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Rev.

E
1

Introduction
The 2600 Microplate Washer is a microprocessor-controlled automatic microplate washer that
accepts many types of standard microplates and microstrip trays. The instrument will accept
microwells having flat-, round-, or V-bottom configurations. It automatically accommodates
partially filled microstrip trays (dummy wells must be used for partial strips). Plates may be washed
in the A to H direction (8 strips of 12 wells each) or in the 1 to 12 direction (12 strips of 8 wells each)
depending upon the plate orientation in the carrier and the number of wash probes on the head with
user changeable wash heads. The 8-probe wash head is standard, and the 12-probe and 16-probe
heads are available as optional accessories.

Do not attempt to make design changes to the circuitry. Do not install any non-specified replacement
parts. All parts must be obtained through Awareness Technology or your dealer. Consult your dealer
to make arrangements. Use of a fuse of the improper rating may constitute a fire hazard.

Layout
Figure 1 shows the exterior of the instrument, Figure 2 shows the rear panel, and Figure 3 shows the
chassis layout. For clarity of illustration, the aerosol shield is not shown in Figure 1. In Figure 3,
the probe arm and plate bed are removed, and the tubing is not shown.

The interface PCB mounted inside the cover behind the front panel connects to the main PCB by a
26-conductor ribbon cable and header. Two-conductor cables connect the pressure control valve,
the pump, and the pressure relief bleed valve. Four-conductor cables connect the dispense valve
assembly and the sensor input jacks to the main PCB. The mechanism PCB connects to the main
PCB via a 14-conductor ribbon cable terminated with IDC 14-pin DIP plugs.

All AC mains (high voltage) circuitry is enclosed behind the AC cover except the step down
transformer primary.

WARNING

Hazardous line voltages are present behind the AC cover.


Always disconnect the external AC power cable before
servicing the instrument.

WARNING: Microplate Washers may contain


biohazardous material. Refer to the Owner's Manual
for biohazard warnings.

2600 Series Microplate Washer Service Manual


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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
2
Display Keypad
Front Panel

Stainless Steel
Plate bed

Head

Reservoir Cover

Plate Carrier
Figure 1. Instrument Exterior (without aerosol shield)

Pressure
Vacuum
Wash
Rinse Power switch
Waste

Door
Fastener

Waste sensor
Rinse sensor Voltage select
Power inlet
switch
Wash sensor

Figure 2. Rear Panel


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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
3
AC cover

Bleed Vacuum Bleed Wash Rinse Waste


Power outlet pump valve** valve valve Valve*
transformer Pressure
pump ***

Pump
exhaust

Mechanism
PCB EPROM
Main
PCB

Probe
motor

Pressure
Left trimpot
plate
Vacuum
sensor
trimpot

Plate
drive
belt
Plate Probe Mechanism Probe Right
motor sensors base rod plate
sensor
* Refer to the "Waste Valve" subheading in the "Principles of Operation"
section of this manual.
** Only the latest bleed valve configuration is illustrated.
*** Dual pump system only. See Figures 3 and 4 for differences in dual
pump and single pump systems.

Figure 3A. Chassis Layout - Dual Pump System


2600 Series Microplate Washer Service Manual
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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
4
Pressure/
Bleed Wash Rinse Control
AC cover Vacuum
Power valve* valve valve Valve
pump
transformer Pressure Bleed
Valve Outlet

Pressure
Control Valve
Outlet

EPROM
Mechanism
PCB
Main
PCB

Probe
motor

Pressure
Left trimpot
plate
Vacuum
sensor
trimpot

Plate
drive
belt
Plate Probe Mechanism Probe Right
motor sensors base rod plate
sensor

* Only the latest bleed valve configuration is illustrated.

**Single pump system only. See Detail of Pump Brackets Figures 4A to 4C


for differences in dual pump and single pump systems.

Figure 3B. Chassis Layout - Single Pump System


2600 Series Microplate Washer Service Manual
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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
5

Pressure
Pump
Bleed
Valve

Vacuum
Pump

Figure 4A. Detail of Pump Bracket for Dual Pump System

Combination
Valve

Bleed
Valve

Pressure /
Vacuum
Pump

Figure 4B. Detail of Pump Bracket for Single Pump System / Combination Valve

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Rev. E
6
To Vacuum
Sensor To Pressure
Sensor
Control Valve Continuous Duty
Bleed Valve

Exhaust

Check
Valve

Back Door
Red

Back Door
Blue
Figure 4C. Detail Of Pump Bracket For Single Pump System/ Control Valve and
Check Valve

Principles of Operation
System Control
The instrument is based on the 8-bit Z80 microprocessor U1. The software is permanently stored
in a 27256 EPROM U2. An MK48T08 battery-backed nonvolatile RAM (random access memory)
with real-time clock, U3, is used to store data such as calibration and test setups, and also maintains
the date and time. Almost all digital I/O is accomplished with 8255 Programmable Peripheral
Interface U5. Time intervals and pulse widths are measured using the counter channels of 8254
programmable timer U4, which drives the Z80 INT input. The Z80 NMI input is driven by TCNT,
which is generated by the rotation of the plate transport motor.

Dispense
A DC pressure pump produces 5 psi air pressure (adjustable in software) at the top of the wash and
rinse bottles. The fluid is forced up from the bottle but is stopped by a solenoid pinch valve. The
valve is opened for a precise interval under microprocessor control to allow fluid to flow into the
dispense cavity of the wash head, where it is distributed to stainless steel capillary tubes and then into
eight (or the optional twelve or sixteen) microplate wells. A bleed valve allows the instrument to
relieve pressure during standby and when power is removed.
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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
7

Aspirate
A vacuum is applied to the waste bottle through a fine hydrophobic aerosol filter and the aspirate
cavity of the wash head. The vacuum is distributed across stainless steel capillary tubes thereby
aspirating the contents of eight (or twelve or sixteen) microplate wells. Early 2600s were configured
with a waste valve on the inlet side of the waste bottle. See the "Waste Valve" subheading below
for a discussion.

Waste Valve
Early instruments in the 2600 series used a waste valve to isolate the waste bottle from the aspirating
tubes when aspiration was not taking place in order to maintain a vacuum in the waste bottle. The
need to maintain a vacuum on the waste bottle was eliminated by Software Revision SRO which
changed the control logic to enable a vacuum cycle on demand only when aspiration is needed. This
software revision allowed the elimination of the waste valve. The software revision and waste valve
deletion was incorporated in production units starting with serial number 2600-1112. In addition,
some of the earlier 2600 models have been modified with Software Revision SRO or newer and the
waste valve has either been removed or bypassed in the field by removing the tubing from the pinch
bar arrangement on the valve. All other 26XX models (2601, 2602, etc.) began manufacture
following the elimination of the waste valve.

Motion Control
Two DC motors, under bidirectional microprocessor control, turn 1/4-20 machined aluminum lead
screws via neoprene belts and nylon pulleys. One motor is dedicated to vertical motion of the probe
arm, the other to the horizontal motion of the plate carrier. Each pulley has several index holes which
create pulses when passing between an IR LED and a phototransistor, providing tachometer pulses
to the microprocessor at the NMI input and via the CLK0 input at 8254 U4. Phototransistors Q3, Q4,
Q6, and Q7, positioned at extremes of the plate and probe movements, disable the motor drivers U17
via NAND gates U18 when the travel limits are reached. Two of these phototransistors, Q3 and Q6,
additionally indicate the home positions to the microprocessor. LEDs D1-D4 provide visual
feedback to the service technician of the tach pulses and home positions. See Figure 6. The
mechanism PCB holds the motor drivers, index pulse buffers, and limit logic, and connects to the
main PCB via a 14-pin DIP cable.
Display and Keypad
A 24 x 2 line character Liquid Crystal Display (LCD) is mounted inside the cover. A 4 x 4 membrane
switch keypad is sealed behind the front panel overlay. The LCD connects to an interface PCB via
a 14-pin DIP cable. The tail of the keypad switch layer is fed through the cover and is also connected
to the interface PCB. The interface PCB connects to the main PCB via a 26-conductor header cable.

Pressure and Vacuum


Solid-state sensors P1 and P2 are amplified at U10 and U11 and multiplexed via U13 into V/F
convertor U14, then measured at 8254 timer U4. This provides feedback to the microprocessor for
coordinating pump activity. The vacuum pump is driven by IRF510 MOSFET Q2A. The pressure
pump and control valve are driven by U9A and U9B in parallel.

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Rev. E
8
Level Sensing
The signal BOTLV is fed through a voltage divider to stainless steel wire probes mounted in the caps
of the wash, rinse, and waste bottles. The signals are multiplexed via U13 into V/F convertor U14
and the resulting frequency appears at the CLK2 input of 8254 timer U4. The microprocessor reads
a change in frequency which corresponds to a change in conductivity of the material between the
probes.

Watchdog Circuit
All valves and pumps are powered through an IRF9530A MOSFET Q1A, which is in turn driven by
the re-triggerable one-shot comprised of C10, RN3A, and U16A. The microprocessor re-triggers
U16A at intervals smaller than the one-shot period. Should the microprocessor system "crash" or
otherwise malfunction, U16A will time out and shut down the valves and pumps by turning off Q1A.
If this occurs, LED D11 will be extinguished to provide a visual indication.

Power Supply
The power supply consists of a transformer, diode bridges, and two regulators. Line voltage supplied
to the transformer is stepped down to 11VAC (rms) and is fed to diode bridge BR1, which provides
+12VDC (raw, 11-13 VDC nominal) to the pumps and valves. VR2 regulates this down to +5VDC
for the logic and control circuits, as well as the plate and probe motors. VR1 regulates down to
+6VDC for the vacuum and pressure sensors.

2600 Series Microplate Washer Service Manual


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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
9

Troubleshooting
In this section, each subassembly or component group is discussed, and possible problems and
solutions are outlined.

Test Mode
The instrument can be placed in "test mode" by holding down the YES and ALT keys simultaneously
while powering up the instrument. When in the test mode, the keypad is redefined as shown in Figure
5. The technician can then exercise various components and subsystems independently, to assist in
isolating problems.

Status Indicators
LED status indicators on the main PCB show the motor pulley index pulses, home sensor states, and
the watchdog status. These indicators, described in Figure 6, provide useful visual feedback while
troubleshooting the sensor and motor control circuits.

Available Tests
In addition to test mode, the following tests are available in normal mode. Press YES to run a test,
then enter the number of the desired test. Also listed are the selections available via the AUX key.
Test Function Range
99 List Stored Programs
101 Restore One or All Tests
183 Erase All User Tests
187 Check Probe Sense
201 Set Pressure Levels 0-15 PSI
210 Enter Plate Alignment Parameter 90-150 counts
212 Volume- Enter/Calibrate 5-40mL
213 Display Parameter Settings
214 Adjust Alignment
215 Display Probe Speed
216 Man Probe Depth-Enter/Calibrate [Aux Key Enables Selection Between
Auto or Manual] 1-115 counts
217 Man Dispense Depth-Enter/Calibrate [Aux Key Enables Selection
Between Auto and Manual] 1-115 count

Aux Key Menu- Refer to Owner's Manual, Section 2.2, Auxiliary Menu For Details
Select Well Type
Run Constant Time
View a Program
Set Auto Rinse
Set Date/Time
Enable Auto DepthVs. Manual Depth
Set Disp Depth

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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
10

Valve operation Hold down YES and UP


is for (ALT-0) during power-
approximately up to enter test mode
0.25 seconds
Cycle Cycle Cycle
wash rinse waste
valve valve valve* Clear display and revert
to test mode prompt

Continuously Continuously display


display v & p level sensors
sensors
Toggles vacuum pump
and opens bleed valve in
dual pump systems;
Move plate toggles pressure /
left vacuum pump in single
pump systems**.
Move plate
right (home) Toggles pressure pump
in dual pump systems;
Toggles combination
valve in single pump
systems**.
Move probe
up (home) Move Display motor
probe pulses & limit Cancel test mode
down sensors

* Refer to the "Waste Valve" subheading in the "Principles of Operation"


section of this manual.
** See Figure 4 for differences in dual pump and single pump systems.

Figure 5. Test Mode Keypad Layout

D11
PROCESSOR
ACTIVE LEGEND
LED ON OFF
D1 Plate pulley index hole Not aligned with hole in pulley, blocked
D2 Probe pulley index hole Not aligned with hole in pulley, blocked
D4 D3 D1 D2
D3 Probe homed (top) Not homed
PLATE PROBE PLATE PROBE
D4 Plate homed (right) Not homed
HOME HOME INDEX INDEX
D11 CPU running CPU malfunction- motors, valves,
Viewed from front of main PCB pump (s) disabled.

Figure 6. Status Indicators

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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
11
Pressure pump
Vacuum pump Bottle Pressure
- or -
- or - Sensors sensor
Combination valve*
Pressure / vacuum
Wash, Rinse, Vacuum Vacuum
pump* Bleed Waste Valves trimpot sensor
valve
Pressure Locking
trimpot lever

EPROM

14-pin DIP cable to


From mechanism PCB 26-conductor cable to
power keypad & display
transformer

* See Figure 4 for differences in dual pump and single pump systems.

Figure 7. Main PCB Connections

Power Supply
An inactive instrument may result from just a blown fuse. However, a blown fuse may indicate a
problem with the main PCB or transformer. The voltage select switch setting must match the line
voltage.

If there is no voltage present at J4, check the fuse. To replace the fuse, disconnect the power cable
and open the instrument. Remove the two #4 screws holding the AC cover and lift the AC cover off.
The double clip fuse holder is mounted on the inside of the rear panel. Locate the blown fuse and
remove it with a fuse puller, or carefully pry it out with a small screwdriver. Install a new 0.5A, T
rating, 250 V, cartridge fuse. The fuse link is in a clear glass package and the element is spirally

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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
12
wound on a fiberglass core. The fuses must be replaced by a 1 1/4 inch glass cartridge fuse commonly
known as 3AG or size '0'. The nominal dimensions are 1.25 x .25 inches. (32 x 6.3 mm). The fuses
must be approved to UL and CSA standards or approved for the country of use. Use only the
recommended fuse. Do not substitute any other rating. Replace the AC cover.

If voltage is present at J4, check for input voltage on VR1 and VR2. If no voltage is present, diode
bridge BR1 may have failed.

Main PCB
Under normal circumstances, there are no adjustments to be made to the main PCB. Circuit failures
are highly unlikely, but if they occur, it is recommended that the repairs be performed by factory
authorized technicians. There are ten test points at J1 which provide access to a number of vital
signals. The instrument can be observed in operation with an oscilloscope. The main PCB is
mounted to the pump bracket. To remove the main PCB, disconnect all attached connectors and
remove the two screws holding the pump bracket assembly to the chassis (from the bottom of the
instrument). Remove the screw holding the main PCB heat sink to the pump bracket (from the pump
side of the bracket). Remove the screw holding the main PCB to the pump bracket (from the main
PCB). Figure 7 shows the main PCB connections and other details.

Keypad
The keypad is a sealed membrane switch layer which is serviceable only by replacement. To test the
keypad (when not in test mode), press YES, then press all keys except NO and YES. Note that each
key causes the instrument to beep and display a character. Press NO and the display clears. Press
YES to end the test.

Display
The display is a 24 x 2 line super twisted nematic liquid crystal display (LCD) module with integrated
controller. The display should be clearly legible at all times, with no dark spots or stray dots. There
are no adjustments and service is limited to replacement.

Valves
Each valve uses a short length of silicone tubing, which may self-adhere or become clogged with
dried residue from fluids. If the valve operates but no fluid is dispensed or aspirated, the valve tubing
may be blocked. You may be able to unblock the tubing. Grasp the tubing on either side of the valve
body and gently stretch it. If needed, pull the tubing from the valve body. Roll the tubing between
your fingers and gently stretch it. Reposition and test. If still blocked, see the section “Valve Tubing
Replacement”.

Motor Control
Failure to move the probe or the plate can probably be attributed to a failure of driver U17. Also,
check the logic at U18 and U19. Check the operation of Q3-Q8 and voltage drop across IR LEDs
D5-D10.

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Rev. E
13

Vacuum and Pressure Systems


Refer to figures 3, and 4 to determine if the unit is configured with a dual pump or single pump system.
The pump(s) require no maintenance. If either pump runs frequently or continuously while the
instrument is not in use, there is probably a leak. Check the bottle caps and fittings. Check that the
tubing is firmly seated on barbs and all fittings are tight. Turn the fittings only until finger-tight. Do
not overtighten the plastic Luer fittings! Check the operation of the valves to ensure they are
closing completely. If the pressure pump (or the pressure / vacuum pump on single pump units) runs
frequently or continuously, check the bleed valve for leakage. It must be completely closed while
the unit is on.

If the wash or waste bottles are located at a different level than the instrument, such as on a shelf, the
pressure and volume calibration may require adjustment. Units which are configured with a waste
valve may also need a vacuum calibration. Refer to the sections of this manual covering “Volume
Calibration,” “Calibrate Pressure,” and “Calibrate Vacuum” as appropriate.

If aspiration is poor or absent, the exhaust filter may be clogged and should be replaced. In the event
that the exhaust filter gets wet due to a waste bottle spill, it must be replaced for continued operation.
See the section “Exhaust Filter Replacement.”

If the pressure pump (dual pump system) or combination valve (single pump system) is inoperative,
check inputs and outputs at U9A and U9B. If the vacuum pump (dual pump system) or pressure /
vacuum pump (single pump system) is inoperative, check Q2A. If pump(s) and all of the valves are
dead (no voltage present at any time), check Q1A and U16A for proper operation. Both should be
active at all times while the instrument is powered. LED D11 should be illuminated.

Incomplete Aspiration
One or more aspirate tubes maybe clogged. Clean the aspirate tubes using the cleaning wire. Check
the tubing path leading from the wash head to the waste bottle for kinked or pinched tubing. Verify
there is a vacuum using a gauge. Check the exhaust filter for clogging.

Incomplete or Inaccurate Dispense


One or more dispense tubes maybe clogged. Clean the dispense tubes using the cleaning wire. Check
the tubing path leading from the wash (or rinse) bottle to the wash head for kinked or pinched tubing.
Check for stuck valves, and clogged or pinched valve tubing. Check the bleed valve for leakage.
Verify the pressure using a gauge. Verify specified pressure level by running test 213 to see level.

If the instrument has been stored for an extended period without rinsing, it may be necessary to unclog
the tubing and/or operate the valves manually in order to prime the instrument. See the section
"Valves".

Error Messages
Error messages are displayed when the instrument fails to operate correctly. They are intended to
help the operator locate the problem. If error messages appear frequently, a hardware problem is

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for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair services.
Rev. E
14
usually indicated.
The following error messages indicate possible interface or component problems.

Message Possible Causes and Solutions


Wait Occurs during normal operation. The instrument
is attempting to build pressure, but has not suc-
ceeded. If message persists, check for leaks in
pressure system and may indicate vacuum prob-
lem on instruments prior to software before SRO
on 2600s.

Wash Bottle is Low The instrument detected an empty condition on


the
Rinse Bottle is Low wash or rinse bottle. If the bottle is full, check that
the sensors lead is securely connected to the bottle
cap and plugged into the jack on the rear panel.
Check the sensor leads for continuity.

Empty the Waste Bottle The instrument detected a full condition on the
waste bottle. If waste bottle is empty, dry waste
cap at terminal entry points. Check sensor lead is
plugged in properly. Check the sensor lead for
shorts.

Check Waste Valve This message applies only to units configured


with a waste valve. If equipped with a waste
valve, this message indicates that the instrument
did not detect a vacuum drop after opening the
waste valve. Check for kinked tubing or stuck
waste valve.

Check Vacuum System The instrument was unable to develop vacuum


within the prescribed length of time. Check for
leaks at the waste bottle and at all connections.

Mech must be realigned The well type was changed and the instrument
detected this condition. Install a plate with the
new well type and press YES to continue.

PROGRAM CANCELED The instrument did not detect the bottom of the
first row of wells. This could be a result of
incorrect well type setting.

*** MECH. JAM: PROBE *** The motor stalled while the instrument was at-
tempting to move the probe. Check for mechani-
cal obstructions or broken belts. Check motor
driver U17 and associated logic.

*** MECH. JAM: PLATE *** The motor stalled while the instrument was at-
tempting to move the plate. Check for mechanical
obstructions or broken belts. Check motor driver

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Rev. E
15
U17 and associated logic.

The following error messages, if displayed repeatedly, indicate possible failure of the NV RAM U3,
which can be checked by substituting a known good device.

*** CHECKSUM ERROR *** Calibration was lost. The display shows:

Enter Plate Align param

Enter the plate alignment parameter from the


calibration label and press YES. The display
shows: Enter measured vol (mL):

Enter the volume from the calibration data label


and press YES.

MEMORY ERROR: Prog Ended A memory error occurred during execution of a


user program. The corrupted user program is
automatically deleted.

Service Procedures
Opening the Instrument
The cover must be removed to allow access to the inside of the instrument.

1. Disconnect the power cable, the tubing, and the sensor leads from the rear panel. Remove
the wash head and the plate carrier and set aside. Lower the aerosol shield.

2. Invert the instrument on a soft nonabrasive surface such as a terry cloth towel. Do not allow
the instrument to rest on the probe arm!! Hold the acrylic aerosol shield in place while
inverting the instrument. The instrument should rest on the area at the top of the keypad
and the front edge of the aerosol shield.

3. Refer to Figure 8. Locate and remove the five screws shown. While holding the cover in
place with both hands, return the instrument to the upright position.

4. Gently lift the cover upward. Do not stretch the 26-conductor cable connecting the main
PCB to the cover assembly. You can prop the cover securely on its right side by placing
the edge of the cover under the chassis base. This allows you to leave the display and
keypad connected while servicing the instrument.

To reinstall the cover, reverse the procedure.

1. Carefully lower the cover until it seats squarely on the plate bed and chassis base, taking
care to not pinch or stretch the 26-conductor cable connecting the main PCB to the cover
assembly. The cover should seal tightly against the back of the plate bed.

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Rev. E
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2. Invert the instrument on a soft nonabrasive surface. Replace the five screws removed in
step 3, above.

3. While holding the aerosol shield in place, return the instrument to the upright position.

4. Install the plate carrier and wash head. Install the tubing, sensor leads, and the power cable
to the rear panel connectors.

Hatch
Door

Front of instrument

Figure 8. Cover Screws


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Rev. E
17

Wash Rinse Waste


valve valve valve*

* Refer to the "Waste Valve" subheading in the "Principles of Operation" section of this
manual.

Figure 9A. Valve Locations

Wash Rinse
Valve Valve

Figure 9B. Valve Locations

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Rev. E
18
Plastic Valve
body

Valve Pinch bracket


tubing

Solenoid

Figure 10A. Valve Tubing Replacement

Metal Valve
body

Valve Pinch bracket


tubing

Solenoid

Figure 10B. Valve Tubing Replacement

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Rev. E
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Valve Tubing Replacement
The silicone tubing used in the valves may become clogged or worn with age. If this occurs, the
tubing must be replaced.

1. Set the power switch to OFF (O). Open the valve door by removing the door fastener. Refer
to Figure 2, Rear Panel.

2. Refer to Figure 9A and 9B. Locate the valve to be serviced.

3. Refer to Figure 10A and 10B. Pull back the pinch bracket and remove the valve tubing from
the valve body.

4. Disconnect the valve tubing from the fittings at both ends.

5. Cut the replacement tubing to match the length of the original.

6. Install the replacement tubing to the valve body. Push the tubing over the fittings until
seated. If you have trouble sliding the tubing over the fittings, dip ends of tubing in
isopropyl alcohol. Be especially careful not to kink, stretch, or tension the tubing. The
replacement tubing should be routed in exactly the same place as the original.

7. Close the valve door and replace the door fastener. Take special care not to pinch, kink,
or stretch any tubing behind the door.

Valve Rebuild
(wash, rinse, and/or waste valve)

1. Follow steps 1 through 4 of "Valve Tubing Replacement" procedure above.

2. Remove solenoid, plunger, and spring. Relocate the wiring soldered to the original
solenoid to the replacement solenoid. Install replacement solenoid, plunger, and spring by
loosely installing the solenoid mounting screws to allow for adjustment.

3. Replacement valves manufactured starting January 1999 are preadjusted and do not need
step 3. Adjust position of solenoid by inserting a 0.092 in (2.337 mm) diameter gage pin
between the pinch bar on the plunger and the valve block (or bracket, depending on which
configuration valve is installed) and move the solenoid toward the block (or bracket) until
plunger bottoms in solenoid. Align pinch bracket, valve bracket, and solenoid. Tighten
mounting screws and remove gage pin.

4. Reinstall the tubing to the valve body. Push the tubing over the fittings until seated. Be
especially careful not to kink, stretch, or tension the tubing. The replacement tubing should
be routed in exactly the same place as the original.

5. Close the valve door and replace the door fastener. Take special care not to pinch, kink,
or stretch any tubing behind the door.
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Rev. E
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Bleed Valve Replacement
1. Set the power switch to OFF (O). Refer to Figure 1 and remove the Aerosol Shield (see
Service Procedures- Opening the Instrument) and Cover (Figure 1 is a view of the
instrument with the Aerosol Shield already removed).

2. Move the solenoid plunger away from the valve tubing and remove the tubing.

NOTE
There are three styles of Bleed Valve in service. See Figure 11 to
determine which style applies to the unit being serviced.

Style A Style B

Style C

Figure 11. Bleed Valve Styles

3. If the unit is fitted with a "Style A" valve, proceed as follows, otherwise proceed to step 4:
Remove the two screws which secure the valve block, spacers and valve bracket to the
Pump Bracket. Care must be taken to account for these parts as they will tend to fall apart
into the unit while the screws are being removed. Discard the removed parts. Install the
replacement "Style B" valve assembly by securing the assembly with the two supplied
mounting screws and lock washers. Proceed to step 5.

4. If the unit is fitted with a "Style B" valve, remove the two screws which secure the Valve
Bracket to the Pump Bracket. Replace with another "Style B" valve assembly by securing
the assembly with the two supplied mounting screws and lock washers.

5. If the unit is fitted with a "Style C" valve, remove the two screws which secure the Valve
Bracket to the Pump Bracket. Replace with another "Style C" valve assembly by securing
the assembly with the two supplied mounting screws and lock washers. Replacement
valves manufactured starting January 1999 are preadjusted and do not need the following
step. Adjust position of solenoid by inserting a 0.082 in (2.083mm) diameter gage pin
between the pinch bar on the plunger and the valve block (or bracket, depending on which
configuration valve is installed) and move the solenoid toward the block (or bracket) until

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plunger bottoms in solenoid. Align pinch bracket, valve bracket, and solenoid. Tighten
mounting screws and remove gage pin.

6. Move the solenoid plunger away from the valve bracket and insert the tubing between the
plunger and the bracket while routing the tubing through the holding slots in the valve
bracket.

Exhaust Filter Replacement


The filter that removes contaminant particles from the exhaust of the vacuum pump may be replaced
if clogged or damaged. If the WAIT message is taking longer to clear, or if the instrument takes
longer to get up to pressure, the filter may be clogged. If the waste bottle is overturned and the filter
gets wet, the filter must be replaced.

To replace the filter:

1. Set the power switch to OFF (O). Pull the tubing from the fittings on the filter.

2. Install the new filter with the INLET side pointing toward the waste bottle. Push the tubing
on the fittings until seated.

Probe Drive Belt Replacement


The neoprene drive belt which couples the probe motor to the probe lead screw pulley can become
worn or loosen with age.

To replace the belt:


Section 1:

1. Check to see if your instrument has a hatch door. If not, open the instrument. If your
instrument does have a hatch door, go to Section 2.

2. Remove the four flat head screws at each corner of the plate bed, and lift the plate bed
upward and forward to clear the probe arm.

3. Refer to Figure 12. Disconnect the 14-pin DIP cable from the mechanism PCB. Mark the
location of the mechanism assembly using the four nuts holding the mechanism assembly
to the chassis. You will need these marks to place the mechanism back in proper alignment.
Remove the nuts. Lift the mechanism assembly upward and off.

4. Look at the rear of the mechanism assembly. Remove the old belt by carefully lifting one
side off the probe motor pulley. Remove the belt from the other pulley. Do not bend the
optical sensors mounted on the edge of the mechanism PCB.

5. Install the new belt first to the probe lead screw pulley, then to the probe motor pulley. Do
not bend the optical sensors mounted on the mechanism PCB. Do not twist the belt.

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14-pin Remove Probe
DIP these nuts motor
cable shaft

Mechanism
PCB

Plate
Sensor
PCB

Plate
Drive
Belt

Figure 12. Removing Mechanism Base

6. Turn the probe motor shaft several revolutions to ensure that the belt is seated without
twisting.

7. Install the mechanism assembly and replace the four nuts. Align the mechanism using the
marks made in step 3, then tighten the nuts. Connect the 14-pin DIP cable to the mechanism
PCB.

8. Install the plate bed and cover.

Section 2:

1. Refer to Figure 8. Open the hatch door on the bottom of the instrument.

2. If Probe Arm is stuck at the top, turn the belt clockwise. If Probe Arm is stuck at the bottom,
turn belt counter clockwise. If belt shows wear, replace belt.

3. Remove the old belt by carefully lifting one side off the probe motor pulley. Remove the
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belt from the other pulley. Do not bend the optical sensors mounted on the edge of the
mechanism PCB.

4. Install the new belt first to the probe lead screw pulley, then to the probe motor pulley. Do
not bend the optical sensors mounted on the mechanism PCB. Do not twist the belt.

5. Turn the probe motor shaft several revolutions to ensure that the belt is seated without
twisting.

6. Reinstall hatch door cover.

Plate Drive Belt Replacement


The neoprene drive belt which couples the plate motor to the plate lead screw pulley can become
worn or loose with age.

To replace the belt:

1. Open the instrument.

2. Remove the four flat head screws at each corner of the plate bed and lift the plate bed upward
and forward to clear the probe arm. Set the plate bed aside.

4. Refer to Figure 12. Look at the left side of the mechanism assembly. Remove the old plate
drive belt by carefully lifting it off the smaller plate motor pulley. Remove the belt from
the other pulley. Do not bend the optical sensors mounted on the edge of the mechanism
PCB.

5. Install the new belt first to the plate lead screw pulley, then to the plate motor pulley. Do
not bend the optical sensors mounted on the plate sensor PCB. Do not twist the belt.

6. Turn the plate motor pulley several revolutions to ensure that the belt is seated without
twisting.

7. Install the plate bed and cover.

EPROM Replacement
The EPROM (Erasable Programmable Read-Only Memory) device U2 holds the microprocessor
operating software. The EPROM label shows the software version number. The EPROM can be
replaced with a newer version to provide new software features (upgrades). See specific information
included with EPROMS for further details.

To replace the EPROM:

1. Open the instrument.

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2. Refer to Figure 3, Chassis Layout, and Figure 7, Main PCB Connections. Locate the
EPROM at the upper right corner of the Main PCB. Lift the locking lever at the top of the
EPROM socket to unlock the EPROM from the socket.

3. Remove the old EPROM. Install the new EPROM in the same orientation. The small
indentation at the end of the EPROM should be oriented as indicated by the white
orientation label on the ZIF socket. See the following CAUTION. While holding the
EPROM in the socket, push the locking lever down toward the PCB. Do not bend the
EPROM pins or apply excessive force to the EPROM, socket, or locking lever.

CAUTION
Some early units were configured with ZIF sockets where the locking
lever is located on the opposite end from the notched end of the
installed EPROM. Be sure to observe the orientation label on the ZIF
socket.

4. Install the cover.

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Calibration
Restore Calibration Data
The calibration data is stored with a check sum that is recalculated and compared each time a mode
is selected. Failure to recover the calibration data properly (checksum failure) will be indicated on
the display:

*** CHECKSUM ERROR ***

In this event, the pressure is set to 5.0 psi. The volume and plate alignment calibration values must
be entered from the calibration label. The instrument will automatically prompt for these values.
Locate the calibration label on the bottom of the unit. There are two values recorded there: Alignment
and Volume. Write down these numbers.

1. The display shows

*** CHECKSUM ERROR ***

2. The display then shows

Ent calibration vol <YES>

Enter the Volume from the calibration data label. Press YES.

3. The display shows

Plate Carrier Alignment

Enter the Alignment from the calibration data label. Press YES.

4. The instrument will now revert to normal operation. Note that all user programs will have
been deleted from memory. You will need to reenter the user programs from a written
listing.

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Volume calibration
Tools and Materials
50 mL graduated cylinder.

1. Select test #213. The display shows:

PD 40 DD 28 10/01/97
Pl 118 Pres 5.0 Vol 27.0

Note: Your display may vary depending on software revision

The top line shows the Plate Depth, Dispense Depth, and last calibration. The bottom line
shows the plate alignment parameter (Pl), pressure (Pres), and volume (Vol). Values in the
display may be different than the example. Write down the display value shown for
volume. Press YES to return to the main prompt.

2. Select test #212. The display shows:

Run a program
Ent calibration vol Y/N

3. Press NO. The display shows:

Run a program
Calibrate volumes Y/N

4. Press YES. The display shows:

Unplug dispense tube


Place in cyl —> <YES>

5. Unplug the plastic dispense tube from the upper fitting (blue fitting) on the side of the head.
Place the end of the tubing in a clean, dry 50 mL graduated cylinder. Position the tubing
so that the tubing remains level with the head. Press YES and the unit will dispense a
relatively large amount of fluid (but not more than 50mL). When this is complete, the
display shows:

Enter measured vol (mL):

6. Read the amount dispensed from the graduated cylinder. Enter the new value read from
the graduated cylinder and press YES. Otherwise, press NO twice in succession to cancel
and return to the main prompt. Record the volume each month. If the volume is trending
lower each time, verify the pressure setting.

7. Connect the plastic dispense tube to the fitting on the head. Be sure to PRIME before
performing any dispense operation, to remove any trapped air from the head.

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Dispense Volume Repeatability Check
This assures that the probes are not clogged or damaged.

1. Fill the wash bottle with a solution containing a wetting agent (such as a drop of liquid
soap).

2. Press PRIME to prime the instrument.

3. Dispense 250 µL into each well of a clean dry microplate.

4. Remove the plate and examine the wells to see that each all wells appear evenly filled.

If any row of wells has lower volumes than the other rows, suspect a clogged probe. Attempt to clean
the dispense probe for the affected row with wire. Repeat the test. If the wells do not appear to be
filling evenly, replacement of the wash head may be required.

Probe Auto Depth vs. Manual Depth


(Plate Sensing, Manual vs. Automatic)
Manual is used if you do not want the instrument to sense the well depth and automatically detect
presence or absence of wells.
Setting Parameter
To set your manual plate depth parameter, select test #216. The display shows:

Enter Well Depth Y/N


If you have set this value before and are either re-entering it because of a memory failure or a software
change, you may press YES to enter the same value as before. Otherwise, install a plate in the plate
bed and press NO. The instrument will position the probe head with the tips in the first row of wells.
The display shows:

Set Well Depth: YES=Done


0=+1, .=+5, 1=-1, 2=-5

To make the probe head go lower, press the 0 or . key. To make the probe head go higher, press the
1 or 2 key. Press YES when the aspirate tubes are where you desire the depth to be set. Auto-detection
for partial plates is disabled when in manual mode, so using NUM (to select the number of strips
being washed) is automatically selected. If you set the depth so the aspirate tubes are not touching
the bottom of the wells, you may notice an increased amount of residual liquid after aspirating, and
double aspiration may not decrease the amount of residual liquid over single aspiration.

Note: This will not enable this setting. To use Manual Depth ,
follow the section below.

Enabling Parameter
Use the AUX key to select Manual verse Auto-Depth. Select NO until you see "Set Auto Depth",
then press YES. Enter 0 for Auto Depth, 1 for Manual Depth. The current manual plate depth value
can be viewed using test #213.
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Rev. E
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Probe Arm Adjustment
This is used if the head is not sitting level to the wells (Z-direction), or if it is out of alignment with
the plate or trough (X-direction). Remove the cover to begin adjustment, and notice the two Phillips
head screws with set screws on each side of the probe rod. Note: Set Depth selection to AUTO for
this process.

If there is a Z-direction alignment problem, depending upon the direction the probe head needs to
be adjusted, loosen the appropriate Phillips head screw approximately 1/4 to 1/2 turn, then retighten
the Phillips head screw. Example: If there is clearance from the bottom of the well to the rear aspirate
tube, loosen the Phillips head screw, tighten the set screw 1/4 turn (to bring the arm down in the back,
up in the front), then retighten the Phillips head screw. Press key #4 (ALIGN) and watch the
movement of the probe head. The aspirate tubes should touch the front wells first, then rock to the
rear wells. When stopped, the aspirate tubes should be even across the bottom of the wells. Repeat
adjustment until alignment is correct.

If there is an X-direction alignment problem (wash head is not parallel to the wells), loosen the
Phillips head screws and use a small squaring tool to align the probe. Retighten the screws, and run
test #214 to adjust the X-direction alignment. After performing this alignment, select test #213, and
read the PL# value. If this number has changed from the value on the calibration label on the bottom
of the instrument, make a note of the new value. If you are running manual depth, be sure to reset
using section Probe Auto Depth vs. Manual Depth and Plate Sensing. If auto, do an align.

Plate Carrier Travel


This is used if the plate carrier moves too far (e.g., jams against the right side of the plate bed).
Remove the cover, probe head, and plate bed. Adjust the optical detector on the right of the
instrument until it is positioned where you want the plate carrier to stop- normally just before it
reaches the edge of the plate bed. After reassembly, run test #214 to confirm plate alignment: adjust
if necessary.

Calibrate Pressure
(applies to all configurations)
Tools and Materials
Reference pressure gauge reading at least 34 kPa (5 psi.)
15 cm length of 3.1 mm ID flexible tubing
3.1 mm barbed “tee” fitting

1. Disconnect the pressure line (red Luer fitting) at the rear panel. Refer to Figure 13A.
Connect the pressure gauge as shown.

2. Open the instrument. Refer to Figure 14. Locate the pressure trimpot R10. Turn trimpot
fully counterclockwise.

3. Set the power switch to ON (1). Wait until the instrument stabilizes and the pumps stop
running. The pressure gage should read much less than 34 kPa (5 psi.)
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Reference pressure
gauge,
6psi

To pressure side
From pressure (red) of wash and rinse
fitting on rear panel bottles
Tee fitting
Figure 13A Gauge Connections - Pressure Calibration

Reference vacuum
gauge,
16 in Hg

From vacuum To vacuum side


(blue) of waste bottle
Tee
fitting on rear
fitting
panel Figure 13B Gauge Connections - Vacuum Calibration

Vacuum Pressure
trimpot trimpot Pressure
Sensor

Vacuum
Sensor

Main PCB viewed from front

Figure 14. Trimpot Locations

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4. Slowly turn the pressure trimpot clockwise until gauge reaches 34± 3.4 kPa (5 psi ±0.5.)
When turning the trimpot, pause while the pump runs to maintain pressure.

5. Set the power switch to OFF (O). Set the Vacuum Trimpot at mid-span of its range. Replace
the cover. Disconnect gauge and tubing. Reconnect the pressure fitting.
Calibrate Vacuum
(applies only to units configured with waste valve)
Tools and Materials
Reference vacuum gauge reading at least negative 51 kPa (16 inches Hg.)
15 cm length of 3.1 mm ID flexible tubing
3.1 mm barbed “tee” fitting

1. Disconnect the vacuum line (blue Luer fitting) at the rear panel. Refer to Figure 13B.
Connect the vacuum gauge as shown.

2. Open the instrument. Refer to Figure 14. Locate the vacuum trimpot R7. Turn trimpot fully
counterclockwise.

3. Set the power switch to ON (1). Wait until the instrument stabilizes and the pumps stop
running. The vacuum gauge should read much less than negative 51 kPA (15 in. Hg.)

4. Slowly turn the vacuum trimpot clockwise until gauge reaches negative 51 ± 2 kPa (15 in.
Hg ±0.5.) When turning the trimpot, pause while the pump runs to maintain vacuum.

5. Set the power switch to OFF (O). Replace the cover. Disconnect gauge and tubing.
Reconnect the pressure and vacuum fittings.
Plate Alignment
The plate is aligned by means of a software adjustment value.

To enter the alignment parameter from the calibration data label, select test #210. The display shows:

Plate carrier alignment

Type the value shown on the calibration data label and press YES.

To realign the plate carrier, install a microplate with flat-bottom wells. Press ALIGN. After the align
is complete, select test #214. The display shows:

Plate Carrier alignment


0=Dec, 1=Inc, YES=Accept

Refer to Figure 15. Press 0 and 1 to achieve the results pictured. Press 1 to move the plate to the right.

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Rev. E
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Press 0 to move the plate to the left. When the results are as shown, note the alignment value
displayed. Press YES to accept the alignment and complete the operation. Update the alignment
value on the calibration data label if necessary.

2. Aspirate tube must


1. Aspirate tube must be not touch side of well
as far to right as possible

Figure 15. Plate Alignment

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Single Pump- Without Check Valve

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Dual Pump Configuration Without Waste Valve

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Dual Pump Configuration with Waste Valve

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Selected Part Illustrations

994027
994029

994028

997423
137140
994011 Complete Bottle and External Tubing Set and
997423 Bottle Rack

163061 NV RAM
162515 Display

1836XX Overlay Set (model specific)


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995102 Mechanism PCA

994023 Mechanism Assembly

991101 Aerosol Shield

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105160 Vacuum Pump


(Pressure / Vacuum Pump on Single Pump
Configuration)

183111 Keypad

105150 Pressure Pump

994021 Plate Carrier

997420 8-Way 997421 12-Way 997424 16-Way


Wash Head Wash Head Wash Head

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Model 2600 Luer Fittings
*indicates minimal stock for repairs. A
Rev. E

Reference Descriptions Part Number versus Color


(uses) White Black Blue Red Green Yellow Locking Nut

A. Luer Locking Nut, 137030* 137027 137028 137029 137026 137025


or Luer Cap B

B. Male Luer 1/8 Barb 137122* 137135 137128 137127 137129 137134
Male Luer
C. Luer Coding Rings 137119* 137115 137117 137118 137114 137116

D. Female Luer 137102* 137107 - - 137106 137105 C


Bulkhead 3/32 Barb

E. Female Luer 137101* 137108 137104 137103 - -


Coded Rings
Bulkhead 1/8 Barb

F. UNF Female Luer 137120* - - - - - D


10-32 thread small hex (manufacturing date before October 1995)
Female Luer
UNF Female Luer - - 137126* 137124* - - Bulkhead
10-32 thread large hex (manufacturing date after October 1995)

2600 Series Microplate Washer Service Manual


E
G. Nut for Bulkhead 121961
1/4-28 thread
UNF Female
I. Flat Washer nylon 121952 Luer
1/4 ID
Notes: Barb connections are 1/8 if clear vinyl tubing, 3/32 if silicone tubing.
Reference uses:
A and B are for external tubing (bottles and head.) C, D, E, G, and I are for Rear panel bulkhead. F is for the wash head.

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39

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Block Diagram-No Waste Valve

No Waste Valve, Single Pump


Systems. Refer to subheadings
in the "Principles of Operation"
section of this manual.

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Block Diagram- Waste Valve

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PCB Layouts 184700J


Main/Mechanism PCB Combo PCA


➝ Rear
Door
Valves
➝ Bottle
Sensor

184703J-2
Opto

184702J
184704J ➝

Mechanism
Rear Tray (Left) PCA
Pulley Sensor 995102SP need
184703J S/N of
Front Tray (Right)
Pulley Sensor
➝ instrument

(Home)

184701J
➝ Main PCA
995101SP need
S/N of
instrument

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Interface PCB
184400M / 995009SP
INTERFACE PCA
DISPLAY AND KEYPAD

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Schematics
Main/Mechanism PCB (1 of 5)

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Main/Mechanism PCB (2 of 5)

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Main/Mechanism PCB (3 of 5)

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Main/Mechanism PCB (4 of 5)

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Main/Mechanism PCB (5 of 5)

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Interface PCB Sheet 1 of 2

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Interface PCB Sheet 2 of 2

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0062 s e i r eS
e ta lporc M
i rehsW
a
Service Manual
Table of Contents

Introduction .................................... 1 Calibration .................................... 25


Layout ............................................. 1 Restore Calibration Data .............. 25
Principles of Operation .................. 6 Volume calibration ....................... 26
System Control ............................... 6 Dispense Volume Repeatability
Dispense ......................................... 6 Check ............................................ 27
Aspirate ........................................... 7 Probe Auto Depth vs. Manual
Waste Valve.................................... 7 Depth ............................................ 27
Motion Control ............................... 7 Probe Arm Adjustment ................. 28
Display and Keypad ....................... 7 Plate Carrier Travel ...................... 28
Pressure and Vacuum ..................... 7 Calibrate Pressure ......................... 28
Level Sensing ................................. 8 Calibrate Vacuum ......................... 30
Watchdog Circuit............................ 8 Plate Alignment ............................ 30
Power Supply .................................. 8 Internal Plumbing ......................... 32
Troubleshooting .............................. 9 Selected Part Illustrations ............ 36
Test Mode ....................................... 9 Block Diagram-No Waste Valve ... 40
Status Indicators ............................. 9 Block Diagram- Waste Valve........ 41
Available Tests ............................... 9 PCB Layouts.................................. 42
Power Supply ................................ 11 Main/Mechanism PCB ................. 42
Main PCB ..................................... 12 Interface PCB ............................... 43
Keypad .......................................... 12 Schematics ..................................... 44
Display .......................................... 12 Main/Mechanism PCB (1 of 5) .... 44
Valves ........................................... 12 Main/Mechanism PCB (2 of 5) .... 45
Motor Control ............................... 12 Main/Mechanism PCB (3 of 5) .... 46
Vacuum and Pressure Systems ..... 13 Main/Mechanism PCB (4 of 5) .... 47
Incomplete Aspiration .................. 13 Main/Mechanism PCB (5 of 5) .... 48
Incomplete or Inaccurate Dispense13 Interface PCB Sheet 1 of 2 ........... 49
Error Messages ............................. 13 Interface PCB Sheet 2 of 2 ........... 50
Service Procedures ........................ 15
Opening the Instrument ................ 15
Valve Tubing Replacement .......... 19
Valve Rebuild ............................... 19
Bleed Valve Replacement ............ 20
Exhaust Filter Replacement .......... 21
Probe Drive Belt Replacement ..... 21
Plate Drive Belt Replacement ...... 23
EPROM Replacement .................. 23

© 1993-2006 Awareness Technology, Inc. Unauthorized duplication is strictly prohibited. Information given in this manual is restricted
for use by authorized personnel and is to be used for the sole purpose of providing routine instrument maintenance and repair service. No
part of this manual may be copied or redistributed without the express consent of Awareness Technology, Inc. There is no transfer of
technology, copyright, trade name, patent, trade secret, or other proprietary right given or implied. Rev E, 08/06

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