 10. Slide a new Plunger Seal in place on the Plunger Tip. 11. Reassemble the Plunger in the reverse order of disassembly; follow the next step before tightening the collar set screw. 12. With the tip of the Plunger resting on the table, ensure no gap between the collar and the top of the plunger body. (Note: very slight pressure can be applied to preload a slightly worn or leaking seal). 13. Tighten the collar set screw being careful to not crush the stainless tube. 14. Reinstall Plunger, Tighten Knurled Nut securely and attach tubing to top of Plunger. 11

13 Kit, 12 Port Valve, Seal & Rotor or Seal alone Procedure PURPOSE: The purpose of this procedure is to provide instruction for the preventative maintenance/service of the SmartPrep 12 Port Valve using the 12 Port Valve PM Service Kit OR Seal Only Kit TOOLS: - Phillips Head Screwdriver - 9/64 inch Hex (Allen) Wrench - Gloves (in case of un-flushed reagents) - Paper Towel PARTS REQUIRED: The Service Kits include either the Valve Seal Disk and the Valve Rotor (1 each) OR just the Valve Seal Disk Valve Seal Disk Valve Rotor PROCEDURE: 1. Prior to starting 12 Port valve maintenance/service, note the tubing orientation and tube number location for the Reagent or Sample Valve being serviced for later reinstallation. Just past the 12 O clock position will be Reagent 8 (Green 8 tag) for the reagent valve and Sample 10 (Blue 10 tag(s)) for sample valve. (Note: Complete tube locations are shown in the Fluidics Schematic in the Smart Prep Operator Manual Appendix for reference.) Individual tubes need not be removed from the valve head for this service but will be kept together as plumbed from the factory. 12

14 Individual tubes could be replaced as desired during this process but would require replacement tubing (available as a roll from Horizon as PN ). 2. Loosen and remove the four Phillips head screws securing the valve face plate in alternating fashion (similar to removing lug nuts from an automobile wheel), setting screws aside for later reinstallation. Reagent Valve Sample Valve PTFE 3 port 2-Way Valve Phillips head screws Phillips head screws Valve Head Valve Face Socket head cap screws 3. Slide the valve face plate (and line markers) gently down the tubing bundle to expose the valve head and socket head cap screws. 4. Loosen and remove the two socket head cap screws securing the valve head, loosening screws in alternating fashion, and setting screws aside for later reinstallation. 13

15 Valve Head Valve Body Valve Rotor Valve Seal Disk Socket head cap screws 5. Remove the brown valve seal disk to be replaced from the valve head, lifting it off of the two positioning pins. This should be placed aside for later discard as recommended (or cleaning for reuse). 6. Remove the rotor to be replaced from the valve body. This should be placed aside for later discard as recommended (or cleaning for reuse). NOTE: If reusing the Rotor it must be cleaned and the sealing surface inspected for any debris or rough edges 7. Using a paper towel carefully clean any remaining deposits from the valve head or body preparing for installation of new components. Valve Body Rotor Pin Drive Slot Valve Head Seal Disk positioning pins 14

16 8. Install the replacement rotor, first finding the pin on the replacement rotor and inserting into the corresponding drive slot in the valve body 9. Install the replacement seal disk onto the two positioning pins of the valve head, either face up. 10. Align the valve head over the rotor and valve body and insert the socket head cap screws tightening partially and alternatively to retain the spring loaded rotor. Note: Verify that the reassembled tube locations are as noted in Step Tighten the valve head screws (Socket Head Cap Screws) until the valve head is firmly bottomed on the valve body. Rotor pin Seal Disk and Rotor installed Valve Body Valve Head Valve Face Plate Socket head cap screws Valve Head Valve Body 12. Slide up the valve face plate and secure into position using the 4 Phillips head screws removed and set aside earlier, tightening screws in an alternating fashion (similar to tightening lug nuts on an automobile wheel). 13. Slide the tube markers back into position close to the valve as convenient. 14. If removed earlier reinstall the PTFE tube to the PTFE 3 port 2- Way valve immediately above the 12 port valve being serviced. Tighten by hand using care not to cross thread the fitting. 15

17 Phillips head screws Valve Face Plate Tube Markers 15. Having fully secured the valve and reconnected all tubing, the Preventative Maintenance Service is complete. 16

18 Kit, Syringe Pump Procedure PURPOSE: The purpose of this procedure is to provide instruction for the preventative maintenance/service of the SmartPrep Syringe pump using the Syringe Pump PM Service Kit These instructions can be used for the replacement of the old style plug with pin with the newer plug fitting. TOOLS: inch Hex (Allen) Wrench for final home positioning of Syringe Plunger (Piston). - Paper Towel - Paper clip (optional) PARTS REQUIRED: - Syringe Pump PM Service Kit The Service Kit includes three major components including the Syringe Pump Glass Tube, Plunger/Piston, and Plug (with Plug Fitting). Plunger Glass Tube Plug fitting consists of: Seal Barb Screw Plug If piston is removed from glass: 1. Remove plug 2. Slide piston into glass as shown 3. Pull piston into glass twist while pulling 4. Re-insert bottom plug twist as needed 17

19 PROCEDURE: 1. Remove the tubing from the Syringe Pump Plug by gently removing from the stainless tube in Plug. A paper towel may be used to gain a better grip on the tubing. Syringe Pump Plug with Stainless tube connection (old style) Tubing 2. Remove the knurled nuts and retention plate from the bottom of the syringe pump glass tube. Save for reinstallation. 3. Remove the glass tube with plug. If the Plunger does not come out with the glass remove by gentle pulling downward. Place aside for later discard as recommended (or place aside for cleaning and reuse). With a marker indicate the up direction on the glass tube. 18

20 4. Remove the Syringe Pump plunger/piston by carefully pulling downward and place aside for later discard as recommended (or place aside for cleaning and reuse). 5. Remove Plug Fitting and Seal from Plug. 6. To upgrade from older pin style or to replace the Plug Fitting assembly: Slide Screw and washer over feed tube. Insert paperclip into Barb. Carefully work the tubing over the Barb fitting 7. Insert Seal into Plug then finger tighten Screw/Barb into Plug 8. Reinstall Plunger assembly into unit. Carefully rotate plunger so that teeth faced the rear of unit and they engage internal gear. Gently rotate Plug so that Plug fitting is facing outward. 19

21 9. Reinstall the tube retention plate and secure with the knurled nuts tightening snugly by hand to secure. 10. Reset the Home position of the Syringe pump plunger as described in the Smart Prep Operators manual and described in brief here. a. First, determine if the syringe plunger is being driven to the preferred location. If the plunger is not driving far enough there will be a small gap between the syringe plunger and the syringe bottom plug seal. If the syringe pump is trying to drive the plunger further than it should, there will be a continual ratchet sound coming from the stepper motor. If the gap is closed and there is no ratcheting sound, the homing process is complete, otherwise proceed to step b. (Typically starting with the set screw turned in flush with the top of the Plunger will provide a starting point for adjustment.) b. Using the Manual Control feature of the Smart Prep Software, move the syringe to the 6 ml position. c. Using a.050 Hex key Allen wrench, insert the end of the Allen wrench into the opening of the set screw located in the top of the plunger shaft. d. If the syringe plunger needs to be lowered to remove an air gap between plunger and plug, rotate the Allen wrench counterclockwise a fraction of a turn, so more set screw is exposed. 20

22 e. If the syringe plunger is driving too far and makes a ratchet sound, rotate the Allen wrench clockwise, so less set screw is exposed. f. Remove the Allen wrench. g. Using the Manual Control function, move the syringe to the HOME position. h. Visually inspect the gap between the syringe plunger seal and the plug. If there is still a gap, return the plunger to the 6 ml position as in step b and repeat this sequence until the air gap is minimal. 11. Having verified the home position of the syringe pump plunger, security of the components and reinstallation of the tubing connection, the Preventative Maintenance Service is completed. 21

23 Waste block Seal Procedure PURPOSE: The purpose of this procedure is to provide instruction for the preventative maintenance/service of the Smart Prep Waste Block using the Waste Block Seal PM Service Kit TOOLS: - Waste Block Tool (Pick) for removing old seal. P.N PARTS REQUIRED: - Waste Block Seal PM Service Kit The Service Kit includes 4 Replacement Waste Block Seals. Waste Block Seals PROCEDURE: To Change the Waste Block Seals. 1. Position the waste block in the W1 to W3 positions using Manual mode by following these next steps. a. Make sure the Plunger is up before moving the slide in Manual mode. b. Start The SmartPrep software and select the correct Module at the top of the screen. c. Click on the Advanced Options button. d. Click on the Manual Control button. e. From the drop down menu select Slide Home. f. Click on Run Step. g. After the Slide is homed, select Slide Pos. h. Click Run Step to move the slide to the W1 (waste port 1) position. To move to Waste port 2 or 3 later in this procedure change the Slide position W1 to W2 or W3. 22

24 Waste Block Waste Block viewed from right rear of module. 2. Use the pick to carefully remove the old seals from the waste block Pick Pick at Waste Block Seal Removed Seal 3. Install a new seal. The pick can be used to drop the new seal into the waste port. The back of the pick can be used to seat the seal. 4. A cartridge can be lowered by hand from above the waste port to further seat the seal. 23

25 5. The waste block can now be moved in Manual Mode for better access to the next seal. 6. Note: Waste port 4 is for future use and does not need to be replaced unless the XP port is being used. Waste ports are numbered 1-4 left to right when viewed from the rear of the module. Waste Port 4 Waste Port 1 Front View 7. Having replaced each seal requiring replacement, the PM Service for the waste block is complete. Manual mode can be exited and use of the module resumed. 24

26 2. Troubleshooting SYMPTOM PROBABLE CAUSE SOLUTION Vent drips Worn valve seal Replace seal and rotor No dwell time between steps (software) Add dwell time Calibration missing Improper shutdown Re-enter calibration save and exit Syringe does not bottom out Syringe bounces (ratcheting noise) at bottom of stroke Stroke not set correctly Stroke not set correctly Plunger squeals Worn o-ring Replace o-ring Loosen setscrew at top of piston Tighten setscrew at top of piston Fluids above plunger o- ring Plunger not centered on cartridge Fluid above syringe piston Drive board not blinking XY platform will not move in X direction Syringe will not stop trying to pump Fluid on top of waste block Alignment Pre-load too high Worn o-ring Preload too low Waste line blockage Calibration Worn piston Waste line blockage Short circuited driver board Not plugged into harness Motor shorted Liquid level sensor set incorrectly Waste bottles placed above machine Waste block/line blockage Use calibration to align carousel to plunger Loosen setscrew at top of plunger to adjust pre-load Replace o-ring Loosen setscrew at top of plunger to adjust pre-load Is fluid being expelled though waste line? Inspect fluid path for blockage. Use calibration to align carousel to plunger Replace syringe assembly Is fluid being expelled though waste line? Inspect fluid path for blockage. Replace driver board Power down system. Connect harness to board Replace motor and board per procedure Adjust liquid level sensor (5/64 set screws) Place bottles below waste line elevation Repair/replace waste block 25

27 XY movement stutters Rails dry Apply small amount of lubrication (Teflon oil) to rails Lead screw dry Apply small amount of lubrication (Teflon oil) to rails XY will not home Wasteline routing Route wastelines above motor housing causing lines to obstruct Y motion Air bubbles in tubing Kinked tubing Trim or replace Loose fitting Worn valve seal Tighten Teflon fittings finger tight only Replace valve seal and rotor Cartridge holder sticking Holder dry Apply small amount of lubrication (Teflon oil) to rails 26

28 3. Service Kits and Replacement Procedures 3.1. Service Parts List This is a list of the standard service kits & accessories that can be purchased from Horizon Technology. Part # Description REAGENT VALVE COMPLETE MODULE SAMPLE VALVE COMPLETE MODULE PLUMBING KIT DRIVER BOARD REPLACEMENT XY PLATFORM MODULE SAMPLE VALVE HEAD (PLUMBED) REAGENT VALVE HEAD (PLUMBED) /3 ml PIERCING PLUNGER ml PIERCING PLUNGER UPGRADE SAMPLE VALVE TO FEP UPGRADE WASTELINE FOR OIL 27

29 3.2. Smart Prep Sample or Reagent Valve Complete Module Procedure PURPOSE: The purpose of this procedure is to provide instruction for the replacement of a 12 port valve complete module. TOOLS: - ¼ socket wrench - Phillips screwdriver - ESD protective equipment - Gloves (in case of un-flushed reagents) PARTS REQUIRED: - Service Kit: Reagent Valve Module and/or Sample Valve Module REPLACEMENT MODULE SHOWN PROCEDURE: Before any service work is to be performed on a SmartPrep unit certain electrical precautions need to be exercised. With the SmartPrep turned off the power cord needs to be unplugged from rear of unit, not only from the wall. Place SmartPrep on an ESD mat if available and ground properly. Since this replacement requires opening the side panel of the SmartPrep personnel performing this procedure should also be properly grounded. Avoid any unnecessary contact with circuit boards. 28

30 3-way Valves Mark To replace valve first shut down software then power down SmartPrep unit. Unplug power to BACK OF UNIT (not just from the wall). The side panel will have to be removed so proper ESD precautions need to be followed. Disconnect plumbing Remove tubing from syringe and mixing chamber Disconnect from both 3-way valves. Label/mark to identify location Mixing Chamber Syringe Nut x4 Electrical connections: Remove two screws that fasten side panel to unit. Slide towards back to remove panel Disconnect both white connectors from driver board. Disconnect motor connector (white) located at bottom of module No need to remove blue connector from board Remove 4 nuts from bracket (retain for installation) Module will slide outside of unit carefully feed tubing thru unit as module is removed. Connectors To re-install Feed tubing of new module thru empty valve hole until module is positioned on mounting studs Fasten with 4 nuts retained from removal of valve Connect 2 harness leads to board and 1 to motor Re-install side panel and fasteners 29 Re-attach plumbing

31 3.3. Smartprep Plumbing Kit Procedure - Installation Procedure PURPOSE: This chart is to aid in the replacement of SmartPrep tubing. Requires 70 feet of x PTFE tubing ( ). Tubing must be cut with appropriate tubing cutter to create clean cut edges for fittings to be installed properly. Be sure tubing is not kinked. Awl or flaring tool may be needed to aid in inserting barbed fittings into tubing Additional tubing used but not on diagram: Waste Port Block Tubing /4 3 input 5 input with blue markers with green markers 30

32 Reference: for reagent lines require green markers at each end 12 for sample lines require blue markers at each end 8 reagent valve to mixing chamber 16 ¾ waste lines require a marker (1-4) at each end The following each require a 3 piece barb fitting ( ) on one end: 7 Sample valve to 3 port sample valve Reagent valve to 3 port reagent valve Reagent valve to syringe Reagent valve to 3 port sample valve 8.5 reagent 3 port valve to plunger 31

33 3.4. Driver Board Replacement Installation Procedure PURPOSE: The purpose of this procedure is to provide instruction for the replacement of the Smart Prep Driver Board using Service Kit : TOOLS: - Phillips Head Screwdriver - Electro Static Discharge Mat and Wrist Strap - Small Common Blade Screwdriver PARTS REQUIRED: - Service Kit, Driver Board, Loctite (small fastener) The Kit includes a SmartPrep driver board that will require it to be addressed accordingly: Address #1 for SYRINGE Address #2 for REAGENT VALVE Address #3 for SAMPLE VALVE Address #4 for PLUNGER Address #5 for CAROUSEL Address #6 for Y-AXIS (front to back) Address #7 for X-AXIS (side to side) Address Indicator NOTE: Unplug power cord from back of machine (not just from wall receptacle) NOTE: Prior to starting any service on the SmartPrep that necessitates accessing the electronics, it is required that ESD precautions be exercised. Position unit on an ESD mat and be sure operator is properly grounded. 32

34 PROCEDURE: 1. Remove side access panel by removing two (2) screws at rear and sliding panel towards the rear. 2. Board locations are as indicated below #1 Syringe #2 Reagent Valve #4 Plunger #3 Sample Valve #5 Carousel #6 Y-Axis #7 X-Axis 3. Unplug the three connectors from the board. NOTE: X and Y axis boards will require the removal of the X-Y Platform. See X-Y Platform Module. 4. Remove two (2) Philips head mounting screws. Set aside as they will be required for new board. 5. HANDLE BOARD BY EDGES! Carefully remove new board from ESD package. 33

35 6. Using small common screwdriver turn address indicator until arrow points to appropriate number. 7. Apply small amount of Loctite 222 to screw threads of (2) screws from Step 4. Secure board with to module with these screws. 8. Reattach connectors. Assure alignment with board receptacles. 9. Reattach panel by aligning panel with chassis recess and sliding forwards. Be sure inner tabs grab chassis. Fasten with screws from step 1. 34

36 3.5. Smartprep XY Platform Module PURPOSE: The purpose of this procedure is to provide instruction for the removal/replacement of the SmartPrep s X-Y platform ( ). This includes the waste block and horizontal mounting plate TOOLS: - Philips screw driver - Short Philips screwdriver - 5/16 wrench pliers can be used - Loctite medium grade (222) - Pencil - Permanent marker - ESD mat and wrist strap PARTS REQUIRED: - XY Slide W/ Base Plate Service Kit Calibration requires a cartridge and collection rack with glassware The Service Kit includes three major components: base plate that gets mounted into unit, X-Y platform which is screwed to the base plate, waste block assembly which is mounted to the X-Y platform. Waste Block X-Y Platform Base Plate 35

37 PROCEDURE: CAUTION: BEFORE ANY SERVICE WORK IS PERFORMED BE SURE POWER HAS BEEN DISCONNECTED FROM UNIT. UNIT TO BE PLACED ON ESD MAT AND TECHNICIAN IS TO WEAR WRIST STRAP OR EQUIVALENT GROUNDING DEVICE 1. Use pencil to mark current location of base plate. Mark along bottom edge and slots at front of unit. These marks will be used for rough alignment during installation 2. Remove two waste block screws. Do not disconnect tubing. Place waste block aside. 36

38 3. Disconnect ground wire. Hardware will be needed for installation of new assembly 4. Disconnect motor power leads black connector 37

39 5. Unscrew base plate from unit. Using a short screwdriver remove three (3) screws from inside the unit between the rails. Remove two (2) screws at front of machine. Carefully slide platform along rails to expose screws as required 6. Carefully slide assembly out from back of unit 38

40 7. Installation of new X-Y Platform: Be sure waste block is not attached Slide new assembly into back of unit and align with pencil marks Install three screws between rails and two smaller screws at front on unit Connect motor power wires black connector Attach ground wire to stud and fasten with hex nut and star washer Insert waste block into holder and fasten with two screws o Be sure ground wire is attached to one screw with star washer o Position block as far down in bracket as possible. With permanent marker write in serial number on label on back of XY platform 8. Calibration: Refer to owner s manual (CD) a. Insert cartridge into position 13 and place collection rack with hardware onto X-Y platform b. From main menu select Advance Options, Set Up Module, Calibration c. Select Plunger Up d. Select Home Shuttle e. Select Offset this homes carousel f. Select W1 g. Set slider of Move Plunger to 0.1 sec h. Repeatedly select Plunger Down until the tip of cartridge is slightly above waste port #1 39

41 i. Note X and Y directions. Adjust WasteY value then select W1. Waste block will move accordingly. In the above picture the WasteY value needs to be increased to move the waste block under the cartridge. Repeat as needed j. Adjust WasteX value to position cartridge over waste port in the X direction k. Select W4 and adjust values to align cartridge to waste port #4 in both X and Y direction l. Repeat for Tube1 position using T1 m. Repeat for Tube12 position using T12 n. Record all valves for future reference o. Select Save and Exit p. Select Plunger Up q. Save all windows r. Exit program as instructed in manual s. Restart program 40

42 3.6. Sample or Reagent Valve Head (Plumbed) Installation Procedure PURPOSE: The purpose of this procedure is to provide instruction for the replacement of the SmartPrep 12 Port Valve using Service Kit: SAMPLE VALVE or REAGENT VALVE TOOLS: - Phillips Head Screwdriver - 9/64 inch Hex (Allen) Wrench - Gloves (in case of un-flushed reagents) - Paper Towel PARTS REQUIRED: - 12 Port Valve Service Kit (sample) or (reagent) The Kits include the front end components of the valve including the assembled Valve Head consisting of: 12 Port Plate, Gasket and Tubing with markers & fittings, Face Plate with (4) 6-32 screws. Also included are the Seal Disk; Valve Rotor; and (2) socket head cap screws. Valve Seal Disk Valve Rotor PROCEDURE: 1. Prior to starting 12 Port valve service, note the tubing orientation and tube number location for the Reagent or Sample Valve being serviced for later reinstallation. Just past the 12 O clock position will be Reagent 8 (Green 8 tag) for the reagent valve and Sample 10 (Blue 10 tag(s)) for sample valve. (Note: Complete tube locations are shown in the Fluidics Schematic in the Smart Prep Operator Manual Appendix for reference.) 41

43 Individual tubes need not be removed from the valve head for this service but will be kept together as plumbed from the factory. Individual tubes could be replaced as desired during this process but would require replacement tubing (available as a roll from Horizon as PN ). 2. Loosen and remove the four Phillips head screws securing the valve face plate in alternating fashion (similar to removing lug nuts from an automobile wheel). Set aside as spares. 42

44 Reagent Valve PTFE 3 port 2-Way Valve Sample Valve Phillips head screws Phillips head screws Valve Head Valve Face Plate Socket head cap screws 3. Slide the Valve Face Plate (and line markers) gently down the tubing bundle to expose the Valve Head and socket head cap screws. 4. Valve Rotor is spring loaded use care as to not drop Rotor when Head is removed. Loosen and remove the two socket head cap screws securing the valve head - loosening screws in alternating fashion. Set aside as spares Valve Head Valve Body Valve Rotor Valve Seal Disk 43

45 Socket head cap screws 5. Remove Valve Rotor from the Body. Using a small screwdriver blade remove the brown Valve Seal Disk from the Valve Head, lifting off of the two positioning pins. These should be discarded as recommended (or cleaned for reuse). 6. Using a paper towel carefully clean any remaining deposits from the Valve Body preparing for installation of new components. Valve Body Rotor Pin Drive Slot Valve Head Seal Disk positioning pins 7. Before installing the replacement Valve remove the (4) screws securing the Valve Face Plate to the Valve Head. Set aside for now. 8. Slide the Valve Face Plate (and line markers) gently down the tubing bundle to expose the Valve Head and socket head cap screws. 9. Remove screws and set aside 10. Install the new Valve Rotor into the Body by aligning it s pin with the slot 11. Press Seal Disc onto Valve Head alignment pins 12. Align the valve head over the rotor and valve body and insert the socket head cap screws tightening partially and alternatively to retain the spring loaded rotor. Note: Verify that the reassembled tube locations are as noted in Step 1. 44

46 Rotor pin Seal Disk and Rotor installed Socket head cap screws Valve Head Valve Body 13. Tighten the valve head screws (Socket Head Cap Screws) until the valve head is firmly bottomed on the valve body. Valve Body Valve Head Valve Face Plate 14. Slide up the valve face plate and secure into position using the 4 Phillips head screws removed and set aside earlier, tightening screws in an alternating fashion (similar to tightening lug nuts on an automobile wheel). USE EXTREME CAUTION. DO NOT CROSS THREAD. IF SCREW DOES NOT ENGAGE AND TURN FREELY ROTATE COUNTER CLOCKWISE AND THEN TRY AGAIN 15. Slide the tube markers back into position close to the valve as convenient. 45

47 16. Reinstall the tube(s) to the 3 port 2- Way valve immediately above the 12 port valve being serviced as removed earlier, taking care not to cross thread the fitting. Tighten by hand. Reinstall other tubes as specified in tube chart Phillips head screws Valve Face Plate Tube Markers 17. Having fully secured the valve checking for any omitted components and having reconnected all tubing, the Service is completed. 46

48 3.7 Piercing Plunger Installation PURPOSE - This procedure establishes the procedure to replace the standard plunger and stripper block with a Piercing Plunger and Stripper Block - 6/3mL Piercing Plunger , Stripper Block mL Piercing Plunger , Stripper Block CAUTION: PLUNGERS MUST BE USED WITH RESPECTIVE STRIPPER BLOCKS. RISK OF PERSONAL INJURY EXISTS!! TOOLS REQUIRED: - Philips #0 screwdriver. PROCEDURE: - Raise side door to allow access to the plunger assembly REMOVAL OF PLUNGER A) Disconnect Feed Tube B) Loosen Retainer Nut C) Tilt and remove Plunger. D) Protect Plunger from damage 47

49 REMOVAL OF STRIPPER BLOCK E) ** Note orientation ** Flat side up F) Remove Stripper screws (2) (3mL shown) (6mL shown) G) Remove Stripper Block CAUTION: PIERCING PLUNGER HAS EXTREMELY SHARP TIP. USE CARE WHEN HANDLING. 48

50 INSTALLATION: Orient Stripper Block with TOP etch facing up. Align with stripper holes and install fasteners. Tighten screws Remove Plunger from package. Loosen retainer nut. Remove protective cap from tip of plunger VERY CAREFULLY insert tip into Stripper Block. Position Plunger onto drive mechanism Finger tighten Retainer Nut Attach feed tube. Hold tubing as close to end as possible to avoid kinking 49

51 4. Schematics 4.1. Electrical Schematics 50

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59 4.2. Tubing Schematics 58

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