MERCK VITALAB SELECTRA VITAL SCIENTIFIC SERVICE MANUAL vitarts Selectra PART NUMBER: 3083-632 Copyright: 1994 Release: 1/94/2.0 VITAL SCIENTIFICMERCK VITALAB SELECTRA CONTENTS SECTION 1 GENERAL Introduction Scope and organization Repair policy warranty Technical assistance Service training Field service information PePPPPP @uarore 2 a a 3 a 8 a x FUNCTIONAL DESIGN Introduction Sample rotor Reagent rotor Sample arm Reagent arm ISE arm Pipettors cuvette rotor Washing unit Diskette drive Monitor Printer Keyboard XT computer Timing principal Mechanical design Reagent arm Sample arn Reagent and sample rotor Measuring unit Wash unit and bellows pump Pipettor ISB arm Motor encoders Detection systems Sample level detection Reagent level detection Water buffer level detection overflow detection for cuvette optical system Fluid and vacuun system Filling of the cuvette rotor Emptying the cuvette rotor Emptying the wash positions Emptying the collecting cask BEL Eb oeaubone BGBES BuodebeE DREN UYU EN NUNN NY NEN NUN ENN NNN OVYRYYNNY BUR DODD AUS RE ARWODUEBUELDENEE EEE EE RPPPPPP BORE VITAL SCIENTIFICMERCK VITALAB SELECTRA SECTION 3 SYSTEM ORGANIZATION Introduction XT computer assembly XT core module Hercules Graphics Board Hercules Graphics Board (conventional) Hercules Graphics Board (industrial Multi I/O board Multi 1/0 board (conventional Multi 1/0 board (industrial) RS 232 card RS 232 card (conventional) RS 232 card (industrial) RAM/ROM board system board Motion control board Stepper motor circuit Power supply Temperature control board Temperature control cuvette rotor Input amplifier Differential amplifier Dual followers Peltier driving circuit Temperature control reagent needle Input amplifier Differential amplifier Driving circuit Lamp voltage and temperature driver Photometer board Photometer circuit Water detection circuit Liquid detection sample needle Power supply Printer control board bE bb bb GheRLOELOREL bb BRERBEREEE bhb BORE BE LVEBELUELUYUUUBUEBEULUULLEBOELUOY bbb BUDDADNANEEATET DS RURSERNONSNONAE INSTALLATION AND MAINTENANCE @ g 8 3 8 g - Introduction Unpacking and installation Preventive maintenance Scheduled maintenance Test and diagnostics procedures Serial interface installation Introduction Software settings Serial output format Interface cables DR aR a Ra bodburooeE BORE CONTENTS VITAL SCIENTIFICMERCK VITALAB SELECTRA CONTENTS SECTION 5 MECHANICAL ADJUSTMENTS PAGE 5.1 Introduction 5.1 5.2 Bellows pump adjustment. 5.2 5.3 Wash unit adjustment 5.3 5.4 Reagent rotor adjustment 5.6 5.5 Sample rotor adjustment. 5.7 5.6 Lamp adjustment 5.8 5.7 Cuvette rotor adjustment 5.10 5.8 Sample arm adjustment 5.11 5.9 Reagent arm adjustment 5.13 5.10 Vacuum sensor adjustment 5.16 5.11 syringe tip adjustment 5.18 5.12 Filter wheel adjustment 5.19 5.13 Opto encoders adjustment 5.20 SECTION 6 ELECTRICAL ADJUSTMENTS ‘PAGE 6.1 Introduction 6.1 6.2 Power supply adjustment 6.1 6.3 Photoneter board adjustment 6.2 6.4 Lamp voltage adjustment 6.4 6.5 Temperature adjustment cuvette rotor 6.4 6.6 Temperature adjustment reagent needle 6.4 SECTION 7 ERROR HANDLING PAGE Ted Error code list Tad Tedd Flag errors Tal Te2.2 Hardware errors 7.3 7103 280 errors 7.3 71.4 Vacuum, water and waste errors 14 7165 Lamp and temperature errors 15 7.1.6 Pipettor errors 1.6 7.167 Measuring disc errors 7.9 7.168 Sample and reagent arm errors 7.13 7.1.9 Sample and reagent disc errors 7.15 7.1.10 ISE errors 7.17 7.2 Trouble shooting 7.22 762.2 Power on sequence 7.21 7.263 List of probable failures 7.26 763 Support tools 7.27 7.3.1 2 Absorbance test box 7.27 7328) Mechanical adjustment tool 7.27 7.3.3 Printed circuit board repair 7.28 SECTION 8 ELECTRICAL DIAGRAMS ‘PAGE SECTION 9 MECKANICAL DRAWINGS ‘PAGE VIVAL SCIENTIFICMERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.2 FUNCTIONAL UNITS 242 INTRODUCTION In the figure below you can find an overview of the main functional units of the Merck Vitalab Selectra. isk drive eaPipettors Contrast sae control Wash Position Keyboard Reagent heater Barcode reader fig. 2.1 overview of Selectra 2.1.2 SAMPLE ROTOR The sample rotor of the Selectra is prepared for: 48 samples 10 calibrators 4 controls 3 emergencies 7 pediatrics The rotor is driven by a stepper motor. 2.1.3 REAGENT ROTOR ‘The reagent rotor can contain 26 bottles of 25ml. The reagent disk compartment is cooled by an external cooling unit to 12 °C below ambient temperature. The reagent rotor is driven by a stepper motor.MERCK VITALAB SELECTRA + FUNCTIONAL DESIGN 2.1.4 SAMPLE ARM The sample needle aspirates any programmed volume between 2 and 30 micro litre (in steps of 1 micro litre), and will dispense it into a cuvette of the cuvette rotor. After pipetting, the sample needle mixes the reaction mixture. After sampling and mixing the needle will be washed in and outside. Because the sample arm has to move in two directions the sample arm is driven by two stepper motors; horizontal and vertical. The sampler arm is equipped with a level detector which will detect the liquid level of the sample cup and will give an error message when not enough sample is present in the cup. 2.265 REAGENT ARN The reagent needle will aspirate a programmed reagent volume and will dispense it into a cuvette of the cuvette rotor. Then the needle will be washed inside and outside. The reagent arm must be able to move in two directions and is therefore driven by two stepper motors. The reagent arm is equipped with a level detector to check if sufficient reagent is present. It is also equipped with a controlled heating element to pre-heat the cooled reagent. 2.2.6 ISB ARM Selectra which are produced after the beginning of 1994 are equipped with an extra option to connect the Selectra with an external ISE (Ion Selective Electrode) measuring unit. This external ISE unit is controlled by the Selectra and the measuring rotor is equipped with an extra ISE arm to aspirate the sample. The ISE arn is integrated in the mixer unit. 2.1.7 PIPETTORS The two Hamilton syringes, a 1000 1 and a 100 yl type, are used in combination with two valves for reagent and sample pipetting. The pipetting system is water filled with air bubble separation. Each syringe is driven by a stepper motor, and the detection of the syringe positions is done by opto-couplers. 2.1.8 CUVETTE ROTOR The cuvette rotor contains 48 cuvettes, which are incubated at 37 °C. The path length of a cuvette is 7mm and the volume is 250 wl. The cuvette rotor is driven by a stepper motor. The heating of the cuvette rotor is done by means of two con- trolled Peltier elements.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN the cover of the cuvette rotor is equipped with a heating element to avoid condensation at the innerside of this cover. 2.1.9 WASHING UNIT The washing unit aspirates the cuvette rotor, after the measurement is completed, with 5*400 #1 water. The aspiration is done by means of a bellows pump. The waste is diluted with water and flushed into the waste container. The washing unit is equipped with liquid sensors to detect that the water level in a cuvette becomes too high. 2.4.10 DISKETTE DRIVE The 3.5 inch diskette drive is used for storage o: Selectra System Software Test parameters Patient data Control data and statistics The 3.5 inch DD floppies are DOS compatible formatted and can contain 720 Kbyte of information. 2.1.11 MONITOR The monitor is a 12 inch CR?, which automatically switches off after 5 minutes of not using the keyboard. It can be activated again by just pressing a key. 2.1.12 PRINTER The Selectra has a built~in 40 column Seiko thermal printer and is controlled by a built-in printer control board. The printer control board is connected to the xT computer via a (parallel) Centronics interface. 2.1.13 KEYBOARD The Selectra is equipped with a 101 keys AT keyboard. 10 of the 12 functions keys are used to obtain the desired functions as displayed on the monitor. 2.1.14 XT COMPUTER A built-in xs computer controls the system software, the monitor, printer, bar-code reader and all internal and external serial connections.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.2 TIMING PRINCIPAL Every 20 seconds a complete instrument cycle is performed. In these 20 seconds 6 cuvettes are’ washed, reagent and sample is pipetted and mixed, and 24 of the cuvettes are measured. Because of the cycle time of 20 seconds, the theoretical throughput of the instrument is 180 tests/hour (3x60). In practice the throughput is a little less, due to possible sample blanks and the start-up time which is 13 minutes. In the figure below is the sequence of the 20 seconds cycle shown. 7 8 9 OH wu 1 we 7 we He ii alae eee el shal 0-0 -ragert pensing “sample dlpansirg eave washing fig. 2.2 The 20-second cycle This cycle is fixed and does always take place even if no measurements have to be taken. In that case the reading of the photometer is ignored. Figure 2.3 shows the cuvettes to be measured in the next instrument cycle. Oo AOnrOw%F Ee Pointe fig. 2.3 Measured cuvettes per cycleMERCK VITALAB SBLECTRA 2. FUNCTIONAL DESIGN 2.3 MECHANICAL DESIGN 2.3.2 REAGENT ARM The reagent arm is responsible for the moving of the reagent needle in the correct position. The construction of the arm is in such a way that the driving for the movements is decoupled; the up/down movement and the sideward-rotating movement are driven by separate stepper motors. The reagent arm has in fact four discrete horizontal posititions in which the arm normally is positioned. The positioned represented by the following stepper motor coordinates: cuvette position Wash position Reagent rotor outer position Reagent rotor inner position There are three discrete vertical positions and one floating position: Up or reset position cuvette position Wash position Reagent level position (floating value, depending on the reagent volume) For the discrete positions a value will be assigned with respect to the reset position, which will comply with the number of steps the stepper motor needs for the arm to reach it’s destination. The floating position for the reagent level indicates the arn to lower itself just below the reagent level in the bottle (enough to aspirate 400 m1). This position is determinated by a level detection and the subsequential lowering with a prede- fined number of steps. 2.3.2 SAMPLE ARM The sample arm is responsible for moving the sample needle in the correct position. The construction of the arm is in such a way that the driving for the movements is decoupled; the up/down movement and the sideward-rotating movement are driven by separate stepper motors. The sample arm has five discrete horizontal positions, which are represented by five stepper motor coordinates: cuvette position Wash position Sample rotor outer position Sample rotor middle position Sample rotor inner positionMERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN vertical there are three discrete and one floating position: Up or reset position cuvette position wash position Sample level position (floating position, depending on the sample volume) 2.3.3 REAGENT AND SAMPLE ROTOR The reagent rotor has 26 discrete positions which correspond with the 26 reagent bottle positions. In the outer ring the bottles 1 to 16 are positioned, at distances of 150 half steps. Bottle 17 to 26 are positioned in the inner ring at a distance of 240 half steps. The sample rotor has 72 discrete positions which correspond with the 72 sample cup positions. In the outer ring cup 1 to 47 (odd numbers) are located at 100 half steps distances. The middle ring contains cup 2-48 (even numbers) with also a distance of 100 half steps (with an offset of 60). The inner ring contains 49-72 at 100 steps distance and an offset of 70 steps with respect to position 1. 2.3.4 MEASURING UNIT The measuring unit consist of the following items which are mounted together as one unit: - measuring rotor - filter wheel with lamp unit The measuring rotor is stepper motor driven and the reset position is detected by an opto-coupler. The measuring rotor has 48 discrete positions which correspond with the 48 cuvettes which must be positioned in the lightpath. Since a full turn of the stepper motor is 2400 steps, the distance between two cuvettes is 50 steps. Under the measuring rotor are the two peltier elements mounted which are heating the cuvette rotor. The selection of the wavelength is automatically by an 8- position filter wheel. The standard mounted filters are 340, 376, 405, 436, 505, 546, 578, and 620 nm The filter wheel has 8 discrete positions which are 48 steps away from each other. The reset position is detected by an opto-coupler. The lamp unit consist of a lamp holder with a mechanism for adjusting the lamp.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.3.5 WASH UNIT AND BELLOWS PUMP The wash unit is built up with a stepper motor which is dri- ving via a timing belt the wash arn. PTET ETS Waste aRM BOARD ~~ _cwerrerome fig. 2.4 Wash unit The positions of the wash arm is detected by three opto-cou- plers. The opto-couplers are mounted on a PCB (the so-called wash arm board). The wash unit has normally three vertical positions. During normal operation two of them are accessed; up and down. Opto 1 is for detecting the up position and opto 2 is for the down position. Opto 0 is for detecting the exchange position of the cuvette rotor. During the reset also the presence of the cuvette rotor is detected. The wash arm will go downwards until it touches the botton of the cuvette. At this position opto 1 should still be 0. When no cuvette is present, opto 1 will be 1, and error NO CUVETTE PRESENT will be displayed. ‘The bellows pump consist of six separate bellows mounted toge- ther in one unit. The bellows are driven by a stepper motor. The bellows pump has two defined positions; a zero position and a predefined full stroke volume position (500 wl is equal to 833 steps). The detection of both positions is done by opto-couplers.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.6 FLUID AND VACUUM SYSTEM A’ general overview of the main parts of the fluid and vacuum system is given in figure 2.13. RAE} sascra ay A A t fig. 2.13 Fluid and vacuum systemev] @ 7] Sigunaios é] wun | eat a @ | 007-4009 | WYU9VIGONIIM-J¥ VELIITIS ss] s Ste oi Se = ¥ ¥ 3 3 } a raeea| | vex 4 Balla : 7 7ev | on [7 2 @| 00-1009 x DHLNAIOS 6] 0 TvLIA WYUSVIC SNISIM~IO VULITIIS Si ; aE care r =| wb evn on sam Temi] ome i sna 8 < (setaeFILTERWHEEL RESET MEASURING DISC RESET MEASURING DISC DRA MEASURING DISC ORB FLTERWHEEL MOTOR M9. MEASURING DISC MOTOR M10 + HEATING ELEMENT COVER CUVETTEN KRANS 6001-554} 6001-407 Xt PB x2 6 PL x6 3 AT-MOTION CONTROL BOARD. 6001-8629 PLZ. A9-PB NS aa ASPB Aldaraaan AS-PLIO, XB— 6001-607 Pig “(AYOG TOLINOD NOLLOW-€¥ = ZANA_L AN LAAN & ad 4% § a} els) sleek} able) slot Zs Ly a ons ERLRRRR RENNER PR ajz eee Sse] 95 ‘ tbl seek! at! sles! ate 8) = wo = feat faeem Fe : Uy LL a 2 remanarareas| eS ses g g Pete eee ee) S z g ir EC 2 z zt ¢ be be fe G 8 2 & 2 = 8 #88 88 Ge & 2 S oO© | ogres nswncsur tea ca re a am on —| wo Bey. 8 gare 483 | “eawaTarreona SDOVSR Ru 2 oe BY —-—| WIRING DIAGRAM SELECTRA ZLANALLAN 142AEE Heating element “RIVOR TORLNOD NOLO Set reerie a SuetCHeCes Feeeiigy L.AnMIe NIACIN AM CrErrtna 7 tl REAGENT ARM HOR, m REAGENT ARM VERT. Me OR A RB ES.HOR, RESVERT. a =a REAGENT SYRINGE | MOTOR MS OWN REAGENS RESET REAGENS DOWN ‘SAMPLE, SAMPLE ‘SAMPLE SYRINGE MOTOR M5 REAGENS VALVE REAGENS, VALVE UP REAGENS: ‘VALVE DOWN VALVE VALVEUP SAMPLE VALVE DOWN PLA ht, 6001-607 ‘A2-MOTION CONTROL BOARD. xp SeWASH ARM (oes PLL__ aE a [2 i}, Ps i PB (i 2 xt eax a t at pe ‘ re ‘ «| (SSeS tle up ara i | Set tow | ° ag a Mal ot KR x |e g og % ° 3 x9 3 2 ae 2 a. 3 i | 4 WATER PUMP i ' och och. ie a xt —ie 8 . aT t w i the PUP = 3 Ly s} As = a 6 mo pecs oe Hho | (We) WATERSAMPLE J<——| i wn H z 5 3 1) 6 S ee 9) ; zB (vio) 7 2 way i AJIDINIC MIACDAM CCLECTDA PARA PAR UNANASPLO XB— 2 “CUVOE TOULNOD NOILOH-9¥ se c FE u C C € c C t L ¢ Z g 3 3 eae ee & of ee ge gd cf ck of af ae )MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.3.6 PIPETTOR The pipettor is a precise diluter with motor driven valves and syringes. The pipettor is controlled via a serial interface. ‘The liquid displacement is controlled by two stepper motor driven syringes; the sample syringe (100 #1) and the reagent syringe (1000 11). Each syringe is connected to a special connection block which contains the valve unit. The valves are @riven by a small Dc-motor via a worm-wheel construction. The syringe drive assembly is shown in figure 2.5. The top and bottom position of the plunger is detected by two opto-cou- plers. SAMPLE SYRINGE 3 opt0- sorte: seitca SWITCH = opto SWETCE STEPPER MOTOR fig. 2.5 syringe drive assembly The lower opto is also used for home initialization, during the reset. The four opto’s are mounted together on a separate PCB. The syringes are made of glass and the plungers are teflon- tipped. The tubes which are connected to the valves are also made of teflon.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.3.7 ISB ARM The ISE arm is integrated in the mixer assembly. In figure 2.6 is the complete assembly shown. The communication with the external ISE measuring unit is done by a serial RS232 inter- face. The serial interface connector is mounted at the left side of the Selectra. Mixer. M : ISE needle ¥ Guide @ Opt ‘f jpto coupler ® (E209 i of fo 0 o| fo P. me) “00 To ISE unit fig. 2.6 ISE arm The ISE needle is driven by an electro magnet which moves the needle into its aspirate position. The lower position of the needle is detected by an opto coupler. The electronical driver circuits for magnet and mixer are located on the ISE driver board. The control of these functions is done by the systen board.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.3.8 MOTOR ENCODERS The stepper motors for sample, reagent rotor and measuring rotor are equipped with so-called motor encoders. The two motor encoders (A and B) are mounted on the shaft of the 200 steps/rotation stepper motors. The encoders ensure a fail-safe operation and prevent malfunctioning of the instrument because of loosing steps. Because at all times, the electrical phase state is known, the motor can only deviate from the intended position by multiples of 4 steps. Therefore a resolution of 50 steps per rotation of the motor is sufficient. A practical solution is a 25 gap - decoder disc with two phase shifted opto-couplers, which provides detection of 100 steps per rotation, while forward and backward movement can be distinguished by the second sensor. ono 400240 > 004300 0 fig. 2.7 Motor encoders The phase relation between the two encoder signals should be around 90 degrees, otherwise the software cannot detect all transitions and loss of steps will be reported, even if no actual loss of steps has occurred.rv U MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 24 DETECTION SYSTEMS The Selectra is equipped with the following detection systems: - sample level detection - reagent level detection - water buffer level detection - overflow detection for cuvette 2.402 SAMPLE LEVEL DETECTION ‘The sample arm is equipped with a detector which will detect the liquid level of the sample and will given an error when not enough sample is present in the cup. The principle of the detection is shown in figure 2.8. ‘SAMPLE ARM No; Loup su oUp SOuREPorrecteo pereere tal OS Fine Fee eee DETECTION window fi _sampte rotor fig. 2.8 Sample level detectionMERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN The principle of this detection is based on capacity. An oscillator signal of 13 kHz is connected to the metal sample rotor. If the oscillator signal is recognized at the metal sample needle, the vertical sample arm motor will be stopped. Note that the oscillator signal must fit in the defined "window detection", therefore the signal must have an ampli- tude of 10V (top-top) and a frequency of 13 kHz. The only way that the oscillator signal can reach the needle is via the sample cup and sample itself (dielectric). When the sample cup is empty, no capacity is detected and error INSUFFICIENT SAMPLE FOR ...... will be generated.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.4.2 REAGENT LEVEL DETECTION The reagent arm is equipped with a level detector to check if sufficient reagent is present. The principle of this detection is given in figure 2.9. i| aoe es ere SEER racreo S oe [es Tine @) REAGENT BOTTLE Ligue SURFACE erecta fig. 2.9 Reagent level detection he detection principle is based on conductivity. The conductivity between the needle and sense probe of the reagent probe is measured. If there is no conductivity (air) the vertical probe will go downwards until there is conductivity measured (reagent) and the probe will stop. When the reagent bottle is empty, no conductivity is detected, the reagent switch will be activated, and error INSUFFICIENT REAGENT FOR .... will be generated.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.4.3 WATER BUFFER LEVEL DETECTION The water cask is provided with a system to detect the water level an@ to switch the water pump on and off. The level is detected by three float switches which are mounted in the water cask (see figure 2.10). hight pumpett middla : pump en x2 water naning out (moot) Jow: ——er7insufient water fig. 2.10 Water level detection The three detection levels are: Level 1 (high) Level 2 (middle) Level 3 (low) When the high switch is active the water pump will be switched off. An inactive middle switch will result in switching on the water pump, the software will check for 20 seconds if the sensor is still inactive and then will give a WATER RUNNING oUT error on the screen. When the water is below the lowest switch, an INSUFFICIENT WATER error will be displayed.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.44 OVERFLOW DETECTION FOR CUVETTE The cuvette rotor is equipped with a overflow detection to avoid that the liquid level in a cuvette becomes too high. The principle of the detection is based on conductivity. The principle is shown in figure 2.11. The resistance between the liquid sensor and the needles is measured; when there is resistance measured the system will report an WATER OVERFLOW MEASUREMENT DISC error. LiquID SENSOR qa a) wast] 0 CUVETTE ROTOR ARM | fig. 2.41 overflow detectionMERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.5 OPTICAL SYSTEM Figure 2.12 shows the optical system of the Selectra Guret Beamsptitter interference Fitter lens Lens. st {=== SSS a Detector YO Diaghrac Reference Oetector fig. 2.12 Optical system The light source consists of a long-life quartz iodine lamp (12V/20W, 2000 hour life-time), and the detector is made of an UV-enhanced silicon photocell. Monochromatic light is achieved by using single IFL (InterFerence Line) filters. The filters are mounted in a steppermotor driven, @-position filter wheel. Depending on the programned wavelength, the microprocessor will automatically select the correct filter, and the filter wheel will move to the correct position. The used IFL filters have an integrated coloured glass filter depending on the wavelength of the IFL filter two types are used. For the low wavelength range a filter is used to reduce the effects from stray-light, by blocking light of higher wavelength For the high wavelength range a filter is used to level difference in energy at the high ends of the spectral range. This will be necessary, because the spectral emission of the quartz iodine and spectral response of the detector are much higher in the visible and near infra-red range than in the near ultra-violet range The filament of the lamp is projected in the lens in front of the filterwheel. After the filterwheel a beam splitter is mounted which splits the light beam; 90% of the signal is going through the second lens and cuvette, and 10% of the signal is going in the direction of the reference detector. The function of the reference detector is to detect and toMERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN eliminate the fluctuations of the lamp. The optimal alignment and lamp intensity can be reached by adjusting the lamp.MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN 2.662 FILLING OF THE CUVETTE ROTOR AND WASH POSITIONS The filling of the cuvette rotor is done by means of a bellows pump which is driven by a stepper motor. The volume is 500 pl per rotation cycle. Totally 5 cuvettes are washed (filled and emptied) at the same time. Also the sample needle is washed with 500 wl water at the wash position. When the water pump is switched on, water will be pumped from the water bottle to the water cask. The water cask is equipped with a system for detecting the water level (see section 2.4.3). When the water level is too low, the water pump will be switched on, and when the level is ‘high enough the pump will be switched off. When the switch-off circuit is defective, the water will flow back into the water container via the overflow connection. The timing diagram in figure 2.14 shows the operating cycle of the concerning components of the fluid/vacuun system.FUNCTIONAL DESIGN 2. MERCK VITALAB SELECTRA Timing diagram fluid/vacuum system fig. 2.14MERCK VITALAB SELECTRA 2. FUNCTIONAL DESIGN The filling of the cuvette rotor and sample wash position is performed as follows: Valve V6 to V11 are not activated, the bellows goes downwards and is aspirating water. The Vé to Vill are activated and the bellows goes upwards and is dispensing water in the cuvette rotor and sample wash position and the valves V6 to Vil are de-activated again. The reagent wash position is filled by the reagent syringe. The reagent valve will move to the aspirate position and the syringe plunger will go downwards and the syringe will be filled with water. Then the valve will move to the dispense position and the plunger will go upwards and water will be dispensed into the reagent wash position. 2.6.2 EMPTYING THE CUVETTE ROTOR The vacuum pump is switched on and V1, V2 and V3 are not activated, therefore the collecting cask is under vacuun. Valve V4 is not activated, the wash unit is going downwards into the cuvette rotor, V2 is activated and the waste of the cuvette is sucked into the collecting cask. The collecting cask will be emptied. 2.6.3 EMPTYING THE WASH POSITIONS valve v2 is not activated and valve V4 and V5 are activated. When v2 will be opened the waste of the reagent wash position will be sucked into the collecting cask. When v5 is de-acti- vated the waste of the sample wash position is sucked into the collecting cask, and the collecting cask will be emptied. 2.6.4 EMPTYING THE COLLECTING CASK Valve V2 will be not activated and v3 will be activated. Pressure will be put on the collecting cask by activating Vi and Vi2, and the collecting cask will be emptied. Valve Vi, V3 and V12 are de-activated again.v MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.2 INTRODUCTION AA general system overview is shown in figure 1. = alex a cave XT-COMPUTER [Sno L[ mentor ASSEMBLY a ean Hy wt l keyboard [ RSaeeA Asss25 Sze becca sone printer cous] com coun bar-code rescoe a eeeaetnee = A SYSTEM BOARD 9 re CRE went ad a ad & core" a Be tt SAR ae Pore ce |= a os = Sb ar tt ae fig. 3.1 System overview The general system control like printer control, disk drive control, graphics control and serial (RS 232) control is done by a built-in x? computer. The communication between the XT computer and the System board is realized by means of a serial line. The System board is connected to six slave controllers, the so-called Motion Control Boards. The Motion Control Boards control all the mechanical movements. Each board contains a (slave) processor and can handle two stepper motors with the corresponding in- and outputs.oO MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION The Selectra is provided with 12 stepper motors with the following subdivision: Board Motor 1 Motor 2 AZ Sample pipettor Reagent pipettor a3 Sample arm vertical Sample arm horizontal Ad Wash unit Bellows pump AG Sample rotor Reagent rotor aT Measuring rotor Filter wheel AB Reagent arm vert. Reagent arm horizontal Po P= |= | pe == | EFRON ||) EPROM | EPROM EPROM |b ePAou| Seo Neal The system Board is also connected to the Photometer Board, where the actual photometric measurement is done. The measured values are transmitted to the System Board and the xT computer. In the drawing above the positions of the @ifferent boards and the concerning EPROM numbers are shown.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.2 XT COMPUTER ASSEMBLY whe XT computer assembly is mounted at the rear of the Selectra underneath the monitor assembly. There are two types of XT; a conventional XT computer and a industrial unit. From about June ‘93 all Selectra’s are equipped with so-called industrial xT/s. Both units are fully compatible, only the construction of the individual boards is different. The XT computer assembly consists of the following items: XT-core module Video module (hercules) Multi I/O module RS 232 card RAM/ROM board A backplane is providing the busconnections between these modules. In figure 3.2 and 3.3 is the location of the boards shown. BACKPLANE RS 232CARD —_ RAM/ROM BOARD XT-CORE MODULE I HERCULES BOARD KEYBOARD | MULTI /O BOARD CONNECTION fia. 3.2 XT computer assembly (conventional)MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION fig. 3.3 XT computer assembly (industrial)MERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION 3.2.2 XT-CORE MODULE The XT-core module is an compact XT computer system located on one module. It uses a 8088 micro processor and is equipped with a bidirectional parallel port and a RS232 serial port. The hardware of XT core module of the conventional and indus- trial computer are equal, only the jumpersetting is different, see figure 3.5 and 3.6. QOD NOAA See ‘SETMG OF rere) We vrs M3 saan Oe s6-9 M5 ste Ws een Wr sae Me ide gy 2 Wh te Bo se = Wht sone vee = wea 2 Ya = vee Ws See va lon “ fig. 3.5 xP-core module (conventional) Pl Expansion bus g2 Serial port (not used) 3 Parallel port (not used) v4 utility/keyboard The real time clock is backed up with a 3.6V Lithium battery. The battery is connected between J4 pin 9 (+BATV) and J4 pin & (GND). Because of the design of the xT-core module it is nearly impossible to repair this module. when defective just replace the complete module.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION © (ane Oils 50 vies BEWBERE © a ye Gl vo toe co ws =o xT mil ‘SETTING WI et? WO: close WZ :2-3:4-5:7-8:6-9 | WA: open wa: Wit 1-2 Wo WB 2-3 WS = Wi +2-3 Wo = WIS 1-2 wre W6 = open we: WAT open wos fig. 3.6 xT-core module (industrial) PL Expansion bus z2 Serial port (COM 1) 33 Parallel port (LPT 1) a4 Utility/keyboard: MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION Vv i j When a XT-core module is replaced by a new one, the software | 1 will automatically update the software settings of the module | | when the Selectra is starting up. The correct settings of the XT module must be as shown below: | cM/XxT Setup Date (mm/dd/yyyy) 11/09/1992 Time (hh:mm:ss) 09:09:15 ist floppy 720K 2na floppy None Video Mono | EMS I/O address 298H | EMS Memory address CO000H 1 CPU speed Normal na DMA Normal Watchdog Timer Disabled Serial Boot Loader Disabled Size Address Socket 0 64K DOO0O Socket 1 64K E0000 Hot Key Setup Enabled Enhanced Bios DisabledMERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION 36262 HERCULES GRAPHICS BOARD There are two types of Hercules Graphics Board one used in the conventional computer and the other used in the indus- trial. 3.2.2.1 HERCULES GRAPHICS BOARD (CONVENTIONAL) The function of the Hercules Graphics board is to control the video monitor and the built-in printer. Figure 3.7 shows the lay-out of this board. The general * ae features of this board are: graphic mode 720h * 348v text mode 80 column * 25 line built-in printer port p64] we6sss [1] p 4464 5 Eee J4 J6 fig. 3.7 Hercules Graphics board (conventional) a1 Light pen connector (not used) g2 disable/enable printer (open = enable) 33 disable/enable ROM (open = disable) va video port 35 printer portMERCK VITALAS SELECTRA 3, SYSTEM ORGANIZATION 3.2.2.2 HERCULES GRAPHICS BOARD (INDUSTRIAL) The function of the Hercules Graphics Board is to control the video monitor. The board can operate in four video modes; MDA, CGA, Double Scan CGA and Hercules Monochrome Graphics Adaptor: For Selectra this modules is configured as Hercules Monochrome Graphics mode with the following features * graphic mode 720h x 348v * text mode 80 column x 25 lines 3.2.3 MULTI I/O BOARD There are two types of Multi I/O modules; one used in the conventional XT computer and one for the industrial xT. Thew modules are not compatible. 3.2.3.1 MULTI I/O BOARD (CONVENTIONAL The multi I/O board has the following functions: * floppy drive control * two serial RS232 ports control * one parallel printer port There are four different types of modules which are fully compatible. Figure 3.8 up to 3.11 shows the lay-out and the jumper setting of the modules.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION v | Prey Remove cover after installation ! 4-6 eer 2 10-9 i eR i 3 16-1 = 0-18 ‘ GD O GI ' Ble t | a : al : wo ts } 1 © | | | | | | fig. 3.8 Multi I/O board (conventional)MERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION It (Ose 22 OSE Bitz etd & a Remove cover after JT :0PEN installation B07 CLOSE ’ 310: OPEN a Fie ean EA aff as 8 8 pL, bea||ch i co 7 fig. 3.9 Multi 1/0 board (conventional)© MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION | 23 u & 3 e fa sBoK 2x50 408 409 4B: a fig. 3.10 Multi 1/0 board (conventional)MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 39 CLOSE. Remove cover after installation £ & a 12 ‘408 469 EEE al ax 5 =EEET fig. 3.11 Multi I/o board (conventional)MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.2.3.2 ‘The multi I/O board has the following functions: MULTI I/O BOARD (INDUSTRIAL) * floppy drive control * two serial RS232 ports control In figure 3.12 is the board shown. lay out and the jumper setting of this wi we W3 ws WS Wo wr wa Wo 235) wen = nen + open = dose + dose + dose open lose 6 WO + dose Wat = open WO 59-10: fig. 3.12 Multi 1/0 board (industrial PL PC expansion bus a2 scsi interface (not used a3 floppy drive interface w4 RS 232 serial port (COM 2)MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.264 RS 232 CARD There are two types of RS232 cards; one used in the convectional xT unit and one used in the industrial one. 3.2.4.1 RS 232 CARD (CONVENTIONAL) The function of the RS 232 card is to provide the serial connection for the bar-code reader and a second serial connector (RS 232A). There are three different types of cards used which are fully compatible. Figure 3.13 up to 3.15 shows the lay-out and jumper setting of the three types. 0. fig. 3.13 RS 232 card (conventional) fig. 3.14 RS 232 card (conventional)MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION g Ba i & = ~ ALCOA fig. 3.15 RS 232 card (conventional) 3.2.4.2 RS 232 CARD (INDUSTRIAL) The function of the RS 232 card is to provide two serial connections (COM 3 and COM 4) and a parallel Centronics con- nections (LP? 2) for the external result printer. The lay out and jumper setting is shown in figure 3.16.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION SETTING | Wt: Wit: 2-3 Ww: WO = 2-3 i Ws WB: 2-3 i Wh WH: 2-3 ' WS WS = op Wo: WAG = pen ' Wr: WAT = pen WB: WB: open Wo: We + dose | Wo: W720 + close oO fig. 3.16 RS 232 card (industrial) gL RS 232 port (COM 3) a2 RS 232 port (COM 4) 33 Parallel port (LPT 2)MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.2.5 RAM/ROM board There are two types of RAM/ROM board; one used in the conven- tional xP unit and one used in the industrial one. The RAM/ROM board contains a number RAM’s and an EPROM for booting the Selectra. The RAM memory consist of 128 kbyte non-volatile RAM for storing system data like: communication info blank data reagent positions test parameters reagent/cuvet incompatibility reagent left result buffer error info and system parameters like: date format auto evaluation printer switch RS 232 format extended auto increment RS 232 device identity auto rerun maximum SD blank save before clear blank time 3.3 SYSTEM BOARD The overall functional control of the Selectra is done by the systen board and is exercised by an 280 microprocessor. The program for the system board is stored in an EPROM device. The system data memory (RAM) consist of a 32 kbyte CMOS RAM and is used for storage of intermediate results. he interface between the system board and the motion control boards is controlled via the three Serial Input Output (280- SIO) devices. The Killer Input output (z80-KIo) is an integrated device which contains a CTC (Counter Timer Control), a PIO (Parallel Input Output) and a SIO. The crc is used for A/D conversion of the measuring signal an timing control. The KIO also generates a clock signal (CLK) for the SI0’s with a frequency of 3.6864 Mhz. The PIO controls the valves V1 to V12 and the signals coming from connector PL3 (cuvette and needle temperature, lamp on/off, needle on/off, disk on/off). he SIO controls the serial connection of the XT computer assembly. The schematics and the wiring diagram of the system board is shown in section 8 of this manual.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.4 NOTION CONTROL BOARD In figure 3.17 is the block diagram given of the motion con- trol board. It is not within the scope of this manual to i explain the operation and architecture of the 280 processor All technical information about the 280 can be found in the manufacturers documentation The stepper motor control and the power supply is explained hereafter. DTAL fy eLock | is} a z00 ge ig} 3 KeRESS |_Beccoen’ Pro ick rid Seconer MOTION CONTROL BOARD fig. 3.17 Motion Control Board Note that there are six motion control boards in the Selectra with each a different function, therefore the EPROM version determines the function of the board.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION Beall STEPPER MOTOR CIRCUIT Figure 3.18 shows the block diagram with the stepper motor circuit. Steoper_metor > Pio Stepper Drivers er cantratier mi praceaeor fig.3.18 Stepper motor circuit The two stepper motors and their control circuits are identical. The first two blocks are the microprocessor and the PIO which is a part of the I/O array. In principle there are only four lines necessary to control the stepper motor device (4297). This device has 8 output lines which control the stepper motor drivers (16203). On the output lines of the drivers fast ramping rectifiers can be found, to protect the drivers against high induction peaks. There are also LED’s to indicate if the output of the driver is activated. When the stepper motors are normally running it seems that all LED’s are on because the switching time is much faster than the human eye can follow. The voltage for the stepper motors is supplied by a secondary switched power supply with a nominal voltage of 30V. 3.4.2 POWER SUPPLY All necessary power supplies to operate the motion control board are made on the board itself. The transformation of the main power (220 or 110V) is done by a ring transformer. Each notion control board is provided with such a transformer The output voltage of the ring transformer is transformed to a De voltage via a bridge rectifier (B1). The voltage is then approx. 35V (Vp), depending on the load which is connected.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION The following voltages are present on the board. +30V for the stepper motors 4+5V for all logic +5V for the stepper motor controllers +10V for the RS232 interface. +15V which is not used ve sv ve rr dover [OO sw a3 afigeWREF our ee Wwe Gus 1 osc he i o uw apilatiog pulse sanse tine cutput vettoae fig. 3.19 | Switched power supply block diagram The main power supply is the switched power supply with a nominal value of +15V or +30V. Figure 3.14 shows the block diagram of the main power supply. +15 Volts: The +15V power supply is built around U1, which is a regulated pulse width modulator. The input voltage is a unregulated 35 volts supply voltage (Vp). This device generates a +5 volts reference voltage (pin 16) and is connected via a resistor divider (2.5V) to the IN+ input (pin 2). The IN-input (pin 1) is connected to the output voltage via the same resistor divider. ‘The resistor are chosen in such manner that if the IN-voltage is 2.5 Volts the output voltage is then +15 Volts. Depending if the IN- voltage is lower or higher than the IN+ voltage the pulse width of the output (pin 11) is controlled. This means that the duty cycle of the output voltage (pin 11) varies if the +15 Volts output voltage varies. |MERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION Depending if the output voltage at pin 11 is zero or at maximum (this is a pulse modulated signal) 35 Volts, one of the transistors (96 or Q7) is driven into saturation. If the output voltage at pin 11 is high, Q7 is conducting and the coil LL1A is loaded. The next time the output voltage at. pin 11 will be zero and transistor Q6 is conducting. At this time the charge of coil LLIA is then transferred to the load. Because the output voltage (+15V) is sensed by the pulse width modulator, the output duty cycle is regulated in such manner that the two transistors are switched in such a way to keep the output voltage at +15 Volts. Transistor Q7 needs a special driving circuit to drive the transistor into saturation. The gate voltage must be higher than the Vp voltage (+ 35V). This higher voltage (45V) is made with the help of the oscillator output of the modulator (pin 4). The two driver control circuits are designed in such manner that always one of the driving transistors (96/7) is driven into saturation. fig. 3.20 15 Volts output doubling.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION v + 30 Volts. As shown in figure 3.20, the output voltage of 15 Volts is also transferred to the other windings like a transformer. Because the two separate windings are connected together in series, the output voltage will be twice as high as the input voltage. This 30 Volts power supply is used to control the stepper motors. + 5 Volts. The +5 Volts is made from the +15 Volts and is regulated by a | standard 7805 voltage regulator. The output voltage (Vss) is used to control all logic. ~ + 5 Volts. VU The second +5 Volts is also made with an 7805 device. This voltage is only used for the stepper motor controllers. +/- 10 Volts. i This voltage is generated by the RS232 controller/driver (MAX232), and is only used for the RS 232C serial interface. on board fuses. on the processor board is one fuse present to protect the circuit (Fl 4A Slow Blow).MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 365 TEMPERATURE CONTROL BOARD The temperature control board has the following functions: - temperature control of the cuvette rotor - temperature control of the reagent needle - lamp voltage control and temperature driver for cuvette cover 3.5.2 TEMPERATURE CONTROL CUVETTE ROTOR The cuvette rotor is heated by two peltier elements and the temperature is measured by a linear thermistor network. This network consists of two precision resistors, which are mounted on the board. The thermistor is mounted inside the cuvette rotor assembly. The thermistor is connected to a 1V precision voltage supply and is wired to produce a voltage output that increases linearly with the temperature. The temperature control circuit can be divided into a number of separate circuits with the following functions: - input amplifier - differential amplifier - dual followers - peltier element driving circuit Figure 3.21 shows the block diagram of the temperature con- trol. A complete schematic diagram is given in section 8 of this manual.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION Eloments inet, >. ee wor mae TEMPERATURE CONTROL CUVETTES fig. 3.22 Temperature control cuvette rotor 3.5.4.2 INPUT AMPLIFIER The input amplifier circuit is built around Ic12 which is a voltage OP-AMP (OP07). The purpose of this amplifier is to amplify the voltage output of the thermistor (5.76 nV/*C) to an adequate level. The amplification is approx. 70x, therefore the output voltage of IC12 is approx. 400 mV/*C fo extend the dynamic range of the amplifier, the inverting C input of IC12 is derived from a reference voltage of 408.8mV. 3.5.1.2 DIFFERENTIAL AMPLIFIER The second stage of the temperature control consists of a differential amplifier (C4) and a compensation circuit board, which is mounted at the front of the Selectra. ‘The compensation board consist of a adjustable current source which is used as a remote sense temperature application. Tc4 will amplify the difference between the inputs. 3.5.2.3 DUAL FOLLOWERS The output signal from the differential amplifier is connected to the inputs of the dual followers (IC5a and b). Depending whether heating or cooling is required, the output eee of the differential amplifier is positive or negative.MERCK VITALAB SBLECTRA 3. SYSTEM ORGANIZATION The two dual driver outputs are connected together via diodes and connected to the switched power supply. This signal which is connected to the switched power supply varies between OV and -15V. When the input signal is ov the output voltage of the power supply is also ov. Depending which output of the followers is positive, one half of the bridge driver is active. This means that the two outputs are controlling the current direction through the peltier elements, and therefore selecting heating or cooling. 3.5.1.4 PELTIER DRIVING CIRCUIT The peltier elements driver circuit is built around the four FET transistors (T2, T3, T4 and 75). The two peltiers are connected in series’ between point 1 and 4 of PL9. If the measured temperature is lower then 37°C, the output voltage of Ic4d is positive. The output voltage of IC5a will also be positive and will drive 2. T6 will take away the gate voltage of 73. The current through the peltier elements is going via 75, the peltier elements and T2 to ground. If the measured temperature is higher then 37°C, the output voltage of IC5b will be positive, and will drive 14. The current through the peltier elements is then going via 73, the peltier elements and T4 to ground. The microprocessor on the System board can monitor if the temperature is within + 0.1 ‘C by means of the READY-signal (RDY). If the temperature is not reached within 5 minutes the microprocessor will switch-off the peltier elements and will generate the CUVETTE TEMPERATURE ERROR.MERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION 3.5.2 TEMPERATURE CONTROL REAGENT NEEDLE The temperature of the reagent needle is controlled by a heating element inside the needle. The temperature is measured by a NTC (Negative Temperature Coefficient). The NTC (with a resistance of 22k at 25°C) is connected to a 1V precision voltage supply and is wired to produce a voltage output that increases with the temperature. The temperature control circuit can be divided into a number of separate circuits with the following functions: - input amplifier - differential amplifier - driving circuit In figure 3.22 is a schematic diagram given for the tempera- ture control. A complete schematic diagram is given in section 8 of this manual. 1V 408.8mV Input t ‘Amplifier Differential amplifier eee 5 Switched Heating coat a Element eal Supply }-—— CS TEMP OK ney. at+/-0.1 C TEMPERATURE CONTROL REAGENT NEEDLE fig.3.22 | Block diagram temperature controlMERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.5.2.1 INPUT AMPLIFIER The input amplifier circuit is built around Ic9 which is a voltage OP-AMP (OP07). The purpose of this amplifier is to amplify the difference at the inputs to an adequate level. The amplification is approx 70x. The non-inverting input is derived from the NTC output (0.408 V at 37°C). To extend the dynamic range of the amplifier, the inverting input of Ics is derived from a reference voltage of 408.8 mV. 3.5.2.2 DIPFERENTIAL AMPLIFIER The second stage of the temperature control consists of a differential amplifier (IC10a). The output of Ic9 which corresponds to the actual temperature is present at the inverting input of Icloa, while the other input is connected to the reference voltage. This reference voltage can be adjusted and is derived from the 10 volts reference source. cl0a will amplify the difference between the inputs. 3.5.2.3 DRIVING CIRCUIT The output signal from Icloa is going via a amplification circuit (Ic10d) to the switched power supply circuit. The microprocessor on the System board can monitor if the temperature is within + 0.1 °C by means of the READY-signal (RDY). If the temperature is not reached within 2.5 minutes the microprocessor will switch-off the heating element and will generate the REAGENT. NEEDLE TEMPERATURE ERROR. 3.5.3 LAMP VOLTAGE AND TEMPERATURE DRIVER CUVETTE The lamp stabilizer circuit is built around Ics, a voltage regulator. One of the lamp leads is always connected to the voltage (12.5 V). The other lead is connected to ground via FET transistor T1. When the power is applied, the gate of the FET is controlled via transistor R40 and diode D9. The lamp voltage is measured via a resistor network and compared against the reference voltage. The regulator controls the gate of the FET transistor in such a way that the measured amp voltage is the same as the reference voltage. The lamp voltage can be adjusted with P2. The lamp can be switched on and off by activating or deactivating opto-coupler 0C1B. The lamp will be activated by the microprocessor on the system board. The overcurrent through the FET transistor Tl is pro- tected by means of transistor 76 and R5. The cover of the cuvette rotor is equipped with a_heating element to prevent condensation. The power supply for this element is supplied by this circuit (oUT+ and oUT-).MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.6 PHOTOMETER BOARD on the Photometer Board are the following electrical circuits located: - photometer circuit - water detection circuit oe liquid detection circuit for the sample needle In figure below is the block diagram of this board shown. y Peon PHOTO bora METER = [p= My y ser | CIRCUIT so (Fer) mie] Hf we esa) WATER ae was OEE] DETECTION | ossey @— 4 crour x0) esa ase Le SAMPLE me vononcomo. te |] LOUD eae U DETECTION soa cms fig. 3.23 Block diagram Photometer Board The complete electrical diagram is given in section 8 of this manual. |MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.6.2 PHOTOMETER CIRCUIT The photometer circuit can be divided into the following two circuits: - programmable input amplifier ~ Lin/log converter on the photometer board are two identical circuits present; one for the actual measurement (PHOTOM), and one for the reference measurement (LAMP-REF). The function of the xeference measurement is to compensate variations of the lamp. Because these circuit are identical only the operation of the actual input amplifier is explained. The principle of the input amplifier is illustrated in figure 3.24. The figure shows the actual amplifier (IC10) with one of the photo-diodes as input source and four switches controlled by the microprocessor (of the system board). By means of these four switches, sixteen different possibilities for the gain settings can be progranmed. al " Ic10. Vx i “ Gain fe be Scania 1 6 olored 15. fig. 3.24 Input amplifier principle diagram Referring to the electrical diagram of the photometer board of section 8, the gain setting is performed by four signals, which are derived from the PIO of the System Board (P-GO to P-G3). These signals directly control the FET switches of ca. Three of these FET switches perform, in combination with the relay contact from REL2, the actual amplification setting, byMERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION switching resistors R26, 29, 34, 36, 37 and 40 into the circuit, whilst the remaining resistor Ré3 is switched by means of the relay contact. The relay REL2 is switched by means of a FET switch IC12c and is controlled by the fourth signal (P-G3). The same fourth signal which controls the relay, controls also FET switch ICl4c and has a compensation function. This FET switch will switch resistor R24 into the circuit from amplification step 8 and onwards. Note that the functions are reverse, from amplification step 0 to 7, P-G3 is active high, this means that REL2 is activated and FET switch ICl4c also, and will short the resistor R24. The gain factor (per step) equals the power of 1.5 and can be programned in 16 steps from 1.5 to the power 0 up to 1.5 to the power 15, which will result in an amplification of 1 and 438 respectively. Changing the amplification by 1 step, will cause an absorbance change of approximately 255 mAbs (log 1.5 x 10/6.88 = 0.255 Abs). According the law of Lambert Beer the absorbance is proportional with the lightpath. The log 1.5 value has to be recalculated because the amplification steps are based on a "standard" lightpath of 1onm. Therefore the absolute range is 15 x 0.255 = 3.82 Abs. During the ‘Blank’ procedure a series of actions is started to produce the optimal gain for the programmable input amplifier. Because the gain of this amplifier is controlled in steps only, It needs no argument that it will be virtually impossible to control the amplifier to produce a certain voltage, corresponding to 100% transmission (0 Abs.) exactly. Therefore, utilizing a method of ‘successive approach’, commonly used in A/D-converters, the gain is set in such a way that it drives the output of the amplifier to fit within a specific window. This window determines the maximum and minimum negative absorbance limits of the instrument. The lower limit is fixed at 145 mAbs, and the upper limit of the blanking window is 436 mAbs. The theoretical range of the photometer is 0.436 + 3.82 = 4.256 Abs., but at this maximum amplification the noise and drift effects are also high. Therefore a maximum amplification of 12 is chosen. At amplification step 12 the maximum absorbance value is 3.06 Abs. The lowest level that still can be measured is therefore 3.496 Abs. (3.06 + 0.436). The table in figure 3.25 illustrates how the FET switches must be set to produce the required gain. Note that if during the blank procedure, the instrument is not able to produce a gain, resulting that the absorbance value is within the ‘blank’ range an error will be displayed. Right after blanking, the output voltage of the input amplifier will be between 5V and 7.94 V, unless over~ range or under-range has occurred.| MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION | ! | G3 G2 G1 Go | RELAY AMPL. ABS. 2 0 0 0 | closed 1 ° a ° o a closed 2.5 0.255 ! ay eeOH a Or | closed 2.25 0.51 | a ° 1 1 closed 3.38 0.765 i 1 2 © © | closed 5.06 1.02 | 1 2 © 4 | closea 7.6 1.275 | a 2 2 0 | closed ai.4 1.53 | 1 1 12 1 | closed a7. 1.785 | 0 0 0 0 | open 25.6 2.04 | 0 0 o 1 | open 38.4 2.295 ! 0 0 2 © | open 57.7 2.55 0 0 2 1 | open 86.5 2.805 o 2 © 0 | open 129.7 3.06 o 2 0 2 | open 194.6 3.315 oO o 1 1. 0 | open 292 3157 i ° 1 iH 1 open 438 3.82 | i fig. 3.25 Amplification steps |MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION hin / log converter: Photo meter boerd System board ' 1 1 cu | rem K10) i | oer ea ! oe F tLe} teis Sa Toae’ | counter t 162 t t LIN-LOG CONVERSION fig. 3.26 Lin/Log converter ‘The conversion is achieved by utilizing the logarithmic discharge curve of a capacitor (C4). The voltage over this capacitor is compared to the linear voltage (Vx) and the time from the beginning of the discharge until both voltages are equal, correspond to the logarithm of the measured signal. The discharge time is measured by starting a counter at the moment that the actual discharge is activated. The counter will be stopped the moment both voltages are equal (measuring and capacitor voltage). The lin/log converter circuit consist of: - Precision voltage source which supplies a very accurate 10V reference voltage (IC18). - Logarithmic curve generator (IC3 and C4) = Comparator (IC13) - FET switches (IC12) - and a digital part which consist of a Counter Time Control (cfc), which is situated on the system board. At the start of the logarithmic conversion, capacitor c4 will be charged to 10 Volts derived from IC18, by means of closing the FET switch (IC12d). After a certain time (1msec.), the counters in the crc will be enabled, while at virtually the same moment, the selection of the input signal for conversion takes place (photocellMERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION signal or reference signal) and the FET switch Icl2d is switched off, causing the logarithmic discharge curve to appear at the output of Ic3. This signal is compared to either a reference voltage via FET switch Ic12a, or to the measuring voltage via FET switch TCcl2b. The reference voltage for the comparison measurement is also obtained from the 10 volts precision reference source, and has a nominal value of 100 nv. During the time the logarithmic decreasing signal is higher than the measuring- or the reference-voltage, depending which of those two has been selected for conversion, the counters in the CTC are fed with the high frequency clock (1.8432 Mhz), derived from the main clock signal (KIO). When the logarithmic decreasing signal is higher than the measuring signal as described above, the output of comparator IC13 is high. This signal is referred as ‘start stop signal’ (PH-STRT) and the time this signal is high is depending of the voltage of the measured signal. This signal together with the high frequency clock are connected to an AND port. The output of this AND port (IC6b) is connected to the CLK/Trigger input of the 16-bits counter of the cTc. When the logarithmic signal becomes less than the measuring / reference signal, the output of comparator C13 is dropped low and the high’ frequency clock will not put through anymore. In case the measuring signal (which is in fact the relative transmission in this stage of the signal processing) is selected, the amount of clock pulses stored in the counters after conversion, corresponds to the logarithm of this signal. To compensate temperature and components variations , measuring-and reference signals are measured alternately. As already mentioned before, the reference value is equal to 100 mVolts, which in turn corresponds to 20.000 counts (and 2.000 mAbs.) after conversion. When due to changes in the characteristics of the circuit the reference value is no longer equal to 20.000 counts, it needs no argument that the measuring value will be affected proportionally! Therefore, measuring values are compensated for variations in the log. conversion circuit by means of the measured reference signal. It will be obvious that this kind of compensation has its limits. Therefore, a range of plus and minus 1000 counts has been established, and as long as the reference value is within the specified window of 19.000 to 21.000 counts, the circuit is assumed to function correctly and compensation will be carried out as described before.MERCK VITALAB SELECTRA 3, SYSTEM ORGANIZATION When a reference value is measured which is outside the specified range, the instrument will give an error.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.6.2 WATER DETECTION CIRCUIT The water cask is provided with three floats which detect the waterlevel in the cask. The electrical signals are transferred via the water buffer board to the photometer board where the actual control of the water pump takes place. The detailed drawings of the water buffer board (6001-621) and the photometer board (6001-622) can be found in section 8 of this manual. The principle is shown in the figure below. igh: pump middle: pump on EL2watorransing ou E604) low: ex7inaufeent water fig. 3.27 Water detection When the highest float is active ("1") the water pump will be switched off. An inactive middle float will result in switch- ing on the water pump, and the software will check for 20 seconds if the float is still inactive an then will give a WATER RUNNING OUT error. When the water level is below the lowest sensor a INSUFFICIENT WATER error will be displayed.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.6.3 LIQUID DETECTION SAMPLE NEEDLE The liquid detection circuit of the sample needle is located on the photometer board and is built around Ic] and Ic2. The detailed diagrams are shown in section 8 of this manual. An oscillator signal of 13 kHz (10V top-top) is made by the oscillator circuit built around opamp 1c2. This signal is connected to the mechanical assembly of the sample rotor. This oscillator signal will be returned this circuitry via the sample rotor, sample needle, the FET transistor of the sample arm board (inside the sample arm) and will be recognized by the PLL (Phase Locked Loop) circuit ICl. The output of ICl will become high and will stop the vertical sample motor via the PIO and KIO of the Motion Control Board (A3) for the sample arm control.MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 37 POWER SUPPLY The DC power supply of the selectra is provided by two switched power supplies (SPS 3160 and 3167) which are mounted at position #1 (A1). fhe primary voltage is routed via the connection terminal to the switched power supply. Note that the power supply accepts input voltages from 100 to 260V with a frequency from 47 to 440 Hz. The specifications of the switched power supplies are as fol- lows: SPS 3160: This power supply is equipped with two connectors; one is used for the AC input (TB 1) and the other (TAB 2) is used for the De output voltages. TAB 2 OUTPUT POWER 1,2 sv LOA max 3,4 GND 5,6 1v 4A max 7 -12V 1A max 8 -5V 1A max These outputs supply the different voltages to the XT, printer, fan’s, etc. , refer to the DC wiring diagran of section 8. SPS_3167:) This power is also equipped with two connectors; TB 1 for AC input and TB2 for the 13V output voltage. This output supplies the voltage to the waterpump (via the water buffer board), the vacuun pump (via the vacuum switch board) and the valves (via the system board).MERCK VITALAB SELECTRA 3. SYSTEM ORGANIZATION 3.8 PRINTER CONTROL BOARD The printer control board is built underneath the mechanical printer assembly and consist of a CPU which controls the thermal head driver, motor driver, printing pulse width cir- cuit and function dipswithes. Because of the small and compact design of the printer mechan- ism and the control board, it is virtually impossible to repair it.MERCK VITALAB SELECTRA 4, INSTALLATION AND MAINTENANCE 4 INSTALLATION AND INITIAL CHECKOUT 4.2 INTRODUCTION This section contains information for unpacking the Merck Vitalab Selectra, and the procedure for installation. Please note that the installation and initial checkout of the instrument must be done by a qualified service technician. Important remarks for installation: cat Install the Merck Vitalab Selectra in such a way that it is not exposed to (high intensity) direct sunlight and vibration (i.e. centrifuges) . - Bvoid extreme high or low temperature and humidity (Ambient temperature 10 to 35 ‘°C, and maximum relative humidity 90% at 35°C non-condensing). = Note that dust, corrosive vaporize, dirt, etc. may affect the performance of the instrument. - The line voltage, preferably a "clean" connection should be selected. Additional connections of instruments with high surge-on (peak) currents to the same line should be avoided. - Do not remove or connect interface cables of the system when the power is on. Power requirements: Analyzer: The Selectra accepts line voltages of 110V (range 95-130) and 220V (range 190-260). Only the line fuses with holder, located at the rear of the instrument below the mains input, has to be checked and the fuses have to be replaced: For 220-240V fuse holder should read 220-240V and two fuses of 6.3A must be placed. For 110-120V fuse holder should read 110-120V and two fuses of 10A must be placed. The power consumption of the analyzer is 600 VA (max). VITAL SCIENTIFIC 4.2MERCK VITALAB SELECTRA 4. INSTALLATION AND MAINTENANCE Cooling unit: The separate cooling unit accepts a line voltage of 110 or 220V. Please note that the line voltage of the cooling unit is fixed and cannot be changed, the line voltage is mentioned at the type plate of the unit. The power consumption of the cooling unit is 350 VA (max). The power cords supplied with the instrument can either be a the 220V (non-polarized), or the 110V type, depending on the type you have ordered. 4.2 UNPACKING AND INSTALLATION Unpacking and installing the Merck Vitalab selectra: The Selectra is shipped in two boxes which contain: * Merck Vitalab Selectra, monitor, accessories * Cooling unit The boxes should be carefully inspected for damage. If there is any major damage, or when parts are missing, this should be reported by means of filling out the Installation forn. The following procedure describes the recommended method for unpacking and installing the instrument: 1) Place the shipping carton with pallet on a flat surface. 2) Cut the tape from the carton top and the remove the carton top. Now are two boxes accessible; the first one contains the monitor and pump unit and second one contains the accessories. The Selectra is fixed to the pallet by means of 4 screws. 3) Remove these fixing screws and the Selectra can be placed into its operating position. VITAL SCIENTIFIC 4.2